CASE CX135SR Service Repair Workshop Manual PDF

REPAIR MANUAL
CX135SR
9-40641 1 14/12/2004
Contents
INTRODUCTION
DISTRIBUTION SYSTEMS A
POWER PRODUCTION B
TRAVELLING D
BODY AND STRUCTURE E
FRAME POSITIONING F
WORKING ARM H
TOOLS AND COUPLERS J
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INTRODUCTION
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Contents
INTRODUCTION
Foreword ( - A.10.A.40) 3
CX135SR
Safety rules ( - A.50.A.10) 4

CX135SR
Basic instructions ( - A.90.A.05) 6

CX135SR
Torque ( - A.90.A.10) 7
CX135SR
Torque ( - A.90.A.10) 8
CX135SR
Dimension ( - A.92.A.30) 11
CX135SR
Weight ( - A.92.A.40) 14
CX135SR
Consumables ( - A.92.A.55) 15
CX135SR
Hydraulic contamination ( - A.92.A.60) 18

CX135SR
Product identication ( - A.80.A.10) 20

CX135SR WE
Product identication ( - A.80.A.10) 21

CX135SR NA
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INTRODUCTION
Foreword ( - A.10.A.40)
CX135SR
INTRODUCTION TO THE REPAIR MANUAL

This manual has been designed so that in the near future it can be made available on CD and in a database
via a computer network.
This will allow fast and targeted search and navigation between the various information modules.
Information search
CRIL03J033E01 1
This manual is organised according to types of function and information.
• The function and information types are codied and appear in parentheses after the title and separated by a dash:
(1) Function
(2) Information type.
• Only the rst letter (A) and the rst number (B) of the function need to be used for the information search.
The rst letter (A) corresponds to the sections of the repair manual.
The rst number (B) corresponds to the chapters of the repair manual.
The rst part of the (A.B) code is reected in the page numbering.
THE REST OF THE CODING IS NOT LISTED IN ALPHA-NUMERIC ORDER IN THIS MANUAL.
• You will nd a table of contents at the beginning and end of each section and chapter.
You will nd an alphabetical index at the end of each chapter.
• Therefore it is the rst part of the (A.B) coding, then the tables of contents and index (page numbers) which will allow you to
quickly nd the information you are looking for.
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INTRODUCTION
Safety rules ( - A.50.A.10)

CX135SR
CAUTION
M171C - THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL.
WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO
THE POSSIBILITY OF DEATH OR SERIOUS INJURY.
ATTENTION: To avoid injury, always observe the Safety Notices, CAUTION and ATTENTION, contained in this
section and throughout the manual.
Place a “Do not start the machine” warning notice on the starter switch key before all maintenance or repair
operations.
CAUTION
M489 - Read the operators manual to familiarize yourself with the correct control functions.
CAUTION
M490 - Operate the machine and equipment controls from the seat position only. Any other method could
result in serious injury.
CAUTION
M265A - A frequent cause of personal injury or death is persons falling off and being run over. Do not
permit anyone to ride on the machine.
CAUTION
SB055 - Before starting engine, study operators manual safety messages. Read all safety signs on machine.
Clear the area of other persons. Learn and practice safe use of controls before operation. It is your
responsibility to understand and follow manufacturers instructions on machine operation, service, and to
observe pertinent laws and regulation. Operators and service manuals can be obtained from your dealer.
ATTENTION: You risk injury if you wear loose clothing or if you do not use safety equipment for your work. Always
wear clothes which are unlikely to become caught in the machinery. Other safety equipment may be required, in
particular: hard hat, safety boots, ear protectors, safety goggles or mask, thick gloves and reective clothing.
CAUTION
M124A - Rotating machine parts, stay clear, keep shields installed to help protect from clothing
entanglement and injury. Wear close-tted clothing.
CAUTION
SB071 - Rotating fan and belts: Contact will cause injury. Keep clear.
ATTENTION: Follow the procedures exactly when carrying out checks or inspections on the vehicle’s hydraulic
systems. DO NOT CHANGE the procedures.
ATTENTION: Before running the hydraulic cylinders in this vehicle through the cycles necessary for checking their
functioning or for draining a circuit, warn people nearby to move away.
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INTRODUCTION
CAUTION
SM121A - Always wear heat protective gloves to prevent burning your hands when handling heated parts.
CAUTION
M132B - Lower or block elevated implements and other attachments before servicing or when leaving the
equipment.
CAUTION
R149C - Hydraulic oil or diesel fuel leaking under pressure can penetrate the skin and cause infection
or other injury. To Prevent Personal Injury: Relieve all pressure, before disconnecting uid lines or
performing work on the hydraulic system. Before applying pressure, make sure all connections are tight
and components are in good condition. Never use your hand to check for suspected leaks under pressure.
Use a piece of cardboard or wood for this purpose. If injured by leaking uid, see your doctor immediately.
ATTENTION: To remove a hardened pin, such as a pivot pin, or a hardened shaft, use a soft-headed hammer
(brass or bronze) or a brass or bronze peg and a steel-headed hammer.
CAUTION
M428 - Always wear safety glasses when using a drill, hammer, saw, or other tools that may cause chips
to y.
ATTENTION: Use suitable servicing jacks or a chain hoist for raising the wheels or tracks. Always chock the
vehicle in place with suitable safety supports.
ATTENTION: When carrying out maintenance or repair operations on the vehicle, keep the workshop oor, the
driving position and the steps free from oil, water, grease, tools, etc... Use an oil absorbent material and/or workshop
cloths as necessary. Always use sound methods.
ATTENTION: Some parts of this vehicle are very heavy. Use lifting devices or additional assistance recommended
in the Operator’s Manual.
CAUTION
M532 - Do not operate the engine in a closed building. Proper ventilation is required under all circumstances.
CAUTION
M503 - When the battery electrolyte is frozen, the battery can explode if (1), you try to charge the battery, or
(2), you try to jump start and run the engine. To prevent the battery electrolyte from freezing, try to keep the
battery at full charge. If you do not follow these instructions, you or others in the area can be injured.
CAUTION
M244A - BATTERIES CONTAIN ACID AND EXPLOSIVE GAS. EXPLOSION CAN RESULT FROM SPARKS,
FLAMES, OR WRONG CABLE CONNECTIONS. TO CONNECT JUMPER CABLES OR CHARGER, SEE
MANUAL(S) FOR THE CORRECT PROCEDURE. FAILURE TO FOLLOW THE ABOVE INSTRUCTIONS CAN
CAUSE SERIOUS PERSONAL INJURY OR DEATH.
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INTRODUCTION
Basic instructions ( - A.90.A.05)

CX135SR
GENERAL
Cleaning
Clean all metal parts except the bearings with white spirit or steam. Do not use caustic soda for steam cleaning.
After each cleaning, dry and oil all parts. Clean the oil ducts with compressed air. Clean the bearings with parafn,
then dry them completely and lubricate them.
Inspection
Check all the parts when they are disassembled. Replace all parts that show signs of wear or damage. Supercial
scratches and grooves can be removed with an oil stone or with a cloth dipped in red oxide. A complete visual
inspection is necessary to detect wear and pitting, and replacing parts as soon as it becomes necessary will help to
avoid premature breakdowns.
Bearings
Check that the bearings turn freely. Replace them if their adjustment is too free or if their functioning is irregular.
Wash the bearings with a good solvent or parafn and allow them to air dry.
DO NOT DRY THE BEARINGS WITH COMPRESSED AIR.
Needle bearings
Before pushing needle bearings into a cylinder bore, always remove all metallic projections from the bore and its
edges. Before pushing in bearings with a press, coat the inside and edges of the bearings with Vaseline.
Gears
Check all the gears and ensure that they do not show any signs of wear or damage. Replace the worn out
or damaged gears.
Gaskets, O-rings and at seals

Always install new gaskets, O-rings, and at seals. Coat the gaskets and O-rings with Vaseline.
Shaft
Check all shafts showing wear or damage. Enusre that the surface of a shaft carrying a bearing or gasket is
not damaged.
Spare parts
Always use CASE spare parts. To order these, refer to the Spare Parts Catalogue and indicate the correct reference
number of the CASE spare parts.
Breakdowns caused by the use of parts other than CASE spare parts are not covered by the warranty.
Lubrication
Use only the oils and lubricants specied in the Operator’s Manual or the Service Manual.
Breakdowns caused by the use of oils and lubricants not specically listed are not covered by the warranty.
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INTRODUCTION
Torque ( - A.90.A.10)
CX135SR
STANDARD TIGHTENING TORQUE
Order of tightening nuts and cap screws.

Tighten alternately so that torque remains uniform. Cap screws which are tted with Loctite (look for traces of a
white residue on the thread after removal), must be cleaned with a thin oil or a suitable solvent, then dried.
Add two or three drops of Loctite to the cap screw thread, then t the screw.
CRIL03H012E01 1
The numbers in the diagrams represent the order of tightening.
Tightening torque
Where there are no special instructions, tighten cap nuts screws to the torques given in the table below.
Standard torque setting table.

Designation of cap screws M6 M8 M10 M12 M14 M16 M18 M20
(dimensions)
Cap screw Spanner in mm 10 13 17 19 22 24 27 30
Torque setting in 6.9 19.6 39.2 58.8 98.1 157.2 196 274
Nm
Socket head Wrench in mm 5 6 8 10 12 14 14 17
screw Torque setting in 8.8 21.6 42.1 78.4 117.6 176.4 245 343
Nm
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INTRODUCTION
Torque ( - A.90.A.10)
CX135SR
SPECIAL TORQUE SETTINGS

No. Component Screw Wrench Tightening torque
diameter in mm
(1)* Travel motor and reduction gear assembly M16 24 267 - 312 Nm
(2)* Sprocket M16 24 267 - 312 Nm
(3)* Idler wheel M16 24 267 - 312 Nm
(4)* Upper roller M16 24 267 - 312 Nm
(5)* Lower roller M16 24 267 - 312 Nm
(6) Shoe M16 24 267 - 312 Nm
(7) Counterweight M30 46 1060 - 1235 Nm
(8) Turntable (chassis) M16 24 267 - 312 Nm
(9) Turntable (upperstructure) M16 24 267 - 312 Nm
(10)* Swing motor and reduction gear assembly M16 24 267 - 312 Nm
(11)* Engine M16 24 265 - 313 Nm
(12)* Engine mounts M10 17 64 - 74 Nm
(13) Radiator M12 19 88 - 111 Nm
(14)* Hydraulic pump M10 17 64 - 74 Nm
M12 Hex 88 - 111 Nm
(15)* Hydraulic reservoir M16 24 232 - 276 Nm
(16)* Fuel tank M16 24 232 - 276 Nm
(17)* Control valve M16 24 267 - 312 Nm
(18)* Hydraulic swivel M12 19 109 - 127 Nm
(19) Cab M16 24 78 - 80 Nm
(20) Batteries M10 17 20 - 29 Nm
Use Loctite 262 or an equivalent on mounting screws for those components marked with an asterisk (*).
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INTRODUCTION
CRIL03L001H01 1
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INTRODUCTION
CRIL03L002H01 2
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INTRODUCTION
Dimension ( - A.92.A.30)
CX135SR
Machine tted with monoblock boom
CRIL03L003G01 1
Item Dippers Item Dippers Item Dippers

2.39 m 2.85 m 2.39 m 2.85 m 2.39 m 2.85 m
(A) 2.75 m 2.60 m (B) 2.75 m (C) 7.24 m 7.23 m
(D) 1.75 m (E) 2.41 m (F) 0.88 m
(G) 1.48 m (H) 3.51 m (I) 2.78 m
(J) 1.99 m (K) 0.60 m (L) 2.59 m
(M) 0.43 m (N) 5.49 m 5.46 m (P) 1.24 m
(Q) 1.17 m
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INTRODUCTION
Machine tted with monoblock boom and dozer blade
CRIL03L004G01 2
Item Dippers Item Dippers Item Dippers

2.39 m 2.85 m 2.39 m 2.85 m 2.39 m 2.85 m
(A) 2.75 m 2.60 m (B) 2.75 m (C) 7.75 m 7.72 m
(D) 2.26 m (E) 2.41 m (F) 0.88 m
(G) 1.48 m (H) 3.51 m (I) 2.78 m
(J) 1.99 m (K) 0.60 m (L) 2.59 m
(M) 0.43 m (N) 5.49 m 5.46 m (P) 1.24 m
(Q) 1.17 m (R) 2.49 m (S) 0.57 m
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INTRODUCTION
Machine tted with backhoe-offset boom and dozer blade
CRIL03L005G01 3
Dippers 2.11 m
(A1) 3.54 m (A2) 2.87 m (B) 2.75 m (C) 7.47 m
(D) 2.26 m (E) 2.41 m (F) 0.88 m (G) 1.48 m
(H) 3.51 m (I) 2.78 m (J) 1.99 m (K) 0.60 m
(L) 2.59 m (M) 0.43 m (N1) 5.27 m (N2) 5.20 m
(P) 1.24 m (Q) 1.17 m (R) 2.49 m (S) 0.57 m
(T) 1.15 m (U) 1.18 m (V) 0.21 m
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INTRODUCTION
Weight ( - A.92.A.40)
CX135SR
Weight of machine
Conguration Weight Ground
pressure
With 600 mm track pads, monobloc boom, 2.40 m dipper, 380 kg backhoe bucket, 13200 kg 0.36 bar
operator and full fuel tank
With 600 mm track pads, monobloc boom, 2.40 m dipper, 380 kg backhoe bucket, 14 100 kg 0.38 bar
operator and full fuel tank
With 600 mm track pads, backhoe-offset boom, 2.10 m dipper, 380 kg backhoe 14 200 kg 0.38 bar
bucket, dozer blade, operator and full fuel tank
Weight of components
Components Mono boom Mono boom Offset
dozer blade backhoe
boom dozer
blade
Engine 363 kg
Hydraulic pump 91 kg 94 kg
Attachment control valve 140 kg 180 kg
Swing motor and reduction gear assembly 103 kg
Travel motor and reduction gear assembly 144 kg
Boom cylinder 121 kg
Dipper cylinder 157 kg
Bucket cylinder 93 kg
Dozer blade cylinder 50 kg
Offset backhoe boom cylinder 71 kg
Counterweight 3330 kg 2770 kg 2780 kg
Cab kg
Turntable 177 kg
Upperstructure assembly 8990 kg 8490 kg 9150 kg
Hydraulic swivel 26 kg 56 kg
Undercarriage assembly 4170 kg 4970 kg
Machine without attachment 11040 kg 11340 kg 11350 kg
Attachment 2140 kg 2770 kg
Boom assembly 1210 kg 1900 kg
Dipper assembly 550 kg 520 kg
Dozer blade 680 kg
Radiator and oil-cooler assembly 55 kg
Fuel tank 62 kg
Hydraulic reservoir 88 kg
Idler wheel 61 kg
Upper roller 16 kg
Lower roller 20 kg
Tension shock absorber 77 kg
Track 500 mm 711 kg
Track 600 mm 793 kg
Track 700 mm 943 kg
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INTRODUCTION
Consumables ( - A.92.A.55)
CX135SR
FLUIDS AND LUBRICANTS

Lubricants must have the correct properties for each application.
ATTENTION: You must respect the operating conditions for the different ingredients.
Hydraulic uid
CASE AKCELA hydraulic uid is specially designed for high pressure applications and for the CASE hydraulic
system.
The type of uid to be used depends on the ambient temperature.
• TEMPERATE COUNTRIES - 20 °C to + 40 °C
CASE AKCELA HYDRAULIC EXCAVATOR FLUID
(MS 1230. ISO VG 46. DIN 51524 PART 2 HV)
• HOT COUNTRIES 0 °C to + 60 °C
CASE AKCELA HYDRAULIC EXCAVATOR FLUID "HOT CLIMATE"
• COLD COUNTRIES - 40 °C to + 20 °C
CASE AKCELA HYDRAULIC EXCAVATOR FLUID "COLD CLIMATE"
• BIODEGRADABLE FLUID - 30 - +40 °C
This yellow uid can be mixed with standard uid.
If this liquid is used, it is advisable to completely drain the hydraulic circuit .
CASE AKCELA HYDRAULIC EXCAVATORS FLUID BIO
Transmission component oil

Extreme pressure oil used in transmission components inside sealed housings.
CASE AKCELA 135H EP GEAR LUBE SAE 80W-90
(SAE 80W-90. API GL 5. MIL-L-2105 D. MS 1316. ZF TE-ML 05A)
Grease
"Extreme Pressure" multi-purpose grease
• CASE AKCELA MOLY GREASE 241H EP-M (251H EP-M NLGI2)
with lithium and molybdenum bisulphide soap.
• CASE AKCELA 251H EP MULTI-PURPOSE GREASE (251H EP. NLGI 2)
with lithium and calcium soap.
• CASE AKCELA PREMIUM GREASE EP-2 (NLGI 2)
with lithium soap.
HYDRAULIC HAMMERS
Use only CASE AKCELA PREMIUM GREASE EP-2 (NLGI 2) grease with lithium soap.
Engine oil
CASE AKCELA NO. 1 ENGINE OIL is recommended for the engine.
This oil provides correct lubrication for your engine in all working conditions.
If CASE AKCELA NO. 1 ENGINE OIL Multigrade cannot be obtained, use oil corresponding to one of the following
categories: ACEA E5. MS 1121. API CH-4.
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INTRODUCTION
CRIL03H015F01 1
OIL USE RANGE
1. Mineral-based
2. Semi-synthetic based
3. Synthetic based
Fuel
Use fuel that is compliant with ASTM (American Society for Testing and Materials) standard D975.
• Use Grade No 2 fuel. The use of other types of fuel can result in a loss of power and may cause high fuel
consumption.
• When the temperature is very cold, the use of a mixture of No 1 and No 2 fuel is permitted. See your fuel
vendor for winter fuel requirements in your area.
• If the temperature falls below the fuel cloud point (point at which wax begins to form) the wax crystals will
cause power loss or will prevent the engine from starting.
IMPORTANT: In cold weather, ll the fuel tank at the end of the day’s work to prevent condensation from forming.
FUEL STORAGE
Long storage can lead to the accumulation of impurities and condensation in the fuel tank. Engine trouble can
often be traced to the presence of water in the fuel.
The storage tank must be placed outside and the temperature of the fuel should be kept as low as possible.
Drain off water and impurities regularly.
Anti-freeze/Anti-corrosion
Use anti-freeze in all seasons to protect the cooling system from corrosion and all risk of freezing.
CASE AKCELA PREMIUM ANTI-FREEZE LRD -25°C
For environments with temperatures falling to - 25 °C, do not mix with water.
CASE AKCELA PREMIUM ANTI-FREEZE (MS 1710)
For environments with temperatures falling to - 38 °C, use with water in a proportion of 50/50.
IMPORTANT: Do not mix products of a different origin or a different make.
The system must be topped up with the same product.
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INTRODUCTION
Environment
Before carrying out any servicing operation on this machine and before disposing of used uids or lubricants, always
think of the environment. Never throw uid or oil on the ground and never keep them in leaking receptacles.
Contact your local ecological recycling centre for information on appropriate ways to dispose of these substances.
Components made from plastic or resin

When cleaning plastic parts, (the console, the instrument panel, the indicators etc...) avoid using petrol, parafn,
paint solvents etc.
Use only water, soap and a soft cloth. The use of petrol, parafn, paint solvents, etc, will cause discoloration,
cracking or deformation of these components.
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INTRODUCTION
Hydraulic contamination ( - A.92.A.60)

CX135SR
CLEANING THE HYDRAULIC SYSTEM
General
Contamination of the hydraulic system is a major cause of incorrect operation of hydraulic components.
Contamination is indicated by the presence of foreign particles in the hydraulic uid.
Contamination of the hydraulic system can occur in any of the following situations:
1. When draining the uid or disconnecting a hydraulic line.
2. When disassembling a component.
3. Due to normal component wear.
4. Due to damaged or worn seals.
5. Due to a damaged component in the hydraulic system.
All hydraulic systems can function even if they are slightly contaminated. The components of the hydraulic system
are designed to support slight contamination. Any increase in the degree of contamination can cause serious
problems in the hydraulic system.
The following is an incomplete list of these problems:

1. The cylinder rod seals leak.
2. Control valve spools do not return to the neutral position.
3. Control valve spools do not move easily.
4. Hydraulic uid is too hot.
5. Hydraulic components wear quickly.
6. Safety valves or check valves do not close due to contamination.
7. Repaired components break down soon.
8. Cycles are slow; the machine does not have enough power.
If any of the above situations occurs, it is an indication of excessive contamination of the hydraulic system.
To eliminate contamination, effectively, refer to PRIMARY HYDRAULIC POWER SYSTEM - Decontaminating
(A.10.A - F.30.A.60).
Types of contamination
Contamination exists basically in two forms: microscopic or visible.
We speak of microscopic contamination when very small particles of foreign bodies are in suspension in the
hydraulic uid. These particles are too small to be seen or felt. Microscopic contamination can be detected by
identifying the problems relating to microscopic contamination or by laboratory tests.
The following are a few examples of problems caused by microscopic contamination:

• The cylinder rod seals leak.
• Control valve spools do not return to the neutral position.
• The operating temperature of the hydraulic system is too high.
• Components wear quickly.
We speak of visible contamination when the presence of foreign bodies can be detected visually, by touch or by
smell. Visible contamination can cause the sudden failure of a component.
The following are a few examples of problems caused by visible contamination:
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INTRODUCTION
• The uid contains metal or other fragments.

• The uid contains air. The uid is dark and thick.
• There is a smell of burning in the uid. The uid contains water.
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INTRODUCTION
Product identication ( - A.80.A.10)

CX135SR WE
NOTE: For all parts orders, requests for information or assistance, always specify the type and the serial number of
the machine to your CASE dealer.
Fill out the following lines with the required information: type, year of manufacture, serial number of the machine
(manufacturer’s plate), mark, type and serial number of the engine, and serial numbers of hydraulic components.
Manufacturer’s plate
CRIL03H001E01 1
(1) TYPE (2) YEAR OF MANUFACTURE (3) SERIAL NUMBER
Engine
MAKE TYPE SERIAL NUMBER
Serial numbers of hydraulic components

COMPONENTS SERIAL NUMBER
Hydraulic pump
Swing reduction gear
Travel reduction gear
Travel control valve
Attachment control valve
Swing control valve
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INTRODUCTION
Product identication ( - A.80.A.10)

CX135SR NA
NOTE: For all parts orders, requests for information or assistance, always specify the type and the serial number of
the machine to your CASE dealer.
Fill out the following lines with the required information: type, year of manufacture, serial number of the machine
(manufacturer’s plate), make, type and serial number of the engine and serial numbers of hydraulic components.
Manufacturer’s plate
CRIL03I175E01 1
(1)TYPE (2)YEAR OF MANUFACTURE (3)SERIAL NUMBER
Engine
MAKE TYPE SERIAL NUMBER
Serial numbers of hydraulic components

COMPONENTS SERIAL NUMBER
Hydraulic pump
Swing reduction gear
Travel reduction gear
Travel control valve
Attachment control valve
Swing control valve
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INTRODUCTION
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REPAIR MANUAL
DISTRIBUTION SYSTEMS
CX135SR
27049 1 14/12/2004
A
Contents
DISTRIBUTION SYSTEMS - A
PRIMARY HYDRAULIC POWER SYSTEM A.10.A

CX135SR
SECONDARY HYDRAULIC POWER SYSTEM A.12.A

CX135SR
HYDRAULIC COMMAND SYSTEM A.14.A

CX135SR
ELECTRICAL POWER SYSTEM A.30.A

CX135SR
LIGHTING SYSTEM A.40.A

CX135SR
27049 1 14/12/2004
A
PRIMARY HYDRAULIC POWER SYSTEM - 10.A
CX135SR
27050 1 14/12/2004
A.10.A / 1
Contents
TECHNICAL DATA
PRIMARY HYDRAULIC POWER SYSTEM - General specication (A.10.A - D.40.A.10) 5
CX135SR

CX135SR
PRIMARY HYDRAULIC POWER SYSTEM - Special tools (A.10.A - D.20.A.40) 9

CX135SR WE

CX135SR NA
PRIMARY HYDRAULIC POWER SYSTEM - Seed rates (A.10.A - D.50.A.60) 13

CX135SR
Hydraulic pump
Hydraulic pump - Special tools (A.10.A.20 - D.20.A.40) 13
CX135SR
Hydraulic pump - Service limits (A.10.A.20 - D.20.A.20) 14

CX135SR
FUNCTIONAL DATA
PRIMARY HYDRAULIC POWER SYSTEM - Static description (A.10.A - C.30.A.20) 15
CX135SR
PRIMARY HYDRAULIC POWER SYSTEM - Dynamic description (A.10.A - C.30.A.10) 16

CX135SR
Stack valve
Stack valve - External view (A.10.A.18 - C.10.A.40) 19
CX135SR
Stack valve - Sectional view (A.10.A.18 - C.10.A.30) 21

CX135SR
Stack valve Inlet section - Sectional view (A.10.A.18.10 - C.10.A.30) 24

CX135SR
Stack valve Outlet section - Sectional view (A.10.A.18.20 - C.10.A.30) 25

CX135SR
Hydraulic pump
Hydraulic pump - Sectional view (A.10.A.20 - C.10.A.30) 27
CX135SR
Hydraulic pump - Exploded view (A.10.A.20 - C.10.A.20) 30

CX135SR
Sensing system
Sensing system Temperature sensor - Electronic schema (A.10.A.95.90 - C.20.A.50) 32
CX135SR
SERVICE
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A.10.A / 2
PRIMARY HYDRAULIC POWER SYSTEM - Warm up (A.10.A - F.35.A.40) 33
CX135SR
PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A - F.35.A.51) 34

CX135SR
PRIMARY HYDRAULIC POWER SYSTEM - Drain uid (A.10.A - F.35.A.20) 35

CX135SR
PRIMARY HYDRAULIC POWER SYSTEM - Bleed (A.10.A - F.35.A.25) 36

CX135SR
PRIMARY HYDRAULIC POWER SYSTEM - Pressure test (A.10.A - F.40.A.30) 37

CX135SR
PRIMARY HYDRAULIC POWER SYSTEM - Decontaminating (A.10.A - F.30.A.60) 39

CX135SR
Stack valve
Stack valve - Remove (A.10.A.18 - F.10.A.10) 41
CX135SR
Stack valve Outlet section - Disassemble (A.10.A.18.20 - F.10.A.25) 42

CX135SR
Stack valve Inlet section - Disassemble (A.10.A.18.10 - F.10.A.25) 44

CX135SR
Stack valve - Visual inspection (A.10.A.18 - F.40.A.10) 45

CX135SR
Stack valve Inlet section - Assemble (A.10.A.18.10 - F.10.A.20) 46

CX135SR
Stack valve Outlet section - Assemble (A.10.A.18.20 - F.10.A.20) 47

CX135SR
Stack valve - Install (A.10.A.18 - F.10.A.15) 49

CX135SR
Relief valve
Relief valve - Disassemble (A.10.A.16 - F.10.A.25) 50
CX135SR
Relief valve - Assemble (A.10.A.16 - F.10.A.20) 51

CX135SR
Relief valve - Pressure setting (A.10.A.16 - F.45.A.70) 52

CX135SR
Hydraulic pump
Hydraulic pump - Remove (A.10.A.20 - F.10.A.10) 53
CX135SR
Hydraulic pump - Disassemble (A.10.A.20 - F.10.A.25) 54

CX135SR
Hydraulic pump - Assemble (A.10.A.20 - F.10.A.20) 58

CX135SR
Hydraulic pump - Install (A.10.A.20 - F.10.A.15) 62

CX135SR
Hydraulic pump - Bleed (A.10.A.20 - F.35.A.25) 63

CX135SR
Hydraulic pump - Pressure test (A.10.A.20 - F.40.A.30) 64

CX135SR
Compensator
Compensator - Disassemble (A.10.A.23 - F.10.A.25) 65
CX135SR
Compensator - Assemble (A.10.A.23 - F.10.A.20) 67

CX135SR
Reservoir
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Reservoir - Remove (A.10.A.22 - F.10.A.10) 69
CX135SR
Reservoir - Install (A.10.A.22 - F.10.A.15) 71

CX135SR
Oil lter
Oil lter - Remove (A.10.A.24 - F.10.A.10) 72
CX135SR
Oil lter - Install (A.10.A.24 - F.10.A.15) 73

CX135SR
Sensing system
Sensing system Temperature sensor - Electrical test (A.10.A.95.90 - F.40.A.50) 74
CX135SR
DIAGNOSTIC
PRIMARY HYDRAULIC POWER SYSTEM - Troubleshooting (A.10.A - G.40.A.10) 75
CX135SR
Stack valve
Stack valve - Troubleshooting (A.10.A.18 - G.40.A.10) 75
CX135SR
Relief valve
Relief valve - Troubleshooting (A.10.A.16 - G.40.A.10) 76
CX135SR
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
PRIMARY HYDRAULIC POWER SYSTEM - General specication

(A.10.A - D.40.A.10)
CX135SR
Capacities
Total hydraulic circuit 125 L
Hydraulic uid reservoir 81 L
Coolant only 7L
Main hydraulic pump

Variable ow twin pump, with axial pistons.
Maximum ow 2 x 117.2 L/min

Displacement 2 x 54.5 cm³
Hydraulic control pump

Fixed ow pump
Maximum ow 21.5 L/min

Displacement 10 cm³
Secondary hydraulic pump

Fixed ow pump
Maximum ow 52 L/min

Displacement 24.9 cm³
Calibration pressure
Pilot circuit main relief valve (± 1 bar) 39 bar
Main relief valve (standard) (± 3 bar) 343 bar
Main relief valve (option) (± 3 bar) 206 bar
Secondary relief valve (boom, dipper and bucket) ( ± 5 bar) 378 bar
Secondary relief valve (swing) (± 4 bar) 280 bar
Secondary relief valve (travel) (± 5 bar) 343 bar
Secondary relief valve (dozer blade) (± 5 bar) 235 bar
Secondary relief valve (backhoe offset) (± 5 bar) 235 bar
Secondary relief valve (boom and dipper) (± 5 bar) 378 bar
Boom cylinder
Barrel diameter 105 mm
Rod diameter 75 mm
Stroke 1120 mm
Dipper cylinder
Rod diameter 80 mm
Stroke 1108 mm
Bucket cylinder
Rod diameter 65 mm
Stroke 881 mm
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Dozer blade cylinder

Rod diameter 70 mm
Stroke 240 mm
Backhoe-offset cylinder
Rod diameter 65 mm
Stroke 863 mm
Cylinder leakage - attachment lowering (without load)

Boom cylinders (rod retraction) 3 mm/ 5 mn
Dipper cylinder (rod extension) 5 mm/ 5 mn
Bucket cylinder (rod extension) 7 mm/ 5 mn
Full (at the end of the attachment) 200 mm/ 5 mn
Control valve
Five-section control valve for dipper, boom acceleration, swing, option and right travel.
Four-section control valve for dipper acceleration, bucket, boom and left travel.
Two-section control valve for dozer blade and backhoe-offset boom.
Load holding relief valve for boom and dipper.
Swing motor
Fixed ow motor with axial pistons.
Automatic disk brakes.
Chassis upperstructure swing speed 13.4 RPM

Working ow 100 L/min
Reduction ratio 19.2
Braking torque 284.7 Nm
Minimum brake release pressure 23 bar
Acceptable motor leakage xx L/min
Travel motor
Two-speed motor with axial pistons.
Automatic disk brake.
Slow speed 3.2 km/h

High speed 5 km/h
Gradeability 70 % (35°)
Tractive effort 11 000 daN
Displacement 52.7/34 cm³
Working ow 117.2 L/min
Reduction ratio 72
Braking torque (excluding reduction gear) 145 Nm
Acceptable motor leakage xx L/min
Attachment
Breakout force 8970 daN
Breakout force (dipper 2.11 m - backhoe-offset) 5950 daN
Breakout force (dipper 2.39 m) 6390 daN
Breakout force (dipper 2.85 m) 5960 daN
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PRIMARY HYDRAULIC POWER SYSTEM - General specication

(A.10.A - D.40.A.10)
CX135SR
CRIL03K035H01 1
Location of secondary relief valves
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Calibration pressure
Item Description Secondary Nominal Pressure For pressure setting
relief pressure with one procedures,
pressure read on the turn of the refer to:
setting machine screw
(or for a
shim*)
Main pump negative pressure 27 bar Hydraulic pump - Pressure
test (A.10.A.20 - F.40.A.30)
Pilot accumulator check Accumulator - Check
(A.14.A.30 - F.40.A.11)
(A) Main relief valve(standard 343 bar to 346 bar 178 bar Relief valve - Pressure setting
pressure) 60 L/min (A.10.A.16 - F.45.A.70)
(B) Boom raising port secondary 378 bar to 391 bar 212 bar Relief valve - Pressure test
relief 20 L/min (H.20.B.16 - F.40.A.30)
(B1) Boom cylinder safety valves 378 bar to 391 bar - Safety valve - Pressure
(B2) secondary relief 20 L/min setting (H.20.B.15 - F.45.A.70)
(C) Boom lowering port secondary 378 bar to 385 bar 212 bar Relief valve - Pressure test
relief 20 L/min (H.20.B.16 - F.40.A.30)
(D) Dipper out port secondary relief 378 bar to 395 bar 212 bar Relief valve - Pressure test
20 L/min (H.25.B.16 - F.40.A.30)
(D1) Dipper cylinder safety valves 378 bar to 395 bar - Safety valve - Pressure
secondary relief 20 L/min setting (H.25.B.15 - F.45.A.70)
(E) Dipper in port secondary relief 378 bar to 393 bar 212 bar Relief valve - Pressure test
20 L/min (H.25.B.16 - F.40.A.30)
(F) Bucket open port secondary 378 bar to 395 bar 212 bar Relief valve - Pressure test
relief 20 L/min (H.30.C.16 - F.40.A.30)
(G) Bucket close port secondary 378 bar to 397 bar 212 bar Relief valve - Pressure test
relief 20 L/min (H.30.C.16 - F.40.A.30)
(H) Pilot circuit main relief 42 bar 39 bar 20 bar Relief valve - Pressure test
(A.14.A.16 - F.40.A.30)
(I) RH swing port secondary relief 280 bar to 285 bar 117 bar Relief valve - Pressure test
78 L/min (F.40.C.16 - F.40.A.30)
(J) LH swing port secondary relief 280 bar to 285 bar 117 bar Relief valve - Pressure test
78 L/min (F.40.C.16 - F.40.A.30)
(K) Forward travel secondary relief 348 bar 348 bar 10 bar* Relief valve - Pressure test
(F.10.F.16 - F.40.A.30)
(L) Reverse travel secondary relief 348 bar 348 bar 10 bar* Relief valve - Pressure test
(F.10.F.16 - F.40.A.30)
(O) Backhoe-offset to the right 275 bar to 230 bar 212 bar Relief valve - Pressure test
secondary relief 20 L/min (H.20.D.16 - F.40.A.30)
(P) Backhoe-offset to the left 216 bar to 188 bar 212 bar Relief valve - Pressure test
secondary relief 20 L/min (H.20.D.16 - F.40.A.30)
(S) Dozer blade and backhoe-offset 206 bar to 215 bar 212 bar Relief valve - Pressure test
main relief 54 L/min (A.12.A.16 - F.40.A.30)
(T) Dozer blade lowering secondary 235 bar to 250 bar 212 bar Relief valve - Pressure test
relief 20 L/min (J.40.F.16 - F.40.A.30)
(U) Dozer blade raising secondary 235 bar to 250 bar 212 bar Relief valve - Pressure test
relief 20 L/min (J.40.F.16 - F.40.A.30)
(W1) Option circuit secondary relief As recom- 212 bar
mended by
manufac-
turer
(W2) Option circuit secondary relief As recom- 212 bar
mended by
manufac-
turer
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PRIMARY HYDRAULIC POWER SYSTEM - Special tools (A.10.A -

D.20.A.40)
CX135SR WE
Digital tester assembly
CRIL03G253E00 1
DESCRIPTION QUANTITY CODE
Tester assembly for Multi-Handy 2051 - E54444449
Multi-Handy 2051 tester 1 D5444448
Pressure sensor (0 bar to 600 bar) 2 V5344460
Straight union for sensor 2 W5344461
Elbow union for sensor 1 X5344462
Engine speed sensor 1 Z5344463
Cable (length 5 m) 3 E3144472
Electric plug 220 volts 50 Hz 1 D5344467
Cigarette lighter cable 1 E5344468
Instruction Sheet 1 -
Carrying case 1 N5344476
The Multi-Handy tester is used to:

Check pressure (two pressure scales)
Check differential pressure (delta P)
Check temperature
Check engine rpm
Check the ow
600 litre turbine
CRIL03G254E00 2
DESCRIPTION QUANTITY CODE
Turbine 1 RE3 Z5344486
Plates M45x2 2 D4323359
Flange diameter 24 mm 2 B8230183
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Semi-ange 4 D4024267
Screw M12 length 75 mm 8 Z1232983
Union assembly for testing pressure and ow
CRIL03G258E00 3
DESCRIPTION CODE
Union assembly for testing pressure and ow CAS30038
Set of high pressure hoses
CRIL03G259E00 4
DESCRIPTION CODE
Set of high pressure hoses CAS30036
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PRIMARY HYDRAULIC POWER SYSTEM - Special tools (A.10.A -

D.20.A.40)
CX135SR NA
Digital tester assembly for pressure measurement
CRIL03G255E00 1
DESCRIPTION CODE
Digital tester assembly for pressure measurement OEM1652
Digital tester assembly for pressure and temperature measurement
CRIL03G256E00 2
DESCRIPTION CODE
Digital tester assembly for pressure and temperature measurement OEM1653
Flowmeter
CRIL03G257E00 3
DESCRIPTION CODE
Flowmeter for a ow of < 75 GPM CAS10280
Flowmeter for a ow of > 75 GPM OEM1240
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Union assembly for testing pressure and ow
CRIL03G258E00 4
DESCRIPTION CODE
Union assembly for testing pressure and ow CAS40023A + CAS40035
Set of high pressure hoses
CRIL03G259E00 5
DESCRIPTION CODE
Set of high pressure hoses CAS30036
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PRIMARY HYDRAULIC POWER SYSTEM - Seed rates (A.10.A -

D.50.A.60)
CX135SR
CRIL03K87F01 1
Main pump ow curve and pressure
• Pump body ow and accumulated pressures for a new pump

• Pressure (P) is equal to two accumulated pressures in the two pump bodies.
• Curve (Pi) gives the main pump ow (1 body) compared with the negative pressure (Pi).
• Curve (q) gives the minimum ow for a pump body (accumulated pressures) (Pi).
Hydraulic pump - Special tools (A.10.A.20 - D.20.A.40)

CX135SR
CRIL03G165E01a 1
Pump bracket (shaft side)
Used to secure the pump in the upright position during pump removal and assembly. To be made locally.
(A) Diameter 150 mm
(B) Diameter 50 - 80 mm
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(C) 65 mm
Hydraulic pump - Service limits (A.10.A.20 - D.20.A.20)

CX135SR
Description of parts Standard Wear limit Action

dimension
Clearance between the piston and 0.039 mm 0.067 mm Replace the cylinder assembly
the cylinder bore
Play between the piston, shoe and 0.1 mm 0.3 mm Replace the piston or the piston
guide wear plate assembly
Shoe thickness 4.9 mm 4.7 mm Replace the pistons
Free height of cylinder block springs 41.1 mm 40.3 mm Replace the springs
Height of the thrust plate and the 12 mm 11 mm Replace the thrust plate and the
spherical bushing spherical bushing
Overhaul dimension of the cylinder block, the valve plate and the swash plate
Valve plate (sliding contact surface) Standard roughness 0.1 Ra or less
Swash plate (at the thrust plate) after grinding
Cylinder block (sliding contact surface) Roughness of the 0.8 Ra
Irregularity of each surface surface at the wear limit
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PRIMARY HYDRAULIC POWER SYSTEM - Static description (A.10.A

- C.30.A.20)
CX135SR
The hydraulic diagram is available as a poster at the end of this manual.

For easier understanding, the same legend is used for components appearing in the hydraulic sections and on
the poster.
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PRIMARY HYDRAULIC POWER SYSTEM - Dynamic description

(A.10.A - C.30.A.10)
CX135SR
TRAVEL
Functions Description Refer to
HIGH SPEED High speed is obtained by changing the travel motors TRAVELLING Travel - Hydraulic
from large displacement to small displacement. schema (F.10.F - C.20.A.20)
When the pressure increases too much, the motors
automatically change to low speed.
LOW SPEED Low speed is obtained when the travel motors are TRAVELLING Travel - Hydraulic
changed to high displacement. schema (F.10.F - C.20.A.20)
STRAIGHT-LINE If you want to use the attachment or the swing during TRAVELLING Travel - Hydraulic
TRAVEL travel, the machine will continue in a straight line without schema (F.10.F - C.20.A.20)
zig-zagging.
SWING
BRAKING When the swing control is in the neutral position, the SWINGING Circular swing -
motor and reduction gear assembly is braked. Hydraulic schema (F.40.C -
When the swing is operated, the motor and reduction C.20.A.20)
gear assembly brake is released.
When the swing control is in the neutral position
and the boom, dipper or bucket is used, the swing
moto-reduction gear assembly brake is released.
The swing is braked 5 seconds after putting the control
into neutral or when the attachment is no longer
operated.
PRIORITY The swing torque is maintained by the priority valve SWINGING Circular swing -
incorporated in the control valve. Hydraulic schema (F.40.C -
When working in a trench, the swing variable priority C.20.A.20)
valve is activated to provide sufcient ow to the dipper.
ANTI-REBOUND This function reduces the number of rebounds when the SWINGING Circular swing -
swing is stopped. Hydraulic schema (F.40.C -
A protective valve is mounted on the swing motor. C.20.A.20)
ATTACHMENT
BOOM LIFTING An internal spool is used to provide two ows when BOOM Lift - Hydraulic schema
raising the boom. (H.20.B - C.20.A.20)
BOOM LOWERING, Boom lowering is made possible by unlocking the load BOOM Lift - Hydraulic schema
LOAD HOLDING holding system which is incorporated in the control valve. (H.20.B - C.20.A.20)
BOOM LOWERING, The acceleration and the ow reduction pressure BOOM Lift - Hydraulic schema
ADDITIONAL information are controlled via the additional supply in (H.20.B - C.20.A.20)
SUPPLY the boom spool and the continuous connection between
the supply and the return.
BOOM LOWERING, The pressure points are controlled by the circuit which BOOM Lift - Hydraulic schema
VIBRATION keeps part of the supply ow for the free passage. This (H.20.B - C.20.A.20)
PREVENTION is used to reduce vibration.
DIPPER OUT An internal spool provides two ows for the dipper. DIPPER Lift - Hydraulic schema
(H.25.B - C.20.A.20)
DIPPER IN, LOAD Dipper in is made possible by unlocking the load holding DIPPER Lift - Hydraulic schema
HOLDING system that is incorporated in the control valve. (H.25.B - C.20.A.20)
DIPPER IN, The additional supply cancellation valve makes DIPPER Lift - Hydraulic schema
ADDITIONAL combined movements quicker. (H.25.B - C.20.A.20)
SUPPLY
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CUSHION VALVE Shocks experienced when the attachment stops moving
are reduced by the cushion valve which incorporates
pilot heating.
BOOM OFFSET A separate circuit (pump and control valve) supplies the BOOM Swing - Hydraulic
offset. schema (H.20.D - C.20.A.20)
BUCKET OPENING ARM TOOL ATTACHMENT Tilt
AND CLOSING - Hydraulic schema (H.30.C -
C.20.A.20)
OPTION 1 An option section incorporated in the control valve can DIGGING Hammer - Hydraulic
be used as a breaker or a grab, for example. schema (J.20.E - C.20.A.20)
OPTION 2 A supplementary two-section control valve is added to DIGGING Hammer - Hydraulic
the main control valve to control a backhoe-offset boom schema (J.20.E - C.20.A.20)
and/or a dozer blade.
OTHERS
DOZER BLADE A separate circuit (pump and control valve) supplies the LANDSCAPING Dozer blade
blade. - Hydraulic schema (J.40.F -
C.20.A.20)
PUMP FLOW Is used to reduce power consumption by decreasing the See following page
REDUCTION INFO pump ow when the machine is not under load or the
controls are in neutral.
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CRIL03J157G01 1
Controls in neutral position
(1) Low pressure pump (2) Pressure limiter
(3) Pressure limiter (4) Calibrated port
(5) Calibrated port (B26) Upper pilot pressure switch
(B27) Travel pilot pressure switch
• In neutral with the engine running, some of the ow from the low pressure pump (1) fed to (PP) is divided by a
calibrated restrictor bridge. One part passes through the two travel spools, and the other passes through all
the other spools before rejoining the general return circuit. When the spools are moved, these circuits will be
locked, which will close upper pilot (B26) and travel pilot (B27) pressure switches.
• Pump outlet (A1) enters (P2) on the control valve, while pump (A2) enters in (P1), passing through the control
valve via the free passages. They are controlled by two pressure limiters (2) and (3) set to 26,7 bar under
27 L/min and two restrictors (4) and (5). Both these pressures are sent to the HP pumps via ports (Pi1)
and (Pi2) to set them at minimum ow.
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Stack valve - External view (A.10.A.18 - C.10.A.40)

CX135SR
CRIL03L043H01 1
Control valve block with options
Description of control valve block

(62) Main relief valve (63) Safety valve
(64) Safety valve (option) (65) Screw
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(66) Screw (67) Screw

(68) Screw (69) Plug assembly
(71) Rod (72) Nut
(73) Rod (74) Nut
(79) Dozer blade and backhoe-offset relief valve (90) Plug assembly
(A-A) Refer to Stack valve - Sectional view (A.10.A.18 - (B-B) Refer to Stack valve - Sectional view
C.10.A.30) (A.10.A.18 - C.10.A.30)
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Stack valve - Sectional view (A.10.A.18 - C.10.A.30)

CX135SR
NOTE: Refer to the functions concerned for sections of the control valve block not described in this chapter.
CRIL03J093F01 1
Section A-A
(1) Timing gear case (2) Spool assembly - RH travel

(3) Spool assembly - option (4) Spool assembly - swing
(5) Boom spool assembly 2 (6) Dipper spool assembly 1
(11) Large cap (12) Seal
(13) Small cap (32) Plug assembly
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CRIL03J092G01 2
Section B-B
(7) Dipper spool assembly 2 (8) Boom spool assembly 1

(9) Bucket spool assembly (10) Straight-line travel spool assembly
(11) Large cap (12) Seal
(13) Small cap (14) Small cap
(15) Large cap (40) Spool assembly - LH travel
(42) Seal (44) Spring
(47) Cap (48) Spool
(61) Outlet plate (62) Main relief valve
(78) Inlet plate - option (83) Backhoe-offset spool assembly
(84) Dozer blade spool assembly
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CRIL03L045F01 3
Other sections
Section Description Refer to

(C-C) Input section Stack valve Inlet section - Sectional view
(A.10.A.18.10 - C.10.A.30)
(D-D) RH travel and straight-line spool section Control valve - Sectional view (F.10.F.14 -
C.10.A.30)
(E-E) Option and LH travel section Control valve - Sectional view (F.10.F.14 -
C.10.A.30)
(F-F) Swing and bucket section Control valve - Sectional view (F.40.C.14 -
C.10.A.30)
Control valve - Sectional view (H.30.C.13 -
C.10.A.30)
(G-G) Boom 1 and 2 section Control valve - Sectional view (H.20.B.14 -
C.10.A.30)
(H-H) Dipper 1 and 2 section Control valve - Sectional view (H.25.B.14 -
C.10.A.30)
(I-I) Output section with swing priority spool, negative Stack valve Outlet section - Sectional view
pressure valves and dipper recycling valve. (A.10.A.18.20 - C.10.A.30)
(J-J) Output section with ow re-injection spool. Stack valve Outlet section - Sectional view
(A.10.A.18.20 - C.10.A.30)
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Stack valve Inlet section - Sectional view (A.10.A.18.10 - C.10.A.30)

CX135SR
CRIL03J089F01 1
(16) Valve
(17) Spring
(18) Seal
(19) Seal
(62) Main relief valve
(69) Plug
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Stack valve Outlet section - Sectional view (A.10.A.18.20 - C.10.A.30)

CX135SR
CRIL03J088F01 1
Section I-I - Swing priority spool, negative pressure valves and dipper recycling valve.
(21) Plug (41) Spool

(42) Seal (43) Spring seat
(44) Spring (45) Spool end
(46) Cap (49) Plug
(50) Seal (51) Spring
(52) Spool assembly (53) Back Up Ring
(54) Seal (55) Negative pressure main relief valve
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CRIL03J104F01 2
Section J-J - Flow re-injection spool

(44) Spring (45) Spool end
(47) Cap (48) Spool
(56) Plug
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Hydraulic pump - Sectional view (A.10.A.20 - C.10.A.30)

CX135SR
CRIL03J050H01 1
(1) Shaft (2) Seal

(3) Cover (4) Seal
(5) Spherical bushing (6) Centring stud
(7) Screw (8) Nut
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(9) Seal Ring (10) Back-up ring

(11) Seal (12) Control piston
(13) Swash plate (14) Control pivot
(15) Seal (16) Seal
(17) Seal (18) Seal Ring
(19) Screw (20) Lifting ring
(21) Cylinder plate (22) Piston
(23) Screw (24) Rear housing
(25) Shaft (26) Rear cylinder block
(27) Centring stud (28) Seal
(29) Main pinion (30) Needle roller bearing
(31) Plug (32) Seal
(33) Intermediate housing (34) Front cylinder block
(35) Plug (36) Seal
(37) Spring (38) Front housing
(39) Thrust plate (40) Piston wear plate
(41) Seal (42) Plug
(43) Front ange (44) Snap ring
(45) Bearing (46) Bushing
(47) Rear ange
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CRIL03K028G01 2
Secondary hydraulic pump coupling
(1) Pinion (2) Bearing

(3) Snap ring (4) Seal
(5) Cover (6) Screw
(7) Snap ring (8) Snap ring
(9) Pin (10) Spacer
(11) Bearing (12) Intermediate pinion
(13) Centring stud (14) Plug
(15) Seal (16) Screw
(17) Power take-off housing
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Hydraulic pump - Exploded view (A.10.A.20 - C.10.A.20)

CX135SR
CRIL03J178H01 1
(1) Screw (2) Hydraulic control pump (3) Seal

(4) Snap ring (5) Bushing (6) Bearing
(7) Bushing (8) Shaft (9) Nut
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(10) Screw (11) Centring stud (12) Seal Ring

(13) Back-up ring (14) Seal (15) Control pivot
(16) Regulator block (17) Seal Ring (18) Back-up ring
(19) Seal (20) Control piston (21) Screw
(22) Rear ange (23) Screw (24) Seal
(25) Rear housing (26) Seal (27) Plug
(28) Swash plate (29) Bushing (30) Piston wear plate
(31) Piston (32) Thrust plate (33) Spherical bushing
(34) Spring (35) Rear cylinder block (36) Cylinder plate
(37) Needle roller bearing (38) Main pinion (39) Seal
(40) Intermediate housing (41) Screw (42) Nut
(43) Lifting ring (44) Screw (45) Needle roller bearing
(46) Cylinder plate (47) Seal (48) Seal
(49) Seal (50) Seal (51) Cover
(52) Screw (53) Centring stud (54) Centring stud
(55) Seal (56) Plug (57) Screw
(58) Secondary hydraulic pump (59) Seal (60) Power take-off
(61) Seal (62) Cover (63) Seal
(64) Centring stud (65) Locking dowel (66) Front housing
(67) Screw
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Sensing system Temperature sensor - Electronic schema

(A.10.A.95.90 - C.20.A.50)
CX135SR
CRIL03K145F01 1
Circuit layout
(1) Coolant temperature indicator (2) Coolant or hydraulic oil overheating indicator
lamp
(3) Audible alarm device (A2) Engine electronic control box
(B1) Coolant solution temperature sensor (B9) Coolant solution temperature sensor
(B10) Hydraulic oil temperature thermo-switch (P1) Instrument panel
CRIL03G094E03 2
Timing diagram
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PRIMARY HYDRAULIC POWER SYSTEM - Warm up (A.10.A -

F.35.A.40)
CX135SR
1. Start the engine. The engine takes 10 to 15 minutes

to warm up.
2. With the engine running at full speed, operate the
bucket and dipper controls in one direction (against
the cylinder stops) for 30 seconds.
3. Actuate the bucket and dipper control in the other
direction (against the cylinder stops) for 30 seconds.
4. Repeat steps 2 and 3 until the hydraulic temperature
reaches 44 - 55 °C.
5. Operate the boom, swing and travel controls in both
directions to warm up all the circuits to 44 - 55 °C.
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PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A -

F.35.A.51)
CX135SR
DANGER
M252A - Hydraulic uid escaping under pressure can have enough force to penetrate the skin. Hydraulic
uid may also infect a minor cut or opening in the skin. If injured by escaping uid, see a doctor at
once. Serious infection or reaction can result if medical treatment is not given immediately. Make sure
all connections are tight and that hoses and lines are in good condition before applying pressure to the
system. Relieve all pressure before disconnecting the lines or performing other work on the hydraulic
system. To nd a leak under pressure use a small piece of cardboard or wood. Never use hands.
IMPORTANT: This operation must be carried out before any work is done on the hydraulic circuit.
1. Park the machine on hard, at ground.
2. Open the bucket until the cylinder rod is completely
retracted.
3. Extend the dipper until the cylinder rod is completely
retracted.
Lower the boom so that the end of the dipper is
resting on the ground.
Lower the tool to the ground.
Lower the dozer blade to the ground
4. Slow the engine speed to idle for 30 seconds, then
switch off the engine.
5. Turn the starter switch key to "ON" without starting
the engine.
6. Lower the pilot control cancellation lever.
7. Operate each control more than 10 times in both
directions to release all pressure in the circuits.
8. Press button (1) located on the hydraulic reservoir
breather to release pressure in the reservoir.
CRIL03J174A01 1
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PRIMARY HYDRAULIC POWER SYSTEM - Drain uid (A.10.A -

F.35.A.20)
CX135SR
Prior operation: PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A - F.35.A.51)

Prior operation: Fuel ller aid - Remove (B.20.A.20 - F.10.A.10)
NOTE: It is recommended to install the vacuum pump before carrying out any work on the hydraulic circuit which
requires opening the circuit.
Installing this pump prevents uid loss when the circuit is opened.
This chapter describes the procedure for installing vacuum pump CAS-10193.
1. Remove plate (A) from the top of the hydraulic
reservoir.
Do not remove the reservoir seal.
CRIL03L075A01 1
2. To install the adapter plate with elbow union, refer

to PRIMARY HYDRAULIC POWER SYSTEM -
Special tools (A.10.A - D.20.A.40).
3. Connect the vacuum pump to the adapter plate
elbow union.
Connect the vacuum pump harness to the batteries.
4. Start the pump before carrying out any work on the
circuit.
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PRIMARY HYDRAULIC POWER SYSTEM - Bleed (A.10.A - F.35.A.25)

CX135SR
IMPORTANT: A hydraulic component and the circuit must be bled after the component has been replaced.
It is essential to ll the pump and motor housings and hydraulic components with oil before starting the machine.
Failure to comply with these two recommendations may damage the component (overheating and seizing).
IMPORTANT: Having bled the components, stop the engine for ve minutes and check for air bubbles in the
hydraulic uid in the reservoir.
1. To ll the housing and drain the hydraulic pump,
refer to Hydraulic pump - Bleed (A.10.A.20 -
F.35.A.25)
2. To bleed the attachment cylinders, extend and
retract each cylinder rod four or ve times without
bringing them up against the stops.
Repeat the operation three or four times, this time
bringing all the cylinder rods up against the stops.
3. To ll the housing and bleed the hydraulic swing
motor, refer to Hydraulic motor - Bleed (F.40.C.28
- F.35.A.25)
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PRIMARY HYDRAULIC POWER SYSTEM - Pressure test (A.10.A -

F.40.A.30)
CX135SR
CRIL03K043F01 1
Port identication marks
Description of ports and location diameters

Port Description Location
(A1) Pump output (P2) SAE 6000 3/4 "
(A2) Pump output (P1) SAE 6000 3/4 "
(A3) Pilot pump output G 1/2
(A4) Option pump output G 1/2
(B1) Main pump intake SAE 2500 2-1/2"
(B3) Pilot pump intake G 3/4
(B4) Option pump intake 1
(Dr1) Leak-off circuit G 1/2
(a1) Plugged - Pressure test point G 1/4
(Pf) Option regulation information G 1/4
(Pi1) Negative pressure G 1/4
(Pi2) Negative pressure G 1/4
27050 1 14/12/2004
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CRIL03K043F02 2
Installation of pressure test points
Pressure test Controlled functions

points
(M1) Working pressure (port (a1) on main pump (A1)
• R.H. travel
• One-piece boom or backhoe-offset boom
• Bucket
(M2) Working pressure (port (a2) on main pump (A2)
• L.H. travel
• Swing
• Dipper
(M3) Pilot pressure (port (a3) on the pilot pump)
(M4) Optional working pressure (port (a4) on the option pump)
• Dozer blade
• Backhoe offset
For pressure setting values, refer to PRIMARY HYDRAULIC POWER SYSTEM - General specication (A.10.A -
D.40.A.10)
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PRIMARY HYDRAULIC POWER SYSTEM - Decontaminating (A.10.A

- F.30.A.60)
CX135SR

Prior operation: To remove the electric pump for lling with fuel, refer to Fuel ller aid - Remove (B.20.A.20
- F.10.A.10)
Prior operation: To remove the protective panel from the hydraulic reservoir, refer to Upper shield - Remove
(E.20.A.71 - F.10.A.10)
Prior operation: To remove the lower access panel to the hydraulic reservoir, refer to Protective shield - Remove
(E.20.A.73 - F.10.A.10)
1. Prepare portable lter CAS10162A as follows:

Expel all hydraulic uid from the portable lter inlet
and outlet hoses.
Remove the portable lter cartridge.
Expel all hydraulic uid from the portable lter.
Clean the interior of the cartridge housing.
Install a new lter cartridge.
CRIL03I082A 1
2. Drain the hydraulic uid from the reservoir and clean

the reservoir, see the Operator’s Manual.
NOTE: Do not re-install the drain plug on the hydraulic
reservoir.
3. Replace the breather element and the return lter
and clean the intake lter, see the Operator’s
Manual.
NOTE: Do not install the plate and the breather.
4. Replace the pilot circuit lter, see the Operator’s
Manual.
5. Replace the Ultra Clean lter, see the Operator’s
Manual.
6. Install the valve from union kit (CAS 10508) on the
reservoir drain port.
Make sure that the valve is closed.
CAS10508-3 2
7. Fill the hydraulic reservoir with clean hydraulic uid,

see the Operator’s Manual.
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8. Install the inlet hose from the portable lter on the

valve under the hydraulic reservoir.
9. Install the long pipe from union kit (CAS 10508) on
the portable lter return hose.
10. Pass the long pipe into the hydraulic reservoir via
the breather port.
Move the intake lter long pipe as far away as
possible.
11. Open the valve under the hydraulic reservoir.
12. Install the portable lter on the upperstructure so
that the machine can be operated.
Attach the portable lter securely to the machine.
13. Connect the portable lter electric cable to the
battery.
Make sure that the electric cable is away from all
moving parts.
14. Start the portable lter.
15. Start the engine, run it at half speed for 10 minutes.
During those ten minutes, stir the hydraulic uid in
the hydraulic reservoir with the long pipe.
16. Bring the hydraulic uid to its operating temperature,
refer to PRIMARY HYDRAULIC POWER SYSTEM
- Warm up (A.10.A - F.35.A.40)
17. With the engine idling, stir the hydraulic uid in the
hydraulic reservoir for 10 minutes with the long pipe.
18. Shut down the portable lter and the engine.
19. Close the valve under the hydraulic reservoir.
20. Remove the inlet pipe from the valve under the
hydraulic reservoir.
21. Remove the long pipe from the hydraulic reservoir.
22. Disconnect the portable lter’s electric cable from
the battery.
Remove the portable lter from the machine.
23. Install a vacuum pump on the hydraulic reservoir,
refer to PRIMARY HYDRAULIC POWER SYSTEM
- Drain uid (A.10.A - F.35.A.20)
Start the vacuum pump.
24. Remove the valve from underneath the reservoir
and install the drain plug.
25. Stop and remove the vacuum pump.
26. Replace the return lter and clean the intake lter,
see the Operator’s Manual.
27. Replace the pilot circuit lter, see the Operator’s
Manual.
28. Replace the Ultra-Clean lter, see the Operator’s
Manual.
29. Check the hydraulic uid level.
Top up as necessary, see the Operator’s Manual.
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Stack valve - Remove (A.10.A.18 - F.10.A.10)

CX135SR
Prior operation: To remove the side protection panels from the hydraulic control valve, refer to Side shield -
Remove (E.20.A.70 - F.10.A.10)
Prior operation: To remove the valve bank hood, the front protection panels from the hydraulic control valve and
the valve bank hood bracket, refer to Upper shield - Remove (E.20.A.71 - F.10.A.10)
Prior operation: PRIMARY HYDRAULIC POWER SYSTEM - Drain uid (A.10.A - F.35.A.20)
1. Mark the position of the hoses (1) and electrical

connectors (2) on control valve block (3).
CRIL03J077B01 1
2. Disconnect the electrical connectors (2) from the

pressure switches.
3. Disconnect and plug hoses (1).
4. Plug the unions on control valve block (3).
5. Attach a lifting device to the control valve block (3).
6. Remove screws and (4) control valve block (3).
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Stack valve Outlet section - Disassemble (A.10.A.18.20 - F.10.A.25)

CX135SR
CRIL03J088G01a 1
Output section - cross-sectional view
1. Remove plugs (21) and (56).

2. Remove negative pressure valves (55) and discard
seals (A) and (B).
NOTE: Valve bodies (55) are installed using a press
(faces (C)). It is impossible to remove the valves without
damaging the body.
CRIL03L050A01 2
3. Remove caps (46) and (47) and discard seals (42).

Remove complete spools (41) and (48).
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4. Remove screws from spool (45).

Remove springs (44) and seats (43).
NOTE: To avoid abrasion of the spool surface during
removal of the spool assembly, use a soft-jawed vice and
clamp the spool as closely as possible to the head (A)
to avoid deformation. If the threaded part of the screw
is coated with locking uid, heat the screw head with an
industrial dryer until it can be removed easily (usually
the temperature should be 200 - 250 °C). If the spring
is damaged (impaired functioning) during this operation,
replace the spring.
CRIL03L053A01 3
5. Remove plug (49) and spring (51).

Discard seal (50).
Remove spool assembly (52).
Remove spool (A) from sleeve (B).
Remove piston (C).
Discard seals (53) and (54).
CRIL03L049A01 4
6. Remove plug (32).

Remove spring (58) and valve (57).
CRIL03L081A01 5
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Stack valve Inlet section - Disassemble (A.10.A.18.10 - F.10.A.25)

CX135SR
CRIL03J089F01 1
Input section - cross-sectional view
1. Remove plugs (69) and discard the seals.

2. Remove plugs (19) and discard the seals (18).
3. Remove springs (17) and check valves (16).
4. Remove main relief valve (62).
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Stack valve - Visual inspection (A.10.A.18 - F.40.A.10)

CX135SR
NOTE: Clean all parts with a suitable light oil based product. Allow to air dry and place each part on a clean sheet
of paper or vinyl for inspection.
NOTE: Inspect the surface of each part for scratches, abrasion and other damage.
1. Check for scratches and dents on the check valve
seats in the control valve body and for traces of rust
and foreign matter.
2. Check for scratches and dents on the outer surface
of the spool. Remove small scratches with a piece
of cloth soaked in an abrasive product.
3. Check that all sliding surfaces move freely. Check
for the absence of foreign matter in passages and
grooves.
4. Check for deformed or worn springs.
5. Replace all seals and backup rings with new original
parts.
6. After removing the caps and plugs, make sure that
there is no trace of paint on the body ports or the
plug rims. (any trace of residual paint might lead
to contamination, which could cause the system to
malfunction and result in possible leaks).
27050 1 14/12/2004
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Stack valve Inlet section - Assemble (A.10.A.18.10 - F.10.A.20)

CX135SR
Prior operation: To clean and check parts before assembling, refer to Stack valve - Visual inspection (A.10.A.18
- F.40.A.10).
CRIL03J089F01 1
Input section - cross-sectional view
Torque settings
Plug (19) 103 - 113 Nm
Valve (62) 78 - 88 Nm
Plug (69) 116 - 128 Nm
1. Install plugs (69) with new seals.
2. Install springs (17) and check valves (16).
3. Install plugs (19) with new seals (18).
4. Install the main relief valve (62).
5. Tighten the plugs and the valve to the required
torque.
27050 1 14/12/2004
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Stack valve Outlet section - Assemble (A.10.A.18.20 - F.10.A.20)

CX135SR
- F.40.A.10).
CRIL03J088G01a 1
Output section - cross-sectional view
Torque settings
Plug (21) 13.5 - 16.5 Nm Plug (32) 73 - 79 Nm
Screw (45) 19 - 22 Nm Plug (49) 103 - 113 Nm
Valves (55) 103 - 113 Nm Cap screws (46) and (47) 8.8 - 10.5 Nm
27050 1 14/12/2004
A.10.A / 47
1. Install spring (58) and check valve (57).

Install and tighten plug (32) to the required torque.
CRIL03L081A01 2
2. Install and tighten plugs (21) and (56) to the required

torque.
3. Install new seals on negative pressure valves (55).
Install and tighten the valves to the required torque.
4. Coat the threaded parts of spools (41) and (48) with
locking uid.
Place the ends (A) of the spools in a soft-jawed vice.
Install springs (44) and seats (43) on screws (45).
Assemble and tighten the screws to the required
torque.
CRIL03L053A01 3
5. Install complete spools (41) and (48).

Install caps (46) and (47) with new seals (42).
Tighten the cap screws to the required torque.
6. Install new seals (53) and (54) on sleeve (B).
Install piston (C) and spool (A) in the sleeve (B).
Install spool assembly (52).
Install spring (51).
Install plug (49) with a new seal (50).
Tighten the plug to the required torque.
CRIL03L049A01 4
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Stack valve - Install (A.10.A.18 - F.10.A.15)

CX135SR
1. Using a lifting device, position control valve block

(3) on the bracket.
CRIL03J077B01 1
2. Install and tighten screws (4) and remove the lifting

device.
Tighten screws (4) to torque 267 - 312 Nm.
3. Install and tighten supply and pilot hoses (1) on
control valve block (3), following the marks made
during removal.
4. Connect electrical connectors (2) to the pressure
switches following the marks made during removal.
27050 1 14/12/2004
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Relief valve - Disassemble (A.10.A.16 - F.10.A.25)

CX135SR
1. Remove the nut (1), the washer (2) and the screw
(3) and discard the seal (4).
CRIL03G175B01 1
2. Remove the spring (5) and the valve (6).

3. Extract the valve tip (8), remove the valve (9) and
the spring (10).
4. Remove and discard the seals (11) and (12).
NOTE: The valve seat (13) cannot be removed.
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A.10.A / 50
Relief valve - Assemble (A.10.A.16 - F.10.A.20)

CX135SR
1. Install the valve (1) in the valve tip (2).
CRIL03G175B02 1
2. Put spring (3) in place.

Install the seals (4) and (5) on the valve seat (6).
3. Install the valve assembly (2) on the valve seat (6).
4. Put the valve (7) and the spring (8) in place in the
body (9).
5. Fit a seal (10) to the screw (11).
6. Tighten the screw (11) a few turns to allow the
washer (12) to be put in place.
7. Engage the nut (13) without locking it, it will
be tightened fully when the main relief valve is
calibrated to a torque of 27-31 Nm.
27050 1 14/12/2004
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Relief valve - Pressure setting (A.10.A.16 - F.45.A.70)

CX135SR
Prior operation: PRIMARY HYDRAULIC POWER SYSTEM - Warm up (A.10.A - F.35.A.40)

Prior operation: Check the pressure on pilot valve (H) and adjust it if necessary, refer to Relief valve - Pressure
setting (A.14.A.16 - F.45.A.70)
1. CHECKING THE MAIN RELIEF VALVE (A)

Connect a 0 - 600 bar (0-60 MPa) pressure gauge
to the pressure test point (M1).
2. With the engine at full speed, operate the dipper
retraction control (as far as the cylinder stop) and
hold it in this position.
Read the pressure gauge: the reading should be
343 ± 2 bar (34,3 ± 0,2 MPa).
3. ADJUSTING THE MAIN RELIEF VALVE (A)
Using a wrench, hold adjusting screw (1) in position
and loosen lock nut (2).
CRIL03G175B03 1
4. Start the engine and run it at maximum speed.

5. Operate the dipper retraction control (cylinder stop)
and hold it in this position.
6. Turn adjusting screw (1) until standard pressure is
reached.
Tighten screw (1) to increase the pressure.
Loosen screw (1) to reduce the pressure.
7. Using a wrench, hold adjusting screw (1) in position
and tighten lock nut (2).
8. Check the pressure again. If the required pressure
has not been reached, repeat instructions 3 to 7.
9. Shut down the engine.
10. Disconnect the pressure gauge.
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Hydraulic pump - Remove (A.10.A.20 - F.10.A.10)

CX135SR
Prior operation: Rear ballasting - Remove (F.20.B.61 - F.10.A.10)
Prior operation: Silencer - Remove (B.40.A.36 - F.10.A.10)
1. Remove and plug suction pipe (1) on main pump (2).
Mark, disconnect and plug all hoses connected to

the main pump, the secondary pump and the control
pump.
CRIL03J132A01 1
2. Install suitable lifting apparatus on the lifting rings of

the main pump (1).
Remove screws (2) that x pump assembly (1) to
ange (3).
NOTE: Do not leave any slack so that the lifting device

supports pump assembly (1) immediately it is removed.
CRIL03J133A01 2
3. Gently pull pump assembly (1) horizontally away

from the ange and the exible coupling secured to
the engine ywheel. Remove the pump assembly
(1) onto a clean bench.
Next operation: To remove the secondary hydraulic pump, refer to Hydraulic pump - Remove (A.12.A.20
- F.10.A.10)
Next operation: To remove the hydraulic control pump, refer to Hydraulic pump - Remove (A.14.A.20 - F.10.A.10)
27050 1 14/12/2004
A.10.A / 53
Hydraulic pump - Disassemble (A.10.A.20 - F.10.A.25)

CX135SR
NOTE: Make identication marks.

Do not mix the parts of the front and rear pumps.
1. Remove the retaining screws from regulator block
(1) and remove it.
CRIL03J055A01 1
2. Place the pump on a table, with the regulators

facing downwards. Remove the retaining screws
and remove front pump body (1).
Remove the cylinder block plate.
Remove the main pinion.
CRIL03J056A01 2
3. Remove the cylinder block assembly (1), the

spherical bushing, the thrust springs and the piston
plate.
NOTE: Do not loosen the control piston stop screws, the
front and rear anges or the intermediate housing, as this
would alter the ow.
CRIL03J057A01 3
27050 1 14/12/2004
A.10.A / 54
4. Remove xing screws from (1) cover (2). Install

two screws in extraction holes (3). Protect the shaft
splines (4) with adhesive tape.
Remove cover (2).
Discard the seals.
CRIL03J058A01 4
5. Remove front ange (1) by tapping it gently with a

plastic mallet.
Discard the seal.
CRIL03J059A01 5
6. Remove swash plate (1) from pump housing (2).
CRIL03J060A01 6
7. Remove shaft (1) from ange (2) using a plastic

mallet.
CRIL03J061A01 7
27050 1 14/12/2004
A.10.A / 55
8. Remove seal plates (1) and (2).

Discard seals (3) and (4).
Force blocking pin (5) out of control pivot (6).
Remove control pivot (6).
Remove control piston (7).
NOTE: The control pivot (6) is installed using Loctite.
CRIL03J069A01 8
9. Remove snap ring (1).

Remove shim (2) and push out shaft (3).
Remove bearing (4) and shim (5).
Proceed in the same manner to remove the other
pump body.
CRIL03J070B01 9
10. Remove the retaining screws and extract power

take-off housing (1) from low pressure pump.
CRIL03J158A01 10
27050 1 14/12/2004
A.10.A / 56
11. Remove the snap ring, push out the shaft and
remove intermediate pinion (1).
Remove the two shims.
CRIL03J159A01 11
12. Remove the snap ring, push out the bearing

assembly and remove secondary pinion (1).
CRIL03J160A01 12
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Hydraulic pump - Assemble (A.10.A.20 - F.10.A.20)

CX135SR
1. Install control piston (7) and control pivot (6) in the

housing, coat the part of the control piston in contact
with the control pivot with light Loctite.
Position the pivot so as to install locking pin (5) and
wipe off the excess Loctite.
Lubricate control piston (7) and its housing, t new
seals on seal plates (1) and (2) and install them in
the housing.
CRIL03J069A01 1
2. Install a seal on ange (1).

Install ange (1) on housing (2), following the marks
made during removal.
CRIL03J094A01 2
3. Place pump housing (1) with the regulator side

facing downwards.
Coat the swash plate bearings (2) with grease and
engage the plate housing in the control pivot.
Check that swash plate (2) is fully home against
housing bearings (1).
Ensure that swash plate (2) can move freely by
pressing on each side with the ngers of both hands.
CRIL03J095A01 3
27050 1 14/12/2004
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4. Install shim (1) on shaft (2). Heat bearing (3) to 80°

in an oven.
Install bearing (3) on shaft (2) using heat protective
gloves.
Install shim (5).
Install snap ring (6).
NOTE: The bearing locking shim (4) is oriented towards
the shaft splines. Adjust bearing (3) correctly.
CRIL03J096B01 4
5. Install tted shaft (1) in ange (2) while supporting

the swash plate. Tap with a plastic mallet.
CRIL03J097A01 5
6. Grease the cover seal (1) Install cover (1) taking

care not to damage the seal on the splines of shaft
(2).
Install screws (3) and tighten them to torque 12 Nm.
CRIL03J098A01 6
27050 1 14/12/2004
A.10.A / 59
7. Install the springs, the spherical bushing, the

pistons complete with the thrust ring on the cylinder
block. Install the piston plate on the swash plate.
Install cylinder block assembly (1) in housing (2) by
engaging the splines of the spherical bushing and
the cylinder block on shaft (3).
CRIL03J099A01 7
8. Install new needle bearings (1) in intermediate

housing (2). Using grease, stick cylinder plate (3)
onto intermediate housing (2) by adjusting it so that
the retaining pin is engaged in the plate housing.
Install a seal (4).
Position the intermediate housing on the pump body
following the marks made during removal.
CRIL03J100A01 8
9. Install screws (1) and tighten them to torque 240

Nm. Install the coupling pinion in the intermediate
housing.
Proceed in the same manner to install the second
pump body.
CRIL03J101A01 9
10. Position pinion (1) complete with two bearings on

the power take-off housing, install the assembly
under a press and push in up to the end stop.
Install the snap ring.
CRIL03J160A01 10
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11. Install intermediate pinion (1) complete with bearing

(2).
Install a shim on each side of the pinion. Install
shaft (boom).
Install the snap ring.
CRIL03J159A02 11
12. Install a seal on the intermediate housing of the

main hydraulic pump.
Install power take-off housing (1).
Install screws and tighten them to torque 33,3 Nm.
CRIL03J158A01 12
13. Install seal (1) on regulator block (2).

Align control level (3) with control pivot shaft (4) and
install the regulator block (2).
Install the retaining screws and tighten them to
torque 29,4 Nm.
NOTE: Proceed in the same manner to assemble the
second regulator block.
CRIL03J055A02 13
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Hydraulic pump - Install (A.10.A.20 - F.10.A.15)

CX135SR
Prior operation: To install the secondary hydraulic pump, refer to Hydraulic pump - Install (A.12.A.20 - F.10.A.15)
Prior operation: To install the hydraulic control pump, refer to Hydraulic pump - Install (A.14.A.20 - F.10.A.15)
1. Using a sling and a suitable lifting device, gently

raise pump assembly (1) horizontally onto ange
(3) and the exible coupling secured to the engine
ywheel.
Install the screws (2) that the x pump assembly
(1) to the ange (3).
Apply locking uid to retaining screws (2) and
tighten to a torque of 64 - 74 Nm
CRIL03J133A01 1
2. Install inlet pipe (1) on main pump (2).

Reconnect all the hoses connected to the main
pump, the secondary pump and the control pump
CRIL03J132A01 2
Next operation: Silencer - Install (B.40.A.36 - F.10.A.15)

Next operation: Rear ballasting - Install (F.20.B.61 - F.10.A.15)
Next operation: PRIMARY HYDRAULIC POWER SYSTEM - Bleed (A.10.A - F.35.A.25)
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Hydraulic pump - Bleed (A.10.A.20 - F.35.A.25)

CX135SR
IMPORTANT: After bleeding the components, shut down the engine for ve minutes, then check for the absence
of air bubbles in the hydraulic uid in the reservoir.
1. Start the engine in idle mode.
Gradually loosen hose (1) retighten it as soon as
uid ows out without air bubbles.
Check the reservoir level and top up as necessary.
CRIL03K048A02 1
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Hydraulic pump - Pressure test (A.10.A.20 - F.40.A.30)

CX135SR
1. NEGATIVE PRESSURE CHECK

Install a T-piece equipped with a pressure test tting
between port (Pi2) on the primary pump and the
negative pressure hose (1).
Connect the pressure controller or a 0 - 25 bar
pressure gauge to the pressure test tting.
Start the engine and run it at maximum speed.
The reading on the pressure gauge should be 27
bar (2.7 MPa).
CRIL03K048A01 1
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Compensator - Disassemble (A.10.A.23 - F.10.A.25)

CX135SR
NOTE: Cover (1) comprises regulating screws (2) and (3), pushrod (4), lock nut (5), adjusting screw (6) and nut
(7). Do not loosen these screws and nuts, failure to comply with this instruction will cause maladjustment of
pressure and ow.
CRIL03J118G01 1
1. Remove screws (15) and cover (1).

Remove outer spring (8), inner spring (9) and spring seat (10) from the compensation section.
2. Remove outer spring (11), spring (12) and spring seat (13).
3. Remove screws (14) and (15), remove cover (16) and spring (17). Remove snap ring (18), spring seat (19), spring (20) and
sleeve (21) and remove outer snap ring (22) from sleeve (21).
4. Remove snap rings (23) and (24), support plug (25) and adjustment plug (26).
5. Remove side lever (27) without removing shaft (28).
6. Remove shaft (29).
Mark and remove control lever (30).
7. Remove side lever (31) without removing shaft (32).
8. Remove pilot piston (33) and spool (34).
9. Remove sleeve (35) by pushing compensating rod (37) to the opposite side.
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10. Remove and discard the seals.
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Compensator - Assemble (A.10.A.23 - F.10.A.20)

CX135SR
CRIL03J117G01 1
1. Press shaft (28) into housing (38).

2. Press shaft (32) into lever (31).
3. Install compensating rod (37) in the housing (38).
4. Install lever (31) on the pin (28) by engaging shaft (32) in the groove of compensating rod (37).
5. Install snap ring (22) on sleeve (21), oil and install the spool (34) in sleeve (21), install the assembly in housing (38) in port
(A), refer to Compensator - Disassemble (A.10.A.23 - F.10.A.25) by adjusting spool (34).
Check that the sleeve and the spool are sliding freely.
6. Install control lever (30) tted with its pin (40) following the markings made during removal.
Align the bores of lever (30) and spool (34) and install pin (29).
7. Install pilot spool (33) in (C), refer to Compensator - Disassemble (A.10.A.23 - F.10.A.25) in housing (38).
8. Install lever (27) by engaging shaft (28) in the groove on the spool (33).
9. Install drain plug (25) equipped with shaft (39) in housing (38).
Position lever (27) correctly so that shaft (39) engages in the lever port (27), then install snap ring (23).
10. Install plug (26) and snap ring (24).
11. Install spring (20), spring seat (19) on the spool (34) and install snap ring (18).
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12. Install spring (17).

13. Install compensating piston (36), sleeve (35), spacer (41) and piston (42) in port (B), refer to Compensator - Disassemble
(A.10.A.23 - F.10.A.25).
14. Install cover (16) and tighten screws (14).
15. Install spring seat (13), spring (12) and spring guide (11) in the housing in (E), refer to Compensator - Disassemble
(A.10.A.23 - F.10.A.25).
16. Install spring seat (10), inner spring (9) and outer spring (8) in the housing in (D), refer to Compensator - Disassemble
(A.10.A.23 - F.10.A.25).
17. Install cover (1) tted with adjusting screws (2), (3) and (6), push rod (4), lock nuts (5) and (7).
18. Install and tighten retaining screws (15).
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Reservoir - Remove (A.10.A.22 - F.10.A.10)

CX135SR
Prior operation: To remove the protective panel from the reservoir, refer to Upper shield - Remove (E.20.A.71
- F.10.A.10)
Prior operation: To remove the electric pump for lling with fuel, refer to Fuel ller aid - Remove (B.20.A.20
- F.10.A.10)
Prior operation: To remove the right guard, refer to Side shield - Remove (E.20.A.70 - F.10.A.10)
Prior operation: To remove the lower access panel to the hydraulic reservoir, refer to Protective shield - Remove
(E.20.A.73 - F.10.A.10)
Prior operation: To release pressure from the hydraulic circuit, refer to PRIMARY HYDRAULIC POWER SYSTEM
- Depressurising (A.10.A - F.35.A.51)
1. Using a suitably-sized container, drain the hydraulic

reservoir, by removing plug (B).
Re-insert and tighten plug (B).
CRIL03J176A01 1
2. Remove engine stop (1) with its bracket and put it

to one side.
Remove accumulator (2) with its bracket and put
it to one side.
CRIL03J177A01 2
3. Attach identication labels and remove the hoses

and hydraulic hoses.
Remove connectors.
Plug the ports and hoses.
4. Remove xing screws (A) from beneath the
Label and remove the adjusting shims located
beneath the hydraulic reservoir.
NOTE: Check that the hydraulic reservoir is free at the
clamping point.
CRIL03J176A02 3
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5. Install lifting rings on the hydraulic reservoir.

Using a sling and a lifting device, carefully remove
the hydraulic reservoir from the machine.
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Reservoir - Install (A.10.A.22 - F.10.A.15)

CX135SR
1. Using a sling and a lifting device, carefully position

the hydraulic reservoir on the machine.
Remove the lifting rings.
Install the adjusting shims beneath the hydraulic
reservoir in accordance with the marks made during
removal.
Install the washers on screws (A) coat with locking
uid and tighten to torque 232,4 - 276 Nm
CRIL03J176A02 1
2. Install and tighten the connectors on the hydraulic

reservoir.
Install the hydraulic hoses in accordance with the
marks made during removal.
3. Install the accumulator (2) on the hydraulic reservoir.
Install the engine stop (1) on the hydraulic reservoir.
CRIL03J177A01 2
4. Fill the hydraulic reservoir.

Check for leaks.
Next operation: To bleed the hydraulic circuit, refer to PRIMARY HYDRAULIC POWER SYSTEM - Bleed (A.10.A
- F.35.A.25)
Next operation: To install the lower access panel to the hydraulic reservoir, refer to Protective shield - Remove
(E.20.A.73 - F.10.A.10)
Next operation: To install the right-hand guard, refer to Side shield - Remove (E.20.A.70 - F.10.A.10)
Next operation: To install the upper guard, refer to Upper shield - Remove (E.20.A.71 - F.10.A.10)
Next operation: To install the electric pump for the fuel, refer to Fuel ller aid - Install (B.20.A.20 - F.10.A.15)
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Oil lter - Remove (A.10.A.24 - F.10.A.10)

CX135SR
Prior operation: To remove side guard (5) from the control valve , refer to Side shield - Remove (E.20.A.70
- F.10.A.10)
Prior operation: To remove upper guard (2) from the oil lter, refer to Upper shield - Remove (E.20.A.71
- F.10.A.10)
1. Mark, disconnect and plug hoses (1) and (2).

Plug the lter ports (3).
Remove bracket xings followed by lter (3).
CRIL03L051A01 1
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Oil lter - Install (A.10.A.24 - F.10.A.15)

CX135SR
1. Place lter (3) on its bracket.

Install the lter and bracket assembly and tighten
the screws.
Remove plugs and hoses (1) and (2).
Remove plugs from lter ports.
Install and tighten hoses (1) and (2) following marks
CRIL03L051A01 1
Next operation: To install side guard (5) on the control valve , refer to Side shield - Remove (E.20.A.70 - F.10.A.10)
Next operation: To install the upper guard (2) on the oil lter, refer to Upper shield - Remove (E.20.A.71
- F.10.A.10)
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Sensing system Temperature sensor - Electrical test (A.10.A.95.90 -

F.40.A.50)
CX135SR
1. Disconnect connector (1) from thermo-switch (B10).
CRIL03K190A01 1
2. Remove thermo-switch (B10).

3. Connect the appropriate electrical test connector (3)
to connector (1) on thermo-switch (B10) then install
multimeter (4), refer to ELECTRICAL POWER
SYSTEM - Special tools (A.30.A - D.20.A.40).
CRIL03I081A01 2
4. Install thermo-switch (B10) in a container of water

(2) and place everything on tripod (6).
5. Using a spirit lamp (7), gradually heat the water in
container (2).
6. Using multimeter (4), check the contact position
on thermo-switch (B10) against the temperature
reading on the thermometer (1), refer to
ELECTRICAL POWER SYSTEM - General
specication (A.30.A - D.40.A.10).
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PRIMARY HYDRAULIC POWER SYSTEM - Troubleshooting (A.10.A

- G.40.A.10)
CX135SR
NOTE: This table summarises the main symptoms relating to the hydraulic circuit in general.
Problem Possible Cause Correction
The hydraulic system Oil level in reservoir too low Rell the tank
is not operating or is
operating incorrectly.
Insufcient pilot pressure Refer to HYDRAULIC COMMAND
SYSTEM - Troubleshooting (A.14.A -
G.40.A.10)
Pump faulty Check the pressures
Test the pump
Main relief valve faulty Refer to Relief valve - Troubleshooting
(A.10.A.16 - G.40.A.10)
Cylinder faulty Check for leaks, traces of aking or
scratches on the cylinder rods.
Pump charge pressure too high Check the pressure
Valves or control valve cracked Replace cracked components
Spool stroke incomplete Refer to Stack valve - Troubleshooting
(A.10.A.18 - G.40.A.10)
Filter clogged in the circuit Clean and replace lters
Blockage in the system Locate and remove the cause of the
blockage
Stack valve - Troubleshooting (A.10.A.18 - G.40.A.10)

CX135SR
NOTE: This table summarises the main symptoms relating to the control valve block in general.
The spool does not move Abnormal rise in oil temperature (ow is Eliminate the cause of the ow resistance
encountering resistance in the lines)
Contaminated hydraulic oil Clean the circuit and replace the hydraulic
oil
Lines with over-tightened port unions Loosen and retighten the unions to the
required torque
Control valve body deformed during Loosen the xing screws and inspect
installation
Excessive pressure Check the inlet (pump side) and supply
pressures
Spool not straight Replace the control valve assembly
Return spring damaged Replace the spring
Spring or cap deformed Loosen the cap xing screws and retighten
them to the required torque
Uneven temperature distribution in the Warm up the oil by operating all the
control valve controls
Control valve obstructed by oil pollution Clean out the control valve and the
hydraulic circuit
Insufcient pilot pressure Check the pilot circuit main relief valve
Does not hold the load Oil leak in the spool Check the spool
Leak in the main relief valve Remove the valve and clean the seats of
the valve and the control valve
Leak in the load holding valve Remove the valve and clean the seats,
replacing them if necessary
Leak in the cylinder Check that the cylinder rings are not
leaking
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Charge drops when Contaminated check valve Remove and clean the valve
moving from neutral to
the Raise position
Damaged check valve or seat Replace the valve or repair the valve and
its seat.
Relief valve - Troubleshooting (A.10.A.16 - G.40.A.10)

CX135SR
NOTE: This table summarises the main symptoms relating to the valve block.
No rise in pressure Main valve, sleeve or pilot valve jammed Replace the valve
open or contamination of seat
Pressure is unstable The pilot valve seat is damaged Replace the valve
Piston or main valve seized Replace the valve
Pressure is incorrect Seat worn by contamination Replace the valve
Lock nut on adjusting device is loose Set and tighten the nut again correctly
Oil leak Damaged valve seat Replace the valve
Components seized by contamination Replace the valve
Damaged seals Replace the seals
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Index

Compensator - Assemble (A.10.A.23 - F.10.A.20) 67
CX135SR
Compensator - Disassemble (A.10.A.23 - F.10.A.25) 65
CX135SR
CX135SR
Hydraulic pump - Bleed (A.10.A.20 - F.35.A.25) 63
CX135SR
CX135SR
CX135SR
CX135SR
Hydraulic pump - Pressure test (A.10.A.20 - F.40.A.30) 64
CX135SR
CX135SR
CX135SR
Hydraulic pump - Service limits (A.10.A.20 - D.20.A.20) 14
CX135SR
Hydraulic pump - Special tools (A.10.A.20 - D.20.A.40) 13
CX135SR
Oil lter - Install (A.10.A.24 - F.10.A.15) 73
CX135SR
Oil lter - Remove (A.10.A.24 - F.10.A.10) 72
CX135SR
PRIMARY HYDRAULIC POWER SYSTEM - Bleed (A.10.A - F.35.A.25) 36
CX135SR
PRIMARY HYDRAULIC POWER SYSTEM - Decontaminating (A.10.A - F.30.A.60) 39
CX135SR
PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A - F.35.A.51) 34
CX135SR
PRIMARY HYDRAULIC POWER SYSTEM - Drain uid (A.10.A - F.35.A.20) 35
CX135SR
PRIMARY HYDRAULIC POWER SYSTEM - Dynamic description (A.10.A - C.30.A.10) 16
CX135SR
CX135SR
CX135SR
PRIMARY HYDRAULIC POWER SYSTEM - Pressure test (A.10.A - F.40.A.30) 37
CX135SR
PRIMARY HYDRAULIC POWER SYSTEM - Seed rates (A.10.A - D.50.A.60) 13
CX135SR
CX135SR WE
CX135SR NA
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PRIMARY HYDRAULIC POWER SYSTEM - Static description (A.10.A - C.30.A.20) 15
CX135SR
PRIMARY HYDRAULIC POWER SYSTEM - Troubleshooting (A.10.A - G.40.A.10) 75
CX135SR
PRIMARY HYDRAULIC POWER SYSTEM - Warm up (A.10.A - F.35.A.40) 33
CX135SR
CX135SR
CX135SR
CX135SR
Relief valve - Troubleshooting (A.10.A.16 - G.40.A.10) 76
CX135SR
Reservoir - Install (A.10.A.22 - F.10.A.15) 71
CX135SR
Reservoir - Remove (A.10.A.22 - F.10.A.10) 69
CX135SR
Sensing system Temperature sensor - Electrical test (A.10.A.95.90 - F.40.A.50) 74
CX135SR
Sensing system Temperature sensor - Electronic schema (A.10.A.95.90 - C.20.A.50) 32
CX135SR
Stack valve - External view (A.10.A.18 - C.10.A.40) 19
CX135SR
Stack valve - Install (A.10.A.18 - F.10.A.15) 49
CX135SR
Stack valve - Remove (A.10.A.18 - F.10.A.10) 41
CX135SR
Stack valve - Sectional view (A.10.A.18 - C.10.A.30) 21
CX135SR
Stack valve - Troubleshooting (A.10.A.18 - G.40.A.10) 75
CX135SR
Stack valve - Visual inspection (A.10.A.18 - F.40.A.10) 45
CX135SR
CX135SR
CX135SR
CX135SR
Stack valve Outlet section - Assemble (A.10.A.18.20 - F.10.A.20) 47
CX135SR
Stack valve Outlet section - Disassemble (A.10.A.18.20 - F.10.A.25) 42
CX135SR
CX135SR
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SECONDARY HYDRAULIC POWER SYSTEM - 12.A
CX135SR
27051 1 14/12/2004
A.12.A / 1
Contents
FUNCTIONAL DATA
Stack valve
CX135SR

CX135SR
Hydraulic pump
CX135SR

CX135SR
SERVICE
Stack valve
Stack valve - Disassemble (A.12.A.18 - F.10.A.25) 7
CX135SR

CX135SR

CX135SR
Stack valve - Assemble (A.12.A.18 - F.10.A.20) 10

CX135SR
Relief valve
CX135SR

CX135SR
Relief valve - Pressure test (A.12.A.16 - F.40.A.30) 13

CX135SR

CX135SR
Hydraulic pump
CX135SR

CX135SR

CX135SR

CX135SR
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A.12.A / 2
DISTRIBUTION SYSTEMS - SECONDARY HYDRAULIC POWER SYSTEM
Stack valve Outlet section - Sectional view (A.12.A.18.20 - C.10.A.30)

CX135SR
CRIL03J090F01 1
(59) Seal
(60) Seal
(61) Outlet section
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A.12.A / 3
Stack valve Inlet section - Sectional view (A.12.A.18.10 - C.10.A.30)

CX135SR
CRIL03J091F01 1
Inlet plate section
(32) Plug
(78) Inlet plate (option)
(79) Main relief valve (option)
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A.12.A / 4
Hydraulic pump - Exploded view (A.12.A.20 - C.10.A.20)

CX135SR
CRIL03J172G01 1
Description
(3) Front seal (4) Bushing
(5) Seal (6) Seal
(7) Flange (8) Drive gear
(9) Driven gear (10) Body
(11) Flange (12) Seal
(13) Seal (14) Bushing
(15) Rear cover (16) Washer
(17) Screw
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A.12.A / 5
Hydraulic pump - Sectional view (A.12.A.20 - C.10.A.30)

CX135SR
CRIL03J173G01 1
Description
(3) Seal (4) Flange
(5) Body (6) Washer
(7) Screw (8) Drive gear
(9) Front seal (10) Bushing
(11) Driven gear (12) Seal
(13) Rear cover
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A.12.A / 6
Stack valve - Disassemble (A.12.A.18 - F.10.A.25)

CX135SR
Prior operation: Stack valve - Remove (A.10.A.18 - F.10.A.10)
1. Remove nuts (1).

Mark the position of the sections and the inlet and
outlet plates.
CRIL03J083B01 1
2. Remove cover plate (2).

3. Remove backhoe-offset section (3).
4. Remove dozer blade section (4).
5. Remove optional inlet plate (5).
6. Discard the section seals.
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A.12.A / 7
Stack valve Inlet section - Disassemble (A.12.A.18.10 - F.10.A.25)

CX135SR
CRIL03J091F01 1
1. Remove plugs (32) and discard the seals.

2. Remove main relief valve (79) from inlet plate (78).
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A.12.A / 8
Stack valve Inlet section - Assemble (A.12.A.18.10 - F.10.A.20)

CX135SR
CRIL03J091F01 1
1. Install and tighten to torque 73 - 79 Nm plugs (32) complete with new seals.
2. Install and tighten to torque 49 - 59 Nm main relief valve (79) on inlet plate (78).
27051 1 14/12/2004
A.12.A / 9
Stack valve - Assemble (A.12.A.18 - F.10.A.20)

CX135SR
Prior operation: Clean and check parts before assembling, refer to Stack valve - Visual inspection (A.10.A.18
- F.40.A.10)
1. Install new seals on the backhoe-offset sections, the

dozer blade section and the inlet and outlet plates.
CRIL03J083B01 1
2. Install optional inlet plate (5) following the marks

3. Install dozer blade section (4).
4. Install backhoe-offset section (3).
5. Install outlet plate (2).
6. Install and tighten to a torque of 89 - 97 Nm nuts (1).
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A.12.A / 10
Relief valve - Disassemble (A.12.A.16 - F.10.A.25)

CX135SR
1. Remove the nut (1), the washer (2) and the screw
(3) and discard the seal (4).
CRIL03G175B01 1
2. Remove the spring (5) and the valve (6).

3. Extract the valve tip (8), remove the valve (9) and
the spring (10).
4. Remove and discard the seals (11) and (12).
NOTE: The valve seat (13) cannot be removed.
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A.12.A / 11
Relief valve - Assemble (A.12.A.16 - F.10.A.20)

CX135SR
1. Install the valve (1) in the valve tip (2).
CRIL03G175B02 1
2. Put spring (3) in place.

Install the seals (4) and (5) on the valve seat (6).
3. Install the valve tip assembly (2) on the valve seat
(6).
4. Put the valve (7) and the spring (8) in place in the
body (9).
5. Fit a seal (10) to the screw (11).
6. Tighten the screw (11) a few turns to allow the
washer (12) to be put in place.
7. Engage the nut (13) without locking it, it will
be tightened fully when the main relief valve is
calibrated.
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A.12.A / 12
Relief valve - Pressure test (A.12.A.16 - F.40.A.30)

CX135SR

Prior operation: To check the pilot pressure and adjust it if necessary, refer to Relief valve - Pressure setting
(A.14.A.16 - F.45.A.70)
1. With the engine switched off, connect a pressure

gauge to the pressure test point. 0 - 600 bar (0-60
MPa) (M4)
2. With the engine at full speed, activate the
backhoe-offset control to the left or the dozer blade
raising control (against cylinder stop) and hold it in
this position.
Read the pressure gauge: the reading should be
206 ± 5 bar (20.6 ± 0.5 MPa).
If the pressure is incorrect, to adjust valve (S) refer
to Relief valve - Pressure setting (A.12.A.16 -
F.45.A.70)
27051 1 14/12/2004
A.12.A / 13

CX135SR
Prior operation: Relief valve - Pressure test (A.12.A.16 - F.40.A.30)

and loosen lock nut (2).
CRIL03G175B03 1

3. Activate the backhoe-offset control to the left or the
dozer blade raising control (against cylinder stop)
and hold it in position.
4. Turn adjusting screw (1) until standard pressure is
reached.
Tighten screw (1) to increase the pressure.
Loosen screw (1) to reduce the pressure.
6. Check the pressure again. If the required pressure
has not been reached, repeat instructions 3 to 5.
27051 1 14/12/2004
A.12.A / 14

CX135SR
1. Open the rear RH side door.

2. Mark, disconnect and plug the hoses on secondary
hydraulic pump (1).
Remove screws (2) and remove secondary
hydraulic pump (1).
CRIL03J045A01 1
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Hydraulic pump - Disassemble (A.12.A.20 - F.10.A.25)

CX135SR
NOTE: Mark each part before disassembling to facilitate reassembly.
CRIL03J173G01 1
1. Place the pump on a clean bench.

2. Remove screws (7) complete with washers (6), then remove the rear cover (13).
3. Remove seal (3) from cover (13).
4. Remove seal (12) from ange (4).
5. Remove bushings (10).
6. Remove body (5).
7. Remove drive gear (8) and driven gear (11).
8. Remove ange (4) and seal (12).
9. Remove bushings (10).
10. Remove seal (3) from cover (9).
12. Remove seal (2).
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Hydraulic pump - Assemble (A.12.A.20 - F.10.A.20)

CX135SR
NOTE: Install the parts following the marks made during removal.
CRIL03J173G01 1
1. Place front cover (9) on a clean bench.

2. Install seal (3) in the groove of front cover (9).
3. Install bushings (10).
4. Install seal (12) on ange (4).
5. Install body (5) complete with ange (4) and seal (12).
6. Install drive gear (8) and driven gear (11).
7. Install rear ange (4) complete with seal (12).
8. Install seal (3) in the groove of rear cover (13).
9. Install cover (13) using washers (6) and screws (7), tighten to torque 88 - 93 Nm
10. Install seal (2) using a suitable centring piece.
27051 1 14/12/2004
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CX135SR
1. Install secondary hydraulic pump (1) on the power

take-off housing on the main hydraulic pump.
Tighten using screws (2).
CRIL03J045A01 1
2. Install the hoses following the marks made during

removal.
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Index

CX135SR
CX135SR
CX135SR
CX135SR
CX135SR
CX135SR
CX135SR
CX135SR
CX135SR
CX135SR
Stack valve - Assemble (A.12.A.18 - F.10.A.20) 10
CX135SR
Stack valve - Disassemble (A.12.A.18 - F.10.A.25) 7
CX135SR
CX135SR
CX135SR
CX135SR
CX135SR
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HYDRAULIC COMMAND SYSTEM - 14.A
CX135SR
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Contents
SERVICE
Relief valve
CX135SR

CX135SR
Hydraulic pump
CX135SR

CX135SR
Accumulator
Accumulator - Check (A.14.A.30 - F.40.A.11) 7
CX135SR
DIAGNOSTIC
HYDRAULIC COMMAND SYSTEM - Troubleshooting (A.14.A - G.40.A.10) 8
CX135SR
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DISTRIBUTION SYSTEMS - HYDRAULIC COMMAND SYSTEM
Relief valve - Pressure test (A.14.A.16 - F.40.A.30)

CX135SR
1. With the engine switched off, connect a 0 - 100 bar

(0 - 10 MPa) pressure gauge to the pressure test
point (M3).
CRIL03K041A01 1
2. With the engine at full speed, move the pilot control

cancellation lever to the low position.
3. With the attachment, swing and travel controls in
neutral, take the reading from the pressure gauge.
The reading should be 39 ± 1 bar (3.9 ± 0.1 MPa).
4. To adjust main relief valve (H) if necessary, refer
to Relief valve - Pressure setting (A.14.A.16 -
F.45.A.70)
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CX135SR
Prior operation: Relief valve - Pressure test (A.14.A.16 - F.40.A.30)
1. Loosen the lock nut and turn valve adjusting screw

(H) until the standard pressure is reached.
Tighten the screw to increase the pressure.
Loosen the screw to reduce the pressure.
2. Tighten the lock nut while holding the adjusting
screw in position.
3. When adjusting screw has been tightened, check
the pressure again and make sure there are no
leaks.
27052 1 14/12/2004
A.14.A / 4

CX135SR
1. Open the rear RH side door.

2. Mark, disconnect and plug hoses (1) and (2).
Remove screws (3) and remove hydraulic control
pump (4).
CRIL03K044A01 1
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A.14.A / 5

CX135SR
1. Install hydraulic control pump (4) on the main

hydraulic pump using screws (3), tighten to a torque
of 12 Nm.
Install hoses (1) and (2) following the marks made
during removal.
CRIL03K044A01 1
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Accumulator - Check (A.14.A.30 - F.40.A.11)

CX135SR
ATTENTION: The accumulator on this machine contains highly pressurized nitrogen gas. If the accumulator system
does not work correctly, replace the accumulator. Do not try to repair the accumulator. Failure to follow these
instructions and the procedure below can cause injury or death.
1. Start the engine.
Raise the boom completely and extend the dipper.
Shut down the engine.
2. Turn the starter switch key to the "ON" position
without starting the engine.
3. Operate the boom lowering or dipper retracting
control several times in succession.
4. The pressure in the accumulator should enable the
boom lowering or dipper retracting function to be
performed about six times.
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HYDRAULIC COMMAND SYSTEM - Troubleshooting (A.14.A -

G.40.A.10)
CX135SR

No movement on any Incorrectly adjusted pilot control Adjust the lever or replace the switch
function cancellation lever or defective electrical
switch
Insufcient pilot pressure at pump outlet Adjust the main relief valve, refer to Relief
valve - Pressure setting (A.14.A.16 -
F.45.A.70)
Insufcient pilot pressure at solenoid valve Test the electrical circuit, refer to Hydraulic
outlet lock-out Electrovalve - Electrical test
(E.50.B.13.10 - F.40.A.50)
Repair or replace the faulty components
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Index

Accumulator - Check (A.14.A.30 - F.40.A.11) 7
CX135SR
HYDRAULIC COMMAND SYSTEM - Troubleshooting (A.14.A - G.40.A.10) 8
CX135SR
CX135SR
CX135SR
CX135SR
CX135SR
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ELECTRICAL POWER SYSTEM - 30.A
CX135SR
27053 1 14/12/2004
A.30.A / 1
Contents
TECHNICAL DATA
ELECTRICAL POWER SYSTEM - General specication (A.30.A - D.40.A.10) 4
CX135SR
ELECTRICAL POWER SYSTEM - Special tools (A.30.A - D.20.A.40) 5

CX135SR WE

CX135SR NA
Battery
Battery - General specication (A.30.A.83 - D.40.A.10) 16
CX135SR
FUNCTIONAL DATA
ELECTRICAL POWER SYSTEM - Static description (A.30.A - C.30.A.20) 18
CX135SR
ELECTRICAL POWER SYSTEM - Overview (A.30.A - C.10.A.10) 19

CX135SR

CX135SR
Fuse and relay box

Fuse and relay box - Overview (A.30.A.80 - C.10.A.10) 23
CX135SR

CX135SR
Fuse and relay box Fuse - Overview (A.30.A.80.81 - C.10.A.10) 25

CX135SR
Alternator
Alternator - Electronic schema (A.30.A.82 - C.20.A.50) 26
CX135SR
SERVICE
Battery
Battery - Visual inspection (A.30.A.83 - F.40.A.10) 27
CX135SR
Battery - Disconnect (A.30.A.83 - F.10.A.11) 28

CX135SR
Battery - Remove (A.30.A.83 - F.10.A.10) 30

CX135SR
Battery - Check (A.30.A.83 - F.40.A.11) 31

CX135SR
Battery - Charging (A.30.A.83 - F.60.A.30) 32

CX135SR
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Battery - Overhaul (A.30.A.83 - F.10.A.40) 33
CX135SR
Battery - Install (A.30.A.83 - F.10.A.15) 34

CX135SR
Battery - Connect (A.30.A.83 - F.10.A.16) 35

CX135SR
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DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM
ELECTRICAL POWER SYSTEM - General specication (A.30.A -

D.40.A.10)
CX135SR
General voltage of electrical system: 24 volts, negative earth
Battery
Number of batteries 2
Voltage for each battery 12 volts
Rated capacity 64 Ah
Reserve 160 min
Cold starting capacity at 17 °C 800 amps
Load for load control 400 amps
Starter motor
Voltage 24 volts
Power 4.5 kW
Alternator
Built-in voltage regulator, without adjustment
Alternator current 50 amps
Attachment working light and cab working light

Voltage 24 volts
Power 55 watts
Coolant temperature sensor (B1)

Temperature -10 °C 20 °C 80 °C
Resistance measured between wires (75) and (27) 20260 ohms 6004 ohms 8949 ohms
Coolant temperature sensor (B9)

Temperature 50 °C 95 °C 115 °C
Resistance 153.9 ohms 32.3 ohms 18.4 ohms
Hydraulic uid temperature thermo switch (B10)

Contact closed 98 °C
Contact open 91 °C
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ELECTRICAL POWER SYSTEM - Special tools (A.30.A - D.20.A.40)

CX135SR WE
Test electrical connector kit
CRIL03G248E00 1
DESCRIPTION CODE
Test electrical connector kit CAS-30039
CONTENTS OF TEST ELECTRICAL CONNECTOR KIT CAS-30039

Test electrical connector.- not used
CRPH03I027A 2
Test electrical connector.- not used
CRPH03I028A 3
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Test electrical connector for emergency stop motor,

motor side.
CRPH03I029A 4
emergency stop motor harness side.
CRPH03I030A 5
Test electrical connector for solenoid and fuel level
sensor.
CRPH03I031A 6
Test electrical connector for hydraulic pump proportional
valve.
CRPH03I032A 7
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valve.
CRPH03I033A 8
Test electrical connector for pressure switch, pressure
switch side.
CRPH03I034A 9
switch harness side.
CRPH03I035A 10
Test electrical connector for air conditioning compressor
clutch contact switch.
CRPH03I036A 11
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Test electrical connector not used.
CRPH03I037A 12
CRPH03I038A 13
CRPH03I039A 14
CRPH03I040A 15
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Test electrical connector for hydraulic uid temperature

sensor and coolant temperature sensor.
CRPH03I041A 16
Test electrical connector for engine rpm sensor.
CRPH03I042A 17
Test electrical connector for pressure detector.
CRPH03I043A 18
Test electrical connector for electronic acceleration
module (RED4).
CRPH03I044A 19
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module (RED4).
CRPH03I045A 20
module (RED4).
CRPH03I046A 21
Digital multimeter
CRIL03G249E00 22
DESCRIPTION CODE
Digital multimeter CAS-1559
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ELECTRICAL POWER SYSTEM - Special tools (A.30.A - D.20.A.40)

CX135SR NA
Electrical connector test kit
CRIL03G248E00 1
DESCRIPTION CODE
Electrical connector test kit CAS-40041
CONTENTS OF ELECTRICAL CONNECTOR TEST KIT CAS-40041

Test electrical connector-not used.
CRPH03I027A 2
Test electrical connector-not used.
CRPH03I028A 3
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motor side.
CRPH03I029A 4
emergency stop motor harness side.
CRPH03I030A 5
Test electrical connector for solenoid and fuel level
sensor.
CRPH03I031A 6
valve.
CRPH03I032A 7
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valve.
CRPH03I033A 8
switch side.
CRPH03I034A 9
switch harness side.
CRPH03I035A 10
Test electrical connector for air conditioning compressor
clutch contact switch.
CRPH03I036A 11
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CRPH03I037A 12
CRPH03I038A 13
CRPH03I039A 14
CRPH03I040A 15
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Test electrical connector for hydraulic uid temperature

sensor and coolant temperature sensor.
CRPH03I041A 16
Test electrical connector for engine rpm sensor.
CRPH03I042A 17
Test electrical connector for pressure sensor.
CRPH03I043A 18
module (RED4).
CRPH03I044A 19
27053 1 14/12/2004
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module (RED4).
CRPH03I045A 20
module (RED4).
CRPH03I046A 21
Digital multimeter
CRIL03G249E00 22
DESCRIPTION CODE
Digital multimeter OEM-1414
Battery - General specication (A.30.A.83 - D.40.A.10)

CX135SR
Discharge test
Discharge test at -15 °C
Discharge current 300 amps
Discharge time at 6 volts 5.2 minutes
Voltage after testing for 30 seconds 10 volts
Cross-reference table between the acidimeter oat graduations and degrees Baumé at 26°C
Density of the electrolyte below Density of the electrolyte at minimum Normal density of the electrolyte
minimum
Float graduation Degrees Baumé Float graduation Degrees Baumé Float graduation Degrees Baumé
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1100 14 1160 20 1250 29

1110 15 1170 21 1260 30
1120 16 1180 22 1275 31
1130 17 1190 23 1290 32
1140 18 1200 24 1305 33
1150 19 1210 25 1320 34
1220 26 1335 35
1230 27 1350 36
1240 28
16 ° Baumé = 25 % of load
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ELECTRICAL POWER SYSTEM - Static description (A.30.A -

C.30.A.20)
CX135SR
The electrical diagram is available as a poster at the end of this manual.

For easier understanding, the same legend is used for components appearing in the electrical sections and on
the poster.
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ELECTRICAL POWER SYSTEM - Overview (A.30.A - C.10.A.10)

CX135SR
CRIL03K117H01 1
GENERAL LOCATION OF COMPONENTS (OUTSIDE THE CAB)

(A3) Electronic acceleration
(B1) Coolant temperature sensor
(B9) Coolant temperature sensor
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(B10) Hydraulic oil temperature thermo -switch

(B21) Pressure switch for engine oil pressure
(B22) Swing pilot pressure switch
(B26) Upper pilot pressure switch
(B27) Travel pilot pressure switch
(B41) Engine speed detector
(B45) Overload indicator pressure sensor
(B81) Horn
(E2) Working light (attachment)
(E3) Working light (cab)
(F22) Fuse 20 amps; main protection for circuits F11 and F12
(F23) Fuse 65 amps; main protection for circuits F1 to F10 and F13 to F20
(G1) Batteries
(G2) Alternator
(H2) Audible travel alarm (North American model)
(K7) Battery relay
(M1) Starter motor
(M2) Engine emergency stop motor
(M4) Windscreen washer motor
(R1) Glow plugs
(R2) Fuel ow adjustment resistor
(R5) Fuel level sensor
(S52) Air conditioning compressor clutch switch
(X2) Rotating beacon connector
(Y2) Pilot pressure solenoid valve
(Y3) Swing brake solenoid valve
(Y4) 2nd gear solenoid valve
(Y8) Air conditioning compressor magnetic clutch
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ELECTRICAL POWER SYSTEM - Overview (A.30.A - C.10.A.10)

CX135SR
CRIL03G085H01 1
GENERAL LOCATION OF COMPONENTS (INSIDE THE CAB)

(E4) Cab lighting
(E52) Air conditioner
(M3) Windscreen wiper motor
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(P1) Instrument panel

(P6) Air conditioner control panel
(P8) Heater control panel
(R3) Engine throttle control
(S1) Starter switch
(S6) Rotating beacon switch
(S9) Engine emergency stop switch
(S13) Overload indicator switch
(S14) Hammer/grab switch
(S15) Audible warning device switch
(S16) Engine idle switch
(S51) Hydraulic control cancellation lever switch
(X8) Radio connector
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Fuse and relay box - Overview (A.30.A.80 - C.10.A.10)

CX135SR
CRIL03K118F01 1
Main relays and fuses
(1) Battery cables

(F22) Fuse 20 amps; main protection for circuits F11 and F12
(F22) Fuse 65 amps; main protection for circuits F1 to F10 and F13 to F20
(K7) Battery relays
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Fuse and relay box - Overview (A.30.A.80 - C.10.A.10)

CX135SR
CRIL03K119G01 1
Relays, fuses, electronic control box (operator’s compartment)
(1) Memory erasing connector (A2) Engine electronic control box

(A7) Overload indicator electronic control box (F21) Fuse box
(H3) Overload indicator audible alarm device (K1) Engine emergency stop relay
(K2) Glow plug relay (K4) Working light relay
(K5) Rotating beacon relay (K18) Travel gear relay
(K19) Swing brake relay (K20) Windscreen wiper motor relay
(K21) Windscreen washer pump relay (K22) Air conditioning compressor magnetic clutch relay
(K23) Slow air conditioning fan motor relay (K24) Medium air conditioning fan motor relay
(K25) Fast air conditioning fan motor relay (U1) DC-DC converter 24 volts - 12 volts
(X4) Engine test point connector (X11) Overload indicator pressure check connector
(X13) Engine fault code erasing connector (X14) Engine fault code detection connector
27053 1 14/12/2004
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Fuse and relay box Fuse - Overview (A.30.A.80.81 - C.10.A.10)

CX135SR
CRIL03G222F01 1
Secondary fuse box

(1) Spare fuses (F1) 15 amps Engine electronic control box
(F2) 10 amps Main instrument panel lighting and air (F3) 10 amps Travel gear relay
conditioner
(F4) 10 amps Cancellation of hydraulic controls (F5) 10 amps Swing brake relay
(F6) 10 amps Rotating beacon relay (European (F7) 20 amps Fuel ller pump
model)
(F8) 15 amps Engine emergency stop motor (F9) 30 amps Glow plugs
(F10) 10 amps Overload indicator electronic control (F11) 10 amps Memory
box
(F12) 10 amps Starter switch (F13) 20 amps Air conditioning, heating
(F14) 10 amps Travel audible alarm device (North (F15) 15 amps Working lights
American model)
(F16) 15 amps Dual ow hammer/grab option (F17) 10 amps DC-DC converter (24 volts - 12
volts)
(F18) 15 amps Windscreen wiper and washer (F19) 10 amps Horn
(F20) 15 amps Cigarette lighter, adjustable cab seat
compressor
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Alternator - Electronic schema (A.30.A.82 - C.20.A.50)

CX135SR
CRIL03G200E01 1
Circuit layout
(1) Starting (2) Battery charge indicator lamp

(3) Audible alarm device (G2) Alternator
(P1) Instrument panel (S1) Starter switch
CRIL03G201E02a 2
Timing diagram
(A) Starting (B) Test
OPERATION
• When the alternator (L) output voltage falls to 6 volts, battery charge indicator lamp (2) lights up and the
audible alarm device (3) sounds.
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Battery - Visual inspection (A.30.A.83 - F.40.A.10)

CX135SR
DANGER
SA046 - Before you service a battery, always wear face protection, protective gloves and protective clothing.
Battery acid or battery explosion can cause serious injuries.
DANGER
D38-14A - Batteries produce explosive gases. Keep sparks, ame and cigarettes away. Ventilate when
charging or using in enclosed space. Always shield eyes when working near batteries.
1. Check that the battery cables are correctly

connected (tightness, insulation, grease on
terminals) and that the battery terminals are free
of salt.
2. Check the battery retaining bracket, inspecting also
for any damage caused by overtightening of the
bracket.
3. Check the battery tray for impacts and cracks.
4. Check the electrolyte level in each battery cell:
If the battery is "maintenance-free", check the
electrolyte level after every 1000 hours of use or
every 6 months, whichever comes rst.
For other types of battery, check the electrolyte level
after every 250 hours of use.
27053 1 14/12/2004
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Battery - Disconnect (A.30.A.83 - F.10.A.11)

CX135SR
DANGER
DANGER
1. Remove thumb screw (1), washers (2) and

protective mat (3).
DANGER
M145B - When working around storage batteries,
remember that all of the exposed metal parts are
"live". Never lay a metal object across the terminals
because a spark, short circuit, explosion or personal
injury may result.
CRIL04B144A01 1
2. Remove the terminal connection covers from the

negative and positive connections.
3. Disconnect the battery cable (1) (0 volts) from the
NEGATIVE terminal, indicated by (-) on the battery
(A).
DANGER
47-55A - Disconnect the ground cable rst when the
battery cables are disconnected from the battery.
Connect the ground cable last when the battery
cables are connected to the battery.
CRIL03K003A02 2
4. Disconnect the battery cable (2) (+24 volts) from

the POSITIVE terminal, indicated by (+) on the
battery (A).
5. Having disconnected both cables from the battery,
keep them well away from the battery’s negative
and positive terminals.
6. Disconnect the battery cable (3) (0 volts) from the
NEGATIVE terminal, indicated by (-) on the battery
(B).
7. Disconnect the battery cable (4) (+12 volts) from
the POSITIVE terminal, indicated by (+) on the
battery (B).
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8. Having disconnected the battery connecting (5)

cable, keep it well clear of the battery’s negative and
positive terminals.
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Battery - Remove (A.30.A.83 - F.10.A.10)

CX135SR
Prior operation: Battery - Disconnect (A.30.A.83 - F.10.A.11)
1. Remove screws and washers (1) and (2).

Remove the tie rod (3) and battery retaining frame
(4).
CRIL03K003A01 1
2. Remove batteries (A) and (B).
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Battery - Check (A.30.A.83 - F.40.A.11)

CX135SR
Prior operation: Battery - Remove (A.30.A.83 - F.10.A.10)
NOTE: Use an acidimeter to check the density of the battery electrolyte. A thermometer graduated to at least 52 °C
must be used to check the temperature of the electrolyte.
NOTE: If the density of the electrolyte cannot be checked without adding water to the battery cell, after adding the
water charge the battery for 15 minutes between 15 amps and 25 amps to mix the water and the electrolyte properly.
1. Using the acidimeter, remove sufcient electrolyte
to allow the oat to move freely in the acidimeter’s
glass tube.
2. Keep the acidimeter upright and read the value
reached by the liquid, as indicated by the oat.
3. Repeat operations 1 and 2 for each battery cell.
Note the values taken from the acidimeter oat and
convert them to degrees Baumé. Refer to Battery -
General specication (A.30.A.83 - D.40.A.10).
4. The minimum density of the electrolyte should
be the 1.24 graduation 1240 on the oat, which
corresponds to 28 ° Baumé.
5. Read the electrolyte temperature on the
thermometer.
6. If the temperature of the electrolyte is above 26
°C add 1/2 ° Baumé to the gure read from the
acidimeter for every 6 °C above 26 °C.
If the temperature of the electrolyte is below 26 °C
subract 1/2 ° Baumé from the gure read from the
acidimeter for every 6 °C below 26 °C.
7. The charge level for each battery cell must be at
least 75 %, corresponding to a corrected density
of 28 ° Baumé.
8. If the difference between the high and low values
for the electrolyte density is less than 5 ° Baumé
and the charge level for each battery cell is at least
75 %, check the charge.
9. If the difference between the high and low values
for the electrolyte density is less than 5 ° Baumé
but the charge level for the battery cell is less
than 75 %, replace the battery, refer to Battery
- Remove (A.30.A.83 - F.10.A.10) and Battery -
Install (A.30.A.83 - F.10.A.15), then check again.
Next operation: Battery - Install (A.30.A.83 - F.10.A.15)
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Battery - Charging (A.30.A.83 - F.60.A.30)

CX135SR
Prior operation: Battery - Visual inspection (A.30.A.83 - F.40.A.10)

Prior operation: Battery - Remove (A.30.A.83 - F.10.A.10)
DANGER
47-83A - Never try to charge the battery if the electrolyte in the battery is frozen.
IMPORTANT: The battery must only be charged using a self-regulating charger with constant voltage and variable
current.
1. Using a charge tester or voltmeter, measure the
battery charge level. For this measurement, the
battery must not have been charged or recharged
for at least one hour.
Refer to Battery - Check (A.30.A.83 - F.40.A.11)
2. Use the following data to decide on the charging
time:
- For a charge level below 20 % or a voltage below
12 volts, the charging time is 24 hours.
- For a charge level between 20 % and 60 % or
a voltage between 12 volts and 12.3 volts, the
charging time is 12 hours.
- For a charge level above 60 % or a voltage above
12.3 volts, the charging time is 6 hours.
3. Connect the charger. Since the device supplies

a constant voltage, the current will be adjusted
automatically according to the discharge status and
rated capacity of the battery.
4. Before reinstalling the battery in the machine, carry
out a rapid discharge test using a battery tester.
5. After installing the battery, refer to Battery - Install
(A.30.A.83 - F.10.A.15), inspect the charge circuit
on the machine and check that there are no rogue
consumers.
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Battery - Overhaul (A.30.A.83 - F.10.A.40)

CX135SR
DANGER
DANGER
1. Carry out regular visual inspections of the battery,

refer to Battery - Visual inspection (A.30.A.83 -
F.40.A.10).
2. If the battery is damaged and leaking, it must be
replaced, refer to Battery - Remove (A.30.A.83
- F.10.A.10) and Battery - Install (A.30.A.83 -
F.10.A.15).
3. If the battery requires cleaning, remove it, refer
to Battery - Remove (A.30.A.83 - F.10.A.10).
Use a product specically intended for cleaning
batteries, in accordance with the manufacturer’s
recommendations.
If a product specically intended for cleaning
batteries is not available, use bicarbonate of soda
and water, making sure that no cleaning solution
gets into the battery cells.
4. After cleaning, install the battery, refer to Battery -
Install (A.30.A.83 - F.10.A.15).
27053 1 14/12/2004
A.30.A / 33
Battery - Install (A.30.A.83 - F.10.A.15)

CX135SR
1. Clean the battery compartment.

Position batteries (A) and (B), making sure the
negative and positive terminals are correctly aligned.
Install retaining frame (4) for the batteries and mat.
Install washers on screws (1) and (2) tighten.
Install and tighten the tie rod (3).
CRIL03K003A01 1
Next operation: Battery - Connect (A.30.A.83 - F.10.A.16)
27053 1 14/12/2004
A.30.A / 34
Battery - Connect (A.30.A.83 - F.10.A.16)

CX135SR
1. Clean the battery connections and cables.

2. Clean and grease the negative and positive
terminals on batteries (A) and (B).
CRIL03K003A02 1
3. Connect battery connecting cable (5) (+12 volts) to

the POSITIVE terminal, indicated by (+) on battery
(A).
4. Connect battery connecting cable (5) (0 volts) to the
NEGATIVE terminal, indicated by (-) on battery (B).
5. Connect battery cable (+24 volts) to the POSITIVE
terminal, indicated by (+) on battery (B).
6. Connect battery cable (0 volts) to the NEGATIVE
terminal, indicated by (-) on battery (A).
7. Install the terminal sleeves on the battery cable
connections, taking care to match the polarity
colours.
8. Fold back the protective mat.
27053 1 14/12/2004
A.30.A / 35
Index

Alternator - Electronic schema (A.30.A.82 - C.20.A.50) 26
CX135SR
Battery - Charging (A.30.A.83 - F.60.A.30) 32
CX135SR
Battery - Check (A.30.A.83 - F.40.A.11) 31
CX135SR
Battery - Connect (A.30.A.83 - F.10.A.16) 35
CX135SR
Battery - Disconnect (A.30.A.83 - F.10.A.11) 28
CX135SR
Battery - General specication (A.30.A.83 - D.40.A.10) 16
CX135SR
Battery - Install (A.30.A.83 - F.10.A.15) 34
CX135SR
Battery - Overhaul (A.30.A.83 - F.10.A.40) 33
CX135SR
Battery - Remove (A.30.A.83 - F.10.A.10) 30
CX135SR
Battery - Visual inspection (A.30.A.83 - F.40.A.10) 27
CX135SR
ELECTRICAL POWER SYSTEM - General specication (A.30.A - D.40.A.10) 4
CX135SR
CX135SR
CX135SR
CX135SR WE
CX135SR NA
ELECTRICAL POWER SYSTEM - Static description (A.30.A - C.30.A.20) 18
CX135SR
CX135SR
CX135SR
Fuse and relay box Fuse - Overview (A.30.A.80.81 - C.10.A.10) 25
CX135SR
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A.30.A / 36
LIGHTING SYSTEM - 40.A
CX135SR
27054 1 14/12/2004
A.40.A / 1
Contents
FUNCTIONAL DATA
Front work light
Front work light - Electronic schema (A.40.A.16 - C.20.A.50) 3
CX135SR
27054 1 14/12/2004
A.40.A / 2
DISTRIBUTION SYSTEMS - LIGHTING SYSTEM
Front work light - Electronic schema (A.40.A.16 - C.20.A.50)

CX135SR
CRIL03G205F01 1
Circuit layout
(1) Instrument panel lighting (2) Air conditioner control panel lighting
(E2) Attachment working light (E3) Working light (cab)
(K4) Working light relay (P1) Instrument panel
(P6) Air conditioner control panel (S10) Working light switch
CRIL03G206E02 2
Timing diagram
OPERATION
• Pressing working light switch (S10) once controls instrument panel lighting (1) and (2) and relay excitation (K4), which
switches on working lights (E2) and (E3).
• Pressing a second time turns off all the lit components.
27054 1 14/12/2004
A.40.A / 3
Index

Front work light - Electronic schema (A.40.A.16 - C.20.A.50) 3
CX135SR
27054 1 14/12/2004
A.40.A / 4
27054 1 14/12/2004
A.40.A / 5
CNH France S.A.- FRANCE
SERVICE
PRINTED IN FRANCE
COPYRIGHT BY CNH France S.A
All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CNH France S.A. company reserves the right to modify without prior notice the characteristics and the design of the
machine without any obligation to carry out those modications on machines already sold.
The description of the models shown in this manual has been made using the technical specications known at the
date on which this document was designed.
27049 1 14/12/2004
REPAIR MANUAL
POWER PRODUCTION
CX135SR
27055 1 14/12/2004
B
Contents
POWER PRODUCTION - B
ENGINE B.10.A
CX135SR
FUEL AND INJECTION SYSTEM B.20.A

CX135SR
AIR INTAKE SYSTEM B.30.A

CX135SR
EXHAUST SYSTEM B.40.A

CX135SR
ENGINE COOLANT SYSTEM B.50.A

CX135SR
LUBRICATION SYSTEM B.60.A

CX135SR
STARTING SYSTEM B.80.A

CX135SR
PTO POWER IN B.90.A

CX135SR
27055 1 14/12/2004
B
ENGINE - 10.A
CX135SR
27056 1 14/12/2004
B.10.A / 1
Contents
ENGINE - 10.A
TECHNICAL DATA
ENGINE - General specication (B.10.A - D.40.A.10) 3
CX135SR
ENGINE - Engine horse power (B.10.A - D.50.A.20) 4

CX135SR
FUNCTIONAL DATA
ENGINE - Electronic schema (B.10.A - C.20.A.50) 5
CX135SR
Electronic control
Electronic control - Electronic schema (B.10.A.92 - C.20.A.50) 7
CX135SR
SERVICE
ENGINE - Remove (B.10.A - F.10.A.10) 11
CX135SR
ENGINE - Install (B.10.A - F.10.A.15) 15

CX135SR
Sensing system
Sensing system Speed sensor - Electrical test (B.10.A.95.80 - F.40.A.50) 18
CX135SR
27056 1 14/12/2004
B.10.A / 2
POWER PRODUCTION - ENGINE
ENGINE - General specication (B.10.A - D.40.A.10)

CX135SR
Manufacturer Isuzu
Model BB-4BG1T
Type
Four-stroke, water-cooled with overhead valves, direct injection, in-line cylinders (electronic control) with
turbocharger
Number of cylinders 4 in line
Bore and stroke 105 x 125 mm
Operating conditions
Idle 1000 tr/min
Max. rpm 2100 tr/min
ECC 1289 Power 65.6 kW (88cv)
Max. torque to 322.3 Nm 1600 tr/min
Capacities
Engine oil 13.2 L
Engine cooling circuit 15.3 L
Radiator alone 6.8 L
Fuel tank 165 L
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B.10.A / 3
ENGINE - Engine horse power (B.10.A - D.50.A.20)

CX135SR
CRIL03K082G01 1
Power and consumption curves
(rpm) engine rpm (g/kWh) fuel consumption in grams per kilowatt hour
(kW) engine power in kilowatts (Nm) engine torque in Newton metres
(A) Fuel consumption (B) Engine power (C) Engine torque

(A1) Less than 246,8 g/kWh (B1) 2150 tr/min (C1) 299,0 Nmto 950 tr/min
(B2) 65,6 kWto 2100 tr/min (C2) 322,3 Nmto 1600 tr/min
(B3) 62,3 kWto 2130 tr/min
(B4) 61,6 kWto 2150 tr/min
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B.10.A / 4
ENGINE - Electronic schema (B.10.A - C.20.A.50)

CX135SR
CRIL03K121H01 1
Engine control
Circuit layout
(1) Engine (2) Rack sensor
(3) Control circuit (4) Linear motor control circuit
27056 1 14/12/2004
B.10.A / 5
(5) Electronic acceleration circuit (A2) Engine electronic control box

(A3) Electronic acceleration (B1) Coolant solution temperature sensor
(B41) Engine speed detector (R2) Fuel ow adjustment resistor
(R3) Engine throttle control (S1) Starter switch
FUEL CONSUMPTION CONTROL

1. The engine electronic control box (A2) calculates the target speed based on:
• voltage signals of throttle control (R3),
• voltage signals from coolant temperature sensor (B1),
• voltage signals (starter switch (S1)) powering the engine electronic control box..
2. Engine electronic control box (A2) calculates the fuel ow by analysing the difference between the target
speed (electronic acceleration tachometric sensor) and the actual speed (engine rpm sensor (B41).
3. Engine electronic control box (A2) converts the fuel ow at the target position of electronic acceleration rack
(A3) and corrects that target position in accordance with regulating resistance (R2).
ENGINE CHECK AT START-UP

1. When contact switch (S1) is in the starting position, the starting signal is sent simultaneously to the starter
motor and engine electronic control box (A2).
2. Engine electronic control box (A2) determines the fuel ow injection. This ow is determined from the water
temperature data and the real number of revolutions of the engine.
3. Once the start signal is switched off, engine electronic control box (A2) goes from start fuel control to
normal ow injection control.
ENGINE CHECK ON SHUTDOWN

On receiving the engine shutdown signal (when ignition is turned off), engine electronic control box (A2)
transmits the rack "no injection" position signal to electronic acceleration (A3) and activates the engine
shutdown signal.
ELECTRONIC ASSISTANCE POWER-ASSIST ERROR AND BACK-UP MODE

1. The rack sensor signal reaches engine electronic control box (A2).
2. Engine electronic control box (A2) compares the target position and the actual position of the rack.
3. If engine electronic control box (A2) determines that the rack is not in its correct target position, it considers it
as a power-assist error and stops the engine.
4. If the back-up mode is activated during an electronic acceleration (A3) power-assist error , the engine runs
in back-up mode.
5. In back-up mode, the rack position is adjusted exclusively by the engine rpm sensor (B41).
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B.10.A / 6
Electronic control - Electronic schema (B.10.A.92 - C.20.A.50)

CX135SR
ELECTRICAL SYSTEM FAULT DETECTION
CRIL03K147F01 1
Circuit layout
(1) Engine electrical system fault indicator lamp (2) Audible alarm device
(3) Fault code detection connection (4) Fault code erasing connection
(5) Engine (A2) Engine electronic control box
(A3) Electronic acceleration (B1) Coolant solution temperature sender
(B41) Engine speed detector (P1) Instrument panel
(R3) Throttle control (X13) Fault code erasing connector
(X14) Fault code detection connector
27056 1 14/12/2004
B.10.A / 7
CRIL03K148F01 2
Timing diagram with error code 41
(1) Engine electrical system fault indicator lamp (2) Audible alarm device
(3) Fault code detection connection (5A) With the engine stopped
(5B) Engine starting (5C) Engine running
OPERATION
• When connection (3) of the fault code connector (X14) is not functioning, the engine electrical system faults
are reported by the continuous lighting up of electrical system fault indicator lamp (1).
• When connection (3) of the fault code connector (X14) is functioning, the engine electrical system faults are
reported by a series of ashes of the electrical system fault indicator lamp (1).
27056 1 14/12/2004
B.10.A / 8
CRIL03K149F01 3
Timing diagram - Error code reader
(1) Engine electrical system fault indicator lamp (3) Fault code detection connection
(5A) With the engine stopped (5C) Engine running
OPERATION
1. When connection (3) of the fault code detection connector (X14) is set up with the engine running, the
current fault code of the engine electrical system are reported by a series of ashes of the electrical system
fault indicator lamp (1).
2. When connection (3) of the fault code detection connector (X14) is set up with the engine switched off, the
current and previous fault code of the engine electrical system are reported by a series of ashes of the
electrical system fault indicator lamp (1).
3. The ashing sequence of a fault code is repeated three times before going on to the ashing sequence
of the next fault code.
CRIL03K184E00 4
The diagram above shows several simultaneous faults of the engine electrical system.
4. With the engine running or stopped, if connection (3) of fault code detection connector (X14) is set up, and if
there is no fault in the engine electrical system, the electrical system fault indicator lamp will ash at regular
intervals (once every second).
CRIL03K185E00 5
The diagram above indicates that there is no fault in the engine electrical system.
27056 1 14/12/2004
B.10.A / 9
List of fault codes

Fault code no. Description Indicator lamp
lighted
(32) Rack position detector YES
(31) Circuit inside the electronic regulator, linear servomotor YES
(41) TDC sensor YES
(42) Engine speed detector YES
(21) Acceleration sensor NO
(15) Coolant solution temperature sensor NO
(25) Resistance to fuel ow adjustment no NO
ERASING FAULT CODES

• To erase the fault code from the electronic control box memory, connect (4) the fault code erasing connector
(X13) for at least one second, then turn the start switch to the "OFF" position for at least half a second.
27056 1 14/12/2004
B.10.A / 10
ENGINE - Remove (B.10.A - F.10.A.10)

CX135SR

Prior operation: Engine hood - Remove (E.20.A.72 - F.10.A.10)
Prior operation: To remove the lower protection panels (1), (5) and (6), refer to Protective shield - Remove
(E.20.A.73 - F.10.A.10)
Prior operation: ENGINE COOLANT SYSTEM - Drain uid (B.50.A - F.35.A.20)
1. Remove the upper protection brackets.

2. Remove and plug the upper and lower radiator
hoses.
Remove and plug the upper and lower refrigerant
hoses.
Place identication labels on heater hoses (1) and
(2), disconnect them and plug the ports.
CRIL03J106A01 1
3. Remove the engine throttle control.

Remove and plug the fuel supply and return pipe.
CRIL03J107A01 2
4. Mark and disconnect water temperature sensors

(1) and (2).
CRIL03J108A01 3
27056 1 14/12/2004
B.10.A / 11
5. Mark and disconnect the glow plugs (1).
CRIL03J109A01 4
6. Mark and disconnect engine oil pressure switch (1)

and engine rpm sensor (2).
CRIL03J110A01 5
7. Mark and disconnect the starter motor.

Remove earth strap (1) at the engine end.
CRIL03J111A01 6
8. Remove and plug hose (1) connecting the

turbocharger to the air lter.
CRIL03J112A01 7
27056 1 14/12/2004
B.10.A / 12
9. Mark and disconnect alternator (1).

NOTE: If the machine is tted with air conditioning,
remove the compressor mountings and place it away from
the engine.
CRIL03J113A01 8
10. Remove and plug the expansion tank hose.

Remove all mountings fastening the electrical
harnesses to the engine and place the harnesses
away from the engine.
Remove the exhaust shield.
11. Remove protective grill (1) from the fan.
CRIL03J114A01 9
12. Place identication labels on the hydraulic pump.

Place a container under the hydraulic pump.
Disconnect hydraulic oil temperature thermo-switch
(1).
Disconnect all hoses.
Plug the hoses and the ports.
CRIL03J115A01 10
27056 1 14/12/2004
B.10.A / 13
13. Install a lifting device in the rings of engine (1) and

hydraulic pump (2).
CRIL03J116B01 11
14. Remove the engine mountings.

Mark each screw for identication purposes.
Carefully raise the engine, moving it until it is free of
the radiator shroud.
When nothing else is in the way, remove the engine.
15. Mount the engine on a repair bench.
Next operation: To remove the hydraulic pump, refer to Hydraulic pump - Remove (A.10.A.20 - F.10.A.10)
27056 1 14/12/2004
B.10.A / 14
ENGINE - Install (B.10.A - F.10.A.15)

CX135SR
Prior operation: To connect the hydraulic pump to the engine, refer to Hydraulic pump - Install (A.10.A.20
- F.10.A.15)
1. Install a lifting device in the rings of engine (1) and

hydraulic pump (2).
CRIL03J116B01 1
2. Carefully raise and install the engine until it engages

with the radiator shroud.
3. Install new exible blocks.
Install the screws and washers following the marks
Coat with locking uid and tighten to torque 264,9
- 313,9 Nm
4. Take the electrical harnesses with all the mounting
hardware and install them.
5. Connect cables (1) and (2) to the alternator.
NOTE: If the machine is tted with air conditioning, install
the compressor, refer to Compressor - Install (E.40.D.31
- F.10.A.15).
CRIL03J113A01 2
27056 1 14/12/2004
B.10.A / 15
6. Install hose (1) connecting the turbo-charger to the

air lter.
CRIL03J112A01 3
7. Connect the starter motor and earth strap (1)

CRIL03J111A01 4
8. Connect engine oil pressure switch (1) and engine

rpm sensor (2).
CRIL03J110A01 5
9. Connect water temperature sensors (1) and (2)

CRIL03J108A01 6
10. Install the upper and lower radiator hoses.

Install the heating circuit hoses following the marks
Install the upper and lower refrigerant hoses.
27056 1 14/12/2004
B.10.A / 16
11. Install the fuel supply pipe.

Install the fuel return pipe.
Loosen screw (1) and operate priming pump (2)
until the fuel ows out without air bubbles.
Retighten the screw (1).
CRIL03I118A01 7
12. Install the engine throttle control.
CRIL03J107A01 8
13. Install the exhaust shield.

Install fan protective grill (1).
Install the expansion tank hose on the radiator.
CRIL03J114A01 9

Next operation: To install the engine hood, refer to Engine hood - Remove (E.20.A.72 - F.10.A.10)
Next operation: To install the lower protection panels (1), (5) and (6), refer to Protective shield - Remove
(E.20.A.73 - F.10.A.10)
Next operation: ENGINE COOLANT SYSTEM - Filling (B.50.A - F.60.A.10)
27056 1 14/12/2004
B.10.A / 17
Sensing system Speed sensor - Electrical test (B.10.A.95.80 -

F.40.A.50)
CX135SR
1. Disconnect connector (1) from engine speed sensor

(B41).
CRIL03K191A01 1
2. Connect the appropriate electrical test connector (3)

to connector (1) on motor speed sensor (B41), then
install the multimeter (2), refer to ELECTRICAL
POWER SYSTEM - Special tools (A.30.A -
D.20.A.40).
CRIL03I078A04 2
3. The motor speed sensor resistance reading (B41)

on multimeter (2) should be between 700 ohms
and 25 °C.
NOTE: The resistance value will vary according to the
heat
27056 1 14/12/2004
B.10.A / 18
Index
ENGINE - 10.A
Electronic control - Electronic schema (B.10.A.92 - C.20.A.50) 7
CX135SR
ENGINE - Electronic schema (B.10.A - C.20.A.50) 5
CX135SR
ENGINE - Engine horse power (B.10.A - D.50.A.20) 4
CX135SR
ENGINE - General specication (B.10.A - D.40.A.10) 3
CX135SR
ENGINE - Install (B.10.A - F.10.A.15) 15
CX135SR
ENGINE - Remove (B.10.A - F.10.A.10) 11
CX135SR
Sensing system Speed sensor - Electrical test (B.10.A.95.80 - F.40.A.50) 18
CX135SR
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B.10.A / 19
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B.10.A / 20
FUEL AND INJECTION SYSTEM - 20.A
CX135SR
27057 1 14/12/2004
B.20.A / 1
Contents
FUNCTIONAL DATA
Throttle command
Throttle command Electronic throttle - Functional diagram (B.20.A.06.91 - C.20.A.70) 3
CX135SR

CX135SR

CX135SR
Fuel shut-off
Fuel shut-off Electrical shut-off - Electronic schema (B.20.A.13.81 - C.20.A.50) 8
CX135SR
Sensing system
Sensing system Level sensor - Electronic schema (B.20.A.95.90 - C.20.A.50) 10
CX135SR
SERVICE
Fuel ller aid
Fuel ller aid - Remove (B.20.A.20 - F.10.A.10) 12
CX135SR
Fuel ller aid - Install (B.20.A.20 - F.10.A.15) 13

CX135SR
Fuel tank
Fuel tank - Remove (B.20.A.22 - F.10.A.10) 14
CX135SR
Fuel tank - Install (B.20.A.22 - F.10.A.15) 15

CX135SR
27057 1 14/12/2004
B.20.A / 2
POWER PRODUCTION - FUEL AND INJECTION SYSTEM
Throttle command Electronic throttle - Functional diagram

(B.20.A.06.91 - C.20.A.70)
CX135SR
THROTTLE CONTROL
CRIL03K122F01 1
Circuit layout

(A3) Electronic acceleration (R3) Engine throttle control
OPERATION
1. The engine electronic control box (A2) calculates the target position of the rack using the target rpm and
data from each sensor (actual engine rpm, actual position of the rack, fuel ow adjustment resistor), and it
transmits the signal to the electronic acceleration.
2. The electronic acceleration (A3) calculates the target position of the rack and its real position (value measured
by the rack detector) and moves the rack by turning the electric motor to adjust the quantity of fuel injected.
3. By repeating this process, the engine electronic control box (A2) controls electronic acceleration (A3) to obtain:
real number of revolutions = target number of revolutions.
27057 1 14/12/2004
B.20.A / 3
Relationship between the throttle control position and the engine rpm
CRIL03K127E01 2
(A) Throttle control position by percentage open
(B) Engine speed in rpm.
(C) Input voltage in volts
27057 1 14/12/2004
B.20.A / 4

(B.20.A.06.91 - C.20.A.70)
CX135SR
ENGINE IDLING CHECK
CRIL03K123E01 1
Circuit layout
(1) Engine (P1) Instrument panel

(A2) Engine electronic control box (S16) Engine idle switch
(A3) Electronic acceleration
CRIL03K124F01 2
Timing diagram
OPERATION
1. If starter switch (S1) is in the "OFF" position when idle switch (S16) is in the "ON" position, starter switch (S16) will return to
the "OFF" position as soon as starter switch (S1) is turned to the "ON" position.
2. Every time idle switch (S16) is activated, engine idle will be alternately activated/deactivated.
27057 1 14/12/2004
B.20.A / 5

(B.20.A.06.91 - C.20.A.70)
CX135SR
INJECTION PUMP ELECTRONIC REGULATOR
CRIL03K146G01 1
Circuit layout
(1) Engine (2) Hydraulic system

(3) Injection pump (4) Electronic regulator
(5) Engine speed signal (6) Rack position detector signal
(7) Rack control signal (8) Engine speed detector signal
(9) Linear motor (10) Rack
(11) Linear motor control section (12) Rack position detector
(A2) Engine electronic control box (B41) Engine speed detector
(R2) Fuel ow adjustment resistor (R3) Engine throttle control
(S1) Starter switch
OPERATION
27057 1 14/12/2004
B.20.A / 6
1. To ensure low fuel consumption and optimum productivity, the calculation section (engine electronic control
box (A2) compares the information received with the stored data, then transmits a control signal to control
section (11) of linear motor (9) through connections, (5), (6), (7) and (8).
2. Control section (11) sends a signal to linear motor (9) of regulator (4) to activate rack control (10) on injection
pump (3).
27057 1 14/12/2004
B.20.A / 7
Fuel shut-off Electrical shut-off - Electronic schema (B.20.A.13.81 -

C.20.A.50)
CX135SR
CRIL03K141F01 1
Circuit layout
(1) Engine (A2) Electronic control box

(A3) Electronic acceleration (K1) Relay-engine emergency stop
(M2) Engine emergency stop motor (S9) Engine emergency stop switch
27057 1 14/12/2004
B.20.A / 8
CRIL03K142F01 2
Timing diagram
EMERGENCY STOP CONTROL OPERATION
1. If engine emergency stop switch (S9) is activated, transistor output (OUT1) = 0 volts.
2. (OUT1) at 0 volts, emergency stop relay (K1) is activated, as is emergency stop motor (M2).
3. Stop signal input (IN1) on engine electronic control box (A2) falls to 0 volts, the engine electronic control box (A2) accepts
that as the emergency stop status and transmits the "stop engine" signal (OUT2) = 0 volts.
4. Electronic acceleration (A3) starts to control the engine shut down when it receives the signal (rack position = 0 mm).
27057 1 14/12/2004
B.20.A / 9
Sensing system Level sensor - Electronic schema (B.20.A.95.90 -

C.20.A.50)
CX135SR
CRIL03G087E01 1
Circuit layout
(1) Fuel level indicator (2) Minimum fuel level indicator lamp
(3) Audible alarm device (P1) Instrument panel
CRIL03G088E01 2
Fuel level indicator (1)
Sensor specication (R5)

(A) Tank full Sensor resistance 10 ohms
(B) Tank empty Sensor resistance 90 ohms
Tank half empty Sensor resistance 38 ohms
27057 1 14/12/2004
B.20.A / 10
CRIL03G089E02 3
Timing diagram
(2) Minimum fuel level indicator lamp (C) Lamp test

(3) Audible alarm device (D) Audible alarm device test
OPERATION
• When sensor resistance (R5) falls to 37 ohms or below, minimum fuel level indicator lamp (2) lights up.
27057 1 14/12/2004
B.20.A / 11
Fuel ller aid - Remove (B.20.A.20 - F.10.A.10)

CX135SR
1. Open the cover on fuel ller casing (1).

Mark and disconnect the supply harness, extract
the protective sheath from wire channel (2).
Remove the retaining screws from the casing
Remove the casing assembly with the fuel ller.
CRIL03J123A01 1
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B.20.A / 12
Fuel ller aid - Install (B.20.A.20 - F.10.A.15)

CX135SR
1. Install the casing with the fuel ller.

Install the retaining screws.
Insert protective sheath (2) in the wire channel.
Connect the harness following the marks made
during removal.
Roll up the hoses and close cover (1).
CRIL03J123A01 1
27057 1 14/12/2004
B.20.A / 13
Fuel tank - Remove (B.20.A.22 - F.10.A.10)

CX135SR
Prior operation: To remove the hydraulic reservoir protection panel, valve bank hood (1) and step (6), the protection
panels giving access to the control valve, the valve bank hood bracket, the hydraulic lter protection panel, refer
to Upper shield - Remove (E.20.A.71 - F.10.A.10)
Prior operation: To remove the right guard, refer to Side shield - Remove (E.20.A.70 - F.10.A.10)
Prior operation: To remove the access panel to the fuel tank piping and the fuel tank access panel, refer to
Protective shield - Remove (E.20.A.73 - F.10.A.10)
1. Open the fuel tank cap.

Using a suitably-sized container, drain the fuel tank
via the plug (1).
Tighten the drain plug.
CRIL03J134A01 1
2. Disconnect the fuel gauge sensor (1) and move

harness (2) to one side.
Remove the hose and harness from the windscreen
washer pump (3).
CRIL03J135A01 2
3. Remove the collar and the fuel supply hose

underneath the tank.
Remove the collar and fuel return hose located on
the side of the tank.
Plug the hoses and the ports
Remove the xing clip from the return hose.
4. Remove the xing screws from fuel tank (1).
NOTE: Check that the fuel tank is not attached at a xing
point.
CRIL03J134A02 3
5. Using a sling and a lifting device, remove the fuel

tank from the machine.
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B.20.A / 14
Fuel tank - Install (B.20.A.22 - F.10.A.15)

CX135SR
1. Using a sling and a lifting device, install the fuel

tank in the machine.
2. Install the washers on screws (1) coat with locking
uid and tighten to torque 232,4 - 276 Nm
CRIL03J134A02 1
3. Install the hose and the collar on the fuel supply

orice underneath the tank.
Install the hose and collar on the return port located
on the side of the fuel tank.
Install retaining clips on the hoses.
Connect harness (2) to fuel gauge sensor (1).
Fix and install the harness and the windscreen
washer pump hose (3).
CRIL03J135A01 2
4. Fill the fuel tank.

Check for leaks.
5. Bleed the fuel circuit.
Loosen screw (1) and operate priming pump (2)
until the fuel ows out without air bubbles.
Retighten the screw (1).
CRIL03I118A01 3
6. Install the protection panels.
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B.20.A / 15
Index

Fuel ller aid - Install (B.20.A.20 - F.10.A.15) 13
CX135SR
Fuel ller aid - Remove (B.20.A.20 - F.10.A.10) 12
CX135SR
Fuel shut-off Electrical shut-off - Electronic schema (B.20.A.13.81 - C.20.A.50) 8
CX135SR
Fuel tank - Install (B.20.A.22 - F.10.A.15) 15
CX135SR
Fuel tank - Remove (B.20.A.22 - F.10.A.10) 14
CX135SR
Sensing system Level sensor - Electronic schema (B.20.A.95.90 - C.20.A.50) 10
CX135SR
CX135SR
CX135SR
CX135SR
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B.20.A / 16
AIR INTAKE SYSTEM - 30.A
CX135SR
27058 1 14/12/2004
B.30.A / 1
Contents
SERVICE
Air cleaner
Air cleaner - Remove (B.30.A.25 - F.10.A.10) 3
CX135SR
Air cleaner - Install (B.30.A.25 - F.10.A.15) 4

CX135SR
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B.30.A / 2
POWER PRODUCTION - AIR INTAKE SYSTEM
Air cleaner - Remove (B.30.A.25 - F.10.A.10)

CX135SR
1. Open the rear LH side door.

Disconnect restriction indicator (1).
Disconnect air intake hose (2).
Plug the ports.
Remove screws (3) and air lter assembly (4).
CRIL03K006A01 1
27058 1 14/12/2004
B.30.A / 3
POWER PRODUCTION - AIR INTAKE SYSTEM
Air cleaner - Install (B.30.A.25 - F.10.A.15)

CX135SR
1. Install air lter assembly (4) in place.

Tighten screws (3) to torque 2,4 - 2,8 Nm.
Remove the plugs.
Connect restriction indicator (1).
Install air intake hose (2).
Close the rear LH side door.
CRIL03K006A01 1
27058 1 14/12/2004
B.30.A / 4
Index

Air cleaner - Install (B.30.A.25 - F.10.A.15) 4
CX135SR
Air cleaner - Remove (B.30.A.25 - F.10.A.10) 3
CX135SR
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B.30.A / 5
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B.30.A / 6
EXHAUST SYSTEM - 40.A
CX135SR
27059 1 14/12/2004
B.40.A / 1
Contents
SERVICE
Silencer
Silencer - Remove (B.40.A.36 - F.10.A.10) 3
CX135SR
Silencer - Install (B.40.A.36 - F.10.A.15) 5

CX135SR
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B.40.A / 2
POWER PRODUCTION - EXHAUST SYSTEM
Silencer - Remove (B.40.A.36 - F.10.A.10)

CX135SR
Prior operation: To remove the hydraulic pump protective panel, refer to Upper shield - Remove (E.20.A.71
- F.10.A.10)
1. Open the engine hood.

Open the rear RH door.
Remove protective panel (1) from the silencer.
CRIL03J139A01 1
2. Remove nuts and lock nuts (1) from exhaust piping

(2).
Remove nuts (3) from retaining collars on exhaust
silencer (4).
Remove the silencer.
Discard the exhaust piping seal.
CRIL03J140B01 2
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B.40.A / 3
3. Remove screws (1) from collar (2) and separate

exhaust silencer (3) from piping (4).
Remove collar (2).
CRIL03J141A01a 3
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B.40.A / 4
Silencer - Install (B.40.A.36 - F.10.A.15)

CX135SR
1. Install collar (2) on exhaust silencer (3).

Install piping (4) in collar (2).
CRIL03J141A02a 1
2. Install a new seal on the turbo-charger.

Install the exhaust silencer on bracket (5).
Install retaining collars on silencer (4).
Install and tighten nuts (3).
Install and tighten nuts and lock nuts (1).
Install and tighten screws (1) on collar (2) mentioned
in instruction 1.
CRIL03J140B01 2
3. Install and tighten screws on protective panel (1).

Close the RH rear door.
Close the engine hood.
CRIL03J139A01 3
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B.40.A / 5
4. Install the hydraulic pump protective panel.
27059 1 14/12/2004
B.40.A / 6
Index

Silencer - Install (B.40.A.36 - F.10.A.15) 5
CX135SR
Silencer - Remove (B.40.A.36 - F.10.A.10) 3
CX135SR
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B.40.A / 8
ENGINE COOLANT SYSTEM - 50.A
CX135SR
27060 1 14/12/2004
B.50.A / 1
Contents
FUNCTIONAL DATA
Sensing system
Sensing system Coolant temperature - Electronic schema (B.50.A.95.90 - C.20.A.50) 3
CX135SR

CX135SR
SERVICE
ENGINE COOLANT SYSTEM - Drain uid (B.50.A - F.35.A.20) 7
CX135SR
ENGINE COOLANT SYSTEM - Interior washing (B.50.A - F.30.A.20) 8

CX135SR
ENGINE COOLANT SYSTEM - Filling (B.50.A - F.60.A.10) 9

CX135SR
Radiator
Radiator - Remove (B.50.A.32 - F.10.A.10) 10
CX135SR
Radiator - Install (B.50.A.32 - F.10.A.15) 12

CX135SR
Sensing system
Sensing system Coolant temperature - Electrical test (B.50.A.95.90 - F.40.A.50) 14
CX135SR
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B.50.A / 2
POWER PRODUCTION - ENGINE COOLANT SYSTEM
Sensing system Coolant temperature - Electronic schema

(B.50.A.95.90 - C.20.A.50)
CX135SR
CRIL03K145F01 1
Circuit layout
(1) Coolant temperature indicator (2) Coolant or hydraulic oil overheating indicator
lamp
(3) Audible alarm device (A2) Engine electronic control box
(B1) Coolant solution temperature sensor (B9) Coolant solution temperature sensor
(B10) Hydraulic oil temperature thermo - switch (P1) Instrument panel
27060 1 14/12/2004
B.50.A / 3
CRIL03G094E03 2
Timing diagram
CRIL03G093E01 3
Coolant temperature indicator specications (1)

(A) 50 °C
(B) 115 °C
Engine electronic control box overheating signal specication (A2)

Output ON 105 °C
Output OFF 92 °C
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B.50.A / 4
Sensing system Coolant temperature - Electronic schema

(B.50.A.95.90 - C.20.A.50)
CX135SR
IDLE CHECKING BY BATTERY VOLTAGE AND COOLANT TEMPERATURE

• The aim of this function is to avoid the battery from being discharged or the lowering of the coolant temperature
in case of too long an idling period.
CRIL03K139F01 1
Circuit layout

(A3) Electronic acceleration (B1) Coolant solution temperature sensor
OPERATION
When the idle time is too long and either the voltage supplied to the engine electronic control box (A2) drops or the
coolant temperature (B1) is low, the idling speed increases automatically.
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B.50.A / 5
CRIL03K140F01 2
Adjustment to idling speed according to battery voltage and coolant temperature.
(1) Idle speed (rpm) (2) Motor electronic control box supply voltage in
volts
(3) Coolant temperature in °C
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B.50.A / 6
ENGINE COOLANT SYSTEM - Drain uid (B.50.A - F.35.A.20)

CX135SR
Prior operation: To remove the access panel to the radiator and engine, refer to Protective shield Guard -
Remove (E.20.A.73.71 - F.10.A.10)
1. Remove the radiator cap.

ATTENTION: Do not remove the radiator cap when the
engine is hot. The circuit is still under pressure and you
could be scalded.
CRIL03I184A01 1
2. Place a container of suitable capacity under the

radiator.
Open the radiator drain valve.
CRIL03L138A01 2
3. Place a suitably-sized container under the engine.

Remove the coolant drain plug located on the
engine block.
CRIL03L139A01 3
4. When no more coolant escapes, close the radiator

drain valve.
Install the coolant drain plug on the engine block.
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B.50.A / 7
ENGINE COOLANT SYSTEM - Interior washing (B.50.A - F.30.A.20)

CX135SR
Prior operation: ENGINE COOLANT SYSTEM - Drain uid (B.50.A - F.35.A.20)
1. Fill the radiator with fresh water until it overows.

Put the radiator cap back on.
CRIL03I184A01 1
2. Start the engine and let it idle for 10 mn until the

engine temperature reaches approximately 80 °C.
3. Drain the cooling circuit, refer to ENGINE
COOLANT SYSTEM - Drain uid (B.50.A -
F.35.A.20)
4. Repeat steps 1 to 3 until the water drained runs
clear.
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B.50.A / 8
ENGINE COOLANT SYSTEM - Filling (B.50.A - F.60.A.10)

CX135SR
1. Fill the radiator with coolant until it overows.

Put the radiator cap back on.
CRIL03I184A01 1
2. Open the hood of swing hydraulic motor.

Remove the expansion tank cap.
Fill the expansion tank with coolant up to the mark
(FULL).
Put the expansion tank cap back on.
CRIL03K004A01 2
3. Start the engine and let it idle for 5 minutes.

Top up the coolant in the expansion tank if the level
has dropped.
NOTE: Do not ll the expansion tank above the mark
(FULL).
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B.50.A / 9
Radiator - Remove (B.50.A.32 - F.10.A.10)

CX135SR
1. Remove and plug suction hose (1) between the air

lter and the inlet manifold.
Remove and plug suction hose (2) between the inlet
manifold and the turbo-charger.
Remove the inlet manifold and section (3).
Remove upper foam pads (4).
Remove the expansion tank hose (5).
NOTE: If the machine is tted with air conditioning,
remove the retaining screws from the condenser and put
it to one side.
CRIL03J170A01 1
2. Remove and plug cooling radiator hoses (1) and (2).

Remove the retaining clips from the protective
sheaths (3).
3. Remove and plug cooling radiator hoses (4) and (5).
4. Remove the protective grill from fan (6).
5. Remove screws (7) from retaining tie rod (8) on the
cooling radiator.
Remove wing nuts (9) and grill (10).
CRIL03J171B01 2
6. Remove the screws xing the cooling radiator to the

hood support and upper guard.
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B.50.A / 10
7. Remove retaining screws (1) from the radiator.

NOTE: Check that the cooling radiator is not attached
at a xing point.
CRIL03I146A01 3
8. Using a sling and a lifting device, carefully remove

the radiator and cooler assembly from the machine.
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B.50.A / 11
Radiator - Install (B.50.A.32 - F.10.A.15)

CX135SR
1. Using a lifting device, carefully install the radiator

on the machine.
2. Install the washers on screws (1) and tighten to
torque 63,8 - 73,6 Nm.
Install the screws xing the cooling radiator to the
hood support and upper guard.
CRIL03I146A01 1
3. Install protection grill (10) and secure it with wing

nuts (9).
Install tie rod (8), install and tighten screws (7).
4. Install protective grill on fan (6).
5. Install hoses (4) and (5) on the oil cooler.
Tighten the clamps.
6. Install hoses (1) and (2) on the cooling radiator.
Tighten the clamps.
Install retaining clips (3) on the sheaths protecting
the heating hoses.
NOTE: If the machine is equipped with air conditioning,
install the condenser with the mountings on each side,
screw up and tighten.
CRIL03J171B01 2
27060 1 14/12/2004
B.50.A / 12
7. Install hose on expansion tank (5).

Install the inlet manifold and section (3).
Install suction hose (1) between the air lter and the
inlet manifold.
Install suction hose (2) between the turbo-charger
and the inlet manifold.
Screw up and tighten the clamps.
Install foam pads (4).
CRIL03J170A01 3

27060 1 14/12/2004
B.50.A / 13
Sensing system Coolant temperature - Electrical test (B.50.A.95.90

- F.40.A.50)
CX135SR
1. Disconnect the connectors.

Remove sensor (B1) or (B9).
CRIL03K189A01 1
2. Connect the appropriate test electrical connector (3)

to sensor (B1) or (B9) then install multimeter (4).
Refer to ELECTRICAL POWER SYSTEM - Special
tools (A.30.A - D.20.A.40)
CRIL03I081A03 2
3. Install sensor (B1) or (B9) in a container (2) full of

water and place everything on tripod (6).
4. Using a spirit lamp (7), gradually heat the water in
container (2).
5. Using a multimeter (4), check the resistance position
of sensor (B1) or (B9) according to the temperature
reading on thermometer (1). Refer to ELECTRICAL
POWER SYSTEM - General specication (A.30.A
- D.40.A.10)
27060 1 14/12/2004
B.50.A / 14
Index

ENGINE COOLANT SYSTEM - Drain uid (B.50.A - F.35.A.20) 7
CX135SR
ENGINE COOLANT SYSTEM - Filling (B.50.A - F.60.A.10) 9
CX135SR
ENGINE COOLANT SYSTEM - Interior washing (B.50.A - F.30.A.20) 8
CX135SR
Radiator - Install (B.50.A.32 - F.10.A.15) 12
CX135SR
Radiator - Remove (B.50.A.32 - F.10.A.10) 10
CX135SR
Sensing system Coolant temperature - Electrical test (B.50.A.95.90 - F.40.A.50) 14
CX135SR
CX135SR
CX135SR
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B.50.A / 15
27060 1 14/12/2004
B.50.A / 16
LUBRICATION SYSTEM - 60.A
CX135SR
27061 1 14/12/2004
B.60.A / 1
Contents
FUNCTIONAL DATA
Sensing system
Sensing system Oil pressure - Electronic schema (B.60.A.95.91 - C.20.A.50) 3
CX135SR
27061 1 14/12/2004
B.60.A / 2
POWER PRODUCTION - LUBRICATION SYSTEM
Sensing system Oil pressure - Electronic schema (B.60.A.95.91 -

C.20.A.50)
CX135SR
CRIL03G090E01 1
Circuit layout
(1) Starting (2) Engine oil pressure indicator lamp

(3) Audible alarm device (B21) Pressure switch for engine oil pressure
CRIL03G091E02 2
Timing diagram
(A) Starting (B) Test
ENGINE OIL PRESSURE SWITCH SPECIFICATION

• Pressure switch (B21) opens at 0.4 MPa.
27061 1 14/12/2004
B.60.A / 3
Index

Sensing system Oil pressure - Electronic schema (B.60.A.95.91 - C.20.A.50) 3
CX135SR
27061 1 14/12/2004
B.60.A / 4
STARTING SYSTEM - 80.A
CX135SR
27062 1 14/12/2004
B.80.A / 1
Contents
TECHNICAL DATA
Engine starter
Engine starter - General specication (B.80.A.82 - D.40.A.10) 3
CX135SR
FUNCTIONAL DATA
Cold start aid
Cold start aid Pre-heating - Electronic schema (B.80.A.30.81 - C.20.A.50) 4
CX135SR
Cold start aid Pre-heating - Dynamic description (B.80.A.30.81 - C.30.A.10) 7

CX135SR
Start control
Start control Start relay - Electronic schema (B.80.A.90.80 - C.20.A.50) 8
CX135SR
27062 1 14/12/2004
B.80.A / 2
POWER PRODUCTION - STARTING SYSTEM
Engine starter - General specication (B.80.A.82 - D.40.A.10)

CX135SR
Voltage 24 volts
Power 4.5 kW
27062 1 14/12/2004
B.80.A / 3
Cold start aid Pre-heating - Electronic schema (B.80.A.30.81 -

C.20.A.50)
CX135SR
AUTOMATIC ENGINE PRE-HEATING
CRIL03K125F01 1
Circuit layout
(1) Engine (2) Preheating indicator lamp

(A2) Engine electronic control box (A3) Electronic acceleration
(B1) Coolant solution temperature sensor (K2) Glow plug relay
(P1) Instrument panel (R1) Glow plug
(S1) Starter switch
27062 1 14/12/2004
B.80.A / 4
OPERATION
1. Once the starter switch is turned to "on" (IN1 = ON), main electronic control box (A1) calculates the preheating
time (Tp) based on the coolant temperatures (see graph).
2. Engine electronic control box (A2) activates pre-heating relay (K2) during preheating period (Tp) calculated
previously.
3. At the end of preheating period (Tp), preheating indicator lamp (1) goes out and preheating relay (K2) remains
activated for 2 seconds.
4. When starter switch (S1) is turned to "START" (ST, IN2 = ON), engine electronic control box (A2) reactivates
preheating relay (K2), without preheating indicator lamp (2) lighting up.
5. Engine electronic control box (A2) calculates the time after post-heating (Ta) based on the coolant temperature
(see graph).
6. When starter switch (S1) is moved from "START" to "ON" (IN1 = ON ; IN2 = OFF), engine electronic control
box (A2) activates preheating relay (K2) during the period after post-heating (Ta), without preheating indicator
lamp (2) lighting up.
7. The post-heating procedure helps stabilise the engine speed when starting, in order to reduce emission of
smoke from the exhaust.
8. The control system mentioned above starts immediately; as soon as the starter switch is turned to "on", the
preheating will begin, only if the preheating time is more than 3 seconds (coolant temperature less than - 5 °C).
CRIL03K135F01 2
Preheating and post-heating time graph
(T) Engine water temperature in °C (Tp) Pre-heating time in seconds

(Ta) Post-heating time in seconds
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B.80.A / 5
TIMING DIAGRAM
1. If the engine is started within 2 seconds of the lighting up of preheating indicator lamp (2)
CRIL03K136E01 3
2. If the engine is started 2 seconds after the lighting up of preheating indicator lamp (2)
CRIL03K137E01 4
3. If the engine is started during the lighting up of preheating indicator lamp (2)
CRIL03K138E01 5
(A) 3 seconds (B) 2 seconds additional pre-heating

(C) Pre-heating time when engine is being (Tp) Pre-heating time
started
(Ta) Post-heating time
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B.80.A / 6
Cold start aid Pre-heating - Dynamic description (B.80.A.30.81 -

C.30.A.10)
CX135SR
Flow chart
Starter switch ON
Water Pre-heating time
temperature calculation
Calculated time
Pre-heat plug Signal active
activated
Elapsed time Signal activated
Pre-heat plug
deactivated
Engine started
Pre-heat plug
activated
Water Post-heating time
temperature calculation
Calculated time
Pre-heat plug
activated
Elapsed time
Pre-heat plug
deactivated
27062 1 14/12/2004
B.80.A / 7
Start control Start relay - Electronic schema (B.80.A.90.80 -

C.20.A.50)
CX135SR
CRIL03K143E01 1
Supply cut-off delay - Circuit conguration
(G1) Battery (K7) Battery relay

CRIL03K144E01 2
Timing diagram
POWER TRANSISTOR PROTECTION
• To protect instrument panel circuits (P1) in the event of a short circuit of a solenoid valve or relay, the power transistors
turn off the electric supply.
27062 1 14/12/2004
B.80.A / 8
Index

Cold start aid Pre-heating - Dynamic description (B.80.A.30.81 - C.30.A.10) 7
CX135SR
Cold start aid Pre-heating - Electronic schema (B.80.A.30.81 - C.20.A.50) 4
CX135SR
Engine starter - General specication (B.80.A.82 - D.40.A.10) 3
CX135SR
Start control Start relay - Electronic schema (B.80.A.90.80 - C.20.A.50) 8
CX135SR
27062 1 14/12/2004
B.80.A / 9
27062 1 14/12/2004
B.80.A / 10
PTO POWER IN - 90.A
CX135SR
27063 1 14/12/2004
B.90.A / 1
Contents
PTO POWER IN - 90.A
SERVICE
Drive system
Drive system - Remove (B.90.A.42 - F.10.A.10) 3
CX135SR
Drive system - Visual inspection (B.90.A.42 - F.40.A.10) 4

CX135SR
Drive system - Install (B.90.A.42 - F.10.A.15) 5

CX135SR
27063 1 14/12/2004
B.90.A / 2
POWER PRODUCTION - PTO POWER IN
Drive system - Remove (B.90.A.42 - F.10.A.10)

CX135SR
Prior operation: Hydraulic pump - Remove (A.10.A.20 - F.10.A.10)
1. Remove retaining screws (1) and washers (2)

from silencer bracket (3), then remove the silencer
bracket.
Remove screws (4) and washers (5) xing ange
(6) to the engine, then remove ange (6).
CRIL03K012A01 1
2. Remove screws (1) xing coupling assembly (2) to

splined sleeve (3).
Remove splined sleeve (3).
Remove screws (4) xing coupling assembly (2) to
engine ywheel (5).
Remove coupling assembly (2).
CRIL03J138B01 2
27063 1 14/12/2004
B.90.A / 3
Drive system - Visual inspection (B.90.A.42 - F.40.A.10)

CX135SR
1. Check for cracked, broken, chipped or worn splines

on the splined sleeve.
Check that the roll pins are not missing, damaged
or worn out.
If any of the above conditions exist, replace the
splined sleeve.
2. Check for cracks, ruptures and other wear and tear
on the coupling assembly.
If any of the above conditions exist, replace the
coupling assembly.
27063 1 14/12/2004
B.90.A / 4
Drive system - Install (B.90.A.42 - F.10.A.15)

CX135SR
1. Install coupling assembly (2) on engine ywheel (5)

using screws (4).
Install splined sleeve (3) in coupling assembly (2).
Coat screws (1) with locking uid and x coupling
assembly (2) onto splined sleeve (3).
CRIL03J138B01 1
2. Using screws (4) and washers (5) install ange (6)

on the engine.
Using screws (1) and washers (2) install silencer
bracket (3).
Tighten the screws to a torque of 62,8 - 72,6 Nm.
CRIL03K012A01 2
Next operation: Hydraulic pump - Install (A.10.A.20 - F.10.A.15)
27063 1 14/12/2004
B.90.A / 5
Index
PTO POWER IN - 90.A

Drive system - Install (B.90.A.42 - F.10.A.15) 5
CX135SR
Drive system - Remove (B.90.A.42 - F.10.A.10) 3
CX135SR
Drive system - Visual inspection (B.90.A.42 - F.40.A.10) 4
CX135SR
27063 1 14/12/2004
B.90.A / 6
27063 1 14/12/2004
B.90.A / 7
SERVICE
PRINTED IN FRANCE
27055 1 14/12/2004
REPAIR MANUAL
TRAVELLING
CX135SR
27064 1 14/12/2004
D
Contents
TRAVELLING - D
WHEELS AND TRACKS Tracks D.50.B

CX135SR
27064 1 14/12/2004
D
TRAVELLING - D
WHEELS AND TRACKS Tracks - 50.B
CX135SR
27065 1 14/12/2004
D.50.B / 1
Contents
TRAVELLING - D
TECHNICAL DATA
Drive sprocket
Drive sprocket - Special tools (D.50.B.45 - D.20.A.40) 5
CX135SR
Drive sprocket - Service limits (D.50.B.45 - D.20.A.20) 6

CX135SR
Steel track
Steel track - Service limits (D.50.B.46 - D.20.A.20) 7
CX135SR
Roller
Roller Lower roller - Special tools (D.50.B.56.10 - D.20.A.40) 8
CX135SR
Roller Lower roller - Service limits (D.50.B.56.10 - D.20.A.20) 9

CX135SR
Roller Upper roller - Special tools (D.50.B.56.20 - D.20.A.40) 10

CX135SR
Roller Upper roller - Service limits (D.50.B.56.20 - D.20.A.20) 11

CX135SR
Idler wheel
Idler wheel - Special tools (D.50.B.57 - D.20.A.40) 12
CX135SR
Idler wheel - Service limits (D.50.B.57 - D.20.A.20) 13

CX135SR
FUNCTIONAL DATA
Steel track
Steel track - Exploded view (D.50.B.46 - C.10.A.20) 14
CX135SR
Track tensioning mechanism

Track tensioning mechanism Shock absorber - Exploded view (D.50.B.48.70 - 15
C.10.A.20)
CX135SR
Track tensioning mechanism Adjuster-recoil mechanism - Exploded view (D.50.B.48.65 16

- C.10.A.20)
CX135SR
Roller
Roller Lower roller - Sectional view (D.50.B.56.10 - C.10.A.30) 17
CX135SR
Roller Upper roller - Sectional view (D.50.B.56.20 - C.10.A.30) 18

CX135SR
SERVICE
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D.50.B / 2
Drive sprocket
Drive sprocket - Remove (D.50.B.45 - F.10.A.10) 19
CX135SR
Drive sprocket - Install (D.50.B.45 - F.10.A.15) 21

CX135SR
Steel track
Steel track - Remove (D.50.B.46 - F.10.A.10) 22
CX135SR
Steel track - Install (D.50.B.46 - F.10.A.15) 26

CX135SR
Steel track Chain - Measure (D.50.B.46.20 - F.40.A.16) 29

CX135SR
Rubber track
Rubber track - Visual inspection (D.50.B.47 - F.40.A.10) 30
CX135SR
Rubber track - Remove (D.50.B.47 - F.10.A.10) 31

CX135SR
Rubber track - Install (D.50.B.47 - F.10.A.15) 33

CX135SR
Track tensioning mechanism

Track tensioning mechanism - Tension adjust (D.50.B.48 - F.45.A.40) 35
CX135SR
Track tensioning mechanism Shock absorber - Remove (D.50.B.48.70 - F.10.A.10) 37

CX135SR
Track tensioning mechanism Shock absorber - Disassemble (D.50.B.48.70 - F.10.A.25) 39

CX135SR
Track tensioning mechanism Shock absorber - Assemble (D.50.B.48.70 - F.10.A.20) 40

CX135SR
Track tensioning mechanism Shock absorber - Install (D.50.B.48.70 - F.10.A.15) 41

CX135SR
Track tensioning mechanism Adjuster-recoil mechanism - Remove (D.50.B.48.65 - 43

F.10.A.10)
CX135SR
Track tensioning mechanism Adjuster-recoil mechanism - Disassemble (D.50.B.48.65 - 44

F.10.A.25)
CX135SR
Track tensioning mechanism Adjuster-recoil mechanism - Assemble (D.50.B.48.65 - 45

F.10.A.20)
CX135SR
Track tensioning mechanism Adjuster-recoil mechanism - Install (D.50.B.48.65 - 46

F.10.A.15)
CX135SR
Roller
Roller - Leakage test (D.50.B.56 - F.40.A.40) 47
CX135SR
Roller Lower roller - Remove (D.50.B.56.10 - F.10.A.10) 48

CX135SR
Roller Lower roller - Disassemble (D.50.B.56.10 - F.10.A.25) 50

CX135SR
Roller Lower roller - Visual inspection (D.50.B.56.10 - F.40.A.10) 52

CX135SR
Roller Lower roller - Assemble (D.50.B.56.10 - F.10.A.20) 53

CX135SR
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D.50.B / 3
Roller Lower roller - Install (D.50.B.56.10 - F.10.A.15) 55
CX135SR
Roller Upper roller - Remove (D.50.B.56.20 - F.10.A.10) 56

CX135SR
Roller Upper roller - Disassemble (D.50.B.56.20 - F.10.A.25) 58

CX135SR
Roller Upper roller - Visual inspection (D.50.B.56.20 - F.40.A.10) 60

CX135SR
Roller Upper roller - Assemble (D.50.B.56.20 - F.10.A.20) 61

CX135SR
Roller Upper roller - Install (D.50.B.56.20 - F.10.A.15) 63

CX135SR
Idler wheel
Idler wheel - Disassemble (D.50.B.57 - F.10.A.25) 64
CX135SR
Idler wheel - Assemble (D.50.B.57 - F.10.A.20) 66

CX135SR
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D.50.B / 4
TRAVELLING - WHEELS AND TRACKS Tracks
Drive sprocket - Special tools (D.50.B.45 - D.20.A.40)

CX135SR
CRIL03G008F01 1
Gauge for checking sprocket wear.
Gauge to be made locally

MARKING SIZE MARKING SIZE
(A) 200 mm (B) 171,45 mm
(C) 84,2 mm (D) 70 mm
(E) 59,9 mm (F) 30,7 mm
(G) 4,2 mm (H) 4,2 mm
(J) 12,7 ° (K) 40,7 °
(L) 26,4 mm (M) radius 35,1 mm
(N) 90 ° (P) 17,1 °
(Q) 17,1 ° (R) radius 65,9 mm
(S) radius 25,5 mm (T) radius 4 mm
(U) 4 mm
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D.50.B / 5
Drive sprocket - Service limits (D.50.B.45 - D.20.A.20)

CX135SR
CRIL032G007F01 1
Sprocket
MARKING STANDARD DIMENSION WEAR LIMIT
(A) 59 mm 53 mm
(B) diameter 530.7 mm 524.7 mm
(C) diameter 594.7 mm 588.07 mm
(D) diameter 581.67 mm -
(P) 171.45 mm -
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D.50.B / 6
Steel track - Service limits (D.50.B.46 - D.20.A.20)

CX135SR
CRIL03G011F01 1
Steel track

(A) 28 mm 18 mm
(B) 89 mm 84 mm
(C) 72.9 mm 78.9 mm
(D) 142.9 mm 136.9 mm
(E) bushing outside diameter 50.57 mm 49.5 mm
(F) bushing inside diameter 34.1 mm 33.1 mm
(G) pin inside diameter 33.25 mm 32.5 mm
(H) 171.5 mm 166.95 mm
(E) bushing outside diameter 50.57 mm 49.5 mm
(F) bushing inside diameter 34.1 mm 35.1 mm
(G) pin inside diameter 33.5 mm 32.5 mm
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D.50.B / 7
Roller Lower roller - Special tools (D.50.B.56.10 - D.20.A.40)

CX135SR
CRIL03J046F01 1
Gauge for checking wear on lower roller

(A) 191 mm (B) 175 mm
(C) 150.6 mm (D) 142 mm
(E) 72 mm (F) 26,1 mm
(G) 23 mm (H) 20 mm
(J) 45 mm (K) 50 mm
(L) 14,1 mm (M) 210 mm
(N) 15 mm (P) 5 mm
(Q) 5° (R) radius 6 x 5 mm
(S) 1.5 ° (T) radius 15 mm
(U) 17 ° (V) 10 °
(W) radius 10 mm (X) radius 4 x 5 mm
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Roller Lower roller - Service limits (D.50.B.56.10 - D.20.A.20)

CX135SR
CRIL03J048F01 1
Upper roller

(A) diameter 130 mm 122 mm
(B) 15 mm 13 mm
(C) 142 mm 148 mm
(D) diameter (pin) 50 mm 49.5 mm
(D) diameter (bushing) 50 mm 50.8 mm
(E) 53 mm 52.6 mm
(F) 24.3 mm 23.8 mm
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D.50.B / 9
Roller Upper roller - Special tools (D.50.B.56.20 - D.20.A.40)

CX135SR
CRIL03J051F01 1
Gauge for checking wear on upper roller

(A) 150 mm (B) 130 mm
(C) 72 mm (D) 68 mm
(E) 50 mm (F) 33 mm
(G) 10 mm (H) 7 mm
(I) radius 3 mm (J) radius 3 mm
(K) radius 3 mm - -
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D.50.B / 10
Roller Upper roller - Service limits (D.50.B.56.20 - D.20.A.20)

CX135SR
CRIL03J049F01 1
Upper roller

(B) 10 mm 8 mm
(C) 72 mm 68 mm
(D) diameter (pin) 40 mm 39.5 mm
(D) diameter (bushing) 40 mm 40.8 mm
(E) 60.5 mm 60.1 mm
(F) 5.5 mm 5 mm
(G) 40.2 mm 39.7 mm
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Idler wheel - Special tools (D.50.B.57 - D.20.A.40)

CX135SR
CRIL03J053F01 1
Gauge for checking idler wheel wear

(A) 155 mm (B) 135 ± 2 mm
(C) 68 +08 -1,2 mm (D) 55 mm
(E) 30,5 mm (F) 17,5 mm
(G) 7 mm (H) 3,6 mm
(I) 17,5 mm (J) 10 °
(K) radius 2 x 3 mm (L) radius 2 x 4 mm
(M) radius 2 x 3 mm (N) radius 2 x 37 mm
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D.50.B / 12
Idler wheel - Service limits (D.50.B.57 - D.20.A.20)

CX135SR
CRIL03J054F01 1
Idler wheel

(B) 17.5 mm 15.5 mm
(C) 68 mm 64 mm
(D) pin diameter 55 mm 54.5 mm
(D) bushing diameter 55 mm 55.8 mm
(E) 54 mm 53.6 mm
(F) 23.4 mm 22.9 mm
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D.50.B / 13
Steel track - Exploded view (D.50.B.46 - C.10.A.20)

CX135SR
CRIL03G115G01 1
(1) Track shoe (2) Screw

(3) Nut (4) End of chain half-link
(5) End of chain half-link (6) End of chain pin
(7) Shim (8) End of chain pin spacer
(9) Pin (10) RH standard pin half-link
(11) LH standard pin half-link (12) Standard pin
(13) Standard pin spacer (14) Seal
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D.50.B / 14
Track tensioning mechanism Shock absorber - Exploded view

(D.50.B.48.70 - C.10.A.20)
CX135SR
CRIL03G207F01 1
(1) Shock absorber spring (2) Pin

(3) Slotted nut (4) Yoke
(5) Spring guide
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Track tensioning mechanism Adjuster-recoil mechanism - Exploded

view (D.50.B.48.65 - C.10.A.20)
CX135SR
CRIL03G208F01 1
(1) Screw (2) Flat washer

(3) Screw (4) Lock washer
(5) Bracket (6) Grease tting
(7) Valve (8) Spring
(9) Ball (10) Check valve body
(11) Cylinder rod (12) Wiper seal
(13) Thrust ring (14) Seal
(15) Cylinder barrel (16) Valve assembly
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D.50.B / 16
Roller Lower roller - Sectional view (D.50.B.56.10 - C.10.A.30)

CX135SR
CRIL03J044F01 1
Assembly dimension
(A) 261 - 259,8 mm
(B) 224 mm
Description
(1) Lower roller (2) Drain plug
(3) Retaining ring (4) Housing
(5) Seal (6) Shaft
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D.50.B / 17
Roller Upper roller - Sectional view (D.50.B.56.20 - C.10.A.30)

CX135SR
CRIL03J043F01 1
Assembly dimension
(A) 94,3 - 94,7 mm
(B) 59 mm
Description
(1) Lower roller (2) Drain plug
(3) Screw (4) Cover
(5) Seal (6) Thrust plate
(7) Shaft (8) Seal
(9) Bushing (10) Support
(11) Screw
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D.50.B / 18
Drive sprocket - Remove (D.50.B.45 - F.10.A.10)

CX135SR
Prior operation: Steel track - Remove (D.50.B.46 - F.10.A.10)
1. Move the machine so that the track is in the position

shown.
CRIL03G116A00 1
2. Rotate the upperstructure so that the cab is over

the side of the machine where the sprocket to be
removed is located.
Using the attachment, raise the side of the machine
until the sprocket teeth arefree of the chain.
CRIL03G117A00 2
3. To facilitate reassembly, make alignment marks (1)

on the sprocket and the reduction gear.
CRIL03G118A01 3
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D.50.B / 19
4. Remove the screws (1) and the washers that attach

the sprocket to the reduction gear.
CRIL03G119A01 4
5. Using a soft face hammer, tap the sprocket off the

reduction gear housing and remove it.
CRIL03G120A00 5
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D.50.B / 20
Drive sprocket - Install (D.50.B.45 - F.10.A.15)

CX135SR
1. Install the sprocket on the drive reduction gear

following the marks (1) made during removal.
CRIL03G118A01 1
2. If necessary, use a soft face hammer to seat the

sprocket correctly o the reduction gear housing.
CRIL03G134A00 2
3. Apply thread lock uid to the screws (1).

Install the washers and the screws, tighten to a
torque of 267 - 312 Nm.
CRIL03G119A01 3
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D.50.B / 21
Steel track - Remove (D.50.B.46 - F.10.A.10)

CX135SR
1. Park the machine on a hard, level surface.

Rotate the upperstructure of the machine so that the
cab is over the track to be removed.
2. Lower the bucket or the tool to lift the track a few

centimetres off the ground.
CRIL03G121A00 1
3. Mark the master pin (1) on the at surfaces on one

side and on the retaining pin (2) at the other end.
CRIL03G122A01 2
4. Bring the master pin to a level halfway up the

sprocket.
Operate the machine to lower the track to be
removed to the ground.
Rotate the upperstructure of the machine so that
the cab is facing forwards.
IMPORTANT: Do not remove the check valve.
DANGER
SA024 - Hydraulic uid or grease injected into
your skin can cause severe injury or death. Keep
your hands and body away from any pressurized CRIL03G123A01 3
leak. If uid is injected into your skin, see a doctor
immediately and have the uid removed.
27065 1 14/12/2004
D.50.B / 22
5. Slacken the track by gradually loosening the check

valve about two turns.
Grease will escape from an orice in the valve
thread.
CRIL03G124A00 4
6. Remove the screws (1) and the track shoe nuts

above the end of chain pin.
Remove the track shoe.
CRIL03G125A01 5
7. Straighten one of the retaining pin ends.
CRIL03G126A01 6
8. Tap the retaining pin out of the end of chain pin.
CRIL03G127A00 7
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D.50.B / 23
9. Remove the screws and the track shoe nuts below

the end of chain pin.
Remove the track shoe.
CRIL03G128A00 8
10. Install the portable hydraulic press CAS-10044 on

the end of chain axle.
Drive the end of chain pin out.
CRIL03G129A00 9
11. Remove the portable hydraulic press.

12. Using a crowbar, separate the chain links.
Remove the two spacers (1).
CRIL03G130A01 10

Using the attachment, raise the chassis on the side
of the track to be removed.
Install stands under the machine to hold it in place
and lower the machine onto the stands.
Stop the engine.
CRIL03G131A00 11
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D.50.B / 24
14. Attach a sling to the lower end of the track.

Start the engine.
Reverse the machine, moving the dipper out at the
same time.
When the track is free of the sprocket, stop the
machine from reversing further.
Continue moving the dipper out until the track is
pulled away from the machine.
Stop the engine, move the track to be replaced
away from the machine.
CRIL03G132A00 12
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D.50.B / 25
Steel track - Install (D.50.B.46 - F.10.A.15)

CX135SR
1. Place and align the new track under the carrier

rollers.
CRIL03G136A00 1
2. Remove the stand.

Lower the machine onto the track chain.
3. Connect a lifting device to the track.
Raise the track on the idler wheel.
CRIL03G137A00 2
4. Attach the track to the attachment with a sling.

Start the engine.
Move the machine forward, moving the dipper out at
the same time to engage the track on the sprocket.
CRIL03G138A00 3
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D.50.B / 26
5. Connect suitable pulling equipment to both ends

of the track chain.
Use the pulling equipment to pull the two ends of
the track chain together.
CRIL03G139A00 4
6. Install the two spacers (1) in the half links where the
end of chain pin is located.
CRIL03G130A01 5
7. Install the end of chain pin using portable hydraulic

press CAS 10044.
CRIL03G140A00 6
8. Remove the portable hydraulic press.

Install a new retaining pin (1) in the end of chain pin.
Bend the ends of the pin to secure the end of chain
pin.
CRIL03G141A01 7
9. Install the two track shoes, the screws and the nuts.
27065 1 14/12/2004
D.50.B / 27
10. Tighten screws (1) to a torque of 392 - 430 Nm
CRIL03G125A01 8
Next operation: Track tensioning mechanism - Tension adjust (D.50.B.48 - F.45.A.40)
27065 1 14/12/2004
D.50.B / 28
Steel track Chain - Measure (D.50.B.46.20 - F.40.A.16)

CX135SR
NOTE: Measure the diameter of the pins and bushings with a micrometer or an outside calliper.
1. Measure the outside diameter of the bushing (2)
using an outside caliper (1).
CRIL03G153A01 1
2. Measure the inside diameter of the bushing.

3. Measure the outside diameter of the track pin.
Refer to Steel track - Service limits (D.50.B.46 -
D.20.A.20).
Replace them if necessary.
27065 1 14/12/2004
D.50.B / 29
Rubber track - Visual inspection (D.50.B.47 - F.40.A.10)

CX135SR
1. Inspect the track for wear, replace it if one of the

following conditions is noted:
Lugs (1) worn, (A) = minimum 5 mm.
Steel (2) showing or damaged.
Metal reinforcement (3) showing or worn.
CRIL03G049A01 1
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D.50.B / 30
Rubber track - Remove (D.50.B.47 - F.10.A.10)

CX135SR
Prior operation: Slacken the track completely, refer to Track tensioning mechanism - Tension adjust (D.50.B.48
- F.45.A.40)
1. Swing the upperstructure at right angles to the

undercarriage.
Press the attachment against the ground until the
track (1) is lifted off the ground.
Shut down the engine and remove the starter switch
key.
CRIL03G050A01 1
2. Place tubes (1) in the slots in the track, in front of

the idler wheel.
IMPORTANT: Before all operations, make sure that the
cylinder is completely depressurised.
CRIL03G051A01 2
3. Operate the reverse travel for the track concerned.

Stop the movement completely when the tubes (1)
are pressing against the idler wheel.
CRIL03G052A01 3
4. Shut down the engine and remove the starter switch

key.
27065 1 14/12/2004
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5. Remove the track (1).
CRIL03G053A01 4
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D.50.B / 32
Rubber track - Install (D.50.B.47 - F.10.A.15)

CX135SR
1. Install the track on the teeth of the sprocket (1), then

on the side member.
CRIL03G053A02 1
2. Place tubes (1) in the slots in the tracks in front of

the idler wheel.
CRIL03G054A01 2
3. Operate the reverse travel for the track concerned.

Stop all movement once the tubes (1) are pressing
against the idler wheel.
CRIL03G055A01 3
4. Shut down the engine and remove the starter switch

key.
27065 1 14/12/2004
D.50.B / 33
5. Mount the track on the idler wheel (1).
CRIL03G052A02 4
6. Operate the travel function for the track concerned

to release the tubes (1).
CRIL03G056A01 5
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D.50.B / 34
Track tensioning mechanism - Tension adjust (D.50.B.48 - F.45.A.40)

CX135SR
NOTE: Check the tension of the tracks as required. Adjust the tension according to the type of surface on which
the machine will be operating. Tighten the track for operation on hard surfaces and loosen the track for operation
on soft surfaces.
1. Park the machine on a hard, level surface. Rotate
the upperstructure of the machine so that the cab is
over the track to be checked.
2. Lower the attachment to raise the machine until
the track to be checked is a few centimetres off the
ground.
CRIL03G121A00 1
3. Measure the distance between the bottom of the

track frame and the top of the track shoe, which
should be:
Steel tracks 240 - 269 mm

Steel tracks with rubber pad 220 - 240 mm
Rubber tracks 125 - 135 mm
CRIL03G143A00 2
4. Proceed as follows to increase the track tension:

Clean the grease tting of the track adjustment
cylinder.
Ensure that the check valve is tight.
CRIL03G124A00 3
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D.50.B / 35
5. Inject grease into the track tension cylinder until the

required tension is obtained.
DANGER
your hands and body away from any pressurized
CRIL03G144A00 4
6. Proceed as follows to reduce the track tension:

Do not remove the check valve. The grease in
the track tension cylinder is under high pressure.
Slacken the track by slowly loosening the check
valve about two turns, the grease will escape from
an orice in the valve thread.
CRIL03G124A00 5
7. When the track tension is correct, tighten the check

valve.
8. Clean the grease from the check valve.
27065 1 14/12/2004
D.50.B / 36
Track tensioning mechanism Shock absorber - Remove

(D.50.B.48.70 - F.10.A.10)
CX135SR

Move the machine until the track chain is free of the
idler wheel.
CRIL03G189A00 1
2. Attach a nylon sling from the lifting device to the

idler wheel.
CRIL03G190A00 2
3. Using a crowbar, move the idler wheel and the

shock absorber/spring assembly out of the chassis
housing.
CRIL03G191A00 3
27065 1 14/12/2004
D.50.B / 37
4. Using a crowbar, move the idler wheel and shock

absorber spring away from the chassis housing
until a nylon sling can be attached to the shock
absorber-spring assembly.
Remove the screws and washers which attach the
idler wheel to the shock absorber yoke.
Remove the idler wheel.
CRIL03G192A00 4
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D.50.B / 38
Track tensioning mechanism Shock absorber - Disassemble

(D.50.B.48.70 - F.10.A.25)
CX135SR
ATTENTION: The shock absorber spring is highly compressed.

1. Place the shock absorber assembly in a hydraulic
press.
Operate the hydraulic press to compress the shock
absorber spring (2).
Remove the pin (5) from the slotted nut (4).
Remove the slotted nut (4) from the spring guide (1).
Carefully operate the press to decompress the
shock absorber spring (2).
Remove the yoke (3) and the shock absorber spring
(2) from the spring guide (1).
CRIL03I148A01 1
27065 1 14/12/2004
D.50.B / 39
Track tensioning mechanism Shock absorber - Assemble

(D.50.B.48.70 - F.10.A.20)
CX135SR
ATTENTION: The shock absorber spring is highly compressed.

1. Mount spring guide (1) in a hydraulic press.
Place shock absorber spring (2) and yoke (3) on
spring guide (1).
CRIL03I148A01 1
2. Carefully operate the hydraulic press to compress

the shock absorber spring (2) to preloaded value
(A).
(A) = 419 mm
CRIL03I147A01 2
3. Install slotted nut (4) in contact with spring guide (1).

Install pin (5) in slotted nut (4) and spring guide
shaft (1).
Operate the hydraulic press to decompress the
assembly and remove the shock absorber.
27065 1 14/12/2004
D.50.B / 40
Track tensioning mechanism Shock absorber - Install (D.50.B.48.70

- F.10.A.15)
CX135SR
1. Attach a suitable lifting device to the idler wheel and

bring it into position on the shock absorber yoke.
Apply thread locking uid to the screws tted with
washers and tighten to a torque of 267 - 312 Nm
2. Attach a sling from the lifting equipment to the idler
wheel and shock absorber assembly.
CRIL03G199A00 1
3. Raise the idler wheel and shock absorber assembly

and install it in the chassis housing.
Push the idler wheel and the shock absorber into
the chassis.
Remove the lifting equipment from the idler wheel
and the back of the shock absorber.
CRIL03G196A00 2
4. Insert the lifting equipment sling into the central

orice of the shock absorber yoke.
CRIL03G197A00 3
27065 1 14/12/2004
D.50.B / 41
5. Raise the assembly and slide it into the chassis,

using a crowbar. Remove the lifting equipment.
CRIL03G198A00 4
Next operation: Steel track - Install (D.50.B.46 - F.10.A.15)
27065 1 14/12/2004
D.50.B / 42
Track tensioning mechanism Adjuster-recoil mechanism - Remove

(D.50.B.48.65 - F.10.A.10)
CX135SR

Prior operation:
Prior operation: Remove the roller located under the tension cylinder, refer to Roller Lower roller - Remove
(D.50.B.56.10 - F.10.A.10)
IMPORTANT: Do not place any part of your body under the tension cylinder.
You could be seriously injured if the cylinder falls when the screws securing it to the machine are removed.
DANGER
SA024 - Hydraulic uid or grease injected into your skin can cause severe injury or death. Keep your hands
and body away from any pressurized leak. If uid is injected into your skin, see a doctor immediately
and have the uid removed.
1. Unscrew the tension cylinder check valve.

Place wooden blocks under the tension cylinder to
prevent it from falling from the machine when the
screws securing it to the machine are removed.
Remove the screws and the at washers.
CRIL03G212A01 1
2. Using a crowbar, push the piston rod into the

cylinder barrel.
The grease will ow out of the check valve.
Remove the tension cylinder from the machine.
CRIL03G213A00 2
27065 1 14/12/2004
D.50.B / 43
Track tensioning mechanism Adjuster-recoil mechanism -

Disassemble (D.50.B.48.65 - F.10.A.25)
CX135SR
NOTE: The numbers in parentheses refer to Track tensioning mechanism Adjuster-recoil mechanism -
Exploded view (D.50.B.48.65 - C.10.A.20)
1. Remove the two screws (3) and the locking washers
(4).
Remove the bracket (5).
2. Remove the grease tting (6) from the check valve.
3. Remove the check valve from the cylinder barrel
(15).
4. If necessary, disassemble the check valve by

removing the valve (7), spring (8) and ball (9) from
the check valve body (10).
5. Remove the cylinder rod (11) from the cylinder
barrel (15).
CRIL03G220A01 1
6. With a screwdriver, remove the seal (12) from the

cylinder barrel (15).
7. Remove the ring (13) and discard the seal (14).
27065 1 14/12/2004
D.50.B / 44
Track tensioning mechanism Adjuster-recoil mechanism -

Assemble (D.50.B.48.65 - F.10.A.20)
CX135SR
NOTE: The numbers in parentheses refer to Track tensioning mechanism Adjuster-recoil mechanism -
Exploded view (D.50.B.48.65 - C.10.A.20)
1. Install the seal (14) and the ring (13) in the cylinder
barrel (15).
CRIL03G220A01 1
2. Use a centring piece (A) to insert the wiper seal

(12) into the cylinder barrel (15) until it touches the
barrel collar.
CRIL03G221A01a 2
3. Install the cylinder rod (11) in the cylinder barrel (15).

4. If the check valve has been dismantled, install the
ball (9) spring (8) and the valve (7) in the check
valve body (10).
Install the grease tting (6) in the check valve body.
5. Install the check valve assembly on the cylinder
barrel (15).
Tighten the check valve to a torque of 59 Nm.
6. Install the bracket (5) on the cylinder barrel (15).
Mount the locking washers (4) on the screws (3)
and fasten the bracket to the cylinder barrel.
27065 1 14/12/2004
D.50.B / 45
Track tensioning mechanism Adjuster-recoil mechanism - Install

(D.50.B.48.65 - F.10.A.15)
CX135SR
1. Check that the cylinder rod is inserted as far as

possible into the cylinder barrel.
CRIL03G213A00 1
2. Move the tension cylinder into position.

Apply thread lock uid to the screws.
Support the tension cylinder whilst an assistant
installs the at washers and screws to secure it.
Tighten the screws.
CRIL03G212A01 2
Next operation: Install the roller located under the tension cylinder, refer to Roller Lower roller - Install
(D.50.B.56.10 - F.10.A.15)
Next operation: Steel track - Install (D.50.B.46 - F.10.A.15)
27065 1 14/12/2004
D.50.B / 46
Roller - Leakage test (D.50.B.56 - F.40.A.40)

CX135SR
Use tools CAS-1450 and CAS-1682 for this test.
1. Connect shut-off valve (1) to pressure regulator

(2). Connect a union for the air supply hose to the
shut-off valve.
CRIL03G154A01 1
2. Install the adapter and a quick coupling on the oil

lling port. Use a sealing ring with the adapter.
3. Turn the knob anti-clockwise to close pressure
regulator (2).
4. Connect the pressure gauge pipe to the quick
coupling.
5. Make sure that shut-off valve (1) is open.
6. Adjust pressure regulator (2) until the pressure
gauge shows 1.9 bar.
7. Turn the shaft of the unit under test four revolutions.
8. Adjust the pressure regulator until the pressure
gauge shows 1 bar.
9. Close the shut-off valve. Maintain air pressure
for 10 seconds. A drop in air pressure during this
time indicates a defective component or incorrect
assembly.
27065 1 14/12/2004
D.50.B / 47
Roller Lower roller - Remove (D.50.B.56.10 - F.10.A.10)

CX135SR
1. Swing the upperstructure at right angles to the

undercarriage.
Press the attachment against the ground until the
track (1) is lifted off the gound and there is sufcient
clearance between the track frame and the track to
remove the lower roller.
Shut down the engine and remove the starter switch
key.
CRIL03G050A01 1
2. Install blocks or a suitable support under the

machine.
CRIL03I176A01 2

thread.
DANGER
CRIL03I179A01 3
4. Place wooden blocks under the track at both ends.
CRIL03I177A01 4
27065 1 14/12/2004
D.50.B / 48
5. Place a wooden block under the lower roller to

support it.
Remove the xing screws and washers.
Remove the lower rollers (A).
CRIL03I178A01 5
27065 1 14/12/2004
D.50.B / 49
Roller Lower roller - Disassemble (D.50.B.56.10 - F.10.A.25)

CX135SR
NOTE: When the lower roller is worn or leaking, it must be reconditioned or replaced with a new one. Refer to
Roller Lower roller - Service limits (D.50.B.56.10 - D.20.A.20)
1. Clean lower roller (1) using a suitable solvent.
Remove the two drain plugs (2) and drain the oil.
CRIL03G214A01 1
2. Discard the circlips (3).

Remove bearings (4).
CRIL03G215A01 2
3. Discard seals (5).

NOTE: The seal (5) has four components: two rubber
rings and two metal rings. When bearings (4) are
removed, one rubber ring and one metal ring are located
in either lower roller seal housing (1), or on shaft (6).
CRIL03G216A01 3
27065 1 14/12/2004
D.50.B / 50

Remove the shaft (6).
CRIL03G217A01 4
5. Discard seals (5) on roller (1) or shaft (6) Refer

to Roller Lower roller - Visual inspection
(D.50.B.56.10 - F.40.A.10)
CRIL03G218A01 5
6. Discard bushings (8) if necessary.
CRIL03G219A01 6
27065 1 14/12/2004
D.50.B / 51
Roller Lower roller - Visual inspection (D.50.B.56.10 - F.40.A.10)

CX135SR
1. Use cleaning solvent to clean all components.

2. Inspect the contact surfaces of the bushings on the
shaft for scoring, pitting and other damage.
Measure the diameter of the shaft at four opposing
points.
Compare the values with the specications, replace
if necessary.
NOTE: for the specications, refer to Roller Lower roller
- Service limits (D.50.B.56.10 - D.20.A.20)
3. Check that the bushings do not show any signs of
wear or damage. Measure the inner diameter and
width of the bushing.
them if necessary.
4. Check for any damage that is likely to cause leaks in
the bore in each end bearing and in the lower roller.
Replace components as necessary.
27065 1 14/12/2004
D.50.B / 52
Roller Lower roller - Assemble (D.50.B.56.10 - F.10.A.20)

CX135SR
1. If bushings (8) have been removed, install new

bushings in the roller using a centring piece and a
hydraulic press.
CRIL03G219A02 1
2. Install one of the rubber sealing rings and one of

the metal sealing rings (5) in the seal housing on
the roller (1).
NOTE: The seal (5) has four components:
Two rubber rings and two metal rings. One rubber ring
and one metal ring are tted in the seal housing on roller
(1). The two remaining rings are tted in the seal housing
of bearing (4).
CRIL03G218A01 2
3. Grease the surface of the shaft (6) and install the

shaft in the roller (1).
Install seals (7) on shaft (6).
CRIL03G217A02 3
4. Install the remaining rubber and metal sealing

rings (5) in the seal bore of bearings (4). Apply a
generous amount of clean oil to the seals.
CRIL03G216A01 4
27065 1 14/12/2004
D.50.B / 53
5. Install bearings (4) on shaft (6) and install circlips

(3).
Install one of the plugs (2).
To check for leaks, refer to, Roller - Leakage test
(D.50.B.56 - F.40.A.40)
CRIL03G215A02 5
6. Fill the roller with oil.

Install the other plug (2).
CRIL03G214A02 6
27065 1 14/12/2004
D.50.B / 54
Roller Lower roller - Install (D.50.B.56.10 - F.10.A.15)

CX135SR
1. Install each lower roller (A) underneath the frame.
CRIL03I178A01 1
2. Install hardened washers on the screws.

Coat the screws with thread locking uid and tighten
them to a torque of 267 - 312 Nm
Repeat the operation for each roller.
3. Remove the wooden shims underneath each end
of the track.
CRIL03I177A01 2
4. Remove the shims or the stand.
CRIL03I176A01 3
27065 1 14/12/2004
D.50.B / 55
Roller Upper roller - Remove (D.50.B.56.20 - F.10.A.10)

CX135SR
1. Park the machine on a hard, level surface.

Lower the tool to the ground.
CRIL03G121A00 1

thread.
DANGER
CRIL03G124A00 2
3. Install a hydraulic jack on the track frame.

Raise the track.
CRIL03G145A00 3
4. Place wooden blocks between the track and the

track frame.
CRIL03G146A00 4
27065 1 14/12/2004
D.50.B / 56
5. Unscrew the screws fastening the upper roller to

the track frame.
CRIL03G147A00 5
6. Remove the upper roller.
CRIL03G148A00 6
27065 1 14/12/2004
D.50.B / 57
Roller Upper roller - Disassemble (D.50.B.56.20 - F.10.A.25)

CX135SR
NOTE: When the upper roller is worn or leaks, it should be reconditioned or replaced by a new one; for wear limits,
refer to Roller Upper roller - Service limits (D.50.B.56.20 - D.20.A.20)
1. Clean upper roller (1) using a suitable solvent.
Remove drain plug (2) and drain the oil.
CRIL03J035A01 1
2. Secure the upper roller in a vice.

Remove screws (2) and cover (3) from upper roller
(1).
Discard seal (4).
CRIL03J036A01 2
3. Remove screws (1) and thrust plate (2).
CRIL03J037A01 3
27065 1 14/12/2004
D.50.B / 58
4. Remove roller (1) from shaft (2).
CRIL03J038A01 4
5. Remove seal (1) from bracket (2) and roller (1).
CRIL03J039A01 5
6. Using a press, remove shaft (1) from bracket (2).

Be careful not to damage the seal bore.
CRIL03J040A01 6
7. Using a hammer and a brass drift, remove bushing

(1) from roller (2).
CRIL03J041A01 7
27065 1 14/12/2004
D.50.B / 59
Roller Upper roller - Visual inspection (D.50.B.56.20 - F.40.A.10)

CX135SR
1. Use cleaning solvent to clean all components.

2. Inspect the contact surfaces on the shaft covers for
scoring, pitting and other damage.
Measure the diameter of the shaft at four opposing
points.
if necessary.
NOTE: for the specications, refer to Roller Upper roller
- Service limits (D.50.B.56.20 - D.20.A.20).
3. Check for wear and damage to the covers.
4. Check for wear or damage to the bearings, replace
them if necessary.
5. Check for any damage that might cause leaks
between the bore in the support and the upper roller.
Replace components as necessary.
27065 1 14/12/2004
D.50.B / 60
Roller Upper roller - Assemble (D.50.B.56.20 - F.10.A.20)

CX135SR
1. Using a press, install shaft (1) in bracket (2).
CRIL03J042A01 1
2. Using a press, install bushing (1) in roller (2).
CRIL03J041A01 2
3. Install seal (1) in bracket bore (2).

Apply a generous amount of clean oil to the seals
(1).
CRIL03J039A01 3
4. Grease shaft (1) and install it in roller (2).
CRIL03J038A01 4
27065 1 14/12/2004
D.50.B / 61
5. Install thrust plate (2) in the roller and install screws

(1).
CRIL03J037A01 5
6. Install seal (4) on cover (3).

Using a press, install the cover on roller (3).
Install cover (3) on roller (1) and install screws (2).
CRIL03J036A01 6
7. To check for leaks, refer to Roller - Leakage test

(D.50.B.56 - F.40.A.40).
Fill the upper roller with oil and install plug (2) on
roller (1).
CRIL03J035A01 7
27065 1 14/12/2004
D.50.B / 62
Roller Upper roller - Install (D.50.B.56.20 - F.10.A.15)

CX135SR
1. Place blocks on the track frame.

Mount and support the upper roller.
CRIL03G152A00 1
2. Apply thread lock uid to the screw threads.

Install hardened washers on the screws.
Fix the upper roller support to the track frame.
Tighten the screws to a torque of 267 - 312 Nm.
CRIL03G147A00 2
3. Remove the wooden blocks between the track shoe

and the track frame.
CRIL03G145A00 3
4. Release the pressure from the hydraulic jack.

Lower the track onto the upper roller.
Remove the jack.
Next operation: .Track tensioning mechanism - Tension adjust (D.50.B.48 - F.45.A.40)
27065 1 14/12/2004
D.50.B / 63
Idler wheel - Disassemble (D.50.B.57 - F.10.A.25)

CX135SR
1. Place idler wheel (2) on supports with drain plug (1)

at the bottom.
Remove drain plug (1) from slide block (4).
CRIL03G233A01 1
2. Remove the pin (3) at one end.

Pull slide block (4) off shaft (6).
CRIL03G234A01 2
3. Discard seal (5).

Remove shaft (6) with slide block (4).
CRIL03G235A01 3
4. Remove pin (3).

Remove the slide block (4) from the shaft (6).
Discard the seal (5) on shaft (6).
CRIL03G236A01 4
27065 1 14/12/2004
D.50.B / 64
5. Discard the seal (7) on slide block (4).
CRIL03G237A01 5
6. Discard the seal on the (7) idler wheel.
CRIL03G238A01 6
7. Discard the bushings (8) if necessary.

Make sure you do not damage the idler wheel seal
bore.
CRIL03G239A01 7
27065 1 14/12/2004
D.50.B / 65
Idler wheel - Assemble (D.50.B.57 - F.10.A.20)

CX135SR
1. Place bushings (8) under a press.

Insert a driver between the bushing and press.
Activate the press.
CRIL03G240B01b 1
2. Fit a seal and a metal bushing in the idler wheel

bore.
Repeat this step to t the seal on the other side of
the idler wheel.
CRIL03G238A01 2
3. Fit the seal and the remaining metal bushing in the

seal bore of slide blocks (4).
CRIL03G237A01 3
27065 1 14/12/2004
D.50.B / 66
4. Fit the seal (5) on the shaft (6).

Fit the shaft in the hub (4).
Secure the guide block and the shaft with pin (3).
CRIL03G236A01 4
5. Install the shaft and slide block assembly on the

idler wheel.
CRIL03G235A01 5
6. Fit the other seal (5) on shaft (6).

Mount guide block (4) on shaft.
Fit pin (3) to secure the slide block and the shaft.
CRIL03G241A01 6
7. Check for leaks, refer to Roller - Leakage test

(D.50.B.56 - F.40.A.40)
8. Fill the slide blocks (4) with oil.
Fit the drain plugs (1).
CRIL03G233A01 7
27065 1 14/12/2004
D.50.B / 67
Index
TRAVELLING - D

Drive sprocket - Install (D.50.B.45 - F.10.A.15) 21
CX135SR
Drive sprocket - Remove (D.50.B.45 - F.10.A.10) 19
CX135SR
Drive sprocket - Service limits (D.50.B.45 - D.20.A.20) 6
CX135SR
Drive sprocket - Special tools (D.50.B.45 - D.20.A.40) 5
CX135SR
Idler wheel - Assemble (D.50.B.57 - F.10.A.20) 66
CX135SR
Idler wheel - Disassemble (D.50.B.57 - F.10.A.25) 64
CX135SR
Idler wheel - Service limits (D.50.B.57 - D.20.A.20) 13
CX135SR
Idler wheel - Special tools (D.50.B.57 - D.20.A.40) 12
CX135SR
Roller - Leakage test (D.50.B.56 - F.40.A.40) 47
CX135SR
Roller Lower roller - Assemble (D.50.B.56.10 - F.10.A.20) 53
CX135SR
Roller Lower roller - Disassemble (D.50.B.56.10 - F.10.A.25) 50
CX135SR
Roller Lower roller - Install (D.50.B.56.10 - F.10.A.15) 55
CX135SR
Roller Lower roller - Remove (D.50.B.56.10 - F.10.A.10) 48
CX135SR
Roller Lower roller - Sectional view (D.50.B.56.10 - C.10.A.30) 17
CX135SR
Roller Lower roller - Service limits (D.50.B.56.10 - D.20.A.20) 9
CX135SR
Roller Lower roller - Special tools (D.50.B.56.10 - D.20.A.40) 8
CX135SR
Roller Lower roller - Visual inspection (D.50.B.56.10 - F.40.A.10) 52
CX135SR
Roller Upper roller - Assemble (D.50.B.56.20 - F.10.A.20) 61
CX135SR
Roller Upper roller - Disassemble (D.50.B.56.20 - F.10.A.25) 58
CX135SR
Roller Upper roller - Install (D.50.B.56.20 - F.10.A.15) 63
CX135SR
Roller Upper roller - Remove (D.50.B.56.20 - F.10.A.10) 56
CX135SR
Roller Upper roller - Sectional view (D.50.B.56.20 - C.10.A.30) 18
CX135SR
Roller Upper roller - Service limits (D.50.B.56.20 - D.20.A.20) 11
CX135SR
Roller Upper roller - Special tools (D.50.B.56.20 - D.20.A.40) 10
CX135SR
Roller Upper roller - Visual inspection (D.50.B.56.20 - F.40.A.10) 60
CX135SR
27065 1 14/12/2004
D.50.B / 68
Rubber track - Install (D.50.B.47 - F.10.A.15) 33
CX135SR
Rubber track - Remove (D.50.B.47 - F.10.A.10) 31
CX135SR
Rubber track - Visual inspection (D.50.B.47 - F.40.A.10) 30
CX135SR
Steel track - Exploded view (D.50.B.46 - C.10.A.20) 14
CX135SR
Steel track - Install (D.50.B.46 - F.10.A.15) 26
CX135SR
Steel track - Remove (D.50.B.46 - F.10.A.10) 22
CX135SR
Steel track - Service limits (D.50.B.46 - D.20.A.20) 7
CX135SR
Steel track Chain - Measure (D.50.B.46.20 - F.40.A.16) 29
CX135SR
Track tensioning mechanism - Tension adjust (D.50.B.48 - F.45.A.40) 35
CX135SR
Track tensioning mechanism Adjuster-recoil mechanism - Assemble (D.50.B.48.65 - F.10.A.20) 45
CX135SR
Track tensioning mechanism Adjuster-recoil mechanism - Disassemble (D.50.B.48.65 - F.10.A.25) 44
CX135SR
Track tensioning mechanism Adjuster-recoil mechanism - Exploded view (D.50.B.48.65 - 16
C.10.A.20)
CX135SR
Track tensioning mechanism Adjuster-recoil mechanism - Install (D.50.B.48.65 - F.10.A.15) 46
CX135SR
Track tensioning mechanism Adjuster-recoil mechanism - Remove (D.50.B.48.65 - F.10.A.10) 43
CX135SR
Track tensioning mechanism Shock absorber - Assemble (D.50.B.48.70 - F.10.A.20) 40
CX135SR
Track tensioning mechanism Shock absorber - Disassemble (D.50.B.48.70 - F.10.A.25) 39
CX135SR
Track tensioning mechanism Shock absorber - Exploded view (D.50.B.48.70 - C.10.A.20) 15
CX135SR
Track tensioning mechanism Shock absorber - Install (D.50.B.48.70 - F.10.A.15) 41
CX135SR
Track tensioning mechanism Shock absorber - Remove (D.50.B.48.70 - F.10.A.10) 37
CX135SR
27065 1 14/12/2004
D.50.B / 69
SERVICE
PRINTED IN FRANCE
27064 1 14/12/2004
REPAIR MANUAL
BODY AND STRUCTURE
CX135SR
27066 1 14/12/2004
E
Contents
BODY AND STRUCTURE - E
SHIELD E.20.A
CX135SR
USER CONTROLS AND SEAT E.32.A

CX135SR
USER PLATFORM E.34.A

CX135SR
ENVIRONMENT CONTROL Heating, ventilation and air-conditioning E.40.D

CX135SR
SAFETY SECURITY ACCESSORIES Safety E.50.B

CX135SR
27066 1 14/12/2004
E
SHIELD - 20.A
CX135SR
27067 1 14/12/2004
E.20.A / 1
Contents
SHIELD - 20.A
SERVICE
Side shield
Side shield - Remove (E.20.A.70 - F.10.A.10) 3
CX135SR
Upper shield
Upper shield - Remove (E.20.A.71 - F.10.A.10) 5
CX135SR
Engine hood
Engine hood - Remove (E.20.A.72 - F.10.A.10) 7
CX135SR
Protective shield
Protective shield - Remove (E.20.A.73 - F.10.A.10) 8
CX135SR
27067 1 14/12/2004
E.20.A / 2
BODY AND STRUCTURE - SHIELD
Side shield - Remove (E.20.A.70 - F.10.A.10)

CX135SR
1. CAB FLOOR PROTECTION

To reach the hardware, remove the mat on the cab
oor (screws under the foam caps).
The other hardware items are underneath the cab
oor.
CRPH03I072A 1
2. RH REAR DOOR
This door is attached by a hinge held by hardware
(1).
CRIL03J072A01 2
3. RH FRONT DOOR
(1).
CRIL03J073A01 3
4. CONTROL VALVE SIDE PROTECTION PANEL

Remove RH front door (7).
Remove the xing with the windscreen washer
reservoir.
To remove upper protective panel (2) from hydraulic
lter, refer to Upper shield - Remove (E.20.A.71 -
F.10.A.10).
To remove valve bank hood (1) and step (6), refer to
Upper shield - Remove (E.20.A.71 - F.10.A.10).
To remove front protective panel (4) from hydraulic
control valve, refer to Upper shield - Remove
(E.20.A.71 - F.10.A.10).
Remove retaining screws
Remove side protection (5) from hydraulic control CRIL03K047A01 4
valve.
27067 1 14/12/2004
E.20.A / 3
5. SIDE TANK PROTECTION

Remove protective panel (1) held by screws (2).
The other hardware items (3) are underneath the
chassis.
CRIL03K046A01 5
6. LH REAR DOOR
(1).
CRIL03J071A01 6
7. TRAVEL MOTOR PROTECTIVE SHIELD

These panels are xed with screws (1).
CRIL03J074A01 7
27067 1 14/12/2004
E.20.A / 4
Upper shield - Remove (E.20.A.71 - F.10.A.10)

CX135SR
1. REAR PROTECTIVE PANELS

(1) Hydraulic pump protective panel.
(2) Counterweight protective panel.
CRIL03J079A01 1
2. SWING MOTOR PROTECTIVE PANEL

(1) Swing motor protective panel.
(1) Access panel to expansion tank.
CRIL03J120A01 2
3. HYDRAULIC RESERVOIR PROTECTIVE PANEL

(1) Fuel and hydraulic tank protective panel.
(2) Hydraulic lter protective panel.
CRIL03J119A01 3
4. CONTROL VALVE COVER

(1) Valve bank hood and step.
CRIL03J080A01 4
27067 1 14/12/2004
E.20.A / 5
5. HYDRAULIC CONTROL VALVE FRONT

PROTECTIVE PANEL
Protective panel (1) gives access to swing pilot
shock absorber.
Protective panels (2), (4) and (5) give access to
control valve hoses.
Protective panel (3) gives access to the horn.
CRIL03J121B01 5
6. SAFETY RAIL.
Remove the RH tank side guard.
Remove the upper protective panel from hydraulic
reservoir.
Remove screws (1) and (2), then remove handrail
(3).
CRIL03L205A01 6
7. VALVE BANK COVER SUPPORT

Remove xing screws (1) and support (2).
CRIL03J122A01 7
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Engine hood - Remove (E.20.A.72 - F.10.A.10)

CX135SR
1. Open the hood.

Attach the hood to a suitable lifting device using
slings.
Remove support strut (2).
Remove xing screws (1) from the hinges.
Remove the hood.
CRIL03J063A01 1
27067 1 14/12/2004
E.20.A / 7
Protective shield - Remove (E.20.A.73 - F.10.A.10)

CX135SR
1. HYDRAULIC SWIVEL PROTECTIVE PANEL

(UNDERNEATH UNDERCARRIAGE)
(1) Hydraulic swivel access panel.
CRIL04C143A01 1
2. LOWER PROTECTIVE PANELS (UNDERNEATH

UPPERSTRUCTURE)
(1) Access panel to engine.
(2) Access panel cab oor.
(3) Access panel to hydraulic pump.
(4) Access panel to hydraulic reservoir.
(5) Access panel to fuel tank.
(6) Access panel to air-conditioning compressor
belt tightener.
(7) Access panel to radiator mounting.
(8) Access panel radiator drain cock.
CRIL04B174B01 2
3. CAB FLOOR PROTECTIVE PANEL

(1) Access panel to cab oor.
CRIL03I143A01 3
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E.20.A / 8
Index
SHIELD - 20.A
Engine hood - Remove (E.20.A.72 - F.10.A.10) 7
CX135SR
Protective shield - Remove (E.20.A.73 - F.10.A.10) 8
CX135SR
Side shield - Remove (E.20.A.70 - F.10.A.10) 3
CX135SR
Upper shield - Remove (E.20.A.71 - F.10.A.10) 5
CX135SR
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USER CONTROLS AND SEAT - 32.A
CX135SR
27068 1 14/12/2004
E.32.A / 1
Contents
FUNCTIONAL DATA
Instrument panel
Instrument panel - Detailed view (E.32.A.81 - C.10.A.50) 3
CX135SR
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E.32.A / 2
BODY AND STRUCTURE - USER CONTROLS AND SEAT
Instrument panel - Detailed view (E.32.A.81 - C.10.A.50)

CX135SR
CRIL03K120F01 1
(1) Coolant or hydraulic oil overheating indicator lamp

(2) Engine oil pressure indicator lamp
(3) Minimum fuel level indicator lamp
(4) Battery charge indicator lamp
(5) Engine electrical system fault indicator lamp
(6) Preheating indicator lamp
(7) Fuel level indicator
(8) Engine coolant temperature gauge
(P5) Hourmeter
(S2) Travel gear switch
(S10) Working light switch
(S11) Windscreen wiper switch
(S12) Windscreen washer switch
27068 1 14/12/2004
E.32.A / 3
Index

Instrument panel - Detailed view (E.32.A.81 - C.10.A.50) 3
CX135SR
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USER PLATFORM - 34.A
CX135SR
27069 1 14/12/2004
E.34.A / 1
Contents
FUNCTIONAL DATA
Wiper system
Wiper system - Electronic schema (E.34.A.65 - C.20.A.50) 3
CX135SR
Windscreen washer system

Windscreen washer system - Electronic schema (E.34.A.66 - C.20.A.50) 4
CX135SR
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E.34.A / 2
BODY AND STRUCTURE - USER PLATFORM
Wiper system - Electronic schema (E.34.A.65 - C.20.A.50)

CX135SR
CRIL03G229E01 1
Circuit layout
(1) Windscreen wiper intermittent indicator lamp (2) Windscreen wiper continuous indicator lamp
(K20) Windscreen wiper motor relay (M3) Windscreen wiper motor
(P1) Instrument panel (S11) Windscreen wiper switch
CRIL03G230E02 2
Timing diagram
(A) Intermittent position (B) Continuous position
OPERATION
• The intermittent (1) and continuous (2) windscreen wiper indicator lamps do not light up when the windscreen
washer switch is operated.
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BODY AND STRUCTURE - USER PLATFORM
Windscreen washer system - Electronic schema (E.34.A.66 -

C.20.A.50)
CX135SR
CRIL03G231E01 1
Circuit layout
(K21) Windscreen washer pump relay (M4) Windscreen washer pump motor
(P1) Instrument panel (S12) Windscreen washer switch
CRIL03G232E02 2
Timing diagram
(K20) Windscreen wiper motor relay
OPERATION
• The intermittent and continuous windscreen wiper indicator lamps do not light up when windscreen washer
switch (S12) is operated.
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Index

Windscreen washer system - Electronic schema (E.34.A.66 - C.20.A.50) 4
CX135SR
Wiper system - Electronic schema (E.34.A.65 - C.20.A.50) 3
CX135SR
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ENVIRONMENT CONTROL Heating, ventilation and air-conditioning

- 40.D
CX135SR
27070 1 14/12/2004
E.40.D / 1
Contents
ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - 40.D
TECHNICAL DATA
ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - Special tools 4
(E.40.D - D.20.A.40)
CX135SR
FUNCTIONAL DATA
ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - Dynamic 6
description (E.40.D - C.30.A.10)
CX135SR
Command
Command - Overview (E.40.D.05 - C.10.A.10) 8
CX135SR
Electronic HVAC control

Electronic HVAC control - Electrical schema (E.40.D.92 - C.20.A.40) 9
CX135SR
SERVICE
ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - Evacuate 10
(E.40.D - F.35.A.35)
CX135SR
ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - Charging (E.40.D 11

- F.60.A.30)
CX135SR
ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - Disassemble 12

(E.40.D - F.10.A.25)
CX135SR
Compressor
Compressor - Remove (E.40.D.31 - F.10.A.10) 16
CX135SR
Compressor - Install (E.40.D.31 - F.10.A.15) 17

CX135SR
Condenser
Condenser - Remove (E.40.D.32 - F.10.A.10) 18
CX135SR
Condenser - Install (E.40.D.32 - F.10.A.15) 19

CX135SR
Receiver/drier
Receiver/drier - Remove (E.40.D.36 - F.10.A.10) 20
CX135SR
Receiver/drier - Install (E.40.D.36 - F.10.A.15) 21

CX135SR
DIAGNOSTIC
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ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - Troubleshooting 22
(E.40.D - G.40.A.10)
CX135SR
Compressor
Compressor Magnetic clutch - Troubleshooting (E.40.D.31.80 - G.40.A.10) 23
CX135SR
Ventilation system
Ventilation system - Troubleshooting (E.40.D.60 - G.40.A.10) 23
CX135SR

CX135SR

CX135SR
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E.40.D / 3
BODY AND STRUCTURE - ENVIRONMENT CONTROL Heating, ventilation and air-conditioning

- Special tools (E.40.D - D.20.A.40)
CX135SR
Tools required for air-conditioning control

Refrigerant recovery, recycling OEM-1418
and charging station
CRPH03I021A 1
Electronic leak detector OEM-1437
CRPH03I022A 2
Thermometer 0 - 250 °C CAS-1048
CRPH03I023A 3
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Belt tensioning tool CAS-10808
CRPH03I024A 4
Protective goggles CAS-10073-3
CRPH03I025A 5
27070 1 14/12/2004
E.40.D / 5

- Dynamic description (E.40.D - C.30.A.10)
CX135SR
The air conditioning system comprises ve major components: the condenser (5), the evaporator (3), the
compressor (4), the expansion valve (1) and the receiver-dryer (6). These components are connected by pipes and
hoses for closed circuit operation. The air-conditioning system runs on R-134a refrigerant.
The compressor receives the refrigerant in the form of gas. The compressor then compresses the refrigerant and,
still in its gaseous form, sends it to the condenser. The air circulates through the condenser and removes the
heat from the refrigerant. As the heat dissipates, the refrigerant becomes liquid. The liquid refrigerant circulates
from the condenser to the receiver-dryer. The receiver-dryer is a container lled with a material to extract the
moisture that accumulates in the air-conditioning circuit. The moisture must be eliminated to prevent the internal
components in the air-conditioning system from corroding. The receiver-dryer also acts as a refrigerant reservoir
for the air-conditioning system.
Still in liquid form, the refrigerant passes to the expansion valve. The expansion valve restricts the ow of the
refrigerant to the evaporator. Because of this restriction, the refrigerant is under less pressure at the expansion
valve outlet than at the inlet. As the refrigerant passes through the evaporator, it is warmed by the air surrounding
the evaporator. The combination of increased warmth and lower pressure causes the refrigerant to evaporate. The
evaporation cools the air circulating in the evaporation coil. The cooled air is then used to cool the driver’s cab.
The refrigerant, now in the gas phase again, returns to the compressor and the cycle is repeated.
27070 1 14/12/2004
E.40.D / 6
CRIL03I010G01 1
Air-conditioning circuit components
(1) Expansion valve (2) Temperature sensor

(3) Evaporator (4) Compressor
(5) Condenser (6) Receiver dehydrator
(7) Gas under low pressure (8) Gas under high pressure
(9) Liquid under low pressure (10) Liquid under high pressure
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Command - Overview (E.40.D.05 - C.10.A.10)

CX135SR
NOTE: Refer to the Operating and Maintenance Manual for the detailed use of these controls.
CRIL03I009F01 1
Heating, ventilation and air conditioning controls.
1. System ON/OFF selector switch and indicator lamp.
2. Air conditioning ON/OFF selector switch and indicator lamp.
3. Fan speed selector switch.
4. Temperature selector switch and indicator lamp.
5. Air circulation selector switches and indicator lamps:
Top front air vent.
Top front and rear vents.
Top and bottom rear vents.
6. Windshield defroster selector switch and indicator lamp.
7. Air inlet selector switch and indicator lamp.
Outside air inlet.
Inside air inlet.
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E.40.D / 8
Electronic HVAC control - Electrical schema (E.40.D.92 - C.20.A.40)

CX135SR
CRIL03I011G01 1
Air conditioning electrical circuit diagram
Description of electrical circuit iagram

(1) Air conditioning control panel (2) Air-conditioning compressor
(3) Pressure switch (4) Compressor clutch supply
(5) Fan speed information (6) Outside or recycled air selection information
(7) Air mixture moderator control (8) Air diffuser selection control
(9) Air conditioning electronic control box (10) Solar ray sensor
(11) Evaporator thermal sensor (12) Recycled air thermal sensor
(13) Anti-frost temperature information (14) windscreen open/closed information
(15) Cab door open/closed information (16) SCM electronic control box
(17) Shutter control motor (18) Fan control
(19) Recycling air sensor
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E.40.D / 9

- Evacuate (E.40.D - F.35.A.35)
CX135SR
CAUTION
M143B - Never attempt to service the air conditioning system unless you are completely familiar with air
conditioning and the safety precautions which must be followed when handling liquid refrigerant. Liquid
refrigerant can cause severe and painful frostbite. Contact your Dealer, who is experienced in servicing
and handling of refrigerants.
CAUTION
SM105A - Always wear safety goggles when working with liquid refrigerant. Liquid refrigerant in your
eyes could cause blindness.
CAUTION
SM109A - When refrigerant comes in contact with an open ame, it forms phosgene gas. Never breathe
these fumes.
CAUTION
M742 - Always reclaim all refrigerant prior to opening an A/C system. A drop of liquid refrigerant on your
skin may cause frostbite. Open ttings carefully and slowly when servicing the air conditioning system.
Your skin must be treated for frostbite or a physician must be seen if you get refrigerant on your skin.
CAUTION
M743 - Keep refrigerant containers in correct upright position. Always keep refrigerant containers away
from heat and sunlight. The pressure in a container will increase with heat.
ATTENTION: Service work on air-conditioning circuits must be carried out by approved service engineers.
NOTE: If possible, run the air-conditioning system for a few minutes before starting the recovery process. Shut
down the system before proceeding.
1. Clean the external surfaces of the compressor and
hoses.
Remove the caps from low (1) and high pressure
(2) test points.
Connect hoses on the recovery station OEM-1418
on the pressure test points:
Low pressure on port (1) (suction),
High pressure on port (2) (discharge).
Start recovery.
CRIL03L159A01 1
27070 1 14/12/2004
E.40.D / 10

- Charging (E.40.D - F.60.A.30)
CX135SR
1. Clean the external surfaces of the compressor and

hoses.
Remove the caps from low (1) and high pressure
(2) test points.
Connect hoses on the recovery station OEM-1418
on the pressure test points:
Low pressure on port (1) (suction),
High pressure on port (2) (discharge).
Load the circuit.
Circuit capacity: 750 - 850 g.
CRIL03L159A01 1
27070 1 14/12/2004
E.40.D / 11

- Disassemble (E.40.D - F.10.A.25)
CX135SR
CRIL03L149G01 1
Air-conditioning group
(1) Case (2) Filter

(3) Cover (4) Heater body
(5) Evaporator (6) Blower motor
(7) Clamp (8) Clips
(9) Filter (10) Filter
1. Remove the six xing screws and extract case (1).
2. Remove lters (2), (9) and (10).

3. Remove clips (8) using a screwdriver.
CRIL03L150A01 2
4. Remove the eleven xing screws and extract cover

(3).
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5. BLOWER MOTOR REPLACEMENT (6)

When assembling, follow the positioning of harness
(3) and heating hose (1) on blower motor (2) and
lower housing (4).
CRIL03L151A01 3
6. When installing a blower motor:

Check the distance between the fan and housing (
(A) more than or equal to 2 mm)
Centre motor fan (1) in housing (2).
CRIL03L152A01 4
7. EVAPORATOR REPLACEMENT (5)

Remove the evaporator from the case.
Remove thermistor (2) with sensor bracket (1).
Install bracket (1) and the sensor for thermistor (2)
on the second bank of ns (3) keeping distance (A)
= 47 - 48 mm.
CRIL03L153A01 5
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8. Position the thermistor in groove (1) provided for

this purpose then install the evaporator in the lower
housing.
CRIL03L154B01 6
9. EXPANSION VALVE REPLACEMENT

Remove the pipe at the expansion valve inlet and
the nut at the evaporator inlet. Discard seals.
Remove insulation from the temperature sensor,
remove the detection tube then remove the
expansion valve from the evaporator.
Install the new expansion valve on the evaporator
using new seals:
Torque setting on expansion valve inlet pipe 11.7
- 14.7 Nm.
Torque setting on nut at evaporator inlet 15.7 - 19.6
Nm - Nm.
Install the temperature sensor following distance
(A) = 105 - 115 mm. CRIL03L156A01 7
10. Insulate temperature sensor (1).
CRIL03L157A01 8
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E.40.D / 14
11. MOTOR CONTROL REPLACEMENT

Push clamp (A) towards the boom to remove it from
the lever.
Remove the four screws holding the control.
Install the lever on the new control.
CRIL03L155B01 9
27070 1 14/12/2004
E.40.D / 15
Compressor - Remove (E.40.D.31 - F.10.A.10)

CX135SR
Prior operation: To discharge the air-conditioning system, refer to ENVIRONMENT CONTROL Heating,
ventilation and air-conditioning - Evacuate (E.40.D - F.35.A.35)
CRIL03L161G01 1
1. Loosen and remove belt (2) by adjusting screw (1)

on the tension pulley.
2. Disconnect electric wire (3).
3. Remove screws (6) and disconnect suction (4) and
delivery (5) hoses.
Discard seal rings
Plug hose and compressor ports
4. Remove retaining screws (7).
Remove compressor (8).
5. Remove compressor bracket and tension pulley (9)
by removing screws (10).
27070 1 14/12/2004
E.40.D / 16
Compressor - Install (E.40.D.31 - F.10.A.15)

CX135SR
CRIL03L161G01 1
Torque settings
(6) Retaining screws for suction and delivery hoses 19.8 - 29.4 Nm
(7) Compressor retaining screws 19.8 - 29.4 Nm
(10) Bracket retaining screws 53.9 - 63.7 Nm
1. Install compressor bracket and tension pulley (9)
with screws (10).
2. Install compressor (8) on its bracket using screws
(7).
3. Connect suction (4) and delivery (5) hoses to the
compressor using screws (6) and new seal rings.
4. Install belt (2).
Tighten belt by adjusting screw (1) on the tension
pulley.
NOTE: By applying pressure of around 10 kg in the
middle of the belt, the tension slack should be 8 - 10 mm.
5. Connect electric wire (3).
Next operation: ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - Charging (E.40.D
- F.60.A.30)
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Condenser - Remove (E.40.D.32 - F.10.A.10)

CX135SR
Prior operation: Air cleaner - Remove (B.30.A.25 - F.10.A.10)
CRIL03L158F01 1
1. Remove screws (1) from the connectors on supply

(IN) and outlet (OUT) hoses on the condenser.
Discard seals.
2. Remove screws (2) and xing lugs (3) holding
condenser (4) on bracket (5).
3. To remove bracket (5), remove the hose supports,
then remove screws (6).
27070 1 14/12/2004
E.40.D / 18
Condenser - Install (E.40.D.32 - F.10.A.15)

CX135SR
CRIL03L158F01 1
1. Install bracket (5), tighten using screws (6).
2. Install condenser (4) on its bracket using screws (2)

and xing lugs (3).
Tighten screws (2) to 7.8 - 11.8 Nm.
3. Connect inlet (IN) and outlet (OUT) hoses to the
condenser using screws (1) and new seals.
Tighten screws (1) to 7.8 - 11.8 Nm.
Next operation: To charge the circuit, refer to ENVIRONMENT CONTROL Heating, ventilation and
air-conditioning - Charging (E.40.D - F.60.A.30)
Next operation: Air cleaner - Install (B.30.A.25 - F.10.A.15)
27070 1 14/12/2004
E.40.D / 19
Receiver/drier - Remove (E.40.D.36 - F.10.A.10)

CX135SR
CRIL03L160F01 1
1. Detach connector (1).

2. Remove screws (2) from the unions on inlet (IN) and
outlet hoses (OUT) on receiver-drier (3)
Discard the seals.
3. Remove screws (4) and remove receiver-drier (3)
from its bracket (5).
4. Remove screws (6) and support (5).
27070 1 14/12/2004
E.40.D / 20
Receiver/drier - Install (E.40.D.36 - F.10.A.15)

CX135SR
CRIL03L160F01 1
1. Install bracket (5) using screws (6).

2. Install receiver-drier (3) on its bracket (5).
Attach screws (4).
3. Connect inlet (IN) and outlet (OUT) hoses of
receiver-drier (3) with new seals and screws (2).
Tighten screws to a torque of 7.8 - 11.8 Nm.
4. Attach connector (1).
Next operation: ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - Charging (E.40.D
- F.60.A.30)
27070 1 14/12/2004
E.40.D / 21

- Troubleshooting (E.40.D - G.40.A.10)
CX135SR
NOTE: AIR CONDITIONING CIRCUIT

The high and low Air in the circuit. Replace the receiver-drier, remove the
pressures are above There are no air bubbles even if water is water and rell with refrigerant.
normal. placed on the condenser (the receiver-drier
remains cool)
Expansion valve defective or not Adjust or replace the valve.
connected to the thermostat pipe. Repair and connect the thermostat pipe to
The low pressure piping is cold, with large the expansion valve.
quantities of water or ice on the pipes.
Defective expansion valve. Clean, repair or replace the expansion
Clogged expansion valve or low pressure valve.
circuit evaporator.
Water placed on the condenser becomes
colder (the high and low pressures return
to normal)
Clogged condenser and/or radiator vanes. Clean the condenser and/or the radiator.
Defective refrigerant fan or slack drive belt. Repair the fan or adjust the belt tension.
The volume of blown air drops when the
air conditioning has been operating for a
long time.
Variation in high and The circuit is full of water Change the receiver-drier, eliminate the
low pressures at regular The blown air does not remain cold water and rell with refrigerant
intervals (they remain
at normal level with no
change in pressure)
The high and low Gas leak from components connected by Replace the parts or the pipes.
pressures are below pipes.
normal. Air bubbles apparent in the visual gauge,
oil in the pipework or the components
(positive reaction from leak tester)
Refrigerant low or non-existent due to poor Rell with refrigerant to normal level.
maintenance.
Air bubbles apparent in the visual gauge,
no oil in the circuit or the components
(negative reaction from leak tester)
Defective or clogged expansion valve. Repair, remove dust or replace the valve.
Clogged low pressure circuit evaporator. Adjust the refrigerant to its correct level.
Excess refrigerant.
Low pressure piping is not cold
Clogged evaporator vanes or air Wash the evaporator and/or replace the
conditioner lter. lter
Thermistor wrongly positioned Adjust the thermistor position
Gas leak in the air conditioner Repair the piping
Defective electrical circuit or thermistor Repair the electrical circuit or the
Ice forms on the evaporator when the thermistor
blower is at low speed Increase the temperature or the blower
The volume of blown air drops when the speed
air conditioning has been operating for a
certain time
Incorrect high and low Defective compressor. Replace the compressor.
pressures With the compressor stopped, the high
pressure drops again to the low pressure
level.
27070 1 14/12/2004
E.40.D / 22
Compressor Magnetic clutch - Troubleshooting (E.40.D.31.80 -

G.40.A.10)
CX135SR
NOTE: Symptom: MAGNETIC CLUTCH IS NOT FUNCTIONING

The "Frost" symbol lights No power supply to the clutch. Check the clutch fuse
up on the screen Check the air conditioning harness
Check the air conditioning control
Defective clutch or compressor Repair or replace
Pressure switch malfunction or incorrect Refer to ENVIRONMENT CONTROL
circuit pressure Heating, ventilation and air-
conditioning - Troubleshooting
(E.40.D - G.40.A.10)
The "Frost" symbol Defective evaporator connection or Repair or replace the parts
ashes and "5E°" is thermal detector
displayed on the screen
Ventilation system - Troubleshooting (E.40.D.60 - G.40.A.10)

CX135SR
NOTE: Electrical circuit fault detection table.

Symptom: THE BLOWN AIR IS NOT COLD ENOUGH
The audible alarm device Anti-overheating device activated Check that the device is functioning
sounds continuously correctly
HLE.0 to HLE.9 displayed Thermal detector or harness short-circuited Repair or replace the parts
on the screen or cut out
No contact with the thermal detector union Repair
HLE is displayed on the 1) Air mixture motor disconnected Repair motor or the electrical circuit
screen 2) Mixture motor defective connections
3) Electrical harness defective
The Frost symbol ashes Evaporator thermal detector connector Repair
on the screen disconnected or cut out
Evaporator thermal detector Replace
HLE.0 to HLE.9 displayed Cab and evaporator thermal detectors Repair or replace the parts
on the screen short-circuited at the same time
AND the Frost symbol
ashes
Defective control See electronic control box
Temperature set to 18° Cold air is reaching the thermal detector Check the conduit and correct the fault
and in rear ventilation allowing cold air to reach the thermal
mode the blown air is detector
colder than normal
Failure of controller and thermal detector Repair
Air mixture moderator in Compressor clutch control Repair the control
"Max. Cold" position
Supply circuit Refer to troubleshooting in the cooling
cycle
Motor actuator does not Defective motor actuator Repair
move and the force of the
blown air is less than 1,5
Kgf
Defective control Repair
Motor actuator does not Defective motor actuator lever Repair or replace the lever
move Clean and grease the lever
27070 1 14/12/2004
E.40.D / 23

CX135SR

Symptom: THE BLOWN AIR IS NOT HOT ENOUGH
HLE.0 to HLE.9 displayed Cab and evaporator thermal detectors Repair or replace the parts
on the screen short-circuited at the same time
AND the Frost symbol
ashes
Defective control See electronic control box
The Frost symbol ashes Evaporator thermal detector connector Repair
on the screen disconnected or cut out
Evaporator thermal detector Replace
With the temperature Hot air is reaching the thermal detector Check the conduit and correct the fault
set to 32° and in "Feet" allowing hot air to reach the thermal
ventilation mode the detector
blown air is hotter than
normal
Failure of controller and thermal detector Repair
Air mixture moderator in Hot water supply circuit Refer to troubleshooting in the cooling
"Max. Hot" position cycle
Motor actuator does not Defective motor actuator Repair
move and the force of the
blown air is less than 1,5
Kgf
Defective control Repair

CX135SR

Symptom: THE FAN SPEED CANNOT BE CHANGED (THEBLOWN AIR CANNOT BE CHANGED TO COLD OR
RECYCLED AIR)
The audible alarm device Anti-overheating device activated Check that the device is functioning
sounds continuously correctly
The ventilation system The door or windscreen are open The limiter is controlled by the door or the
only operates when the air windshield
conditioning is in "Head"
mode
The door or windshield are closed The limiter is controlled by the "Max. cold"
state
HLE.0 to HLE.9 displayed Thermal detector or harness short-circuited Repair or replace the parts
on the screen or cut out
No contact with the thermal detector union Repair
Cold air or recycled air Motor actuator union on the cold Reconnect or repair the union
indicator ashes on the or recycled air control defective or
screen disconnected
Defective motor actuator Repair or replace the actuator
Defective main harness Repair or replace the harness
27070 1 14/12/2004
E.40.D / 24
Index
ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - 40.D

Command - Overview (E.40.D.05 - C.10.A.10) 8
CX135SR
Compressor - Install (E.40.D.31 - F.10.A.15) 17
CX135SR
Compressor - Remove (E.40.D.31 - F.10.A.10) 16
CX135SR
Compressor Magnetic clutch - Troubleshooting (E.40.D.31.80 - G.40.A.10) 23
CX135SR
Condenser - Install (E.40.D.32 - F.10.A.15) 19
CX135SR
Condenser - Remove (E.40.D.32 - F.10.A.10) 18
CX135SR
Electronic HVAC control - Electrical schema (E.40.D.92 - C.20.A.40) 9
CX135SR
ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - Charging (E.40.D - 11
F.60.A.30)
CX135SR
ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - Disassemble (E.40.D - 12
F.10.A.25)
CX135SR
ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - Dynamic description 6
(E.40.D - C.30.A.10)
CX135SR
ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - Evacuate (E.40.D - 10
F.35.A.35)
CX135SR
ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - Special tools (E.40.D - 4
D.20.A.40)
CX135SR
ENVIRONMENT CONTROL Heating, ventilation and air-conditioning - Troubleshooting (E.40.D - 22
G.40.A.10)
CX135SR
Receiver/drier - Install (E.40.D.36 - F.10.A.15) 21
CX135SR
Receiver/drier - Remove (E.40.D.36 - F.10.A.10) 20
CX135SR
CX135SR
CX135SR
CX135SR
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E.40.D / 25
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E.40.D / 26
SAFETY SECURITY ACCESSORIES Safety - 50.B
CX135SR
27071 1 14/12/2004
E.50.B / 1
Contents
FUNCTIONAL DATA
Hydraulic lock-out
Hydraulic lock-out - Electrical schema (E.50.B.13 - C.20.A.40) 3
CX135SR
Hydraulic lock-out Electrovalve - External view (E.50.B.13.10 - C.10.A.40) 4

CX135SR
Hydraulic lock-out Electrovalve - Sectional view (E.50.B.13.10 - C.10.A.30) 5

CX135SR
SERVICE
Hydraulic lock-out
Hydraulic lock-out Electrovalve - Electrical test (E.50.B.13.10 - F.40.A.50) 6
CX135SR
Hydraulic lock-out Electrovalve - Remove (E.50.B.13.10 - F.10.A.10) 7

CX135SR
Hydraulic lock-out Electrovalve - Disassemble (E.50.B.13.10 - F.10.A.25) 8

CX135SR
Hydraulic lock-out Electrovalve - Visual inspection (E.50.B.13.10 - F.40.A.10) 9

CX135SR
Hydraulic lock-out Electrovalve - Assemble (E.50.B.13.10 - F.10.A.20) 10

CX135SR
Hydraulic lock-out Electrovalve - Install (E.50.B.13.10 - F.10.A.15) 11

CX135SR
27071 1 14/12/2004
E.50.B / 2
BODY AND STRUCTURE - SAFETY SECURITY ACCESSORIES Safety
Hydraulic lock-out - Electrical schema (E.50.B.13 - C.20.A.40)

CX135SR
CRIL03G202F02 1
Circuit layout
(F4) Fuse 10 amps: hydraulic control cancellation

(F21) Fuse box
(F23) Fuse 65 amps: main protection for circuits (F1) to (F10) and (F13) to (F20)
(G1) Battery
(K7) Battery relay
(S51) Hydraulic control cancellation lever switch
(Y2) Pilot pressure solenoid valve (blue band)
OPERATION
• When the engine is running and the hydraulic control cancellation lever is in the working position, contact
switch (S51) is closed and pilot pressure solenoid valve (Y2) is energised. Pilot pressure is supplied to the
servo-mechanism and the machine’s hydraulic controls are operational.
27071 1 14/12/2004
E.50.B / 3
Hydraulic lock-out Electrovalve - External view (E.50.B.13.10 -

C.10.A.40)
CX135SR
CRIL03I136F01a 1
(B) Pilot manifold supply

(C1) 2nd travel gear pilot
(C2) Swing brake pilot
(P) Pilot pressure supply
(T) Return to reservoir
(Y2) Pilot pressure solenoid valve
(Y3) Swing brake solenoid valve
(Y4) 2nd travel gear solenoid valve
27071 1 14/12/2004
E.50.B / 4
Hydraulic lock-out Electrovalve - Sectional view (E.50.B.13.10 -

C.10.A.30)
CX135SR
CRIL03I138F01 1
(1) Retaining nut

(2) Coil
(3) Core
(4) Seal
(5) Spool
(6) Spring
(7) Plug
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E.50.B / 5
Hydraulic lock-out Electrovalve - Electrical test (E.50.B.13.10 -

F.40.A.50)
CX135SR
To carry out this test, use the solenoid valve electrical connector and a multimeter, refer to ELECTRICAL POWER
SYSTEM - Special tools (A.30.A - D.20.A.40).
1. Disconnect connector (1) from pilot pressure

solenoid valve (Y2).
CRIL03L141A01 1
2. Connect the electrical connector (3) on connector

(1) from solenoid valve (Y2) to connector of solenoid
valve (2) then install the multimeter.
CRIL03I078A01 2
3. The solenoid resistance reading for solenoid valve

(Y2) on multimeter (2) should be 45 ohms at a
temperature of 20 °C.
NOTE: The resistance value will vary depending on the
temperature.
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E.50.B / 6
Hydraulic lock-out Electrovalve - Remove (E.50.B.13.10 - F.10.A.10)

CX135SR
Prior operation: To remove the side cover plate in the cab oor, refer to Side shield - Remove (E.20.A.70 -
F.10.A.10).
Prior operation: To remove the access panel in the cab oor, refer to Protective shield Guard - Remove
(E.20.A.73.71 - F.10.A.10).
1. Disconnect the electrical connectors from the wiring

harness (1) taking care to mark the coloured bands.
Disconnect hose (2) from port union (C2).
Disconnect hose (3) from port union (P).
Disconnect hose (4) from port union (C1).
Disconnect hose (5) from port union (B).
Disconnect hoses (6) and (7) from port union (T).
For port markings, refer to Hydraulic lock-out
Electrovalve - External view (E.50.B.13.10 -
C.10.A.40)
CRIL03I149A01 1
2. Disconnect electrical connectors of solenoid valves

(1) from their brackets (2).
CRIL03L141A04 2
3. Remove xing screws (1) and spacers (2) from

solenoid valve block (3).
CRIL03I163A01 3
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E.50.B / 7
Hydraulic lock-out Electrovalve - Disassemble (E.50.B.13.10 -

F.10.A.25)
CX135SR
NOTE: Mark each part of every element during disassembly to make reassembly easier.
1. Remove retaining nut (1) from the coil.
Remove the coil (2) from the solenoid.
CRIL03I157A01 1
2. Remove core from the solenoid (3).

Remove and discard the O-rings (4).
3. Remove spool (1) from the solenoid valve element
Remove spring (2) from the solenoid valve element.
NOTE: The spool of solenoid valve element (Y3) differs

from the spools of solenoid valve elements (Y2), (Y4)
and (Y5).
To identify them, refer to Hydraulic lock-out Electrovalve
- External view (E.50.B.13.10 - C.10.A.40)
CRIL03I153A01 2
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E.50.B / 8
Hydraulic lock-out Electrovalve - Visual inspection (E.50.B.13.10 -

F.40.A.10)
CX135SR
1. Inspect springs for cracks, distortion, or evidence

of permanent blocking.
Replace the spring (s) if any of these defects is
noted.
2. Check the spools for cracks, pitting, distortion or
other damage. Check that the spools are functioning
correctly in the bores of the solenoid valve block
body.
Replace the spool (s) or the solenoid valve block
body if any of these defects is noted.
3. Check for damage to the internal thread and for
evidence of wear in the solenoid valve block body.
Replace the solenoid valve block body if any of
these defects is noted.
4. Measure the clearance between the spools and
the bores of the solenoid valve block body. The
clearance should be approximately 0.01 mm.
If this is not the case, replace the spools and the
solenoid valve block body.
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E.50.B / 9
Hydraulic lock-out Electrovalve - Assemble (E.50.B.13.10 -

F.10.A.20)
CX135SR
Prior operation: Hydraulic lock-out Electrovalve - Visual inspection (E.50.B.13.10 - F.40.A.10).
1. To reassemble the solenoid valve, follow the steps

for disassembly in the reverse order. Refer to
Hydraulic lock-out Electrovalve - Disassemble
(E.50.B.13.10 - F.10.A.25).
Tighten core (3) to a torque of 30 - 37 Nm.
Tighten nut (1) to a torque of 4.9 Nm.
CRIL03I157A01 1
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E.50.B / 10
Hydraulic lock-out Electrovalve - Install (E.50.B.13.10 - F.10.A.15)

CX135SR
1. To install the solenoid valve, follow the removal

procedure steps in reverse order, refer to Hydraulic
lock-out Electrovalve - Remove (E.50.B.13.10 -
F.10.A.10).
2. Replace the access panel in the cab oor, refer to
Protective shield Guard - Remove (E.20.A.73.71
- F.10.A.10).
3. Replace the cab oor side cover plate, refer to Side
shield - Remove (E.20.A.70 - F.10.A.10).
27071 1 14/12/2004
E.50.B / 11
Index

Hydraulic lock-out - Electrical schema (E.50.B.13 - C.20.A.40) 3
CX135SR
Hydraulic lock-out Electrovalve - Assemble (E.50.B.13.10 - F.10.A.20) 10
CX135SR
Hydraulic lock-out Electrovalve - Disassemble (E.50.B.13.10 - F.10.A.25) 8
CX135SR
Hydraulic lock-out Electrovalve - Electrical test (E.50.B.13.10 - F.40.A.50) 6
CX135SR
Hydraulic lock-out Electrovalve - External view (E.50.B.13.10 - C.10.A.40) 4
CX135SR
Hydraulic lock-out Electrovalve - Install (E.50.B.13.10 - F.10.A.15) 11
CX135SR
Hydraulic lock-out Electrovalve - Remove (E.50.B.13.10 - F.10.A.10) 7
CX135SR
Hydraulic lock-out Electrovalve - Sectional view (E.50.B.13.10 - C.10.A.30) 5
CX135SR
Hydraulic lock-out Electrovalve - Visual inspection (E.50.B.13.10 - F.40.A.10) 9
CX135SR
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E.50.B / 12
27071 1 14/12/2004
E.50.B / 13
SERVICE
PRINTED IN FRANCE
27066 1 14/12/2004
REPAIR MANUAL
FRAME POSITIONING
CX135SR
27072 1 14/12/2004
F
Contents
FRAME POSITIONING - F
TRAVELLING Travel F.10.F

CX135SR
STABILISING Ballasting F.20.B

CX135SR
SWINGING Circular swing F.40.C

CX135SR
27072 1 14/12/2004
F
TRAVELLING Travel - 10.F
CX135SR
27073 1 14/12/2004
F.10.F / 1
Contents
TECHNICAL DATA
Command valve
Command valve Foot command valve - Special tools (F.10.F.12.10 - D.20.A.40) 5
CX135SR
Command valve Foot command valve - General specication (F.10.F.12.10 - D.40.A.10) 5

CX135SR
Hydraulic motor
Hydraulic motor - Torque (F.10.F.28 - D.20.A.10) 6
CX135SR
Reducer, spur gear

Reducer, spur gear - Special tools (F.10.F.44 - D.20.A.40) 6
CX135SR
FUNCTIONAL DATA
TRAVELLING Travel - Electronic schema (F.10.F - C.20.A.50) 12
CX135SR
TRAVELLING Travel - Hydraulic schema (F.10.F - C.20.A.20) 13

CX135SR

CX135SR

CX135SR
Command valve
Command valve Foot command valve - Sectional view (F.10.F.12.10 - C.10.A.30) 17
CX135SR
Control valve
Control valve - Sectional view (F.10.F.14 - C.10.A.30) 19
CX135SR
Hydraulic motor
Hydraulic motor - Exploded view (F.10.F.28 - C.10.A.20) 20
CX135SR
Hydraulic motor - Sectional view (F.10.F.28 - C.10.A.30) 22

CX135SR
Reducer, spur gear

Reducer, spur gear - Exploded view (F.10.F.44 - C.10.A.20) 24
CX135SR
Reducer, spur gear - Sectional view (F.10.F.44 - C.10.A.30) 26

CX135SR
Sensing system
Sensing system Alarm - Electronic schema (F.10.F.95.90 - C.20.A.50) 27
CX135SR NA
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F.10.F / 2
SERVICE
Command valve
Command valve Foot command valve - Remove (F.10.F.12.10 - F.10.A.10) 28
CX135SR
Command valve Foot command valve - Disassemble (F.10.F.12.10 - F.10.A.25) 29

CX135SR
Command valve Foot command valve - Visual inspection (F.10.F.12.10 - F.40.A.10) 35

CX135SR
Command valve Foot command valve - Assemble (F.10.F.12.10 - F.10.A.20) 36

CX135SR
Command valve Foot command valve - Install (F.10.F.12.10 - F.10.A.15) 42

CX135SR
Command valve Speed selection valve - Overhaul (F.10.F.12.15 - F.10.A.40) 43

CX135SR
Command valve Speed selection valve - Electrical test (F.10.F.12.15 - F.40.A.50) 44

CX135SR
Control valve
Control valve - Disassemble (F.10.F.14 - F.10.A.25) 45
CX135SR
Control valve - Assemble (F.10.F.14 - F.10.A.20) 47

CX135SR
Relief valve
Relief valve - Pressure test (F.10.F.16 - F.40.A.30) 49
CX135SR
Relief valve - Pressure setting (F.10.F.16 - F.45.A.70) 51

CX135SR
Hydraulic motor
Hydraulic motor - Remove (F.10.F.28 - F.10.A.10) 52
CX135SR
Hydraulic motor - Disassemble (F.10.F.28 - F.10.A.25) 54

CX135SR
Hydraulic motor - Check (F.10.F.28 - F.40.A.11) 62

CX135SR
Hydraulic motor - Assemble (F.10.F.28 - F.10.A.20) 63

CX135SR
Hydraulic motor - Install (F.10.F.28 - F.10.A.15) 70

CX135SR
Hydraulic motor - Leakage test (F.10.F.28 - F.40.A.40) 72

CX135SR
Reducer, spur gear

Reducer, spur gear - Remove (F.10.F.44 - F.10.A.10) 74
CX135SR
Reducer, spur gear - Disassemble (F.10.F.44 - F.10.A.25) 75

CX135SR
Reducer, spur gear - Visual inspection (F.10.F.44 - F.40.A.10) 81

CX135SR
Reducer, spur gear - Measure (F.10.F.44 - F.40.A.16) 82

CX135SR
Reducer, spur gear Bearing - Preload (F.10.F.44.10 - F.45.A.30) 84

CX135SR
Reducer, spur gear - Assemble (F.10.F.44 - F.10.A.20) 86

CX135SR
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F.10.F / 3
Reducer, spur gear - Install (F.10.F.44 - F.10.A.15) 92
CX135SR
DIAGNOSTIC
TRAVELLING Travel - Troubleshooting (F.10.F - G.40.A.10) 93
CX135SR
Command valve
Command valve Foot command valve - Troubleshooting (F.10.F.12.10 - G.40.A.10) 93
CX135SR
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F.10.F / 4
FRAME POSITIONING - TRAVELLING Travel
Command valve Foot command valve - Special tools (F.10.F.12.10 -

D.20.A.40)
CX135SR
NOTE: Tool to be manufactured locally
CRIL03L111A01 1
Used for removing and installing the cover bushing.

(A) 10 mm
(B) 8 mm
(C) 20 mm
(D) 30 mm
(E) 2 mm
Command valve Foot command valve - General specication

(F.10.F.12.10 - D.40.A.10)
CX135SR
Working pressure 68 bar

Secondary pressure (max. control pressure at end of stroke) 0 - 44 bar
Authorised return pressure 2.9 bar
Rated ow 10 L/min
Operating angle ±10 ° ±12.4 °
Operating temperature range -20 - 100 °C
27073 1 14/12/2004
F.10.F / 5
Hydraulic motor - Torque (F.10.F.28 - D.20.A.10)

CX135SR
CRIL03K086G01 1
Description
(1) 78 - 128 Nm (2) 78 - 118 Nm
(3) 24 - 34 Nm (4) 107 - 147 Nm
(5) 58 - 98 Nm (6) 112 - 142 Nm
(7) 313 - 393 Nm (8) 78 - 128 Nm
(9) 12 - 14 Nm (10) 5,6 - 6,1 Nm
(11) 48 - 66 Nm (12) 24 - 34 Nm
Reducer, spur gear - Special tools (F.10.F.44 - D.20.A.40)

CX135SR
NOTE: The tools listed below are to be made locally.

NOTE: Numbers in brackets refer to Reducer, spur gear - Exploded view (F.10.F.44 - C.10.A.20)
27073 1 14/12/2004
F.10.F / 6
CRIL03F009E01 1
Pin diameter 2.
Used for removing ring (18).
(A) 150 mm
CRIL03F010E01 2
Lifting ring
Used for removing cover (8).
(A) PT3/8
CRIL03F011E01 3
Lifting ring
Used to lift the travel motor reduction gear, spindle (2) and housing (1).
(A) Housing M14 , spindle and motor reduction gear M16
27073 1 14/12/2004
F.10.F / 7
CRIL03F013E01 4
Punch
Used to remove the outer ring from bearing (21).
(A) 150 mm
(B) 1 mm
(C) 10 mm
CRIL03F015F01 5
Support
Used to hold housing (1) on spindle (2).
Dimensions unavailable at time of publication
27073 1 14/12/2004
F.10.F / 8
CRIL03F016E01 6
Guide
Used for installing bearings (22).
CRIL03F018E01 7
Guide
Used for installing seal (132).
CRIL03F021E01 8
Checking tool
Used to check the preloading of bearing (21).
A. Brake piston cup
27073 1 14/12/2004
F.10.F / 9
CRIL03F022E01 9

B. Counter cup
CRIL03F023E01 10

C. Bushing
CRIL03F024E01 11

D. Nut
27073 1 14/12/2004
F.10.F / 10
CRIL03F025E01 12
(A) 19,5 mm (E) 24,5 mm

(B) 2,5 mm (F) M20
(C) 29 mm (G) 34,6 mm
(D) 40 mm (H) 30 mm
E. Stop
CRIL03F026E01 13
(A) 21 mm (C) 10 mm
(B) 15 mm (D) M6
27073 1 14/12/2004
F.10.F / 11
TRAVELLING Travel - Electronic schema (F.10.F - C.20.A.50)

CX135SR
CRIL03G097E01 1
Circuit layout
(1) Travel gear indicator lamp (K18) Travel gear relay

(P1) Instrument panel (S2) Travel gear switch
(Y4) 2nd travel gear solenoid valve (red band)
CRIL03G098E02 2
Timing diagram
(A) Lamp test (B) Reset
TRAVEL GEAR OPERATION

1. When the starter switch is in the "ON" position, 1st gear is selected by default.
2. Every time travel gear switch (S2) is pressed, the travel gear changes as follows: 1 to 2, 2 to 1 and the
corresponding indicator lamp lights up.
27073 1 14/12/2004
F.10.F / 12
TRAVELLING Travel - Hydraulic schema (F.10.F - C.20.A.20)

CX135SR
CRIL03J142G01 1
High speed travel circuit - Dynamic Description
(16) Hydraulic swivel (21) Travel motor
(C1) 2nd gear travel pilot (Pa1/A1) RH forward travel
(Pb1/B1) RH reverse travel (Pa6/A6) LH forward travel
(Pb6/B6) LH reverse travel (P1) Instrument panel
(S2) Travel gear switch (Y4) 2nd gear travel solenoid valve
HIGH GEAR CIRCUIT

• Travel motors (21) are fed by two ows.
• At high speed, the travel motors are set to low displacement.
• The travel motors have an internal circuit which enables them to change from low to high displacement
when the supply pressure exceeds a certain value.
• Pump outlet (A1) enters in (P2) on the control valve whilst pump (A2) enters in (P1). One ow goes directly to
the LH travel valve spool and the other to the RH travel valve spool.
27073 1 14/12/2004
F.10.F / 13
• 2nd travel gear solenoid valve (red band) (Y4) must be activated to change to a high gear. The 2nd gear travel
speed pilot pressure 39 bar from 2nd gear travel solenoid valve (Y4), passes through hydraulic swivel (16) and
continues to control the displacement change spools on travel motors (21).
27073 1 14/12/2004
F.10.F / 14

CX135SR
CRIL03J143G01 1
Low gear travel circuit - Dynamic Description
(21) Travel motor (C1) 2nd gear travel pilot
(Pa1/A1) RH forward travel (Pb1/B1) RH reverse travel
(Pa6/A6) LH forward travel (Pb6/B6) LH reverse travel
(P1) Instrument panel (S2) Travel gear switch
(Y4) 2nd gear travel solenoid valve
LOW GEAR CIRCUIT

• Low gear is selected on travel motors (21) by default. Even if the machine is in a high gear when the engine is
switched off, low gear is automatically selected for travel motors (21) when the engine is restarted.
• Pump outlet (A1) enters in (P2) on the control valve whilst pump (A2) enters in (P1). One ow goes directly to
the LH travel valve spool and the other to the RH travel valve spool.
• 2nd gear travel solenoid valve (red band) (Y4) is de-activated and the displacement change spools on travel
motors (21) are connected to the return circuit.
27073 1 14/12/2004
F.10.F / 15

CX135SR
CRIL03J144G01 1
Straight-line travel circuit - Dynamic Description
(1) Straight-line travel valve (21) Travel motor
(Pa1/A1) RH forward travel (Pb1/B1) RH reverse travel
(Pa6/A6) LH forward travel (Pb6/B6) LH reverse travel
(Pa4) Boom spool 2 (Pa8/A8) Boom raising
(Pb8/B8) Boom lowering
STRAIGHT-LINE TRAVEL
This chapter describes the situation in which the boom is raised as the machine is travelling.
• When the boom requires raising, the boom spool is operated and the low pressure circuit coming from (PP)
and passing through all attachment and swing spools is closed. This circuit increases in pressure up to 39 bar,
which pilots the straight-line travel valve (1). The output from pump (A2) therefore supplies the two travel
systems at (P1) and the output from pump (A1) supplies the attachment at (P2). As both travel motors
(21) are supplied in parallel, their pressure is equal and the machine travels in a straight line. In addition, if
the ow is not completely expended on the attachment, the surplus from this ow is used for travel and
the loss of speed is minimal.
• If functions other than the boom are used at the same time as travel, their operation is exactly the same.
27073 1 14/12/2004
F.10.F / 16
Command valve Foot command valve - Sectional view (F.10.F.12.10

- C.10.A.30)
CX135SR
CRIL03L070G01a 1
Description
(1) Lower body (2) Spool
(3) Shim (4) Washer
(5) Recoil Spring (6) Calibrated spring
(7) Spring seat (8) Seal
(9) Plug (10) Seal
(11) Push rod guide (12) Seal
(13) Pusher (14) Cover
(15) Ball (16) Screw
(17) Shaft (18) Cam
(19) Bushing (20) Boot
(21) Piston (22) Upper body
(23) Spring (24) Spring seat
(25) Ball (26) Guard
27073 1 14/12/2004
F.10.F / 17

(29) Seal
27073 1 14/12/2004
F.10.F / 18
Control valve - Sectional view (F.10.F.14 - C.10.A.30)

CX135SR
CRIL03J084F01 1
RH and straight-line travel section
(2) RH travel spool (10) Straight-line travel spool

(11) Large cap (13) Small cap
(18) Seal (19) Plug
(20) Connecting block with calibrated ports (21) Plug
(22) Plug
CRIL03J085E01 2
LH travel section

(17) Spring (18) Seal
(19) Plug (26) Valve
27073 1 14/12/2004
F.10.F / 19
Hydraulic motor - Exploded view (F.10.F.28 - C.10.A.20)

CX135SR
CRIL03K029H01 1
Description
(102) Shaft (230) Spring
(103) Swash plate (236) Seal
27073 1 14/12/2004
F.10.F / 20
(104) Cylinder barrel (238) Seal

(105) Piston assembly (242) Centring stud
(106) Shoe (245) Screw
(107) Retaining plate (252) Anti-rebound block
(108) Thrust ball (268) Seal
(109) Valve plate (271) Spool
(110) Washer (272) Valve
(112) Brake piston (275) Plug
(113) Spring (278) Calibrated port
(114) Spring (279) Filter
(115) Friction plate (280) Plug
(116) Plate (281) Spring
(135) Seal (282) Plug
(146) Snap ring (284) Plug
(149) Bearing (285) Seal
(150) Bearing (286) Piston
(151) Roller (287) Seal
(161) Piston (288) Valve seat
(162) Shoe (289) Shim
(176) Pivot (290) Spring
(177) Centring stud (291) Seal
(185) Spring (292) Seal
(201) Hydraulic motor cover (293) Back Up Ring
(221) Plug (294) Back Up Ring
(223) Spool (296) Ball
(224) Plug (297) Washer
(225) Spring guide (299) Plate
(227) Bushing (300) Plug
(228) Spring (301) Stop valve
(229) Bushing (302) Seal
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F.10.F / 21
Hydraulic motor - Sectional view (F.10.F.28 - C.10.A.30)

CX135SR
CRIL03K129H01a 1
Description
(102) Shaft (230) Spring
(103) Swash plate (236) Seal
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F.10.F / 22
(104) Cylinder barrel (238) Seal

(105) Piston assembly (242) Centring stud
(106) Shoe (245) Screw
(107) Retaining plate (252) Anti-rebound valve
(108) Thrust ball (271) Spool
(109) Valve plate (272) Valve
(110) Washer (275) Plug
(112) Brake piston (279) Filter
(113) Spring (280) Plug
(114) Spring (281) Spring
(115) Friction plate (282) Plug
(116) Plate (284) Plug
(135) Seal (285) Seal
(141) Seal (288) Valve seat
(146) Snap ring (290) Spring
(149) Bearing (292) Seal
(150) Bearing (296) Ball
(151) Roller (299) Plate
(161) Piston (301) Stop valve
(162) Shoe (302) Seal
(176) Pivot
(177) Centring stud
(185) Spring
(196) Ball
(201) Housing
(221) Plug
(224) Plug
(225) Spring guide
(228) Spring
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F.10.F / 23
Reducer, spur gear - Exploded view (F.10.F.44 - C.10.A.20)

CX135SR
CRIL03K026H01 1
Description
(1) Housing (21) Bearing
(2) Knuckle (22) Bearing
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F.10.F / 24
(3) Retaining ange (23) Bearing

(4) Gear (25) Snap ring
(5) Gear (28) Seal
(6) Sun pinion (29) Seal
(7) Planetary pinion (30) Seal
(8) Cover (31) Face seal
(9) Pin (33) Plug
(12) Spacer (36) Ball
(15) Coupling (43) Centring stud
(17) Roller (132) Seal
(18) Screw
(19) Screw
(20) Snap ring
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F.10.F / 25
Reducer, spur gear - Sectional view (F.10.F.44 - C.10.A.30)

CX135SR
CRIL03K126G01a 1
Description
(1) Housing (2) Spindle
(3) Retaining ange (4) Gear
(5) Gear (6) Sun pinion
(7) Planetary pinion (8) Cover
(9) Pin (12) Spacer
(15) Coupling (17) Roller
(20) Snap ring (21) Bearing
(22) Bearing (23) Bearing
(29) Seal (30) Seal
(31) Face seal (33) Plug
(36) Ball (43) Centring stud
(132) Seal
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F.10.F / 26
Sensing system Alarm - Electronic schema (F.10.F.95.90 - C.20.A.50)

CX135SR NA
CRIL03G225E02 1
Travel audible alarm device - Circuit layout
(B27) Travel pilot pressure switch (H2) TRAVEL AUDIBLE ALARM DEVICE
CRIL03G226E02 2
Timing diagram
OPERATION
• When the travel mode is active, the travel pilot pressure closes the contact with pressure switch (B27), a signal is sent to
instrument panel (P1) and travel audible alarm device (H2) sounds.
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F.10.F / 27
Command valve Foot command valve - Remove (F.10.F.12.10 -

F.10.A.10)
CX135SR
Prior operation: To remove the side guard from under the cab oor, refer to Side shield - Remove (E.20.A.70
- F.10.A.10)
1. Attach identication labels to all the control pedal

hoses.
Disconnect the hoses.
Plug the ports.
CRIL03L107A00 1
2. Remove pedals (1), brackets (2) and levers (3).
CRIL03I083A01 2
3. Remove the oor mat.

Remove screws (1) and the foot control.
CRIL03I083A02 3
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F.10.F / 28
Command valve Foot command valve - Disassemble (F.10.F.12.10 -

F.10.A.25)
CX135SR
NOTE: Always handle high precision parts with the greatest care to prevent them being damaged by being knocked
or dropped.
The control pedal components may rust due to contamination and humidity if they are left without protection
after disassembly.
If work has to be interrupted, the components must be protected from contamination or corrosion.
NOTE: Mark the position and bore of all parts.
1. Tighten the control pedal in a vice with soft jaws.
Remove the boot.
CRPH03I047A 1
2. Remove the locking screw from the camshaft.
CRPH03I048A 2
3. Remove the camshaft using a drift punch.
CRPH03I049A 3
27073 1 14/12/2004
F.10.F / 29
4. Remove the cam and steel ball assembly.
CRPH03I050A 4
5. Remove the cover xing screws.
CRPH03I051A 5
6. Remove the cover.

NOTE: Repeat steps 2 to 6 for the second control pedal
body.
CRPH03I052A 6
7. Remove the upper body.
CRIL03L095A00 7
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F.10.F / 30
8. Remove the spool assembly.
CRIL03L096A00 8
9. Remove the guide assembly.
CRIL03L092A00 9
10. Remove the piston.
CRIL03L093A00 10
11. Remove the spring.
CRIL03L094A00 11
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F.10.F / 31
12. Remove the spring seat.
CRPH03I060A 12
13. Remove the balls using a magnet.
CRIL03L106A00 13
14. Discard the seals.
CRIL03L097A00 14
CRPH03I061A 15
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F.10.F / 32
CRPH03I062A 16
17. To remove the bushings, refer to Command valve

Foot command valve - Special tools (F.10.F.12.10
- D.20.A.40).
CRIL03L098A00 17
18. Compress the spool return spring with the seat so

as to be able to tap it out.
NOTE: Be careful not to damage the spool surface. Do
not compress the spring by more than 4 mm.
CRPH03I064A 18
19. Remove the spool, spring seat, calibrated spring,

shim and washer.
CRPH03I065A 19
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F.10.F / 33
20. Remove the bushing from the push-rod guide.
CRIL03L099A00 20
21. Remove the inner seal from the push-rod guide.
CRIL03L100A00 21
22. Remove the outer seal from the push-rod guide.

NOTE: Repeat steps 7 to 22 for the second control pedal
body.
CRIL03L101A00 22
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F.10.F / 34
Command valve Foot command valve - Visual inspection

(F.10.F.12.10 - F.40.A.10)
CX135SR
1. Check for cracks, distortion or blocking of the

springs.
If defects are found, replace the springs.
2. Inspect the spools to ensure that their nish is not
damaged and that they are not bent or otherwise
defective.
Make sure that the spool slides freely in the foot
control body bore.
If defects are found, replace the foot control
assembly.
3. Check the bores for damage, internal damage
to housings or evidence of any othe foot control
internal wear.
If the foot control is damaged, replace the entire
assembly.
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F.10.F / 35
Command valve Foot command valve - Assemble (F.10.F.12.10 -

F.10.A.20)
CX135SR
NOTE: Immerse all components in clean hydraulic uid to guarantee proper lubrication when assembling and
resuming operation.
NOTE: Assemble following the markings made during removal.
1. Install washer, shim, calibrated spring and spring
seat on the spool.
CRPH03I065A 1
2. Compress and engage the spring seat.

NOTE: Be careful not to damage the spool surface.
Do not compress the spring by more than 4 mm.
CRPH03I064A 2
3. Install the return spring.
CRPH03I062A 3
27073 1 14/12/2004
F.10.F / 36
4. Install the spool assembly in the bore of the foot

control body.
CRPH03I061A 4
5. Install the seals.
CRIL03L097A00 5
6. Install the balls.
CRIL03L106A00 6
7. Install the spring seat.
CRIL03L102A00 7
27073 1 14/12/2004
F.10.F / 37
8. Install the spring.
CRIL03L094A00 8
9. Install the piston.
CRIL03L093A00 9
10. Install the seal in the push-rod guide.
CRIL03L100A00 10
11. Installer the bushing in the push-rod guide.
CRIL03L099A00 11
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F.10.F / 38
12. Oil and install the push-rod in the guide.
CRIL03L103A00 12
13. Assemble the push-rod guide assembly.

NOTE: Repeat steps 1 to 13 for the other control pedal
body.
CRIL03L104A00 13
14. To install the bushings, refer to Command valve

Foot command valve - Special tools (F.10.F.12.10
- D.20.A.40)
CRIL03L098A00 14
15. Install the upper body.
CRIL03L095A00 15
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F.10.F / 39
16. Install the cover.
CRPH03I052A 16
17. Install the retaining screws and tighten them to

torque 8 - 10 Nm.
CRPH03I068A 17
18. Mount the cam and install the cam shaft.

NOTE: Repeat steps 13 to 18 for the other control pedal
body.
CRPH03I050A 18
19. Coat the threads of the linkage pin locking screw

with Loctite 241 and tighten it to torque 6 - 8 Nm
CRPH03I069A 19
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F.10.F / 40
20. Tilt the cam and apply grease at the ends of the
push-rods and inject grease in the tappet guide
bushings.
CRIL03I073A01 20
21. Install the upper part of the gusset on the cam.

Apply a moisture repellent to the groove of the cover
to prevent any oxidation.
Install the lower part of the gusset on the cover.
CRPH03I070A 21
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F.10.F / 41
Command valve Foot command valve - Install (F.10.F.12.10 -

F.10.A.15)
CX135SR
1. Install the foot control in position and x screws (1).

Install the oor mat.
CRIL03I083A02 1
2. Install levers (3), brackets (2) and pedals (1).
CRIL03I083A01 2
3. Remove the plugs.

Connect all hoses to the foot control following the
markings made during removal.
CRIL03L107A00 3

Install the side guard under the cab oor.
27073 1 14/12/2004
F.10.F / 42
Command valve Speed selection valve - Overhaul (F.10.F.12.15 -

F.10.A.40)
CX135SR
1. Removal, refer to Hydraulic lock-out Electrovalve

- Remove (E.50.B.13.10 - F.10.A.10).
2. Dismantling, refer to Hydraulic lock-out
Electrovalve - Disassemble (E.50.B.13.10 -
F.10.A.25).
3. For visual inspection, refer to Hydraulic lock-out
Electrovalve - Visual inspection (E.50.B.13.10 -
F.40.A.10).
4. For assembly, refer to Hydraulic lock-out
Electrovalve - Assemble (E.50.B.13.10 -
F.10.A.20).
5. For installation, refer to Hydraulic lock-out
Electrovalve - Install (E.50.B.13.10 - F.10.A.15).
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F.10.F / 43
Command valve Speed selection valve - Electrical test (F.10.F.12.15

- F.40.A.50)
CX135SR
SYSTEM - Special tools (A.30.A - D.20.A.40)
1. Disconnect connector (1) from the 2nd travel gear

solenoid valve (Y4).
CRIL03L141A03 1
2. Connect the appropriate test electrical connector

(3) to connector (1) on solenoid (Y4), then attach
multimeter (2).
CRIL03I078A03 2
3. The solenoid resistance reading of solenoid valve

(Y4) on multimeter (2) should be 45 ohms for a
temperature.
27073 1 14/12/2004
F.10.F / 44
Control valve - Disassemble (F.10.F.14 - F.10.A.25)

CX135SR
CRIL03J084F01 1
RH and straight-line travel spools
CRIL03J085E01 2
LH travel spool
1. Remove caps (11) and (13) and discard seals.

2. Remove spools (2), (10) and (40).
IMPORTANT: Mark each spool to ensure that it is returned
to the correct housing during re-assembly.
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F.10.F / 45

industrial drier until it can be removed easily (usually
replace the spring.
CRIL03L053A01 3

Discard seals (18).
Remove springs (17) and check valves (16) and
(26).
5. Remove plug (21) and the union block with
calibrated ports (20).
Discard seals.
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F.10.F / 46
Control valve - Assemble (F.10.F.14 - F.10.A.20)

CX135SR
- F.40.A.10)
CRIL03J084F01 1
RH and straight-line travel spools
CRIL03J085E01 2
LH travel spool
Torque settings
Fixing screws for return springs on spools (2), (10) and (40) 9.8 - 11.8 Nm
Cap screws (11) and (13) 20 - 25 Nm
Plugs (19) and (22) 103 - 113 Nm
Union (20) 49 - 59 Nm
Plug (21) 13.5 - 16.5 Nm
1. Install check valves (16) and (26) and springs (17).
2. Install plugs (19) and (22) complete with new seals
(18) and tighten to the required torque.
27073 1 14/12/2004
F.10.F / 47
3. Install plug (21) complete with a new seal and

tighten to the required torque.
4. Install plugs (20) complete with new seals to the
required torque.
5. Coat the threaded parts of spools (2), (10) and (40)
with locking uid.
Install springs (44) and seats (43 ) on screws (45).
torque.
Install spools (2), (10) and (40) in their respective
housings.
CRIL03L053A01 3
6. Install caps (11) and (13) tted with new seals.

torque.
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F.10.F / 48
Relief valve - Pressure test (F.10.F.16 - F.40.A.30)

CX135SR
NOTE: Travel secondary relief valves (K) and (L) are calibrated to a higher pressure than the main relief valve (A).
To check or calibrate the travel secondary relief valves, main relief valve (A) must be overcalibrated.
1. Overcalibrate main relief valve (A) by tightening the
adjusting screw by 180 °, refer to Relief valve -
Pressure setting (A.10.A.16 - F.45.A.70).
2. Connect a 0-600 bar (0-60 MPa) pressure gauge to
the pressure test point (M2) for right-hand travel and
to (M1) for left-hand travel.
3. Have a locking pin produced locally:
(A) = 35 mm
(B) = 68 mm
(C) = 250 mm
(D) = 70 mm
CRIL03I164A01 1
4. Start the engine at idling speed.

5. Carefully block the travel mechanically on the
side to be checked by positioning the locking pin
(A) between the sprocket and the chassis (see
drawing).
CRIL03I165A01 2
6. With the engine at full speed, operate the

corresponding travel control lever and hold it in
position (sprocket locked).
7. Read the forward and reverse travel pressures from
the pressure gauge, they should be 348 ± 5 bar
(34.8 ± 0.5 MPa)
Note incorrect pressures to determine the number
of shims needed for adjustment.
8. If the pressures are incorrect, calibrate travel relief
valves (K) and (L), refer to Relief valve - Pressure
setting (F.10.F.16 - F.45.A.70)
9. Recalibrate main relief valve (A), refer to Relief
valve - Pressure setting (A.10.A.16 - F.45.A.70).
10. Check that the relief valve is at the standard
pressure.
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F.10.F / 49
12. Reconnect the power boost pilot hose to the main

relief valve.
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F.10.F / 50
Relief valve - Pressure setting (F.10.F.16 - F.45.A.70)

CX135SR
Prior operation: Relief valve - Pressure test (F.10.F.16 - F.40.A.30)
1. Remove the main relief valve concerned (K), the

reverse travel main relief valve (L) or the forward
travel relief valve of the hydraulic travel motor.
If both valves have to be removed, mark them to
ensure they are replaced in their original position.
CRIL03K063A01 1
2. Clamp valve body (1) in a vice and remove plug (2),

adjusting shims (3), seat (4), spring (5) and check
valve (6).
CRIL03K061A01 2
3. Remove (to reduce the pressure) or add (to increase

the pressure) the number of adjusting shims (3)
required to obtain the correct pressure, 1 0,10 mm
SHIM corresponds to 10 bar (1 MPa).
4. Reinstall the parts in the body of valve (1) and
tighten plug (2) to torque 57 - 95 Nm.
5. Reinstall main relief valve (K) or (L) in the hydraulic
travel motor and tighten to torque 107 - 148 Nm.
6. Check the pressure again. If the desired value is
not obtained, make the adjustment again.
Next operation: Reset main relief valve (A), refer to Relief valve - Pressure setting (A.10.A.16 - F.45.A.70)
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F.10.F / 51
Hydraulic motor - Remove (F.10.F.28 - F.10.A.10)

CX135SR
1. Remove screws and washers (1) and (2).
CRIL03K049A01 1
2. Remove anti-rebound assembly (3) from the cover

of hydraulic motor (6).
Discard seals (4).
CRIL03K050A01 2
3. Remove screws (5).
CRIL03K051A01 3
4. Connect a suitable lifting device to the cover of

hydraulic motor (6).
CRIL03K052A01 4
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F.10.F / 52
5. Discard seals (1) and (2) from the spindle.
CRIL03K053A01 5
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F.10.F / 53
Hydraulic motor - Disassemble (F.10.F.28 - F.10.A.25)

CX135SR
NOTE: The numbers in brackets refer to the hydraulic motor exploded view Hydraulic motor - Exploded view
(F.10.F.28 - C.10.A.20)
1. Remove springs (113) and valve plate (109).
CRIL03F165A00 1
2. Remove two centring studs (242).
CRIL03F166A00 2
3. Remove bearing (150).
CRIL03F167A00 3
27073 1 14/12/2004
F.10.F / 54
4. Remove plug (224), discard seal (236).

Remove spring guide (225) and spring (228).
CRIL03K066A01 4
5. Remove spool (223).
CRIL03K067A01 5
6. Remove plug (282), discard seal (238).
CRIL03K068A01 6
7. Remove spring (230) and spring guide (225).
CRIL03K069A01 7
27073 1 14/12/2004
F.10.F / 55
8. Remove plug (221) and seal (292).
CRIL03K070A01 8
9. Remove spool (271), calibrated port (278) and

spring (281).
CRIL03K071A01 9
10. Remove plugs (275).

Remove plug (280) and obturator (301).
Remove plugs (284) seal (285) and ball (296).
11. Remove plugs (300).
Remove plug (221) and seal (292).
Remove lter (279).
12. Remove plugs (284) and seals (285). Remove balls
(296) and calibrated seals (278).
13. Remove plugs (221) and seals (292).
Remove spool (271), check valve (272) and spring
(281).
14. Remove plug (252), screw (283) and ball (268).
15. Remove plugs (275), (279) and (280).
16. Remove plug (282) from the anti-rebound block.
Discard seal (238).
Remove piston (286).
CRIL03K072A01 10
27073 1 14/12/2004
F.10.F / 56

Discard seal (285).
Remove ball (296).
CRIL03K073A01 11
18. Remove safety valve (288).

Remove plug (284), discard seal (285).
Remove plugs (275).
CRIL03K074A01 12
19. Remove shim (289) spring (290) and spring guide

(225).
Remove check valve (272), discard seal (302).
Discard back-up rings (293) and seal (292).
Discard back-up rings (294) and seal (291).
CRIL03K075A01 13
20. Remove brake piston (112) from the spindle by

applying a jet of compressed air through the parking
brake port.
IMPORTANT: Adjust the compressed air to minimum
pressure.
CRIL03F176A00 14
27073 1 14/12/2004
F.10.F / 57
21. Remove seals (135) and (141) from piston (112).
CRIL03F177A00 15
22. Remove plugs (275), (279) and (280) from housing

(201).
23. Rotate cylinder barrel (104) to disengage the shoes.
Remove the cylinder barrel.
CRIL03F220A00 16
24. Remove plates (116) and friction plates (115).

25. Remove piston assembly (105).
CRIL03F179A00 17
26. Remove retaining plate (107).
CRIL03F180A00 18
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F.10.F / 58
27. Remove thrust ball (108) with washer (227).
CRIL03F181A00 19
28. Remove roller bearings (151).
CRIL03F182A00 20
29. Place barrel (104) under a press.

Insert guide Hydraulic motor - Special tools
(F.10.F.28 - D.20.A.40) between the press and the
washer (110).
Activate the press.
Remove snap ring (146).
CRIL03F183B01 21
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F.10.F / 59
30. Remove washers (110) and spring (114).
CRIL03F185A00 22
31. Remove swash plate (103), paying attention to

pivots (176).
CRIL03F186A00 23
32. Remove pivots (176) and centring pins (177).

33. Remove shaft (102).
CRIL03F187A00a 24
34. Remove the gear selector assembly, piston (161),

shoe (162) and spring (185) by applying a jet of
compressed air through the orice in the spindle.
IMPORTANT: Adjust the compressed air to minimum
pressure.
CRIL03F188A00 25
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F.10.F / 60
35. Insert guide Hydraulic motor - Special tools

(F.10.F.28 - D.20.A.40) between the press and the
washer (149).
Activate the press to remove the washer and ring
(229) from shaft (102).
CRIL03G113A01 26
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F.10.F / 61
Hydraulic motor - Check (F.10.F.28 - F.40.A.11)

CX135SR
IMPORTANT: Handle parts carefully to avoid damaging them.

IMPORTANT: Replace parts that show the following defects:
1. Shaft worn at the sealing surface with the lip seal.
Shaft splines damaged.
2. Cylinder barrel splines damaged.
Interior surface of the cylinder bore worn.
Bearing surface of the valve plate on the cylinder
barrel scratched or worn unevenly.
3. Piston shoe showing abnormal or uneven wear.
Axial clearance between piston and shoe greater
than 0.14 mm (value when new 0.04 mm).
4. Irregular wear of the internal circumference of the
retaining plate.
5. Traces of thermal seizing on the swash plate.
6. Irregular surface wear or traces of thermal seizing
on the brake friction plates. The brake does not hold
for a torque of 14.8 Nm.
7. Pressure points, aking and/or irregular wear on the
bearings.
8. Irregular wear and/or traces of thermal seizing on
the valve plate.
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F.10.F / 62
Hydraulic motor - Assemble (F.10.F.28 - F.10.A.20)

CX135SR
NOTE: Numbers in parentheses refer to Hydraulic motor - Exploded view (F.40.C.28 - C.10.A.20)Hydraulic
motor - Exploded view (F.10.F.28 - C.10.A.20)
1. Place bearing (149) into a bearing oven and heat it
to 100 °C for 10 minutes.
Install bushing (229) on shaft (102) and install the
bearing.
DANGER
SM121A - Always wear heat protective gloves to
prevent burning your hands when handling heated
parts.
CRIL03F208A00 1
2. Install centring pins (177) in the spindle orices.

Install pivots (176) on the centring pins.
CRIL03F209A00 2
3. Install piston assembly (161) and shoe (162) with

spring (185) on the spindle.
4. Install shaft (102) carefully in the spindle, taking
care not to damage the seal.
CRIL03F187A00a 3
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F.10.F / 63
5. Install swash plate (103).
CRIL03F186A00 4
6. If spring (114) has been removed:

Place barrel (104) under a press.
Insert the guide between the press and the washer
(110).
Activate the press.
Fit snap ring (146).
CRIL03F183B01 5
7. Install rollers (151) in the cylinder orices.
CRIL03F182A00 6
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F.10.F / 64
8. Install thrust ball (108) with washer (227).
CRIL03F181A00 7
9. Install pistons (105) on retaining plate (107).

Install the assembly in barrel (104).
CRIL03F180A00 8
10. Install the cylinder barrel in the spindle.

Turn the cylinder barrel by hand to ensure that it
revolves freely.
CRIL03G006A00 9
11. Install plates (116) and friction plates (115).
CRIL03F220A00 10
27073 1 14/12/2004
F.10.F / 65
12. Install seals (135) and (141) on piston (112).

Install piston (112) by tapping.
CRIL03F177A00 11
13. Fit seal (287) on valve seat (288).

Fit seal (292) between back-up rings (293).
Fit seal (291) between back-up rings (294).
Fit seal (302) on valve (272).
Install spring (290), guide (225) and shim (289).
Install seal (285) on plug (284).
Install plug (284) and tighten it to the required
torque.
CRIL03K075A01 12
14. Install secondary relief valve (288) on anti-rebound

block (252).
Install the valve and tighten it to the required torque.
CRIL03K074A01 13
15. Install plugs (275) and tighten them to the required

torque.
Install piston (286) and seal (238) on plug (282).
Install plug (282) and tighten it to the required
torque.
CRIL03K072A01 14
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F.10.F / 66
16. Install balls (296).

Install seals (285) on plugs (284).
Install the plugs and tighten them to the required
torque.
CRIL03K073A01 15
17. Secure the cover of hydraulic motor (201).

Install and tighten plugs (275), (300) and (280) to
the required torque.
Install lter (279).
18. Fit ring (301) and plug (280).
19. Fit seal (292) on plug (221).
Fit plug (221) and tighten it to the required torque.
20. Install spring (281), calibrated port (278) and spool
(271).
CRIL03K071A01 16
21. Fit seal (292) on plug (221).

Install the plug and tighten it to the required torque.
CRIL03K070A01 17
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F.10.F / 67
22. Install spring (230) and spring guide (225).
CRIL03K069A01 18
23. Fit seal (238) on plug (282).

CRIL03K068A01 19
24. Install spool (223).
CRIL03K067A01 20
25. Install spring guide (225) and spring (228).

Install seal (236) on plug (224), tighten to the
required torque.
CRIL03K066A01 21
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F.10.F / 68
26. Install guide (225).

Install spring (228).
Fit seal (236) on plugs (224).
Install the plugs and tighten them to the required
torque.
27. Install ball (296).
Fit seal (285) on plug (284).
28. Install bearing (150).
CRIL03F229A 22
29. Install centring studs (242).
CRIL03F166A00 23
30. Install valve plate (109) on the housing using

centring pins (242) as a guide.
Install springs (113).
CRIL03F165A00 24
Next operation: To install the hydraulic motor cover on the reduction gear housing, refer to Hydraulic motor -
Install (F.10.F.28 - F.10.A.15)
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F.10.F / 69
Hydraulic motor - Install (F.10.F.28 - F.10.A.15)

CX135SR
1. Install seals (1) and (2).
CRIL03K053A01 1
2. Align the centring pins with the ports on the hydraulic

motor cover.
Install the cover of hydraulic motor (6) on the travel
reduction gear.
CRIL03K052A01 2
3. Install screws (5) and tighten them evenly to the

required torque.
CRIL03K051A01 3
4. Install seals (4) on the cover of hydraulic motor (6).

Install anti-rebound block (3).
CRIL03K050A01 4
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5. Install washers (2) on screws (1).

Install screws and tighten them to the required
torque.
CRIL03K049A01 5
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F.10.F / 71
Hydraulic motor - Leakage test (F.10.F.28 - F.40.A.40)

CX135SR
1. CHECKING FOR TRAVEL DRIFT

Make sure that the track tension is correct.
2. This test must be carried out with the hydraulic oil at
a temperature of 50 °C and on a hard, at stretch of
ground about 30 m long.
3. With the engine at full speed, press and hold the
travel pedals down as far as they will go.
4. Drive forwards for 25 m, making a note of the drift
over the last 20 m of travel.
5. If the drift is greater than 1 m:
Check the pilot pressure values on both travel valve
spools (must be more than 30 bar).
Check the leak values from the travel motors.
6. CHECKING FOR LEAKS FROM THE TRAVEL
MOTORS
TOOLS REQUIRED:
1 locking pin to be manufactured locally with the
following dimensions:
(A) = 35 mm
(B) = 68 mm
(C) = 250 mm
(D) = 70 mm
1 receptacle of 10 L,
1 hose,
1 plug.
CRIL03I164A01 1
7. Press the breather to relieve the pressure in the

8. Remove the travel motor shield.
9. Disconnect and plug the hydraulic motor drain hose.
10. Attach a hose between the drain port and the
receptacle.
11. Mechanically block the travel to be checked by
placing pin (A) carefully between the sprocket and
the chassis.
Forward travel (B) (see gure).
CRIL03I165A01 2
12. With the engine at full speed, operate the travel

control corresponding to the blocked sprocket.
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F.10.F / 72
13. Measure the quantity of oil that escapes from the

drain in 1 minute.
CRIL03I168A00 3
14. Check for leaks on the other motor.

Compare the quantities of oil collected; if the
difference between the two motors is greater than 1
L/min, repair or replace the motor which produced
the most oil.
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F.10.F / 73
Reducer, spur gear - Remove (F.10.F.44 - F.10.A.10)

CX135SR
Prior operation: Drive sprocket - Remove (D.50.B.45 - F.10.A.10)

Prior operation: Remove shield panel from travel motor, refer to.Side shield - Remove (E.20.A.70 - F.10.A.10)
1. Place a container under the reduction gear.

Drain the reduction gear.
Re-insert the drain plug on the reduction gear.
2. Place identication tags.
Place a container under the hydraulic motor.
Disconnect the supply hoses from the hydraulic
motor.
Plug the hoses and the ports.
CRIL03F153A01a 1
3. Using a suitable lifting device, attach and support

the moto-reduction gear.
Remove xing screws (1) and washers (2) from the
reduction gear.
Remove the reduction gear from the machine.
CRIL03F154A01a 2
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F.10.F / 74
Reducer, spur gear - Disassemble (F.10.F.44 - F.10.A.25)

CX135SR
Prior operation: Hydraulic motor - Remove (F.10.F.28 - F.10.A.10)

Prior operation: To remove the brake assembly and barrel assembly, refer to Hydraulic motor - Disassemble
(F.10.F.28 - F.10.A.25)
NOTE: numbers in brackets refer to Reducer, spur gear - Exploded view (F.10.F.44 - C.10.A.20)
1. Make identication markings on housing (1) and
cover (8).
Remove screws (18).
CRIL03K013A00 1
2. Remove plugs (33) from cover.
CRIL03K014A01 2
3. Install the lifting rings.

Remove cover (8).
CRIL03K015A00 3
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CRIL03K016A01 4
5. Put identication marks on pinion assembly (7) and

sun gear (6).
CRIL03K017A00 5
6. Remove ball bearing, (36) sun gear (6) and coupling

sleeve (15).
CRIL03K018A00 6
7. Remove snap rings (25).
CRIL03F045A00 7
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F.10.F / 76
8. Remove pinions (7).
CRIL03F046A00 8
9. Remove spacers (12).
CRIL03F047A00 9
10. Install and tighten the retaining tool between

housing (1) and spindle (2).
NOTE: If the retaining ange is removed without being
held, housing (2) and spindle (1) will come apart and the
spindle risks being damaged.
CRIL03F048A00 10
11. Remove snap rings (20) from retaining ange (3).
CRIL03F049A00 11
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F.10.F / 77
12. To make re-assembly easier, make identication

marks on all the snap rings.
CRIL03F050A00 12
13. Remove screws (19).

If the screws seize whilst being loosened, tighten
then loosen them again.
CRIL03F051A00 13
14. Put identication marks on retaining ange (3) and

then remove it.
CRIL03F052A00 14
15. Turn the travel motor reduction gear and remove

the retaining tools.
CRIL03F053A00 15
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F.10.F / 78
16. Using lifting rings, remove knuckle (2) from housing

(1).
CRIL03F054A00 16
17. Discard seals (28) and (30).

Remove two centring studs (43).
CRIL03F056A00 17
18. Insert a pin and push rollers (17) symmetrically so

as to remove bearing (21).
CRIL03F057A01 18
19. Remove gears (4) and (5) shafts (9) only if replacing
bearings (22) and (23) proves necessary.
20. Turn the housing over.
Using a punch, remove bearing (21).
CRIL03F058A01a 19
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F.10.F / 79
21. Discard gasket (132).
CRIL03F059A01 20
CRIL03F060A00 21
23. Remove outer bearing rings (22).
CRIL03F061A00 22
24. Remove outer bearing rings (22) from retaining

ange (3).
CRIL03F062A00 23
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F.10.F / 80
Reducer, spur gear - Visual inspection (F.10.F.44 - F.40.A.10)

CX135SR
IMPORTANT: Handle the parts carefully to avoid damaging them.

IMPORTANT: Replace removed seals systematically.
IMPORTANT: Replace parts that show the following defects:
1. Signicant visible damage or abnormal wear
(chang or scratches).
2. Irregular wear on gear teeth.
3. Outside edge of the snap ring worn abnormally.
4. Pressure points, aked surface and irregular wear
of bearings.
IMPORTANT: When certain parts are replaced, the
preload or axial clearance must be readjusted. Refer to
Reducer, spur gear - Measure (F.10.F.44 - F.40.A.16)
and Reducer, spur gear Bearing - Preload (F.10.F.44.10
- F.45.A.30) .Reducer, spur gear Bearing - Preload
(F.10.F.44.10 - F.45.A.30)
IMPORTANT: Replacing certain parts necessitates
making adjustments to the bearing preload, refer to
Reducer, spur gear Bearing - Preload (F.10.F.44.10
- F.45.A.30).
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F.10.F / 81
Reducer, spur gear - Measure (F.10.F.44 - F.40.A.16)

CX135SR
NOTE: If any of the following parts are replaced, the axial play of bearing (22) will require adjusting to the
recommended value, as will the thickness of snap ring (20).
Parts affected by the adjustment of axial play on bearing (22):
spindle (2),
retaining ange (3),
crankshaft (9),
spacer (12),
snap ring (20)
and bearing (22).
NOTE: Numbers in brackets refer to Reducer, spur gear - Exploded view (F.10.F.44 - C.10.A.20).
1. Using a hammer and suitable tool, lightly tap
the outside rings of bearings (22) tted to the
crankshafts (9).
CRIL03F072A00 1
2. Install snap rings (20) in the grooves in retaining

ange (3).
CRIL03F049A00 2
3. Using a hammer and suitable tting tool, lightly tap

the outside of snap rings (20).
CRIL03F073A00 3
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F.10.F / 82
4. Place a feeler gauge between snap rings (20) and

bearing (22) and measure the clearance.
CRIL03F149A00 4
5. Measure thickness (t) of snap rings (20).

Maximum thickness (MAX) of snap rings (20)
MAX = Thickness of the feeler gauge + the actual
thickness of snap (20) ring.
Minimum thickness (MIN) of snap rings (20)
MIN = MAX - 0.05.
Depending on the MAX and MIN differential
obtained, use snap ring (20) from the thicknesses
(t) available.
THICKNESS (t) AND CLASSIFICATION SYMBOLS
OF RINGS :
(A) 2,20 - 2,25 mm
(B) 2,25 - 2,30 mm
(C) 2,30 - 2,35 mm CRIL03G178A01 5
(D) 2,35 - 2,40 mm
(E) 2,40 - 2,45 mm
(F) 2,45 - 2,50 mm
(G) 2,50 - 2,55 mm
(H) 2,55 - 2,60 mm
(I) 2,60 - 2,65 mm
(J) 2,65 - 2,70 mm
(K) 2,25 - 2,30 mm
(L) 2,30 - 2,35 mm
6. Install snap rings (20).
CRIL03F049A00 6
7. Continue the assembly procedure.
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F.10.F / 83
Reducer, spur gear Bearing - Preload (F.10.F.44.10 - F.45.A.30)

CX135SR
NOTE: Numbers in parentheses refer to Reducer, spur gear - Exploded view (F.10.F.44 - C.10.A.20)
1. Install the main bearing preload adjustment tool,
refer to Reducer, spur gear - Special tools
(F.10.F.44 - D.20.A.40).
Push bearing (21) into the housing.
Tighten special nut (1) to a torque of 40 Nm.
CRIL03F069A00a 1
2. Measure thickness (A) using a depth gauge and via

the measurement port on the adjustment tool.
If value (B) of the main bearing preload adjustment
tool is known, play (C) = (A) - (B).
(A) Measurement Taken.
(B) Dimensions of the main body of the tool.
(C) Recommended dimension.
(F) Depth gauge.
(G) Main bearing preload adjustment tool.
CRIL03F199B01a 2
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F.10.F / 84
3. Measure dimension (D) of retaining ange (3).

If (D) is less than (C): Machine surface (E).
If (D) = (C): Reassemble.
If (D) is more than (C): Replace.
IMPORTANT: Since retaining ange (3) and the knuckle
form part of a tted assembly, it is not possible to replace
only the retaining ange.
Replace the knuckle assembly.
CRIL03F150A01a 3
4. Remove the main bearing preload adjustment tool

and continue the reassembly procedure.
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F.10.F / 85
Reducer, spur gear - Assemble (F.10.F.44 - F.10.A.20)

CX135SR
NOTE: Numbers in brackets refer to Reducer, spur gear - Exploded view (F.10.F.44 - C.10.A.20)
1. Using a punch, install bearing (21) in the housing.
CRIL03F079A01 1
2. Using the guide, t seal (132).

3. Install seal (31).
Ensure that the seal is parallel to the surface of the
groove in the spindle.
CRIL03F060A00 2
4. Using lifting rings, carefully mount the spindle in the

housing.
CRIL03F054A00 3
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F.10.F / 86
5. Install the retaining tools between the housing and

the spindle.
CRIL03F053A00 4
6. Install seal (30), seals (28) and centring pins (43).

7. Turn the housing over.
Install outer bearing rings (22).
CRIL03F074A00 5
8. Install gear (4).
CRIL03F075A00 6
9. Install bearings (22) and (23) on shafts (9).
CRIL03F076A00 7
10. Install gear (5) following the markings made during

removal.
27073 1 14/12/2004
F.10.F / 87
11. Install rollers (7) in their bores.
CRIL03F078A00 8
12. Using a punch, install bearing (21) and tap all the
way round to drive it gradually into position.
CRIL03G251A00 9
13. To adjust the preloading on main bearing (21),

refer to Reducer, spur gear Bearing - Preload
(F.10.F.44.10 - F.45.A.30).
14. Install retaining ange (3) following the markings
CRIL03F080A00 10
15. Coat screws (19) with locking uid and tighten them
to torque 637 - 735 Nm.
Check that retaining ange (3) is correctly inserted
in the bearing.
CRIL03F051A00 11
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F.10.F / 88
16. Turn the reduction gear over.

Install outer bearing rings (22).
IMPORTANT: If any of the following parts are replaced:
spindle (2), retaining ange (3), shafts (9) or bearings
(22), adjust the bearing end play.
CRIL03G005A00 12
17. Install snap rings (20) following the markings made

during removal.
IMPORTANT: Only replace a snap ring with a snap ring of

the same thickness.
IMPORTANT: For snap ring replacement, refer to
Reducer, spur gear - Measure (F.10.F.44 - F.40.A.16).
CRIL03F049A00 13
18. Install spacers (12).
CRIL03F047A00 14
19. Install planetary pinions (7).
CRIL03F046A00 15
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F.10.F / 89
20. Install upper snap rings (25).
CRIL03F045A00 16
21. Install sun pinion (6) with coupling sleeve (15).

Grease steel ball (36) and install it.
CRIL03K018A00 17
CRIL03K016A01 18
23. Install cover (8) following the markings made during

removal.
Be careful not to damage the seal.
CRIL03K015A00 19
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F.10.F / 90
24. Install screws (18) on the cover and tighten to

torque 86,5 - 117,7 Nm.
CRIL03K013A00 20
25. Install plugs (33) and tighten to torque 49 - 68 Nm.
CRIL03K014A01 21
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F.10.F / 91
Reducer, spur gear - Install (F.10.F.44 - F.10.A.15)

CX135SR
1. Using a suitable lifting device, place the

moto-reduction gear in position.
CRIL03F159A01a 1
2. Fit washers (2) on screws (1), coat them with thread

locking uid and tighten them in the order indicated
to a torque of 267 - 312 Nm.
CRIL03F158A00a 2
3. Connect the hoses to the hydraulic motor, following

the markings made during removal.
CRIL03F153A01a 3
4. Fill the moto-reduction gear housings with oil.
Next operation: Drive sprocket - Install (D.50.B.45 - F.10.A.15).

Next operation: PRIMARY HYDRAULIC POWER SYSTEM - Bleed (A.10.A - F.35.A.25).
Next operation: Install the upper shield panel on the travel motor, refer to Side shield - Install (E.20.A.70 -
F.10.A.15).
27073 1 14/12/2004
F.10.F / 92
TRAVELLING Travel - Troubleshooting (F.10.F - G.40.A.10)

CX135SR

Travel drift Difference in speed between the two Check the travel motors for leaks. Refer
tracks. to Hydraulic motor - Leakage test
(F.10.F.28 - F.40.A.40)
Leaks in travel motor higher than Replace or repair the travel motor
authorised
Signicant travel pressure without load at Drain the travel reduction gear and check
(M1) or (M2). for contamination (metal particles).
Replace or repair the travel reduction gear
Pressure difference between P1 and P2 Check for negative pressures on pumps.
more than 30 bar (3 MPa). Refer to Hydraulic pump - Pressure test
(A.10.A.20 - F.40.A.30)
Negative pressure out of tolerance limits Check negative pressure valve (N1) or
(N2)
Pilot pressure below 30 bar (3 MPa) on To check control pedal operation, refer
travel pilot spool. to Command valve Foot command
valve - Troubleshooting (F.10.F.12.10 -
G.40.A.10).
Defective travel pilot spool. Check travel spool operation (spool spring,
scratched spool, etc.)
Defective regulator or pump. Check the defective regulator or pump
body
Leak between motor and travel reduction Replace the central seal.
gear
Unable to select 2nd travel Inadequate pilot pressure at the solenoid Test the electrical circuit of the solenoid
gear valve outlet valve, refer to Command valve Speed
selection valve - Electrical test
(F.10.F.12.15 - F.40.A.50)
Inadequate pilot pressure on the travel Internal leakage in the hydraulic swivel,
motors’ displacement change valve spool. repair or replace the hydraulic swivel
Travel motor’s displacement change valve Repair or replace the travel motor
spool defective
Command valve Foot command valve - Troubleshooting

(F.10.F.12.10 - G.40.A.10)
CX135SR
NOTE: The table below shows a list of common problems. This list is not exhaustive.
External oil leaks O-ring bearing surfaces scratched Repair or replace the parts
Defective seals Replace the seals
The secondary pressure Worn or broken spool return spring Replace the spring
does not increase
gradually or is out of
tolerance.
Dirt on the spool. Disassemble, clean and repair. Replace
the assembly if necessary
The lever does not move Dirt in the piston Disassemble, clean and repair. Replace
freely or does not return the assembly if necessary
to the neutral position
Dirt in the pushrod Disassemble, clean and repair. Replace
Dirt on the pivot pin and cam Disassemble, clean and repair. Replace
Worn or broken piston return spring Replace the spring
Damping force too weak Broken damper pin Replace the pin.
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F.10.F / 93

Dirt in the piston Disassemble, clean and repair. Replace
Damping force too strong Piston restrictor port blocked Disassemble, clean and repair. Replace
27073 1 14/12/2004
F.10.F / 94
Index

Command valve Foot command valve - Assemble (F.10.F.12.10 - F.10.A.20) 36
CX135SR
Command valve Foot command valve - Disassemble (F.10.F.12.10 - F.10.A.25) 29
CX135SR
Command valve Foot command valve - General specication (F.10.F.12.10 - D.40.A.10) 5
CX135SR
Command valve Foot command valve - Install (F.10.F.12.10 - F.10.A.15) 42
CX135SR
Command valve Foot command valve - Remove (F.10.F.12.10 - F.10.A.10) 28
CX135SR
Command valve Foot command valve - Sectional view (F.10.F.12.10 - C.10.A.30) 17
CX135SR
Command valve Foot command valve - Special tools (F.10.F.12.10 - D.20.A.40) 5
CX135SR
Command valve Foot command valve - Troubleshooting (F.10.F.12.10 - G.40.A.10) 93
CX135SR
Command valve Foot command valve - Visual inspection (F.10.F.12.10 - F.40.A.10) 35
CX135SR
Command valve Speed selection valve - Electrical test (F.10.F.12.15 - F.40.A.50) 44
CX135SR
Command valve Speed selection valve - Overhaul (F.10.F.12.15 - F.10.A.40) 43
CX135SR
Control valve - Assemble (F.10.F.14 - F.10.A.20) 47
CX135SR
Control valve - Disassemble (F.10.F.14 - F.10.A.25) 45
CX135SR
Control valve - Sectional view (F.10.F.14 - C.10.A.30) 19
CX135SR
Hydraulic motor - Assemble (F.10.F.28 - F.10.A.20) 63
CX135SR
Hydraulic motor - Check (F.10.F.28 - F.40.A.11) 62
CX135SR
Hydraulic motor - Disassemble (F.10.F.28 - F.10.A.25) 54
CX135SR
Hydraulic motor - Exploded view (F.10.F.28 - C.10.A.20) 20
CX135SR
Hydraulic motor - Install (F.10.F.28 - F.10.A.15) 70
CX135SR
Hydraulic motor - Leakage test (F.10.F.28 - F.40.A.40) 72
CX135SR
Hydraulic motor - Remove (F.10.F.28 - F.10.A.10) 52
CX135SR
Hydraulic motor - Sectional view (F.10.F.28 - C.10.A.30) 22
CX135SR
Hydraulic motor - Torque (F.10.F.28 - D.20.A.10) 6
CX135SR
Reducer, spur gear - Assemble (F.10.F.44 - F.10.A.20) 86
CX135SR
Reducer, spur gear - Disassemble (F.10.F.44 - F.10.A.25) 75
CX135SR
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F.10.F / 95
Reducer, spur gear - Exploded view (F.10.F.44 - C.10.A.20) 24
CX135SR
Reducer, spur gear - Install (F.10.F.44 - F.10.A.15) 92
CX135SR
Reducer, spur gear - Measure (F.10.F.44 - F.40.A.16) 82
CX135SR
Reducer, spur gear - Remove (F.10.F.44 - F.10.A.10) 74
CX135SR
Reducer, spur gear - Sectional view (F.10.F.44 - C.10.A.30) 26
CX135SR
Reducer, spur gear - Special tools (F.10.F.44 - D.20.A.40) 6
CX135SR
Reducer, spur gear - Visual inspection (F.10.F.44 - F.40.A.10) 81
CX135SR
Reducer, spur gear Bearing - Preload (F.10.F.44.10 - F.45.A.30) 84
CX135SR
Relief valve - Pressure setting (F.10.F.16 - F.45.A.70) 51
CX135SR
Relief valve - Pressure test (F.10.F.16 - F.40.A.30) 49
CX135SR
Sensing system Alarm - Electronic schema (F.10.F.95.90 - C.20.A.50) 27
CX135SR NA
TRAVELLING Travel - Electronic schema (F.10.F - C.20.A.50) 12
CX135SR
CX135SR
CX135SR
CX135SR
TRAVELLING Travel - Troubleshooting (F.10.F - G.40.A.10) 93
CX135SR
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F.10.F / 96
STABILISING Ballasting - 20.B
CX135SR
27074 1 14/12/2004
F.20.B / 1
Contents
SERVICE
Rear ballasting
Rear ballasting - Remove (F.20.B.61 - F.10.A.10) 3
CX135SR
Rear ballasting - Install (F.20.B.61 - F.10.A.15) 4

CX135SR
27074 1 14/12/2004
F.20.B / 2
FRAME POSITIONING - STABILISING Ballasting
Rear ballasting - Remove (F.20.B.61 - F.10.A.10)

CX135SR
Prior operation: To remove the rear protective panels, refer to Upper shield - Remove (E.20.A.71 - F.10.A.10)
Prior operation: To remove the rear RH and LH doors, refer to Side shield - Remove (E.20.A.70 - F.10.A.10)

Screw lifting rings (1) into the holes provided on the
rear counterweight.
Remove the back rear-view mirror.
CRIL03K042A01 1
2. With the upperstructure perpendicular to the

undercarriage and attachments on the ground,
attach the slings of a suitable lifting device to the
lifting rings on the rear counterweight.
Take up the slack in the slings.
Remove xing screws (2) located under the rear
counterweight.
Gently lift and remove the counterweight towards

the rear of the machine, avoiding damage to the
adjacent components.
Place the rear counterweight on a safe platform.
CRIL03K094A01 2
27074 1 14/12/2004
F.20.B / 3
FRAME POSITIONING - STABILISING Ballasting
Rear ballasting - Install (F.20.B.61 - F.10.A.15)

CX135SR
1. Attach the slings on a suitable lifting device to the

lifting rings on the rear counterweight.
Tighten the slings and lift.
2. Install the counterweight on the rear of the machine
avoiding damage to adjacent components.
Install screws (2) and tighten them to a torque of
1060 - 1235 Nm.
Remove the slings and lifting rings
CRIL03K094A01 1
3. Install the back rear-view mirror.

4. Install the doors and protective panels.
27074 1 14/12/2004
F.20.B / 4
Index

Rear ballasting - Install (F.20.B.61 - F.10.A.15) 4
CX135SR
Rear ballasting - Remove (F.20.B.61 - F.10.A.10) 3
CX135SR
27074 1 14/12/2004
F.20.B / 5
27074 1 14/12/2004
F.20.B / 6
SWINGING Circular swing - 40.C
CX135SR
27075 1 14/12/2004
F.40.C / 1
Contents
TECHNICAL DATA
Command valve
Command valve Hand command valve - Torque (F.40.C.12.10 - D.20.A.10) 5
CX135SR
Hydraulic motor
Hydraulic motor - Service limits (F.40.C.28 - D.20.A.20) 5
CX135SR
Hydraulic motor - Special tools (F.40.C.28 - D.20.A.40) 5

CX135SR
Hydraulic motor - Torque (F.40.C.28 - D.20.A.10) 7

CX135SR
Reducer, spur gear

Reducer, spur gear - Special tools (F.40.C.44 - D.20.A.40) 8
CX135SR
Swivel
Swivel - General specication (F.40.C.69 - D.40.A.10) 9
CX135SR
FUNCTIONAL DATA
SWINGING Circular swing - Hydraulic schema (F.40.C - C.20.A.20) 10
CX135SR

CX135SR
Command valve
Command valve Hand command valve - Sectional view (F.40.C.12.10 - C.10.A.30) 14
CX135SR
Control valve
Control valve - Sectional view (F.40.C.14 - C.10.A.30) 15
CX135SR
Hydraulic motor
Hydraulic motor - Sectional view (F.40.C.28 - C.10.A.30) 16
CX135SR
Reducer, spur gear

Reducer, spur gear - Sectional view (F.40.C.44 - C.10.A.30) 18
CX135SR
Hydraulic brake
Hydraulic brake - Electronic schema (F.40.C.59 - C.20.A.50) 19
CX135SR
Swivel
Swivel - Exploded view (F.40.C.69 - C.10.A.20) 21
CX135SR
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F.40.C / 2
SERVICE
Command valve
Command valve Hand command valve - Remove (F.40.C.12.10 - F.10.A.10) 22
CX135SR
Command valve Hand command valve - Disassemble (F.40.C.12.10 - F.10.A.25) 23

CX135SR
Command valve Hand command valve - Cleaning (F.40.C.12.10 - F.30.A.10) 28

CX135SR
Command valve Hand command valve - Visual inspection (F.40.C.12.10 - F.40.A.10) 29

CX135SR
Command valve Hand command valve - Assemble (F.40.C.12.10 - F.10.A.20) 30

CX135SR
Command valve Hand command valve - Install (F.40.C.12.10 - F.10.A.15) 35

CX135SR
Control valve
Control valve - Disassemble (F.40.C.14 - F.10.A.25) 36
CX135SR
Control valve - Assemble (F.40.C.14 - F.10.A.20) 37

CX135SR
Relief valve
Relief valve - Pressure test (F.40.C.16 - F.40.A.30) 38
CX135SR
Relief valve - Pressure setting (F.40.C.16 - F.45.A.70) 39

CX135SR
Hydraulic motor
Hydraulic motor - Leakage test (F.40.C.28 - F.40.A.40) 40
CX135SR
Hydraulic motor - Remove (F.40.C.28 - F.10.A.10) 41

CX135SR
Hydraulic motor - Disassemble (F.40.C.28 - F.10.A.25) 42

CX135SR
Hydraulic motor - Visual inspection (F.40.C.28 - F.40.A.10) 46

CX135SR
Hydraulic motor - Assemble (F.40.C.28 - F.10.A.20) 47

CX135SR
Hydraulic motor - Install (F.40.C.28 - F.10.A.15) 52

CX135SR
Hydraulic motor - Bleed (F.40.C.28 - F.35.A.25) 53

CX135SR
Reducer, spur gear

Reducer, spur gear - Remove (F.40.C.44 - F.10.A.10) 54
CX135SR
Reducer, spur gear - Disassemble (F.40.C.44 - F.10.A.25) 56

CX135SR
Reducer, spur gear - Visual inspection (F.40.C.44 - F.40.A.10) 59

CX135SR
Reducer, spur gear - Assemble (F.40.C.44 - F.10.A.20) 60

CX135SR
Reducer, spur gear - Install (F.40.C.44 - F.10.A.15) 64

CX135SR
Bearing and ring gear
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F.40.C / 3
Bearing and ring gear - Remove (F.40.C.45 - F.10.A.10) 65
CX135SR
Bearing and ring gear - Check (F.40.C.45 - F.40.A.11) 66

CX135SR
Bearing and ring gear - Install (F.40.C.45 - F.10.A.15) 67

CX135SR
Hydraulic brake
Hydraulic brake - Pressure test (F.40.C.59 - F.40.A.30) 68
CX135SR
Hydraulic brake Electrovalve - Electrical test (F.40.C.59.10 - F.40.A.50) 69

CX135SR
Swivel
Swivel - Remove (F.40.C.69 - F.10.A.10) 70
CX135SR
Swivel - Disassemble (F.40.C.69 - F.10.A.25) 71

CX135SR
Swivel - Cleaning (F.40.C.69 - F.30.A.10) 73

CX135SR
Swivel - Assemble (F.40.C.69 - F.10.A.20) 74

CX135SR
Swivel - Install (F.40.C.69 - F.10.A.15) 76

CX135SR
DIAGNOSTIC
SWINGING Circular swing - Troubleshooting (F.40.C - G.40.A.10) 77
CX135SR
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F.40.C / 4
FRAME POSITIONING - SWINGING Circular swing
Command valve Hand command valve - Torque (F.40.C.12.10 -

D.20.A.10)
CX135SR
Port plate xing screws 27.9 - 30.9 Nm

Universal joint on the control lever 44.2 - 50.0 Nm
Lock nut on the universal joint 63.7 - 73.5 Nm
Hydraulic motor - Service limits (F.40.C.28 - D.20.A.20)

CX135SR
Wear Limit
Description Standard Minimum Solution
dimensions dimensions
(mm) (mm)
Play between piston and barrel bore 0,016 0,046 Replace the barrel and the pistons
Play between piston and shoe (A) 0 0,3 Change the pistons and the pads
Thickness of shoes (B) 4 3,8 Change the pistons and the pads
Assembled height of thrust plate and 5,5 5,0 Replace the thrust pad and the spherical
spherical bearing (H - h) bearing
Thickness of the friction plate 3,5 3,1 Replace the plate
CRIL03K157E01 1
Wear limits
Surface roughness
Description Surface roughness Surface roughness (RA)
(RA) STANDARD WEAR LIMIT
Shoe 0,2 0,8
Piston wear plate 0,1 0,8
Cylinder barrel 0,4 3,2
Valve plate 0,2 1,6
NOTE: If the roughness of the sliding surfaces exceeds the tolerance limit, repair or replace the defective parts.
Hydraulic motor - Special tools (F.40.C.28 - D.20.A.40)

CX135SR
NOTE: The tool below should be manufactured locally.
27075 1 14/12/2004
F.40.C / 5
CRIL03K160F01 1
Tool for removing the brake piston

(A) 10 mm
(B) 128 mm
(C) 118 mm
(D) 138 mm
(E) 125 mm
(F) 10 mm
(G) 123 mm
(H) 200 mm
(J) 10 mm
(K) 250 mm
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F.40.C / 6
Hydraulic motor - Torque (F.40.C.28 - D.20.A.10)

CX135SR
CRIL03K088H02 1
Description
(1) Plug 36 Nm
(2) Plug 4,4 Nm
(3) Plug 1,7 Nm
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F.40.C / 7
(4) Plug 108 Nm

(5) Screw 240 Nm
(6) Safety valve 177 Nm
(7) Plug 36 Nm
(8) Plug 0,9 Nm
(9) Plug 22 Nm
Reducer, spur gear - Special tools (F.40.C.44 - D.20.A.40)

CX135SR
NOTE: The tools listed below are to be manufactured locally.
CRIL03L007A01 1
Used for installing the lip seal.

(A) 93 mm
(B) 10 mm
CRIL03L008A01 2
Used for installing the housing bearing.

(A) 74 mm
(B) 140 mm
(C) 45 mm
CRIL03L009E01 3
Used for removing the bearing from the shaft.
27075 1 14/12/2004
F.40.C / 8
(A) 10 mm
(B) 128 mm
(C) 118 mm
(D) 138 mm
(E) 125 mm
Swivel - General specication (F.40.C.69 - D.40.A.10)

CX135SR
Use of ports
Port A LH forward travel
Port B RH forward travel
Port C LH reverse travel
Port D RH reverse travel
Port E Raising the dozer blade
Port F Lowering the dozer blade
Port P Pilot
Port T Leak -off return
27075 1 14/12/2004
F.40.C / 9
SWINGING Circular swing - Hydraulic schema (F.40.C - C.20.A.20)

CX135SR
CRIL03J145G01 1
Swing circuit - Dynamic description
(22) Swing motor (B22) Swing pilot pressure switch
(B26) Upper pilot pressure switch (C2) Swing brake pilot
(Pa3/A3) Swing left (Pb3/B3) Swing right
(P1) Instrument panel (Y3) Swing brake solenoid valve (pink band)
BRAKING
• Swing motor (22) is supplied by a ow.
• On starting the engine, if the swing control is in the neutral position, swing brake solenoid valve (Y3) is
activated and the swing motor is braked.
• When the swing is operated, swing pilot pressure switch (B22) closes. The swing brake solenoid valve (pink
band) (Y3) is deactivated and the swing motor (22) brake is released. The upperstructure can then turn.
• When the attachment is operated within the 5 seconds following the return of the swing control to the neutral
position, lateral forces are generated on the attachment. To avoid these twisting forces, swing motor (22)
brake is released.
27075 1 14/12/2004
F.40.C / 10
• Five seconds after the attachment or swing control has returned to neutral, the swing brake solenoid valve
(Y3) is activated and swing motor (22) is braked.
Starter switch Functions Swing pilot Upper pilot Swing brake Swing motor
pressure switch pressure switch solenoid valve
Open none Open Open De-activated Braked
Closed none Open Open Activated Braked
Attachment Open Closed Activated Braked
Swing Closed Closed De-activated Brake is released
Attachment Closed Closed De-activated Brake is released
+ Swing
Stop Open Open Activated after Braked
Attachment 5 secondes
27075 1 14/12/2004
F.40.C / 11
SWINGING Circular swing - Hydraulic schema (F.40.C - C.20.A.20)

CX135SR
CRIL03J146G01 1
Swing variable priority circuit - Dynamic description
(1) Swing priority valve (15) Main control valve
(22) Swing motor (81) Swing shuttle block
(Pa3/A3) Swing left (Pb3/B3) Swing right
(Pa5/A5) Dipper out (Pb5/B5) Dipper return
(Pa9/Pb9) Dipper valve spool 2 (Pc3) Priority to swing
(Pb4) Boom valve spool 2 (Pc3) Swing priority valve piloting
VARIABLE PRIORITY
• The swing pilot pressure arrives in the main control valve (15) via port (Pc3) after passing through swing
shuttle block (81) and pilots swing priority valve (1). This provides the maximum possible torque to swing
motor (22) with high swing pressure, even the dipper is used at the same time.
• When digging, the pilot pressure for raising the boom actuates the swing priority valve (1) via orice (Pbu).
The swing ow is therefore in parallel with the dipper via swing priority valve (1). This has the effect of
improving the speed of the dipper.
• The trench is dug more uniformly even if the free passage is closed by the valve spool on boom 2.
27075 1 14/12/2004
F.40.C / 12
• When the upperstructure is rotated and the dipper is retracted or the boom is raised at the same time, the
parallel arrangement is reduced and the swing pressure is maintained.
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F.40.C / 13
Command valve Hand command valve - Sectional view (F.40.C.12.10

- C.10.A.30)
CX135SR
CRIL03I001G01 1
Description
(1) Lock nut (2) Boot
(3) Disc (4) Pusher
(5) Plate (6) Guide
(11) Spool (12) Body
(13) Port plate (14) Screw
(17) Spool (18) Spring
(19) Seal (20) Universal joint
(21) Retaining pin (22) Washer
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F.40.C / 14
Control valve - Sectional view (F.40.C.14 - C.10.A.30)

CX135SR
CRIL03J102E01 1
(4) Spool
(11) Large cap
(12) Seal
(13) Small cap
(16) Valve
(17) Spring
(18) Seal
(19) Plug
(65) Screw
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F.40.C / 15
Hydraulic motor - Sectional view (F.40.C.28 - C.10.A.30)

CX135SR
CRIL03K088H01 1
(1) Drive shaft (2) Spacer (3) Snap ring

(4) Roller bearing (5) Seal (6) Spacer
(7) Push-rod (8) Seal (9) Plug
(10) Friction disc (11) Steel disc (12) Seal
27075 1 14/12/2004
F.40.C / 16
(13) Cylinder barrel (14) Brake piston (15) Pin

(16) Cover (17) Valve plate (18) Seal
(19) Plug (20) Roller bearing (21) Snap ring
(22) Plug (23) Rivet (24) Plate
(25) Spacer (26) Plug (27) Snap ring
(28) Spring (29) Seal (30) Seal
(31) Plug (32) Spring (33) Spacer
(34) Piston (35) Spherical bushing (36) Thrust plate
(37) Plug (38) Shoe (39) Housing
(40) Piston wear plate (41) Snap ring (42) Cover
(43) Seal (44) Check valve (45) Spring
(46) Screw (47) Seal (48) Plug
(49) Seal (50) Safety valve
27075 1 14/12/2004
F.40.C / 17
Reducer, spur gear - Sectional view (F.40.C.44 - C.10.A.30)

CX135SR
CRIL03K183G01 1
(1) Drive shaft (2) Seal (3) Snap ring

(4) Bearing (5) Housing (6) Seal
(7) Bearing (8) Planetary carrier (9) Ring gear
(10) Sun pinion (11) Screw (12) Planetary pinion
(13) Planetary carrier (14) Planetary pinion (15) Pin
(16) Plug (17) Sun pinion (18) Washer
(19) Plug (20) Retaining pin (21) Washer
(22) Pin (23) Bearing (24) Snap ring
(25) Washer (26) Washer
27075 1 14/12/2004
F.40.C / 18
Hydraulic brake - Electronic schema (F.40.C.59 - C.20.A.50)

CX135SR
CRIL03G187F01 1
Circuit layout
(1) Swing brake (B22) Swing pilot pressure switch

(B26) Upper pilot pressure switch (yellow band) (K19) Swing brake relay
(Y3) Swing brake solenoid valve (pink band)
27075 1 14/12/2004
F.40.C / 19
CRIL03G188F02 2
Timing diagram
OPERATION OF THE SWING BRAKE CONTROL
1. Swing brake (1) will be activated 5 seconds after upper pilot pressure switch (B26) is in the open position.
2. Swing brake (1) will be activated 3 seconds after the supply cut-off delay.
27075 1 14/12/2004
F.40.C / 20
Swivel - Exploded view (F.40.C.69 - C.10.A.20)

CX135SR
CRIL03K081G01 1
(1) Pivot (2) Seal

(3) Seal (4) Seal Ring
(5) Seal (6) Base plate
(7) Seal (8) Cover
(11) Plate (12) Screw
(13) Washer (14) Screw
(15) Washer (16) Locking bar
27075 1 14/12/2004
F.40.C / 21
Command valve Hand command valve - Remove (F.40.C.12.10 -

F.10.A.10)
CX135SR
1. Remove the screws (1).

Raise the shield (2) and attach identication labels
to the electrical harnesses.
Disconnect the electrical harnesses.
Remove shields (2) and (3).
CRIL03I107B01 1
2. Attach identication labels to all the control lever

hoses.
Plug the ports.
3. Remove the screws (1) and the control lever.
CRIL03I119A01 2
27075 1 14/12/2004
F.40.C / 22
Command valve Hand command valve - Disassemble (F.40.C.12.10

- F.10.A.25)
CX135SR
or dropped.
The components of the control lever may rust due to dirt and moisture if they are left unprotected after dismantling.
If work has to be interrupted, the components must be protected from contamination or corrosion.
1. Install the control lever in a soft-jawed vice.
Remove the boot.
CRPH03I001A 1
2. Remove the lock nut.
CRPH03I002A 2
3. Remove the disc.
CRPH03I003A 3
27075 1 14/12/2004
F.40.C / 23
4. Mount two nuts on the universal joint and tighten

them as far as the stop.
Holding the upper nut in place, turn the lower nut
anti-clockwise to loosen the universal joint.
Remove the universal joint.
NOTE: Remove the universal joint with care, making sure
that the plate and the push rods, which are spring-loaded,
do not spring out too quickly.
CRPH03I004A 4
5. Remove the plate.

NOTE: Make marks on the components removed in the
following steps to make their re-installation in their original
bores easier.
CRPH03I005A 5
6. Depending on the condition of the return springs,

the guides can be retained in place in the body by
the friction of the seals.
In this case, use a at screwdriver to remove the
guides.
Slide a screwdriver into the outer groove on the
guide, making sure not to damage the guide.
Proceed with caution as the guide can be ejected
very suddenly under the pressure of the return
springs.
CRPH03I006A 6
CRPH03I007A 7
27075 1 14/12/2004
F.40.C / 24
8. Turn the control valve the other way up in the vice.

Remove the screws and the washers.
CRPH03I008A 8
9. Remove the port plate.

Discard the seal.
CRPH03I009A 9
10. Remove the ring.
CRPH03I010A 10
27075 1 14/12/2004
F.40.C / 25
11. Push the spring in a few millimetres so as to

disengage the spool (11) from the spring seat (8).
Separate the spool (11) from the spring (10) and
the washer (22).
Keep these components together until required for
reassembly.
CRIL03I002B01 11
12. Remove the spool (17) and the spring (18) from the
guide.
CRIL03I003A01 12
13. Remove the push rod (4) from the guide (6).
CRIL03I004A01 13
27075 1 14/12/2004
F.40.C / 26
14. Discard the guide seal.
CRPH03I011A 14
15. Discard the guide seal.
CRPH03I012A 15
27075 1 14/12/2004
F.40.C / 27
Command valve Hand command valve - Cleaning (F.40.C.12.10 -

F.30.A.10)
CX135SR
1. Cleaning the components:

Soak them in a suitable cleaning solvent until dirt
and oil are removed.
The components can be damaged if they are
washed while still dirty.
2. Final washing:
Immerse the components in a clean receptacle
containing a suitable cleaning solvent.
Rotate the receptacle so as to wash the inner
surfaces of the components as well.
Dry the components with a clean cloth.
NOTE: Never use compressed air to dry the components.
The dust and water in the air could cause surface damage
or corrosion.
3. Corrosion prevention:
Apply an anti-rust product to all components.
NOTE: Components can rust if they are left exposed to
the open air after cleaning.
27075 1 14/12/2004
F.40.C / 28
Command valve Hand command valve - Visual inspection

(F.40.C.12.10 - F.40.A.10)
CX135SR

defective.
Make sure that the spool slides freely in the control
lever body bore.
If defects are found, replace the hand control
assembly.
2. Inspect the controls.
Replace the components if the wear on the shaft
pin and the seal causes play in the controls of more
than 2 mm.
A : 1 mm
B : 7 mm
CRIL03I005A01 1
3. If it is impossible to determine the cause of an

abnormal noise or a fall in primary pressure by
inspecting the parts, replace the the hand control.
27075 1 14/12/2004
F.40.C / 29
Command valve Hand command valve - Assemble (F.40.C.12.10 -

F.10.A.20)
CX135SR
1. Install the bushing in the body.
CRPH03I010A 1
2. Install the seal in the body groove.
CRPH03I013A 2
3. Install the port plate (13) with the plastic pin (21) in
port (A) of the body.
CRIL03I006A01 3
27075 1 14/12/2004
F.40.C / 30
4. Mount the screws and washers on the port plate.

Tighten the screws alternately to the required
torque.
CRPH03I014A 4
5. Assemble the spool assembly by installing the

washer (22), the spring (10) and the spring seat (8)
on the spool (11).
CRIL03I007A01 5
6. Turn the control lever the other way up in the vice.

Install the return spring and the spool assembly
in the body following the markings made during
removal.
CRPH03I015A 6
7. Install the seal on the guide.
CRPH03I016A 7
27075 1 14/12/2004
F.40.C / 31
8. Install the seals (19) with lips as shown opposite.
CRIL03I008B01 8
9. Coat the surfaces of push rod (4) with hydraulic uid

and install in the guide (6).
CRIL03I004A01 9
10. Install the spool (17) and the spring (18) in the guide
(6).
CRIL03I003A01 10
27075 1 14/12/2004
F.40.C / 32
11. Install the guide in the body.

Depending on the condition of the return springs,
the guides can be retained in place in the body by
the friction of the seals.
CRPH03I017A 11
12. Repeat steps 5 to 11 for the other three bores.

13. Install the plate and hold it in place with the universal
joint.
Tighten the universal joint to the required torque.
CRPH03I018A 12
14. Install the disc on the universal joint.

Tighten until the disc is in equal contact with the
four pushers.
CRPH03I003A 13
15. Install the lock nut and tighten it to the required

torque, retaining the disc ats with an open wrench.
CRPH03I019A 14
27075 1 14/12/2004
F.40.C / 33
16. Place a few spots of grease on the pushers.
CRPH03I020A 15
17. Install the gusset.
CRPH03I001A 16
27075 1 14/12/2004
F.40.C / 34
Command valve Hand command valve - Install (F.40.C.12.10 -

F.10.A.15)
CX135SR
1. Position the control lever and install the screws (1).
CRIL03I119A01 1

Connect all hoses to the control lever following the
3. Put the shields (2) and (3) in place.
Connect all electrical harnesses following the
Install the screws (1).
CRIL03I107B01 2
27075 1 14/12/2004
F.40.C / 35
Control valve - Disassemble (F.40.C.14 - F.10.A.25)

CX135SR
CRIL03J102E01 1
1. Remove caps (11) and (13).

Discard seals (12).
Remove spool (4).
2. Remove the screw from spool (45).
Remove spring (44) and seats (43).
replace the spring.
CRIL03L053A01 2

Discard seal (18).
Remove spring (17) and check valve (16).
4. Remove valves (63). Discard seals.
27075 1 14/12/2004
F.40.C / 36
Control valve - Assemble (F.40.C.14 - F.10.A.20)

CX135SR
Prior operation: Stack valve - Visual inspection (A.10.A.18 - F.40.A.10)
CRIL03J102E01 1
Torque settings
Fixing screws for spool return spring (4) 9.8 - 11.8 Nm
Plug (19) 103 - 113 Nm
Main relief valve (63) 78 - 88 Nm
Cap xing screws (65) 20 - 25 Nm
1. Install check valve (16) and spring (17).
Install plug (19) tted with a new seal and tighten to
the required torque (18).
2. Install valves (63) and tighten to the required torque.
3. Coat the threaded part of spool (A) with locking uid.
Clamp the end of the spool in a soft-jawed vice.
Install spring (44) and seats (43) on screw (45).
Install and tighten the screws to the required torque.
Install spool (4) in its housing.
CRIL03L053A01 2
4. Install caps (11) and (13) tted with new seals (12).
Install and tighten screws (65) to the required
torque.
27075 1 14/12/2004
F.40.C / 37
Relief valve - Pressure test (F.40.C.16 - F.40.A.30)

CX135SR
1. Disconnect and plug swing brake pilot hose (1) from

port (PG) on swing motor.
CRIL03K062A02 1

the pressure test point (M2) on the main pump.
4. Slowly operate the swing control lever to the right or
the left, then gradually increase the engine speed to
full speed to ensure that the swing is locked.
5. Repeat step 4, for the swing to be checked, the
pressures should be in (M2): LH and RH swing 285
± 4 bar (28.5 ± 0.4 MPa)
6. If the pressures are incorrect, to set main relief
valves (I) and (J), refer to Relief valve - Pressure
setting (F.40.C.16 - F.45.A.70)
7. Connect swing brake pilot hose (1) to port (PG) on
swing motor.
8. Stop the engine and disconnect the pressure gauge.
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Relief valve - Pressure setting (F.40.C.16 - F.45.A.70)

CX135SR
Prior operation: Relief valve - Pressure test (F.40.C.16 - F.40.A.30)
1. Using a wrench, hold adjusting screw (3) of the

main relief valve concerned in position and loosen
the lock nut (2).
CRIL03K062A01 1
2. Operate and hold in position the swing control that

is to be calibrated.
3. Turn adjusting screw (3) on the main relief valve
concerned until the correct pressure is obtained.
5. Check the pressure again and repeat the operations
if the required value is not obtained.
6. Reconnect the swing brake pilot hose (1) to port
(PG).
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Hydraulic motor - Leakage test (F.40.C.28 - F.40.A.40)

CX135SR
1. Disconnect the swing brake pilot hose from the port

(PG) on the swing motor and plug it.
3. Slowly operate the swing control lever and gradually
increase the engine speed to full speed to ensure
that swing is locked.
4. Stop the engine.
5. Press the breather to relieve the pressure in the
6. Disconnect hose (1) from the hydraulic motor orice
(drain) and plug it.
CRIL03I156A01 1
7. Use a hose to connect the drain orice to a

receptacle with a capacity of about 10 L.
8. Start the engine and run it at full speed. Operate
the swing control to the right or left and measure the
quantity of oil that escapes from the drain in 1 mn.
9. As the quantity of oil can vary depending on the
test point used, repeat the measurement with the
upperstructure at 90 °, then at 180 °.
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Hydraulic motor - Remove (F.40.C.28 - F.10.A.10)

CX135SR

Prior operation: To remove the protective panel, refer to Upper shield - Remove (E.20.A.71 - F.10.A.10)
1. Mark, disconnect and plug all hoses and connectors

on the hydraulic swing motor.
Mark the hydraulic swing motor in relation to the
reduction gear.
Attach a suitable lifting device to the hydraulic swing
motor.
Remove screws (1).
CRIL03K083A01 1
2. Lift and carefully disengage the hydraulic swing

motor from the reduction gear.
Place the motor on a clean bench.

Discard the seal for the reduction gear housing.
NOTE: In order to avoid any contamination of the swing
reduction gear, cover the reduction gear with suitable
protection.
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Hydraulic motor - Disassemble (F.40.C.28 - F.10.A.25)

CX135SR
1. Remove the connectors from the swing motor.

Discard the seals.
NOTE: Install the plugs in the ports of the motor.
2. Mark and remove secondary relief valves (1) and
(2) from cover (3).
Discard the seals.
CRIL03K095A01 1
3. Remove plug (1).

Discard seal (2).
CRIL03K096A01 2
CRIL03K097A00 3
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5. Remove the check valve.
CRIL03K098A00 4
6. Turn the cover 180 degrees and repeat steps 3 to 5

to remove the other check valve.
7. Put identication marks on cover (1) and housing
(2).
Remove screws (3) from cover (1).
CRIL03K099A01 5
8. Remove cover (1).

Place the cover on its top and discard the seal.
Remove valve plate (2).
NOTE: Take care not to damage the valve plate during
removal. Mark the valve plate and cover with an indelible
ink felt tip pen prior to removal to ensure correct alignment
when reassembling.
CRIL03K100A01 6
9. Remove the springs from the brake piston.
CRIL03K101A00 7
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10. Place the manufactured tool (1) on brake piston (2)

and remove the brake piston from housing (3).
Discard the inner seals from the housing.
CRIL03K102A01 8
11. Place the motor horizontally, remove barrel

assembly (1).
CRIL03K103A01 9
12. Remove piston plate (1), piston assembly (2) and

thrust plate (3) from barrel (4), all in one piece.
Slip piston plate (1) out of the sliding surfaces of
piston assemblies (2), taking care not to damage
them.
Remove the pistons from thrust plate (3).
Remove spherical bushing (5) and thrust rods (6)
from barrel (4).
Remove snap ring (7), spacer (8), spring (9) and
spacer (10) from barrel (4).
NOTE: Mark the location of the pistons on the base plate
and on the barrel. It is essential that pistons are installed
in their original positions when re-assembling. CRIL03K104A01 10
13. Mark and remove friction plates (1) and steel plates
(2) from housing (3).
CRIL03K105A01 11
14. Remove the snap ring from the tip of the drive shaft
and remove the inner ring from the bearing.
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Remove front cover (2).
CRIL03K109A01 12
16. Remove the drive shaft from the housing by tapping

lightly on the valve cover side at the tip of the shaft
using a plastic hammer.
17. Remove the snap rings and spacers from the drive
shaft.
Mark the position of the bearing.

Using a press, remove and discard roller bearing
(1) from drive shaft (2).
CRIL03K108A01 13
18. Using the appropriate tool, mark, remove and

discard seal (1) from front cover (2).
CRIL03K106A01 14
19. Using a slide-hammer puller, remove and discard

roller bearing (1) from cover (2).
CRIL03K107B01 15
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Hydraulic motor - Visual inspection (F.40.C.28 - F.40.A.10)

CX135SR
1. The valve plate includes crescent-shaped apertures

that ensure modulation between oil at high pressure
and oil at low pressure. Any damage to the contact
surface between the valve plate and the end
face of the cylinder barrel may cause leaks and
lead to reduced volumetric efciency, possibly
accompanied by increased "skating". Possible
seizing at these two contact surfaces may result
in a loss of mechanical efciency and cause more
signicant damage.
2. Repair all damage to the contact surface of the
piston shoes. If the shoe surfaces are seriously
damaged, replace the entire motor.
3. The external surface of the piston assembly should
show practically no wear. The motor should be
replaced if a piston assembly shows the slightest
evidence of seizing.
4. The cylinder barrel bores should show practically no
signs of wear. If the bores show signs of seizing or
abnormal wear, replace the entire motor.
5. Replace the bearings if damage is found on the
roller contact surfaces. We recommend replacing
the bearings as routine when reassembling the
motor, since they can easily be damaged when the
motor is disassembled.
6. Replace seals that show signs of damage. In
addition, replace seals even if there are no leaks
or signs of deterioration. Use new seals when
reassembling the motor.
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Hydraulic motor - Assemble (F.40.C.28 - F.10.A.20)

CX135SR
1. Position the housing with its upper portion facing

upwards.
2. Install snap ring (3) and spacer (2) on drive shaft (1).
Position bearing (4) following marks made during
removal.
Install the other spacer (2) and the other snap ring
(3).
CRIL03K110A01 1
3. Install inner bushing (1) of the bearing on shaft (2)

and install the snap ring.
CRIL03K111A01 2
4. Install drive shaft (1) in housing (2). Hammer lightly

and uniformly the outer portion of bearing (3) to
position the bearing in its housing correctly.
CRIL03K112A01 3
5. Using a seal driver, install seal (1) in front cover (2)

CRIL03K113A01 4
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6. Install seal (1) in housing (2).

Install front cover (3) in housing (2) by tapping lightly
with a plastic hammer.

NOTE: Thinly coat lip seal (5) with grease to make
assembly easier. Protect the splines on drive shaft (6) to
avoid damaging seal (5) during assembly.
CRIL03K114A01 5
7. Position the housing horizontally. Thinly coat the

piston plate with grease (chamfered side in contact
with the housing) and install the plate in the housing.
8. Install in barrel (4) spacer (10), spring (9) and
spacer (8). Install snap ring (7).
Install thrust rods (6) and spherical bushing (5) on
barrel (4).
Install pistons (2) on thrust plate (3).
Apply clean hydraulic oil to the bores of barrel (4)
and install the plate/piston assembly in barrel (4)
CRIL03K115A01 6
9. Install cylinder barrel assembly (1).
CRIL03K103A01 7
10. Position the housing with its upper portion facing

upwards.
Apply clean hydraulic uid to both faces of friction
plates (1) and steel plates (2).
Install steel plates (2) and friction plates (1)
alternately following the marks made during
removal.
CRIL03K105A01 8
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11. Install the inner seals in the housing .

NOTE: Apply a thin coat of grease to the seals to facilitate
the assembly of the brake piston in the housing.
CRIL03K116A00 9
12. Apply clean hydraulic uid around the brake piston

(1) and install the brake piston in the housing
CRIL03K132A01 10
13. Install the springs on the brake piston in their

original positions.
CRIL03K101A00 11
14. Using a suitable tool, install the outer bushing of

bearing (1) in cover (2).
CRIL03K133A01 12
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15. Install valve plate (1) on cover (2) following the

Thinly coat seal (3) with grease and install it on
cover (2).
NOTE: Apply a thin coat of grease to hold the parts
together.
CRIL03K134A01 13
16. Install cover (1) on housing (2) following the marks

made during removal
CRIL03K100A02 14
17. Install xing screws (1) on cover (2) and tighten to a

torque of 240 Nm.
CRIL03K099A02 15
18. Install the check valve.
CRIL03K098A00 16
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19. Install the spring.
CRIL03K097A00 17
20. Install plug (1) complete with seal (2) on the cover
and tighten to torque .
NOTE: Turn the cover 180 degrees and repeat steps 23
to 25 to install the other check valve.
CRIL03K096A01 18
21. Install a seal on secondary relief valves (1) and (2)

and install them on cover (3) following marks made
during removal, tighten to torque .
CRIL03K095A01 19
22. Install installation unions on the motor.

23. Apply a pilot pressure of 30 bar in the brake port.
Check that the drive shaft can turn freely at least
one turn by applying a torque of around 39 Nm.
NOTE: If the shaft does not turn, the unit has not been
assembled correctly. Disassemble and repeat assembly
steps.
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Hydraulic motor - Install (F.40.C.28 - F.10.A.15)

CX135SR
1. Install a seal on the reduction gear housing.

2. Attach a suitable lifting device to the swing motor.
Position the swing motor above the reduction gear.
Carefully lower the motor onto the swing reduction
gear, following the identication marks made during
removal.
Remove the lifting device.
3. Install xing screws (1) and tighten them to torque
- Nm.
Remove the plugs.
Install the connectors and hoses on the motor.

Remove plug (2).
Fill the hydraulic swing motor.
Fit and tighten plug (2).
CRIL03K083A02 1

Next operation: Hydraulic motor - Bleed (F.40.C.28 - F.35.A.25)
Next operation: To install upper protective panel on hydraulic swing motor, refer to Upper shield - Remove
(E.20.A.71 - F.10.A.10)
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Hydraulic motor - Bleed (F.40.C.28 - F.35.A.25)

CX135SR
1. Start and run the engine at idling speed.

Loosen bleed plug (1) and check that hydraulic uid
escapes through this port.
If necessary, stop the engine and add uid through
this port.
Re-t the plug without tightening, then start and run
the engine at idling speed, allowing it to run until the
hydraulic uid escapes through the port.
Fully tighten the air bleed plug.
Rotate the upperstructure through at least two
complete revolutions to the left and the right.
Check the reservoir level and top up as necessary.
CRIL03K174A01 1
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Reducer, spur gear - Remove (F.40.C.44 - F.10.A.10)

CX135SR

Prior operation: Remove lower shield panel (5), refer to Protective shield - Remove (E.20.A.73 - F.10.A.10)
Prior operation:
Prior operation: Remove upper shield panel (1) from hydraulic swing motor, refer to Upper shield - Remove
(E.20.A.71 - F.10.A.10)
1. Place a container under the drain plug (1).

Remove the drain plug and drain the oil.
Re-insert the drain plug.
CRIL03L046A01 1
2. Mark, disconnect and plug all the hoses and unions

connected to the swing moto-reduction gear.
CRIL03K083A00 2
3. Attach a suitable lifting device to the swing

moto-reduction gear.
4. Mark the swing moto-reduction gear with reference
to the chassis.
Remove the swing moto-reduction gear retaining
screws.
5. Carefully lift and remove the swing rmoto-reduction
gear from the machine.
NOTE: Place the swing moto-reduction gear on suitable
stands, so that the pinion does not touch the oor.
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6. Make an alignment mark (2) between the swing

motor and the reduction gear.
Remove xing screws (1) from the hydraulic swing
motor.
Carefully lift the swing motor and place it in a clean
area.
CRIL03I051B01 3
7. Discard the seal for the reduction gear housing.
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Reducer, spur gear - Disassemble (F.40.C.44 - F.10.A.25)

CX135SR
1. Remove the second stage sun gear.
CRIL03L016A00 1
2. Remove rst stage satellite carrier assembly (1),

then remove snap ring (2), washer (3), planetary
pinion (4), roller bearing (5), washers (6) and (7).
If necessary, mark and remove planetary carrier pin
(8).
CRIL03L017A01a 2
3. Remove sun gear (1) and second stage planetary

carrier assembly (2).
CRIL03L018A01 3
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4. If necessary, remove and discard locking pin (1),

remove roll pin (2), planetary pinion (3), washer (4)
and planetary carrier pin (5) from planetary carrier
(6).
CRIL03L019A01 4
5. Mark and remove ring gear from reduction gear

housing (1) by xing engine xing screws into the
two orices provided on the ring gear (2).
CRIL03L020A01 5
6. Remove snap ring (1) from pinion shaft (2).
CRIL03L021B01 6
7. Use a puller with the jaws under the ring gear

mating ange of the housing to remove pinion shaft
assembly (1) from the housing.
NOTE: If the pinion shaft assembly shows signs of wear,
it is advisable to change the entire assembly.
CRIL03L022A01 7
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8. If necessary, using a press and a special tool, refer

to Reducer, spur gear - Special tools (F.40.C.44 -
D.20.A.40) to extract bearing (1) and seal (2) from
pinion shaft (3).
CRIL03L023B01 8
9. Remove roller bearings (1) from housing (2).
CRIL03L024A01 9
CRIL03L025A01 10
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Reducer, spur gear - Visual inspection (F.40.C.44 - F.40.A.10)

CX135SR
IMPORTANT: Handle parts with care to avoid damaging them.

IMPORTANT: Replace the removed seals.
IMPORTANT: Replace parts which have the following defects:
1. Heavy visible damage or abnormal wear (chang
and scratches).
2. Irregular wear on the gear teeth.
3. Pressure points, surface aking and irregular wear
on the bearings.
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Reducer, spur gear - Assemble (F.40.C.44 - F.10.A.20)

CX135SR
1. If necessary, clamp the pinion shaft into a press and

install the bearing seal.
2. Heat the bearing to a temperature of 80°C in an oil
bath and push it onto the pinion shaft using a press.
NOTE: Do not heat the bearing to a temperature greater
than 100°C.
3. Fill the roller bearings with grease.
CRIL03L026A00 1
4. Clamp the reduction gear housing in a press.

5. Install a ring screw in pinion shaft (1), then lift it
vertically and t it into reduction gear housing (2)
using a press.
CRIL03L027A01 2
6. Using the tool to be manufactured, refer to Reducer,

spur gear - Special tools (F.40.C.44 - D.20.A.40)
to install seal (1) in housing (2).
NOTE: Coat the seal with oil, taking care not to damage
the lips during installation.
CRIL03L029A01 3
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7. Using the tool to be manufactured, refer to Reducer,

spur gear - Special tools (F.40.C.44 - D.20.A.40)
and a press, to install the bearing (1).
CRIL03L030A01 4
8. Apply axial pressure on bearing (1) to be able to

install snap ring (2) in the groove of the pinion shaft
(3).
Through port (A) ll the inside of housing (4) with

grease, install plug (5), tighten to 22 Nm.
CRIL03L028B01 5
9. If necessary, install pin (5), roll pin (2), washer (4),

planetary pinion (3) and locking pin (1) on planetary
carrier (6).
CRIL03L019A01 6
10. Wipe off grease from the mating surfaces of the

reduction gear housing and the ring gear. Apply a
sealant to the mating surfaces.
CRIL03L034A00 7
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11. Install the ring gear following the marks made during
removal.
NOTE: Install it provisionally using motor xing screws.
CRIL03L036A00 8
12. Install the second stage planetary gear assembly so

that it meshes correctly with the ring gear internal
teeth. Turn the planetary gear assembly to mesh
with the uting of the pinion shaft.
CRIL03L037A00 9
13. Install the second stage sun gear so that it meshes

with the planetary gear assembly.
CRIL03L038A00 10
14. Place the rst stage satellite carrier on a at surface.

If necessary, install planetary carrier shafts (1),
following the position of the oil passage ports (A),
crimp with a special tool.
CRIL03L039A01 11
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15. Install rst stage satellite carrier (1) washer (6),

washer (7), roller bearing (5), planetary pinion (4),
washer (3) and snap ring (2).
CRIL03L042A01 12
16. Install the rst stage planetary gear assembly so

that it meshes with the ring gear internal teeth. Turn
the planetary gear assembly slightly to mesh the
teeth of the planetary gears with the teeth of the
second stage sun gear.
CRIL03L040A00 13
17. Install the rst stage sun gear. Mesh the teeth
of the sun gear with the teeth of the planetary
gear assembly. Turn the rst stage planetary gear
assembly by hand to check that the output shaft
rotates smoothly.
CRIL03L016A00 14
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Reducer, spur gear - Install (F.40.C.44 - F.10.A.15)

CX135SR
1. Fit the seal to the reduction gear housing.

2. Mount the hydraulic swing motor to the reduction
gear, following the markings (2) made during
removal.
Install screws (1) and tighten them to torque .
CRIL03I051B01 1
3. Using a suitable lifting device, attach and raise

the moto-reduction gear, place it on the machine,
following the markings made during removal.
4. Apply thread lock uid to the screws and tighten to
a torque of 267 - 312 Nm.
5. Fill the hydraulic motor with 4.8 L of hydraulic oil.
6. Remove the plugs and connect the hoses and
unions, following the markings made during
removal.
Next operation: Battery - Connect (A.30.A.83 - F.10.A.16).

Next operation: PRIMARY HYDRAULIC POWER SYSTEM - Bleed (A.10.A - F.35.A.25).
Next operation: Install the shield panel (1) on the hydraulic swing motor, refer to Upper shield - Remove
(E.20.A.71 - F.10.A.10).
Next operation: Install the lower shield panel for the hydraulic swivel, refer to Protective shield - Remove
(E.20.A.73 - F.10.A.10).
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Bearing and ring gear - Remove (F.40.C.45 - F.10.A.10)

CX135SR

Prior operation: Protective shield Guard - Remove (E.20.A.73.71 - F.10.A.10)
Prior operation: Swivel - Remove (F.40.C.69 - F.10.A.10)
Prior operation: Remove the attachment, refer to Arm - Remove (H.20.B.50 - F.10.A.10)
Prior operation: Remove the counterweight, refer to Rear ballasting - Remove (F.20.B.61 - F.10.A.10)
1. Drain the fuel tank.

2. Drain the hydraulic circuit.
3. Install lifting rings at the rear of the upperstructure.
Attach a suitable lifting device to these lifting rings
and to the lifting rings located at the front of the
upperstructure, above the boom brackets.
4. Mark the position of the ring gear in relation to the
upperstructure frame and undercarriage, to make
reassembly easier.
5. Remove thering gear mountings on the
upperstructure.
6. Carefully raise the upperstructure and place it on
suitable stands.
7. Install lifting rings on the turntable. Attach a suitable
lifting device to the lifting rings.
8. Remove the ring gear mountings from the carrier
chassis. Remove the lifting device from the lifting
rings and dismantle the lifting rings from the
turntable.
9. Carefully raise the turntable. Place the turntable on
suitable stands in order to protect its surfaces from
any damage.
10. Remove the lifting device and dismantle the lifting
rings.
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Bearing and ring gear - Check (F.40.C.45 - F.40.A.11)

CX135SR
If the upperstructure squeals, does not revolve properly or pauses before revolving, this indicates that the turntable
is worn or damaged. When an operator is working with the machine, he must pay attention to any unusual noises
that may indicate turntable wear. If the operator hears unusual noises and if the upperstructure pauses before
revolving, he must carry out the following inspection.
1. Park the machine on hard, level ground. Lower the

attachment to the ground.
2. Let the engine idle for 30 secondes then stop the
engine.
3. Remove the lower protective hood for the hydraulic
swivel and the lubrication access panel for the
turntable bearing.
4. Ask another person to operate the swing.
Use a torch to check for scratches, missing teeth,
aking, cracking or other damage to the ring gear.
If damage is found, replace the upperstructure ring
gear.
ATTENTION: You may be seriously injured if your hand is
in the access port to the ring gear when the upperstructure
is revolving. Before lubricating the ring gear by hand,
always check that the bucket or the tool is on the ground
and that the engine is stopped.
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Bearing and ring gear - Install (F.40.C.45 - F.10.A.15)

CX135SR
1. Clean the contact surfaces of the upperstructure,

the undercarriage and the turntable bearing.
2. Reassemble the ring gear and upperstructure in the
reverse order of removal, refer to Bearing and ring
gear - Remove (F.40.C.45 - F.10.A.10).
NOTE: The xing screws for the ring gear on the
undercarriage and upperstructure must be tightened to
a torque of 267 - 312 Nm.
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Hydraulic brake - Pressure test (F.40.C.59 - F.40.A.30)

CX135SR
1. Disconnect swing brake pilot hose (1) from the port

(PG) on the swing motor.
CRIL03K062A02 1
2. To swing brake exible hose (1), attach a pressure

test point and a manometer 0 - 100 bar
4. Slowly operate the swing control lever to the right or
the left and gradually increase the engine speed to
full speed so that the swing is locked.
At that moment the reading on the pressure gauge
should be about 39 bar.
5. Place the swing control lever in neutral. At that
moment the reading on the pressure gauge should
be 0 - 3 bar.
6. Reconnect swing brake pilot hose (1) to port (PG)
on the swing motor.
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Hydraulic brake Electrovalve - Electrical test (F.40.C.59.10 -

F.40.A.50)
CX135SR
SYSTEM - Special tools (A.30.A - D.20.A.40)
1. Disconnect connector (1) from swing brake solenoid

valve (Y3).
CRIL03L141A02 1
2. Connect the appropriate test electrical connector

(3) to connector (1) on solenoid (Y3), then attach
multimeter (2).
CRIL03I078A02 2
3. The solenoid resistance reading of solenoid valve

(Y3) on multimeter (2) should be 45 ohms for a
temperature.
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Swivel - Remove (F.40.C.69 - F.10.A.10)

CX135SR
Prior operation: To remove the protective panel, refer to Upper shield - Remove (E.20.A.71 - F.10.A.10)
Prior operation: To remove hydraulic swivel lower protective panel, refer to Protective shield - Remove
(E.20.A.73 - F.10.A.10)
1. Attach identication labels to all the hydraulic swivel

hoses.
2. Disconnect all the hoses on the hydraulic swivel
pivot.
Plug the ports.
CRIL03K058A00 1
3. Disconnect all the hoses on the hydraulic swivel

body.
Plug the ports.
CRIL03K059A00 2
4. Remove screws (1), washers (2), locking bar (3)

and washers (4).
Remove screws (5).
Lift the hydraulic swivel sufciently to disengage it
from its mounting.
Rotate it 90°.
Place the hydraulic swivel on the ground.
CRIL03K060A01 3
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Swivel - Disassemble (F.40.C.69 - F.10.A.25)

CX135SR
1. Remove screws (1) and cover (2) from bushing (3).
CRIL03K076A01 1
CRIL03K077A01 2
3. Remove base plate (1).
CRIL03K078A01 3
4. Using a press, remove pivot (1) from bushing (2).
CRIL03F004A03 4
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5. Discard seal (2) on pivot (1).
CRIL03F005A01 5
6. Discard seals (1) and (2) from bushing (3).
CRIL03K079A01 6
27075 1 14/12/2004
F.40.C / 72
Swivel - Cleaning (F.40.C.69 - F.30.A.10)

CX135SR
1. Clean all the components. Polish any scratched or

rough areas with an oil stone.
2. Clean the bushing with a cleaning solvent or
compressed air at low pressure.
27075 1 14/12/2004
F.40.C / 73
Swivel - Assemble (F.40.C.69 - F.10.A.20)

CX135SR
1. Install seal (1) in the upper groove of bushing (3).

Install rings (2) starting from the second groove
counting from the top of bushing (3).
CRIL03K079A01 1
2. Check the seal and rings are correctly tted, using

a mirror. Apply hydraulic uid, and ensure that the
components are not protruding, twisted, etc.
CRIL03F008A01a 2
3. Install seal (2) on pivot (1).
CRIL03F005A01 3
4. Insert pivot (1) in bushing (2).
CRIL03K080A01 4
27075 1 14/12/2004
F.40.C / 74
5. Install base plate (1).
CRIL03K078A01 5
CRIL03K077A01 6
7. Install cover (2) on bushing (3).

Install screws (1) and tighten them to torque 31,4
- 37,3 Nm
CRIL03K076A01 7
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F.40.C / 75
Swivel - Install (F.40.C.69 - F.10.A.15)

CX135SR
1. Attach a suitable lifting device to the hydraulic

swivel.
2. Place the hydraulic swivel in position.
Tighten screws (5) to torque 109 - 127 Nm.
Install washers (4), locking bar (3) and tighten
screws (1) complete with washers (2) to torque 109
- 127 Nm
CRIL03K060A01 1

Connect all the hoses to the hydraulic swivel body,
following the markings made during removal.
CRIL03K059A00 2

Connect all the hoses to the pivot of the hydraulic
swivel, following the markings made during removal.
CRIL03K058A00 3
Next operation: To install the protective panel, refer to Upper shield - Remove (E.20.A.71 - F.10.A.10)
Next operation: To install hydraulic swivel lower protective panel, refer to Protective shield - Remove (E.20.A.73
- F.10.A.10)
27075 1 14/12/2004
F.40.C / 76
SWINGING Circular swing - Troubleshooting (F.40.C - G.40.A.10)

CX135SR

No swing or slow swing Swing pressure too low. Adjust or replace the relief valves
(No problems with other
functions)
Brake release pressure lower than 30 bar Test the electrical circuit, refer to Hydraulic
brake Electrovalve - Electrical test
(F.40.C.59.10 - F.40.A.50)
Repair or replace the components in
question
Defective swing brake Repair the swing brake
Substantial leakage from the swing motor Repair or replace the motor
The swing brake does not Swing pressure too low. Adjust or replace the secondary relief
hold with the excavator valves
on a slope.
Pilot pressure at the brake solenoid valve Test the electrical circuit, refer to Hydraulic
outlet greater than 1 bar brake Electrovalve - Electrical test
(F.40.C.59.10 - F.40.A.50)
Repair or replace the components in
question
Defective swing brake Repair the swing brake
Signicant leakage from the swing motor Repair or replace the motor
27075 1 14/12/2004
F.40.C / 77
Index

Bearing and ring gear - Check (F.40.C.45 - F.40.A.11) 66
CX135SR
Bearing and ring gear - Install (F.40.C.45 - F.10.A.15) 67
CX135SR
Bearing and ring gear - Remove (F.40.C.45 - F.10.A.10) 65
CX135SR
Command valve Hand command valve - Assemble (F.40.C.12.10 - F.10.A.20) 30
CX135SR
Command valve Hand command valve - Cleaning (F.40.C.12.10 - F.30.A.10) 28
CX135SR
Command valve Hand command valve - Disassemble (F.40.C.12.10 - F.10.A.25) 23
CX135SR
Command valve Hand command valve - Install (F.40.C.12.10 - F.10.A.15) 35
CX135SR
Command valve Hand command valve - Remove (F.40.C.12.10 - F.10.A.10) 22
CX135SR
Command valve Hand command valve - Sectional view (F.40.C.12.10 - C.10.A.30) 14
CX135SR
Command valve Hand command valve - Torque (F.40.C.12.10 - D.20.A.10) 5
CX135SR
Command valve Hand command valve - Visual inspection (F.40.C.12.10 - F.40.A.10) 29
CX135SR
Control valve - Assemble (F.40.C.14 - F.10.A.20) 37
CX135SR
Control valve - Disassemble (F.40.C.14 - F.10.A.25) 36
CX135SR
Control valve - Sectional view (F.40.C.14 - C.10.A.30) 15
CX135SR
Hydraulic brake - Electronic schema (F.40.C.59 - C.20.A.50) 19
CX135SR
Hydraulic brake - Pressure test (F.40.C.59 - F.40.A.30) 68
CX135SR
Hydraulic brake Electrovalve - Electrical test (F.40.C.59.10 - F.40.A.50) 69
CX135SR
Hydraulic motor - Assemble (F.40.C.28 - F.10.A.20) 47
CX135SR
Hydraulic motor - Bleed (F.40.C.28 - F.35.A.25) 53
CX135SR
Hydraulic motor - Disassemble (F.40.C.28 - F.10.A.25) 42
CX135SR
Hydraulic motor - Install (F.40.C.28 - F.10.A.15) 52
CX135SR
Hydraulic motor - Leakage test (F.40.C.28 - F.40.A.40) 40
CX135SR
Hydraulic motor - Remove (F.40.C.28 - F.10.A.10) 41
CX135SR
Hydraulic motor - Sectional view (F.40.C.28 - C.10.A.30) 16
CX135SR
Hydraulic motor - Service limits (F.40.C.28 - D.20.A.20) 5
CX135SR
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Hydraulic motor - Special tools (F.40.C.28 - D.20.A.40) 5
CX135SR
Hydraulic motor - Torque (F.40.C.28 - D.20.A.10) 7
CX135SR
Hydraulic motor - Visual inspection (F.40.C.28 - F.40.A.10) 46
CX135SR
Reducer, spur gear - Assemble (F.40.C.44 - F.10.A.20) 60
CX135SR
Reducer, spur gear - Disassemble (F.40.C.44 - F.10.A.25) 56
CX135SR
Reducer, spur gear - Install (F.40.C.44 - F.10.A.15) 64
CX135SR
Reducer, spur gear - Remove (F.40.C.44 - F.10.A.10) 54
CX135SR
Reducer, spur gear - Sectional view (F.40.C.44 - C.10.A.30) 18
CX135SR
Reducer, spur gear - Special tools (F.40.C.44 - D.20.A.40) 8
CX135SR
Reducer, spur gear - Visual inspection (F.40.C.44 - F.40.A.10) 59
CX135SR
Relief valve - Pressure setting (F.40.C.16 - F.45.A.70) 39
CX135SR
Relief valve - Pressure test (F.40.C.16 - F.40.A.30) 38
CX135SR
CX135SR
CX135SR
SWINGING Circular swing - Troubleshooting (F.40.C - G.40.A.10) 77
CX135SR
Swivel - Assemble (F.40.C.69 - F.10.A.20) 74
CX135SR
Swivel - Cleaning (F.40.C.69 - F.30.A.10) 73
CX135SR
Swivel - Disassemble (F.40.C.69 - F.10.A.25) 71
CX135SR
Swivel - Exploded view (F.40.C.69 - C.10.A.20) 21
CX135SR
Swivel - General specication (F.40.C.69 - D.40.A.10) 9
CX135SR
Swivel - Install (F.40.C.69 - F.10.A.15) 76
CX135SR
Swivel - Remove (F.40.C.69 - F.10.A.10) 70
CX135SR
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F.40.C / 79
SERVICE
PRINTED IN FRANCE
27072 1 14/12/2004
REPAIR MANUAL
WORKING ARM
CX135SR
27076 1 14/12/2004
H
Contents
WORKING ARM - H
BOOM Lift H.20.B

CX135SR
BOOM Swing H.20.D

CX135SR
DIPPER Lift H.25.B

CX135SR
ARM TOOL ATTACHMENT Tilt H.30.C

CX135SR
27076 1 14/12/2004
H
WORKING ARM - H
BOOM Lift - 20.B
CX135SR
27077 1 14/12/2004
H.20.B / 1
Contents
WORKING ARM - H
BOOM Lift - 20.B
TECHNICAL DATA
BOOM Lift - Service limits (H.20.B - D.20.A.20) 4
CX135SR
Command valve
Command valve Hand control valve - Torque (H.20.B.12.10 - D.20.A.10) 5
CX135SR
Cylinder
Cylinder - Torque (H.20.B.26 - D.20.A.10) 6
CX135SR
Cylinder - Special tools (H.20.B.26 - D.20.A.40) 7

CX135SR
FUNCTIONAL DATA
BOOM Lift - Hydraulic schema (H.20.B - C.20.A.20) 8
CX135SR

CX135SR
Command valve
Command valve Hand control valve - Sectional view (H.20.B.12.10 - C.10.A.30) 11
CX135SR
Control valve
Control valve - Sectional view (H.20.B.14 - C.10.A.30) 12
CX135SR
Cylinder
Cylinder - Sectional view (H.20.B.26 - C.10.A.30) 13
CX135SR
Arm
Arm - Exploded view (H.20.B.50 - C.10.A.20) 14
CX135SR
Sensing system
Sensing system - Electronic schema (H.20.B.95 - C.20.A.50) 15
CX135SR
SERVICE
Command valve
Command valve Hand control valve - Overhaul (H.20.B.12.10 - F.10.A.40) 16
CX135SR
Command valve Cushion valve - Remove (H.20.B.12.20 - F.10.A.10) 17

CX135SR
Command valve Cushion valve - Disassemble (H.20.B.12.20 - F.10.A.25) 18

CX135SR
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H.20.B / 2
Command valve Cushion valve - Assemble (H.20.B.12.20 - F.10.A.20) 19
CX135SR
Command valve Cushion valve - Install (H.20.B.12.20 - F.10.A.15) 20

CX135SR
Control valve
Control valve - Disassemble (H.20.B.14 - F.10.A.25) 21
CX135SR
Control valve - Assemble (H.20.B.14 - F.10.A.20) 23

CX135SR
Safety valve
Safety valve - Remove (H.20.B.15 - F.10.A.10) 25
CX135SR
Safety valve - Disassemble (H.20.B.15 - F.10.A.25) 26

CX135SR
Safety valve - Assemble (H.20.B.15 - F.10.A.20) 28

CX135SR
Safety valve - Install (H.20.B.15 - F.10.A.15) 29

CX135SR
Safety valve - Pressure setting (H.20.B.15 - F.45.A.70) 30

CX135SR
Relief valve
Relief valve - Disassemble (H.20.B.16 - F.10.A.25) 31
CX135SR
Relief valve - Assemble (H.20.B.16 - F.10.A.20) 32

CX135SR
Relief valve - Pressure test (H.20.B.16 - F.40.A.30) 33

CX135SR
Relief valve - Pressure setting (H.20.B.16 - F.45.A.70) 34

CX135SR
Load holding valve

Load holding valve - Disassemble (H.20.B.19 - F.10.A.25) 35
CX135SR
Load holding valve - Assemble (H.20.B.19 - F.10.A.20) 36

CX135SR
Arm
Arm - Remove (H.20.B.50 - F.10.A.10) 37
CX135SR
Arm - Install (H.20.B.50 - F.10.A.15) 38

CX135SR
Cylinder
Cylinder - Remove (H.20.B.26 - F.10.A.10) 39
CX135SR
Cylinder - Disassemble (H.20.B.26 - F.10.A.25) 42

CX135SR
Cylinder - Visual inspection (H.20.B.26 - F.40.A.10) 45

CX135SR
Cylinder - Assemble (H.20.B.26 - F.10.A.20) 46

CX135SR
Cylinder - Install (H.20.B.26 - F.10.A.15) 49

CX135SR
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H.20.B / 3
WORKING ARM - BOOM Lift
BOOM Lift - Service limits (H.20.B - D.20.A.20)

CX135SR
CRIL03G012E01 1
Linkage points
1. Foot of boom on chassis
CRIL03G015E01 2
(A) 589 mm 599 mm
(B) 568 mm 566 mm
(C) (a-b) 1 - 3.5 mm Shims
(D) pin diameter 75 mm 74 mm
(D) bushing diameter 75 mm 76,5 mm
2. Foot of boom cylinder on chassis
CRIL03L133E01 3
(A) 83,5 mm 89,5 mm
(B) 82,5 mm 80,5 mm
(C) play 1 - 2.5 mm Shims
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H.20.B / 4
3. Boom cylinder head on boom
CRIL03L134E01 4
(A) 92 mm 90 mm
(B) 437 mm 431 mm
(C) play 1 - 2.5 mm Shims
Command valve Hand control valve - Torque (H.20.B.12.10 -

D.20.A.10)
CX135SR
NOTE: Refer to Command valve Hand command valve - Torque (F.40.C.12.10 - D.20.A.10)
27077 1 14/12/2004
H.20.B / 5
Cylinder - Torque (H.20.B.26 - D.20.A.10)

CX135SR
CRIL03L044G02 1
Description
(1) Screw 171 Nm
(2) Plug 97,5 - 102,8 Nm
(3) Screw 25,62 - 37,88 Nm
(4) Screw 46,2 - 67,6 Nm
(5) Nut (M 52) 3180 Nm
(6) Screw 21,4 - 31,2 Nm
(7) Screw 46,2 - 67,6 Nm
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H.20.B / 6
Cylinder - Special tools (H.20.B.26 - D.20.A.40)

CX135SR
CRIL03J014E 1
Repair bench 380000812.
Used for repairing cylinders.
Piston screw ats (for information)

Nominal diameter Flats in mm Nominal diameter Flats in mm
M45 70 M48 75
M52 80 M55 85
M58 85 M62 90
M65 95 M68 100
M70 100 M75 110
M80 115
CRPH03J001E 2
Gland wrench.
Used for removing and retting glands.
OEM6210: opening capacity 50 - 120 mm
OEM6203: opening capacity 120 - 320 mm
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H.20.B / 7
BOOM Lift - Hydraulic schema (H.20.B - C.20.A.20)

CX135SR
CRIL03J147G01 1
Boom raising circuit - Dynamic Description
(1) Straight-line travel valve (2) RH travel spool
(3) Boom valve spool 2 (4) Boom spool 1
(25) Boom cylinder (26) Boom cylinder
(32) Boom load holding valve (P1) Flow at pump outlet A2
(P2) Flow at pump outlet A1 (Pa8/A8) Boom raising
(Pb8/B8) Boom lowering
BOOM LIFTING
• Boom raising (large cylinder chamber) (25) and (26) is supplied by outputs from pumps (P1) and (P2).
• The ow from pump (P1) passes through the straight-line travel valve (1) or the RH travel spool (2), then the
parallel feed passage to pass through boom spool 2 (3) and arrive at the outlet of the boom 1 spool (4).
• The ow from pump (P2) passes through the 2nd parallel feed passage and the boom spool 1 (4) and joins
the ow from pump (P1).
• The outputs from pumps (P1) and (P2) supply the large boom cylinder chambers (25) and (26) by passing
through the boom load holding valve (32).
27077 1 14/12/2004
H.20.B / 8
BOOM Lift - Hydraulic schema (H.20.B - C.20.A.20)

CX135SR
CRIL03J148G01 1
Boom lowering circuit - Dynamic Description
(1) Boom spool 1 (25) Boom cylinder
(32) Boom load holding valve (P2) Flow at pump outlet A2
(Pa8/A8) Boom raising (Pb8/B8) Boom lowering
(Pc2) Boom load holding
BOOM LOWERING CIRCUIT, LOAD HOLDING VALVE

Boom lowering (small cylinder chamber) (25) and (26) is fed by pump ow (A1) via port (P2).
When the boom lowering control is not activated, the oil from the large chamber on boom cylinders (25) and (26) is
held by boom load holding valve (32). This minimises leakage from boom spool 1 (1).
When the boom lowering control is activated, the boom spool 1 alone (1) is piloted by port (Pb8).
At the same time, the pilot pressure reaches (Pc2) and unlocks the boom load holding valve (32). This means that
the oil from the large chamber in boom cylinders (25) and (26) can return to the reservoir.
BOOM LOWERING CIRCUIT, ADDITIONAL SUPPLY

When the boom is lowered, (1) boom spool 1 is piloted. Boom load holding valve (32) is unlocked and part of the oil
from the large chambers on boom cylinders (25) and (26) is re-injected into the small chambers on boom cylinders
27077 1 14/12/2004
H.20.B / 9
(25) and (26), passing via non-return valve (2). The lower the pressure in the boom cylinder small chambers
(25) and (26), the greater the ow of reinjected oil.
Even if boom spool 1 (1) is completely piloted, a connection still exists with the free passage via a jet (4) that
generates ow reduction information pressure towards the pump. This ow reduction is compensated by the
re-injection circuit. In addition, the engine power can be used more efciently.
BOOM LOWERING CIRCUIT, ANTI-VIBRATION

When the boom is lowered suddenly, a jet (3) located between the supply and the free passage on boom spool 1
(1) reduces pressure points and vibration.
27077 1 14/12/2004
H.20.B / 10
Command valve Hand control valve - Sectional view (H.20.B.12.10 -

C.10.A.30)
CX135SR
NOTE: Refer to Command valve Hand command valve - Sectional view (F.40.C.12.10 - C.10.A.30)
27077 1 14/12/2004
H.20.B / 11
Control valve - Sectional view (H.20.B.14 - C.10.A.30)

CX135SR
CRIL03J087F01 1
Cross-sectional view - Boom section 1 and 2
(5) Boom spool 2 (8) Boom spool 1

(18) Seal (19) Plug
(28) Spring (29) Spacer
(30) Load holding valve (31) Seal
(32) Plug (63) Relief valve
(65) Cap screw (67) Load holding valve screw
27077 1 14/12/2004
H.20.B / 12
Cylinder - Sectional view (H.20.B.26 - C.10.A.30)

CX135SR
CRIL03L044G01 1
(1) Screw (2) Washer (3) Clamp

(4) Pipe (5) Clamp (6) Screw
(7) Washer (8) Screw (9) Plug
(10) Seal (11) Barrel (12) Grease tting
(13) Bushing (14) Bushing (15) Seal
(16) Ball (17) Screw (18) Seal
(19) Seal (20) Shim (21) Seal
(22) Seal (23) Screw (24) Seal
(25) Bushing (26) Seal (27) Back-up ring
(28) Nut (29) Seal (30) Seal
(31) Snap ring (32) Gland (33) Rod
(34) Piston (35) Bushing
27077 1 14/12/2004
H.20.B / 13
Arm - Exploded view (H.20.B.50 - C.10.A.20)

CX135SR
CRIL03L137F01 1
(1) Screw
(2) Nut
(3) Pin
(4) Shim
(5) Bushing
(6) Seal
(7) Grease tting
27077 1 14/12/2004
H.20.B / 14
Sensing system - Electronic schema (H.20.B.95 - C.20.A.50)

CX135SR
OVERLOAD INDICATOR
CRIL03G223E01 1
Circuit layout
(A7) Overload indicator electronic control box (B45) Overload indicator pressure sensor
(H3) Overload indicator audible alarm device (S13) Overload indicator switch
CRIL03G224E02 2
Timing diagram
OVERLOAD INDICATOR PRESSURE SENSOR SPECIFICATION (B45)

Alarm ON 16.1 MPa (161 bar)
Alarm OFF 15.1 MPa (151 bar)
27077 1 14/12/2004
H.20.B / 15
Command valve Hand control valve - Overhaul (H.20.B.12.10 -

F.10.A.40)
CX135SR
1. Refer to:
Command valve Hand command valve - Remove
(F.40.C.12.10 - F.10.A.10)
Command valve Hand command valve -
Disassemble (F.40.C.12.10 - F.10.A.25)
Cleaning (F.40.C.12.10 - F.30.A.10)
Command valve Hand command valve - Visual
inspection (F.40.C.12.10 - F.40.A.10)
Assemble (F.40.C.12.10 - F.10.A.20)
Command valve Hand command valve - Install
(F.40.C.12.10 - F.10.A.15)
27077 1 14/12/2004
H.20.B / 16
Command valve Cushion valve - Remove (H.20.B.12.20 - F.10.A.10)

CX135SR
Prior operation: Remove the side guard from under the oor, refer to Side shield - Remove (E.20.A.70 -
F.10.A.10).
1. Attach identifying tags to all the damper hoses.

Disconnect the hoses (1).
Plug the ports.
Stop the vacuum pump.
Remove screws (2) and damper (3).
CRIL03L109A01 1
27077 1 14/12/2004
H.20.B / 17
Command valve Cushion valve - Disassemble (H.20.B.12.20 -

F.10.A.25)
CX135SR
CRIL03L110F01 1
(1) Cushion valve (2) Spring

(3) Spool (4) Seal
(5) Connector (6) Plug
(7) Seal (8) Spring
(9) Spring guide (10) Seal
(11) Spool
1. Mark parts to ensure correct assembly in their
original positions.
2. Remove plugs (6) and springs (8).
Discard seal (7).
Clamp the spool in a vice, protecting it with wooden
blocks.
Remove spring guide (9) and discard seal (10).
4. Remove unions (5).
Discard seals (4).
5. Install an M4 screw in the threaded orice of spool
(3) to extract it.
Remove spring (2).
27077 1 14/12/2004
H.20.B / 18
Command valve Cushion valve - Assemble (H.20.B.12.20 - F.10.A.20)

CX135SR
1. Check condition and clean parts before assembling.

2. Assemble the parts in the reverse order of
disassembly, refer to Command valve Cushion
valve - Disassemble (H.20.B.12.20 - F.10.A.25)
27077 1 14/12/2004
H.20.B / 19
Command valve Cushion valve - Install (H.20.B.12.20 - F.10.A.15)

CX135SR
1. Attach the damper (3) with screws (2).

Remove the plugs.
Connect the hoses (1).
CRIL03L109A01 1
2. Remove the vacuum pump.

Ensure there are no leaks.
Install the side guard under the oor.
27077 1 14/12/2004
H.20.B / 20
Control valve - Disassemble (H.20.B.14 - F.10.A.25)

CX135SR
CRIL03J087F01 1
Boom section spools 1 and 2
1. Unscrew and remove screws (65).

Remove caps (11) and (13) and discard the seals.
Remove spools (5) and (8).
NOTE: Mark each spool to ensure that it is returned to the
correct housing during re-assembly.
replace the spring.
CRIL03L053A01 2
27077 1 14/12/2004
H.20.B / 21
3. Remove plug (A) from spool (8).

Discard seal (C) and back-up ring (B).
Remove spring (D) and check valve (E).
CRIL03L076A01 3

Remove load holding valve assembly (30), then
remove seal (31) from the control valve.
To remove load holding valve components, refer to
Load holding valve - Disassemble (H.20.B.19 -
F.10.A.25).
5. Use a 6 x 1,0 mm screw as an extraction device to
remove the spacer assembly (29).
Remove and discard seals (A) and (B) and back-up
ring (C).
CRIL03L078A01 4
6. Remove plugs (19) and discard the seals (18).

Remove springs (17) and check valves (16).
7. Remove plugs (21) and (32) and discard the seals.
Remove valves (63).
27077 1 14/12/2004
H.20.B / 22
Control valve - Assemble (H.20.B.14 - F.10.A.20)

CX135SR
- F.40.A.10)
CRIL03J087F01 1
Boom section spools 1 and 2
Torque settings
Fixing screws (45) for return springs on spools (5) and (8) 9.8 - 11.8 Nm
Plug (A) of spool (8) 9.8 - 11.8 Nm
Plug (19) 103 - 113 Nm
Plug (21) 13.5 - 16.5 Nm
Plug (32) 73 - 79 Nm
Valves (63) 78 - 88 Nm
Screws (65) and (67) 20 - 25 Nm
and tighten them to the required torque.
2. Install valves (63) and tighten them to the required
torque.
3. Install check valves (16) and springs (17).
Install plugs (19) complete with new seals (18) and
tighten them to the required torque.
27077 1 14/12/2004
H.20.B / 23
4. Install seals (A) and (B) and back-up ring (C) on

spacer (29).
Install spring (28), check valve (27) and spacer
assembly (29).
CRIL03L078A01 2
5. Install load holding valve assembly (30) with a seal

(31).
torque.
locking uid.
Install springs (44) and seats (43 ) on screws (45).
CRIL03L053A01 3
7. Install spring (D) and check valve (E) on spool (8).

Install seal (C) and back-up ring (B) on plug (A).
Install and tighten plug (A) to the required torque.
Install spools (5) and (8) in their respective housings.
CRIL03L076A01 4
8. Install caps (11) and (13) complete with new seals.

torque.
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H.20.B / 24
Safety valve - Remove (H.20.B.15 - F.10.A.10)

CX135SR
1. Disconnect and plug hoses (1) on the safety valves.

Unscrew xing screws (2) and remove safety valves.
CRIL03K055A03 1
27077 1 14/12/2004
H.20.B / 25
Safety valve - Disassemble (H.20.B.15 - F.10.A.25)

CX135SR
CRIL03L119G01 1
Description of components
(1) Spool stop plug (2) Seal
(3) Spool cap (4) Seal
(7) Spring seat (8) Spool
(9) Seal (10) Valve
(11) Plug (12) Seal
(13) Spring (14) Check valve
(15) Plug (16) Seal
(17) Spring (18) Piloted check valve
1. Remove plug (1).
Discard seal (2).
2. Remove cap (3).
Discard seal (4)
Remove the springs (5) and (6).
Remove seat (7).
Remove spool (8).
Discard seal (12).
Remove spring (13) and check valve (14) after
marking their positions.
27077 1 14/12/2004
H.20.B / 26

Discard seal (16).
5. Remove valve (10).
Discard seal (9).
6. To remove valve (10), refer to Relief valve -
Disassemble (H.20.B.16 - F.10.A.25).
27077 1 14/12/2004
H.20.B / 27
Safety valve - Assemble (H.20.B.15 - F.10.A.20)

CX135SR
CRIL03L119G01 1
Tightening torque
(1) Spool stop plug 77.8 - 79.2 Nm
(3) Spool cap 271.6 - 277.6 Nm
(10) Valve 58.2 - 59.4 Nm
(11) Plug 213.8 - 217.8 Nm
(15) Plug 77.8 - 79.2 Nm
1. Install plug (1) complete with a new seal (2) and
2. Oil and install spool (8).
Install seat (7).
Install springs (5) and (6).
Install spool cap (3) complete with a new seal (4)
and tighten to the required torque.
3. Oil and install check valve (14) and spring (13) in
their original positions.
Install plug (11) complete with a new seal (12) and
5. Install valve (10) complete with a new seal (9) and
27077 1 14/12/2004
H.20.B / 28
Safety valve - Install (H.20.B.15 - F.10.A.15)

CX135SR
1. Install the safety valves with new seal rings and

xing screws (2).
Connect hoses (1) to the safety valves.
CRIL03K055A03 1
27077 1 14/12/2004
H.20.B / 29
Safety valve - Pressure setting (H.20.B.15 - F.45.A.70)

CX135SR
1. Disconnect the balance hose (1) from the safety

valve (B2) of the LH boom cylinder.
Install a male coupling connection on the hose,
complete with its union.
Plug the elbow union of the safety valve (B2) of the
LH boom cylinder.
Connect to the hose (1) a female coupling
connection, tted with a pressure test tting.
Connect the pressure controller or a 0 - 600 bar
pressure gauge to the pressure test tting.
Disconnect and plug the pilot hose on the safety
valve to be adjusted.
Place a receptacle under connection
to catch any leaks. Plug the union that has been left CRIL03K055A01 1
free by the disconnection of the pilot hose.
Start the engine.
Set the engine speed to 1000 tr/mn on the
instrument panel potentiometer.
Move the boom to mid-height.
Operate the boom lowering control and note the
pressure setting for valve (B1).
Repeat this operation several times, noting the
pressure each time.
The pressure read on the pressure gauge must be:
373 ± 5 bar (37.3 ± 0.5 MPa)
2. If the value is not correct, loosen lock nut (2) and
turn screw (3) to adjust the pressure whilst operating
the boom lowering control.
Tighten to increase the pressure, loosen to
decrease.
Re-tighten the lock nut (2).
CRIL03K055A02 2
3. To release pressure in the large chamber of the

boom cylinder, rst connect the pilot hose (1).
Start the engine to ll the accumulator.
Release the pressure in the hydraulic system.
4. Remove the plug from the safety valve connection
(B2) of the LH boom cylinder.
Disconnect the coupling connection of the pressure
test point.
Reconnect the balancing hose (1).
5. LH CHECK AND CALIBRATION (B2)
Carry out the same operations as for the RH side.
The difference between the two valves must be less
than 5 bar
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H.20.B / 30
Relief valve - Disassemble (H.20.B.16 - F.10.A.25)

CX135SR
1. Discard seal (1) on body (2).
CRIL03L105B01 1
2. Remove plug (3) from body (2) and discard seal (4).
3. Remove the springs (5) and (6).
4. Remove the valve (7).
5. Remove nut (8) screw (9), washer (10), and discard
the seal (11).
6. Remove the tip of valve (12) from the body (2).
7. Extract the valve seat (13) and discard seals (14)
and (15).
8. Remove the spring (16) and valve seat (17).
9. Remove valve (18) and discard seals (19) and (20).
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H.20.B / 31
Relief valve - Assemble (H.20.B.16 - F.10.A.20)

CX135SR
1. Install seals (19) and (20) on valve (18).
CRIL03L105B01 1
2. Install valve (18) in the tip of valve (12).

3. Install the valve seat (17) and spring (16) in position.
4. Install seals (14) and (15) on valve seat (13).
5. Install valve seat (13) in the tip of valve (12).
6. Install the tip of the valve (12) in the body (2).
7. Install spring (5), valve (7) and spring (6).
8. Fit the screw (9) with a seal (11).
9. Fit the plug (3) with a seal (4).
10. Install and tighten to a torque of 59 - 69 Nm the
plug (3).
11. Fit the screw (9) in a way that allows positioning of
a washer (10).
12. Install nut (8) without locking it, nal tightening will
be done when the relief valve is adjusted to a torque
of 27 - 31 Nm.
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H.20.B / 32
Relief valve - Pressure test (H.20.B.16 - F.40.A.30)

CX135SR
NOTE: The secondary relief valves on the boom (B) and (C) are calibrated to a higher pressure than the main relief
valve (A). To check or calibrate the secondary relief valves, main relief valve (A) must be overcalibrated.
NOTE: If the excavator is equipped with safety valves on the boom, the secondary relief valves are not tted on
the valve block, or they are overcalibrated. In this case, the secondary relief valves mounted on the safety valves
must be calibrated.
the pressure test point M1.
4. Operate the control for the function to be checked
and hold it against the stop.
5. The raising and lowering pressures of the boom as
displayed on the pressure gauge should be 395 ±
10 bar (39.5 ± 1 MPa)
6. If the pressures are incorrect, calibrate boom relief
valves (B) and (C), refer to Relief valve - Pressure
setting (H.20.B.16 - F.45.A.70)
Next operation: To recalibrate main relief valve (A), refer to Relief valve - Pressure setting (A.10.A.16 - F.45.A.70)
27077 1 14/12/2004
H.20.B / 33
Relief valve - Pressure setting (H.20.B.16 - F.45.A.70)

CX135SR
Prior operation: Relief valve - Pressure test (H.20.B.16 - F.40.A.30)

main relief valve in position and loosen lock nut (1).
CRIL03K054A01 1
2. Operate the control for the attachment to be

calibrated and hold it up against the stops.
3. Turn adjusting screw (2) until the correct pressure
is reached.
NOTE: Tighten the screw to increase pressure, loosen
the screw to reduce pressure.
Next operation: Reset main relief valve (A), refer to Relief valve - Pressure setting (A.10.A.16 - F.45.A.70).
27077 1 14/12/2004
H.20.B / 34
Load holding valve - Disassemble (H.20.B.19 - F.10.A.25)

CX135SR
NOTE: Take care when disassembling the load holding valve, some parts are under pressure from the springs.
1. Place the load holding valve assembly (30) in a
soft-jawed vice.
2. Remove the plug (P).
Remove piston (D), spool (E) and spring (G).
Unscrew and remove plug (C) then remove seal (N).
CRIL03L080B01 1
3. Remove sleeve (F) and valve (B).

4. Remove seals (J) and (K) and backup rings (L) and
(M) from the sleeve (F).
5. Remove spring seat (Q) and spring (H).
27077 1 14/12/2004
H.20.B / 35
Load holding valve - Assemble (H.20.B.19 - F.10.A.20)

CX135SR
1. Fit seals (K) and (J) back-up rings (L) and (M) into
the grooves of the sleeve (F).
NOTE: Follow the positions of the seals and backup rings.
CRIL03L080B01 1
2. Install valve (B) and spool (E) in the oroce of

sleeve (F).
3. Fit spring seat (Q) on the end of valve (B), t spring
(H) on spring seat.
Insert the assembly in the load holding valve body.
Install a seal (N) on the plug (C).
Install and tighten to a torque of (147 - 157 Nm) the
plug (C).
Fit spring (G), spool (E) and piston (D) in the load
holding valve.
Fit a seal on plug (P).
plug (P).
27077 1 14/12/2004
H.20.B / 36
Arm - Remove (H.20.B.50 - F.10.A.10)

CX135SR
Prior operation: To remove the side protective panel from the control valve , refer to Side shield - Remove
(E.20.A.70 - F.10.A.10)
NOTE: Numbers in brackets refer to Arm - Exploded view (H.20.B.50 - C.10.A.20)

1. To disconnect the boom cylinder rods, refer to
Cylinder - Remove (H.20.B.26 - F.10.A.10).
2. Start the vacuum pump.
Mark and disconnect the hoses connecting the
boom foot and the chassis.
Plug the ports.
CRIL03L140A00 1
3. Unplug the working light electrical harness.

4. Attach a suitable lifting device to the boom.
Use all the play necessary to obtain sufcient
support during removal of the boom.
5. Remove nuts (2) and screw (1).
Remove pin (3) using a slide-hammer.
Move the machine backwards to separate the boom
from the chassis.
Recover shims (4).
7. Place the boom on suitable stands.
9. Remove grease tting (7).
10. To remove bushings (5) but only if they need
replacing, refer to BOOM Lift - Service limits
(H.20.B - D.20.A.20)
27077 1 14/12/2004
H.20.B / 37
Arm - Install (H.20.B.50 - F.10.A.15)

CX135SR
NOTE: Numbers in brackets refer to Arm - Exploded view (H.20.B.50 - C.10.A.20)

1. Install bushings (5).
2. Install seals (6).
3. Install grease tting (7).
4. Attach a suitable lifting device to the boom.
Bring the boom close to the machine.
Start the engine.
Align the boom ports with the ports on the chassis.
5. Install pin (3) and screw (1).
6. To check for play between the boom and the
chassis, refer to BOOM Lift - Service limits
(H.20.B - D.20.A.20).
If necessary, remove the pin and add shims as
required to obtain the correct play, re-install the pin
and the screw.
7. Install the rst nut on the screw (2) and tighten until
the nut touches the boss.
Loosen the nut a quarter of a turn.
Fit the second nut (2) to keep the rst in position.
8. To connect the boom cylinder rods, refer to Cylinder
- Install (H.20.B.26 - F.10.A.15).
Remove the plugs.
Connect the boom foot/chassis hoses, following the
Stop and remove the vacuum pump.
CRIL03L140A00 1
10. Connect the boom working light electrical harness.

11. Grease the linkages.
12. Install the control valve side protective panel.
27077 1 14/12/2004
H.20.B / 38
Cylinder - Remove (H.20.B.26 - F.10.A.10)

CX135SR
1. Attach a suitable lifting device to the cylinder. Use

the all the play necessary to ensure sufcient
support during removal of the cylinder.
CRIL03K175A00 1
2. Remove nuts (3), screw (1) and bushing (2).

Recover the shim.
CRIL03K176A01 2
3. Tap out pin (3) to free up the cylinder head.

Recover the shim.
NOTE: Do not remove the pin which would cause the
second cylinder to fall.
CRIL03K177A01 3
27077 1 14/12/2004
H.20.B / 39
4. Place the cylinder on a stand.
CRIL03K178A01 4
5. Attach a sling to retain the cylinder rod in the

cylinder barrel.
CRIL03K179A00 5

Disconnect hoses (1).
Plug the ports.
CRIL03K180A01 6
7. If the machine is equipped with a safety valve.

Disconnect hoses from (1) to (6).
Plug the ports.
Disconnect the pressure sensor harness.
CRIL03K181A01 7
8. Stop the vacuum pump.
27077 1 14/12/2004
H.20.B / 40

Remove pin (3).
Carefully lift the cylinder and place it on suitable
stands.
CRIL03K182A01 8
10. Remove the sling that holds the rod together with
the cylinder barrel.
27077 1 14/12/2004
H.20.B / 41
Cylinder - Disassemble (H.20.B.26 - F.10.A.25)

CX135SR
To use a cylinder bench for removal operations, refer to Cylinder - Special tools (H.20.B.26 - D.20.A.40)
1. Mark the retaining clips on the piping.

Remove the collars from piping if necessary.
Remove the lines and connectors from the cylinder
barrel.
Discard the seals.
2. Mount the cylinder on the repair bench.
Pull the rod out about 200 mm.
CRPH03J002A 1
3. Mark the gland and cylinder barrel.

Remove screws (1) from the gland.
CRIL03K193A01 2
4. Using slings and a suitable lifting device, remove

complete rod (1) from cylinder barrel (2).
Remove cylinder tube (2) from the repair bench.
CRIL03K194A01 3
27077 1 14/12/2004
H.20.B / 42
5. Mount the rod assembly on the repair bench.

Remove screw (1) and ball (2).
NOTE: During assembly, the locking screw is crimped
in two places with a punch.
Bore out the crimped section with a drill.
CRIL03K195A01 4
6. Remove the xing nut from the piston and the

washer.
NOTE: Unscrewing the nut requires a torque about 1,5
times greater than the tightening torque.
CRPH03J005A 5
7. Remove piston (2) and cushion bushing (1).

Discard seal (3).
CRIL03K196A01 6
8. Discard carrier seals (1), seals (2), (3), (4) and

back-up rings (5).
CRIL03K197A01 7
27077 1 14/12/2004
H.20.B / 43
9. Remove gland (1) from cylinder rod (2).

Discard seals (3), retaining ring (4), bushing (5),
seals (6), (7), back-up ring (8) and seal (9).
CRIL03K198A01 8
10. Discard seals (1) from the cylinder head.

Remove grease ttings (2).
CRIL03J023A01 9
11. Place the boom cylinder head in a press.

Using a suitable driver, remove the cylinder head
bushing.
NOTE: Repeat steps 10 and 11 for the cylinder foot.
CRPH03J006A 10
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H.20.B / 44
Cylinder - Visual inspection (H.20.B.26 - F.40.A.10)

CX135SR
NOTE: Clean each part with a suitable detergent and inspect the parts listed below. Replace all seals with new
seals from the manufacturer.
1. INSPECTING THE ROD
If the rod is cracked, replace it.
If the thread is damaged, re-thread it or replace the
rod.
If the chrome surface is cracked, rusty or defective,
replace the rod.
If the bushing bore is poorly dened or worn, replace
the rod.
If the eye ring is worn, replace the ring.
If the rod has run-out deection greater than 1 mm
per 1 m, replace the rod.
2. ROD RUN OUT MEASUREMENT
Place the rod horizontally on V-shaped blocks, at
each end of the sliding surface.
Place a dial gauge in contact with the rod, positioned
halfway between the two supports.
Rotate the rod about its own axis and note the
differences displayed on the dial gauge between the
minimum and maximum.
This difference will correspond to the amount of rod
run out.
CRPH03J008A 1
3. BARREL INSPECTION
If cracks appear around the weld joints, replace the
tube.
If there are scratches in the tube bore, replace the
tube.
If the tube eye ring is worn, replace the ring.
4. INSPECTING THE GLAND
If the surface is worn and the clearance between
the rod and the gland exceeds 0.25 mm, replace
the ring.
If excessively deep scratches appear on the ring,
replace the ring.
5. INSPECTING SLIDING PARTS
Check sliding parts for wear or damage such as
scratches, dents, or bent components.
Small scratches can be removed with a hone or
crocus cloth.
27077 1 14/12/2004
H.20.B / 45
Cylinder - Assemble (H.20.B.26 - F.10.A.20)

CX135SR
Prior operation: Cylinder - Visual inspection (H.20.B.26 - F.40.A.10)
NOTE: Oil all parts before assembly.

1. Place the cylinder head in a press.
Using a suitable centring piece, install the bushing
in the cylinder head.
CRPH03J006A 1
2. Install seals (1) in the cylinder head.

Install grease ttings (2).
NOTE: Repeat instructions 1 and 2 for the cylinder foot.
CRIL03J023A01 2
3. Place gland (1) in a press.

Using a suitable driver, install bushing (5).
Install seals (6), (7), back-up ring (8) and seal (9).
Installer (3).
Fit seal Mount gland (1) on cylinder rod (2).
CRIL03K198A01 3
27077 1 14/12/2004
H.20.B / 46
4. Install seal (4), seal (3) and back-up rings (5) on

piston.
Install carrier seals (1) and (2) on the piston.
CRIL03K197A01 4
5. Install seal (3), cushion bushing (1) and piston (2)

on the cylinder rod.
CRIL03K196A01 5
6. Place the piston xing nut in position on the cylinder

rod.
Mount the cylinder rod on the repair bench.
Tighten the nut to the required torque.
CRPH03J005A 6
7. Install ball (2) and tighten locking screw (1) to the

required torque.
CRIL03L032A01 7
27077 1 14/12/2004
H.20.B / 47
8. Peen locking screw (1) in two places (2) and (3)

using a punch.
CRIL03J02601A 8
9. Using a sling and a suitable lifting device, install rod

(1) in cylinder barrel (2).
NOTE: Take care not to damage the various seals.
CRIL03K194A01 9
10. Tighten the gland screws to the required torque.

Follow the tightening order.
CRIL03L033A01 10
11. Attach the seals, connectors and lines to the

cylinder barrel.
Tighten to the required torque.
27077 1 14/12/2004
H.20.B / 48
Cylinder - Install (H.20.B.26 - F.10.A.15)

CX135SR

cylinder barrel.
CRIL03K179A00 1
2. Using a suitable lifting device, raise the cylinder.

Align the cylinder foot with the mounting brackets
on the chassis.
Support the cylinder on a stand.
CRIL03K178A01 2
3. Install pin (3).

Install the shims.
Install screw (2) and the rst nut (1) and tighten until
CRIL03K182A01 3

Remove the plugs.
Connect hoses (1).
CRIL03K180A01 4
27077 1 14/12/2004
H.20.B / 49

Connect hoses (1) to (6).
Connect the pressure sensor harness.
CRIL03K181A01 5

Remove the sling that holds the rod together with
7. Align the cylinder rod with the boom mounting
brackets.
Install pin (3).
To check for play between the cylinder head and
the assembly support, refer to BOOM Lift - Service
limits (H.20.B - D.20.A.20).
If necessary remove the pin and add or remove
shims as required to obtain the correct clearance,
replace the pin.
Install bushing (2) screw (1), the rst nut (3) and
tighten until the nut touches the shoulder.
CRIL03K176A01 6

27077 1 14/12/2004
H.20.B / 50
Index
WORKING ARM - H
BOOM Lift - 20.B

Arm - Exploded view (H.20.B.50 - C.10.A.20) 14
CX135SR
Arm - Install (H.20.B.50 - F.10.A.15) 38
CX135SR
Arm - Remove (H.20.B.50 - F.10.A.10) 37
CX135SR
CX135SR
CX135SR
BOOM Lift - Service limits (H.20.B - D.20.A.20) 4
CX135SR
CX135SR
CX135SR
CX135SR
CX135SR
CX135SR
CX135SR
CX135SR
CX135SR
CX135SR
CX135SR
CX135SR
CX135SR
CX135SR
CX135SR
CX135SR
Cylinder - Special tools (H.20.B.26 - D.20.A.40) 7
CX135SR
CX135SR
Cylinder - Visual inspection (H.20.B.26 - F.40.A.10) 45
CX135SR
CX135SR
27077 1 14/12/2004
H.20.B / 51
CX135SR
Relief valve - Assemble (H.20.B.16 - F.10.A.20) 32
CX135SR
Relief valve - Disassemble (H.20.B.16 - F.10.A.25) 31
CX135SR
CX135SR
CX135SR
CX135SR
CX135SR
CX135SR
CX135SR
CX135SR
Sensing system - Electronic schema (H.20.B.95 - C.20.A.50) 15
CX135SR
27077 1 14/12/2004
H.20.B / 52
WORKING ARM - H
BOOM Swing - 20.D
CX135SR
27078 1 14/12/2004
H.20.D / 1
Contents
WORKING ARM - H
BOOM Swing - 20.D
TECHNICAL DATA
Cylinder
Cylinder - Torque (H.20.D.26 - D.20.A.10) 4
CX135SR
Boom
Boom - Service limits (H.20.D.50 - D.20.A.20) 5
CX135SR
FUNCTIONAL DATA
BOOM Swing - Hydraulic schema (H.20.D - C.20.A.20) 10
CX135SR
Control valve
Control valve - Sectional view (H.20.D.14 - C.10.A.30) 11
CX135SR
Cylinder
Cylinder - Sectional view (H.20.D.26 - C.10.A.30) 12
CX135SR
SERVICE
Command valve
Command valve Foot command valve - Remove (H.20.D.12.10 - F.10.A.10) 13
CX135SR
Command valve Foot command valve - Install (H.20.D.12.10 - F.20.A.20) 14

CX135SR
Command valve Foot command valve - Overhaul (H.20.D.12.10 - F.10.A.40) 15

CX135SR
Control valve
Control valve - Disassemble (H.20.D.14 - F.10.A.25) 16
CX135SR
Control valve - Assemble (H.20.D.14 - F.10.A.20) 17

CX135SR
Relief valve
Relief valve - Overhaul (H.20.D.16 - F.10.A.40) 19
CX135SR
Relief valve - Pressure test (H.20.D.16 - F.40.A.30) 20

CX135SR
Relief valve - Pressure setting (H.20.D.16 - F.45.A.70) 21

CX135SR
Cylinder
Cylinder - Remove (H.20.D.26 - F.10.A.10) 22
CX135SR
27078 1 14/12/2004
H.20.D / 2
Cylinder - Disassemble (H.20.D.26 - F.10.A.25) 24
CX135SR
Cylinder - Assemble (H.20.D.26 - F.10.A.20) 27

CX135SR
Cylinder - Install (H.20.D.26 - F.10.A.15) 30

CX135SR
27078 1 14/12/2004
H.20.D / 3
WORKING ARM - BOOM Swing
Cylinder - Torque (H.20.D.26 - D.20.A.10)

CX135SR
CRIL03L112G01 1
Description
(1) Screw 21.4 - 31.2 Nm
(2) Gland 834 Nm
(3) Nut (M 52) 2620 Nm
(4) Screw 46.2 - 67.6 Nm
27078 1 14/12/2004
H.20.D / 4
Boom - Service limits (H.20.D.50 - D.20.A.20)

CX135SR
CRIL03G026F01 1
Articulation points
1. Foot of backhoe-offset boom on pre-boom head
CRIL03G027E01 2
(A) frame 485 mm 491 mm
(B) boom foot 484.5 mm 482.5 mm
(C) play 1 - 1.5 mm shims
(E) bushing diameter 110 mm 111.5 mm
27078 1 14/12/2004
H.20.D / 5
2. Backhoe-offset cylinder foot and tie rod on pre-boom
CRIL03G028E01 3
(A) pre-boom 98 mm 104 mm
(B) cylinder foot 97 mm 95 mm
(C) (play) 0.5 - 0.3 mm shims
(D) 201 mm 207 mm
(E) bushing diameter 200 mm 198 mm
(F) play 0.5 - 3 mm shims
(G) pin diameter 65 mm 64 mm
(H) cylinder foot bushing diameter 65 mm 66.5 mm
(I) tie rod bushing diameter 65 mm 66.5 mm
3. Backhoe-offset cylinder head on backhoe-offset pre-boom
CRIL03G029E01 4
(A) pre-boom 98 mm 104 mm
(B) cylinder head 97 mm 95 mm
(C) play 0.5 - 3.0 mm shims
27078 1 14/12/2004
H.20.D / 6
4. Backhoe-offset tie rod on backhoe-offset dipper
CRIL03G030E01 5
(A) dipper 201 mm 207 mm
(B) tie rod 200 mm 198 mm
(C) play 0.5 - 3 mm shims
5. Backhoe-offset dipper on backhoe-offset boom
CRIL03G031E01 6
(A) boom 400 mm 406 mm
(B) dipper 399.5 mm 397.5 mm
(E) pin diameter 110 mm 111.5 mm
6. Dipper cylinder on backhoe-offset dipper
CRIL03G032E01 7
27078 1 14/12/2004
H.20.D / 7
(B) cylinder 290 mm 288 mm

7. Dipper foot on backhoe-offset dipper
CRIL03G033E01 8
(A) backhoe-offset dipper 231 mm 237 mm
(B) dipper foot 230.5 mm 228.5 mm
8. Dipper cylinder head on dipper
CRIL03G034E01 9
27078 1 14/12/2004
H.20.D / 8
9. Backhoe-offset dipper on dipper
CRIL03G035E01 10
(B) backhoe-offset dipper 87 mm 85 mm
27078 1 14/12/2004
H.20.D / 9
BOOM Swing - Hydraulic schema (H.20.D - C.20.A.20)

CX135SR
CRIL03J156G01 1
Backhoe-offset circuit - Dynamic description
(1) Backhoe-offset control pedal (optional) (2) Backhoe-offset cylinder
(pr) Flow at pump outlet A3 (Pra2/AR2) RH backhoe-offset
(Prb2/BR2) LH backhoe-offset
BACKHOE-OFFSET
• The backhoe-offset cylinder is supplied by the ow from pump (pr). When backhoe-offset control pedal (1)
is activated, the corresponding spool is piloted by port (pra2) or (prb2), which feeds the backhoe-offset
cylinder (2) via port (AR2) or (BR2).
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H.20.D / 10
Control valve - Sectional view (H.20.D.14 - C.10.A.30)

CX135SR
CRIL03J105F01a 1

(18) Seal (24) Valve
(25) Spring (63) Relief valve
(81) Plug (83) Backhoe-offset spool assembly
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H.20.D / 11
Cylinder - Sectional view (H.20.D.26 - C.10.A.30)

CX135SR
CRIL03L112G02 1
Description
(1) Screw (2) Pipe
(3) Seal (4) Seal
(5) Bushing (6) Grease tting
(7) Barrel (8) Gland
(9) Seal (10) Seal
(11) Seal (12) Seal
(13) Bushing (14) Snap ring
(15) Seal (16) Seal
(17) Screw (18) Ball
(19) Piston (20) Seal
(21) Seal (22) Nut
(23) Rod
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H.20.D / 12
Command valve Foot command valve - Remove (H.20.D.12.10 -

F.10.A.10)
CX135SR
Prior operation: To remove the side guard from under the cab oor, refer to Side shield - Remove (E.20.A.70
- F.10.A.10)
1. Attach identication labels to all hoses on control

pedal (1).
Plug the ports.
CRIL03L135A01 1
2. Remove nut (1), screws (2) and remove pedal (3).

Remove the oor mat.
Remove screws and washers (4) then remove
control pedal (5).
CRIL03L136A01 2
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H.20.D / 13
Command valve Foot command valve - Install (H.20.D.12.10 -

F.20.A.20)
CX135SR
1. Position control pedal (5) and install screws and

washers (4).
Install the oor mat.

Install pedal (3), nut (1) and screws (2).
CRIL03L136A01 1

Connect hoses (2) to control pedal (1), following the
CRIL03L135A01 2
Next operation: To install the side guard under the cab oor, refer to Side shield - Remove (E.20.A.70 - F.10.A.10).
27078 1 14/12/2004
H.20.D / 14
Command valve Foot command valve - Overhaul (H.20.D.12.10 -

F.10.A.40)
CX135SR
1. Special tools, refer to Command valve Foot

command valve - Special tools (J.40.F.12.10 -
D.20.A.40)
2. General specication, refer to Command valve
Foot command valve - General specication
(H.20.D.12.10 - D.40.A.10)
3. Removal, refer to:Command valve Foot command
valve - Disassemble (J.40.F.12.10 - F.10.A.25)
4. Visual inspection, refer to Command valve Foot
command valve - Visual inspection (F.10.F.12.10
- F.40.A.10)
5. Assembly, refer to Command valve Foot
command valve - Assemble (J.40.F.12.10 -
F.10.A.20)
6. Fault detection, refer to Command valve Foot
command valve - Troubleshooting (F.10.F.12.10 -
G.40.A.10)
27078 1 14/12/2004
H.20.D / 15
Control valve - Disassemble (H.20.D.14 - F.10.A.25)

CX135SR
CRIL03J105F03a 1

Discard seals (12).
Remove spool (A).
2. Remove screw from spool (45).
replace the spring.
CRIL03L053A01 2

Discard seal (18).
4. Remove valves (63).
Discard the seals.
27078 1 14/12/2004
H.20.D / 16
Control valve - Assemble (H.20.D.14 - F.10.A.20)

CX135SR
CRIL03J105F03a 1
Torque settings
Fixing screws for spool return spring (A) 9.8 - 11.8 Nm
Plug (81) 89 - 97 Nm
Install spool (A) in its housing.
CRIL03L053A01 2
27078 1 14/12/2004
H.20.D / 17
4. Install caps (11) and (13) complete with new seals

(12).
torque.
27078 1 14/12/2004
H.20.D / 18
Relief valve - Overhaul (H.20.D.16 - F.10.A.40)

CX135SR
1. To disassemble this valve, refer to Relief valve -

2. For assembly, refer to Relief valve - Assemble
(H.20.B.16 - F.10.A.20)
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H.20.D / 19
Relief valve - Pressure test (H.20.D.16 - F.40.A.30)

CX135SR
NOTE: The secondary relief valves on the backhoe-offset (O) and (P) are calibrated to a higher pressure than the
main relief valve (S). To check or calibrate the secondary relief valves, main relief valve (S) must be overcalibrated.
1. Overcalibrate main relief valve (S) by tightening the
pressure test point M4.
and hold it up against the stop.
5. The pressure readings on the pressure gauge
should be 185 ± 10 bar (18.5 ± 1 MPa) for the boom
to the right. And 230 ± 10 bar (23 ± 1 MPa) for the
boom to the left.
6. If the pressures are incorrect, calibrate
backhoe-offset boom relief valves (0) and (P), refer
to Relief valve - Pressure setting (H.20.D.16 -
F.45.A.70)
Next operation: To reset main relief valve (S), refer to Relief valve - Pressure setting (A.12.A.16 - F.45.A.70).
27078 1 14/12/2004
H.20.D / 20
Relief valve - Pressure setting (H.20.D.16 - F.45.A.70)

CX135SR
Prior operation: Relief valve - Pressure test (H.20.D.16 - F.40.A.30)

CRIL03K054A01 1

is reached.
Next operation: Reset main relief valve (S), refer to Relief valve - Pressure setting (A.12.A.16 - F.45.A.70).
27078 1 14/12/2004
H.20.D / 21
Cylinder - Remove (H.20.D.26 - F.10.A.10)

CX135SR
1. Attach a suitable lifting device to the cylinder.

Use the complete set of slings to ensure sufcient
CRIL03G107A00 1
2. Remove the nuts (1) and the screw (2).

Remove the pin (3).
CRIL03G108A01 2

cylinder barrel.
CRIL03G061A00 3
27078 1 14/12/2004
H.20.D / 22

Disconnect the supply hoses (1).
Plug the ports.
CRIL03G108A02 4
5. Remove the screws (1) and the plate (2).

Remove the pin (3).
Raise the cylinder carefully and place it on suitable
stands.
Recuperate the shims (4).
CRIL03G108A03 5
6. Remove the sling that holds the cylinder rod

together with the cylinder barrel.
27078 1 14/12/2004
H.20.D / 23
Cylinder - Disassemble (H.20.D.26 - F.10.A.25)

CX135SR
To use a cylinder bench and bearing wrench for removal operations, refer to Cylinder - Special tools (H.20.B.26 -
D.20.A.40)
1. Remove the lines and connectors from the cylinder

barrel.
Discard the seals.
CRPH03J002A 1
3. Straighten the locking tab on the gland.
CRPH03J003A 2
4. Remove the gland using a gland wrench.

Remove the rod tted with the cylinder barrel.
Remove the cylinder barrel from the repair bench.
ATTENTION: Take care not to scratch the bearing surface

of the cylinder barrel.
CRPH03J004A 3
27078 1 14/12/2004
H.20.D / 24

Remove locking screw (1) and ball (2) from piston.
NOTE: During assembly, the locking screw is peened in
two places with a punch.
Bore out the peened section with a drill.
CRIL03K195A01 4
6. Remove the nut from the piston.

NOTE: Unscrewing the piston nut requires a torque about
1,5 times greater than the tightening torque.
CRPH03J005A 5
7. Discard carrier seals (1) and seals (2) and (3).
CRIL03J019A01 6
8. Remove the bearing from the cylinder rod.

Discard seals (1), (2), (3), (4) and (5).
Place the gland in a press.
Using a suitable driver, remove bushing (7).
CRIL03J022A01 7
27078 1 14/12/2004
H.20.D / 25

CRIL03J023A01 8

Using a suitable centring piece, remove the cylinder
head bushing.
CRPH03J006A 9
27078 1 14/12/2004
H.20.D / 26
Cylinder - Assemble (H.20.D.26 - F.10.A.20)

CX135SR
To use a cylinder bench and bearing wrench for assembly operations, refer to Cylinder - Special tools (H.20.B.26 -
D.20.A.40)

CRPH03J006A 1

CRIL03J023A01 2
3. Place the gland in a press.

Using a suitable centring piece, install bushing (7).
Install seals (1), (2), (3), (4) and (5).
Mount the gland on the cylinder rod.
CRIL03J022A01 3
27078 1 14/12/2004
H.20.D / 27
4. Install carrier seals (1) and joints (2) and (3) on the
piston.
CRIL03J019A01 4
5. Place the piston in position on the cylinder rod.

Tighten the piston nut to the required torque.
CRPH03J005A 5

required torque
CRIL03J032A01 6

using a punch.
CRIL03J02601A 7
27078 1 14/12/2004
H.20.D / 28
8. Place the cylinder barrel horizontally.

Fit the rod assembly inside the cylinder barrel.
CRPH03J007A 8
9. Tighten the gland to the required torque.
CRPH03J004A 9
10. Bend the locking tab on the bearing.
CRPH03J003A 10

cylinder barrel.
27078 1 14/12/2004
H.20.D / 29
Cylinder - Install (H.20.D.26 - F.10.A.15)

CX135SR

cylinder barrel.
CRIL03G061A00 1
2. Using a suitable lifting device, lift the cylinder.

Align the cylinder foot with the pre-boom mounting
brackets.
3. Fit the shims (4) and pin (3).
Check the play between the cylinder foot and the
mounting bracket, refer to BOOM Swing - Service
limits (H.20.D - D.20.A.20).
replace the pin.
Fit the plate (2) and screw (1).
CRIL03G108A03 2

Remove the plugs.
Connect the supply hoses (1).
CRIL03G108A02 3

27078 1 14/12/2004
H.20.D / 30
6. Align the cylinder rod with the mounting port in the

boom.
Install the pin (3) and the screw (2).
Check the play between the cylinder head and the
mounting bracket, refer to BOOM Swing - Service
limits (H.20.D - D.20.A.20).
If necessary, remove the pin and screw and add
replace the pin and screw.
Engage the rst nut (1) on the screw and tighten
until the nut touches the boss.
Engage the second screw (1) to keep the rst in
position. CRIL03G108A01 4

27078 1 14/12/2004
H.20.D / 31
Index
WORKING ARM - H
BOOM Swing - 20.D

Boom - Service limits (H.20.D.50 - D.20.A.20) 5
CX135SR
BOOM Swing - Hydraulic schema (H.20.D - C.20.A.20) 10
CX135SR
Command valve Foot command valve - Install (H.20.D.12.10 - F.20.A.20) 14
CX135SR
Command valve Foot command valve - Overhaul (H.20.D.12.10 - F.10.A.40) 15
CX135SR
Command valve Foot command valve - Remove (H.20.D.12.10 - F.10.A.10) 13
CX135SR
Control valve - Assemble (H.20.D.14 - F.10.A.20) 17
CX135SR
Control valve - Disassemble (H.20.D.14 - F.10.A.25) 16
CX135SR
Control valve - Sectional view (H.20.D.14 - C.10.A.30) 11
CX135SR
Cylinder - Assemble (H.20.D.26 - F.10.A.20) 27
CX135SR
Cylinder - Disassemble (H.20.D.26 - F.10.A.25) 24
CX135SR
Cylinder - Install (H.20.D.26 - F.10.A.15) 30
CX135SR
Cylinder - Remove (H.20.D.26 - F.10.A.10) 22
CX135SR
Cylinder - Sectional view (H.20.D.26 - C.10.A.30) 12
CX135SR
Cylinder - Torque (H.20.D.26 - D.20.A.10) 4
CX135SR
Relief valve - Overhaul (H.20.D.16 - F.10.A.40) 19
CX135SR
Relief valve - Pressure setting (H.20.D.16 - F.45.A.70) 21
CX135SR
Relief valve - Pressure test (H.20.D.16 - F.40.A.30) 20
CX135SR
27078 1 14/12/2004
H.20.D / 32
WORKING ARM - H
DIPPER Lift - 25.B
CX135SR
27079 1 14/12/2004
H.25.B / 1
Contents
WORKING ARM - H
DIPPER Lift - 25.B
TECHNICAL DATA
DIPPER Lift - Service limits (H.25.B - D.20.A.20) 4
CX135SR
Command valve
CX135SR
Cylinder
CX135SR
FUNCTIONAL DATA
DIPPER Lift - Hydraulic schema (H.25.B - C.20.A.20) 7
CX135SR

CX135SR
Command valve
CX135SR
Control valve
CX135SR
Cylinder
CX135SR OFFSET BOOM
SERVICE
Command valve
CX135SR

CX135SR

CX135SR

CX135SR

CX135SR

CX135SR

CX135SR
Control valve
27079 1 14/12/2004
H.25.B / 2
CX135SR

CX135SR
Safety valve
CX135SR

CX135SR

CX135SR

CX135SR

CX135SR
Relief valve
Relief valve - Overhaul (H.25.B.16 - F.10.A.40) 31
CX135SR

CX135SR

CX135SR
Load holding valve

CX135SR

CX135SR
Cylinder
CX135SR MONOBLOC BOOM



Cylinder
CX135SR OFFSET BOOM

CX135SR OFFSET BOOM

CX135SR OFFSET BOOM

CX135SR OFFSET BOOM
Arm
Arm - Remove (H.25.B.50 - F.10.A.10) 59
CX135SR
Arm - Install (H.25.B.50 - F.10.A.15) 61

CX135SR
27079 1 14/12/2004
H.25.B / 3
WORKING ARM - DIPPER Lift
DIPPER Lift - Service limits (H.25.B - D.20.A.20)

CX135SR
CRIL03G012E02 1
Linkage points
1. Dipper cylinder foot on boom
CRIL03G018E01 2
(C) (A-B) 0.5 - 3 mm shims
2. Cylinder foot on boom head
CRIL03G019E01 3
(A) boom 259 mm 262 mm
(B) dipper 258.5 mm 256.5 mm
27079 1 14/12/2004
H.25.B / 4
3. Dipper cylinder head on dipper
CRIL03G020E01 4
(A) frame 96.5 mm 102.5 mm
(B) cylinder 95.5 mm 93.5 mm
(C) play (A-B) 0.5 - 3.0 mm shims
Command valve Hand control valve - Torque (H.25.B.12.10 -

D.20.A.10)
CX135SR
27079 1 14/12/2004
H.25.B / 5
Cylinder - Torque (H.25.B.26 - D.20.A.10)

CX135SR
CRIL03L069G02 1
Description
(1) Screw 171 Nm
(2) Plug 191,7 - 260,3 Nm
(3) Screw 25,62 - 37,88 Nm
(4) Screw 51,21 - 62,59 Nm
(5) Nut (M52) 4780 Nm
(6) Screw 41,59 - 60,81 Nm
(7) Screw 46,2 - 67,6 Nm
27079 1 14/12/2004
H.25.B / 6
DIPPER Lift - Hydraulic schema (H.25.B - C.20.A.20)

CX135SR
CRIL03J149G01 1
Dipper out circuit, load holding valve - Dynamic Description
(1) Dipper spool 1 (2) Straight-line travel valve
(3) Dipper spool 2 (27) Dipper cylinder
(31) Load holding valve (P1) Flow at pump outlet A2
(P2) Flow at pump outlet A1 (Pa5/A5) Dipper out
(Pb5/B5) Dipper in
DIPPER OUT
Dipper cylinder (27) is fed by the ow from pumps (A1) and (A2) via ports (P1) and (P2).
• When the dipper out is not activated, the oil from the small chamber on dipper cylinder (27) is retained by
load holding valve (31). This minimises leakage from dipper 1 spool (1)
• When the dipper out control is activated, the spools on dipper 1 (1) and dipper 2 (3) are piloted via the
ports (Pa5) and (Pa9).
At the same time, the pilot pressure reaches (Pc1) and unlocks the load holding valve (31). This means that
the oil in the large chamber on dipper cylinder (27) can return to the reservoir.
27079 1 14/12/2004
H.25.B / 7
DIPPER Lift - Hydraulic schema (H.25.B - C.20.A.20)

CX135SR
CRIL03J150G01 1
Dipper in circuit - Dynamic description.
(1) Dipper spool 1 (2) Straight-line travel valve
(3) Dipper spool 2 (4) Recycling valve
(5) Check valve (27) Dipper cylinder
(31) Load holding valve (P1) Flow at pump outlet A2
(P2) Flow at pump outlet A1 (Pa5/A5) Dipper out
(Pb5/B5) Dipper in (Pa9/pb9) Dipper spool pilot
DIPPER IN
• Dipper cylinder (27) is fed by ows from pumps (A1) and (A2) via ports (P1) and (P2).
• When the dipper in control is activated, the spools on dipper 1 (1) and dipper 2 (3) are piloted via ports
(Pa5) and (Pa9).
DIPPER IN, ADDITIONAL SUPPLY

• When the dipper in control is activated, the pilot pressure reaches (Pc1) and unlocks load holding valve (31).
27079 1 14/12/2004
H.25.B / 8
This means that the oil from the small chamber on dipper cylinder (27) is reinjected into the large chamber on
dipper cylinder (27) passing through the small restriction in recycling valve (4) and check valve (5).
• When the pressure in the large chamber on the dipper cylinder (27) increases, recycling valve (4) is activated
and placed in restriction position.
This stops the reinjection from the small chamber to the large chamber on dipper cylinder (27).
27079 1 14/12/2004
H.25.B / 9
Command valve Hand control valve - Sectional view (H.25.B.12.10 -

C.10.A.30)
CX135SR
27079 1 14/12/2004
H.25.B / 10
Control valve - Sectional view (H.25.B.14 - C.10.A.30)

CX135SR
CRIL03J086F01 1
Cross-sectional view - Dipper section 1 and 2
(6) Dipper spool 1 (7) Dipper spool 2

(18) Seal (19) Plug
(28) Spring (29) Spacer
(30) Load holding valve (31) Seal
(32) Plug (33) Sleeve
(38) Seal (39) Flange
(63) Relief valve (65) Cap screw
(67) Load holding valve screw
27079 1 14/12/2004
H.25.B / 11
Cylinder - Sectional view (H.25.B.26 - C.10.A.30)

CX135SR OFFSET BOOM
CRIL03L069G01a 1

(7) Washer (8) Screw (9) Plug
(13) Bushing (14) Bushing (15) Seal
(28) Nut (29) Seal (30) Seal
(34) Piston (35) Bushing (36) Seal
(37) Seal (38) Stop (39) Ring
27079 1 14/12/2004
H.25.B / 12
Command valve Hand control valve - Overhaul (H.25.B.12.10 -

F.10.A.40)
CX135SR
1. Refer to:
(F.40.C.12.10 - F.10.A.10)
Cleaning (F.40.C.12.10 - F.30.A.10)
inspection (F.40.C.12.10 - F.40.A.10)
Assemble (F.40.C.12.10 - F.10.A.20)
(F.40.C.12.10 - F.10.A.15)
27079 1 14/12/2004
H.25.B / 13
Command valve Cushion valve - Remove (H.25.B.12.20 - F.10.A.10)

CX135SR
Prior operation: Remove the side guard from under the oor, refer to Side shield - Remove (E.20.A.70 -
F.10.A.10).
1. Attach identifying tags to all the damper hoses.

Disconnect the hoses (1).
Plug the ports.
Remove screws (2) and damper (3).
CRIL03L109A01 1
27079 1 14/12/2004
H.25.B / 14

F.10.A.25)
CX135SR
CRIL03L110F01 1
(1) Cushion valve (2) Spring

(3) Spool (4) Seal
(5) Connector (6) Plug
(7) Seal (8) Spring
(9) Spring guide (10) Seal
(11) Spool
1. Mark parts to ensure correct assembly in their
original positions.
2. Remove plugs (6) and springs (8).
Discard seal (7).
Clamp the spool in a vice, protecting it with wooden
blocks.
Remove spring guide (9) and discard seal (10).
4. Remove unions (5).
Discard seals (4).
5. Install an M4 screw in the threaded orice of spool
(3) to extract it.
Remove spring (2).
27079 1 14/12/2004
H.25.B / 15

CX135SR
1. Check condition and clean parts before assembling.

2. Assemble the parts in the reverse order of
disassembly, refer to Command valve Cushion
valve - Disassemble (H.20.B.12.20 - F.10.A.25)
27079 1 14/12/2004
H.25.B / 16
Command valve Cushion valve - Install (H.25.B.12.20 - F.10.A.15)

CX135SR
1. Attach the damper (3) with screws (2).

Remove the plugs.
Connect the hoses (1).
CRIL03L109A01 1
2. Remove the vacuum pump.

Ensure there are no leaks.
Install the side guard under the oor.
27079 1 14/12/2004
H.25.B / 17

F.10.A.25)
CX135SR
CRIL03F201E01 1
Dipper pilot outlet 2
(1) Spring (7) Ring
(2) Calibrated port (8) Snap ring
(3) Body (9) Seal
(4) Connector (10) Seal
(5) Sleeve (11) Seal
(6) Plunger (12) Plunger sub-assembly
1. Disconnect hose (A) and remove cushion valve (B)

from dipper pilot outlet 2.
CRIL03L114A01a 2
2. Remove snap ring (8), sleeve (5). Discard seals

(11).
CRIL03F202E01 3
27079 1 14/12/2004
H.25.B / 18
3. Remove union (4). Discard seal (9).
CRIL03F203A01 4
4. Remove spring (1), plunger sub-assembly (12) and

spring (1). Discard seal (10).
NOTE: Calibrated port (2) and ring (7) should not be
removed.
CRIL03F204A01 5
27079 1 14/12/2004
H.25.B / 19

CX135SR
1. Place the spring (1), the plunger sub-assembly (12)

and the spring (1) in the body (3). Install a seal (10).
NOTE: Make sure the plunger sub-assembly (12) is
installed the right way round.
CRIL03F204A01 1
2. Tighten the union (4) on the body (3) to a torque

of 21.1 - 27.4 Nm.
Install the seal (9).
CRIL03F203A01 2
3. Install the seals (11) on the body (3).

Install the sleeve (5) on the body (3).
Install the snap ring (8).
CRIL03F202E01 3
27079 1 14/12/2004
H.25.B / 20
Control valve - Disassemble (H.25.B.14 - F.10.A.25)

CX135SR
CRIL03J086F01 1
Dipper section 1 and 2

Remove caps (11) and (13) and discard the seals.
Remove spools (6) and (7).
NOTE: Mark each spool to ensure that it is returned to the
correct housing during re-assembly.
removal of the spool assembly, use a (A) soft-jawed vice
and clamp the spool as closely as possible to the head
industrial drier until it can be removed easily (usually the
temperature should be 200 - 250 °C ). If the spring is
damaged (impaired functioning) during this operation,
replace the spring.
CRIL03L053A01 2
27079 1 14/12/2004
H.25.B / 21
3. Remove plug (A) from spool (6).

Discard seal (C) and backing ring (B).
Remove spring (D) and check valve (E).
CRIL03L077A01 3

Remove load holding valve assembly (30), then
remove seal (31) from the control valve.
Disassemble the parts of the load holding valve,
refer to Load holding valve - Disassemble
(H.20.B.19 - F.10.A.25).
5. Use a screw 6x1,0 mm as an extracting screw to
remove the spacer assembly (29).
Remove and discard seals (A) and (B) and the
back-up ring (C).
CRIL03L078A01 4
6. Remove plug (19) and discard seal (18).

7. Remove ange (39), and discard seal (38).
Remove springs (37) and (35) and check valves
(36) and (34).
Remove sleeve (33).
8. Remove plugs (21) and (32) and discard the seals.
Remove valves (63).
27079 1 14/12/2004
H.25.B / 22
Control valve - Assemble (H.25.B.14 - F.10.A.20)

CX135SR
- F.40.A.10)
CRIL03J086F01 1
Dipper section 1 and 2
Torque settings
Fixing screws (45) for return springs on spools (6) and (7) 9.8 - 11.8 Nm
Plug (A) of spool (6) 9.8 - 11.8 Nm
Plug (19) 103 - 113 Nm
Plug (21) 13.5 - 16.5 Nm
Plug (32) 73 - 79 Nm
Fixing screws for ange (39) 39 - 44 Nm
Valves (63) 78 - 88 Nm
Screws (65) and (67) 20 - 25 Nm
and tighten them to the required torque.
2. Install valves (63) and tighten them to the required
torque.
4. Install sleeve (33).
Install springs (37) and (35) and check valves (36)
and (34).
Install ange (39) complete with new seal (38).
Tighten the screws to the required torque.
27079 1 14/12/2004
H.25.B / 23
5. Install seals (A) and (B) and back-up ring (C) on

spacer (29).
Install spring (28), check valve (27) and spacer
assembly (29).
CRIL03L078A01 2
6. Install load holding valve assembly (30) with a seal

(31).
torque.
locking uid.
Install springs (44) and seats (43) on screws (45).
CRIL03L053A01 3
8. Install spring (D) and check valve (E) on spool (6).

Install seal (C) and back-up ring (B) on plug (A).
Install and tighten plug (A) to the required torque.
Install spools (6) and (7) in their respective housings.
CRIL03L077A01 4

torque.
27079 1 14/12/2004
H.25.B / 24
Safety valve - Remove (H.25.B.15 - F.10.A.10)

CX135SR
1. Disconnect hoses (1) from the valve.

Plug the union and the hoses.
Remove screws (2) and remove the safety valve.
Plug the cylinder port.
CRIL03L131A01 1
27079 1 14/12/2004
H.25.B / 25
Safety valve - Disassemble (H.25.B.15 - F.10.A.25)

CX135SR
CRIL03L120G01 1
(1) Spool stop cap (2) Seal
(3) Spool cap (4) Seal
(5) Spring (6) Spring seat
(7) Spring seat (8) Spool
(9) Seal (10) Valve
(11) Plug (12) Seal
(13) Spring (14) Check valve
(15) Plug (16) Seal
(17) Spring (18) Piloted check valve
1. Remove cap (1).
Discard seal (2).
2. Remove cap (3).
Discard seal (4)
Remove springs (5).
Remove seats (6) and (7).
Remove spool (8).
Discard seal (12).
27079 1 14/12/2004
H.25.B / 26

Discard seal (16).
5. Remove valve (10).
Discard seal (9).
6. To remove valve (10), refer to Relief valve -
27079 1 14/12/2004
H.25.B / 27
Safety valve - Assemble (H.25.B.15 - F.10.A.20)

CX135SR
CRIL03L120G01 1
Tightening torque
Cap screws on spool (1) and (3) 38.8 - 39.6 Nm
Valve (10) 58.2 - 59.4 Nm
Plugs (11) and (15) 213.8 - 217.8 Nm
1. Install cap (1) complete with new seal (2).
Install cap xing screws and tighten to the required
torque.
2. Oil and install spool (8).
Install springs (5) and check valves (6) and (7).
Install spool cap (3) complete with new seal (4).
Install cap xing screws and tighten to the required
torque.
5. Install valve (10) complete with a new seal (9) and
27079 1 14/12/2004
H.25.B / 28
Safety valve - Install (H.25.B.15 - F.10.A.15)

CX135SR
1. Install the safety valve on the cylinder with a new

seal ring.
Install and tighten screws (2).
Connect hoses (1) to the valve.
CRIL03L131A01 1
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H.25.B / 29
Safety valve - Pressure setting (H.25.B.15 - F.45.A.70)

CX135SR
1. Disconnect and plug the pilot hose (1) on the safety

valve.
Place a receptacle under union (2) to catch any
leaks.
Remove plug (3)
On the port remaining free (layout (21G), install a
union equipped with a pressure test point (4).
Connect a pressure controller or a 0 - 600 bar
pressure gauge to pressure test point (4).
Start the engine.
Set the engine speed to 1000 tr/mn on the
instrument panel potentiometer.
Bring the boom to mid-height and extend the dipper.
Operate the dipper retracting control and CRIL03K056A01 1
read the calibrated pressure for the valve. Repeat
this operation several times, noting the pressure
each time.
The pressure read on the pressure gauge must be:
363 ± 5 bar (36.3 ± 0.5 MPa).
2. If the value is not correct, loosen lock nut (5) and
turn calibrating screw (6) to adjust the pressure.
Tighten to increase the pressure, loosen to
decrease. While activating the dipper in control,
tighten lock nut (5).
CRIL03K057A01 2
3. Connect pilot hose (1) before releasing the pressure

in the small chamber of the dipper cylinder.
Start the engine to ll the accumulator.
Release the pressure in the hydraulic system.
4. Disconnect the union tted with the pressure test
point.
Install plug (3) on the safety valve.
27079 1 14/12/2004
H.25.B / 30
Relief valve - Overhaul (H.25.B.16 - F.10.A.40)

CX135SR

(H.20.B.16 - F.10.A.20)
27079 1 14/12/2004
H.25.B / 31
Relief valve - Pressure test (H.25.B.16 - F.40.A.30)

CX135SR
NOTE: The dipper secondary relief valves (D) and (E) are calibrated to a higher pressure than the main relief valve
(A). To check or calibrate the secondary relief valves, main relief valve (A) must be overcalibrated.
NOTE: If the excavator is equipped with a safety valve on the dipper, secondary relief valve (D) is not tted on the
valve block, or it is overcalibrated. In this case, valve (D1) mounted on the safety valve must be calibrated.
the pressure test point .
should be 395 ± 10 bar (39.5 ± 1 MPa).
6. If the pressures are incorrect, calibrate dipper relief
valves (D) and (E), refer to Relief valve - Pressure
setting (H.25.B.16 - F.45.A.70)
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H.25.B / 32
Relief valve - Pressure setting (H.25.B.16 - F.45.A.70)

CX135SR
Prior operation: Relief valve - Pressure test (H.25.B.16 - F.40.A.30)
1. Using a wrench, hold the adjusting screw (2) of the

relief valve and loosen the lock nut (1).
CRIL03K054A01 1

calibrated and hold against the stops.
3. Turn the adjusting screw (2) until the correct
pressure is obtained.
Next operation: To re-calibrate main relief valve (A), refer to Relief valve - Pressure setting (A.10.A.16
- F.45.A.70)
27079 1 14/12/2004
H.25.B / 33
Load holding valve - Disassemble (H.25.B.19 - F.10.A.25)

CX135SR
NOTE: Take care when disassembling the load holding valve, some parts are under pressure from the springs.
1. Place the load holding valve assembly (30) in a
soft-jawed vice.
2. Remove the plug (P).
Remove piston (D), spool (E) and spring (G).
Unscrew and remove plug (C) then remove seal (N).
CRIL03L080B01 1
3. Remove sleeve (F) and valve (B).

4. Remove seals (J) and (K) and backup rings (L) and
(M) from the sleeve (F).
5. Remove spring seat (Q) and spring (H).
27079 1 14/12/2004
H.25.B / 34
Load holding valve - Assemble (H.25.B.19 - F.10.A.20)

CX135SR
1. Fit seals (K) and (J) back-up rings (L) and (M) into
the grooves of the sleeve (F).
NOTE: Follow the positions of the seals and backup rings.
CRIL03L080B01 1
2. Install valve (B) and spool (E) in the oroce of

sleeve (F).
3. Fit spring seat (Q) on the end of valve (B), t spring
(H) on spring seat.
Insert the assembly in the load holding valve body.
Install a seal (N) on the plug (C).
plug (C).
Fit spring (G), spool (E) and piston (D) in the load
holding valve.
Fit a seal on plug (P).
plug (P).
27079 1 14/12/2004
H.25.B / 35

1. Place a wooden wedge under the cylinder.
CRIL03G066A00 1
2. Remove screw (1) and plate (2).

Remove pin (3).
CRIL03G067A01 2
3. Carefully raise the cylinder.

Attach a sling to retain the cylinder rod in the
cylinder barrel.
CRIL03G061A00 3
27079 1 14/12/2004
H.25.B / 36

Plug the ports.
CRIL03G068A01 4

Disconnect hoses (1), (2), (3) and (4).
Plug the ports.
CRIL03L047A01 5

7. Disconnect lubrication hose (1).
CRIL03G069A01 6

Use all the play to ensure sufcient support during
removal of the cylinder.
CRIL03G071A00 7
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H.25.B / 37

Remove pin (3).
stands.
Recover the shims.
CRIL03L048A01 8
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H.25.B / 38

1. Remove the collars from piping.

barrel.
Discard the seals.
CRPH03J002A 1
3. Remove screws (1) from the gland.
CRIL03K193A01 2

Remove cylinder barrel (2) from the repair bench.
CRIL03K194A01 3
27079 1 14/12/2004
H.25.B / 39

NOTE: During assembly, the locking screw is crimped
in two places with a punch.
Bore out the crimped section with a drill.
CRIL03K195A01 4
6. Unscrew the nut from the piston.

CRPH03J005A 5
7. Remove piston (2) and cushion bushing (1).

Discard seal (3).
CRIL03K196A01 6
8. Discard carrier seals (1), seals (2), (3) and (4), and
back-up rings (5).
CRIL03K197A01 7
27079 1 14/12/2004
H.25.B / 40

seals (6) and (7), back-up ring (8) and seal (9).
CRIL03K198A01 8

Remove grease tting (2).
CRIL03J023A01 9

Using a suitable driver, remove the cylinder head
bushing.
CRPH03J006A 10
27079 1 14/12/2004
H.25.B / 41


CRPH03J006A 1

Install grease tting (2).
CRIL03J023A01 2

Install seals (6) and (7), back-up ring (8) and seal
(9).
Fit seal (3).
Mount gland (1) on cylinder rod (2).
CRIL03K198A01 3
27079 1 14/12/2004
H.25.B / 42

piston.
CRIL03K197A01 4
5. Install seal (3), cushion bushing (1) and piston (2)

on the cylinder rod.
CRIL03K196A01 5
6. Place the piston nut in position on the cylinder rod.

CRPH03J005A 6
7. Install the ball (2)

Install locking screw (1) and tighten it to the required
torque.
CRIL03L032A01 7
27079 1 14/12/2004
H.25.B / 43

using a punch.
CRIL03J02601A 8
9. Using slings and a suitable lifting device, install rod

CRIL03K194A01 9

CRIL03L033A01 10

cylinder barrel.
27079 1 14/12/2004
H.25.B / 44


cylinder barrel.
CRIL03G061A00 1

Align the cylinder foot with the boom mounting
brackets.
Install the shims and pin (3).
To check for play between the cylinder foot and the
assembly support, refer to DIPPER Lift - Service
limits (H.25.B - D.20.A.20).
shims as required to obtain the correct play, replace
the pin.
Install screw (2) and the rst nut (1) and tighten until
the nut touches the shoulder.
Fit the second nut (1) to keep the rst in position. CRIL03L048A01 2
3. Connect lubrication hose (1) to the cylinder.
CRIL03G069A01 3

Remove the plugs.
Connect hoses (1).
CRIL03G068A01 4
27079 1 14/12/2004
H.25.B / 45

Connect hoses (1), (2), (3) and (4).
CRIL03L047A01 5

7. Align the cylinder rod with the dipper mounting
brackets.
Install pin (3).
Check for play between the cylinder head and the
assembly support, refer to DIPPER Lift - Service
limits (H.25.B - D.20.A.20).
replace the pin.
Install plate (2) and screws (1).
CRIL03G067A01 6

27079 1 14/12/2004
H.25.B / 46

CX135SR OFFSET BOOM

Use all the play to ensure sufcient support during
removal of the cylinder.
CRIL03L052A00 1

Remove pin (3).
CRIL03L054B01 2

cylinder barrel.
CRIL03G061A00 3
27079 1 14/12/2004
H.25.B / 47

Plug the ports.
CRIL03G111A01 4
5. If the machine is tted with a safety valve,

disconnect hoses (1) and (2).
Plug the ports.
CRIL03L055B01 5
27079 1 14/12/2004
H.25.B / 48

Remove pin (3).
Repeat the instructions for the opposite pin.
stands.
Recover shims (4).
CRIL03L054B02 6
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H.25.B / 49

CX135SR OFFSET BOOM
1. Remove the collars from piping.

barrel.
Discard the seals.
CRPH03J002A 1

CRIL03K193A01 2

Remove cylinder tube (2) from the repair bench.
CRIL03K194A01 3
27079 1 14/12/2004
H.25.B / 50

CRIL03K195A01 4
6. Remove nut (5)

CRPH03J005A 5
7. Remove stop (9).

Discard seal (8), rings (6) and (7).
Remove shim (4) and piston (3).
Remove cushion bushing (1) and discard seal (2).
CRIL03L072A01 6
8. Discard carrier seals (1), seals (2), (3) and (4), and
back-up rings (5).
CRIL03K197A01 7
27079 1 14/12/2004
H.25.B / 51

seals (6) and (7), back-up ring (8) and seal (9).
CRIL03K198A01 8

Remove grease tting (2).
CRIL03J023A01 9

head bushing.
CRPH03J006A 10
12. Remove grease tting (1).

Discard bushings (2).
Remove bushings (3).
CRIL03L073A01 11
27079 1 14/12/2004
H.25.B / 52

CX135SR OFFSET BOOM

CRPH03J006A 1

Install grease tting (2).
CRIL03J023A01 2
3. Place the cylinder barrel in a press.

Using a suitable driver, install bushings (3) in the
cylinder barrel.
Install seals (2).
CRIL03L073A01 3
27079 1 14/12/2004
H.25.B / 53

(9).
Install seals (3).
Fit seal Mount gland (1) on cylinder rod (2).
CRIL03K198A01 4
5. Install seal (1), seals (2), (3) and (4) and back-up
rings (5) on the piston.
CRIL03K197A01 5
6. Install seal (2), cushion bushing (1).

Install piston (3).
Install shim (4).
Fit seal (8).
Install rings (6) and (7).
Install stop (9).
Install nut (5).
CRIL03L072A01 6
7. Mount the cylinder rod on the repair bench.

Tighten nut (5) to the required torque.
CRPH03J005A 7
27079 1 14/12/2004
H.25.B / 54

required torque.
CRIL03L032A01 8

using a punch.
CRIL03J02601A 9

(1) in the cylinder tube.
CRIL03K194A01 10

CRIL03L033A01 11

cylinder barrel.
27079 1 14/12/2004
H.25.B / 55

CX135SR OFFSET BOOM
1. Attach a sling to hold the cylinder rod to the cylinder

barrel.
CRIL03G061A00 1

Align the cylinder foot with the boom mounting
brackets.
3. Install shims (4), pins (3) and screws (2).
To check for play between the cylinder barrel and
the assembly support, refer to Arm - Service limits
(H.25.B.50 - D.20.A.20).
If necessary remove the pins, and add or remove
replace the pins and the screws.
Install the rst nuts (1) on screws (2) until the nuts
touch the boss.
Loosen the nuts a quarter of a turn.
Install the second nuts (1) to hold the rst in position.
CRIL03L054B02 2
27079 1 14/12/2004
H.25.B / 56

Remove the plugs.
Connect supply hoses (1).
CRIL03G111A01 3
5. If the machine is tted with a safety valve, connect

hoses (1) and (2).
CRIL03L055B01 4

27079 1 14/12/2004
H.25.B / 57
7. Align the cylinder rod with the dipper mounting

brackets.
Install pin (3).
To check for play between the cylinder head and
the assembly support, refer to Arm - Service limits
(H.25.B.50 - D.20.A.20).
replace the pin.
Install plate (2) and screw (1).
CRIL03L054B01 5

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H.25.B / 58
Arm - Remove (H.25.B.50 - F.10.A.10)

CX135SR
Prior operation: To remove the bucket, refer to Arm - Remove (H.30.C.50 - F.10.A.10).
CRIL03L142G01 1
(1) Screw (2) Nut
(3) Pin (4) Bushing
(9) Seal (10) Seal
1. To disconnect the dipper cylinder rod, refer to
Cylinder - Remove (H.25.B.26 - F.10.A.10).
Attach the dipper cylinder to the boom.
2. To install a vacuum pump, refer to PRIMARY
HYDRAULIC POWER SYSTEM - Drain uid
(A.10.A - F.35.A.20).
27079 1 14/12/2004
H.25.B / 59

Mark and disconnect the hoses between the boom
and the dipper.
Plug the ports.
CRIL03H006A00 2
4. Attach a suitable lifting device to the dipper.

Use all the play necessary to obtain sufcient
support during removal of the dipper.
Remove pin (3).
Move the machine backwards to separate the
dipper from the boom.
Lower the boom to the ground.
7. Place the dipper on suitable stands.
8. Discard seals (5), (9) and (10).
9. Remove grease ttings (8).
10. To remove bushings (4) only if they need replacing,
refer to DIPPER Lift - Service limits (H.25.B -
D.20.A.20).
11. To remove bushings (6) and (7) only if they need
replacing, refer to ARM TOOL ATTACHMENT Tilt -
Service limits (H.30.C - D.20.A.20).
27079 1 14/12/2004
H.25.B / 60
Arm - Install (H.25.B.50 - F.10.A.15)

CX135SR
CRIL03L142G01 1
(1) Screw (2) Nut
(3) Pin (4) Bushing
(9) Seal (10) Seal
1. Install bushings (4), (6) and (7).
3. Install grease ttings (8).
4. Attach a suitable lifting device to the dipper.
Bring the dipper close to the machine.
Start the engine.
Align the dipper orices with the orices on the
boom.
27079 1 14/12/2004
H.25.B / 61
5. Install pin (3) and screw (1).

6. To check for play between the dipper and the boom,
refer to DIPPER Lift - Service limits (H.25.B -
D.20.A.20).
If necessary, remove the pin and add shims as
required to obtain the correct play, re-install the pin
and the screw.
8. To connect the boom cylinder rod, refer to Cylinder
- Install (H.25.B.26 - F.10.A.15).
Remove the plugs.
Connect the hoses between the boom and the
dipper, following the markings made during removal.
Stop and remove the vacuum pump.
CRIL03H006A00 2
27079 1 14/12/2004
H.25.B / 62
Index
WORKING ARM - H
DIPPER Lift - 25.B

Arm - Install (H.25.B.50 - F.10.A.15) 61
CX135SR
Arm - Remove (H.25.B.50 - F.10.A.10) 59
CX135SR
CX135SR
CX135SR
CX135SR
CX135SR
CX135SR
CX135SR
CX135SR
CX135SR
CX135SR
CX135SR
CX135SR
CX135SR
CX135SR OFFSET BOOM
CX135SR OFFSET BOOM
CX135SR OFFSET BOOM
CX135SR OFFSET BOOM
CX135SR OFFSET BOOM
CX135SR
CX135SR
27079 1 14/12/2004
H.25.B / 63
CX135SR
DIPPER Lift - Service limits (H.25.B - D.20.A.20) 4
CX135SR
CX135SR
CX135SR
Relief valve - Overhaul (H.25.B.16 - F.10.A.40) 31
CX135SR
CX135SR
CX135SR
CX135SR
CX135SR
CX135SR
CX135SR
CX135SR
27079 1 14/12/2004
H.25.B / 64
WORKING ARM - H
ARM TOOL ATTACHMENT Tilt - 30.C
CX135SR
27080 1 14/12/2004
H.30.C / 1
Contents
WORKING ARM - H
TECHNICAL DATA
ARM TOOL ATTACHMENT Tilt - Service limits (H.30.C - D.20.A.20) 4
CX135SR
Command valve
Command valve Hand control valve - Torque (H.30.C.12.10 - D.20.A.10) 6
CX135SR
Cylinder
Cylinder - Torque (H.30.C.26 - D.20.A.10) 7
CX135SR
FUNCTIONAL DATA
ARM TOOL ATTACHMENT Tilt - Hydraulic schema (H.30.C - C.20.A.20) 8
CX135SR
Command valve
Command valve Hand control valve - Sectional view (H.30.C.12.10 - C.10.A.30) 10
CX135SR
Control valve
Control valve - Sectional view (H.30.C.13 - C.10.A.30) 11
CX135SR
Cylinder
Cylinder - Sectional view (H.30.C.26 - C.10.A.30) 12
CX135SR
SERVICE
Command valve
Command valve Hand control valve - Overhaul (H.30.C.12.10 - F.10.A.40) 13
CX135SR
Control valve
Control valve - Disassemble (H.30.C.13 - F.10.A.25) 14
CX135SR
Control valve - Assemble (H.30.C.13 - F.10.A.20) 15

CX135SR
Relief valve
Relief valve - Overhaul (H.30.C.16 - F.10.A.40) 16
CX135SR
Relief valve - Pressure test (H.30.C.16 - F.40.A.30) 17

CX135SR
Relief valve - Pressure setting (H.30.C.16 - F.45.A.70) 18

CX135SR
Cylinder
Cylinder - Remove (H.30.C.26 - F.10.A.10) 19
CX135SR
27080 1 14/12/2004
H.30.C / 2
Cylinder - Disassemble (H.30.C.26 - F.10.A.25) 21
CX135SR
Cylinder - Assemble (H.30.C.26 - F.10.A.20) 24

CX135SR
Cylinder - Install (H.30.C.26 - F.10.A.15) 27

CX135SR
Arm
Arm - Remove (H.30.C.50 - F.10.A.10) 29
CX135SR
Arm - Install (H.30.C.50 - F.10.A.15) 31

CX135SR
27080 1 14/12/2004
H.30.C / 3
WORKING ARM - ARM TOOL ATTACHMENT Tilt
ARM TOOL ATTACHMENT Tilt - Service limits (H.30.C - D.20.A.20)

CX135SR
CRIL03G012E03 1
Linkage points
1. Bucket cylinder foot on dipper
CRIL03G021E01 2
(C) (a-b) 0.5 - 3 mm shims
2. Yoke on dipper
CRIL03G022E01 3
(A) 32 mm 29 mm
(B) 254 mm 252 mm
27080 1 14/12/2004
H.30.C / 4
3. Connecting rod on bucket
CRIL03G023E01 4
(A) bucket 255 mm 261 mm
(B) connecting rod 254 mm 252 mm
4. Connecting rod, yoke and bucket cylinder head
CRIL03G024E01 5
(A) yoke 32 mm 29 mm
(D) 92 mm 94 mm
(E) 91 mm 89 mm
(F) play 1 - 2 mm shims
(G) pin diameter 70 mm 69 mm
(G) yoke bushing diameter 70 mm 71.5 mm
(G) bucket cylinder head bushing 70 mm 71.5 mm
diameter
27080 1 14/12/2004
H.30.C / 5
5. Bucket on bucket head
CRIL03G025E01 6
(A) bucket 255 mm 261 mm
(B) bucket head 254 mm 252 mm
(C) (a-b) 1 - 3.5 mm shims
(D) 16 mm 8 mm
(E) pin diameter 65 mm 64 mm
(E) dipper head bushing diameter 65 mm 66.5 mm
(E) bucket bushing diameter 65 mm 66.5 mm
Command valve Hand control valve - Torque (H.30.C.12.10 -

D.20.A.10)
CX135SR
27080 1 14/12/2004
H.30.C / 6
Cylinder - Torque (H.30.C.26 - D.20.A.10)

CX135SR
CRIL03L108G01 1
Description Offset Standard

(1) Screw 171 Nm 171 Nm
(2) Screw 21.4 - 31.2 Nm 21.4 - 31.2 Nm
(3) Screw 25.62 - 37.88 Nm 25.62 - 37.88 Nm
(4) Screw 51.21 - 62.59 Nm 51.21 - 62.59 Nm
(5) Nut 3580 Nm 3660 Nm
(6) Screw 25.62 - 37.38 Nm 25.62 - 37.38 Nm
(7) Screw 41.59 - 60.81 Nm 41.59 - 60.81 Nm
27080 1 14/12/2004
H.30.C / 7
ARM TOOL ATTACHMENT Tilt - Hydraulic schema (H.30.C -

C.20.A.20)
CX135SR
CRIL03I029G01 1
Bucket opening circuit - Dynamic Description
Bucket opening (small cylinder chamber) (28) is supplied by the output from pump (P2).
(28) Bucket cylinder (P2) Pump outlet ow
(Pa7/A7) Bucket closing (Pb7/B7) Bucket opening
27080 1 14/12/2004
H.30.C / 8
CRIL03I030G01 2
Bucket closing circuit - Dynamic Description
Bucket closing (large cylinder chamber) (28) is supplied by the output from pump (P2).
(28) Bucket cylinder (P2) Pump outlet ow
(Pa7/A7) Bucket closing (Pb7/B7) Bucket opening
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H.30.C / 9
Command valve Hand control valve - Sectional view (H.30.C.12.10 -

C.10.A.30)
CX135SR
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H.30.C / 10
Control valve - Sectional view (H.30.C.13 - C.10.A.30)

CX135SR
CRIL03J103E01 1
Bucket section
(9) Spool
(11) Large cap
(12) Seal
(13) Small cap
(16) Valve
(17) Spring
(18) Seal
(19) Plug
(63) Relief valve
(65) Screw
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H.30.C / 11
Cylinder - Sectional view (H.30.C.26 - C.10.A.30)

CX135SR
CRIL03L108G02 1

(7) Washer (8) Screw (9) Washer
(13) Bushing (14) Cushion bushing (15) Seal
(28) Nut (29) Seal (30) Piston
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H.30.C / 12
Command valve Hand control valve - Overhaul (H.30.C.12.10 -

F.10.A.40)
CX135SR
1. Refer to:
(F.40.C.12.10 - F.10.A.10)
Cleaning (F.40.C.12.10 - F.30.A.10)
inspection (F.40.C.12.10 - F.40.A.10)
Assemble (F.40.C.12.10 - F.10.A.20)
(F.40.C.12.10 - F.10.A.15)
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H.30.C / 13
Control valve - Disassemble (H.30.C.13 - F.10.A.25)

CX135SR
CRIL03J103E01 1

Discard seals (12).
Remove spool (9).
replace the spring.
CRIL03L053A01 2

Discard seal (18).
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H.30.C / 14
Control valve - Assemble (H.30.C.13 - F.10.A.20)

CX135SR
CRIL03J103E01 1
Torque settings
Plug (19) 103 - 113 Nm
CRIL03L053A01 2

(12).
torque.
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H.30.C / 15
Relief valve - Overhaul (H.30.C.16 - F.10.A.40)

CX135SR

(H.20.B.16 - F.10.A.20)
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H.30.C / 16
Relief valve - Pressure test (H.30.C.16 - F.40.A.30)

CX135SR
NOTE: The secondary relief valves on the bucket, (F) and (G) are calibrated to a higher pressure than the main
relief valve (A). To check or calibrate the secondary relief valves, main relief valve (A) must be overcalibrated.
the pressure test point .
should be 395 ± 10 bar (39.5 ± 1 MPa)
6. If the pressures are incorrect, calibrate bucket relief
valves (F) and (G), refer to Relief valve - Pressure
setting (H.30.C.16 - F.45.A.70)
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H.30.C / 17
Relief valve - Pressure setting (H.30.C.16 - F.45.A.70)

CX135SR
Prior operation: Relief valve - Pressure test (H.30.C.16 - F.40.A.30)

CRIL03K054A01 1

is reached.
Next operation: Reset main relief valve (A), refer to Relief valve - Pressure setting (A.10.A.16 - F.45.A.70)
27080 1 14/12/2004
H.30.C / 18
Cylinder - Remove (H.30.C.26 - F.10.A.10)

CX135SR

Use all equipment necessary to ensure sufcient
Place a wooden chock under the cylinder.
CRIL03G073A00 1
CRIL03G074A01 2
3. Remove pin (1).
CRIL03G075A01 3
27080 1 14/12/2004
H.30.C / 19
4. Carefully lift the cylinder and attach a sling to retain

the cylinder rod in the cylinder barrel.
Recover shims (1).
CRIL03G076A01 4

Disconnect the supply hoses (1).
Plug ports.
CRIL03G077A01 5
6. Remove screws (1), plate (2) and pin (3).
CRIL03G078A01 6
7. Carefully lift the cylinder and place it on suitable

stands.
Recover shims (1).
CRIL03G079A01 7
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H.30.C / 20
Cylinder - Disassemble (H.30.C.26 - F.10.A.25)

CX135SR
1. Mark the retaining clips on the piping.

Remove the collars from piping if necessary.
barrel.
Discard the seals.
CRPH03J002A 1

CRIL03K193A01 2

Remove cylinder barrel (2) from the repair bench.
CRIL03K194A01 3
27080 1 14/12/2004
H.30.C / 21

Remove screw (1) and ball (2).
CRIL03K195A01 4
6. Unscrew the piston xing nut.

NOTE: Unscrewing the nut requires a torque about 1,5
times greater than the tightening torque.
CRPH03J005A 5
7. Remove the xing nut from piston (4) and washer

(3).
Remove piston (2) and cushion bushing (1).
CRIL03L079A01 6
8. Discard carrier seals (1), seals (2), (3), (4) and

back-up rings (5).
CRIL03K197A01 7
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H.30.C / 22

seals (6) and (7), back-up ring and seal (8), (9).
CRIL03K198A01 8

CRIL03J023A01 9
11. Place the boom cylinder head in a press.

head bushing.
CRPH03J006A 10
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Cylinder - Assemble (H.30.C.26 - F.10.A.20)

CX135SR

CRPH03J006A 1

CRIL03J023A01 2

(9).
Fit seal (3).
Mount gland (1) on cylinder rod (2).
CRIL03K198A01 3
27080 1 14/12/2004
H.30.C / 24

piston.
CRIL03K197A01 4
5. Install cushion bushing (1), piston (2) and washer

(3) on the cylinder rod.
CRIL03L079A01 5
6. Place the piston xing nut in position on the cylinder

rod.
Tighten the nut to the required torque.
CRPH03J005A 6

required torque.
CRIL03L032A01 7
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H.30.C / 25

using a punch.
CRIL03J02601A 8

CRIL03K194A01 9

CRIL03L033A01 10

cylinder barrel.
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H.30.C / 26
Cylinder - Install (H.30.C.26 - F.10.A.15)

CX135SR

cylinder barrel.
CRIL03G061A00 1

Align the cylinder foot with the dipper mounting
brackets.
Fit shims (1).
CRIL03G079A01 2
3. Install pin (3).

Check clearance between the cylinder foot
and the mounting bracket, refer to ARM TOOL
ATTACHMENT Tilt - Service limits (H.30.C -
D.20.A.20).
replace the pin.
Install pin (4).
Fit screw (3) and rst nut (1) and tighten until the
nut touches the shoulder.
Fit the second nut to keep the rst in position. CRIL03G078A01 3

Remove the plugs.
Connect hoses (1).
CRIL03G077A01 4
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H.30.C / 27
5. Align the cylinder rod with the yoke/connecting rod

assembly.
Fit the shims.
CRIL03G080A00 5
6. Install pin (3).

Check the clearance between the cylinder head and
the yoke/connecting rod assembly, refer to ARM
TOOL ATTACHMENT Tilt - Service limits (H.30.C
- D.20.A.20).
If necessary remove pin (3) and add or remove
replace the pin.
Fit screw (2) and rst nut (1) and tighten until the
nut touches the shoulder.
CRIL03G081A01 6

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H.30.C / 28
Arm - Remove (H.30.C.50 - F.10.A.10)

CX135SR
CRIL03L143G01 1
(1) Pin (2) Retaining pin
(3) Pin (4) Snap ring
(5) Seal (6) Yoke
(7) Connecting rod (8) Grease tting
(9) Nut (10) Screw
(11) Pin (12) Shim
(13) Seal (14) Pin
(15) Bushing
1. Place the bucket at on at, level ground.
Operate the attachment controls so that pin (1) is
not under stress from the dipper load.
2. Remove snap rings (4) and retaining pins (2).
3. Remove pins (1) and (3).
27080 1 14/12/2004
H.30.C / 29

Disengage the bucket dipper.
6. Attach a suitable lifting device to yoke (6).
To disconnect the bucket cylinder rod from the
yoke and the connecting rods, refer to Cylinder -
Remove (H.30.C.26 - F.10.A.10).
9. Remove shaft (11) and connecting rods (7).
10. Recover shims (12).
11. To remove bushings (15), only if they need
replacing, refer to ARM TOOL ATTACHMENT Tilt -
Service limits (H.30.C - D.20.A.20).
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H.30.C / 30
Arm - Install (H.30.C.50 - F.10.A.15)

CX135SR
CRIL03L143G01 1
(1) Pin (2) Retaining pin
(3) Pin (4) Snap ring
(5) Seal (6) Yoke
(7) Connecting rod (8) Grease tting
(9) Nut (10) Screw
(11) Pin (12) Shim
(13) Seal (14) Pin
(15) Bushing
1. Install bushings (15) in yoke (6).
2. Install pin (11), connecting rods (7), shims (12) and
screws (10).
27080 1 14/12/2004
H.30.C / 31
3. To check for play between the dipper and

the connecting rods, refer to ARM TOOL
ATTACHMENT Tilt - Service limits (H.30.C -
D.20.A.20).
If necessary, remove the pin and add or remove
shims as required to obtain the correct play, reinstall
the pin and the screw.
6. Install the bucket cylinder rod on the connecting
rod/yoke assembly, refer to Cylinder - Install
(H.30.C.26 - F.10.A.15).
Align the dipper’s orices with the ports on the
bucket.
Install pin (1), cotter pin (2) and snap ring (4).
9. Align the orices on the yoke with the ports on the
bucket.
Install pin (3), cotter pin (2) and snap ring (4).
10. To check for play between the yoke and the bucket,
refer to ARM TOOL ATTACHMENT Tilt - Service
limits (H.30.C - D.20.A.20).
If necessary, remove the pin and add or remove
the pin.
27080 1 14/12/2004
H.30.C / 32
Index
WORKING ARM - H

Arm - Install (H.30.C.50 - F.10.A.15) 31
CX135SR
Arm - Remove (H.30.C.50 - F.10.A.10) 29
CX135SR
ARM TOOL ATTACHMENT Tilt - Hydraulic schema (H.30.C - C.20.A.20) 8
CX135SR
ARM TOOL ATTACHMENT Tilt - Service limits (H.30.C - D.20.A.20) 4
CX135SR
Command valve Hand control valve - Overhaul (H.30.C.12.10 - F.10.A.40) 13
CX135SR
Command valve Hand control valve - Sectional view (H.30.C.12.10 - C.10.A.30) 10
CX135SR
Command valve Hand control valve - Torque (H.30.C.12.10 - D.20.A.10) 6
CX135SR
Control valve - Assemble (H.30.C.13 - F.10.A.20) 15
CX135SR
Control valve - Disassemble (H.30.C.13 - F.10.A.25) 14
CX135SR
Control valve - Sectional view (H.30.C.13 - C.10.A.30) 11
CX135SR
Cylinder - Assemble (H.30.C.26 - F.10.A.20) 24
CX135SR
Cylinder - Disassemble (H.30.C.26 - F.10.A.25) 21
CX135SR
Cylinder - Install (H.30.C.26 - F.10.A.15) 27
CX135SR
Cylinder - Remove (H.30.C.26 - F.10.A.10) 19
CX135SR
Cylinder - Sectional view (H.30.C.26 - C.10.A.30) 12
CX135SR
Cylinder - Torque (H.30.C.26 - D.20.A.10) 7
CX135SR
Relief valve - Overhaul (H.30.C.16 - F.10.A.40) 16
CX135SR
Relief valve - Pressure setting (H.30.C.16 - F.45.A.70) 18
CX135SR
Relief valve - Pressure test (H.30.C.16 - F.40.A.30) 17
CX135SR
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H.30.C / 33
SERVICE
PRINTED IN FRANCE
27076 1 14/12/2004
REPAIR MANUAL
TOOLS AND COUPLERS
CX135SR
27081 1 14/12/2004
J
Contents
TOOLS AND COUPLERS - J
DIGGING Hammer J.20.E

CX135SR
LANDSCAPING Dozer blade J.40.F

CX135SR
27081 1 14/12/2004
J
DIGGING Hammer - 20.E
CX135SR
27082 1 14/12/2004
J.20.E / 1
Contents
FUNCTIONAL DATA
DIGGING Hammer - Hydraulic schema (J.20.E - C.20.A.20) 3
CX135SR
Control valve
Control valve - Sectional view (J.20.E.14 - C.10.A.30) 6
CX135SR
SERVICE
Command valve
Command valve Foot command valve - Overhaul (J.20.E.12.10 - F.10.A.40) 7
CX135SR
Control valve
Control valve - Disassemble (J.20.E.14 - F.10.A.25) 8
CX135SR
Control valve - Assemble (J.20.E.14 - F.10.A.20) 9

CX135SR
27082 1 14/12/2004
J.20.E / 2
TOOLS AND COUPLERS - DIGGING Hammer
DIGGING Hammer - Hydraulic schema (J.20.E - C.20.A.20)

CX135SR
CRIL03J154G01 1
Hammer circuit - dynamic description
(72) Control pedal (76) 3-way selector
(P1) Flow at outlet A2 (Pa2/A2) Option circuit
(Pb2/B2) Option circuit (Y9) Dual ow hammer/grab option solenoid valve .
HAMMER
• 3-way selector (76) must be positioned for the hammer function.
The hammer is supplied by the ow from pump (P1).
• When hammer/grab switch (S14) is in the hammer position and control pedal (72) is moved towards the front
of the machine, the option spool is piloted by port (Pb2) which allows the hammer to be supplied via port (B2).
• As soon as the hammer return pressure is higher than the regulating pressure for the safety valve for the
3-way selector (76), the oil returns to the reservoir via this same safety valve.
27082 1 14/12/2004
J.20.E / 3
CRIL03J153G01 2
Grab circuit - dynamic description
(61) Flow reinjection spool (72) Control pedal
(75) Flow reinjection valve (76) 3-way selector
(79) Control shuttle block (P1) Flow at pump outlet A2
(P2) Flow at pump outlet A1 (Pa2/A2) Option circuit
(Pb2/B2) Option circuit (S14) Hammer/grab switch
(Y9) Dual output hammer/grab option solenoid
valve .
SHEARS
• 3-way selector (76) must be positioned for the grab function.
• The grab can be supplied by the outputs from pumps (P1) and (P2).
• The output from pump (P1) directly supplies the option spool. The output from pump (P2) is forced towards the
ow reinjection valve (75) and joins the output from pump (P1) at the option spool inlet.
• When hammer/grab switch (S14) is in the grab position, the hammer/grab dual output solenoid valve option
(Y9) is activated.
• When control pedal (72) is moved forwards or backwards, the pilot pressure, after passing through control
shuttle block (79) and hammer/grab dual ow option solenoid valve (Y9), unlocks ow reinjection valve (75)
27082 1 14/12/2004
J.20.E / 4
and pilots ow reinjection valve spool (61). This closes the free passage of the ow reinjection spool (61) and
allows the ow from pump (P2) to be reinjected into ow reinjection valve (75) via port (P3).
• The pilot pressure from hammer/grab dual ow option solenoid valve (Y9) reaches port (P) of the ow
reinjection valve (75) and activates the unlocking spool on the load holding check valve of ow reinjection
valve (75). The oil reaching port (B), therefore, is reinjected via port (A) on ow reinjection valve (75) towards
port (P4) on main control valve (15) to join pump ow (P1) at the option spool inlet.
• When the dipper out control is operated at the same time as the grab, the ow from pump (P1) supplies the
grab and the ow from pump (P2) supplies the dipper.
27082 1 14/12/2004
J.20.E / 5
Control valve - Sectional view (J.20.E.14 - C.10.A.30)

CX135SR
CRIL03J078E01 1
Section E-E _ Hydraulic breaker or shears (high ow option)
(3) Spool (11) Large cap

(13) Small cap (18) Seal
(25) Spring (64) Secondary relief valve plug
(81) Plug (88) Seal
(89) Plug (90) Plug assembly
27082 1 14/12/2004
J.20.E / 6
Command valve Foot command valve - Overhaul (J.20.E.12.10 -

F.10.A.40)
CX135SR
NOTE: This control pedal is identical to the one operating the dozer blade.
Refer to the following locations to service this component.
1. Command valve Foot command valve - Special
tools (F.10.F.12.10 - D.20.A.40)
2. Command valve Foot command valve - General
specication (J.40.F.12.10 - D.40.A.10)
3. Command valve Foot command valve - Remove
(H.20.D.12.10 - F.10.A.10)
4. Command valve Foot command valve -
Disassemble (J.40.F.12.10 - F.10.A.25)
5. Command valve Foot command valve - Visual
inspection (F.10.F.12.10 - F.40.A.10)
Assemble (J.40.F.12.10 - F.10.A.20)
7. Command valve Foot command valve - Install
(H.20.D.12.10 - F.20.A.20)
Troubleshooting (F.10.F.12.10 - G.40.A.10)
27082 1 14/12/2004
J.20.E / 7
Control valve - Disassemble (J.20.E.14 - F.10.A.25)

CX135SR
CRIL03J078E01 1
1. Remove plugs (89). Discard seals (88).

Remove caps (11) and (13) and discard seals.
replace the spring.
CRIL03L053A01 2

Discard seal (18).
Discard the seals.
27082 1 14/12/2004
J.20.E / 8
Control valve - Assemble (J.20.E.14 - F.10.A.20)

CX135SR
CRIL03J078E01 1

Fixing screws for caps (11) and (13) 20 - 25 Nm
Plug (23) 103 - 113 Nm
Secondary relief valve plug (64) 78 - 88 Nm
Plug (81) 89 - 97 Nm
Plug (89) 19 - 22 Nm
Plug (90) 205 - 227 Nm
Install plugs (23) and (81) complete with new seals
(18) and tighten to the required torque.
and tighten to the required torque.
3. Install plugs (20) complete with new seals to the
required torque.
4. Coat the threaded part of spool (3) with locking uid.
Clamp end (A) of the spool in a soft-jawed vice.
CRIL03L053A01 2

Install and tighten to the require torque plugs (89)
complete with new seals
27082 1 14/12/2004
J.20.E / 9
Index

Command valve Foot command valve - Overhaul (J.20.E.12.10 - F.10.A.40) 7
CX135SR
Control valve - Assemble (J.20.E.14 - F.10.A.20) 9
CX135SR
Control valve - Disassemble (J.20.E.14 - F.10.A.25) 8
CX135SR
Control valve - Sectional view (J.20.E.14 - C.10.A.30) 6
CX135SR
DIGGING Hammer - Hydraulic schema (J.20.E - C.20.A.20) 3
CX135SR
27082 1 14/12/2004
J.20.E / 10
LANDSCAPING Dozer blade - 40.F
CX135SR
27083 1 14/12/2004
J.40.F / 1
Contents
TECHNICAL DATA
LANDSCAPING Dozer blade - Service limits (J.40.F - D.20.A.20) 4
CX135SR
Command valve
Command valve Foot command valve - Special tools (J.40.F.12.10 - D.20.A.40) 5
CX135SR
Command valve Foot command valve - General specication (J.40.F.12.10 - D.40.A.10) 5

CX135SR
Cylinder
Cylinder - Torque (J.40.F.26 - D.20.A.10) 6
CX135SR
FUNCTIONAL DATA
LANDSCAPING Dozer blade - Hydraulic schema (J.40.F - C.20.A.20) 7
CX135SR
Control valve
Control valve - Sectional view (J.40.F.14 - C.10.A.30) 8
CX135SR
Cylinder
Cylinder - Sectional view (J.40.F.26 - C.10.A.30) 9
CX135SR
SERVICE
Command valve
Command valve Foot command valve - Remove (J.40.F.12.10 - F.10.A.10) 10
CX135SR
Command valve Foot command valve - Disassemble (J.40.F.12.10 - F.10.A.25) 11

CX135SR
Command valve Foot command valve - Visual inspection (J.40.F.12.10 - F.40.A.10) 13

CX135SR
Command valve Foot command valve - Assemble (J.40.F.12.10 - F.10.A.20) 14

CX135SR
Command valve Foot command valve - Install (J.40.F.12.10 - F.10.A.15) 15

CX135SR
Control valve
Control valve - Disassemble (J.40.F.14 - F.10.A.25) 16
CX135SR
Control valve - Assemble (J.40.F.14 - F.10.A.20) 17

CX135SR
Relief valve
Relief valve - Overhaul (J.40.F.16 - F.10.A.40) 19
CX135SR
27083 1 14/12/2004
J.40.F / 2
Relief valve - Pressure test (J.40.F.16 - F.40.A.30) 20
CX135SR
Relief valve - Pressure setting (J.40.F.16 - F.45.A.70) 21

CX135SR
Cylinder
Cylinder - Remove (J.40.F.26 - F.10.A.10) 22
CX135SR
Cylinder - Disassemble (J.40.F.26 - F.10.A.25) 24

CX135SR
Cylinder - Assemble (J.40.F.26 - F.10.A.20) 27

CX135SR
Cylinder - Install (J.40.F.26 - F.10.A.15) 30

CX135SR
DIAGNOSTIC
Command valve
Command valve Foot command valve - Troubleshooting (J.40.F.12.10 - G.40.A.10) 31
CX135SR
27083 1 14/12/2004
J.40.F / 3
TOOLS AND COUPLERS - LANDSCAPING Dozer blade
LANDSCAPING Dozer blade - Service limits (J.40.F - D.20.A.20)

CX135SR
CRIL03G036F01 1
Linkage points
1. Foot of dozer blade cylinder on dozer blade
CRIL03G037E01 2
(A) 76 mm 82 mm
(B) 75 mm 73 mm
(C) (a-b) 1 - 2.5 mm shims
(E) bushing diameter 55 mm 56,5 mm
27083 1 14/12/2004
J.40.F / 4
2. Dozer blade cylinder head on undercarriage
CRIL03G038E01 3
(A) 79 mm 85 mm
(B) 75 mm 73 mm
(C) 3 - 4.5 mm shims
(E) bushing diameter 55 mm 56,5 mm
3. Dozer blade on chassis
CRIL03G039E01 4
(A) 79 mm 85 mm
(B) 75 mm 73 mm
(C) play 3 - 6 mm shims
Command valve Foot command valve - Special tools (J.40.F.12.10 -

D.20.A.40)
CX135SR
NOTE: Refer to Command valve Foot command valve - Special tools (F.10.F.12.10 - D.20.A.40)
Command valve Foot command valve - General specication

(J.40.F.12.10 - D.40.A.10)
CX135SR
Working pressure 69 bar

Secondary pressure (Max. control pressure) 0 barto 29 bar
Authorised return pressure 2,9 bar
27083 1 14/12/2004
J.40.F / 5
Rated ow 10 L/min

Operating angle ±10 °, ± 12,4 °, ± 15 °
Cylinder - Torque (J.40.F.26 - D.20.A.10)

CX135SR
CRIL03L115G01 1
(1) Screw 16,3 - 18,1 Nm (2) Screw 31,2 - 21,4 Nm

(3) Gland 834 Nm (4) Nut (M 52) 2100 Nm
(5) Screw 46,2 - 67,6 Nm
27083 1 14/12/2004
J.40.F / 6
LANDSCAPING Dozer blade - Hydraulic schema (J.40.F - C.20.A.20)

CX135SR
CRIL03J155G01 1
Dozer blade circuit - dynamic description
Dozer blade cylinder (2) is supplied by the ow from pump (Pr).
When the dozer blade control lever (1) is activated, the corresponding spool is piloted by port (pra1) or (prb1), which allows the
dozer blade cylinder to be supplied via port (AR1) or (BR1).
(1) Dozer blade control lever
(2) Dozer blade cylinder
(Pr) Flow at pump outlet A4
(Pra1/AR1) Dozer blade raising
(Prb1/BR1) Dozer blade lowering
27083 1 14/12/2004
J.40.F / 7
Control valve - Sectional view (J.40.F.14 - C.10.A.30)

CX135SR
CRIL03J105F02a 1

(18) Seal (24) Valve
(25) Spring (63) Relief valve
(81) Plug assembly (84) Dozer blade spool assembly
27083 1 14/12/2004
J.40.F / 8
Cylinder - Sectional view (J.40.F.26 - C.10.A.30)

CX135SR
CRIL03L115G02 1
Description
(1) Screw (2) Clamp
(3) Pipe (4) Screw
(5) Seal (6) Seal
(9) Cylinder rod (10) Barrel
(11) Seal (12) Gland
(13) Seal (14) Seal
(15) Bushing (16) seal
(19) Ball (20) Piston
(21) Seal (22) Seal
27083 1 14/12/2004
J.40.F / 9
Command valve Foot command valve - Remove (J.40.F.12.10 -

F.10.A.10)
CX135SR
1. Attach identication labels to all the control pedal

hoses.
Plug the ports.
2. Remove screws (1), then remove foot control pedal
(2).
CRIL03L132A01 1
27083 1 14/12/2004
J.40.F / 10
Command valve Foot command valve - Disassemble (J.40.F.12.10 -

F.10.A.25)
CX135SR
or dropped.
The control pedal components may rust due to contamination and humidity if they are left
without protection after disassembly.If work has to be interrupted, the components must be protected from
contamination or corrosion.
NOTE: Mark the position and bore of all parts.
CRIL03L116G01 1
Cross-sectional view
1. Tighten the control pedal in a vice with soft jaws.
Remove bellows (16).

2. Remove locking screw (18) from cam pin (21).
3. Remove cam pin (21) using a drift.
27083 1 14/12/2004
J.40.F / 11
4. Remove cam (20) complete with steel balls (17).

NOTE: Do not remove steel balls (17).
5. To remove bushings (19) from cam (20), refer to
Command valve Foot command valve - Special
tools (J.40.F.12.10 - D.20.A.40)
6. Remove xing screws (13) from cover (11).
7. Remove cover (11) from body (1).
8. Remove push rod guides (12) complete with seals
(10) and (14) push rod (15).
9. Remove push rod (15) from guide (12).
10. Remove seals (14) and (10) from guide (12).
11. Remove the spool assembly (2).
12. Remove return spring (8).
13. Compress the spool return spring with the seat so
as to be able to push it out.
NOTE: Be careful not to damage the spool surface.
Do not compress the spring by more than 4 mm.
14. Remove spool (2), spring seat (9), calibrated spring
(7), shim (6) and washer (5).
16. Discard seal (3)
27083 1 14/12/2004
J.40.F / 12
Command valve Foot command valve - Visual inspection

(J.40.F.12.10 - F.40.A.10)
CX135SR
1. Check for cracks, distortion or blocking of the

springs.
If defects are found, replace the springs.
defective.
Make sure that the spool slides freely in the foot
control body bore.
If defects are found, replace the foot control
assembly.
3. Check the bores for damage, internal damage
to housings or evidence of any othe foot control
internal wear.
If the foot control is damaged, replace the entire
assembly.
27083 1 14/12/2004
J.40.F / 13
Command valve Foot command valve - Assemble (J.40.F.12.10 -

F.10.A.20)
CX135SR
CRIL03L116G02 1
Torque settings
Plug (4) 25.4 - 33.4 Nm
Fixing screws (13) on cover (11) 27.4 - 31.11 Nm
Locking screw (18) on the cam pin (21) 5.9 - 7.9 Nm (to be installed with thread lock uid)
1. The parts are assembled in the reverse order
of disassembly, refer to Command valve Foot
command valve - Disassemble (J.40.F.12.10 -
F.10.A.25)
27083 1 14/12/2004
J.40.F / 14
Command valve Foot command valve - Install (J.40.F.12.10 -

F.10.A.15)
CX135SR
1. Install and x foot control (2) using screws (1).
CRIL03L132A01 1

Connect all hoses to the foot control following the
27083 1 14/12/2004
J.40.F / 15
Control valve - Disassemble (J.40.F.14 - F.10.A.25)

CX135SR
CRIL03J105F03a 1

Discard seals (12).
Remove spool (A).
replace the spring.
CRIL03L053A01 2

Discard seal (18).
27083 1 14/12/2004
J.40.F / 16
Control valve - Assemble (J.40.F.14 - F.10.A.20)

CX135SR
CRIL03J105F03a 1
Torque settings
Fixing screws for spool return spring (A) 9.8 - 11.8 Nm
Plug (81) 89 - 97 Nm
Install spool (A) in its housing.
CRIL03L053A01 2
27083 1 14/12/2004
J.40.F / 17

(12).
torque.
27083 1 14/12/2004
J.40.F / 18
Relief valve - Overhaul (J.40.F.16 - F.10.A.40)

CX135SR

(H.20.B.16 - F.10.A.20)
27083 1 14/12/2004
J.40.F / 19
Relief valve - Pressure test (J.40.F.16 - F.40.A.30)

CX135SR
NOTE: Dozer blade secondary relief valves (T) and (U) are calibrated to a higher pressure than the main relief valve
(S). To check or calibrate the secondary relief valves, main relief valve (S) must be overcalibrated.
1. Overcalibrate main relief valve (S) by tightening the
pressure test point M4.
4. Activate the control for the blade to be checked and
maintain against the stops.
5. The pressure reading on the pressure gauge should
be: 250 ± 10 bar (25 ± 1 MPa)
6. If the pressures are incorrect, calibrate dozer blade
relief valves (T) and (U), refer to Relief valve -
Pressure setting (J.40.F.16 - F.45.A.70)
27083 1 14/12/2004
J.40.F / 20
Relief valve - Pressure setting (J.40.F.16 - F.45.A.70)

CX135SR
Prior operation: Relief valve - Pressure test (J.40.F.16 - F.40.A.30)

CRIL03K054A01 1
2. Activate the control for the blade to be calibrated

and hold up against the stops.
is reached.
27083 1 14/12/2004
J.40.F / 21
Cylinder - Remove (J.40.F.26 - F.10.A.10)

CX135SR

Use the complete set of slings to ensure sufcient
CRIL03G193A00 1

Disconnect hoses (3) and (4).
Plug the ports.
CRIL03L117A01 2

Disconnect hoses (1), (2), (3) and (4).
Plug the ports.
CRIL03L130A01 3
27083 1 14/12/2004
J.40.F / 22
4. Remove screws (1) and plates (2) from the head

of the cylinder foot.
Remove pins (3).
CRIL03L118A01 4
5. Carefully lift the cylinder and place it on suitable

stands.
Recover shims (4).
27083 1 14/12/2004
J.40.F / 23
Cylinder - Disassemble (J.40.F.26 - F.10.A.25)

CX135SR
To use a cylinder bench and bearing wrench for removal operations, refer to Cylinder - Special tools (H.20.B.26 -
D.20.A.40)
1. Remove the lines and connectors from the cylinder

barrel.
Discard the seals.
CRPH03J002A 1
3. Straighten the locking tab on the gland.
CRPH03J003A 2
4. Remove the gland using a gland wrench.

Remove the rod tted with the cylinder barrel.
Remove the cylinder barrel from the repair bench.
ATTENTION: Take care not to scratch the bearing surface

of the cylinder barrel.
CRPH03J004A 3
27083 1 14/12/2004
J.40.F / 24

CRIL03K195A01 4
6. Remove the nut from the piston.

CRPH03J005A 5
7. Discard carrier seals (1) and seals (2) and (3).
CRIL03J019A01 6
8. Remove the bearing from the cylinder rod.

Discard seals (1), (2), (3), (4) and (5).
Place the gland in a press.
Using a suitable driver, remove bushing (7).
CRIL03J022A01 7
27083 1 14/12/2004
J.40.F / 25

CRIL03J023A01 8

head bushing.
CRPH03J006A 9
27083 1 14/12/2004
J.40.F / 26
Cylinder - Assemble (J.40.F.26 - F.10.A.20)

CX135SR
To use a cylinder bench and bearing wrench for assembly operations, refer to Cylinder - Special tools (H.20.B.26 -
D.20.A.40)

CRPH03J006A 1

CRIL03J023A01 2
3. Place the gland in a press.

Using a suitable centring piece, install bushing (7).
Install seals (1), (2), (3), (4) and (5).
Mount the gland on the cylinder rod.
CRIL03J022A01 3
27083 1 14/12/2004
J.40.F / 27
4. Install carrier seals (1) and joints (2) and (3) on the
piston.
CRIL03J019A01 4
5. Place the piston in position on the cylinder rod.

CRPH03J005A 5

required torque
CRIL03J032A01 6

using a punch.
CRIL03J02601A 7
27083 1 14/12/2004
J.40.F / 28
8. Place the cylinder barrel horizontally.

Fit the rod assembly inside the cylinder barrel.
CRPH03J007A 8
9. Tighten the gland to the required torque.
CRPH03J004A 9
10. Bend the locking tab on the bearing.
CRPH03J003A 10

cylinder barrel.
27083 1 14/12/2004
J.40.F / 29
Cylinder - Install (J.40.F.26 - F.10.A.15)

CX135SR

Align the cylinder foot with the dozer blade supports.
Install the shims (4) and pin (3).
To check for play between the cylinder foot and the
assembly support, refer to LANDSCAPING Dozer
blade - Service limits (J.40.F - D.20.A.20).
the pin.
Align the cylinder head with the chassis mounting
supports.
Install pin (3).
To check for play between the cylinder head and the CRIL03L118A01 1
assembly support, refer to LANDSCAPING Dozer
blade - Service limits (J.40.F - D.20.A.20).
replace the pin.
Remove the plugs.
Connect hoses (3) and (4).
CRIL03L117A01 2

Connect hoses (1), (2), (3) and (4).
CRIL03L130A01 3

27083 1 14/12/2004
J.40.F / 30
Command valve Foot command valve - Troubleshooting

(J.40.F.12.10 - G.40.A.10)
CX135SR
NOTE: The table below shows a list of common problems. This list is not exhaustive.
External oil leaks O-ring bearing surfaces scratched Repair or replace the parts
Defective seals Replace the seals
The secondary pressure Worn or broken spool return spring Replace the spring
does not increase
gradually or is out of
tolerance.
Dirt on the spool. Disassemble, clean and repair. Replace
The lever does not move Dirt in the piston Disassemble, clean and repair. Replace
freely or does not return the assembly if necessary
to the neutral position
Dirt in the pushrod Disassemble, clean and repair. Replace
Dirt on the pivot pin and cam Disassemble, clean and repair. Replace
Worn or broken piston return spring Replace the spring
Damping force too weak Broken damper pin Replace the pin.
Dirt in the piston Disassemble, clean and repair. Replace
Damping force too strong Piston restrictor port blocked Disassemble, clean and repair. Replace
27083 1 14/12/2004
J.40.F / 31
Index

Command valve Foot command valve - Assemble (J.40.F.12.10 - F.10.A.20) 14
CX135SR
Command valve Foot command valve - Disassemble (J.40.F.12.10 - F.10.A.25) 11
CX135SR
Command valve Foot command valve - General specication (J.40.F.12.10 - D.40.A.10) 5
CX135SR
Command valve Foot command valve - Install (J.40.F.12.10 - F.10.A.15) 15
CX135SR
Command valve Foot command valve - Remove (J.40.F.12.10 - F.10.A.10) 10
CX135SR
Command valve Foot command valve - Special tools (J.40.F.12.10 - D.20.A.40) 5
CX135SR
Command valve Foot command valve - Troubleshooting (J.40.F.12.10 - G.40.A.10) 31
CX135SR
Command valve Foot command valve - Visual inspection (J.40.F.12.10 - F.40.A.10) 13
CX135SR
Control valve - Assemble (J.40.F.14 - F.10.A.20) 17
CX135SR
Control valve - Disassemble (J.40.F.14 - F.10.A.25) 16
CX135SR
Control valve - Sectional view (J.40.F.14 - C.10.A.30) 8
CX135SR
Cylinder - Assemble (J.40.F.26 - F.10.A.20) 27
CX135SR
Cylinder - Disassemble (J.40.F.26 - F.10.A.25) 24
CX135SR
Cylinder - Install (J.40.F.26 - F.10.A.15) 30
CX135SR
Cylinder - Remove (J.40.F.26 - F.10.A.10) 22
CX135SR
Cylinder - Sectional view (J.40.F.26 - C.10.A.30) 9
CX135SR
Cylinder - Torque (J.40.F.26 - D.20.A.10) 6
CX135SR
LANDSCAPING Dozer blade - Hydraulic schema (J.40.F - C.20.A.20) 7
CX135SR
LANDSCAPING Dozer blade - Service limits (J.40.F - D.20.A.20) 4
CX135SR
Relief valve - Overhaul (J.40.F.16 - F.10.A.40) 19
CX135SR
Relief valve - Pressure setting (J.40.F.16 - F.45.A.70) 21
CX135SR
Relief valve - Pressure test (J.40.F.16 - F.40.A.30) 20
CX135SR
27083 1 14/12/2004
J.40.F / 32
27083 1 14/12/2004
J.40.F / 33
SERVICE
PRINTED IN FRANCE
27081 1 14/12/2004
27081 1 14/12/2004
SERVICE
PRINTED IN FRANCE
9-40641 1 14/12/2004
22 27 D2 P3 P P P3 D2 * 101 28 26 25
* 100 ITEM DESCRIPTION PRESSURE SETTING
*B45 A= MAIN RELIEF (STANDARD) 34.3 MPa / 343 bar / 4977 psi
ITEM
1.
DESCRIPTION
HYDRAULIC RESERVOIR
2. BREATHER
100 B= BOOM RAISING PORT SECONDARY RELIEF 37.8 MPa / 378 bar / 5729 psi
G * 29 * 29
4.
5.
BY-PASS VALVE
SCREEN FILTER
30 *
B1/B2 = RELIEF ON BOOM HBCV 37.3 MPa / 373 bar / 5410 psi
6. RETURN FILTER
C= BOOM LOWERING PORT SECONDARY RELIEF 37.8 MPa / 378 bar / 5482 psi
100 10. MAIN HYDRAULIC PUMP
P P D= DIPPER OUT PORT SECONDARY RELIEF 37.8 MPa / 378 bar / 5482 psi 15. MAIN CONTROL VALVE
16. HYDRAULIC SWIVEL
D1 = RELIEF ON DIPPER HBCV 36.3 MPa / 363 bar / 5265 psi 21. TRAVEL MOTOR
B B E= DIPPER IN PORT SECONDARY RELIEF 37.8 MPa / 378 bar / 5482 psi
22. SWING MOTOR
P2 P3 P3 P2 23. TRAVEL MOTOR BRAKE
RED
RED
L1 K1 A A
K2 L2 F= BUCKET OPEN PORT SECONDARY RELIEF 37.8 MPa / 378 bar / 5482 psi 25.
26.
RIGHT BOOM CYLINDER
LEFT BOOM CYLINDER
G= BUCKET CLOSE PORT SECONDARY RELIEF 37.8 MPa / 378 bar / 5482 psi
Dr 27. DIPPER CYLINDER
T2 H= PILOT PRESSURE RELIEF 3.9 MPa / 39 bar / 566 psi 28. BUCKET CYLINDER
29. BOOM SAFETY VALVE
I= RIGHT-HAND SWING PORT SECONDARY RELIEF 28.5 MPa / 285 bar / 4133 psi
30. DIPPER SAFETY VALVE
J I Pi Pi J= LEFT-HAND SWING PORT SECONDARY RELIEF 28.5 MPa / 285 bar / 4133 psi 31. DIPPER LOAD HOLDING VALVE
PA PB Pi 32. BOOM LOAD HOLDING VALVE
K1/K2 = TRAVEL REVERSE PORT SECONDARY RELIEF 34.8 MPa / 348 bar / 5047 psi 41. FILTER (ULTRA-CLEAN)
L1/L2 = TRAVEL FORWARD PORT SECONDARY RELIEF 34.8 MPa / 348 bar / 5047 psi 42. OIL COOLER
43. RETURN MANIFOLD
N1/N2 = NEGATIVE CONTROL RELIEF 2.7 MPa / 27 bar / 392 psi 44. OIL COOLER BY-PASS VALVE
T1 P1 D1 P2 P2 D1
C P1 T T P1 O= OFFSET BACKHOE SECONDARY RELIEF VALVE, RIGHT-HAND 23.5 MPa / 235 bar / 3408 psi
51. ACCUMULATOR
53. BOOM & BUCKET CONTROL LEVER
A 83 83 P G P= OFFSET BACKHOE SECONDARY RELIEF VALVE, LEFT-HAND 23.5 MPa / 235 bar / 3408 psi 54. SWING & DIPPER CONTROL LEVER
B
D1 23 21 21 23 3 2 55. TRAVEL CONTROL PEDAL
15 83
S= DOZER BLADE + OFFSET BACKHOE MAIN RELIEF 20.6 MPa / 206 bar / 2988 psi
56. DIPPER CONTROL SHOCK ABSORBER
pb5 1
16
15
Pa8 B2 43
B1 * 98
16
E
16
F
T=
U=
DOZER BLADE LOWERING SECONDARY RELIEF
DOZER BLADE RAISING SECONDARY RELIEF

23.5 MPa / 235 bar / 3408 psi
23.5 MPa / 235 bar / 3408 psi

57.
60.
72.
BOOM & DIPPER CONTROL SHOCK ABSORBER
PILOT SYSTEM MANIFOLD
CONTROL PEDAL (OPTIONAL)
B
D C W1/W2 = CRUSHER OPTION SECONDARY RELIEF VALVE 37.8 MPa / 378 bar / 5482 psi 75. FLOW RE-INJECTION BLOCK (OPTIONAL)
T P F E A 76. 3-WAY SELECTOR (OPTIONAL)
51 = ACCUMULATOR PRECHARGE 1.5 MPa / 15 bar / 218 psi 78. RETURN FILTER (OPTIONAL)
79. CONTROL SHUTTLE BLOCK (OPTIONAL)
RH FORWARD LH REVERSE OFFSET BACKHOE 81. SWING SHUTTLE BLOCK
RH REVERSE 82. PILOT CIRCUIT FILTER
LH FORWARD LEGEND 83. SHUT-OFF VALVE (OPTIONAL)
85. HAND/FOOT CONTROL PILOT FILTER
P1 PUMP
86. PILOT FILTER BY-PASS VALVE
93. PILOT CIRCUIT SUPPLY MANIFOLD
B A RIGHT TR4 94. PILOT CIRCUIT RETURN MANIFOLD
P2 PUMP
LEFT 95. BOOM/DIPPER PILOT CIRCUIT MANIFOLD
O BR2
96. SWING PILOT CIRCUIT CUSHION VALVE
PILOT SYSTEM PUMP 97. HYDRAULIC BREAKER FOOT CONTROL
98. OFFSET BACKHOE FOOT CONTROL
AR2 99. DOZER BLADE HAND CONTROL
RETURN TO RESERVOIR 100. DOZER BLADE CYLINDER
Prb2 1 T 2
P Pra2
101.
102.
OFFSET BACKHOE CYLINDER
3 ELECTROVALVE BLOCK
LEAK-OFF RETURN B22. SWING PILOT PRESSURE SWITCH
78 OFFSET
T BACKHOE
P 85 B26. UPPER PILOT PRESSURE SWITCH (YELLOW BAND)
U BR1 SUPPLY CIRCUIT

B27.
B45.
TRAVEL PILOT PRESSURE SWITCH
OVERLOAD INDICATOR PRESSURE SWITCH
DOZER BLADE
42 M3.
Y2.
PRESSURE TEST POINT (a3)
PILOT PRESSURE SOLENOID VALVE (BLUE BAND)
41 AR1
* PILOT SYSTEM CIRCUIT
HOSE Y3. SWING BRAKE SOLENOID VALVE (PINK BAND)
T
Prb1 99 Y4.
Y9.
2 STAGE TRAVEL SOLENOID VALVE (RED BAND)
CRUSHER/BREAKER OPTION TWO FLOW SOLENOID VALVE
COMPONENT BOUNDARY
A Pra1 72 55 55 72
10µ
44 DOZER P P
5a4 T
5a4 T
BLADE 97 97
2 Pr
P T
PIPING CONNECTION
15 Tr6
1 T 2
0.02 MPa 0.004 MPa Pcc
PIPING CROSS-OVER
Dr T1 T2
3 psi 0.58 psi
Ps1 Ps2
0.2 bar 0,04 bar
41 COMPONENT ITEM NO.
15 Y9
P 85
S N2 DR A
COMPONENT NUMBER
B A
N1 Pcc
C
15 15 9
Pc1 al1
15 31 RETRACTED Pb5
93 94
43 Pb9
Pc1 DIPPER (2)
4
5a4 4
5a4 CONNECTION ITEM NO.
Pb9 15
0.1 MPa 10µ A5 Pa5
Pa9 OPTIONAL ITEM NO.
150 MESH
14.5 psi
1 bar B5
DIPPER (1) EXTENDED *
RETRACTED
15 Pb5
56
Pb9 Pa5
B Pc2
30
Pi EXTENDED
5 1 4 6 56 15
C 32 A8
6 B2
B8 102
29
WITHOUT DUAL
FLOW OPTION
D E
BOOM (1)
LOWER * 83 T 1
T
81 Pc3 B T A
Pb8 15
S3
Pbu
BOOM (2)
RAISE Pa8 Pa4
C1
51 82 M3 * 78
10µ
Pb4
HYDRAULIC / ELECTRIC
B7
CX135SR EXCAVATOR
15 Pa4 Y4 Y2 P3 15
OPEN A7 10 µ 5 B2
Pb8 BUCKET
B3 P P0 P
A3 RIGHT SWING F
Pb7 53
3 29 0.2 MPa
* 83 15
T Pi C2 29 psi
CLOSED Pa7 4 A2
Pb3 53 2 bar
Pa3 W1 W2 1
P
B6 Y3
SCHEMATIC
LEFT
83 83 76 TRAVEL 0.103 MPa
86
6 5 A B2 A6 15 psi 15
1.03 bar 3 BR2
Pb6 55
83 76 A2 HAMMER (H) G
* 75 A
4 D Pb2
REAR 1
P2 P1
* 83 15
FRONT Pa6
97 79 55 2 AR2
1 97 79 Pa2 ON
2
B1
2 B2 60
B 15 P4
16
P3
1 T
B1
TRAVEL
B A 15 A1 REAR
B2 55
3
Pb1
83 55 Pa1 FRONT
4
C D 15 Ts3
A PH1 PH2
* 78
A2
Ts5 A1 A2
P1 P2
PT PP PA P3 10
* 76 75
a1 a2
T T 1 B27 B26 15 B (FRONT) (REAR)

10µ A
99 99
P T
3 4 3 4
* * 97
2 1 P 2 1 T 72 Pi1 Pi2
96 A
55
93 94 OPTION HAMMER
B 2
RAISE TRAVEL (LEFT) TRAVEL (RIGHT)

C
85 P 54 85 P 53 REVERSE FORWARD FORWARD REVERSE
T D
LOWER
T T M
1 T 2 1 T 2
ISUZU
B
4BG1T H
65,6 Kw
A 1 T R P 85 P 85 à 2100 tr/mn
F Dr A3
DIPPER SWING BOOM BUCKET 98 B1

IN OUT LEFT RIGHT LOWER RAISE OPEN CLOSE 98 T
5a4
P
5a4
3 1 3 1 2S S2 15 98 98 15
H OUT Pb2 P
5a4 T
5a4 Pa2 A4 B3 a3
B22
95 15
3S S3 1 2 4 T 3
A1 S1 A2 P T
2 4 2 4
15 Pa7 G IN
1S S1
B4
85
Pb7
1
81 P
A
85 B 2
98 98 15 15 15 15
D
C
4
3 E P T Pb6 85 Pa6 Pa1 Pb1 * B1 S2 B2 A
79
15 *
Pc3 Y9
57 15 15 15 CX135SR EXCAVATOR
Pb2
5a4 Pa2 Pcc
HYDRAULIC SCHEMATIC
Number 9-43660
F21
5 R 207 5 R 207 1 5 R 207 5 R 207 2 ITEM DESCRIPTION
2 LR 261 2 LR 061 2 2 LR 061 2 LR 061 5 R 204 1 F23
A2. ENGINE CONTROLLER
RW 206 206, 484, 540, 544, 546, 013
CN C1
5 R 100
5 R 204
0.85 GR 312, OW 355 A3. ELECTRONIC ACCELERATION
CN 22
2
013, 418, 419, 430, 431, 436, 439, 451, 455, 514, 540, 544, 546, 820 A7. OVER LOAD WARNING CONTROLLER
1
2
F22
1
484, 506, 830, 890, 899, 900, 902, 903, 930, 980 1
B1. COOLANT TEMPERATURE SENSOR
2
0.85 BrR 544

WR 546
F8 F17 F7 F3 F9 F4 F6 F2 F20 F1 F16 F19 F18 F14 F5 F15 F10 F13 F11 F12 B10. HYDRAULIC OIL TEMPERATURE SENSOR
2
1
15A 10A 20A 10A 30A 10A 10A 10A 15A 15A 15A 10A 15A 10A 10A 15A 10A 20A 10A 10A CN C2
K7 B21. ENGINE OIL PRESSURE SWITCH
RW 203
R 206
CONNECTION
0.85 LR 380
RG 243
LR 250
VW 280
1.25 GrR 330
LgR 305
2 WR 052
0.85 W 323
0.85 YR 278
0.85 GR 310
0.85 OR 379
L 290
0.85 BrR 360
OW 355
BrW 232
0.85 WR 370
R 295
1.25 LW 340
R 222
RY 220
4
OFF ACC B22. SWING PILOT PRESSURE SWITCH
20
HEAT B G1 G2 Acc M ST
5R
ON B26. UPPER PILOT PRESSURE SWITCH (YELLOW BAND)
ST HEAT
R 206 RW 203
OFF B27. TRAVEL PILOT PRESSURE SWITCH
ACC 60 R 200 60 R 201 60 R 001
M8 24V 40A B41. ENGINE RPM SENSOR
60 B 799
M8 5 B 797 M5 E
R3 ON
S16
W 328
0.85 GR 312
0.85 BrR 304
R 279
START M10 M10 M10 M10
LgR 540 G2 B45. OVERLOAD INDICATOR PRESSURE SWITCH
R 225
M4
3
2
1
- + - + WR 546 B81. HORN
M8
0.85 LgR 020

M4
B9. COOLANT TEMPERATURE SENSOR
S1
0.85 B
0.85 Y
0.85 L
1 2 3
4 5 6 12V 12V E2. WORKING LIGHT (ATTACHMENT)
6
2
1
4
5
0.85 W 323
3 2 1 E3. WORKING LIGHT (CAB)
WR 391
LgR 542
GrR 010
RY 220
CN A
1
2
3
G1 M5
1
2
3
4
1 2 3 4 B E4. CAB LIGHT
CN 50 1 5 R 100
1
G 450
BG 603
E52. AIR CONDITIONER
0.85 L 480
0.85 BL 490
0.85 LY 470
CN C0
CN C9
F1. FUSE 20A; ENGINE CONTROLLER
1
B 750
2
F10. FUSE 10A; OVER LOAD WARNING CONTROLLER
SG
60 B 799
0.85 BrR 544
F11. FUSE 10A; BACK-UP
WR 546
602, 606
M8 F12. FUSE 10A; KEY SWITCH
RY 220 2 B 600 0.85 BrR 544 2 L
2 BrR 547 2 B 700 F13. FUSE 20A; HEATER / AIR CONDITIONER
010, 450, 542 0.85 LgR 020 1 R
9 10 11 12 13 14 15 16 17 18
0.85 BrW 549

8
0.85 BrR 543

0.85 BrR 544
1
2
1 WR 548 RW 206 RW 206 F14. FUSE 10A; NOT USED
M8
BrR 030
603, 607 GND
P1
CN 9
7
2
1
LgR 540 LgR 540
F15. FUSE 15A; WORKING LIGHT
R
WR 391
6
WR 546 3 WR 546
F16. FUSE 15A; CRUSHER/BREAKER OPTION TWO FLOW
5
470, 480, 490 YR 830 4 YR 830
GrR 504
WR 390 0.85 BrR 544 5 0.85 BrR 544 F17. FUSE 10A; DC-DC (24V-12V) CONVERTER
LgR 502
1 1 GrR 013 6 GrR 013
GrR 013 F18. FUSE 15A; WIPER AND WASHER
1
2
1
2
7 0.85 GR 312
3 4
2 2 0.85 GR 312
24V STARTER 1 GrR 010 OR 506
OR 506 8 F19. FUSE 10A; HORN
2 LgR 542
OG 514 9 OG 514
2
3 60 R 001 M10 B F2. FUSE 10A;
CONTROL 24V LgR 540 CN P6 CN P5 0.85 PL 484 10 0.85 PL 484 M
1
POWER 24V 4 0.85 W 324 F20. FUSE 15A; CIGARETTE LIGHTER AND CAB SEAT COMPRESSOR ADJUSTMENT
S51 S15 YW 899 11 YW 899
11 12 13 14 15 16 17 18 19 20
9 10
5 S14 12 0.85 BW 520 2 F21. FUSE BOX

GND (POWER) 6 0.85 BG 605 0.85 WL 930 13 0.85 WL 930 0.85 WL 930
M
M4 M1
E4 1
F22. FUSE 20A; MAIN FUSE FOR F11 AND F12 CIRCUITS
8
GND (HOUR METER) 7 0.85 BG 602 14

0.85 GR 890 0.85 GR 890
7
8 F23. FUSE 65A; MAIN FUSE FOR F1 TO F10 AND F13 TO F20 CIRCUITS
CN M1A
1 VW 902 15 VW 902 24V

BY 971
6
HOUR METER 9 0.85 BrW 549

WG 820 16 WG 820 F3. FUSE 10A; TRAVEL MODE RELAY
CN B4
2 YW 970 GrR 013 S
5
ALTERNATOR 10 0.85 BrR 543
R 770
B 771
1
2
3 BL 973 OW 355 17 OW 355
0.85 Y 419 F4. FUSE 10A; HYDRAULIC FUNCTION CANCELLATION LEVER SWITCH
3 4
FUEL SENSOR 11
1
2
1
2
3
4
LW 972 18
1
4
2
3
WATER TEMP SENSOR 12 1 2 1 2 3 4 BrR 030 R
0.85 YB 418 F5. FUSE 10A; SWING BRAKE RELAY
1
18 17 16 15 14 13 12 11 10 9
5 0.85 B 724 1
1
2
ILLUMINATION POWER 13
2
YR 830
RG 243
VR 900
L 290
0.85 W 323
0.85 LW 914
OR 379
2 3 1 2 F6. FUSE 10A; ROTARY LIGHT
2
6 WR 390 WR 390
14
1
WL 587
7 0.85 LR 836
3
GND ILLUMINATION 15 WL 808 F7. FUSE 20A; FUEL FILLER PUMP
8 0.85 L 835 CN A
4
16 M F8. FUSE 15A; ENGINE STOP MOTOR
CN 4
9 0.85 B 711
BATTERY RELAY 17 WR 546
10 0.85 BrR 304 BrR 304 H2 2 LR 061 M4
F9. FUSE 30A; GLOW PLUG
18 835, 836, 892
11 0.85 GR 892
5
243, 900 G1. BATTERY
19 12 0.85 B 742 0.85 B 742
6
20 830, 290 WG 820 G2. ALTERNATOR
13
R1
7
14 OW 355 H3. OVER LOAD WARNING AUDIBLE ALARM
8
M3
312, 506, 514

K1. RELAY-ENGINE EMERGENCY STOP
W1
R 766
B 767
K18. RELAY-TRAVEL MODE
CN D7
1
K19. RELAY-SWING BRAKE
2
K2 K18 K19 K4
1
2
BG 640 K2. RELAY-GLOW PLUG
0.85 GR 890 1 0.85 GR 890 1 1
24V
LgY 436 B21 K20. RELAY-WIPER MOTOR
970, 971, 972, 973

0.85 B 740 2 0.85 B 740 2 2
24V 70W
WG 513 K21. RELAY-WASHER PUMP MOTOR
55W
OVER HEAT SW (WATER,OIL) WR 1 WL 439 K22. RELAY-AIR CONDITIONER MAGNET CLUTCH
CN A5
OIL PRESSURE SWITCH VW 2 LgY 436
E2
1
3
K23. RELAY-LOW BLOWER
SWING PRESSURE SWITCH VR BrY 451
E3
2
1 2 1 4 2 1 4 2 1 4 2 1 4 2
4 K24. RELAY-MEDIUM BLOWER
1
2
2
5 5 5 5
0.85 BP 494 1 t C
5
2
2
4
4
TRAVEL SW
3
1
3
1
3
1
3
1
BW 5 YG 431 3 3 3 3
B1 K25. RELAY-HIGHT BLOWER
BG 607
BG 606
BG 603
BG 602
UPPER SW 0.85 BrR 6 LG 430 0.85 BW 520 0.85 PL 484 2
2 WR 052
1.25 WR 051
OR 506
2 LR 061
LgR 306
LgR 305
Lg 805
YW 899
BrW 232
BrW 233
VW 809
VW 902
0.85 WR 370
0.85 WR 371
WL 808
0.85 GR 890
K4. RELAY-WORKING LIGHT
9 10 11 12 13 14 15 16
8
FUEL EMPTY THERMISTOR LW 7 L 455 0.85 B 740

2 B 600
7
BL 8 K5. RELAY-ROTARY LIGHT

CN M1B
312, 506, 514

222, 391
6
GrR 9
K7. RELAY BATTERY
5
10
CN A7
M1. STARTER MOTOR
3 4
E/G ERROR YR 11 LW 512
1
WR 391
YW 970
LW 972
2 B 600
BY 971
12
BL 973
GLOW LAMP WY OG 514 M2. ENGINE EMERGENCY STOP MOTOR
2
R 222
13 LgR 307 0.85 GR 892

2
ONE TOUCH IDLE SW WV G 450

1 2 3 4 YL 488 1 M3. WIPER MOTOR
1
BrW 14
1
GND (SIGNAL) BG 606

X8 5 6 7 8 9 805, 808, 809, 822, 892 BY 498 2 M4. WASHER MOTOR
2
15
1
2
3
4
5
6
7
8
9
16
052, 232, 305, 370
061, 506, 890, 899, 902, 903 0.85 LW 914 1 Y9
R2 M5. MOTOR (AIR CHANGING)
M6. AIR VENT DIRECTION CONTROL MOTOR
CN A8
B 700 B 700 2
1
M7. MOTOR ACT (AIR-MIX)
2
1
M8. BLOWER MOTOR
0.85 LW 379
2 M14. FUEL FEED PUMP MOTOR

D 487 1
B41 P1. INSTRUMENT PANEL
B 700
CN A W 497 2
K20 K21 K1 K5 P6. AIR CONDITIONER CONTROL PANEL
3 2 1
TRAVEL MODE WR 1 Lg 805
X12 P8. HEATER CONTROL PANEL
1
1
2
WIPER 2
CN 27 R1. GLOW PLUG
VW YL 804
1
5 6
2
CN A2
WASHER 3
2B 700
VR YG 803
0.85 OR 379
R2. FUEL FLOW ADJUSTMENT RESISTOR
2
A3
9 10 11 12
6
4
WORKING LIGHT WV WL 806 VW 902 Y3
7 8
3
1
0.85 TR 278
R3. THROTTLE VOLUME

5
0.85 B 742
SWING BRAKE
CN M2
BW 5 VW 809
4
B 762 2
3 4
TRAVEL ALARM 6 WG 820 1 4 2 1 4 2 1 4 2 1 4 2 R4. THERMISTOR

7 5 5 5 5 1.25 RG 950 1 VB R5. FUEL SENSOR
5
X13 X14
2
4
4
3
1
3
1
3
1
3
1
2
3 3 3 3
8
8 1.25 BrB 951 2 POWER GND

R R7. RESISTOR
1
7
0.85 LR 836
0.85 BrR 361
YL 804
0.85 B 722
0.85 L 835
0.85 BrR 362

0.85 BrR 360
YG 803
0.85 WL 930
0.85 L 910
0.85 LR 381
0.85 BrR 530
0.85 LY 912
0.85 LW 911
LR 250
LR 251
GR 533
GrR 893
YW 899 0.85 GR 954 3 PWM
Y4
1
2
3
1
10 X4 S1. KEY SWITCH
ONE TOUCH IDLE LW 11 GR 511 278, 379
B 761 2 0.85 WL 482 4 RACK 1ST
E
BP 633
P 588
BP 632
0.85 WY 472 5 S13. OVERLOAD SWITCH

0.85 BrY 575
VCC
BG 620
VY 577
12 L 496 6 TACHO SENSOR (SIG) D S14. BREAKER / CRUSHER SWITCH

Y 486 7 TACHO SENSOR (GND)
BG 620
S15. HORN SWITCH
VG 576
YR 830 1 0.85 YG 508 PULL DOWN

B 760 2
Y2 8
S16. ONE TOUCH IDLE
575, 576, 577, 588 4 S51. HYDRAULIC FUNCTION CANCELLATION LEVER SWITCH
9 10
4
0.85 B 722
1
4
S52. AIR CONDITIONING COMPRESSOR CLUTCH SWITCH
CN A3
830, 804, 835, 836
2
5
CN 5
250, 360 330, 380 S6. ROTARY LIGHT SWITCH
3
6
0.85 WL 930 381, 530, 893, 910, 911, 912
6 7
S9. ENGINE EMERGENCY STOP SWITCH
2
1.25 LG 952 1 VB
U1. DC-DC (24V-12V) CONVERTER
5
1
1.25 GrB 953 4 POWER GND
1
5 6
W1. ANTENNA
U1 B 760 2
2
PA
B 761 0.85 BG 955 3 PWM X1. FUEL FILLER PUMP CONNECTOR

7 8
3
0.85 BW 492 5 SIG GND

S13 S9 S6 B 762 X2. ROTARY LIGHT CONNECTOR
4
0.85 YB 418 1 0.85 YB 418 0.85 WG 473 6 VCC

BrY 451 2 BrY 451 B 745 X4. ENGINE TEST POINT CONNECTOR
WL 439 3 WL 439 X8. RADIO CONNETOR
VW 280 6
LgY 436 4 LgY 436
R 279 2 X11. OVER LOAD PRESSURE CHECK CONNECTOR
YG 431 5 YG 431
B 702 5 X12. CIGAR LIGHTER CONNECTOR
E52 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 0.85 YR 281 1
LG 430 6 LG 430 1
1
L 455 L 455
2
3
2
3
2
3
7 2 X13. FAULT DIAGNOSTIS CONNECTOR
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 9 10 11 12 13 14 15 16 17 18 12V 0.85 RW 282 3 1 1 1 0.85 Y 419 8 0.85 Y 419 0.85 LG 507 3 LIMP HOME
0.85 BY 729 4 X14. CLEAR MEMORY CONNECTOR
W 833
L 834
0.85 BrR 501

0.85 B 720
GR 533
B 723
2 3 2 3 2 3 VR 900 9 VR 900 VR 900
7 Y2. PILOT PRESSURE SOLENOID VALVE (BLUE BAND)
CN AC1 CN AC2 0.85 WR 980 10 0.85 WR 980 B 753 B81
80 B 798
1
CN A4
CN A CN A CN A Y3. SWING BRAKE SOLENOID VALVE (PINK BAND)
2
24V. 95 105dB
3
Y4. 2 STAGE TRAVEL SOLENOID VALVE (RED BAND)
CN H1
1
B 753
1
2
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
1
2
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
M10 Y8. AIR CONDITIONER MAGNET CLUTCH
2
0.85 WR 530 Y9. CRUSHER/BREAKER OPTION TWO FLOW SOLENOID VALVE
YR 1409
R 225
GY 1400
YB 1413
R 346
Y 1433
RY 1407
WL 1405
WR 1408
WB 1434
LR 528
OL 529
WG 527
O 1410
B 701
L 1414
L BG 1411
G 1404
L gB 1406
LR 1432
YW 1403
GR 526
LR 1427
RY 1422
WR 1430
RW 1423
GW 1421
LgR 1425
OR 1424
BW 1429
WG 1431
BrR 1426
LW 1420
GR 1428
0.85 BrR 501

WL 449 1
B10
0.85 LR 381
0.85 B 720
BG 643 2
1.25 B 743
BG 643 LEGEND
GrR 893 1 GrR 893
1.25 GrR 330 2 1.25 GrR 330
WL 449
NOT CONNECTED
H3 0.85 LR 380 3 0.85 LR 380 CONNECTED
0.85 L 910 4 0.85 L 910 0.85 YB 418
B 701 W 833 0.85 LW 911 5 0.85 LW 911 M4 B9 M14
1
1 1.25 LW 340 1.25LW 340 24V. 71 83dB R 818 0.85 LY 912 6 0.85 LY 912
2
M8 M 2 1.25 LB 1415 R 225 7 BOOT GROUND CABLE GROUND
0.85 LR 407 0.85 LR 407
1.25 LW 345
8
0.85 WR 417 9 0.85 WR 417
1.25 GrR 330 1 1.25 GrR 330
0.85 BL 427 10 0.85 BL 427 M
1.25 B 743 2 1.25 B 743 SINGLE WIRE CONNECTOR HARNESS
CN A
R 295 11
2
1
B 710 12 M5
L 455 1 24V
13
2
X11 1.25 B 743 14 1.25 B 743 BG 660
R5
0.85 WR 417
0.85 RL 407
0.85 BL 427
0.85 Y 419 3 CONNECTOR (FEMALE)

X1 CONNECTOR (MALE)
G 572
R 295
B 710
Y 573
L 834
1 0.85 LY 905
2 1 W 328 W 328
CN B3
1
1 2 3 4
R7
6
7
3 1.25 LB 904 2 WL 567 WL 567
2
1
2
3
4
5
6
7
8
5 6 7 8
INSULATION AGAINST MAGNETISM
5
8
3
4 0.85 LW 906 3 BrR 1426
GrR 893
B
R
L
RL
WR
BL
G
Y
14 13 12 11 10 9
4
SWP
CN 13
4 BW 1429 B 755 X2 INDICATES CONSTANT POWER
5 WR 1430
9 10 11 12 13 14 15 16 17 18
8
BrY 451 2
6 1
CN A
RY 1422
3
2
4
7
BG 652 1 B22 INDICATES POWER WHEN KEY SWITCH IS ON
6
2
1
3
GW 1421
5
1
8 LW 1420
WB 1434
YW 1403
WL 1405
GY 1400
4 5 6
LY 1432
1 2 3
CN12 (R)
O 1401
G 1404
Y 1433
B 1402
9
A7 K22 K23 K24 K25
M6 1 2 3
10
1 2
M2
4
4 5 6
11 CONNECTOR NUMBER COLOR OF CONNECTOR
3
(IN CAB) (IF NOT INDICATED COLOR IS WHITE)

5
4
6
2
3
1
2
1
3
6
5
4
5 O 1410 CN A 12
2
YG 431 2 0.85 L 910 1 L

CONNECTOR LETTER LOCATED
B27
1
4 YR 1409 13 LgR 1425

BG 651 1 0.85 LW 911 2 LW (OUTSIDE CAB)
6 BG 1411 14 WG 1431 0.85 LR 380 4 LR
M
2 RY 1407 15 RW 1423 1 4 2 1 4 2 1 4 2 1 4 2
0.85 LY 912 5 LY 60 B 001
5 5 5 5
WR 1408 1 2 0.85 B 748 6 B AREA
5
CIRCUIT NUMBER
2
2
4
4
3
1
3
1
3
1
3
1
3 16 OR 1424 3 3 3 3
M 3
1 LgB 1406 17 GR 1428 COLOR
1.25 LW 341
1.25 LW 342
GR 526
0.85 WR 980
0.85 LW 906
1.25 LW 343
WG 527
1.25 B 691
0.85 LW 905
1.25 LW 344
LR 528
1.25 B 692
1.25 LB 904
1.25 LW 345
OL 529
1.25 B 693
18 LR 1427
TABLE OF COLOR SYMBOLS
LG 430 2
M5 M7 BG 650 1 B26 SYMBOL COLOR
CN D6
4
1
B BLACK
5
2
0.85 B 749
0.85 L 913
6
0.85 WR 980
6
3
W WHITE
5
1.25 B 693 1 2
M
P6 P8
4
1.25 LW 345 Br BROWN

3
526, 527, 528, 529, 904, 905, 906
1
2
P PINK
2
1
1 2 VIOLET
1 2 V
2
CN 21
0.85 WR 980
S52 G GREEN
1
2
1.25 W 981 1
O ORANGE
1 OB 1412 CN B9
R4 2 YB 1413 R RED
2B 700 2 2B 700 1
CN A0 CN A1 CN 7 CN 8 0.85 BL 427 3 0.85 BL 427 Y YELLOW
2B 600 1 2B 600 1
0.85 RL 407 1 0.85 RL 407 2
B45 Lg LIGHT GREEN
CN A
0.85 WR 417 2 0.85 WR 417 3

CN C8
1
2
1 2 3 4 5 6 7 8 9 10 11 33 34 35 36 37 38 39 40 58 59 60 61 62 63 64 65 66 67 89 90 91 92 93 BW 505
Sb SKY BLUE
12 13 14 15 16 17 18 19 20 21 22 23 24 41 42 43 44 45 46 47 48 49 50 68 69 70 71 72 73 74 75 76 77 78 79 94 95 96 97 98 99 100 484, 501
1.25 B 730
1
25 26 27 28 29 30 31 32 51 52 53 54 55 56 57 80 81 82 83 84 85 86 87 88 101 102 103 104 1.25 W 981 1 L BLUE
0.85 GR 310
2
Gr GRAY
1
3
3
2
470, 480, 490, 502, 504, 511, 512, 513, 575, 576, 577, 588
NOTE :
Y8 1. "BR" INDICATES BLACK CABLE WITH RED STRIPE.
1.25 GrB 953
0.85 WG 473
1.25 BrB 951
0.85 WY 472
1.25 RG 950
0.85 GR 313
0.85 GR 312
0.85 GR 954
0.85 BrR 501

0.85 YG 508
0.85 BG 955
0.85 BrY 575

1.25 LG 952
0.85BW 492
0.85 LG 507
0.85 BP 494
0.85 GR 311
0.85 GR 310
0.85 WL482
2. WATERPROOF CONNECTORS USED OUTSIDE OF CAB.

0.85 BG 631
1.25 BG 630
0.85 LY 470
0.85 PL 484
0.85 BL 490
2B 700
BG 660
BG 652
BG 651
BG 650
1.25 B 731
1.25 B 730
2B 600
0.85 L 481
0.85 L 480
680
681
CN A0
CN A1
GrR 504
LgR 503
LgR 502
OG 514
WG 513
OR 506
BW 505
BY 498
GR 511
LW 512
VG 576
BL 782
YL 488
VY 577
W 497
O 487
Y 486
L 496
P 588
1.25 B 743
CN 7
CN 8
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
39
42
33
51
54
52
34
35
36
37
38
40
41
43
44
45
46
7
8
9
10
11
12
13
14
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
47
48
49
50
53
55
56
57
1
2
4
15
16
5
17
6
HEAT RELAY
TACHO SENSOR (SIG)
TACHO SENSOR (GND)
RPM SENSOR (SIG)

RPM SENSOR (GND)
PULL DOWN (RED 4)
NV VB
PS (GE) PWR VB
GLOW LAMP SIGNAL
TF SENSOR (SIG)
LIMP HOME (RED 4)
GND (TW & TF SENSOR)
PS (GE) PWR GND
GND (MV)
VBB (RED 4)
GND (RED 4)
SHLD (RED 4)
GND (RED 4)
VBB (RED 4)
REGULATION (RED 4)
5V (RED 4)
REGULATION DEBIT CARBURANT
CAN-H
V 1ST (RED 4)
PWM SOLL (RED 4)
5V (RED 4)
Q ADJUST RES.
CAN-L
SIG GND (RED 4)
CAN GND
CAN SELECTING SWITCH.
KEY SWITCH
KEY SWITCH
ACCEL VOLUME (5V)
START SWITCH
LIMP HOME SW.

MAP SELECT-3
MAP SELECT-1
DIAG-MODE SWITCH
THROTTLE (SIG)
THROTTLE (SIG)
TW SENSOR (SIG)
OVER HEAT (WATER)
ENGINE STOP SIG IN

MAP SELECT-2
MEMORY CLEAR
THROTTLE (GND)
ENGINE ROTATE
MAP SELECT-0
TECH 2 (TXD)
DIAG-LAMP OUT
MAIN POWER (VB)
MAIN POWER (VB)
TECH 2 (RXD)
CHECKER SELECT
GND
GND
ENGINE STOP MOTOR
CX 135SR EXCAVATOR
A2
5 B 796
ELECTRICAL SCHEMATIC
M6 M6 Part Number 9-43660

CASE CX135SR Service Repair Workshop Manual PDF

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REPAIR MANUAL

Safety rules ( - A.50.A.10) 4

Basic instructions ( - A.90.A.05) 6

Hydraulic contamination ( - A.92.A.60) 18

Product identication ( - A.80.A.10) 20

Product identication ( - A.80.A.10) 21

INTRODUCTION TO THE REPAIR MANUAL

This manual is organised according to types of function and information.

Safety rules ( - A.50.A.10)

Basic instructions ( - A.90.A.05)

Gaskets, O-rings and at seals

STANDARD TIGHTENING TORQUE

Order of tightening nuts and cap screws.

Standard torque setting table.

SPECIAL TORQUE SETTINGS

Machine tted with monoblock boom

Item Dippers Item Dippers Item Dippers

Machine tted with monoblock boom and dozer blade

Item Dippers Item Dippers Item Dippers

Machine tted with backhoe-offset boom and dozer blade

FLUIDS AND LUBRICANTS

Transmission component oil

Components made from plastic or resin

Hydraulic contamination ( - A.92.A.60)

CLEANING THE HYDRAULIC SYSTEM

The following is an incomplete list of these problems:

The following are a few examples of problems caused by microscopic contamination:

The following are a few examples of problems caused by visible contamination:

• The uid contains metal or other fragments.

Product identication ( - A.80.A.10)

(1) TYPE (2) YEAR OF MANUFACTURE (3) SERIAL NUMBER

Serial numbers of hydraulic components

Product identication ( - A.80.A.10)

(1)TYPE (2)YEAR OF MANUFACTURE (3)SERIAL NUMBER

Serial numbers of hydraulic components

PRIMARY HYDRAULIC POWER SYSTEM A.10.A

SECONDARY HYDRAULIC POWER SYSTEM A.12.A

HYDRAULIC COMMAND SYSTEM A.14.A

ELECTRICAL POWER SYSTEM A.30.A

LIGHTING SYSTEM A.40.A

PRIMARY HYDRAULIC POWER SYSTEM - 10.A

PRIMARY HYDRAULIC POWER SYSTEM - 10.A

PRIMARY HYDRAULIC POWER SYSTEM - General specication (A.10.A - D.40.A.10) 7

PRIMARY HYDRAULIC POWER SYSTEM - Special tools (A.10.A - D.20.A.40) 9

PRIMARY HYDRAULIC POWER SYSTEM - Special tools (A.10.A - D.20.A.40) 11

PRIMARY HYDRAULIC POWER SYSTEM - Seed rates (A.10.A - D.50.A.60) 13

Hydraulic pump - Service limits (A.10.A.20 - D.20.A.20) 14

PRIMARY HYDRAULIC POWER SYSTEM - Dynamic description (A.10.A - C.30.A.10) 16

Stack valve - Sectional view (A.10.A.18 - C.10.A.30) 21

Stack valve Inlet section - Sectional view (A.10.A.18.10 - C.10.A.30) 24

Stack valve Outlet section - Sectional view (A.10.A.18.20 - C.10.A.30) 25

Hydraulic pump - Exploded view (A.10.A.20 - C.10.A.20) 30

PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A - F.35.A.51) 34

PRIMARY HYDRAULIC POWER SYSTEM - Drain uid (A.10.A - F.35.A.20) 35

PRIMARY HYDRAULIC POWER SYSTEM - Bleed (A.10.A - F.35.A.25) 36

PRIMARY HYDRAULIC POWER SYSTEM - Pressure test (A.10.A - F.40.A.30) 37

PRIMARY HYDRAULIC POWER SYSTEM - Decontaminating (A.10.A - F.30.A.60) 39

Stack valve Outlet section - Disassemble (A.10.A.18.20 - F.10.A.25) 42

Stack valve Inlet section - Disassemble (A.10.A.18.10 - F.10.A.25) 44

Stack valve - Visual inspection (A.10.A.18 - F.40.A.10) 45

Stack valve Inlet section - Assemble (A.10.A.18.10 - F.10.A.20) 46

Stack valve Outlet section - Assemble (A.10.A.18.20 - F.10.A.20) 47

Stack valve - Install (A.10.A.18 - F.10.A.15) 49