wx150 Service 9-44771

Service Manual
WX150 wheeled excavator

Table of contents
DIVISION/SECTION SECTION No. REFERENCE No.
1 GENERAL INFORMATION
Safety, general section and standard torque settings ......................................1001 *
Specifications (Wheeled excavators)...............................................................1002 *
2 ENGINE
Removal and installation of the engine ............................................................2002 9-54130GB
Removal and installation of the engine
WX150 : CGG0228401..., WX170 : CGG0232601...,
WX200 : CGG0231801 ..., WX200M : CGG0233301....................................2002 9-88230GB
Radiator and oil-cooler.....................................................................................2003 9-53720GB
Engine specifications .......................................................................................2401 **
Cylinder head and valve assembly ..................................................................2415 **
Engine block ....................................................................................................2425 **
Lubrication circuit .............................................................................................2445 **
Cooling circuit ..................................................................................................2455 **
Turbocharger....................................................................................................2465 **
Analysis of turbocharger failures......................................................................2565 **
3 FUEL SYSTEM
Fuel circuit and filter.........................................................................................3410 **
CAV injection pump..........................................................................................3411 **
BOSCH injection pump ....................................................................................3412 **
Fuel injector .....................................................................................................3412 **
BOSCH ANEROID injection pump...................................................................3416 **
4 ELECTRICAL SYSTEM
Electrical schematics .......................................................................................4001 *
Electronic system and troubleshooting ............................................................4002 *
Starter motor ....................................................................................................4003 7-58691GB
Alternator .........................................................................................................4004 7-58701GB
5 UNDERCARRIAGE
6 DRIVE TRAIN
Reduction gear and swing brake Trasmital 705T2...........................................6003 7-80671GB
Reduction gear and swing brake Trasmital 757T2...........................................6003 7-84141GB
Front axle and service brake - CARRARO 638LD and 638FR axle ................6004 9-53250GB
Front axle and service brake - CARRARO 652FR axle ...................................6004 9-53260GB
Rear axle and service brake - CARRARO 852FR axle....................................6005 9-53270GB
Rear axle and service brake - CARRARO 838LD and 838FR axle .................6005 9-53290GB
Gearbox and parking brake .............................................................................6008 7-80701GB
Twin wheels .....................................................................................................6020 9-53300GB
7 UNDERCARRIAGE HYDRAULICS
Hydraulic travel motor ......................................................................................7003 7-80731GB
One-piece control valve for travel, stabilizers and dozer blade .......................7031 9-53620GB
Two section control valve for travel, stabilizers and dozer blade .....................7031 7-84151GB
Cylinders for steering, stabilizers, dozer blade
and front axle locking (WX150-WX170).......................................................7080 9-53440GB
* Refer to the Schematic Set WX150

* * Consult the engine Service Manual.
Copyright  2003 CNH France S.A.

Printed in France
CNH Cre 9-53961GB March 2003
DIVISION/SECTION SECTION No. REFERENCE No.
8 UPPERSTRUCTURE HYDRAULICS
Hydraulic inspections, adjustments and schematics (Wheeled excavators)....8001 *
Hydraulic swivel ...............................................................................................8011 7-80801GB
High pressure and swing hydraulic pump (WX150) .........................................8020 9-54030GB
MARREL attachment control valve ..................................................................8031 7-80822GB
REXROTH attachment control valve ...............................................................8031 9-53860GB
One-piece swing control valve .........................................................................8033 7-79241GB
Two-piece swing control valve .........................................................................8033 7-80832GB
Swing control valve (Orbitrol) ...........................................................................8037 7-80841GB
Hydraulic swing motor and safety and force-feeding block..............................8040 7-80852GB
Hydraulic fan motor..........................................................................................8041 9-54010GB
Attachment and swing control block ................................................................8050 9-53680GB
Option control block .........................................................................................8051 9-53610GB
Direction of travel inverter control block...........................................................8053 7-80290GB
Travel control block ..........................................................................................8054 7-80301GB
Brake unit.........................................................................................................8060 9-53570GB
Parking brake electro-control valve..................................................................8061 9-54040GB
Electro-control valve block ..............................................................................8071 9-54120GB
Flow cancellation over-pressure selector block ...............................................8072 7-26651GB
Electro-control valve block DRE4 ....................................................................8073 9-54110GB
Attachment cylinders........................................................................................8080 9-53560GB
Safety valves....................................................................................................8081 7-26641GB
9 UPPERSTRUCTURE
Upperstructure and turntable ...........................................................................9002 9-53830GB
Cab ..................................................................................................................9004 9-53840GB
* Refer to the Schematic Set WX150
NOTE: 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 modifications on machines already sold.
The description of the models shown in this manual has been made using the technical specifications known at the date on which this
document was designed.
Cre 9-53961GB Issued 03-03

Section
2002
2002
ENGINE REMOVAL AND INSTALLATION

Printed in France
2002-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................................... 2
SPECIAL TORQUES................................................................................................................................................ 2
TOOLS REQUIRED ................................................................................................................................................ 2
REMOVAL AND INSTALLATION............................................................................................................................. 3
CHECKING ELECTRICAL CONNECTIONS ON TEMPERATURE SENSORS ...................................................... 9
This symbol is used in this manual to indicate important safety messages. Whenever you see this
symbol, carefully read the message that follows, as there is a risk of serious injury.
SPECIFICATIONS
Weights:
Engine (without hydraulic pump)
WX150 model......................................................................................................................................... 350 kg
WX170-200 model ................................................................................................................................. 443 kg
High pressure hydraulic pump
WX150 model......................................................................................................................................... 100 kg
WX170-200 model ................................................................................................................................. 130 kg
Upper hood
WX150 model........................................................................................................................................... 26 kg
WX170-200 model ................................................................................................................................... 43 kg
Complete cooling circuit
WX150 model.................................................................................................................................... 14.5 litres
WX170-200 model ............................................................................................................................... 20 litres
Lubricant and coolant solution...................................................................................................... (see section 1002)
SPECIAL TORQUES
Engine/hydraulic pump retaining screws ......................................................................................................... 44 Nm
Splined sleeve retaining screws .................................................................................................................... 120 Nm
Shock absorber centring stud retaining screws............................................................................................. 220 Nm
Engine bracket retaining screws......................................................................................................... 217 to 271 Nm
TOOLS REQUIRED
1 1 Torque wrench (10 to 50 Nm)
4 1 Sling (400 to 600 kg)
5 2 Slings (150 to 200 kg)
6 1 Receptacle (30 litres)
7 1 Plugging shaft - length 100 mm and diameter 27 mm
8 1 Loctite 638

2002-3
Before carrying out any servicing on the machine, perform the following operations in the order shown:
- Park the machine on flat, hard ground.
- Lower the attachment to the ground.
- Shut down the engine and allow it to cool down.
- Place the battery master switch in the "OFF" position and remove the key.
When the machine is operating, the engine and hydraulic pump reach high temperatures. To avoid being
burnt by hot metal or scalded by high temperature oil or water, allow the machine to cool down before
starting any servicing operation.
Removal and installation

STEP 1 WX150 model STEP 3
Remove the exhaust silencer outlet pipe.
NOTE: When installing, make sure that the exhaust
1 outlet is oriented rearwards.
STEP 4
Remove the upper hood using suitable lifting
equipment.
STEP 5
Remove the side hood, at the walkway end.
CD02J005
PG02234 STEP 6
WX170-200 model Remove the exhaust silencer and its bracket.
STEP 7
(WX150 model)
1 Remove the hose which connects the turbo-charger
to the air filter.
(WX170-200 model)
Remove the hose connecting the air filter to the
turbo-charger, disconnect the air filter restriction
pressure switch harness (see item (7) Step 11), then
remove the air filter.
PG03613
Disconnect the negative cable (1) first, then

disconnect the other cables.
STEP 2
Remove the access panels located under the engine.

2002-4
STEP 8 WX150 model STEP 11

WX150 model
3
1
2
2 5
CD96D002
Disconnect the connector (1) from the speed detector
(2). 4
1 6
STEP 9
PDG0416
2 WX170-200 model
2
7
1
CDCD02J006
CD96A00
CK96F001
Disconnect the electrical supply (1) from the

proportional pressure reduction valve DRE4 (2). 5
STEP 10
1
3
6 4
PDG0415
Disconnect the electrical wires and harnesses
connected to the engine.
4 2 1 9 Engine oil pressure switch

10 Engine coolant solution temperature sender
11 Engine stop solenoid valve
12 Alternator (see section 4003 for wire identification)
13 Starter motor (see section 4004 for wire
CD96A008
identification)
Disconnect the electrical supply (1) from the 14 Earthing braid
proportional pressure reduction valve DRE4 (2) and 15 Air filter restriction pressure switch
the connector (3) from the speed detector (4).

2002-5
STEP 12 STEP 14
3
1
4
CD96A009 PG01706
Disconnect the connector (1) from the servo-motor Turn the heater lever to the left.
(2) and the connector (3) from the injection pump (4).
STEP 15
STEP 13
PE07509
PG02824A
Remove the lower tray under the operator’s
Remove the expansion reservoir cap. compartment. Position a receptacle of about 30 litres
capacity, then disconnect the hose (1) from the
NOTE: Do not remove the cap when the engine is
heater unit and allow the coolant solution to drain out.
hot, since the system would still be under pressure
and you could be scalded.

2002-6
STEP 16 STEP 17
WX150 model WX150 model
1 1
2
3
4
2
5
PDG0407 PDG0412
WX170-200 model WX170-200 model
1
7 3 2
4
6 2
1
5
5
PDG0410 PDG0411
Disconnect, label, then remove the engine cooling At the engine, disconnect the hoses (1) and (2) from
system hoses in numerical order. the heater system.
NOTE: When installing, make sure that the system
hoses are clean.
1 Overflow hose
2 Engine gas relief hose
3 Radiator gas relief hose
4 Engine/radiator return hose
5 Pump/radiator inlet hose
6 Coolant solution supply hose
7 Expansion reservoir

2002-7
STEP 18 STEP 20
2
3
1
PDG0409 B20308
Disconnect the fuel supply pipe (1) and plug it. Install suitable lifting equipment on the engine lifting
Disconnect the fuel return pipe (2) and plug it. eyes.
Engine weight:
NOTE: When installing, change the filter (3).
WX150 model ............................................. 350 kg
STEP 19 WX150 model WX170-200 model ......................................443 kg
STEP 21
PG02824B
Remove and plug the hydraulic oil return hose to gain C24000
access to the sleeve retainers.
Using a suitable sling, support the hydraulic pump to
NOTE: Refer to the "Tools required" section, page 2, hold it in position when removing the engine.
for plugging the hydraulic oil return hose.
STEP 22
C24000A
Remove the hydraulic pump retaining hardware.

NOTE: When installing, tighten the hydraulic pump
retaining screws to a torque of 44 Nm.

2002-8
NOTE: (WX150), when installing, install the pressure STEP 25
control hose and its bracket.
STEP 23
1
WX150 model
5 3
3
4
4
5
5
B20402
2
Remove the flexible coupling (1), check it visually for
1 5 wear and condition and replace it if necessary.
2 STEP 26
1
PDG0413
2
WX170-200 model
3
4 3
5 4 1
B20404
5
Remove the screws (1) then remove the centring
studs (2). Check the centring studs for wear and
condition and replace them if necessary.
NOTE:
5
5
2 2
1 1

PDG0414

Remove the nuts (1), the washers (2) then remove

the screws (3) and the thrust washers (4).
NOTE: When installing, make a visual check of the

condition of the rubber spacers (5), replace them if
necessary, tighten the engine bracket retaining INCORRECT CORRECT
screws to a torque of 217 to 271 Nm.
PDG0419
STEP 24
When installing, apply Loctite 638 to the screws,
Carefully raise the engine and move it towards the position the centring studs correctly, then tighten the
radiator until it is clear of the pump coupling. When screws to a torque of 220 Nm.
there is nothing to prevent the engine being removed,
lift the engine and install it on a suitable repair bench.

2002-9
NOTE: If wear on the flexible coupling and centring Checking electrical connections on
studs necessitates their replacement, change the
splined sleeve at the same time.
temperature sensors
1 1
C18226 CD02H010
Remove the splined sleeve (1) from the hydraulic

pump and change it if necessary.
NOTE: When installing the splined sleeve (1)
assemble the splined sleeve on the pump shaft. The
splined sleeve must butt up against the shoulder on
2
the pump shaft. Tighten the retaining screws (2) to a
torque of 100 Nm.
NOTE: When installing the engine, proceed in the
reverse order from removal.
Before using the machine, perform all the
following operations:
CD02H0011
- Fill the cooling system (see operator’s manual).
- Turn the battery master switch to the "ON" position.
- Bleed and prime the fuel system (see operator’s Disconnect the water temperature sensor on the
manual). engine cylinder head (2).
- Check that the engine oil pressure warning lamp - Defect D005 shown on the control panel
goes out when the engine is running. "Connection correct".
- Adjust the engine speed detector if it has been - Defect D007 shown "Error in connections
removed, see section 4002. between the engine water temperature detectors
- Calibrate the servo-motor if it has been removed, (2) and the cooling system detector (1)".
see section 4002. Reverse the temperature sensor connection (1) and
- Bleed air from the cooling system (see operator’s (2), the defect should disappear on the control
manual). screen.
- Check the hydraulic system, fuel system and
cooling system for leaks.
- Shut down the engine and check all the levels. Top
up if necessary.

2002-10

2002
Section
2002
ENGINE REMOVAL AND INSTALLATION
WX150 : CGG0228401...
WX170 : CGG0232601...
WX200 : CGG0231801...
WX200M : CGG0233301...

Printed in France.
2002-2
TABLE OF CONTENTS
SPECIFICATIONS ................................................................................................................................................... 2
SPECIAL TORQUES................................................................................................................................................ 2
TOOLS REQUIRED ................................................................................................................................................ 2
Removal and installation ..................................................................................................................................... 3
CHECKING ELECTRICAL CONNECTIONS TO THE RADIATOR TEMPERATURE SENSORS........................ 9
This symbol is used in this manual to indicate important safety messages. When ever you see this sym-
bol, carefully read the message that follows, as there is a risk of serious injury.
SPECIFICATIONS
Weights:
Engine, (without hydraulic pump)
Model WX150............................................................................................................................................... 350kg
Modèl WX170-200 ....................................................................................................................................... 443kg
High pressure hydraulic pump ...............................................................................................................................
Model WX150............................................................................................................................................... 100kg
Modèl WX170-200 ....................................................................................................................................... 130kg
Upper hood
Model WX150................................................................................................................................................. 26kg
Modèl WX170-200 ......................................................................................................................................... 43kg
Capacity complete cooling system
Model WX150........................................................................................................................................... 14 Litres
Modèl WX170-200 ................................................................................................................................... 20 Litres
Lubricants and coolant .............................................................................................................(see Section 1002)
SPECIAL TORQUES
Engine/hydraulic pump retaining screws ......................................................................................................... 44 Nm
Splined sleeve retaining screws .................................................................................................................... 120 Nm
Shock absorber centering lug retaining screws............................................................................................. 220 Nm
Engine support retaining screws ........................................................................................................ 217 to 271 Nm
TOOLS REQUIRED
- 1 torque wrench (10 to 15 Nm)
- 1 sling (400 to 600 kg)
- 2 slings (150 to 200 kg)
- 1 receptacle (30 litres)
- 1plugging spigot length 100 mm diameter 27 mm
- 1 Loctite 638

2002-3
Before performing any service work on a machine, the following steps must be carried out in the order shown:
- Park the machine on hard, flat ground.
- Stop the engine and let it cool down.
- Turn the battery master switch to the “OFF” position and remove the key.
When the machine is running, the engine components and the hydraulic pump reach a high temperature.
To avoid being burnt by hot metal or scalded by high temperature water or oil, let the machine cool down
before beginning any operation.

STEP 1 STEP 3
WX150 model Drain the cooling circuit. See the Operator’s Manual.
Remove the upper hood using a suitable lifting
device.
1 NOTE : When installing, make sure that the exhaust
outlet is pointing towards the rear.
STEP 4
Remove the upper hood using a suitable lifting
device.
STEP 5
Remove the side panel on the walkway side.
CD02K027 STEP 6
WX170 and WX200 models
Remove the exhaust silencer and its bracket.
STEP 7
1
Remove the hose connecting the air filter to the turbo
charger, disconnect the air filter restriction pressostat
and remove the air filter.
PG03613
Disconnect the negative cable (1) first and then the
other cables.
STEP 2
Remove the access panels located under the engine.

2002-4
STEP 8 STEP 10
WX150 model
1
CD02J006
CS03A536
2
Disconnect the connector (1) from the speed detector CD02K015
(2). WX170 and WX200 models
STEP 9
1 2
CD02K014
Disconnect the connector (1) and (2) from the injec-
tion pump
CD96A008
Disconnect the electrical supply (1) from the propor-
tional pressure reduction valve DRE4 (2)

2002-5
STEP 11 STEP 12
CS03A544
CD02K016
CD02K025
PDG0416
CS03A545
Disconnect and place identification labels on the air
circuit hoses.
NOTE : When installing, make sure the pipes and
hoses are clean.
PDG0415
Disconnect the wires and electrical harnesses con-
nected to the engine.
Engine oil pressure pressostat.
Engine coolant solution temperature sender.
Engine cut-out solenoid valve.
Alternator
Starter motor (see Section 4004), for wiring identifica-
tion.
Earthing strap.
Air filter restriction pressostat.

2002-6
NOTE : When installing, make sure that the system
WX150 model hoses are clean.
Engine gas evacuation hose
Radiator gas evacuation hose
Engine/radiator return hose
Pump/radiator inlet hose
Coolant solution supply hose
Expansion reservoir
STEP 13
3
2 1
CS03A547
Disconnect, label and remove the cooling system

hoses from the engine in numerical order.
CD02K017
NOTE : When installing, make sure that the system
hoses are clean. Disconnect the fuel supply pipe (1) and plug it.
Overflow hose Disconnect the fuel return pipe (2) and plug it.
Engine gas evacuation hose NOTE : When installing, change the filter (3).
Radiator gas evacuation hose
Engine/radiator return hose STEP 14
Pump/radiator inlet hose Remove and plug the hydraulic fluid return hose to
Coolant solution supply hose gain access to the shroud retainers.
Expansion reservoir NOTE : Refer to “Tools required” on page 2 for plug-
ging the hydraulic fluid return hose.
CS03A546
Disconnect, label and remove the cooling system
hoses from the engine in numerical order.

2002-7
STEP 15 STEP 17
WX150 model
1
2
4
3
3
5 4 CD02K019
CD02K018
Attach a suitable lifting device to the engine lifting
eyes. 4
WX170 and WX200 model
5
5
1
2
1
2 3
Remove the nuts (1), the washers (2) and remove the
screws (3) and the thrust washers (4).
CS03A537
CS03A537
NOTE : When installing, make a visual check of the
Weight of engine:
"
condition of the rubber spacers (5). Replace them

WX150 model ..............................................410 kg
with new spacers if necessary. Tighten the engine
WX170 and WX200 model..............................527 kg
bearer retaining screws to a torque of 217 to 271 Nm.
STEP 16 STEP 18
C24000
CS03A538
Using a suitable sling, support the hydraulic pump so
Remove the hydraulic pump fastening hardware.
as to keep it in place during the removal of the
When installing, tighten the hydraulic pump retaining
engine. screws to a torque of 44 Nm.

2002-8
STEP 19 STEP 21
Carefully lift the engine. Move it towards the radiator
until it is disengaged from the pump coupling. When 2
there is nothing to prevent the removal of the engine,
install it on a suitable repair bench.
STEP 20
CD02K021
1
Remove the splined sleeve (1) from the hydraulic
pump. Replace it if necessary.
NOTE : When installing the splined sleeve (1), install
the splined sleeve on the pump shaft. The splined
CD02K020 sleeve should be pushed fully home against the
Remove the 8 screws (1) from the coupling, check pump shaft shoulder. Tighten the retaining screws (2)
that is in good condition and replace it if necessary. to a torque of 120 Nm.
NOTE: When installing the engine, proceed in the
- Fill the cooling system (see operator’s manual).
Turn the battery master switch to the "ON" position.
- Bleed and prime the fuel system (see operator’s
manual).
- Check that the engine oil pressure warning lamp
goes out when the engine is running.
- Adjust the engine speed detector if it has been
B20404
CD02K026 removed, see section 4002.
- Calibrate the servo-motor if it has been removed,
When installing, apply Loctite 638 on the screws, and
see section 4002.
tighten the screws to a torque of 46 Nm.
Bleed air from the cooling system (see operator’s
manual).
- Check the hydraulic system, fuel system and
cooling system for leaks.
Stop the engine and check all levels. Top up if
necessary.

2002-9
Checking electrical connections to the radiator temperature sensors.

WX150 model - Code D005 is displayed on the control panel
"Connections corect".
- Code D007 is displayed
"connection error between temperature detectors (2)
and cooling circuit detector (1)".
Invert the wiring between temperature senders (2)
and temperature sender (1). The message should
disappear. I
1
CD02K024
CD02K023
CD02K024
C24000A
CD02H0011
Remove the temperature sender from the engine
cylinder head (2).

2002-10

Section
2003
2003
RADIATOR AND OIL-COOLER

Printed in France
CNH Cre 9-53720GB June 2002
2003-2
TABLE OF CONTENTS
SPECIFICATIONS .................................................................................................................................................. 3
TOOLS REQUIRED ............................................................................................................................................... 3
RADIATOR AND OIL-COOLER ............................................................................................................................. 4
REPLACING THE RADIATOR OR THE OIL-COOLER ......................................................................................... 7
WX170 and WX200 model .................................................................................................................................. 7
Disassembly and assembly ................................................................................................................................. 7
WARNING: This symbol is used in this manual to indicate important safety messages. When you see the
! symbol, carefully read the message which follows. Your safety depends on it.

2003-3
SPECIFICATIONS
See Section 1002.
IMPORTANT: When an ethylene-glycol based coolant is used, a minimum of 50% ethylene-glycol should always be
present in the cooling circuit. Do not put more than 50% of ethylene-glycol in the cooling circuit, unless the ambient
temperature is less than -36°C. A percentage greater than 50% of ethylene-glycol reduces temperature transfer and
then the surface temperature of the engine rises above normal.
TOOLS REQUIRED
1 Torque wrench (10 to 50 Nm)
1 Sling (50 to 100 kg)
1 Container (30 litres)
2 Plugging pins 100 mm long and 27 mm in diameter

2003-4
RADIATOR AND OIL-COOLER

Before performing any service work on the machine, the following steps must be carried out in the order shown:
- Stop the engine.
- Turn the battery master switch to the "OFF" position and remove the key.
- Simultaneously operate the emergency foot pump and the control lever so as to release the pressure in the
hydraulic system.
- Unscrew the pressure release plug on the hydraulic reservoir by two or three turns, then retighten the plug.
WARNING: When the machine is running, the engine and hydraulic pump components attain a high tem-
perature. To avoid risk of burns from hot metal or boiling oil or water, allow the machine to cool down com-
! pletely before carrying out any work.

STEP 1 STEP 4
Remove the lower drawer under the operator’s com- Disconnect the heater return hose and let the cooling
partment and the panels under the upperstructure. fluid flow into an appropriate receptacle. Reconnect
the hose after the circuit has completely drained.
STEP 2
STEP 5
Remove the expansion tank plug.
IMPORTANT: Do not remove the plug when the
engine is hot, as the circuit is under pressure and you
risk getting scalded.
STEP 3
CD99H009
Close the valve on the hydraulic reservoir.
IMPORTANT: After an operation that requires closing
the valve, never start the engine without ensuring that
the valve has been reopened.
CD99H004
Move the heating lever to the opening position.

2003-5
STEP 6 STEP 8
3
2
4 6
1
PDG0422BIS
Remove the lower retainers (1) and (6) and the upper
CS02H502 retainers (5) from the radiator (3). Remove the lower
Remove the engine upper hood. (4) and upper (5) flexible mountings.
Remove the upper hood traverse.
WX170 - WX200 model
Remove the RH side panel.
Remove the inspection panel. 2
Remove and plug the radiator degassing hose.
Remove the expansion vessel. 5
Remove the upper panel.
Remove and plug the hydraulic fluid upper hose. To
avoid losing fluid, disconnect the oil cooler return 3
hose from the hydraulic reservoir and drain the oil
from it into a clean receptacle. Reconnect the reser-
voir return hose and remove and plug the oil cooler 4
hose.
1
NOTE: Refer to the section "Tooling required" on
page 3 for plugging the hoses.
PDG0423
STEP 7 Remove the lower retainers (1) and then the upper
Remove and plug the engine/radiator return hose. retainers (2) from the radiator (3). Remove the lower
Remove and plug the water pump/radiator inlet hose. (4) and upper (5) flexible mountings.
NOTE: When installing, check visually for wear and
the general condition of the flexible mountings (4) and
(5) and change them if necessary.

2003-6
STEP 9
PDG0431
Using a suitable sling, encircle the radiator, then
remove it.
NOTE: When installing, proceed in the reverse order
to that of removal.
Before using the machine, carry out all the following
operations:
- Check the oil level in the hydraulic reservoir. Top up
if necessary.
- Fill the cooling system (see Operator’s Manual).
- Bleed the cooling system (see Operator’s Manual).
- Check the hydraulic cooling circuit for leaks.

2003-7
REPLACING THE RADIATOR OR THE OIL-COOLER

Disassembly and assembly
NOTE: The parts are numbered in the order of disassembly, when assembling follow the reverse order.
4 1
CS02H503
1 BRACKET
2 NUT
3 COOLING FLUID RADIATOR
4 SCREW
5 FOAM SEAL
6 HYDRAULIC OIL COOLER

2003-8

Section
4003
4003
STARTER MOTOR

Printed in France
CNH Cre 7-58691GB November 1999
4003-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................................... 2
SPECIAL TORQUES................................................................................................................................................ 2
SHOP EQUIPMENT TOOLS .................................................................................................................................... 2
STARTER MOTOR
Removal and Installation ...................................................................................................................................... 3
No-Load test procedure ....................................................................................................................................... 4
Understanding No-Load test results..................................................................................................................... 5
Disassembly and Assembly ................................................................................................................................. 6
Inspection............................................................................................................................................................. 7
SPECIFICATIONS
Manufacturer ............................................................................................................................................... .....Bosch
Weight ...........................................................................................................................................................................25.5 kg
No-Load test at 27°C
Volts ................................................................................................................................................................24 V
Current draw ............................................................................................................................85 amps maximum
Brush length................................................................................................................................................. 8.5 mm minimum
Commutator diameter................................................................................................................................ 42.5 mm minimum
Armature shaft end play .................................................................................................................................. 0.05 to 0.5 mm
Armature shaft run-out.............................................................................................................................. 0.03 mm maximum
Lubricant for thrust bearing and splines on armature shaft......................................................................GE silicone grease
G321 Versilube
SPECIAL TORQUES
Drive housing screws .............................................................................................................................. 4.5 to 6 Nm
Starter motor mounting bolts.........................................................................................................................................43 Nm
WORKSHOP TOOLS
1 Sun electric VAT-33
2 Hand-held tachometer CAS 10756
3 Multimeter CAS 1559
4 Dial indicator CAS 10066-1A
5 Magnetic base for dial indicator OEM 1030
6 Torque wrench OEM 6479

4003-3
STARTER MOTOR
Removal and Installation STEP 3
STEP 1 Fasten identification tags to and disconnect the
cables and wires from the starter motor and solenoid.
Park the machine on hard level ground and stop the Remove the three mounting bolts and washers and
engine. remove the starter motor.
STEP 2 NOTE : For installation, follow the same procedure in
reverse order and tighten the starter motor mounting
Turn the master disconnect switch to the OFF position
bolts to a torque of 43 Nm.
and remove the key.

4003-4
No-Load test procedure

The No-Load test is carried out with the starter motor The No-Load test can be carried out using a Sun
removed from the machine. Check to make sure the Electric VAT-33 tester or an equivalent tester. A hand
drive clutch slides freely on the armature shaft and held tachometer is required to measure the speed of
the armature rotates freely. the armature shaft. A remote starter switch is
required to actuate the starter motor and two fully
charged 12 volt batteries to supply the electricity to
turn the starter motor.
1 HAND TACHOMETER
2 STARTING TERMINAL
3 NEGATIVE CHARGE TERMINAL
4 REMOTE STARTING SWITCH 4 5 6 7 3 8 9
5 AMMETER
6 VOLTMETER
B
7 LOAD CONTROL
8 POSITIVE CHARGE CABLE
9 JUMPER LEAD
10 STARTING TERMINAL A
11 AMMETER CLAMP
12 POSITIVE BATTERY CABLE
13 NEGATIVE BATTERY CABLE
14 NEGATIVE VOLTMETER LEAD
15 POSITIVE VOLTMETER LEAD 11
12
15
14
13
1 2 10
A87754
STEP 4 STEP 6
Fasten the starter motor in a soft jawed vise. Connect Connect the positive voltmeter lead of the tester to
the positive battery cable to the positive post (A) and post (A).
to the battery terminal on the starter solenoid. Con- Connect the negative voltmeter lead of the tester to post
nect the negative battery cable to the negative post (B).
(B) and to the mounting flange on the starter.
STEP 7
STEP 5
Connect the load leads of the tester as shown.
Adjust the controls for the Sun Electric VAT-33 tester
as follows : STEP 8
1 Move the load control to the OFF position. Fasten the ammeter clamp around the negative bat-
2 Move the volt range control to the 10 to 30 volt tery cable. The point of the arrow on the ammeter
range. clamp must be toward the battery.
3 Move the amp. range control to the 0 to 1000
amperes range.
4 Move the volt lead switch to the EXT. position.

4003-5
STEP 9 STEP 16
Connect the leads of the remote starter switch to the If the armature does not rotate and the current draw
battery terminal and the switch terminal on the starter is high, possible causes are :
motor solenoid. 1 Field terminal making contact with the field
frame. Inspect the insulators for the field termi-
NOTE : Steps 10 to 13 must be done rapidly. DO
nal.
NOT apply a load to the battery for more than 15 sec-
2 Damaged field coil, refer to the test on page 8.
onds at one time. After 15 seconds turn the load con-
3 Damaged bearings.
trol to the off position for 60 seconds to allow the
tester to cool. STEP 17
STEP 10 If the armature does not rotate and the current draw
is zero, possible causes are :
Actuate the remote starter switch and turn the load
1 An open field circuit, disassemble the starter
control until the voltmeter indicates 23 volts.
motor and inspect the field coil connections.
STEP 11 2 An open armature coil, disassemble the starter
motor and check for burned commutator seg-
Make a note of the reading on the ammeter. ments. Use an armature tester to test the arma-
STEP 12 ture.
3 Brushes not making good contact with the com-
Use the hand-held tachometer to check the armature mutator segments. Check for high insulation
shaft speed. Make a note of the armature shaft between the commutator segments, broken
speed. brush springs or worn brushes.
STEP 13 STEP 18
Release the remote starter switch and turn the load Low armature shaft speed and low current draw are
control to the OFF position. indications of :
1 Dirt or corrosion on connections.
STEP 14
2 Damaged wiring.
Disconnect the negative battery cable from the 3 Dirty commutator segments.
starter. Disconnect the remainder of the test connec- 4 All causes in Step 17.
tions.
STEP 19
NOTE : Refer to Specifications, on page 2, to check
the readings obtained in Steps 11 and 12. High armature shaft speed and high current draw are
indications of a short circuit in the field coil. Replace
Understanding No-Load test the field coil by a new field coil. Repeat the No-Load
test, on page 4, and check the operation of the starter
results motor.
STEP 15
Low armature shaft speed and high current draw are
indications of too much friction. Possible causes of
too much friction are :
1 Tight, dirty or worn bearings.
2 A bent armature shaft.
3 Loose pole shoes (pole shoes make contact
with the armature).
4 A short circuit in the armature winding. Disas-
semble the starter motor. Use an armature
tester to test the armature.
5 Damaged field coil, refer to the test on page 8.

4003-6
Disassembly and Assembly
6 7
5 12
10
3
11
2 14
1
4
19
13
20
18
16
15 17
DPH0205
1 NUT 9 TIE-ROD 16 BRUSH

2 WASHER 10 HOUSING 17 SPRING
3 SCREW 11 BEARING 18 COVER
4 ENGAGING FORK 12 CYLINDER GLAND 19 SCREW
5 SCREW 13 OVERRUNNING CLUTCH AND DRIVE 20 CAP
6 SWITCH PINION
7 NUT 14 ARMATURE
8 WASHER 15 BRUSH HOLDER

4003-7
Inspection STEP 24
STEP 20
Use a clean dry cloth to clean the drive clutch, arma-
ture, field frame and starter solenoid. Use cleaning
solvent to clean the remaining parts.
STEP 21
Measure the length of the brushes connected to the
brush holder. If the length of any brush is less than
8.5 mm both brushes must be replaced. Measure the
length of the brushes connected to the field coil. If the
length of any brush is less than 8.5 mm both brushes
must be replaced.
A05527
STEP 22 Place the probes of the multimeter to two segments of

the commutator. If there is no continuity the winding has
an open circuit and the armature must be replaced.
STEP 25
A06513
Connect one probe of the multimeter to the brush holder

frame and the other probe to each insulated brush
holder in turn. There must be no continuity. Replace the
675970
assembly if continuity exists.
Put the armature on vee-blocks and check the run out of
STEP 23 the armature with a dial indicator. The run out must not
be more than 0.03 mm. If necessary, put the armature
in a lathe and remove enough material to make the run
out less than 0.03 mm.
A06523
Place one probe of the multimeter to a commutator seg-

ment and the other probe to the armature core. There
must be no continuity. If there is continuity the armature
has an earth and must be replaced.

4003-8
STEP 26 STEP 28
A05521 A05537
Place the armature on vee-blocks and check for distor- Place one probe of the multimeter on the field coil termi-
tion. If the armature is distorted it must be replaced. nal and the other probe on an unpainted area on the
surface of the frame. If there is continuity the field wind-
ing is earthed and must be replaced.
STEP 27
STEP 29
A05533
If the depth of the groove between the commutator seg- A06506
ments is less than 0.2 mm, cut the insulation between Place one probe of the multimeter on the field coil termi-
the commutator segments to a depth of 0.5 mm. Use nal and the other probe on the brush connection. If
sandpaper to remove the rough edges from the commu- there is no continuity the field winding has an open cir-
tator segments. Do not use emery cloth. cuit and must be replaced.
STEP 30
Check the splines and teeth of the overrunning clutch
for wear and damage. Make sure the drive clutch
moves freely on the armature shaft.
STEP 31
Check the bushings in the drive clutch, drive housing
and end cover, replace if worn or damaged.

Section
4004
4004
ALTERNATOR

Printed in France
4004-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................................... 2
SPECIAL TORQUES................................................................................................................................................ 2
Shop equipment tools .......................................................................................................................................... 2
Testing on the machine ........................................................................................................................................ 3
Voltage test at the alternator terminals ................................................................................................................ 3
Alternator and voltage regulator test .................................................................................................................... 4
Removal and installation ...................................................................................................................................... 5
Disassembly and assembly .................................................................................................................................. 6
Inspection ............................................................................................................................................................. 8
This safety alert symbol indicates important safety messages in this manual. When you see this sym-
bol, carefully read the message that follows and be alert to the possibility of personal injury or death.
SPECIFICATIONS
Manufacturer .................................................................................................................................................... Bosch
Weight ................................................................................................................................................................. 5 kg
Output current.................................................................................................................................... 28 volts to 45 A
Resistance of rotor winding ............................................................................................................................ 9 ohms
Resistance of stator winding...................................................................................................................... 0.22 ohms
Brush length .................................................................................................................................................... 14 mm
Rotor shaft run-out....................................................................................................................... 0.05 mm maximum
SPECIAL TORQUES
Alternator mounting bolts................................................................................................................................. 24 Nm
Pulley retaining nut .......................................................................................................................................... 68 Nm
Shop equipment tools

1 Multimeter CAS 1559
2 Sun electric VAT-33
3 Soldering iron OEM 6156

4004-3
Testing on the machine New model
STEP 1
Park the machine on hard level ground and stop the 1
engine.
STEP 2
Make sure that all electrical connections are tight and
free of corrosion.
STEP 3
Make sure that the alternator drive belt is tight and is 2
free of oil or grease that would cause the belt to slip.
STEP 4
Check the operation of the battery warning lamp, 3
Steps 2 and 3 may have corrected the fault.
CS99H535
STEP 5 1 B+ Terminal
Test the batteries, each battery must be fully charged 2 D+ Terminal
and have a voltage of a least 12 volts. 3 W Terminal
Voltage test at the alternator terminals STEP 6

Carry out Steps 1 to 5 before doing this test. Use a Connect the positive multimeter lead to the B+ termi-
multimeter set to read volts for the test. nal of the alternator.
Connect the negative multimeter lead to a good ground
Old model connection on the engine.
If the multimeter indicates less than rated voltage or
indicates zero, refer to Step 7.
If the multimeter indicates rated voltage, refer to Step
1 9.
STEP 7
Connect the positive multimeter lead to the battery
B+ terminal of the starter solenoid.
Connect the negative multimeter lead to a good ground
W connection on the engine.
If the multimeter indicates rated voltage, repair or
replace the wire between the alternator and the starter
D+ + solenoid.
If the multimeter does not indicate rated voltage,
replace the positive battery cable.
2 3 STEP 8
Turn the starter key switch to the ON position. Dis-
connect the connector from the D+ terminal of the
851746 alternator. Connect the positive multimeter lead to the
terminal in the connector and the negative multimeter
lead to a good ground connection on the engine.
If the multimeter indicates rated voltage, connect the
connector to the alternator and refer to the Alternaotr
and voltage regulator test, on page 4.
Refer to Section 4001 if the multimeter does not indi-
cate rated voltage.

4004-4
Alternator and voltage regulator test
5 -- +
- +
+ -
3
PDF01419
1 Sun electric vat-33 tester

2 12 Volt battery (2 required)
3 Positive (+) voltmeter lead
4 Negative (-) voltmeter lead
5 Ammeter clamp lead
NOTE: Refer to Steps 1 to 8, on page 3, before carry- STEP 10

ing out this test. Use a Sun electric VAT-33 or other
suitable equipment to carry out the following test. Connect the positive load lead of the tester to the
positive post of one of the batteries.
STEP 9 Connect the negative load lead of the tester to the
negative post of the same battery.
Adjust the controls for the Sun electric VAT-33 as fol-
lows : STEP 11
1 Put the load control to the OFF position.
2 Select the volt range that will measure 18 to 40 Connect the positive voltmeter lead of the tester to
volts. the B+ terminal on the alternator.
3 Select the ampere range that will measure 0 to Connect the negative voltmeter lead of the tester to a
100 amperes. good ground connection on the engine.
4 Put the volt lead select switch to the EXT. posi-
tion.

4004-5
STEP 12 Removal and installation

Connect the ammeter clamp around the wire that fas- STEP 1
tens the B+ terminal on the alternator to the battery
Park the machine on hard level ground and stop the
terminal of the starter. The clamp must be at least 50
engine.
mm from the alternator. The point of the arrow on the
ammeter clamp must be pointing away from the alter- STEP 2
nator.
Turn the master disconnect switch to the OFF posi-
STEP 13 tion and remove the key.
Start and run the engine at 3/4 throttle. STEP 3
Install a 13 mm square drive lever into the tension
Never run the engine in a closed building. Pro- pulley bracket, use the lever to release the tension
per ventilation is required under all circums- and remove the drive belt.
tances.
STEP 4
NOTE: Carry out Steps 14 and 15 rapidly. Do not Fasten identification tags to and disconnect the wires
apply a load at the battery for more than 15 seconds from the alternator. Remove the top and bottom alter-
at a time. After 15 seconds turn the load control to the nator mounting bolts and remove the alternator.
OFF position for 60 seconds before applying the load
again. NOTE: For installation, follow the same procedure in
reverse order and tighten the alternator mounting
STEP 14 bolts to a torque of 24 Nm.
Adjust the load control of the tester to get the maxi-
mum ammeter indication, make a note of the amme-
ter and voltmeter readings.
Turn the load control to the OFF position.
STEP 15
Slowly decrease the engine speed and stop the
engine.
STEP 16
The ammeter reading in Step 14 must be more than
the rated output (45 A). The voltmeter reading in Step
14 must be 25 to 29 volts.
If the ammeter and voltmeter readings are correct the
alternator and voltage regulator are good.
If the ammeter and voltmeter readings are not correct
replace the voltage regulator and brush holder, then
repeat the test.
If the ammeter and voltmeter readings are still not
correct repair the alternator.

4004-6

Old model
STEP 5
10
12
9 21
17 *
11 22
19
7 18
20
16
15
5
14
4
3
2
1
68 mN
13 DPH0206
NOTE: Items marked * must be replaced.

NOTE: Items are numbered in order of disassembly.
1 Nut 7 Screw 11 Screw 17 O-ring
2 Washer 8 Voltage regulator and 12 Capacitor 18 Screw
3 Pulley retainer brush holder 13 Screw 19 Rectifier bridge
4 Pulley 9 Nut 14 Cover 20 Stator
5 Fan 10 Fiber washer 15 Screw 21 Housing
6 Key 16 Rotor 22 Insulator
4004-7
New model
22
10
9
18
9
19
17
10
8 6
12 16
7 20
11
1
3
4
15
5
14
13
CS99H534
NOTE: Items are numbered in order of disassembly
1 Nut 7 Screw 11 Screw 17 Shield
2 Washer 8 Voltage regulator 12 Capacitor 18 Screw
3 Pulley retainer and brush holder 13 Screw 19 Rectifier bridge
4 Pulley 9 Nut 14 Cover 20 Stator
5 Fan 10 Fiber washer 15 Screw 21 Housing
6 Key 16 Rotor 22 Insulator

4004-8
Inspection STEP 8
NOTE: Use a multimeter set to read ohms for the
inspection.
STEP 6
517936
Check the positive diodes in the rectifier bridge.
a Connect the negative lead of the multimeter to
the output (B+) terminal. Connect the positive
517928 lead of the multimeter to one of the leads for the
Check the stator resistance. The resistance in each positive diodes. The positive diodes are the
coil must be 0.22 ohms. If the resistance in a coil is three diodes that are closest to the output (B+)
not 0.22 ohms, refer to Step 10 and install a new sta- terminal. Read the multimeter.
tor. b Reverse the multimeter leads. Read the multim-
eter.
STEP 7 c There must be a high reading and a low read-
ing. If the readings are the same, replace the
rectifier bridge.
d Repeat this procedure for the other two positive
diodes.
STEP 9
703630
Check the stator for a short circuit. Make sure the
rectifier bridge does not touch the stator. Connect
one lead of the multimeter to the housing of the sta-
tor. Connect the other lead of the multimeter to each
of the three leads from the stator. If the pointer of the
multimeter moved, there is a short circuit in the stator. 703628
Refer to Step 10 and install a new stator. Check the negative diodes in the rectifier bridge.
a Connect the negative lead of the multimeter to
the surface of the diode plate that is not painted.
Connect the positive lead of the multimeter to
one of the leads for the negative diodes. Read
the multimeter.
b Reverse the multimeter leads. Read the multim-
eter.
c There must be a high reading and a low read-
ing. If the readings are the same, replace the
rectifier bridge.
d Repeat this procedure for the other two nega-
tive diodes.
4004-9
STEP 10 STEP 12
517942 517904
If any of the diodes are damaged or the stator wind- Hold one lead of the multimeter on the slip ring and
ing is faulty, use a soldering iron to separate the recti- the other lead of the multimeter on the housing. If the
fier bridge from the stator. Disconnect the wires pointer moved, there is a short circuit between the
quickly to prevent damage to the diodes. Replace the housing and the rotor coil, replace the rotor.
faulty rectifier bridge or stator.
STEP 13
STEP 11
Check the bearings on the rotor for wear or damage
and replace if necessary.
STEP 14
517902
Use the multimeter to check the resistance of the
rotor winging. The resistance must be 9.0 ohms. If
the resistance is not 9.0 ohms the rotor is faulty and
517814
must be replaced. Check for continuity between the capacitor mounting
tab and the lead. If there is continuity, the capacitor is
faulty and must be replaced.

4004-10
STEP 15
Measure the length of each brush, this must be more
than 14 mm. If the length of a brush is less than
14 mm, replace the voltage regulator and brush
holder.
STEP 16
517914
Check for continuity between each brush and the
brush terminal. If there is no continuity, replace the
voltage regulator and brush holder.

Section
6003
6003
SWING REDUCTION GEAR AND BRAKE

Printed in France
6003-2
TABLE OF CONTENTS
SPECIFICATIONS .................................................................................................................................................. 3
SPECIAL TORQUES .............................................................................................................................................. 3
WORKSHOP TOOLS ............................................................................................................................................. 3
TOOLS TO BE MADE ............................................................................................................................................ 4
SWING MOTOR/REDUCTION GEAR ASSEMBLY ............................................................................................... 5
SWING BRAKE ...................................................................................................................................................... 6
Cross-sectional drawing ...................................................................................................................................... 6
Exploded view ..................................................................................................................................................... 7
Replacing the swing brake discs with the reduction gear in place on the machine ............................................ 8
Inspection ............................................................................................................................................................ 9
SWING REDUCTION GEAR ................................................................................................................................ 10
Removal and Installation ................................................................................................................................... 10
Cross-sectional drawing .................................................................................................................................... 11
Exploded view ................................................................................................................................................... 12
Disassembly and Assembly .............................................................................................................................. 13
Inspection .......................................................................................................................................................... 15
WARNING: This symbol is used in this manual to indicate important safety messages. Whenever you see
! this symbol, carefully read the message that follows, as there is a risk of serious injury.

6003-3
SPECIFICATIONS
Make........................................................................................................................................................ TRASMITAL
Type................................................................................................................................................................................ 705T2
Swing reduction gear weight ...........................................................................................................................................80 kg
BRAKE
Minimum pressure for complete brake release .............................................................................................18 bar
Maximum brake release pressure .................................................................................................................50 bar
Number of brake discs:
- Friction discs .......................................................................................................................................................4
- Steel discs...........................................................................................................................................................3
Thickness of new friction discs....................................................................................................................2.9 mm
Mimimum thickness of friction discs ............................................................................................................2.7 mm
Brake torque............................................................................................................................................... 200 Nm
REDUCTION GEAR
Reduction ratio ..............................................................................................................................................1/24.5
Upperstructure braking torque ............................................................................................................. 2980 mdaN
Theoretical output shaft speed ..............................................................................................................46.676 rpm
Swing gear ................................................................................................................................. 13 teeth module 9
Turntable bearing ....................................................................................................................... 79 teeth module 9
Reduction gear oil capacity ....................................................................................................................... 2.1 litres
Recommended oil .................................................................................................TRANSELF B 80W 90 API GL5
Grease recommended for bearings ................................................................................................. EP2 GREASE
Swing motor installation tolerance ................................................................................................91.8 to 92.8 mm
Swing reduction gear installation tolerance.................................................................................93.45 to 94.7 mm
SPECIAL TORQUES
Swing motor retaining screws on reduction gear............................................................................................ 200 Nm
Swing reduction gear retaining screws on upperstructure.........................................................................................500 Nm
Brake housing screws ...................................................................................................................................................50 Nm
Oil level dipstick .............................................................................................................................................................70 Nm
Drain plug.......................................................................................................................................................................30 Nm
Swing pinion lubrication pipe.........................................................................................................................................36 Nm
WORKSHOP TOOLS
1 Torque wrench, OEM 6472 (14 to 82 Nm)

6003-4
TOOLS TO BE MADE
Tool for compressing swing brake springs, used on page 8.
240

= =

20
Ø17
=
50
=
= = M16
200
CM96G003
120
M16
PDG0391
154
20
40
PDG0393

6003-5
SWING MOTOR/REDUCTION GEAR ASSEMBLY

2

3
A

A

CM96F009
A Lifetime lubricated bearings. For recommended grease see "Specifications”

1 Swing motor
- For removal/installation and disassembly/assembly see Section 8040
2 Swing brake
- Replacing the swing brake discs with the reduction gear in place on the machine
3 Swing reduction gear
- Remove and install
- For disassembly/reassembly

6003-6
SWING BRAKE
Cross-sectional drawing
1 2 3

13
4

12

11
5

6
10

9
8 7
CM96F010
1 BRAKE HOUSING 8 CENTRAL GEAR
2 SNAP RING 9 SNAP RING
3 SPRING THRUST WASHER 10 BRAKE STOP
4 PISTON RETURN SPRINGS 11 O-RING
5 BRAKE PISTON 12 O-RING
6 FRICTION DISCS 13 OIL FILLING AND LEVEL PLUG
7 STEEL DISCS

6003-7
Exploded view
11
12
1
10
9
8
7
6
5
3
2
CS96F222
1 SWING BRAKE 8 STEEL DISCS
2 SNAP RING 9 FRICTION DISCS
3 SPRING THRUST WASHER 10 CENTRAL GEAR
4 PISTON RETURN SPRINGS 11 OIL FILLING AND LEVEL PLUG
5 BRAKE PISTON 12 SEAL
6 O-RING
7 O-RING

6003-8
Replacing the swing brake discs with the reduction gear in place on the
machine
Before performing any service work on a machine, the following steps must be carried out in the order shown:
- Stop the engine.
- Turn the battery master switch to the "Off" position and remove the key.
- Operate the emergency pump and the control levers simultaneously to release pressure in the hydraulic circuit.
STEP 1 STEP 4
Remove the swing motor. Refer to Section 8040.
STEP 2
C02320
Remove the brake spring thrust washer.

STEP 5
C02314
Install the special swing brake return spring compres-

sion tool. (See "Tools to be made"). Tighten the screw
until the snap ring is freed.
STEP 3
C02322
Remove the ten brake piston springs.
C02318
Dislodge the snap ring from its housing. Remove the

special tool and the snap ring.

6003-9
STEP 6 NOTE:

2 1
3

1

5

A

2

4

CM96F012

Remove the brake piston (1) and the central gear (2) CM96F013
from the brake housing (3). Remove and discard the O- When assembling, the friction discs (1) and the steel
rings (4) and (5). discs (2) must be installed alternately as shown in the
drawing.
NOTE: To remove the brake piston (1), carefully use
a compressed air jet, adjusted to minimum pressure, Inspection
via orifice A.
STEP 7
PE12006
Check friction disc wear.

C02330
Minimum thickness of friction discs should be 2.7 mm.
Remove the friction discs and the steel discs (see
“Inspection”). NOTE: For installation, follow the same procedure in
the reverse order from that of removal. Replace all
seals by new seals which have been lubricated prior
to use.
Before using the machine, all the following operations must be carried out in the order shown:
- Turn the battery master switch to the “ON” position.
- Start the engine.
- Check that the swing brake is operating correctly. See Section 8001.
- Check the hydraulic circuit for leaks.
- Check the oil levels.

6003-10
SWING REDUCTION GEAR

Removal and Installation
Before performing any service work on a machine, the following steps must be carried out in the order shown :
- Stop the engine.
STEP 1 STEP 3
Disconnect and plug the swing brake release hose
from the swing reduction gear.
STEP 4
1
C01334
Remove the drain plug from the swing reduction gear.

Drain the oil into a receptacle with a capacity of 5 litres.
Install and tighten the drain plug to the correct torque.
Disconnect the lubrication pipe (2). C02304
NOTE: When installing, remove the breather, fill the Mark the position of the reduction gear on the upper
reduction gear with the recommended oil, see "Spec- structure frame, by making marks on the reduction gear
ifications". Check the level using the oil dip-stick. and on the upperstructure frame. Remove the swing
Tighten the oil dip-stick and the lubrication pipe to the reduction gear retaining bolts.
correct torque. Install the breather. The time required NOTE: When installing, tighten the bolts to the cor-
to fill the reduction gear is quite long. rect torque.
STEP 2 STEP 5
Remove the swing motor. Refer to Section 8040. Using a suitable lifting device, remove the swing
reduction gear from the machine. Weight of reduction
gear: about 80 kg.
to that of removal.
Before using the machine, all the following operations must be carried out in the order shown :
- Start the engine.
- Run the swing motor.

6003-11

1

2

3

4

25 5
24

6

7

23
22

8
21

9

20 10
19

11

18

14 12
17
16 15 13
CM96F011
1 BRAKE HOUSING 14 SEAL
2 FIRST STAGE SATELLITE CARRIER 15 SCREW
3 ALIGNMENT BUSHING 16 SEAL
4 CENTRAL GEAR 17 LOWER BEARING
5 O-RING 18 SEAL
6 SECOND STAGE SATELLITE CARRIER 19 SWING GEAR
7 CROWN WHEEL 20 LIP SEAL
8 O-RING 21 O-RING
9 SNAP RING 22 COVER
10 REDUCTION GEAR HOUSING 23 UPPER BEARING
11 PLUG 24 SNAP RING
12 SEAL 25 SCREW
13 DRAIN PLUG

6003-12
Exploded view
8
1
6 7
20 19
5 18
4
21
22
17
9 16
15
14
13
12
11
10
CS96F223
1 SCREW 12 COVER
2 BRAKE HOUSING 13 SWING GEAR
3 O-RING 14 SEAL
4 FIRST STAGE SATELLITE CARRIER 15 LOWER BEARING
5 ALIGNMENT BUSHING 16 O-RING
6 CROWN WHEEL 17 REDUCTION GEAR HOUSING
7 CENTRAL GEAR 18 DRAIN PLUG
8 SECOND STAGE SATELLITE CARRIER 19 SEAL
9 SNAP RING 20 PLUG
10 UPPER BEARING 21 SCREW
11 LIP SEAL 22 SEAL

6003-13

STEP 1 STEP 3
Remove the swing brake, see "Replacing the brake 1

discs with the reduction gear in place on the
machine”.

5 4

2
STEP 2

2

1

3

6

3

7

CM96F014

Remove the satellite carrier assembly (1), the alignment
bushing (2), the central gear (3), the crown wheel (4)

and the satellite carrier assembly (5) from the reduction
gear housing assembly (7). Remove and discard the O-
CM96F011 ring (6).
Remove the three screws (1) and remove the brake
STEP 4
housing assembly (2). Remove and discard the O-ring
(3).
1 4
NOTE: When installing the brake housing, tighten the

screws (1) to the correct torque.

3
2
CM96F015
Remove the snap ring (1) and the screw (2) from the
reduction gear housing assembly (4). Remove and dis-
card the O-ring (3).

6003-14
STEP 5 STEP 7

1 2
3

1

2

4 3
CM96F018
Remove the snap ring (1) and the upper bearing (2)
from the cover (3). Remove and discard the lip seal (4).

NOTE:
CM96F016

Using a drift and a hammer, tap the swing gear assem-
bly (1) out of the reduction gear housing (2).

NOTE: When removing the swing gear assembly (1),
the lower bearing (3) may remain in the reduction

gear housing (2). If the lower bearing remains in the
reduction gear housing, extract the lower bearing
using a suitable extractor.
STEP 6 CM96F019
When assembling, position the lip seal as shown in the

1
drawing.

3
2

CM96F017
Remove the cover assembly (1) from the swing gear (2).
Remove and discard the O-ring (3).

6003-15
STEP 8 Inspection

1
Clean all the parts using a non-inflammable solvent.
Check the condition of the bearings : look for wear,

scaling, scratches. The bearing races should not
show signs of cavities scaling. Check the gears. They

should not show signs of irregular wear or scaling.
3
1 2

A

4

2

CM96F020

Using a suitable extractor, extract the upper bearing

inner cage (1) and the lower bearing (2) from the swing
gear (3). Discard the seal (4).

!
WARNING: Use heat protective gloves when
handling hot parts.

NOTE: When assembling, heat the upper bearing

inner cage (1) and the lower bearing (2) in an oil bath
to 80 °C. Install the new sealing ring (4) and then CM96G001
install the lower bearing (2) on the swing pinion (3). Check the swing reduction gear assembly tolerance by
Install the upper bearing inner cage (1) on the swing measuring the distance (A) between the brake housing
pinion. thrust face (1) and the upper face of the central pinion
(2) of the first stage. The distance (A) should be
between 93.45 mm and 94.7 mm.
NOTE: When assembling the reduction gear, pro-
ceed in the reverse order from that of the disassem-
bly. Replace all seals with new seals, lubricated prior
to use.

6003-16

Section
6003
6003

Printed in France
6003-2
TABLE OF CONTENTS
SPECIFICATIONS..................................................................................................................................................... 2
SPECIAL TORQUES................................................................................................................................................. 3
WORKSHOP TOOLS ................................................................................................................................................ 3
TOOLS TO BE MADE ............................................................................................................................................... 3
SWING MOTOR/REDUCTION GEAR ASSEMBLY .................................................................................................. 5
SWING REDUCTION GEAR AND BRAKE ............................................................................................................... 6
Cross-sectional view .............................................................................................................................................6
Exploded view ....................................................................................................................................................... 7
Removal and installation .......................................................................................................................................8
Disassembly ..........................................................................................................................................................9
Inspection............................................................................................................................................................11
Assembly.............................................................................................................................................................12
! this symbol, carefully read the message which follows, since there is a danger of serious injury.
SPECIFICATIONS
Make........................................................................................................................................................ TRASMITAL
Type................................................................................................................................................................................ 757T2
Weight of swing motor and reduction gear assembly ..................................................................................................125 kg
BRAKE
Minimum braking pressure..............................................................................................................................9 bar
Maximum control pressure............................................................................................................................50 bar
Number of brake discs :
- Friction discs ....................................................................................................................................................... 6
- Steel discs........................................................................................................................................................... 5
Thickness of new friction discs....................................................................................................................2.9 mm
Minimum thickness of friction discs .............................................................................................................2.7 mm
Minimum piston stroke with new discs ........................................................................................................2.5 mm
Maximum piston stroke with worn discs ......................................................................................................5.5 mm
Braking torque................................................................................................................................. 415 to 425 Nm
REDUCTION GEAR
Reduction ratio .............................................................................................................................................. 1/34.5
Upperstructure braking torque ............................................................................................................. 7644 mdaN
Theoretical shaft output speed.....................................................................................................................45 rpm
Swing pinion............................................................................................................................ 13 teeth, module 11
Turntable ................................................................................................................................. 72 teeth, module 11
Reduction gear oil capacity .......................................................................................................................... 5 litres
Specified type of oil ................................................................................................TRANSELF B 80W90 API GL5
Type of grease specified for ball or roller bearings .......................................................................... GREASE EP2
Swing motor locating dimension ...................................................................................................92.5 to 93.5 mm

6003-3
SPECIAL TORQUES
Swing motor retaining screws on reduction gear............................................................................................ 200 Nm
Swing reduction gear retaining screws on upperstructure.........................................................................................300 Nm
Brake housing retaining screws ..................................................................................................................................120 Nm
Drain plug.......................................................................................................................................................................90 Nm
Oil dipstick.............................................................................................................................................................60 to 80 Nm
Plug M22 x 1.5......................................................................................................................................................60 to 80 Nm
Lock-nut ....................................................................................................................................................... 1550 to 1650 Nm
WORKSHOP TOOLS
TOOLS TO BE MADE
Tool for compressing the swing brake springs
226
= =

20
= =
17
40
= = M16
190
PDG0390
70
M16
PDG0391
154
20
40
PDG0393

6003-4
CAS-2448 Tool for assembling and disassembling the reduction gear bearing lock nut
CM95M004

6003-5
SWING MOTOR/REDUCTION GEAR ASSEMBLY
92.5 to 93.5
2
CS95M068
1 Swing motor
- Removal and installation/Disassembly and Assembly, See Section 8040.
2 Swing brake
- Disassembly: STEPS 6 to 11
- Assembly: STEPS 29 to 32
3 Reduction gear
- Removal and installation: STEPS 1 to 5
- Disassembly: STEPS 12 to 16
- Assembly: STEPS 18 to 28
6003-6

Cross-sectional view
1
31
2
30
29 3
28 4
27 5
26
26 6
25 7
24 8
23 9
10
22
21 11
20 12
19 13
14
18
15
17 16
CS95M070
1 ADAPTER SPACER 21 CROWN WHEEL

2 SNAP RING 22 SECOND STAGE PLANETARY SHAFT
3 BRAKE PISTON RETURN SPRINGS 23 O-RING
4 BRAKE PISTON 24 BRAKE HOUSING
5 O-RING 25 SNAP RING
6 FRICTION DISCS 26 BRAKE DISC STOP
7 STEEL DISCS 27 SPLINED SLEEVE
8 SCREW 28 O-RING
9 SECOND STAGE SATELLITE CARRIER 29 SPACER
10 O-RING 30 DIPSTICK
11 FIRST STAGE SATELLITE CARRIER 31 O-RING
12 ADJUSTMENT SHIM
13 TAPER ROLLER BEARING
14 SEAL
15 REDUCTION GEAR HOUSING
16 GEAR SHAFT
17 SEALING RING
18 TAPER ROLLER BEARING
19 PLUG
20 LOCK NUT

6003-7
Exploded view
14 15 *
13
11
10
9
19
5 18
4 17
3 16
*2
1 12
8 *
7
28
6 *
*
23
22
*21 31
20 30 *
29
27
26
25
24
CS95M072
NOTE: Parts shown with an asterisk must always be replaced.

1 SPACER 21 O-RING
2 O-RING 22 SATELLITE CARRIER
3 SNAP RING 23 LOCK NUT
4 SPACER 24 ADJUSTMENT SHIM
5 BRAKE PISTON RETURN SPRINGS 25 TAPER ROLLER BEARING
6 BRAKE PISTON 26 SEAL
7 O-RING 27 PLUG
8 O-RING 28 REDUCTION GEAR HOUSING
9 STEEL DISCS 29 TAPER ROLLER BEARING
10 FRICTION DISCS 30 SEALING RING
11 SPLINED SLEEVE 31 GEAR SHAFT
12 DIPSTICK
13 SCREW
14 BRAKE HOUSING
15 O-RING
16 BRAKE STOP RING
17 SNAP RING
18 PLANETARY SHAFT
19 SATELLITE CARRIER
20 CROWN WHEEL

6003-8

- Stop the engine.
- Unscrew the hydraulic reservoir cap two or three turns to release the pressure and re-tighten the cap.
STEP 1 STEP 3
Remove the swing motor. Refer to section 8040.
STEP 4
1 Disconnect and plug the swing brake release hose
and the swing reduction gear drain hose.
2 STEP 5
2
PH07627
Remove the swing reduction gear (2) dipstick (1). 1

STEP 2 1
1
CK95M059
Mark the position of the reduction gear on the upper

structure frame, by making marks on the reduction gear
and on the upperstructure frame. Remove the retaining
screws (1) and their washers from the swing reduction
gear (2).
STEP 6
Using a suitable lifting device, remove the swing
PH00501 reduction gear from the machine. The weight of the
Place a receptacle of a capacity of about 7 litres under reduction gear is 125 kg.
the upperstructure frame. Remove the drain plug (1) NOTE: When installing, proceed in the reverse order
and drain the oil. to that of removal.

6003-9
- Turn the battery master switch to the "On" position.
- Start the engine.
- Operate the swing motor.
Disassembly
NOTE: The swing brake can be disassembled on the STEP 9
machine.
1 2
STEP 7
1 3
2
CS95M076
Remove the snap ring (1) from the reduction gear (2)
and remove the special tool.
CS95M075
STEP 10
Remove the adapter spacer (1) from the reduction gear
(2). Discard the O-ring (3). 1
7
STEP 8
2
3
A
4
5
6
CS95M077
C02314 Remove in the following order: the spacer (1), the return
Install the special tool for compressing the swing brake springs (2), the brake piston (3), the splined sleeve (4)
return springs. See "Tools to be made". Tighten the and the brake discs (5). Scrap the O-rings (6) and (7).
screw until the snap ring is freed. NOTE: To remove the brake piston (3), carefully use
a jet of compressed air, set to minimum pressure,
through orifice A.

6003-10
STEP 11 STEP 13
2 1
3 2
4
5
3 CS95M086
CS95M081
Remove in the following order: the planetary shaft (1),
Remove the retaining screws (1) from the brake the satellite carrier (2), the crown wheel (3) and the
housing (2) and remove the brake housing. Scrap the satellite carrier (4). Scrap the O-ring (5).
O-ring (3). STEP 14
STEP 12
3 2 1
CS95M085
Remove the snap ring (1) and the brake stop ring (2)
from the brake housing (3).
CS95M067
Straighten the three retaining lugs on the lock nut (1)

and remove it from the pinion shaft (2), using the special
tool (CAS-2448). Remove the adjusting shim (3). Scrap
the lock nut.

6003-11
STEP 15 STEP 17
1
2
2
3
CS95M090
Using an extractor, remove the bearing (1) from the

gear shaft (2). Scrap the sealing ring (3).
Inspection
CS95M088
STEP 18
Using a press, remove the gear shaft (1) from the
reduction gear housing (2) and remove the bearing (3). Clean all the parts with a non-inflammable solvent.
Check the condition of the bearings: wear, scaling,
STEP 16 scratches. The bearing race surfaces should show no
signs of pitting or scaling. Check the gears. They
4 should show no signs of irregular wear or scaling.
Check the friction discs for wear. The minimum
thickness of the discs should be 1.5 mm.
1
CS95M089
Using an extractor, remove the bearing cups (1) and (2)

from the reduction gear housing (3). Scrap the seal (4).

6003-12
Assembly STEP 21
STEP 19
1
(C)
2
2 1 CS95M091
Install the pinion shaft (1) in the reduction gear housing

(2) and fill the space (C) with the recommended grease,
CS95M180 see "Specifications".
Place the new sealing ring (1) on the gear shaft (2) and
fill the sealing ring with the recommended grease, see STEP 22
"Specifications". Using a press, install the bearing (3) on
the gear shaft (2).
STEP 20 1
2
3
1 CS95M110
CS95M108 1
Install the bearing cups (1) and (2) in the reduction gear
housing (3).
2
CS95M092
Install the new seal (1) in the reduction gear housing

assembly (2) as shown.

6003-13
STEP 23 STEP 25
2
1
3
2 1
CS95M094
Prevent the pinion shaft (3) from turning. Install the

adjusting shim (1) and the new lock nut (2) on the pinion
CS95M093
shaft (3).
Using a press, install the bearing (1) on the gear shaft
(2). Using the special tool (CAS-2448), tighten the lock-
nut (2) to torque.
STEP 24
STEP 26
1 1
CS95M096
Using a torque wrench and the special tool (CAS-2448),

turn the pinion shaft (1) and note the torque reading
required to turn the pinion shaft.
CS95M093
The torque required to turn the pinion shaft (1) should
Using a press, gradually apply an axial pre-load until a be between 8 and 10 Nm.
load of between 23000 and 28000 N is obtained on the
bearing (1) then turn the reduction gear housing (2) in If the pinion shaft will turn at a lower torque than
both directions. Release the pressure. 8 Nm, reduce the thickness of the adjusting shim (2)
by machining.
Repeat this operation several times to obtain the
correct pinion shaft turning torque.

6003-14
STEP 27 STEP 29
2 1 8
6
9
5
4
2 1
CS95M099
Peen the edge of the lock nut (1) onto the pinion shaft 3
(2) at three places at 120° from each other, as shown in
the drawing. 2
STEP 28 1
CS95M081
2 1 Install, in the following order: the new O-ring (2), the
crown wheel (3), the new O-ring (4), the first stage
satellite carrier (5), the second stage satellite carrier (6),
the planetary shaft (7) and the brake housing (8) on the
reduction gear housing (1). Install the retaining screws
(9) and tighten them to torque.
STEP 30
3
CS95M085
Install, in the following order: the brake stop ring (1) and
the snap ring (2) in the brake housing (3).
CS95M102
Assemble and interpolate the discs (friction discs (1),

then steel discs (2)), as shown in the drawing.

6003-15
STEP 31 STEP 33
1
6 5
2
4
CS95M075
1 2 3 Install the new O-ring (1) on the adapter spacer (2) and
install the spacer assembly in the brake housing (3).
CS95M076 STEP 34
Install in the following order: the splined shaft (1), the
new O-rings (2) and (3), the brake piston (4), the return 1
springs (5) and the spacer (6) in the brake housing.
STEP 32
C
2
C02314
Place the snap ring in the brake housing. Using the

special tool, compress the swing brake return springs. 3
Install the snap ring in its groove and remove the
special tool. CS95M103
Check the assembly tolerance of the swing motor by

measuring the distance (C) between the thrust face of
the brake housing (1) and the upper face of the brake
shaft (2). The distance (C) should be between 92.5 and
93.5 mm.
If the dimension is greater than 93.5 mm, machine
the thrust face of the central ring (3).
If the dimension is less than 92.5 mm, replace the
central ring (3).

6003-16

Section
6004
6004
FRONT AXLE AND SERVICE BRAKE
CARRARO 638LD AND 638FR AXLE

Printed in France
6004-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................................... 3
SPECIAL TORQUE SETTINGS ............................................................................................................................... 3
SPECIAL TOOLS ..................................................................................................................................................... 4
Kit (CAS-40008) ................................................................................................................................................... 5
Tools to be manufactured .................................................................................................................................... 6
WORKSHOP TOOLS ............................................................................................................................................... 6
FRONT AXLE ........................................................................................................................................................... 8
Cross-sectional drawing ....................................................................................................................................... 8
Removal and installation .................................................................................................................................... 10
Disassembly and assembly................................................................................................................................ 12
REDUCTION GEAR ............................................................................................................................................... 14
WHEEL HUB AND SERVICE BRAKE.................................................................................................................... 16
STEERING PIVOT ................................................................................................................................................. 18
Adjusting the preload of the steering pivot pins ................................................................................................. 21
DIFFERENTIAL CARRIER COUPLING CLAMP.................................................................................................... 22
Disassembly ....................................................................................................................................................... 22
Assembly............................................................................................................................................................ 22
CROWN WHEEL AND PINION.............................................................................................................................. 24
Disassembly ....................................................................................................................................................... 24
Inspection ........................................................................................................................................................... 25
Assembly............................................................................................................................................................ 26
Adjusting the pinion conical distance ................................................................................................................. 26
Preloading the bearings of the pinion shaft ........................................................................................................ 28
Adjusting the clearance between crown wheel and pinion teeth........................................................................ 29
Preloading the differential taper roller bearings ................................................................................................. 30
DIFFERENTIAL ...................................................................................................................................................... 32
Inspection ........................................................................................................................................................... 33

6004-3
SPECIFICATIONS
Weight of front axle without oil.......................................................................................................................... 630 kg
Oil capacity of wheel reduction gear.............................................................................................................. 2.5 litres
Axle housing oil capacity
Carraro 638LD............................................................................................................................................ 15 litres
Carraro 638FR ........................................................................................................................................... 16 litres
Type of oil ...................................................................................................................TRANSELF B 80W90 API GL5
Type of grease ...................................................................................................................................... GREASE EP2
Crown wheel and pinion - differential
Crown wheel/pinion ratio .............................................................................................................................2.846:1
Clearance between pinion/crown wheel teeth ...............................................................................0.21 to 0.28 mm
Preload on differential pinion shaft bearings ..................................................................................P = 84 to 126 N
Total preload on differential pinion shaft bearings .......................................................... T = (P + 29) to (P + 44) N
Thickness of pinion shaft shims .................................................................. 2.5 to 3.4 mm (from 0.10 in 0.10 mm)
Steering pivot
Thickness of shims for adjusting the pivot bushings .........................................................................0.1 to 0.3 mm
Preload on pivot bushings ...............................................................................................................0.0 to 0.10 mm
Clearance between the bushing and the half-shaft at the wheel end..........................................0.16 to 0.265 mm
Clearance between the bushing and the half-shaft at the differential end...................................0.16 to 0.265 mm
Final drive
Reduction gear ratio ......................................................................................................................................6.23:1
Transmission total ratio................................................................................................................................17.73:1
Brake
Thickness of a new brake disc ..........................................................................................................4.8 to 4.9 mm
Wear limit ....................................................................................................................................................3.9 mm
SPECIAL TORQUE SETTINGS

Crown wheel retaining screws ........................................................................................................................ 190 Nm
Pinion nut.............................................................................................................................................. as per preload
Coupling clamp retaining screw...................................................................................................................... 139 Nm
Braking mechanism retaining screws ............................................................................................................. 220 Nm
Satellite carrier retaining screws..................................................................................................................... 530 Nm
Reduction gear cover screws ........................................................................................................................... 23 Nm
Differential yoke screws .................................................................................................................................. 413 Nm
Differential brake plate screw ........................................................................................................................... 13 Nm
Steering pivot cover screws ............................................................................................................................ 190 Nm
Universal joint shaft coupling .......................................................................................................................... 120 Nm
Wheel retaining nuts ....................................................................................................................................... 540 Nm
Differential carrier retaining screw .................................................................................................................. 150 Nm
Differential carrier retaining nut....................................................................................................................... 145 Nm
Differential carrier retaining stud....................................................................................................................... 40 Nm
Axle and reduction gear drain plug ................................................................................................................... 60 Nm
Breather.............................................................................................................................................................. 5 Nm
Breather bracket ............................................................................................................................................... 15 Nm
Brake supply union .................................................................................................................................. 12 to 16 Nm
Brake bleed screw ............................................................................................................................................ 10 Nm
Steering stop screw nut .................................................................................................................................. 100 Nm
Pivot extension stop screw ............................................................................................................................. 156 Nm
Differential carrier cover retaining screws......................................................................................................... 27 Nm

6004-4
SPECIAL TOOLS
CS96A240 CS96A243
CAS-1840B Adjustable spanner CAS-1964-1 Centring piece
Used for the first time on page 24. CAS-1964-2 Centring piece. Used for the first time on
page 26.
CS96A244
CAS-1967-1 Centring piece CD96A010
CAS-1967-2 Centring piece. Used for the first time on CAS-10803 Removing tool for retaining ring
page 20. Used for the first time on page 17.
CS96A007 CS96A016
CAS-2453 Centring piece CAS-2454 Centring piece
Used for the first time on page 13. Used for the first time on page 13.
CS96A015 CS96A016
CAS-2455 Centring piece CAS-2452 Centring piece

6004-5
CS96A255 CS96A237
CAS-1716-3 Interchangeable handle CAS-1596B-5 Calibrating block
Used on pages 20, 26 and 30. Used for the first time on page 26.
Kit (CAS-40008)
CS96A239
CAS-1596A-7 Pilot (screw)
CS96A236 Used for the first time on page 26.
CAS-1596B-1 Calibrating tube
Used for the first time on page 26.
CS96A242
CAS-1668 Feeler gauge
CAS-1596A-6 Aligning disc
CS96A241
CAS-2078 Wrench for nut
CAS-1596A-4 Handle

6004-6
Tools to be manufactured
Case seal mounting tool (wheel hub), used for the first time on page 17.
ø 30

200

32

R1
5.5 0
+0.3 +0.5
8 0
+0.5
16 14.5 0
ø 148

ø 176.85±0.05 2 to 15°
ø 199.5±0.1
ø 204.5±0.1
ø 218.5±0.2
PDH0030
WORKSHOP TOOLS
Screw........................................................................................................................................................ CAS-10355
Release tool.............................................................................................................................................. CAS-10563
Extractor ................................................................................................................................................... CAS-10692
Torque wrench 0-22 Nm
Loctite 270
Loctite 510

6004-7
This page is intentionally left blank

6004-8
FRONT AXLE
7 8 9 10 9 11 12 13 14 16 17 18 21 22 23 25 26

27

28

6

32

5

31
24

4

29

3 2
15 11 20 1 16 19 30
CM96B001
56 55 54 53
52
51
50
61 49
47
48
55
46
45
44
43
42
41
37
60
36
40
57
39 35
58 59 38
49
PDH0159A
33 34 PDH0046

6004-9
Description
1 REDUCTION GEAR COVER 32 AXLE HOUSING
2 SATELLITE CARRIER 33 SCREW
3 RING 34 WASHER
4 SCREW 35 COUPLING CLAMP
5 THRUST WASHER 36 ADJUSTMENT SHIM
6 GEAR SHAFT 37 LIP SEAL
7 THRUST WASHER 38 O-RING
8 PINION 39 WASHER
9 NEEDLE ROLLER BEARING 40 LOCK NUT
10 SPACER 41 BEARING
11 LOCKING RING 42 WASHER
12 REACTION PLATE 43 COMPRESSIBLE SPACER
13 BRAKE DISC 44 WASHER
14 BRAKE CROWN 45 BEARING
15 CROWN WHEEL 46 ADJUSTMENT SHIM
16 BEARING 47 GEAR SHAFT
17 O-RING 48 DIFFERENTIAL BRACKET
18 WHEEL HUB 49 ADJUSTING RING
19 CASE SEAL 50 BEARING
20 BRAKE MECHANISM 51 BRAKE PLATE
21 UPPER PIVOT 52 SCREW
22 SEAL 53 SCREW
23 GREASE FITTING 54 CROWN WHEEL
24 TRANSMISSION SHAFT 55 YOKE
25 SEAL 56 DIFFERENTIAL
26 RING 57 SCREW
27 RING 58 WASHER
28 SEAL 59 COVER
29 ADJUSTMENT SHIM 60 O-RING
30 LOWER PIVOT 61 RING
31 PIVOT HOUSING

6004-10

- Park the machine on flat and horizontal ground.
- Position the attachment to the front of the machine with the upperstructure aligned with the undercarriage.
- Engage the upperstructure swing locking pin.
- Lower the stabilizers or the dozer blade to raise the wheels off the ground. If the machine is not equipped with
stabilizers or dozer blade, raise the rear wheels on blocks.
- Using the attachment, lift the machine and place axle stands in front of each side of the undercarriage and then
place the undercarriage resting on the axle stands and the stabilizers so as to distribute the weight between the
stabilizers and the axle stands.
- Stop the engine.
- Operate the emergency pump while at the same time operating the control levers to release pressure in the
hydraulic systems.
- Unscrew the pressure release plug on the hydraulic reservoir by two to three turns to release pressure in the
hydraulic circuit, then retighten the plug.
STEP 1 STEP 5
Remove the front wheels. If the machine is equipped with a dozer blade,
remove the pin from the dozer blade cylinder and
NOTE: When installing, tighten the wheel nuts to a
push the cylinder forward to gain access to the axle
torque of 540 Nm.
pivot pin.
STEP 2 STEP 6
Remove the steps.
Place a roller jack under the centre of the front axle
STEP 3 and wedge the axle on the jack so that it does not tip
during the disengagement stage.
Remove the supply hoses for the service brakes and
the supply hoses for the steering cylinder. STEP 7
STEP 4 Remove the axle pivot pin and slowly lower the jack
so as to remove and disengage the axle from the
Remove, at the front axle end, the transmission machine. Place the axle on a suitable support.
universal joint retaining screws and uncouple the
transmission universal joint. NOTE: When installing the engine, proceed in the
NOTE: When installing, tighten the screws to a
torque of 120 Nm.
- Start the engine.
- Check the hydraulic oil level in the reservoir. Top up if necessary.
- Bleed the brakes.
- Check that there are no leaks in the hydraulic system or the brake system.
- Check that the service brakes work properly.

6004-11

6004-12
25 11 10 9 240 Nm
26
24
26 8
27 10 Nm
25
10 Nm
7
3 5 Nm 20
15 Nm 150 Nm
5 4
18 145 Nm 6
23 22 40 Nm
156 Nm 19
28 21 Loctite 510
1 14
60 Nm
13
2
60 Nm
12
17 60 Nm
16 29
15
PDH0051
1 FILLER PLUG 16 LIP SEAL

2 DRAIN PLUG 17 RING
3 BREATHER 18 NUT
4 SEAL 19 WASHER
5 BREATHER BRACKET 20 SCREW
6 PIN 21 DIFFERENTIAL CARRIER
7 SHAFT 22 PLUG
8 GREASE FITTING 23 PIVOT EXTENSION STOP SCREW
9 SCREW 24 PIVOT EXTENSION
10 WASHER 25 LIP SEAL
11 STEERING CYLINDER 26 RING
12 REDUCTION GEAR 27 GREASE FITTING
13 HUB AND SERVICE BRAKE 28 AXLE HOUSING
14 STEERING PIVOT 29 REDUCTION GEAR DRAIN PLUG
15 AXLE HALF-SHAFT

6004-13
STEP 1 STEP 8
Drain the reduction gears and the axle housing. Remove and scrap the lip seals (16).
NOTE: When installing, fill the reduction gears and NOTE: When reinstalling, use the centring piece
the axle housing with oil (see the specifications) and (CAS-2454) fitted with the interchangeable handle
tighten the plugs to a torque of 60 Nm. (CAS-1716-3), and the felted edge of the seal
oriented towards the outside of the axle.
STEP 2
STEP 9
Remove the parts of (6) to (10) then remove the
steering cylinder assembly (11). To disassemble and Remove and scrap the lip seals (25).
reassemble the steering cylinder, refer to section
NOTE: When reinstalling, use an appropriate
7080.
centring piece, the felted side of the seal must be
NOTE: When assembling, tighten the screws (9) to a oriented towards the outside of the pivot extension
torque of 240 Nm. (24).
STEP 3 STEP 10
Remove the reduction gears (12). See section Remove the bushings (17) to (26), use the extractor
"Reduction gear". (CAS-10692) and the screw (CAS-10355).
STEP 4 NOTE: When reinstalling, use the centring piece
(CAS-2453) fitted with the interchangeable handle
Remove the hubs (13) complete with their brake. See (CAS-1716-3) for the bushings (17) and an
section "Wheel hub and service brake". appropriate centring piece for the bushings (26).
STEP 5 STEP 11
Remove the steering pivots (14). See section Remove the parts of (18) to (20) then remove the
"Steering pivot". differential carrier (21).
STEP 6 NOTE: When reinstalling the differential carrier on
Remove the axle half-shafts (15). Check wear on the the axle housing (28), clean and degrease the
spiders, replace them if necessary. differential carrier coupling and the axle housing, also
the threads of the axle retaining holes. Apply a 1 mm
STEP 7 wide bead of Loctite 510 on the axle housing face
and around the threads of each hole. Tighten the
Remove the pivot extension stop screw (23) then the
screws (20) to a torque of 150 Nm, the studs (22) to a
pivot extension (24).
torque of 40 Nm and the nuts (18) to a torque of
NOTE: When reinstalling, tighten the screws (23) to a 145 Nm.
torque of 156 Nm.

6004-14
REDUCTION GEAR
Loctite 510
18
26
29
27
20
32
530 Nm
35 28
32
36
33
31
34 30 60 Nm
23 Nm
PDH0036
36 32 34 33 35 34 32 18 17

28 27 29 20 26 30
CM96B001

6004-15
STEP 1 STEP 3
Remove the screws (30). Extract the reduction gear Check the needle roller bearings (34), the pinions
cover (26) using two screws and the two extraction (33), the spacers (35), the pinion shafts (36) and the
orifices on the cover. thrust washers (32). Replace them if necessary.
NOTE: When assembling, tighten the screws to a NOTE: When reinstalling the pinions (33) and the
torque of 23 Nm. needle roller bearings (34) in the reduction gear
housing (26), hold them in position with grease.
STEP 2
STEP 4
Slacken but do not remove the three screws (28) then
tap the screw heads with a mallet to release the Check the bushings (27) and the half-shaft thrust
satellite carrier (20). Remove the three screws (28), washer (29). Replace them if necessary.
retain the satellite carrier (20). Remove the O-ring
(18) from the wheel hub (17) and scrap it.
NOTE: When reinstalling, mount the satellite carrier,
applying Loctite 510 to its thrust face, then tighten it
to a torque of 530 Nm.

6004-16
WHEEL HUB AND SERVICE BRAKE

6 12
14
15
8-12 Nm 16
37 17
2
21 16
22
9 19
13
39
48
47
23 46
43
220 Nm 25 19
24
44
45
PDH0038
19 45 44 22 37 2 48 16 14 16 12
25

46

47

23

6
24 39 43 19 42 13 9 21 17 15
CM96B002

6004-17
STEP 1 STEP 8
Remove the reduction gear. See section "Reduction Remove the hub (17) and the outer bearing (16) from
gear". the pivot (6), holding the hub using an appropriate
lifting device. Remove the inner bearing (16) and the
STEP 2 spacer (15) from the pivot (6).
Remove the retaining ring (19) using tool CAS-10803
STEP 9
and the reaction plate (46) then extract the brake disc
(45). Check for wear, scratches and other damage to Remove the two bearing races (16) and remove the
the brake disc and the reaction plate. Scratches on case seal (12) from the hub (17).
the plate and the disc must not be deeper than
NOTE:
0.2 mm. The wear limit of the brake disc is 3.9 mm.
STEP 3
Remove the snap ring (47) and the washer (48) from
the transmission shaft.
17
STEP 4
Using tool CAS-10803, remove the second retaining
ring (19) then remove the crown wheel (24).
A
STEP 5
12
PDH0037
When reassembling the case seal (12), use special
tool (A) (see "Tools to be manufactured").
NOTE:
PD00219
Remove the screws (23). Remove the brake
mechanism (42) by screwing three screws into the
threaded holes provided for this purpose, then extract
the mechanism. Scrap the two O-rings (2).
NOTE: When reassembling, tighten the screws to a
torque of 220 Nm.
STEP 6 PDH0039
When reassembling, no adjustment to the bearings is
Tighten the brake mechanism, using a clamp (42) necessary. However, before installing new parts,
then remove the retaining rings (39), the spring check the following dimensions and change any parts
guides (9) and the springs (13). Extract the bushes which are out of tolerance.
(21) from the brake mechanism (42). A = 51.95 to 52.00 mm
STEP 7 B = 114.175 to 114.225 mm
C = 29.00 to 29.15 mm
Remove the brake crown (44) and the piston (43). D = 3.95 to 4.00 mm
Scrap the two seals (25) and (22).

6004-18
STEERING PIVOT
11
12-16 Nm
12 40 5 10 Nm
13 1 190 Nm
41
38
13
15 6
12 10
14 4
11
3
48
PDH0040
15 10 38 12 41 1 40

11

13

13

11
4
3
14 6 12 1 48
CM96B003

6004-19
STEP 1 STEP 6
Remove the reduction gear. See section "Reduction
gear".
STEP 2
Remove the wheel hub. See section "Wheel hub and
service brake".
STEP 3
E067023
Remove the covers (11), the joints (12) then using an
extractor, remove the bushings (13).
STEP 7
PD00417
Support the pivot (6) using a suitable lifting device
and remove the retaining screws (1) from the upper
pivot pin (41). Extract the upper pivot pin by screwing
two screws in the extraction holes. Scrap the two
O-rings (38).
torque of 190 Nm.
STEP 4 E067012
Remove the seal (10) then using an extractor
Remove the retaining screws (1) from the lower pivot
CAS-10692 and the screw CAS-10355, remove the
pin (3). Extract the lower pivot pin by screwing two
bushing (14).
screws in the extraction holes. Remove and note the
thickness of the adjusting shims (4).
NOTE: When reinstalling, note the thickness of the
adjusting shims, put them in place on the lower pivot
pin, remount the lower pivot pin and tighten the
screws to a torque of 190 Nm.
STEP 5
Slowly remove the steering pivot (6) and remove the
half-shaft (15).

6004-20
NOTE:

10

14
CM96A039
When reinstalling the bushings (14), use the centring
piece (CAS-1967-2) fitted with the interchangeable
handle (CAS-1716-3). Position the seals (10) as
shown in the drawing, using tool (CAS-2455) fitted
with the interchangeable handle (CAS-1716-3).
NOTE: When reinstalling, adjust the preload of the
steering pivot pins.

6004-21
Adjusting the preload of the steering pivot pins
190 Nm 1 41

4
6

3
190 Nm 1
CM96B003
NOTE: Correct operation of the steering pivot STEP 2

requires a preload of 0.0 to 0.10 mm on the pivot
pins. The adjustment is made with the pivot Subtract the preload of the pivot pins (that is 0.0 to
reinstalled with the original adjusting shims and 0.10 mm) from the value found.
taking into account the thickness of those shims. Example: 0.20 - (0.0 to 0.10) = 0.10 to 0.20 mm
Example: Shim thickness = 1 mm STEP 3
STEP 1 Then subtract the value of the original adjusting
shims (4) from the result. The final result is the
thickness of the shims to be used under the lower
pivot pin (3).
Example: 1 - (0.10 to 0.20) = 0.80 to 0.90 mm
STEP 4
Disassemble the lower pivot pin (3), remove the
original shims, install on the lower pivot pin (3) the
correct number of shims (4) corresponding to the
thickness which was calculated in Step 3.
NOTE: Thickness of available shims: 0.1 to 0.3 mm.
STEP 5
PD03713
Place a dial gauge on the upper pivot pin (41) then Reinstall the lower pivot pin (3) and tighten the
measure and note down the clearance by levering screws to a torque of 190 Nm.
between the pivot and the axle housing.
Example: Clearance found = 0.20 mm

6004-22
DIFFERENTIAL CARRIER COUPLING CLAMP

Disassembly
STEP 2

5

4

3 4

3

6
6 25
25
2 1 2
139 Nm Loctite 510
1
CM96F005
PDH0047
Remove in this order: the screw (1), the washer (2), Remove the clamp (4), install the seal (5), reinstall
the adjusting shim (3), the clamp (4), the seal (5) and the clamp (4) and then install the number of shims (3)
the washer (6) from the pinion shaft (25). found in Step 1 between the pinion (25) and the
washer (2) (the washer must first be coated with
Assembly Loctite 510). Tighten the screw (1) to a torque of

139 Nm.
STEP 1

NOTE: Thickness of available shims: 0.05; 0.1 and

6 0.2.

4

5

A
25
CM96A038
Place, temporarily, on the shaft (25), the clamp (4)
and the washer (6) without the seal (5) and using a
depth gauge, measure and note the clearance (A)
between the shaft (25) and the clamp (4).

6004-23

6004-24
CROWN WHEEL AND PINION

Disassembly
36
37 33
35
29 28
31
32
20
22
20 36
14 37
13
25
8 24
7 28 29
23
21
15
12
9
11
10
PDH0043
STEP 1 STEP 4
Remove the steering pivots and the half-shafts. See Remove the screws (36) and the locking tabs (37).
section "Steering pivot".
STEP 5
STEP 2
Untighten the adjusting rings (29) using special tool
Remove the coupling clamp. See section "Differential (CAS-1840B).
carrier coupling clamp". Remove the differential
carrier. STEP 6
Remove the screws (31) and the washers (32), then
STEP 3
remove the yoke (33).
remove the cover (9). Remove and scrap the lip seal STEP 7
(12) and the O-ring (13) from the cover (9). Remove the adjustment shims (29).

6004-25
STEP 8 STEP 12
Remove the differential assembly (35) with the Extract the bearing (23) from the pinion shaft (25)
bearing races (28). If these are to be reinstalled, using special tool (CAS-10563) then remove the
identify them. adjusting shim (24).
NOTE: For disassembly and reassembly of the STEP 13
differential, see section "Differential".
Remove the bearing races (14) and (23) from the
STEP 9 differential support (15).
Straighten the nut tab washer (7) and remove it using Inspection
special tool (CAS-2078), then remove the lock
washer (8). Check the condition and wear on the pinion shaft
teeth (25). If the pinion shaft teeth are damaged,
STEP 10 change the pinion shaft and the differential crown
Using a mallet, drive out the pinion shaft (25) and wheel.
remove the bearing (14).
STEP 11
Remove the pinion shaft (25), the two washers (20)
and (21), the compressible spacer (22) and the
washer (20). Scrap the compressible spacer (22).

6004-26
Assembly

25 B

33
24
000.00

A
00
CAS-1596B-1

CAS-1596A-6

CAS-1596B-5

PDH0044A
C

15
23

CAS-1596A-7
14
CAS-1596A-4

PDH0044
(B) VALUE OF PINION SHAFT OVERHANG
(C) PINION/CROWN WHEEL COUPLING NUMBER
STEP 1 STEP 5
Using special tool (CAS-1964-2) fitted with the inter- Install the handle (CAS-1596A-4), then tighten until it
changeable handle (CAS-1716-3), install the bearing becomes difficult to turn the bearings.
races (14) and (23) in the differential support (15).
STEP 6
STEP 2
Install the calibrating tube (CAS-1596B-1) on the
Place the bearing (23) in the differential support (15). differential support (15).
Adjusting the pinion conical STEP 7

distance Place the yoke (33) on the differential support (15),
and tighten the screws (24) to a torque of 413 Nm.
STEP 3
STEP 8
Assemble the calibrating block (CAS-1596B-5), the
alignment disc (CAS-1596A-6) and the screw Using a feeler gauge, measure and note the distance
(CAS-1596A-7), then place them on the bearing (23). "A" between the calibrating block (CAS 1596B-5) and
the calibrating tube (CAS-1596B-1).
STEP 4
STEP 9
Place the bearing (14) in the differential support (15).
Read and note the value "B" written on the end of the
pinion shaft (25).

6004-27
STEP 10
Calculate the thickness of shims necessary to adjust
the conical distance of the pinion shaft (25).
134.5 mm + A - B = thickness of the shim in mm
NOTE: The value of 134.5 mm corresponds to the
radius of the calibrating tube (CAS-1596B-1) + the
height of the calibrating block (CAS-1596B-5).
STEP 11
Remove the yoke (33), the special tools and the
bearings (23) and (14).

6004-28
25
15
24
23
21
20
20 22
14
84-126 N 8
PDH0045
STEP 12 Preloading the bearings of the

Place the adjusting shim (24), corresponding to the pinion shaft
thickness calculated in Step 10 on the pinion shaft
(25). STEP 17
NOTE: The chamfer on the internal diameter of the While preventing the pinion shaft (25) from rotating,
adjusting shim must be oriented towards the pinion. tighten the nut (7) to a torque of between 17 and
Thickness of available shims: 2.5 to 3.4 mm (from 18 Nm.
0.10 in 0.10 mm). STEP 18
STEP 13 Place a torque wench on the pinion shaft (25) to
Using a suitable centring piece, install the bearing measure the preload of the bearings.
(23), the washer (20), a new compressible spacer STEP 19
(22) and the two washers (20) and (21) on the pinion
shaft (25), Tighten the nut (7) until a preload is obtained of
between 84 and 126 N. When the preload is correct,
STEP 14 hammer over the edge of the nut on the pinion shaft.
Lubricate the bearing with clean oil and install the
pinion shaft assembly (25) in the differential support
(15).
STEP 15
Lubricate the bearing (14) with clean oil and install it
on the pinion shaft (25).
STEP 16
Install the washer (8) and a new nut (7) on the pinion
shaft (25).

6004-29
10
1
7
13 Nm 9
9 13 Nm
8 8
2 6
3 5
413 Nm 11
12
113-170 N
13 PDH0159
PDH0046B
STEP 20 Adjusting the clearance between

Install the differential (10) complete with bearings (3) crown wheel and pinion teeth
and (5) on the differential support (11).
STEP 22
STEP 21
Install the adjusting rings (2) and (6) using the adjust-
Install the yoke (1) on the differential support (11) and able spanner (CAS-1840B). Screw the adjusting ring
install the washers (13) and the screws (12). Tighten (6) until the crown wheel (7) is in contact with the pin-
the screws. ion shaft (4). Screw the adjusting ring (2) until it
becomes difficult to turn.
NOTE: When assembling the bushings (2) and (6)
tap the yoke (1) using a mallet so as to place the
bearings (3) and (5) correctly.

6004-30
STEP 23 STEP 28
Check the clearance between the teeth of the pinion
shaft and the crown wheel by repeating Step 24.
STEP 29
Tighten the yoke (1) screws (12) to a torque of
413 Nm.
STEP 30
Install the locking tab washers (8) then install the
screws (9) and tighten them to a torque of 13 Nm.
NOTE: It may be necessary to turn the adjusting
rings (2) and (6) to install the locking tab washers (8).
E069036
Do not turn the adjusting rings more than a half-
Place a dial gauge on one tooth of the crown wheel
notch.

(7) positioning the rod of dial gauge perpendicular to
STEP 31

the face of the tooth.

STEP 24

Inspect and note the clearance between the crown 4
wheel (7) and the pinion shaft (4) and repeat the
operation on three other teeth at intervals of 90°. If

the readings are not identical, put the rod of the dial 6
gauge on the tooth of the crown wheel with the
smallest reading. 1
STEP 25
Adjust the clearance between the crown wheel (7) 5 3 2
and the pinion shaft (4) by unscrewing the adjusting 27 Nm
ring (2) or (6) depending on the case and screwing in
the other by the same value until the clearance is CM96A036
from 0.21 to 0.28 mm. Install the O-ring (1) and, using a press and the spe-
cial tool (CAS-2452) fitted with the interchangeable
Preloading the differential taper handle (CAS-1716-3), the lip seal (2) on the cover (3)
then install the cover assembly on the differential sup-
roller bearings port (4). Install the screws (5) and the washers (6)
STEP 26 then tighten the screws to a torque of 27 Nm.
Place a torque wrench on the pinion shaft (4) to STEP 32

measure the bearing preload. Install the differential carrier coupling clamp. See
STEP 27 section "Differential carrier coupling clamp".
Tighten the adjusting rings (2) and (6) to an identical

value until a preload of between 113 and 170 N is
obtained.
NOTE: The total preload value of 113 to 170 N
corresponds to the value P of pinion shaft preloading
(84 to 126 N) + the preload value of the differential
taper roller bearings (29 to 44 N).

6004-31

6004-32
DIFFERENTIAL
Carraro 638LD axle
17
12
13
19 15
28
18 34
10
14
16
29
12
19
17
14
18 11
22 Loctite 270 190 Nm
PDH0048
Carraro 638FR axle
17 12
17
12
13
15
19 14
18 34
14 10
16
19
17
12 17 11
18 190 Nm
22 Loctite 270
PDH0049

6004-33
STEP 1 STEP 6
Remove the steering pivots and the half-shafts. See Remove the pinion shafts (13), washers (14) and
section "Steering pivot". (17), satellites (12), planetaries (15) and (16) and the
differential housings (18).
STEP 2
STEP 7
Remove the coupling clamp from the differential
carrier. See section "Differential carrier coupling Remove the pin (29) and the bushing (28).
clamp".
Inspection
STEP 3
Check condition and the wear of the differential parts.
Remove the crown wheel and pinion. See section If the crown wheel (34) is damaged, change the
"Crown wheel and pinion". crown wheel and the pinion shaft.
STEP 4 NOTE: When installing, proceed in the reverse order
Remove and scrap the screws (11). Remove the of removal.
crown wheel (34) and the centring studs (10).
NOTE: When reinstalling, install new screws with
Loctite 270 and tighten them to a torque of 190 Nm.
STEP 5
Extract the bearings (19) and remove the washer
(22).

6004-34

Section
6004
6004
FRONT AXLE AND SERVICE BRAKE
CARRARO 652FR AXLE

Printed in France
6004-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................................... 3
SPECIAL TOOLS ..................................................................................................................................................... 4
Kit (CAS-40008) ................................................................................................................................................... 5
Tools to be manufactured .................................................................................................................................... 6
STANDARD TOOLS................................................................................................................................................. 6
FRONT AXLE ........................................................................................................................................................... 7
Disassembly and assembly.................................................................................................................................. 8
REDUCTION GEAR ............................................................................................................................................... 10
WHEEL HUB AND SERVICE BRAKE.................................................................................................................... 12
STEERING PIVOT ................................................................................................................................................. 14
Adjusting the preload of the steering pivot pins ................................................................................................. 16
Disassembly ....................................................................................................................................................... 17
Assembly............................................................................................................................................................ 17
Disassembly ....................................................................................................................................................... 18
Inspection ........................................................................................................................................................... 19
Assembly............................................................................................................................................................ 20
Preloading the bearings on the pinion shaft ....................................................................................................... 21
DIFFERENTIAL ...................................................................................................................................................... 24
Inspection ........................................................................................................................................................... 24

6004-3
SPECIFICATIONS
Weight of front axle........................................................................................................................................... 730 kg
Oil capacity of wheel reduction gear.............................................................................................................. 2.5 litres
Oil capacity of axle housing............................................................................................................................ 17 litres
Type of oil ...................................................................................................................TRANSELF B 80W90 API GL5
Type of grease ...................................................................................................................................... GREASE EP2
Crown wheel/pinion ratio ...............................................................................................................................3.36:1
Steering pivot
Thickness of shims for adjusting the pivot bushings .........................................................................0.1 to 0.3 mm
Preload on pivot bushings ...............................................................................................................0.0 to 0.10 mm
Clearance between the bushing and the half-shaft at the wheel end............................................0.16 to 0.25 mm
Clearance between the bushing and the half-shaft at the differential end...................................0.13 to 0.232 mm
Final drive
Brake
Thickness of a new brake disc ..........................................................................................................4.8 to 4.9 mm
Wear limit ....................................................................................................................................................3.9 mm

Pinion nut.............................................................................................................................................. as per preload
Coupling clamp retaining screw...................................................................................................................... 139 Nm
Braking mechanism retaining screws ............................................................................................................. 220 Nm
Satellite carrier retaining screws..................................................................................................................... 530 Nm
Reduction gear cover screws ........................................................................................................................... 23 Nm
Differential yoke screws .................................................................................................................................. 413 Nm
Steering pivot cover screws ............................................................................................................................ 190 Nm
Universal joint shaft coupling .......................................................................................................................... 120 Nm
Wheel retaining nuts ....................................................................................................................................... 540 Nm
Differential carrier retaining screw .................................................................................................................. 266 Nm
Axle and reduction gear drain plug ................................................................................................................... 60 Nm
Breather.............................................................................................................................................................. 5 Nm
Breather bracket ............................................................................................................................................... 15 Nm
Brake supply union .................................................................................................................................. 12 to 16 Nm
Brake bleed screw ..................................................................................................................................... 8 to 12 Nm
Steering stop screw nut .................................................................................................................................. 100 Nm
Pivot extension stop screw ............................................................................................................................. 156 Nm
Differential carrier cover retaining screws......................................................................................................... 27 Nm
Grease fittings on steering pivot and pivot extension ....................................................................................... 10 Nm

6004-4
SPECIAL TOOLS
CS96A240 CS96A243
CAS-1840B Adjustable spanner. CAS-1964-1 Centring piece.
Used for the first time on page 18. CAS-1964-2 Centring piece. Used for the first time on
page 20.
CS96A244
CAS-1967-1 Centring piece. CD96A010
CAS-1967-2 Centring piece. Used for the first time on CAS-10803 Removing tool for snap ring.
page 15. Used for the first time on page 13.
CS96A007 CS96A008
CAS-2453 Centring piece. CAS-2454 Centring piece.

CS96A015 CS96A016
CAS-2455 Centring piece. CAS-2452 Centring piece.

6004-5
CS96A237
CS96A255
CAS-1716-3 Interchangeable handle. CAS-1596A-8 Calibrating block.
Used on pages 9, 15, 20 and 23. Used for the first time on page 20.
Kit (CAS-40008)
CS96A239
CAS-1596A-7 Pilot (screw).
CS96A236
CAS-1596B-1 Calibrating tube.

CS96A242
CAS-1668 Feeler gauge.

CS96A238
CAS-1596A-9 Aligning disc.
CS96A241
CAS-2078 Wrench for nut.
CS96A245
CAS-1596A-4 Handle.

6004-6
Assembly tool for case seal (wheel hub). Used for the first time on page 13.
ø 30
200
+0.3 +0.5
5.5 0 8 0
32
R1 +0.5
16 14.5 0
ø 148
ø 176.85±0.05 2 to 15°
ø 199.5±0.1
ø 204.5±0.1
ø 218.5±0.2 PDH0030
STANDARD TOOLS
Screw........................................................................................................................................................ CAS-10355
Release tool.............................................................................................................................................. CAS-10563
Extractor ................................................................................................................................................... CAS-10692
Loctite 271
Loctite 574

6004-7
FRONT AXLE
- Park the machine on flat, horizontal ground.
- Lower the stabilizers and the dozer blade (if fitted) to lift the wheels off the ground. If the machine is not equipped
with stabilizers or dozer blade, raise the rear wheels on blocks.
- Using the attachment, lift the machine and place axle stands in front of each side of the undercarriage and then
place the undercarriage resting on the axle stands and the stabilizers so as to distribute the weight between the
stabilizers and the axle stands.
- Stop the engine.
hydraulic system.
Removal and installation STEP 6

STEP 1 Place a rolling jack under the centre of the front axle
and wedge the axle on the jack so that it does not tip
Remove the front wheels. during the disengagement stage.
NOTE: When installing, tighten the wheel nuts to a STEP 7
torque of 540 Nm.
Remove the axle pivot pin and slowly lower the jack
STEP 2 so as to remove and disengage the axle from the
Remove the steps and the LH tool box. machine. Place the axle on a suitable support.
STEP 3 NOTE: When installing, proceed in the reverse order

to that of removal.
Remove the supply hoses for the service brakes and
the supply hoses for the steering cylinder. Before using the machine, all the following operations
must be carried out in the order shown:
STEP 4 - Turn the battery master switch to the "ON" position.
Remove, at the front axle end, the transmission uni- - Start the engine.
versal joint retaining screws and uncouple the trans- - Check the level of hydraulic fluid in the reservoir and
mission universal joint. top up if necessary.
- Bleed the brakes.
- Check that there are no leaks in the hydraulic
torque of 120 Nm.
system or the brake system.
STEP 5 - Check that the service brakes work properly.
If the machine is equipped with a dozer blade,

remove the pin form the dozer blade cylinder and
push the cylinder forward to gain access to the axle
pivot pin.

6004-8
11 10 9 156 Nm 8
22 10 Nm
23
21
7
23 24
22 10 Nm
6
3 5 Nm
15 Nm
5 4
18
20 266 Nm
156 Nm Loctite 574
19
1
60 Nm 14
25
13
2
60 Nm 12
17
16
26
15 60 Nm
CS96A001
1 Filler plug 11 Steering cylinder 21 Pivot extension

2 Drain plug 12 Reduction gear 22 Lip seal
3 Breather 13 Hub and service brake 23 Ring
4 Seal 14 Steering pivot 24 Grease fitting
5 Breather bracket 15 Axle half-shaft 25 Axle housing
6 Pin 16 Lip seal 26 Reduction gear drain plug
7 Shaft 17 Ring
8 Grease fitting 18 Screw
9 Screw 19 Differential carrier
10 Washer 20 Pivot extension stop screw

6004-9
STEP 1 STEP 9
Drain the reduction gears and the axle housing. Remove and scrap the lip seals (22).
NOTE: When installing, fill the reduction gears and NOTE: When reinstalling, use an appropriate
the axle housing with oil (see the specifications) and centring piece, the felted side of the seal must be
tighten the plugs to a torque of 60 Nm. oriented towards the outside of the pivot extension
(21).
STEP 2
STEP 10
Remove the parts of (6) to (10) then remove the
steering cylinder assembly (11). To disassemble and Remove and scrap the bushings (17) and (23), use
reassemble the steering cylinder, refer to section the extractor (CAS-10692) and the screw
7080. (CAS-10355).
NOTE: When assembling, tighten the screws (9) to a NOTE: When reinstalling, use the centring piece
torque of 156 Nm. (CAS-2453) fitted with the interchangeable handle
(CAS-1716-3) for the bushings (17) and an
STEP 3 appropriate centring piece for the bushings (23).
Remove the reduction gears (12). See section
STEP 11
"Reduction gear".
Remove the screws (18) then remove the differential
STEP 4 carrier (19).
Remove the hubs (13) complete with their brake. See NOTE: When reinstalling the differential carrier on
section "Wheel hub and service brake". the axle housing (25), clean and degrease the
STEP 5 differential carrier coupling and the axle housing, also
Remove the steering pivots (14). See section wide bead of Loctite 574 on the axle housing face
"Steering pivot". and around the threads of each hole. Tighten the
screws (18) to a torque of 266 Nm.
STEP 6
Remove axle half-shafts (15). Check wear on the
spiders, replace them if necessary.
STEP 7
Remove the pivot extension stop screw (20) then the
pivot extension (21).
NOTE: When reinstalling, tighten the screws (20) to a
torque of 156 Nm.
STEP 8
Remove and scrap the lip seals (16).
NOTE: When reinstalling, use the centring piece
(CAS-2454) fitted with the interchangeable handle
(CAS-1716-3), and the felted edge of the seal
oriented towards the outside of the axle.

6004-10
REDUCTION GEAR
Loctite 271
18
26
29
27
20
32
530 Nm
35 28
32
36
33 31
34 30 60 Nm
23 Nm
PDH0036
36 32 34 33 35 34 32 18 17
28 27 29 20 26 30
CM96B001

6004-11
STEP 1 STEP 3
Remove the screws (30). Extract the reduction gear Check the needle roller bearings (34), the pinions
cover (26) using two screws and the two extraction (33), the spacers (35), the pinion shafts (36) and the
orifices on the cover. thrust washers (32). Replace them if necessary.
NOTE: When reassembling, tighten the screws to a NOTE: When reassembling the pinions (33) and the
torque of 23 Nm. needle roller bearings (34) in the reduction gear
cover (26), use grease to keep them in position.
STEP 2
STEP 4
retain the satellite carrier (20). Remove the O-ring
(18) from the wheel hub (17) and scrap it.
applying Loctite 271 on its thrust face, then tighten it

6004-12
WHEEL HUB AND SERVICE BRAKE
6 2
12 14
15
8-12 Nm 16
37 17
21 16
22 19
9
13
39
42 48
23 47
220 Nm 46
43
25 19
24
44
45 CS96A002
19 45 44 22 37 2 48 16 14 16 12
25
46
47
23
24 39 43 19 42 13 9 21 17 15 CM96B002

6004-13
STEP 1 STEP 8
Remove the reduction gear. See section "Reduction Remove the hub (17) and the external bearing (16)
gear". from the pivot (6), holding the hub using an appropri-
ate lifting device. Remove the inner bearing (16) and
STEP 2 the spacer (15) from the pivot (6).
Remove the retaining ring (19) using tool CAS-10803
STEP 9
and the reaction plate (46) then extract the brake disc
(45). Check the brake disc and the reaction plate for Remove the two bearing races (16) and remove the
wear, scratches and any other damage. Scratches on case seal (12) from the hub (17).
the plate and the disc must not be deeper than
NOTE:
0.2 mm. The wear limit of the brake disc is 3.9 mm.
STEP 3
Remove the snap ring (47) and the washer (48) from
the transmission shaft. 17
STEP 4
Remove the second retaining ring (19) using tool
CAS-10803, then remove the crown wheel (24). A
STEP 5 12
PDH0037

tool (A) (see "Tools to be manufactured").
NOTE:
PD00219
Remove the screws (23). Remove the brake mecha-

nism (42) by screwing three screws into the threaded
holes provided for this purpose, then extract the
mechanism. Scrap the two O-rings (2).
CS96A003
torque of 220 Nm.
STEP 6 When reassembling, no adjustment to the bearings is
necessary. However, before installing new parts,
Tighten the brake mechanism, using a clamp (42) check the following dimensions and change any parts
then remove the retaining rings (39), the spring which are out of tolerance.
guides (9) and the springs (13). Extract the bushes
A = 68.95 to 69 mm
(21) from the brake mechanism (42).
B = 132.225 to 132.175 mm
STEP 7 C = 21 mm
D = 29 to 29.15 mm
Remove the brake crown (44) and the piston (43). E = 3.95 to 4 mm
Scrap the two seals (25) and (22).

6004-14
STEERING PIVOT

11 12-16 Nm
12 40
5 10 Nm
13
190 Nm
1
41
13
38
12
15
11 10 6
14
4
3
48
CS96A004
15 10 38 12 41 1 40

11

13

13

11
3
14 6 12 1 48 CM96B003

6004-15
STEP 1 STEP 6
gear".
STEP 2
service brake".
STEP 3
E06723
Remove the covers (11), the joints (12) then using an

extractor, remove the bushings (13).
STEP 7
PD00417
Support the pivot (6) using a suitable lifting device

and remove the retaining screws (1) from the upper
pivot pin (41). Extract the upper pivot pin by screwing
two screws in the extraction holes. Scrap the two
O-rings (38).
torque of 190 Nm.
E06712
STEP 4 Remove the seal (10) then using an extractor
Remove the retaining screws (1) from the lower pivot (CAS-10692) and the screw (CAS-10355), remove
pin (3). Extract the lower pivot pin by screwing two the bushing (14).
screws in the extraction holes. Remove and note the

NOTE:
thickness of the adjusting shims (4).
NOTE: When reinstalling, note the thickness of the

adjusting shims, put them in place on the lower pivot
pin, remount the lower pivot pin and tighten the

STEP 5
Slowly remove the steering pivot (6) and remove the
half-shaft (15).

10

14

CM96A039

piece (CAS1967-2) fitted with the interchangeable
NOTE: When reinstalling, adjust the preload of the
steering pivot pins.

6004-16
Adjusting the preload of the steering pivot pins
190 Nm 1 41

6

4

3
1
190 Nm CM96B003
NOTE: Correct operation of the steering pivot STEP 2

requires a preload of 0.0 to 0.10 mm on the pivot
pins. The adjustment is made with the pivot Subtract the preload of the pivot pins (that is 0.0 to
reinstalled with the original adjusting shims and 0.10 mm) from the value found.
taking into account the thickness of those shims. Example: 0.20 - (0.0 to 0.10) = 0.10 to 0.20 mm
Example: Shim thickness = 1 mm STEP 3
STEP 1 Then subtract the value of the original adjusting
shims (4) from the result. The final result is the
thickness of the shims to be used under the lower
pivot pin (3).
Example: 1 - (0.10 to 0.20) = 0.80 to 0.90 mm
STEP 4
Disassemble the lower pivot pin (3), remove the origi-
nal shims, install on the lower pivot pin (3) the correct
number of shims (4) corresponding to the thickness
which was calculated in Step 3.
NOTE: Thickness of available shims: 0.1 to 0.3 mm.
PD03713
STEP 5
Place a dial gauge on the upper pivot pin (41) then
measure and note down the clearance by levering Reinstall the lower pivot pin (3) and tighten the
between the pivot and the axle housing. screws to a torque of 190 Nm.
Example: Clearance found = 0.20 mm
6004-17

Disassembly

STEP 2

STEP 1

22

16
20

7

5
6

4
5 6

20

Loctite 574
4 3 2 1
3 139 Nm CM96A037
1
2 Disassemble the clamp (5), install the seal (6),
CS96A006
reassemble the clamp (5) then place between the
Remove in this order: the snap ring (1), the screw (2), pinion (20) and the washer (3) (previously coated with
the washer (3), the adjusting shim (4), the clamp (5), Loctite 574), the number of shims (4) corresponding
the seal (6) and the washer (7) from the pinion shaft to Step 1. Tighten the screws to a torque of 139 Nm.
(20). Discard the seal (6). Remove and scrap the seal Install the snap ring (1).
(22) on the differential bracket (16).
0.2.
Assembly

STEP 1

7

5

20

6
A
CM96A038

6004-18
Disassembly
22 26 27 28 23
24
25
21
20 27
26
19
18
17
9 22
10 11 14 12
13 15 16
CS96A014
STEP 1 STEP 5
Remove the steering pivots and the half-shafts. See Untighten the adjusting rings (26) using special tool
section "Steering pivot". (CAS-1840B).
STEP 2 STEP 6
Remove the coupling clamp. See section "Differential Remove the screws (23) and the washers (24), then
carrier coupling clamp". Remove the differential car- remove the two yokes (25).
rier.
STEP 7
STEP 3
Remove the adjustment shims (26).
remove the cover (10). Remove and scrap the lip seal STEP 8
(11) and the O-ring (14) from the cover (10). Remove the differential assembly (28) with the bear-
ing races (27). If these are to be reinstalled, label
STEP 4
them.
Remove the locking pins (22).

6004-19
NOTE: For disassembly and reassembly of the Inspection
Check the condition and wear on the pinion shaft
STEP 9 teeth (21). If the pinion shaft teeth are damaged,
Straighten the nut tab washer (12) and remove it change the pinion shaft and the differential crown
using special tool (CAS-2078), then remove the lock wheel.
washer (13).
STEP 10
Using a mallet, drive out the pinion shaft (21) and
STEP 11
Remove the washer (17) and the compressible
spacer (18) from the pinion shaft (21). Scrap the
compressible spacer (18).
STEP 12
Extract the bearing (19) from the pinion shaft (21)
using special tool (CAS-10563) then remove the
adjusting shim (20).
STEP 13
differential support (16).

6004-20
Assembly

23 B

21
25

A

CAS-1596B-1 000.00
CAS-1596A-9 00

CAS-1596A-8

19 PDH0044A

C
CAS-1596A-7

16 B Pinion shaft projection
value
CAS-1596A-4

15
C Pinion/crown wheel coupling
number
CM96A001
STEP 1 STEP 7
Using special tool (CAS-1964-2) fitted with the inter- Place the yokes (25) on the differential support (16),
changeable handle (CAS-1716-3), install the bearing and tighten the screws (23) to a torque of 413 Nm.
STEP 8
STEP 2
Using a feeler gauge (CAS-1668), measure and
Place the bearing (19) in the differential support (16). note the distance "A" between the calibrating block
(CAS-1596A-8) and the calibrating tube
Adjusting the pinion conical (CAS-1596B-1).
distance STEP 9
STEP 3 Read and note the value "B" written on the end of the
pinion shaft (21).
Assemble the calibrating block (CAS-1596A-8), the
alignment disc (CAS-1596A-9) and the pilot STEP 10
(CAS-1596A-7), then place them on the bearing (19).
STEP 4 the conical distance of the pinion shaft (21).
Place the bearing (15) in the differential support (16). 135.224 mm + A - B = Thickness of the shim in mm
STEP 5 NOTE: The value 135.224 mm corresponds to the

Install the handle (CAS-1596A-4), then tighten until it height of the calibrating block (CAS-1596A-8).
becomes difficult to turn the bearings.
STEP 11
STEP 6
Remove the yokes (25), the special tools and the
Install the calibrating tube (CAS-1596B-1) on the bearings (19) and (15).

6004-21

21
16

20
17

19

18

15
13

76-114 N 12
CM96A035
STEP 12 Preloading the bearings on the

thickness calculated in Step 10 on the pinion shaft STEP 17
(21).
While preventing the pinion shaft (21) from rotating,
NOTE: The chamfer on the internal diameter of the
tighten the nut (12) to a torque of between 17 and
adjusting shim must be oriented towards the pinion.
18 Nm.
Thickness of available shims: 2.5 to 3.4 mm (from
0.10 in 0.10 mm). STEP 18
STEP 13 Place a torque wrench on the pinion shaft (21) to
measure the bearing preload.
Assemble the following on the pinion shaft (21): the
bearing (19) using a suitable centring piece, a new STEP 19
compressible spacer (18) and the washer (17).
Tighten the nut (12) until a preload is obtained of
STEP 14 between 76 and 114 N. When the preload is correct,
hammer over the edge of the nut on the pinion shaft.
Lubricate the bearing with clean oil and install the
(16).
STEP 15
STEP 16
Install the washer (13) and a new nut (12) on the
pinion shaft (21).

6004-22
1 12
413 Nm

9 413 Nm7

11 11

12
1

8

8

2

6

3

5

4

10
98-148 N
CM96A034
STEP 20 STEP 23
Install the differential (9) complete with bearings (3)
STEP 21
Install the yokes (1) on the differential support (10)
and install the washers (12) and the screws (11).
Tighten the screws.
Adjusting the clearance between

crown wheel and pinion teeth
STEP 22 E069036
Install the adjusting rings (2) and (6) using the Place a dial gauge on one tooth of the crown wheel
adjustable spanner (CAS-1840B). Screw the (7) positioning the rod of dial gauge perpendicular to
adjusting ring (6) until the crown wheel (7) is in the face of the tooth.
contact with the pinion shaft (4). Screw the adjusting
ring (2) until it becomes difficult to turn.
tap the yokes (1) using a mallet so as to place the

6004-23
STEP 24
Inspect and note the clearance between the crown

STEP 31


the readings are not identical, put the rod of the dial
gauge on the tooth of the crown wheel with the small-

est reading.
STEP 25
Adjust the clearance between the crown wheel (7)

4

and the pinion shaft (4) by unscrewing the adjusting
the other by the same value until the clearance is
from 0.21 to 0.28 mm.
6
1
Preloading the differential taper
roller bearings 5 3 2
STEP 26 27 Nm
CM96A036
Place a torque wrench on the pinion shaft (4) to
measure the bearing preload. Install the O-ring (1) and, using a press and the spe-
STEP 27 handle (CAS-1716-3), the lip seal (2) on the cover (3)
Tighten the adjusting rings (2) and (6) to an identical then install the cover assembly on the differential sup-
value until a preload of between 98 and 148 N is port (4). Install the screws (5) and the washers (6)
obtained. then tighten the screws to a torque of 27 Nm.
NOTE: The total preload value of 98 to 148 N STEP 32

corresponds to the value P of pinion shaft preloading Install the differential carrier coupling clamp. See
(76 to 114 N) + the preload value of the differential section "Differential carrier coupling clamp".
STEP 28
STEP 29
Disassemble and then reassemble, one by one, the
screws (11) for the yokes (1) using Loctite 271 then
tighten them to a torque of 413 Nm.
STEP 30
rings (2) and (6) to install the locking pins (8). Do not
turn the adjusting rings more than a half-notch.

6004-24
DIFFERENTIAL
19 18 17
12
13
14
18
14 34 10
16
22
12
15 19
17
11
190 Nm
Loctite 271
CS96A017
STEP 1 STEP 5
Remove the steering pivots and the half-shafts. See Using the release tool (CAS-10563) and a press,
section "Steering pivot". extract the bearings (19) and remove the washer
(22).
STEP 2
STEP 6
Remove the coupling clamp from the differential car-
rier. See section "Differential carrier coupling clamp". Remove the pinion shafts (13), washers (14) and
(17), satellites (12), planetaries (15) and (16) and the
STEP 3 differential housings (18).
Remove the crown wheel and pinion. See section
"Crown wheel and pinion". Inspection
STEP 4 Check condition and the wear of the differential parts.
If the crown wheel (34) is damaged, change the
Remove and scrap the screws (11). Remove the
crown wheel and the pinion shaft.
crown wheel (34) and the centring studs (10).
from removal.

Section
6005
REAR AXLE AND SERVICE BRAKE

CARRARO 838LD AND 838FR AXLE
6005

Printed in France
6005-2
TABLE OF CONTENTS
SPECIFICATIONS.....................................................................................................................................................3
SPECIAL TORQUE SETTINGS ................................................................................................................................ 3
SPECIAL TOOLS ...................................................................................................................................................... 4
Kit (CAS-40008) .................................................................................................................................................... 5
Tools to be manufactured ..................................................................................................................................... 6
WORKSHOP TOOLS ................................................................................................................................................6
REAR AXLE .............................................................................................................................................................. 8
Cross-sectional drawing ........................................................................................................................................ 8
Disassembly and assembly................................................................................................................................. 12
REDUCTION GEAR ................................................................................................................................................ 14
WHEEL HUB ........................................................................................................................................................... 16
HUB SHAFT AND SERVICE BRAKE......................................................................................................................18
CROWN WHEEL AND PINION............................................................................................................................... 20
Disassembly ........................................................................................................................................................ 20
Inspection ............................................................................................................................................................ 21
Assembly............................................................................................................................................................. 22
Adjusting the pinion conical distance .................................................................................................................. 22
Preloading the bearings on the pinion shaft ........................................................................................................23
Adjusting the clearance between crown wheel and pinion teeth.........................................................................24
Preloading the differential taper roller bearings .................................................................................................. 25
DIFFERENTIAL ....................................................................................................................................................... 26
Inspection ............................................................................................................................................................ 27
DIFFERENTIAL CARRIER COUPLING CLAMP..................................................................................................... 28
Disassembly ........................................................................................................................................................ 28
Assembly............................................................................................................................................................. 28

6005-3
SPECIFICATIONS
Weight of rear axle without oil .......................................................................................................................................550 kg
Oil capacity of wheel reduction gear
Carraro 838LD........................................................................................................................................... 2.7 litres
Carraro 838FR .......................................................................................................................................... 2.5 litres
Oil capacity of axle housing
Carraro 838LD............................................................................................................................................ 20 litres
Carraro 838FR ........................................................................................................................................... 21 litres
Type of oil ...............................................................................................................................TRANSELF B 80W90 API GL5
Type of grease .................................................................................................................................................. GREASE EP2
Crown wheel/pinion ratio .............................................................................................................................2.846:1
Final drive
Brake
Thickness of a new brake disc ........................................................................................................9.9 to 10.1 mm
Wear limit ..........................................................................................................................................7.9 to 8.3 mm

Pinion nut .......................................................................................................................................................... as per preload
Coupling clamp retaining screw ..................................................................................................................................139 Nm
Braking mechanism retaining screws .........................................................................................................................220 Nm
Satellite carrier retaining screws .................................................................................................................................530 Nm
Reduction gear cover screws ........................................................................................................................................23 Nm
Differential yoke screws...............................................................................................................................................413 Nm
Differential brake plate screw ........................................................................................................................................13 Nm
Universal joint shaft coupling.......................................................................................................................................120 Nm
Wheel retaining nuts....................................................................................................................................................540 Nm
Differential carrier retaining screw...............................................................................................................................150 Nm
Differential carrier retaining nut ...................................................................................................................................145 Nm
Differential carrier retaining stud....................................................................................................................................40 Nm
Hub shaft retaining nuts...............................................................................................................................................143 Nm
Hub shaft retaining stud.................................................................................................................................................70 Nm
Axle drain and filling plug...............................................................................................................................................60 Nm
Axle and reduction gear drain plug ...............................................................................................................................60 Nm
Axle drain plug at brake .................................................................................................................................................30 Nm
Breather ........................................................................................................................................................................... 5 Nm
Breather bracket ............................................................................................................................................................15 Nm
Brake bleed screws union .............................................................................................................................................90 Nm
Brake bleed screw ......................................................................................................................................................8-12 Nm
Differential carrier cover retaining screws .....................................................................................................................27 Nm
Pinion shaft nut ........................................................................................................................................................ 17-18 Nm

6005-4
SPECIAL TOOLS
CS96A240 CD96A010
CAS-1840B Adjustable spanner. CAS-10803 Removing tool for retaining ring.

CS96A248 CS96A008
CAS-2097 Brake spring removal and installation device. CAS-2098 Centring piece. Used for the first time on
Used for the first time on page 19. page 17. Toothed wheel extractor device.
CS96A243 CS96A253
CAS-1964-1 Centring piece. CAS-2457 Centring piece.

CAS-1964-2 Centring piece. Used for the first time on Used for the first time on page 19.
page 22.
CS96A016
CS96A254 CAS-2452 Centring piece.

CAS-2456 Centring piece. Used for the first time on page 25.
6005-5
Kit (CAS-40008)
CS96A236 CS96A237
CAS-1596B-1 Calibrating tube. CAS-1596B-5 Calibrating block.

CS96A238 CS96A239
CAS-1596A-6 Aligning disc. CAS-1596A-7 Pilot (screw).

CS96A245 CS96A242
CAS-1596A-4 Handle. CAS-1668 Feeler gauge.

CS96A241 CS96A255
CAS-2078 Wrench for pinion shaft nut. CAS-1716-3 Interchangeable handle.

Used for the first time on page 21. Used on pages 19, 22 and 25.

6005-6
Case seal mounting tool (wheel hub), used for the first time on page 17.
ø 30
200
+0.3 +0.5
5.5 0 8 0
32
R1
+0.5
16 14.5 0
ø 148
ø 176.85±0.05 2 to 15°
ø 199.5±0.1
ø 204.5±0.1
ø 218.5±0.2
PDH0150
WORKSHOP TOOLS
Screw........................................................................................................................................................ CAS-10355
Release tool...........................................................................................................................................................CAS-10563
Extractor.................................................................................................................................................................CAS-10692
Loctite 270
Loctite 510

6005-7

6005-8
REAR AXLE
7 8 9 10 11 10 8 12 13 14 15 16 17 18 19 20 22 21 23 24
25
26
27
41
28
30
29
40
31
6 32
CM96F006
5 4 26 3 39 38 37 2 1 36 35 34 33
67 65 64
63
66
62
61
60
55
57
66
59 56
54
52
50
58
46
45
68 53
51
69 60
PDH0159
49 48 47 42 43 44 PDH0156

6005-9
Description
1 SCREW 44 CLAMP
2 REDUCTION GEAR COVER 45 ADJUSTMENT SHIM
3 SATELLITE CARRIER 46 LIP SEAL
4 RING 47 SEAL
5 SCREW 48 WASHER
6 HALF-SHAFT STOP 49 COVER
7 GEAR SHAFT 50 O-RING
8 THRUST WASHER 51 LOCK NUT
9 PINION 52 BEARING
10 NEEDLE ROLLER BEARING 53 WASHER
11 SPACER 54 COMPRESSIBLE SPACER
12 CROWN WHEEL 55 RING
13 BEARING 56 BEARING
14 WHEEL HUB 57 ADJUSTMENT SHIM
15 O-RING 58 GEAR SHAFT
16 SPACER 59 DIFFERENTIAL BRACKET
17 SCREW 60 ADJUSTING RING
18 CASE SEAL 61 BEARING
19 REACTION PLATE 62 PLATE
20 BRAKE DISC 63 SCREW
21 GREASE FITTING 64 SCREW
22 O-RING 65 CROWN WHEEL
23 O-RING 66 YOKE
24 RETURN SPRING 67 DIFFERENTIAL
25 COUPLING SLEEVE 68 SCREW
26 TRANSMISSION SHAFT 69 WASHER
27 HOOKING RING
28 HOOKING RING
29 AXLE HOUSING
30 PISTON
31 PIN
32 NUT
33 PIN
34 HUB SHAFT
35 SEAL
36 RING
37 BEARING
38 LOCKING RING
39 SPROCKET
40 RING
41 SCREW
42 SCREW
43 WASHER

6005-10

- Park the machine on flat and horizontal ground.
with stabilizers or dozer blade, raise the rear wheels on blocks.
- Using the attachment, lift the rear of the machine and place axle stands behind each side of the undercarriage
and then place the undercarriage resting on the axle stands and the stabilizers so as to distribute the weight
between the stabilizers and the axle stands.
- Stop the engine.
hydraulic systems.
STEP 1 STEP 5
Remove the rear wheels. Place a rolling jack under the centre of the rear axle
NOTE: When installing, tighten the wheel nuts to a
during the disengagement stage.
torque of 540 Nm.
STEP 6
STEP 2
Remove the nuts, screws and washers which retain
Remove the steps and the LH tool box.
each end of the axle to the undercarriage, then slowly
STEP 3 lower the jack so as to remove and disengage the
axles form the machine. Place the axle on a suitable
Remove the service brake supply hoses. support.
STEP 4 NOTE: When installing the rear axle, proceed in the
Remove, at the rear axle end, the transmission uni- reverse order from removal.
versal joint retaining screws and uncouple the trans-
mission universal joint.
torque of 120 Nm.
- Start the engine.
- Bleed the brakes.

6005-11

6005-12
1 2
5
3
6
4
7
9
18
10
11
15
14
13
12
16
17
19
PDH0141
1 AXLE HOUSING 11 DRAIN PLUG

2 BREATHER 12 DIFFERENTIAL CARRIER RETAINING NUT
3 SEAL 13 DIFFERENTIAL CARRIER STUD
4 BREATHER BRACKET 14 WASHER
5 BLEED SCREW 15 DIFFERENTIAL CARRIER RETAINING SCREW
6 BLEED SCREW UNION 16 WHEEL HUB
7 SEAL 17 REDUCTION GEAR
8 DRAIN PLUG 18 HUB SHAFT AND SERVICE BRAKE
9 FILLER PLUG 19 REDUCTION GEAR DRAIN PLUG
10 DIFFERENTIAL CARRIER

6005-13
STEP 1 STEP 5
Drain the reduction gears and the axle housing. Remove the nuts (12), studs (13), washers (14) and
screws (15) from the differential carrier (10) and
NOTE: When reassembling, fill the reduction gears
remove it.
and the axle housing with oil (see the specifications)
and tighten the plugs (11) on the differential carrier NOTE: When reinstalling the differential carrier on
and the reduction gear plug (19) to a torque of 60 Nm the axle housing (1), clean and degrease the
and the service brake plug (8) to a torque of 30 Nm. differential carrier coupling and the axle housing, also
STEP 2 wide bead of Loctite 510 on the axle housing face
Remove the reduction gears (17). See section and around the threads of each hole. Tighten the
"Reduction gear". screws (15) to a torque of 150 Nm, the studs (13) to a
torque of 40 Nm and the nuts (12) to a torque of
STEP 3 145 Nm.
Remove the wheel hubs (16). See section "Wheel
hub".
STEP 4
Remove the hub shafts (18) and the service brakes.
See section "Hub shaft and service brake".

6005-14
REDUCTION GEAR
2
13
11
4 12
9
11
10
8
7 3
1 14
PDH0151
10 11 7 8 9 7 11 5 6
3 12 13 4 2 1
CM96F006

6005-15
STEP 1 STEP 3
Remove the screws (1). Extract the reduction gear Check the needle roller bearings (7), the pinions (8),
cover (2) using two screws and the two extraction the spacers (9), the pinion shafts (10) and the thrust
orifices on the cover. washers (11). Replace them if necessary.
torque of 23 Nm. needle roller bearings (7) in the reduction gear cover
(2), use grease to keep them in position.
STEP 2
STEP 4
tap the screw heads with a mallet to release the sat- Check the bushings (12) and the half-shaft thrust
ellite carrier (4). Remove the three screws (3), retain washer (13). Replace them if necessary.
the satellite carrier (4). Remove the O-ring (5) from
the wheel hub (6) and scrap it.

6005-16
WHEEL HUB
13
12
10
8 11
1
5
6
3
9
PDH0142
2 7 8 9
6 1 13 10 11 12
CM96F007

6005-17
STEP 1 STEP 8
Remove the reduction gear. See section "Reduction Extract the bearing (10) and extract the spacer (11)
gear". from the hub shaft (13).
STEP 2 STEP 9
Remove the retaining ring (1) using tool CAS-10803, Remove the case seal (12) from the hub shaft (13).
crown wheel (2) and the transmission shaft (3).
NOTE:
STEP 3
Remove the retaining screws (4) for the toothed
wheel (5).
NOTE: When reassembling, tighten the screws to a 13
torque of 220 Nm.
STEP 4 A
12
PDH0152

tool (A) (see "Tool to be manufactured").
NOTE:
PD01121
Remove the toothed wheel (5) using special tool

(CAS-2098).
STEP 5
PDH0153

check the following dimensions and change any parts
which are out of tolerance.
A = 68.95 to 69.00 mm
PDH0037
B = 132.175 to 132.225 mm
Extract the bushings (6). C = 29.00 to 29.15 mm
STEP 6 D = 4.95 to 5.00 mm
Extract the wheel hub (8) and the bearing (7) from the
axle shaft (13) while supporting the hub using a
suitable lifting device.
STEP 7
wheel hub (8).

6005-18
HUB SHAFT AND SERVICE BRAKE

4
10
17
9
8
20 16
11
15
1
13
19
12
7
14
5
18 2
PDH0043

3

15

13

5

16

7

18 8

11

10
12

17

20

14

2

19

1

9

6
CM96F008

6005-19
STEP 1 STEP 9
gear".
STEP 2
service brake".
STEP 3
Remove and scrap the retaining nuts (1) for the hub
shaft (2).
torque of 143 Nm.
PD04517
STEP 4 Remove the return springs (11) from the piston (13)
using special tool (CAS-2097) then remove the
Support the hub shaft (2) using a suitable device.
hooking ring from the return springs (12).
Extract the hub shaft (2) by removing the two plastic
plugs on the axle housing and by screwing in their STEP 10
place the M10x1.5 extraction screws. Tighten the
extraction screws uniformly and release the hub shaft Extract the piston (13). Scrap the two piston O-rings
(2) from the axle shaft (20). (15) and (16).
STEP 5 STEP 11
Remove and scrap the two O-rings (3). Remove the hooking ring (17) complete with the
return springs (11).
STEP 6
STEP 12
Remove the reaction plate (5) then remove the brake
disc (7). Check the brake disc and the reaction plate Remove the seal (18) then using an extractor
for wear. Wear on the plate and the brake disc must (CAS-10692) and the screw (CAS-10563), remove
not exceed 0.2 mm. The wear limit on the brake disc the bushing (19).
must be between 7.9 and 8.3 mm. NOTE:
STEP 7

Remove the coupling sleeve (8) then remove the
snap ring (9).

STEP 8

Remove the transmission shaft (10).

18

19
CM96A039

piece (CAS-2456) fitted with the interchangeable

6005-20

Disassembly
18 21
17
15
22 19
16
20
11
18
10
17
8
14
5 15
13 16
7 12
6
4
3
2
1
PDH0144
STEP 1 STEP 5
Remove the hub shafts complete with their wheel hub Untighten the adjusting rings (16) using special tool
and their reduction gear. See section "Hub shaft and (CAS-1840B).
service brake".
STEP 6
STEP 2
Remove the coupling clamp. See section "Coupling remove the yoke (21).
clamp". Remove the differential carrier.
STEP 7
STEP 3
remove the cover (3). Remove and scrap the lip seal
(4) and the O-ring (5) from the cover (3).
STEP 4
Remove the screws (18) and the lock tabs (17).

6005-21
STEP 8 STEP 12
Remove the differential assembly (22) with the Extract the bearing (12) from the pinion shaft (14)
bearing races (15). If these are to be reinstalled, label using special tool (CAS-10563) then remove the
them. adjusting shim (13).
Straighten the nut tab washer (6) and remove it using Inspection
special tool (CAS-2078), then remove the lock
washer (7). Check the condition and wear on the pinion shaft
STEP 10 change the pinion shaft and the differential crown
Using a mallet, drive out the pinion shaft (14) and wheel.
STEP 11
Remove the following from the pinion shaft (14): the
washer (10) and the compressible spacer (11). Scrap
the compressible spacer (11).

6005-22
Assembly

21 14
B
19

000.00

00
CAS-1596B-1

CAS-1596A-6

CAS-1596B-5

C PDH0155A

9
12

CAS-1596A-7 B Pinion shaft projection
8

value
number
CAS-1596A-4
PDH0155
STEP 1 STEP 7
Using special tool (CAS-1964-2) fitted with the inter- Place the yoke (21) on the differential support (9),
changeable handle (CAS-1716-3), install the bearing and tighten the screws (19) to a torque of 413 Nm.
STEP 8
STEP 2
Using a feeler gauge (CAS-1668), measure and note
Place the bearing (12) in the differential support (9). the distance "A" between the calibrating block
(CAS-1596B-5) and the calibrating tube
Adjusting the pinion conical (CAS-1596B-1).
distance STEP 9
STEP 3 Read and note the value "B" written on the end of the
Assemble the calibrating block (CAS-1596B-5), the pinion shaft (14).
alignment disc (CAS-1596A-6) and the screw STEP 10
(CAS-1596A-7), then place them on the bearing (12).
STEP 4 the conical distance of the pinion shaft (14).
Place the bearing (8) in the differential support (9). 134.5 mm + A - B = thickness of the shim in mm
NOTE: The value of 134.5 mm corresponds to the
STEP 5
Install the handle (CAS-1596A-4), then tighten until it height of the calibrating block (CAS-1596B-5).
becomes difficult to turn the bearings.
STEP 11
STEP 6
Remove the yoke (21), the special tools and the
Install the calibrating tube (CAS-1596B-1) on the dif- bearings (8) and (12).
ferential support (9).

6005-23
14
9
13
12
10
11
P
7
CS96G062

(14). STEP 17
0.10 in 0.10 mm). STEP 18
Assemble the following on the pinion shaft (14): the measure the bearing preload.
compressible spacer (11) and a washer (10).
Tighten the nut (6) until a preload (P) is obtained of
Lubricate the bearing with clean oil and install the hammer over the edge of the nut on the pinion shaft.
(9).
STEP 15
STEP 16
shaft (14).

6005-24
10 7
1 9
9
8
8
2 6
3
5
11
12
P1
PDH0159A
13
PDH0156B
STEP 20 STEP 23
STEP 21
Install the yoke (1) on the differential support (11) and
install the washers (13) and the screws (12). Tighten
the screws.

STEP 22
Install the adjusting rings (2) and (6) using the adjust- E069036
able spanner (CAS-1840B). Screw the adjusting ring Place a dial gauge on one tooth of the crown wheel
(6) until the crown wheel (7) is in contact with the pin- (7) positioning the rod of dial gauge perpendicular to
ion shaft (4). Screw the adjusting ring (2) until it the face of the tooth.
tap the yoke (1) using a mallet so as to place the

6005-25
STEP 24 STEP 30
Inspect and note the clearance between the crown Install the lock tab washers (8) then install the screws
wheel (7) and the pinion shaft (4) and repeat the (9) and tighten them to a torque of 13 Nm.
rings (2) and (6) to install the locking tab washers (8).
gauge on the tooth of the crown wheel with the
Do not turn the adjusting rings more than half a
smallest reading.
notch.
STEP 25
STEP 31


4
from 0.21 to 0.28 mm.

6

roller bearings 1
STEP 26
Place a torque wrench on the pinion shaft (4) to 5 3 2
measure the bearing preload.
STEP 27 CM96A036
Install the O-ring (1) and, using a press and the special
Tighten the adjusting rings (2) and (6) to an identical tool (CAS-2452) fitted with the interchangeable handle
value until a preload P1 of between 113 and 170 N is (CAS-1716-3), the lip seal (2) on the cover (3) then
obtained. install the cover assembly on the differential support (4).
NOTE: The total preload value P1 of 113 to 170 N Install the screws (5) and the washers (6) then tighten
corresponds to the value P of pinion shaft preloading the screws to a torque of 27 Nm.
(84 to 126 N) + the preload value of the differential
STEP 32
Install the differential carrier coupling clamp. See
STEP 28 section "Differential carrier coupling clamp".
STEP 29
Tighten the screws (12) of the yoke (1) to a torque of
413 Nm.

6005-26
DIFFERENTIAL
Carraro 838LD axle
17
12
13
19 15
28
18 34
10
14
16
29
12
17 19
14
18 11
22
PDH0048
Carraro 838FR axle
17 12 17
12
13
19 15
14
18 34
14 10
16
19
17
12 17 11
18
22
PDH0049

6005-27
STEP 1 STEP 5
Remove the hub shafts complete with their wheel hub Using the release tool (CAS-10563) and a press,
and their reduction gear. See section "Hub shaft". extract the bearings (19) and remove the washer
(22).
STEP 2
STEP 6
Remove the coupling clamp from the differential
carrier. See section "Differential carrier coupling Remove the pinion shafts (13), washers (14) and
clamp". (17), satellites (12), planetaries (15) and (16) and the
differential housings (18).
STEP 3
STEP 7
Remove the crown wheel and pinion. See section
"Crown wheel and pinion". Remove the pin (29) and the bushing (28).
STEP 4 Inspection
Remove and scrap the screws (11). Remove the Check condition and the wear of the differential parts.
crown wheel (34) and the centring studs (10). If the crown wheel (34) is damaged, change the
NOTE: When reinstalling, install new screws with crown wheel and the pinion shaft.
Loctite 270 and tighten them to a torque of 190 Nm. NOTE: When installing, proceed in the reverse order
of removal.

6005-28

Disassembly STEP 2

4
5

4

3

3

5

6 25 25
1 2
2
1 CM96F005
Disassemble the clamp (4), install the seal (5),

PDH0145 reassemble the clamp (4) then place between the
Remove in the following order: the screw (1), the pinion (25) and the washer (2) (previously coated with
washer (2), the adjusting shim (3), the clamp (4), the Loctite 510), the number of shims (3) corresponding to
seal (5) and the washer (6) from the pinion shaft (25). Step 1. Tighten the screw (1) to a torque of 139 Nm.
Assembly NOTE: Thickness of available shims: 0.05; 0.1 and
0.2.

STEP 1
6

4

5
A
25
CM96A038


Section
6005
REAR AXLE AND SERVICE BRAKE

CARRARO 852FR AXLE
6005

Printed in France
6005-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................................... 3
SPECIAL TOOLS ..................................................................................................................................................... 4
Kit (CAS-40008) ................................................................................................................................................... 5
Tool to be manufactured ...................................................................................................................................... 6
STANDARD TOOLS................................................................................................................................................. 6
REAR AXLE ............................................................................................................................................................. 7
REDUCTION GEAR ............................................................................................................................................... 10
WHEEL HUB .......................................................................................................................................................... 12
HUB SHAFT AND SERVICE BRAKE..................................................................................................................... 14
Disassembly ....................................................................................................................................................... 16
Inspection ........................................................................................................................................................... 17
Assembly............................................................................................................................................................ 18
Preloading the bearings on the pinion shaft ....................................................................................................... 19
DIFFERENTIAL ...................................................................................................................................................... 22
Inspection ........................................................................................................................................................... 22
Disassembly ....................................................................................................................................................... 23
Assembly............................................................................................................................................................ 23

6005-3
SPECIFICATIONS
Weight of rear axle without oil.......................................................................................................................... 636 kg
Oil capacity of wheel reduction gear............................................................................................................. 2.5 litres
Oil capacity of axle housing........................................................................................................................... 25 litres
Type of oil ..................................................................................................................TRANSELF B 80W90 API GL5
Type of grease ..................................................................................................................................... GREASE EP2
Pinion/crown wheel ratio ............................................................................................................................ 3.363:1
Clearance between pinion/crown wheel teeth .............................................................................. 0.21 to 0.28 mm
Preload on differential pinion shaft bearings .................................................................................P = 76 to 114 N
Total preload on differential pinion shaft bearings ......................................................... T = (P + 22) to (P + 34) N
Thickness of pinion shaft shims ..................................................................2.5 to 3.4 mm (from 0.10 in 0.10 mm)
Final drive
Reduction gear ratio ..................................................................................................................................... 6.23:1
Total transmission ratio............................................................................................................................... 20.95:1
Brake
Thickness of a new brake disc ....................................................................................................... 9.9 to 10.1 mm
Wear limit ......................................................................................................................................... 8.5 to 8.7 mm
Maximum wear per brake disc ................................................................................................................... 1.4 mm
Reaction plate thickness .................................................................................................................. 9.5 to 9.6 mm

Crown wheel retaining screws ....................................................................................................................... 190 Nm
Pinion nut............................................................................................................................................. as per preload
Coupling clamp retaining screw..................................................................................................................... 139 Nm
Braking mechanism retaining screws ............................................................................................................ 220 Nm
Satellite carrier retaining screws.................................................................................................................... 530 Nm
Reduction gear cover screws .......................................................................................................................... 23 Nm
Axle and differential screws ........................................................................................................................... 413 Nm
Universal joint shaft coupling ......................................................................................................................... 120 Nm
Wheel retaining nuts ...................................................................................................................................... 540 Nm
Differential carrier retaining screw ................................................................................................................. 266 Nm
Hub shaft retaining nuts................................................................................................................................. 143 Nm
Hub shaft retaining stud................................................................................................................................... 70 Nm
Axle drain and filling plug................................................................................................................................. 60 Nm
Reduction gear drain and filling plug ............................................................................................................... 60 Nm
Axle drain plug at brake ................................................................................................................................... 30 Nm
Breather............................................................................................................................................................. 5 Nm
Breather bracket .............................................................................................................................................. 15 Nm
Brake bleed screw union ................................................................................................................................. 90 Nm
Brake bleed screw ........................................................................................................................................ 8-12 Nm
Differential carrier cover retaining screws........................................................................................................ 27 Nm

6005-4
SPECIAL TOOLS
CS96A240 CD96A010
CAS-1840B Adjustable spanner. CAS-10803 Removing tool for snap ring.
CS96A248 CS96A247
CAS-2097 Brake spring removal and installation CAS-2798 Toothed wheel extraction device.
device. Used for the first time on page 15. Used for the first time on page 13.
CS96A243
CS96A253
CAS-1964-1 Centring piece. CAS-2457 Centring piece.
CAS-1964-2 Centring piece. Used for the first time on Used for the first time on page 15.
page 18.
CS96A016
CS96A254
CAS-2452 Centring piece.
CAS-2457 Centring piece. Used for the first time on page 21.

6005-5
Kit (CAS-40008)
CS96A237
CS96A236 CAS-1596A-8 Calibrating block.

CAS-1596B-1 Calibrating tube. Used for the first time on page 18.
CS96A239
CS96A238 CAS-1596A-7 Pilot (screw).

CAS-1596A-9 Aligning disc. Used for the first time on page 18.
CS96A242
CS96A245 CAS-1668 Thickness gauge.

CAS-1596A-4 Handle. Used for the first time on page 18.
CS96A255
CS96A241
CAS-1716-3 Interchangeable handle.
CAS-2078 Wrench for pinion shaft nut. Used on pages 15, 18 and 21.

6005-6
Tool to be manufactured
Assembly tool for case seal (wheel hub). Used for the first time on page 13.
ø 30

200

32

R1
5.5 0
+0.3 8 0
+0.5
+0.5
16 14.5 0
ø 148
ø 176.85±0.05 2 to 15°
ø 199.5±0.1
ø 204.5±0.1
ø 218.5±0.2 PDH0150
STANDARD TOOLS
Screw....................................................................................................................................................... CAS-10355
Release tool............................................................................................................................................. CAS-10563
Extractor .................................................................................................................................................. CAS-10692
Loctite 271
Loctite 510

6005-7
REAR AXLE
with stabilizers or dozer blade, wedge the front wheels on blocks.
- Using the attachment, lift the rear of the machine and place axle stands behind each side of the undercarriage
and then place the undercarriage resting on the axle stands and the stabilizers so as to distribute the weight
between the stabilizers and the axle stands.
- Stop the engine.
hydraulic system.
- Unscrew the pressure release plug on the hydraulic reservoir two to three turns to release pressure in the

STEP 1 Place a rolling jack under the centre of the rear axle
Remove the rear wheels. during the disengagement stage.
NOTE: When installing, tighten the wheel nuts to a STEP 6
torque of 540 Nm.
Remove the nuts, screws and washers which fasten
STEP 2 each end of the axle to the undercarriage, then slowly
Remove the steps and the LH tool box. lower the jack so as to remove and disengage the
axles form the machine. Place the axle on a suitable
STEP 3 support.
Remove the service brake supply hoses. NOTE: When installing, proceed in the reverse order
to that of removal.
STEP 4
Remove, at the rear axle end, the transmission uni-
versal joint retaining screws and uncouple the trans-
mission universal joint.
torque of 120 Nm.
- Start the engine.
- Bleed the brakes.

6005-8
2 5 Nm
8 30 Nm
3
1 4 15 Nm
9 60 Nm
5 8-12 Nm
6 90 Nm
7
16
11
15
14
Loctite 510
12
60 Nm
13 10
266 Nm 30 Nm
17
60 Nm
CS96A051
1 Axle housing 8 Drain plug 14 Reduction gear

2 Breather 9 Filler plug 15 Wheel hub
3 Seal 10 Drain plug at service brake 16 Hub shaft and service brake
4 Breather bracket 11 Differential carrier 17 Reduction gear drain plug
5 Bleed screw 12 Drain plug
6 Bleed screw union 13 Differential carrier retaining
7 Seal screw

6005-9
STEP 1 STEP 4
Drain the reduction gears and the axle housing. Remove the hub shafts (16) and the service brakes.
See section "Hub shaft and service brake".
NOTE: When reassembling, fill the reduction gears
and the axle housing with oil (see "Specifications") STEP 5
and tighten the plug (12) on the differential carrier
and the plug (17) on the reduction gear to a torque of Remove the screws (13) then remove the differential
60 Nm and the plug (10) on the service bake to a carrier (11).
torque of 30 Nm. NOTE: When reinstalling the differential carrier on
the axle housing (1), clean and degrease the
STEP 2
differential carrier coupling and the axle housing, also
Remove the reduction gears (14). See section the threads of the axle retaining holes. Apply a 1 mm
"Reduction gear". wide bead of Loctite 510 on the axle housing face
and around the threads of each hole. Tighten the
STEP 3 screws (13) to a torque of 266 Nm.
Remove the wheel hubs (15). See section "Wheel
hub".

6005-10
REDUCTION GEAR
Loctite 271
2
5 13
4 12
530 Nm
9 3
11
10
11
8
7 1 14
23 Nm 60 Nm
PDH0151
7 8 9 7 11 5 6
11

10

3 12 13 4 2 1
CM96A031

6005-11
STEP 1 STEP 3
Remove the screws (1). Extract the reduction gear Check the needle roller bearings (7), the pinions (8),
cover (2) using two screws and the two extraction the spacers (9), the pinion shafts (10) and the thrust
orifices on the cover. washers (11). Replace them if necessary.
torque of 23 Nm. needle roller bearings (7) in the reduction gear cover
(2), use grease to keep them in position.
STEP 2
STEP 4
retain the satellite carrier (4). Remove the O-ring (5)
from the wheel hub (6) and scrap it.

6005-12
WHEEL HUB
14 13
12
10 11
8
7
1
5
6
2
4 220 Nm CS95A052

7 8 9

2

5

4

3

6
1 13

10 11 12
CM96A032

6005-13
STEP 1 STEP 8
Remove the reduction gear. See section "Reduction Extract the bearing (10) and extract the spacer (11)
gear". from the hub shaft (13).
STEP 2 STEP 9
Remove the retaining ring (1) using tool CAS-10803, Remove the case seal (12) from the hub shaft (13).
crown wheel (2) and the transmission shaft (3).
NOTE:
STEP 3
Remove the retaining screws (4) for the toothed 13 A
wheel (5).
torque of 220 Nm. 12
STEP 4
PDH0152

tool (A). See section "Tool to be manufactured".
NOTE:
PD01121
Remove the toothed wheel (5) using special tool

(CAS-2098).
STEP 5
CS96A003

check the following dimensions and change any parts
which are out of tolerance:
A = 68.95 to 69.00 mm
B = 69.275 to 69.235 mm
C = 21 mm
PD01910
D = 23.070 to 23.172 mm
Extract the bushings (6). E = 4.95 to 5 mm
STEP 6
Extract the wheel hub (8) and the bearing (7) from the
axle shaft (13) while supporting the hub using a
suitable lifting device.
STEP 7
wheel hub (8).

6005-14
HUB SHAFT AND SERVICE BRAKE

3
13
19
12
11
18
23 17
20
1 15
14
143 Nm 10
4
8
7
5
16 24
2
6 9
21
22
70 Nm CS96A054

8
3

10 20

7

17

23

5

11

13

12

19
2

18

22 16

21

1

14

6

15
CM96A033

6005-15
STEP 1 STEP 9
gear".
STEP 2
Remove the wheel hub. See section "Wheel hub".
STEP 3
Remove and scrap the retaining nuts (1) for the hub
shaft (2).
torque of 143 Nm.
PD04517
STEP 4
Remove the return springs (20) from the piston (15)
Support the hub shaft (2) using a suitable device. using special tool (CAS-2097) then remove the hook-
Extract the hub shaft (2) by removing the two plastic ing ring from the return springs (14).
plugs on the axle housing and by screwing in their
place the M10x1.5 extraction screws. Tighten the STEP 10
extraction screws uniformly and release the hub shaft Extract the piston (15). Scrap the two piston O-rings
(2) from the axle shaft (23). (17) and (18).
STEP 5 STEP 11
Remove and scrap the two O-rings (3). Remove the hooking ring (19) complete with the
return springs (20).
STEP 6
Remove the reaction plate (5), the first brake disc (7), STEP 12
the intermediate plate (8) and the second brake disc Remove the seal (21) then using an extractor
(10). Check the brake discs for wear. Wear on each (CAS-10692) and the screw (CAS-10563), remove
brake disc must not exceed 1.4 mm. The wear limit the bushing (22).
on each disc is between 8.5 and 8.7 mm.

NOTE:
STEP 7

Remove the coupling sleeve (11) then remove the
snap ring (12).

STEP 8

Remove the transmission shaft (13).

21

22

CM96A039
When reinstalling the bushing (22), use the centring

piece (CAS-2456) fitted with the interchangeable
handle (CAS-1716-3). Position the seal (21) as

6005-16

Disassembly
17 16 15 21 18
19
20
15
14
13
12 16
11
10
8 17
6
2
4
7 9
5
3
CS95A055
STEP 1 STEP 5
Remove the hub shafts complete with their wheel hub Untighten the adjusting rings (16) using special tool
and their reduction gear. See section "Hub shaft and (CAS-1840B).
service brake".
STEP 6
STEP 2
Remove the differential carrier. Remove the coupling remove the two yokes (20).
clamp. See section "Coupling clamp".
STEP 7
STEP 3
remove the cover (3). Remove and scrap the lip seal
(4) and the O-ring (5) from the cover (3).
STEP 4

6005-17
STEP 8 STEP 11
Remove the differential assembly (21) with the Remove the pinion shaft (14): the washer (10) and
bearing races (15). If these are to be reinstalled, label the compressible spacer (11). Scrap the compressi-
them. ble spacer (11).
Extract the bearing (12) from the pinion shaft (14)
STEP 9 using special tool (CAS-10563) then remove the
adjusting shim (13).
Straighten the nut tab washer (6) and remove it using
special tool (CAS-2078), then remove the lock STEP 13
washer (7).
Using a mallet, drive out the pinion shaft (14) and Inspection
Check the condition and wear on the pinion shaft
change the pinion shaft and the differential crown
wheel.

6005-18
Assembly

18 B

14
20

A

CAS-1596B-1 000.00
CAS-1596A-9 00

CAS-1596A-8

12 PDH0044A

C
CAS-1596A-7

9 B Pinion shaft projection
value
CAS-1596A-4

8
number
CM96A001
STEP 1 STEP 7
Using special tool (CAS-1964-2) fitted with the Place the yokes (20) on the differential support (9),
interchangeable handle (CAS-1716-3), install the and tighten the screws (18) to a torque of 413 Nm.
bearing races (8) and (12) in the differential support
(9). STEP 8
Using a feeler gauge (CAS-1668), measure and
STEP 2
note the distance "A" between the calibrating block
Place the bearing (12) in the differential support (9). (CAS-1596A-8) and the calibrating tube
(CAS-1596B-1).
Adjusting the pinion conical
STEP 9
distance
Read and note the value "B" written on the end of the
STEP 3 pinion shaft (14).
Assemble the calibrating block (CAS-1596A-8), the STEP 10
alignment disc (CAS-1596A-9) and the pilot
(CAS-1596A-7), then place them on the bearing (12). Calculate the thickness of shims necessary to adjust
the conical distance of the pinion shaft (14).
STEP 4
135.224 mm + A - B = Thickness of the shim in mm
Place the bearing (8) in the differential support (9).
NOTE: The value 135.224 mm corresponds to the
STEP 5 radius of the calibrating tube (CAS-1596B-1) + the
height of the calibrating block (CAS-1596A-8).
Install the handle (CAS-1596A-4), then tighten until it
becomes difficult to turn the bearings. STEP 11
STEP 6 Remove the yokes (20), the special tools and the
bearings (8) and (12).
Install the calibrating tube (CAS-1596B-1) on the

6005-19

14
9

13
10

12

11

8
7

76-114 N 6
CM96A035

(14). STEP 17
0.10 in 0.10 mm). STEP 18
Assemble the following on the pinion shaft (14): the measure the bearing preload.
compressible spacer (11) and the washer (10).
Tighten the nut (6) until a preload is obtained of
Lubricate the bearing with clean oil and install the hammer over the edge of the nut on the pinion shaft.
(9).
STEP 15
STEP 16
shaft (14).

6005-20
1 12
413 Nm

10 413 Nm 7

11 11

12
1

8

8

2

6

3

5

4

9
98-148 N
CM96A034
STEP 20 STEP 23
STEP 21
Install the yokes (1) on the differential support (9) and
install the washers (12) and the screws (11). Tighten
the screws.

STEP 22 E069036
Install the adjusting rings (2) and (6) using the adjust- Place a dial gauge on one tooth of the crown wheel
able spanner (CAS-1840B). Screw the adjusting ring (7) positioning the rod of dial gauge perpendicular to
(6) until the crown wheel (7) is in contact with the pin- the face of the tooth.
ion shaft (4). Screw the adjusting ring (2) until it
tap the yokes (1) using a mallet so as to place the

6005-21
STEP 24
Inspect and note the clearance between the crown

STEP 31


gauge on the tooth of the crown wheel with the small-

est reading.
STEP 25

4

from 0.21 to 0.28 mm.
6
1
roller bearings 5 3 2
STEP 26 27 Nm
Place a torque wrench on the pinion shaft (4) to CM96A036
measure the bearing preload. Install the O-ring (1) and, using a press and the spe-
STEP 27 handle (CAS-1716-3), the lip seal (2) on the cover (3)
Tighten the adjusting rings (2) and (6) to an identical then install the cover assembly on the differential sup-
value until a preload of between 98 and 148 N is port (4). Install the screws (5) and the washers (6)
obtained. then tighten the screws to a torque of 27 Nm.
NOTE: The total preload value of 98 to 148 N STEP 32
corresponds to the value P of pinion shaft preloading Install the differential carrier coupling clamp. See
(76 to 114 N) + the preload value of the differential section "Differential carrier coupling clamp".
STEP 28
STEP 29
Disassemble and then reassemble, one by one, the
screws (11) for the yokes (1) using Loctite 271 then
tighten them to a torque of 413 Nm.
STEP 30
rings (2) and (6) to install the locking pins (8). Do not
turn the adjusting rings more than half a notch.

6005-22
DIFFERENTIAL
19 18 17
12
13
14
18
14 34 10
16
22
12
15 19
17
11
190 Nm
Loctite 271
CS96A017
STEP 1 STEP 5
Remove the hub shafts complete with their wheel hub Using the release tool (CAS-10563) and a press,
and their reduction gear. See section "Hub shaft and extract the bearings (19) and remove the washer
service brake". (22).
STEP 2 STEP 6
Remove the coupling clamp from the differential Remove the pinion shafts (13), washers (14) and
carrier. See section "Differential carrier coupling (17), satellites (12), planetaries (15) and (16) and the
clamp". differential housings (18).
STEP 3 Inspection
Remove the crown wheel and pinion. See section Check condition and the wear of the differential parts.
"Crown wheel and pinion". If the crown wheel (34) is damaged, change the
STEP 4 crown wheel and the pinion shaft.
Remove and scrap the screws (11). Remove the NOTE: When installing, proceed in the reverse order
crown wheel (34) and the centring studs (10). of removal.


6005-23

Disassembly

STEP 3

STEP 1
16
22

20

5
7

4
5 6
4

20

6 Loctite 510
3 2 1
3
2 139 Nm CM96A037
1 CS96A056
Disassemble the clamp (5), install the seal (6), reas-
semble the clamp (5) then place between the pinion
Remove in the following order: the snap ring (1), the shaft (20) and the washer (3) (previously coated with
screw (2), the washer (3), the adjusting shim (4), the Loctite 510), the number of shims (4) corresponding
clamp (5), the seal (6) and the washer (7) from the to Step 2. Tighten the screw (2) to a torque of
pinion shaft (20). Discard the seal (6). Remove and 139 Nm. Install the snap ring (1).
scrap the seal (22) on the differential bracket (16).
Assembly 0.2.

STEP 2

7

5

20

6
A
CM96A038
Place, temporarily, on the pinion shaft (20), the clamp

(5) and the washer (7) without the seal (6) and using
a depth gauge, measure and note the clearance (A)
between the pinion shaft (20) and the clamp (5).
6005-24

Section
6008
GEAR BOX AND PARKING BRAKE
6008

Printed in France
6008-2
TABLE OF CONTENTS
SPECIFICATIONS .................................................................................................................................................. 3
SPECIAL TORQUE SETTINGS ............................................................................................................................. 3
TOOLS REQUIRED ............................................................................................................................................... 3
Special tools ........................................................................................................................................................ 3
PARKING BRAKE .................................................................................................................................................. 4
Cross-sectional drawing of parking brake ........................................................................................................... 4
Exploded view of parking brake .......................................................................................................................... 5
Disassembly and Assembly ................................................................................................................................ 6
GEAR BOX ............................................................................................................................................................. 8
Cross-sectional drawing of gear box ................................................................................................................... 8
Exploded view of gear box .................................................................................................................................. 9
Removal and Installation ................................................................................................................................... 10
Disassembly and Assembly .............................................................................................................................. 11

6008-3
SPECIFICATIONS
Weight when empty ............................................................................................................................................ 94 kg
Reduction ratio in first speed...............................................................................................................................................1/6
Reduction ratio in second speed......................................................................................................................................1/1.8
Number of brake discs:
Steel discs .............................................................................................................................................................9
Friction discs .......................................................................................................................................................10
Total thickness of new friction discs and new steel discs............................................................................................ 27 mm
Total minimum thickness of friction discs and steel discs ........................................................................................... 24 mm
Quantity of parking brake spring washers .............................................................................................................................8
Speed change control pressure ........................................................................................................................... 34 to 36 bar
Parking brake pressure ....................................................................................................................................120 to 160 bar
Oil capacity.................................................................................................................................................................. 2.3 liters
Oil ..........................................................................................................................................TRANSELF B 80W 90 API GL5

Engagement fork support pin retaining screws ................................................................................................ 35 Nm
Input shaft retaining nut ...............................................................................................................................................240 Nm
Output shaft retaining nuts ..........................................................................................................................................240 Nm
Brake housing cover retaining nuts......................................................................................................................73 to 87 Nm
Brake housing retaining screws ...........................................................................................................................73 to 87 Nm
Transmission shaft universal joint retaining screws ...................................................................................................120 Nm
TOOLS REQUIRED
2 Extractor
3 Loctite 270
4 Loctite 515
Special tools
PDH0053
Nut wrench CAS 2104, used on pages 11 and 13

6008-4
PARKING BRAKE
Cross-sectional drawing of parking brake
6 7 7 6 10 5
11
1 9 3 13 12
PDH0058
1 BRAKE HOUSING 8 BELLEVILLE WASHER
2 BRAKE COVER 9 BRAKE PISTON
3 SCREW 10 STEEL DISCS AND FRICTION DISCS
4 THRUST WASHER 11 THRUST WASHER
5 O-RING 12 POSITIONING LUG
6 BACK-UP RING 13 BUSHING
7 O-RING

6008-5
Exploded view of parking brake
* 5
*7
9
3
13
2
* 5
8
6
*
12
7
6 *
1 *
10b
10a
11
PDH0054
NOTE: Parts shown with an asterisk must always be replaced.

1 BRAKE HOUSING 8 BELLEVILLE WASHER
2 BRAKE COVER 9 BRAKE PISTON
3 SCREW 10a FRICTION DISCS
4 THRUST WASHER 10b STEEL DISCS
5 O-RING 11 THRUST WASHER
6 BACK-UP RING 12 POSITIONING LUG
7 O-RING 13 BUSHING

6008-6

Before performing any service work on the machine, the following steps must be carried out in the order shown :
- Immobilise the machine by lifting the wheels off the ground using the stabilizers and the dozer blade or, if the
machine is not fitted with stabilizers and dozer blade, place chocks to the front and rear of the front and rear
wheels.
- Stop the engine.
STEP 1 STEP 3
E120016 E122004
Disconnect and plug the parking brake supply hose. Remove the thrust washer and the positioning lug.
STEP 2 NOTE: When assembling, make sure that the posi-
tioning lug is correctly placed in the gear box housing
notch.
STEP 4
E20024
Remove the parking brake assembly retaining screws

and remove the parking brake.
NOTE: When assembling, tighten the parking brake E120032
assembly retaining screws to a torque of between 73 Remove the friction discs and the steel discs. Check
and 87 Nm. friction disc wear. See "Specifications" for minimum fric-
tion disc thickness.
NOTE: When assembling, the first disc and the last
disc must be friction discs.

6008-7
NOTE: If new friction discs are installed, they must be STEP 7
immersed in a receptacle of hydraulic fluid for ten
minutes prior to installation.
STEP 5
E121011
Using a compressed air jet introduced into the braking

line, remove the brake piston. Remove and discard the
O-rings and the back-up rings.
E121004
Remove the screws and the cover. Remove and discard NOTE: When installing, position the O-rings and the
the O-ring. back-up rings correctly (see parking brake cross-sec-
tional drawing).
NOTE: When installing, tighten the cover retaining
screws to a torque of between 73 and 87 Nm. STEP 8
STEP 6
E121025
Remove and discard the O-ring.

E121008
Remove the spring washers and the thrust washers.

NOTE: When assembling, make sure that the spring
washers are orientated in the correct direction (see
parking brake cross-sectional drawing).
For installation, follow the same procedure in the reverse order from that of removal. Before using the machine, all
the following operations must be carried out in the order shown:
- Start the engine.
- Check the hydraulic system for leaks.
- Check the level of hydraulic oil in the reservoir. Top up if necessary.

6008-8
GEAR BOX
Cross-sectional drawing of gear box
21 20 19 18 17 16 9 7 6 10 8
22 11
23
2
15
14 1
13
12
24
3
25
28 4
26 45
27
46
29
44
30 43
35
41
31
42
46 5
32 40
39
33 34 36 37 38
CS99J523
1 NUT 13 INPUT PINION 24 SNAP RING 37 BEARING STOP

2 HUB 14 BEARING 25 ENGAGEMENT BUSHING 38 GEARS
3 SECONDARY SHAFT 15 O-RING 26 SCREW 39 SCREW
4 BEARING 16 FORK LINK SHAFT 27 ENGINE FLANGE 40 PLUG
5 HOUSING COVER 17 FORK 28 O-RING 41 SEAL
6 CENTERING STUD 18 SPEED SELECTOR PIS- 29 SEAL 42 BEARING
7 HOUSING TON 30 THRUST WASHER 43 OUTPUT SHAFT
8 GEAR 19 O-RING 31 WASHER 44 NUT
9 IDLER GEAR 20 O-RING 32 BEARING 45 FLANGE
10 NEEDLE BEARING CAGE 21 SEAL 33 BEARING STOP 46 SEAL PROTECTOR
11 LOWER BUSHING 22 O-RING 34 NEEDLE BEARING CAGE
12 NEEDLE BEARING 23 SCREW 35 SPACER
36 DOUBLE GEAR

6008-9
Exploded view of gear box
5 1
2
3
4
13
6 12
9 14
11
10 27
7 8
26
25
17 15 24
16 23
21 54
20 28
22 53
19
38
34
18
39
33
29 51
45
50
49
31
35 48
47
30
36
32 46
44
42 43
41
40
PDH0052
1 O-RING 14 ENGAGEMENT BUSHING 27 NUT 41 NEEDLE BEARING

2 RING 15 O-RING 28 CENTERING STUD 42 BEARING
3 O-RING 16 PLUG 29 HOUSING 43 THRUST WASHER
4 SPEED SELECTOR PIS- 17 SCREW 30 NUT 44 OUTPUT SHAFT
TON 18 FORK 31 FLANGE 45 SPACER
5 SCREW 19 O-RING 32 SEAL 46 NEEDLE BEARING
6 O-RING 20 FORK LINK SHAFT 33 HOUSING COVER 47 DOUBLE GEAR
7 ENGINE FLANGE 21 LOWER BUSHING 34 PLUG 48 THRUST WASHER
8 O-RING 22 NEEDLE ROLLER BEAR- 35 SCREW 49 BEARING STOP
9 SNAP RING ING 36 SEAL 50 GEAR
10 BEARING 23 IDLER GEAR 37 PARKING BRAKE 51 BEARING
11 INPUT PINION 24 GEAR 38 NUT 52 O-RING
12 NEEDLE ROLLER BEAR- 25 BEARING 39 FLANGE 53 BUSHING
ING 26 BRAKE HUB 40 WASHER 54 SCREW
13 SECONDARY SHAFT

6008-10

- Immobilise the machine by raising the wheels off the ground by means of the stabilizers and the dozer blade or if
the machine is not fitted with stabilizers or dozer blade, place chocks to the front and rear of the front and rear
wheels.
- Stop the engine.
STEP 1 STEP 4
Place a receptacle of a minimum capacity of 3 litres
under the gear box. Remove the drain plug and after
draining all the oil, install and tighten the drain plug.
NOTE: When installing, fill the gear box housing with
the recommended oil (see "Specifications", page 2).
STEP 2
Remove the hydraulic travel motor. Refer to Section
7003.
STEP 3
Remove the front and rear universal joints from the
gear box. 3
NOTE: When installing, tighten the universal joint
1 7
6
2
PDH0055
Attach identification labels and disconnect (1), (2), (3),

(4), (5) and (6) and remove the indexing and safety
selector (7).

6008-11
STEP 5 STEP 4
Using a suitable lifting device, support the gear box
and remove the right and left-hand mounting retain-
ing screws. Place the gear box on a clean bench.
NOTE: When installing, carry out the same proce-
dure in the reverse order.

STEP 1
D06622
Turn the gear box the other way up. Unlock the output
shaft lock nut on the gear box housing side and remove
it using the nut wrench CAS-2104. Remove the pinion
shaft drive flange.
NOTE: When assembling, tighten the lock nut to a
torque of 240 Nm, by means of the nut wrench CAS-
2104, and then lock the nut by bending it back
against the flat on the shaft.
D07021
STEP 5
Unlock the output shaft lock nut on the cover end of the
gear box and remove it using the nut wrench CAS-2104.
Remove the pinion shaft drive flange.
NOTE: When assembling, tighten the lock nut to a
torque of 240 Nm, by means of the nut wrench CAS-
2104, and then lock the nut by bending it back
against the flat on the shaft.
STEP 2
Remove the parking brake assembly retaining screws
and remove the parking brake.
NOTE: When assembling, tighten the parking brake
assembly retaining screws to a torque of between 73 D06618
and 87 Nm. Remove the engine flange retaining screws and remove
STEP 3 the flange.
Remove the thrust washer and the positioning lug.

NOTE: When assembling, make sure that the posi-
tioning lug is correctly placed in the gear box housing
notch.

6008-12
STEP 6 STEP 9
D06816 D07035
Remove and discard the O-ring. Remove the snap ring (1) from the coupling shaft and
STEP 7
STEP 10
D06604
Remove the input shaft coupling shaft assembly. D06525
Turn the gear box the other way up. Remove the cover
STEP 8 retaining screws and remove the cover.
NOTE: When assembling, coat the sealing surface
with Loctite 515.
STEP 11
D06602
Remove the input shaft needle roller bearing.
D06523
Remove and discard the output shaft seal.

6008-13
STEP 12 STEP 15
2
3
D06521
Remove the output shaft bearing.

STEP 13
PDH0057
Place the input shaft assembly in a soft-jawed vice.

Unlock the lock nut (1) and remove it by means of the
nut wrench CAS-2104.
D06519 NOTE: When assembling, tighten the lock nut (1) to a
Remove the output shaft bearing. torque of 240 Nm by means of the nut wrench CAS-
2104 and then lock it by bending it back against the
STEP 14 flat (2) on the shaft (3).
STEP 16
1
2
3
4
D06517
Remove the input shaft assembly.

D06402
Remove the hub (1), the bearing (2) and the gears (3)
from the input shaft (4).

6008-14
STEP 17 STEP 19
D06513 D06510
Remove the output shaft assembly. Remove the selector ring.

STEP 18 STEP 20
1
5
4 2
3 D06507
Remove the selector ring fork support shaft screw.

9
7 NOTE: When assembling the screw, apply Loctite
270 and tighten to a torque of 35 Nm.
STEP 21
8 6
PDH0059
Place the output shaft assembly in a soft-jawed vice.

- Remove the bearing (1).
- Remove the washer (2).
- Remove the bearings (3) and the spacer (4) with
the gear (5).
- Remove the lower bearing (6). D06505
- Remove the spacer washer (7). Remove the ring fork.
- Remove the bearing (8).
- Remove the spacer washer (9).

6008-15
STEP 22 STEP 25
D06503 D06428
Remove and discard the O-ring. Remove and discard the output shaft seal.
STEP 23 NOTE: For installation, follow the same procedure in
the reverse order from that of removal.
When installing the seal, position it 3 ± 0,25 mm from
the edge of the housing, as shown in the drawing.
D06500
Remove the selector ring control piston.

STEP 24
CS99K539
1 UNIVERSAL JOINT FLANGE
2 SEAL
D06435
Remove and discard the three O-rings.

6008-16

Section
6020
TWIN WHEELS
6020
Copyright © 2002 CNH France S.A.

Cre 9-53300GB Printed in France
CNH June 2002
6020-2
TABLE OF CONTENTS
IMPORTANT COMMENT.......................................................................................................................................... 2
TOOLS REQUIRED .................................................................................................................................................. 3
SPECIFICATIONS.....................................................................................................................................................3
TWIN WHEELS ......................................................................................................................................................... 4
Safety rules ........................................................................................................................................................... 4
General instructions .............................................................................................................................................. 4
Tyre pressures ...................................................................................................................................................... 6
Wheel retaining nuts ............................................................................................................................................. 6
Replacing twin wheels........................................................................................................................................... 6
Removal and installation of the two piece wheel-rim tyre ..................................................................................... 8
Install the wheels on the machine ....................................................................................................................... 11
IMPORTANT COMMENT
WARNING: Installing wheel components of different makes from those specified or formally approved
by CASE can cause the characteristics of the excavator to change.
! Any new installation must be submitted to CASE for prior certification approval.
Without that certification and in case of an accident caused by the use of components which are not
specified or approved by CASE, the installer is entirely liable for the installation.

6020-3
TOOLS REQUIRED
- Levers for unseating and installing the retaining ring.
- Rubber, plastic or copper mallet.
- Wire brush.
- Suitable lubricant for installing tyres.
- Pipe for remote inflation.
- Air inflation pressure gauge.
- Compressor - minimum capacity 7 bar.
- One inflation cage.
- Check valve extractor - Part Number B842606.
- 36 and 33 mm hexagonal wrench.
SPECIFICATIONS
Wheel nut - torque setting ................................................................................................................... 460 to 620 Nm
Tyre pressure .......................................................................................................................................................7 bar

6020-4
TWIN WHEELS
Safety rules General instructions
WARNING: Before disassembling twin wheels • Use suitable, good quality tools to disassemble the
! and in all cases, completely deflate both tyres. various parts of the tyre. Never use a metal hammer.
Use a mallet with a rubber, plastic or copper face.
WARNING: A tyre bursting can cause serious IMPORTANT: To enable inflation and deflation to be
bodily injury. Regularly check the condition of carried out later, never remove the internal tyre valve
! the tyres and always respect the specified extension.
inflation pressure for the type of tyre. IMPORTANT: In cases where the tyre valve or
extension is not longer accessible, you must take the
WARNING: When checking pressure or any necessary measures for protection, and then you
inflation operation, do not face the side of the must, imperatively, puncture the tyre.
tyre. Face the tyre tread. Always use an • To facilitate assembly or disassembly of the tyre, use
inflation cage when the wheel is not on the
! machine. Make sure that any other persons in
a suitable lubricant.
the vicinity are kept well away from the working • Never re-use a tyre which has been run totally
area. deflated (at less than 80% of the recommended
pressure). Disassemble and inspect the tyre and all
the components of the wheel before re-inflating it in
WARNING: Never weld close to a tyre. It is
an inflation cage.
imperative that tyre is removed from the wheel
! before any welding is carried out. • Check the various parts: the tyre, wheel rim, wheel
shoulder, retaining ring and change any defective
WARNING: Make sure that the decals on the part.
machine are perfectly legible - clean them • Never re-use a misshapen or rusty retaining ring.
! regularly, replace them with new decals when
• Before removing twin wheels both tyre must be
they are damaged, missing or painted over.
completely deflated. If it proves impossible to deflate
a tyre by removing the check valve from the tyre
WARNING: Tyres must always be inflated in valve, it is essential that you puncture the tyre.
an inflation cage before being installed on the
! excavator. Never try to inflate tyres when the
wheels are installed on the excavator.

6020-5
CS99C617
• To inflate the tyre on a wheel which is not installed on

the machine, place the wheel in an inflation cage and
inflate to the pressure specified by CASE. See
section "Specifications".
IMPORTANT: When inflating a tyre, never face the
side of the tyre. Always position yourself facing the
tread.
• Safety decals are stuck to the right and left-hand
sides of the machine. Make sure that these decals
are perfectly legible. Clean them regularly, replace
them with new decals if they are damaged, missing
or painted over (see photo above).
CD02G002

6020-6
Tyre pressures
Maintenance specifications
Check pressures................................................................................................................................Every 100 hours
Checking the torque setting of the wheel nuts...................................................................................Every 250 hours
(after 10 hours after re-installing a wheel
or during the running-in period)
Recommended inflation pressure

Tyre set and type
Front tyres Rear tyres
WX150 and WX170 4 wheels 18 x 19.5 XF 6 bar 6.5 bar

series 8 wheels 11.00-20 PR16 7 bar 7 bar
4 wheels 18 x 22.5 XF 6 bar 6.5 bar
WX200 series
8 wheels 11.00-20 7 bar 7 bar
Wheel retaining nuts Replacing twin wheels

The retaining nuts are different on the 4 wheel WARNING: Before disassembling twin wheels
configuration and on the 8 wheel configuration. ! and in all cases, completely deflate both tyres.
To prevent nuts becoming loose, follow the following
assembly instructions: Deflation and removal
Nut Part Number: STEP 1
(1) 4 wheel configuration: W2434501. Lift the machine and place blocks under the front or
rear axle as required.
(2) 8 wheel configuration: C1734501.
STEP 2
1 Completely deflate the tyres, even after they have
been punctured, by removing the check valve
(internal sealing mechanism) from the tyre valve.
Unscrew it using check valve extractor Part Number
B842606.
IMPORTANT: If the valve or the valve extension is no
longer accessible, take the necessary measures for
protection and then deflate the tyre by cutting through
the valve or, imperatively, by puncturing the tyre.
2 WARNING: Never face the side of the tyre.

Always face the tyre tread. Wait for the
PDG0141
! complete deflation of the tyre (when hissing
stops).

6020-7
STEP 3 STEP 5
CS01A514 CS99F506
Detach the valve extension from its clip. Remove Check the marking on the wheels to identify them.
eight retaining nuts using a 33 mm hexagonal
wrench, leaving two diametrically opposed nuts still WARNING: Never face the side of the tyre.
tightened. Always face the tyre tread. Wait for the
! complete deflation of the tyre (when hissing
Check that no pressure is exerted on these two nuts stops).
while they are being gradually unscrewed. If there is
any such pressure, check that the two tyres are
completely deflated, loosen the two nuts a few turns
and free up the wheel-rim if necessary.
STEP 4
When the inner and outer wheels are free, remove
the two remaining nuts and remove the wheels and
the twinning ring. Identify the direction of assembly
on the tyre on the wheel-rim (for example, draw a
cross on the retaining ring side).

6020-8
STEP 6
See table below before removing the tyre.
Type of marking Type of wheel-rim Removal and installation of the tyre

MEFRO Two piece See "Removal and installation" in this section
NS ----- Three piece See Service Manual 788/988 and 1188, section 6020
Removal and installation of the two STEP 2

piece wheel-rim tyre
Removal
NOTE: Use a bead-driver and two suitable levers
(tyre removal levers) to remove the tyre.
STEP 1 A
1
CT02D074
Insert one of the levers (tyre removal levers) into the

orifice (A) provided for removing the wheel shoulder,
then exert leverage to extract the end of the wheel
shoulder from its housing. Push the tyre removal
2 levers gradually forward, keeping them fairly close to
each other, to remove the wheel shoulder.
CS01A510
STEP 3
Insert the bead-driver between the tyre (1) and the
wheel shoulder (2) and move it forward, progres- Remove the tyre (1).
sively, tapping lightly on the bead-driver so as to
unseat the tyre over its entire circumference.

6020-9
Installation STEP 5
IMPORTANT: The groove in the rim where the wheel
shoulder fits must be perfectly clean.
STEP 1 6
8 8
4 2
1 5 7 3
CS01A510
3 2 Reinstall the flap (5) (rubber flap) which protects the

inner tube (4).
CS01A510
STEP 6
Clean the wheel shoulder (2) and the rim (3) with a Apply suitable grease to the beads (6) of the tyre.
hard brush. Remove any rust if necessary.
STEP 7
STEP 2
Install the tyre on the wheel rim, making sure that it is
Check the condition of the rim (3) and of the shoulder fitted in the right direction. See the section
(2) for any cracks, rust attacks or deformation. If nec- "Replacement of twin wheels" for the marking made
essary replace the rim/shoulder assembly by a part in Step 4.
which is identical with the CASE original specifica-
IMPORTANT: For tyres with asymmetric treads, it is
tions.
essential that you mount the tyre on the wheel rim in
STEP 3 the right direction.
Carefully check the condition of the tyre (1), if neces-
sary replace it by a tyre which is identical with the
CASE original specifications or consult your CASE
distributor for any other type of tyre.
STEP 4
Inflate the inner tube slightly to put it into shape, coat A A
it with talcum powder and insert it into the tyre.
CS99K549
NOTE: An arrow on the side of the tyre shows the

tread rotation direction.

6020-10
STEP 8 STEP 11
A
9
CI99K512 CS99C617
Install the tyre (1), the inner tube (4) and the flap (5) Place the wheel in an inflating cage (9), inflate the
on the wheel rim (3) and make sure that the valve (7), tyre to a pressure of 2 bar.
complete with its cap, is correctly positioned in
accordance with the specifications shown below: STEP 12
- Inner wheel: the end of the valve must be oriented
towards the wheel run-out.
- Outer wheel: the end of the valve must be oriented in 8
the opposite direction to the wheel run-out.
IMPORTANT: Never unscrew the valve end to obtain
the desired orientation (risk of a leak). 3
STEP 9
CS01A514
Check that:
- Condition 1: the wheel shoulder (2) is correctly
centred in its housing over its entire circumference.
- Condition 2: it is imperative that the centring portions
(8) of the tyre remain concentric with the wheel rim (3)
and with the wheel shoulder (2).
If one of these two conditions is not met, the tyre
CT02D075 assembly is incorrect. Carry out the following
Ask an assistant to help with installing the wheel operations:
shoulder (2) on the wheel rim (3). Use a heavy ham-
- Deflate the tyre completely (1).
mer with rubber, plastic or brass faces to position the
- Remove the wheel shoulder (2).
wheel shoulder in its housing.
- Repeat Steps 9 to 12.
IMPORTANT: It is imperative that the wheel shoulder
If condition 1 is still not respected, the wheel rim or
fits exactly into its housing over its entire
the wheel shoulder is not in conformity. Replace the
circumference.
wheel rim/wheel shoulder assembly with a part which
STEP 10 is identical to the CASE original specifications.
Make sure, before inflating the tyre, that the centring STEP 13
portions (8) of the tyre (1) are concentric with the
Inflate the tyre to the pressure specified by CASE
wheel rim (3) and the shoulder (2).
(7 bar).
Remove the wheel from the inflation cage.
6020-11
Install the wheels on the machine
A B
CS01A524
IMPORTANT: It is imperative that the direction of

installation of the wheels is respected (B is always
equal to or greater than A).
STEP 1
10 11
13
12
CS99C625
Install the inner wheel (10), the twinning ring (12) and
then the outer wheel (11). Centre the valve extension
(13) in its housing. Fasten the valve extension in the
clip provided for that purpose.
STEP 2
Centre the twinning ring (12), then coat the ten nuts
with oil and install and tighten them to a torque of
54 ± 8 daNm, using a 33 mm hexagonal head
wrench.
STEP 3
Remove the blocks under the front or rear axles and
lower the machine to the ground.

6020-12

Section
7003
7003
HYDRAULIC TRAVEL MOTOR

Printed in France
7003-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................................... 3
TOOLS REQUIRED ................................................................................................................................................. 3
TRAVEL MOTOR ..................................................................................................................................................... 4
SPEED LIMITER ...................................................................................................................................................... 6
FORCED FEED AND IRRIGATION BLOCK ............................................................................................................ 7
TRAVEL MOTOR REGULATOR.............................................................................................................................. 8
TRAVEL MOTOR ..................................................................................................................................................... 9
Cross-sectional view of the travel motor .............................................................................................................. 9
Exploded view of the travel motor ...................................................................................................................... 10
Removal and installation of the hydraulic travel motor....................................................................................... 11
Inspection ........................................................................................................................................................... 14
FORCED FEED AND IRRIGATION BLOCK .......................................................................................................... 15
Cross-sectional drawing ..................................................................................................................................... 15
SPEED LIMITER .................................................................................................................................................... 16
Cross-sectional view of the speed limiter ........................................................................................................... 18
TRAVEL MOTOR REGULATOR............................................................................................................................ 19
Cross-sectional drawing ..................................................................................................................................... 19
Disassembling and reassembling the regulator ................................................................................................. 20
MEASURE THE LEAK FLOW FROM THE TRAVEL MOTOR............................................................................... 22

7003-3
SPECIFICATIONS
Type ...................................................................................... A6VM107/43-97..................................A6VM107/40-93
Weight............................................................................................ 85 kg ........................................................... 85 kg
Minimum displacement.................................................................. 43 cc ........................................................ 40.8 cc
Maximum displacement ................................................................. 97 cc ........................................................... 93 cc
Maximum speed ....................................................................... 4226.5 rpm .............................................3952.9 rpm
Travel motor leak flow ................................................................. 23 L/min.................................................... 23 L/min
Adjusting the travel motor, see section 8001.

Travel motor retaining screws .............................................................................................................. 170 to 200 Nm
Speed limiter retaining screws ............................................................................................................ 170 to 200 Nm
Forced feed and irrigation block retaining screws ............................................................................... 170 to 200 Nm
Travel motor regulator retaining screws .................................................................................................. 60 to 84 Nm
Forced feed and irrigation block
Jet .................................................................................................................................................................. 5 Nm
Forced feed check valve plug ..................................................................................................................... 200 Nm
Speed limiter
Spool cap screw ......................................................................................................................................... 280 Nm
Bleed screw.................................................................................................................................................... 9 Nm
Secondary relief ......................................................................................................................................... 100 Nm
Braking check valve...................................................................................................................................... 30 Nm
Plugs ............................................................................................................................................................ 30 Nm
Plug ................................................................................................................................................................ 8 Nm
Travel motor regulator
Large cap retaining screws ................................................................................................................ 17 to 24 Nm
Small cap retaining screws ................................................................................................................. 34 to 48 Nm
Jet .................................................................................................................................................................. 8 Nm
Locking screw .......................................................................................................................................... M8 = 10 Nm
M10 = 25 Nm
M12 = 49 Nm
M16 = 86 Nm
Piston retaining screws ........................................................................................................................... 60 to 84 Nm
TOOLS REQUIRED
1 Torque spanner (0 to 245 Nm)
2 One rolling jack with a one-ton capacity
3 Loctite 262 - 601
4 Two release tools OEM 4174

7003-4
TRAVEL MOTOR
- Stop the engine.
- Turn the battery master switch key to the "OFF" position and remove the key.
hydraulic systems.
- Unscrew the pressure release plug on the hydraulic reservoir by two or three full turns, then retighten the plug.
WARNING: When the machine is running, the components attain a high temperature. To avoid risk of
burns from hot metal or boiling oil or water, allow the machine to cool down completely before carrying out
! any work.
7 2
14 170-200 Nm
R2 X 3
9
11
10
A
B R1
T G 5
12 15 1
9
8
13 6
PDH0321

7003-5
STEP 1 STEP 8
Remove the tool box, located on the left of the Disconnect at port T and plug the hose (13) coming
machine. from the hydraulic swivel.
STEP 2 STEP 9
Disconnect at port G and plug the hose (1) which Support the travel motor using the rolling jack.
comes from the pressure release selector.
STEP 10
STEP 3
Unscrew and remove the retaining screws (14) and
Disconnect at port X and plug the hose (2) which (15) on the travel motor.
comes from the travel control valve.
NOTE: When installing, tighten the screws (14) to a
STEP 4 torque of 170 to 200 Nm.
Unscrew the clip (3) then disconnect at port (4) and STEP 11
plug the leak return hose (5) which comes from the
Carefully disengage the travel motor from the
hydraulic swivel.
gearbox. Place the travel motor on a clean bench.
STEP 5 Motor weight: 85 kg
Remove the secondary relief blow off hose (6) which NOTE: When installing, proceed in the reverse order
comes from the union (4) and goes to port R1 on the to that of removal. Before reconnecting the hoses to
travel motor. the travel motor, fill it with hydraulic oil via the various
ports.
STEP 6
Remove the secondary relief blow off hose (7) which
comes from the union (4) and goes to port R2 on the
travel motor.
STEP 7
Remove the screws (8) and clamps (9) from ports A
and B, then remove and plug the supply and return
hoses (10) and (11). Scrap the O-ring (12).
- Start the engine.
- Check the system for leaks.
- Check the hydraulic oil level in the reservoir. Top up if necessary
- Carry out the adjustments to the travel motor. Refer to section 8001.

7003-6
SPEED LIMITER
1 170-200 Nm
2
STEP 1 STEP 3
Label all the components before disassembling them. Remove the speed limiter (2). Remove and scrap the
three speed limiter O-rings.
STEP 2
NOTE: When installing, use new O-rings.
Unscrew and remove the four Allen screws (1) which
retain the speed limiter (2). NOTE: For removal and installation of the speed
limiter, refer to page 16. When installing the speed
NOTE: When installing, tighten the screws to a limiter, proceed in the reverse order from that of
torque of 170 to 200 Nm. removal.
Identifying the speed limiter ports

A-B Travel motor supply or return
A B C-D Travel motor supply or return
(forced feed block end)
G1 Travel motor supply pressure
information
R1-R2 Return circuit (secondary reliefs
blow off)
X Not used (plugged)
MA-MB Not used (plugged)
MA G1 MB
D
R1 R2
C
X
PDG0350

7003-7
FORCED FEED AND IRRIGATION BLOCK

1
170-200 Nm
PDH0323
STEP 1 NOTE: When installing, use new O-rings.
Unscrew and remove the four Allen screws Allen (1) NOTE: To disassemble and reassemble the forced
from the forced feed and irrigation block (2). feed and irrigation block, refer to page 15. When
installing the forced feed and irrigation block, proceed
NOTE: When installing, tighten the screws to a in the reverse order from removal.
torque of 170 to 200 Nm.
STEP 2
Remove the forced feed and irrigation block (2).
Remove and scrap the four O-rings from the forced
feed and irrigation block.
Identifying the forced feed and irrigation block ports
C G1 D A-B Travel motor supply or return

C-D Travel motor supply or return

(speed limiter end)

L Irrigation flow circuit

F T Forced feed circuit

G1 Motor supply pressure

information

L G1 T
F G1

B A
L
PDG0348

7003-8
TRAVEL MOTOR REGULATOR

STEP 1 STEP 3
1
2
3
5
4
D03018
Unscrew and remove the eight Allen screws from the

regulator. Remove the regulator.
STEP 4
PDH0324
Extract the pin (1) then remove the union (2). Remove
the end (4), scrap the seals (3) and (5).
STEP 2
Place the hydraulic travel motor in a vice equipped
with jaws to make removal easier.
D03606
Label and remove the regulator control pin distribution

machined face.
NOTE: When installing, use grease to maintain the
distribution plate in place.
NOTE: To disassemble and reassemble the
regulator, refer to page 20. To install the regulator,
proceed in the reverse order to removal.

7003-9
TRAVEL MOTOR
Cross-sectional view of the travel motor
24
1
23
22
21 2
20
19
3
18
16
17
15 4
5
14
13
6
12 7
8
11
10 9
PDH0325
1 CYLINDER BARREL 19 MAIN AXLE

2 MAXIMUM DISPLACEMENT ADJUSTING SCREW 20 PISTON RING
3 RETAINING PLATE 21 BELLEVILLE WASHERS
4 BEARING 22 BELLEVILLE WASHER GUIDE
5 SPACER 23 MINIMUM DISPLACEMENT ADJUSTING SCREW
6 O-RING 24 MOTOR HOUSING
7 SEAL CARRIER
8 SNAP RING
9 LIP SEAL
10 ROTOR SHAFT
11 NUT
12 WASHER
13 SNAP RING
14 BEARING
15 ADJUSTMENT SHIM
16 PLUG
17 SCREW
18 PISTON

7003-10
Exploded view of the travel motor
17
16
15
14
13
12
11 10
9
8
7
6
2
18
5
19
4
3
PDH0326
NOTE: The assembled rotor (11) is sold as a whole unit. Do not remove the adjusting screws (18) and (19).
1 MOTOR HOUSING 13 WASHER
2 PLUG 14 O-RING
3 CYLINDER BARREL 15 LIP SEAL
4 SCREW 16 SEAL CARRIER
5 RETAINING PLATE 17 SNAP RING
6 BELLEVILLE WASHER GUIDE
7 BELLEVILLE WASHERS
8 MAIN AXLE
9 PISTON RING
10 PISTON
11 ASSEMBLED ROTOR
12 SNAP RING

7003-11
Removal and installation of the STEP 4

hydraulic travel motor
STEP 1
D03012
Remove the seal carrier.

NOTE: When reassembling, protect the motor shaft
D03608
so as not to damage the lip seal.
Place the motor in a vice with soft jaws. Remove and
discard the seal. Do not remove the adjusting screws STEP 5
(1) and (2).
STEP 2
D03009
Remove and scrap the lip seal from the seal carrier.
NOTE:

D03602
Remove the centring studs from the motor housing or

from the regulator.
STEP 3

PDH0327
When reassembling, install the lip seal, as shown.
D03014
Remove the retaining ring.

7003-12
STEP 6 STEP 9
D03010 D03002
Remove and scrap the O-ring. Extract the rotor assembly and place it on a clean
bench.
STEP 7
NOTE: When reassembling, heat the pump housing
to 80°C.
STEP 10
D03003
Remove the snap ring.

STEP 8
D02234
Remove the cylinder barrel from the pistons.

STEP 11
D03005
Remove the washer.
D02232
Remove the Belleville washers and the washer guide

from the barrel central hole.

7003-13
NOTE: STEP 14
PDH0164
When reassembling, install the Belleville washers in the

barrel central bore, as shown.
STEP 12 D02224
Remove the pistons and the central pin from the

retaining plate.
of removal.
There are two types of A6VM107/40-93 travel motors.
- One standard motor
- One motor for excavators for Germany
The difference between these two version is only the
setting of the minimum displacement by the screw
(23).
The minimum displacement adjusting screws (23) as
D02230
well as the maximum displacement retaining screws
Remove the retaining screws from the retaining plate.
(2) should not be removed.
NOTE: When reassembling, install the screws with
Loctite 262.
STEP 13 2
23
D02226
Carefully remove the retaining plate complete with the

pistons and the central pin.
PDH0325

7003-14
Inspection STEP 19 Cylinder barrel

STEP 15 Drive shafts
2 2
2
1 1
1
2
PDH0167
Check that the inner surface (1) of the barrel and

PDH0170 distribution plate surfaces (2) are not worn or damaged.
Check that the spherical journals (1) and the spline (2)
are not worn or damaged. STEP 20
STEP 16 Piston
1 2
1
1
2
PDH0165
PDH0168
Position the pistons (1) and the retaining plate (2). Install
Check that the surface of the sphere (1) and the piston the screws and check for lateral movement.
rings (2) are not worn or damaged.
STEP 21
STEP 17 Main axle
The travel motor should be replaced if any one of the
following parts is worn or damaged: drive shaft, drive
1 2 bearings and motor housing.
STEP 22
After checking the following parts: pistons, central
pin, cylinder barrel, swash plate and retaining plate, if
any one of the parts is worn or damaged, all the parts
have to be replaced.
PDH0166
Check that the surface of the sphere (1) and the sliding STEP 23
surface (2) are not worn or damaged. All the O-rings, washers and seals are supplied in the
STEP 18 Retaining plate form of a kit and cannot be obtained separately.
1
PDH0169
Check that the inner surfaces are not worn or damaged.

7003-15
FORCED FEED AND IRRIGATION BLOCK

6
1

1

2 2
3 4 5 4 3
PDH0329
1 PLUG 4 FORCED-FEED CHECK VALVE
2 SPRING 5 IRRIGATION JET
3 O-RING 6 FORCED FEED AND IRRIGATION BLOCK
6 5 Nm
5 Loctite
200 Nm 1
3
2
4 4
2
3
1 200 Nm
PDH0330
STEP 1 Inspection
Remove the plug (1) and extract the spring (2) and Check the mating face of the forced feed check valve
the forced feed check valve (4). Discard the O-ring on its seat. If the face is defective, the complete
(3). forced feed and irrigation block must be replaced.
STEP 2 NOTE: Separate parts of the forced feed and
irrigation block are not sold separately. When
Remove the jet (5) (if necessary). installing, proceed in the reverse order of removal.

7003-16
SPEED LIMITER
9 280 Nm
9 Nm 10
11 14
13
12
15
16
30 Nm
26 26 30 Nm
100 Nm
2 27
30 Nm
23
24
30 Nm
25
23
30 Nm 100 Nm
20 1
4
280 Nm
3
22 19
21
18 6
8 Nm
17
7
8
9 Nm 5
PDH0331

7003-17
STEP 1 STEP 9
Remove the secondary reliefs (1) and (2).
STEP 2
Unscrew and remove the screws (3) from the small
spool cap (4) and remove the cap.
STEP 3
Remove from the small spool cap (4): the screw (5),
seal (6), O-ring (7) and Teflon bushing (8). Scrap the
seals and the Teflon bushing.
STEP 4
Unscrew and remove the screws (9) from the large D05912
spool cap (10) and remove the cap. Remove the retaining ring. Decompress the return
spring (18) and remove the release tools.
STEP 5
STEP 10
Remove from the large spool cap (10): the screw
(11), seal (12), O-ring (13) and Teflon bushing (14). Remove from the limiter spool (15): the cup (17), the
Scrap the seals and the Teflon bushing. return spring (18) and the cup (19).
STEP 6 STEP 11
Remove the limiter spool (15) from the limiter block Remove the braking check valve (20) with its ball,
(25). scrap the seals.
STEP 7 STEP 12
Place the spool assembly (15) in a soft-jawed vice to Remove the plugs (21), (23) and (26), scrap the O-rings
remove the return spring (18). (22), (24) and (27).
STEP 8 STEP 13
Check that none of the parts is worn or damaged.
Change if necessary.
of removal. Replace all joints with new joints.
D05914
Install on the spool (15) two release tools OEM 4174

with two threaded rods and nuts, as shown. Compress
the return spring (18).

7003-18
Cross-sectional view of the speed limiter
1 2 3 4 5 6 7 8 9 10 11 12 13 14

15

27

16

26

17

25 24 23 22 21 20 19 18
PDG0339A
1 BLEED SCREW 15 SEAL

2 SPRING CUP 16 SPOOL PLUG
3 RETURN SPRING 17 SPOOL SMALL CAP
4 SPRING CUP 18 SAFETY VALVE
5 O-RING AND TEFLON BUSHING 19 PLUG
6 NON-RETURN VALVE SPRING 20 O-RING
7 NON-RETURN VALVE 21 O-RING
8 SPEED LIMITER SPOOL 22 PLUG
9 BRAKING CHECK VALVE 23 SAFETY VALVE
10 NON-RETURN VALVE 24 RETAINING SCREW
11 NON-RETURN VALVE SPRING 25 SPOOL END
12 O-RING AND TEFLON BUSHING 26 LOCKING RING
13 SMALL CAP RETAINING SCREW 27 LARGE SPOOL CAP
14 BLEED SCREW

7003-19
TRAVEL MOTOR REGULATOR

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
18
26 25 30 24 23 22 21 20 19
27
28
29
PDH0332
1 CAP SCREW 18 SNAP RING

2 SMALL CAP 19 BLEED SCREW
3 SCREW 20 NUT
4 SEAL 21 THRUST PIN
5 SEAL 22 SNAP RING
6 BALL-JOINT LOCKING SCREW 23 O-RING
7 CONTROL PISTON 24 SPRING GUIDE THRUSTER
8 SPRING 25 BALL-JOINT
9 SPRING 26 PISTON
10 SPRING GUIDE 27 CALIBRATED ORIFICE
11 SPRING GUIDE 28 O-RING
12 O-RING 29 SEAL
13 CALIBRATED ORIFICE 30 SPRING
14 JACKET
15 SPOOL
16 LARGE CAP
17 SCREW

7003-20
Disassembling and reassembling the regulator
20
17-24 Nm 29
12
14
11
30
13 30
18
8 Nm 19
33
15
21 31
17
32
16
22
23
10 Loctite 601
24 M8 = 10 Nm
M10 = 25 Nm
8 M12 = 49 Nm
M16 = 86 Nm
25
9
26 3
7 60-84 Nm
27
2 4
28
6 8 Nm
1 5
34-48 Nm
PDH0333

7003-21
STEP 1 STEP 7
Identify all the parts. Extract the snap ring (16) from the cap (13) and
extract the complete liner (17).
STEP 2
STEP 8
Unscrew and remove the retaining screws (1) for the
cap (2) and remove the cap (2). Discard the O-rings Remove the plug (18) and the jet (19) from the cap
(3) and (4). (13). Do not remove the adjusting screw and the nut
(20).
torque of 34 to 48 Nm. NOTE: When reassembling, tighten the jet to a
torque of 8 Nm.
STEP 3
STEP 9
Remove the plug (5) and the jet (6) from the cap (2).
Remove the snap ring (21) from the liner (17) and
NOTE: When reassembling, tighten the jet to a
extract the spool (22).
torque of 8 Nm.
STEP 10
STEP 4
Remove, in this order, the thruster (23), spring (24),
Unscrew and remove the retaining screw (7) then
spring guide (25), large spring (26), spring cup (27),
extract the piston (8). Scrap the seals (9).
spring (28) and the piston (29) from the regulator
NOTE: When installing, tighten the screw (7) to a housing (31). Scrap the two O-rings (30).
NOTE: Clean the interior threads of the piston (29).
STEP 5 STEP 11
Unscrew and remove the screw (10) from the ball-
Remove the plug (32) and the centring studs (33)
joint (11) then remove the ball-joint (11).
from the regulator housing (31).
NOTE: To unscrew the screw (10) the ball-joint (11)
has to be heated to 120°. STEP 12
When reassembling, install the screw (10) using Check that none of the parts is worn or damaged.
Loctite 601 and tighten it to a torque of: Change if necessary.
M8 = 10 Nm
M10 = 25 Nm NOTE: When installing, proceed in the reverse order
M12 = 49 Nm of removal. Replace all seals with new seals
M16 = 86 Nm lubricated beforehand.
STEP 6
Unscrew and remove the retaining screws (12) from
the cap (13) and remove the cap (13) and the thrust
pin (14) (Caution: there is a spring compressed by
the cap (13)). Discard the O-ring (15).

7003-22
MEASURE THE LEAK FLOW FROM THE TRAVEL MOTOR

The measurement should be made with:
- Hydraulic oil at 50°C.
- Engine running at full speed. V17 V19
F31 F4 F3 F10 F11 F27 1
S7 N°1
15A 5A 7,5A15A 7,5A 5A
- Flow cancellation valve set to 200 bar.
7 11 12 13 14 15 17 19 19 19 19 22 28 42 8
- Regulating the travel motor, adjusted correctly (see
94
section 8001). S4 N°2 27
Method: 1 2 3 4 5 20 30
N°3
- Lift the excavator on the stabilizers and the dozer 6 7 9 11 12 14 16 28 42 8
blade.
28
- Set the flow cancellation valve to 200 bar.

PDH0334
- Disconnect wire 94 (brown) at ∆26, behind the
electric cabinet printed circuit.
- Apply the parking brake. 1
- Shut down the engine.
- Disconnect and plug the leak return hose (1) and
connect in its place a hose (2) with a length of one
metre minimum. Put the end of the hose (2) in a
graduated receptacle (3) with a capacity of 25 litres. 2
- Run the engine at full speed.
- Operate the direction of travel inverter in one 3
direction.
- Press the forward travel pedal. PDH0335
- Measure the volume of oil recovered in one minute

from the hose (2). If it is in excess of 23 litres a
minute, renovate or replace the travel motor.
- Reconnect the hose (1).
- Reset the flow cancellation valve to its initial value
(see section 8001).

7031
Section
7031
TWO SECTION CONTROL VALVE FOR TRAVEL,

STABILIZERS AND DOZER BLADE

Printed in France
7031-2
TABLE OF CONTENTS
SPECIFICATIONS.....................................................................................................................................................3
SPECIAL TORQUES................................................................................................................................................. 3
TOOLS REQUIRED .................................................................................................................................................. 3
CONTROL VALVE FOR TRAVEL, STABILIZER AND DOZER BLADE ................................................................... 4
Removal and installation ....................................................................................................................................... 5
Disassembly and assembly................................................................................................................................... 6
Disassembly and assembly of inlet plate .............................................................................................................. 7
Stabilizer/dozer blade control valve section disassembly and assembly .............................................................. 8
Cross-sectional drawing of the stabilizer/dozer blade control valve section ......................................................... 9
Travel control valve section disassembly and assembly.....................................................................................10
Cross-sectional drawing of the travel control valve section ................................................................................ 11
Cross-sectional drawing of the flow control (balance) valve assembly ............................................................... 12
Cross-sectional drawing of the secondary relief valve ........................................................................................ 13

7031-3
SPECIFICATIONS
Calibre ..................................................................................................................................................................... 20
Spool stroke...................................................................................................................................................... 10 mm
Spool pilot pressure....................................................................................................................................8 to 22 bar
Adjusting the travel motor control valve ............................................................................................see section 8001
SPECIAL TORQUES
Control valve section assembly nut .................................................................................................................. 90 Nm
Control valve section assembly lock nut ........................................................................................................... 50 Nm
Travel control valve section
Adjusting assembly guide........................................................................................................................... 100 Nm
Balance plug .............................................................................................................................................. 130 Nm
Spool plug ...............................................................................................................................10 Nm + Loctite 270
Spool caps retaining screw .......................................................................................................................... 17 Nm
Pressure selector plug ................................................................................................................................. 17 Nm
Stabilizer/dozer blade control valve section
Secondary relief ........................................................................................................................................... 85 Nm
Adjusting assembly guide........................................................................................................................... 100 Nm
Balance plug .............................................................................................................................................. 130 Nm
Spool plug ...............................................................................................................................10 Nm + Loctite 270
Spool caps retaining screw .......................................................................................................................... 17 Nm
Plug .............................................................................................................................................................. 17 Nm
Plug .............................................................................................................................................................. 40 Nm
Screw used with beam G1 ........................................................................................................................... 12 Nm
Jet .................................................................................................................................................................. 2 Nm
Hollow screw ................................................................................................................................................ 12 Nm
TOOLS REQUIRED
2 Loctite 270

7031-4
CONTROL VALVE FOR TRAVEL, STABILIZER AND DOZER BLADE
G
M
LS
Y
8 9
PDG0344
Identification of ports:
B5 Zb5 Zb6
A5 Forward travel supply
1 2 3 4 5 A6 Stabilizer and dozer blade lowering supply
B5 Reverse travel supply
B6 Stabilizer and dozer blade raising supply
G Not used (plugged)
LS Information from pump Load-Sensing valve
M Not used (plugged)
P Arrival from variable flow pump
T T Return to reservoir
B6
Y Travel motor displacement change pilot circuit
Za5 Forward travel pilot system
Za6 Stabilizer and dozer blade lowering pilot circuit
Zb5 Reverse travel pilot system
P A6 Zb6 Stabilizer and dozer blade raising pilot circuit
A5
Za6 Za5
7 6
Location of components:
1 INLET PLATE
2 TRAVEL CONTROL VALVE SECTION
3 PLUG WITH TRAVEL FORCED-FEED VALVE
4 STABILIZER AND DOZER BLADE RAISING SAFETY VALVE
5 STABILIZER AND DOZER BLADE CONTROL VALVE SECTION
6 STABILIZER AND DOZER BLADE LOWERING SAFETY VALVE
7 PLUG WITH TRAVEL FORCED-FEED VALVE
8 TRAVEL FLOW REGULATOR (BALANCE VALVE)
9 STABILIZER AND DOZER BLADE FLOW REGULATOR
ASSEMBLY (BALANCE VALVE)

7031-5

- Stop the engine.
- Loosen the hydraulic reservoir pressure release plug two turns. Retighten the plug.
- Operate simultaneously the emergency pump and the control levers to release pressure in the hydraulic system.
STEP 1 STEP 4
Remove the control valve block housing. 3
STEP 2
Place identification tags on all the control valve block
hoses and pipes. Disconnect and plug the hoses and
pipes. Plug the control valve block orifices. 4
STEP 3
1
Attach a suitable lifting device to the control valve
2
block.
PG03901
Remove the screws (1) with the washers (2), then
remove the selector valve (3). Remove the nuts (4)
with their screws and remove the travel control valve.
NOTE: For installation, follow the same procedure in
- Start the engine.
- Check the hydraulic oil level in the reservoir. Top up if necessary
- Set the correct pressures for the safety valves, the balance valve flows on the travel control valve, the speed
limiter and the anti-excess flow valve. Refer to Section 8001.

7031-6

NOTE: The parts are numbered in order of disassembly. They must be assembled in the reverse order.
1 50 Nm
2 90 Nm
PDH0131
1 LOCK NUT 4 TRAVEL CONTROL VALVE SECTION

2 NUT 5 STABILIZER/DOZER BLADE CONTROL VALVE SECTION
3 CONTROL VALVE BLOCK BASE PLATE 6 INLET PLATE

7031-7
Disassembly and assembly of inlet plate
2
4 3
PDH0132
NOTE: When assembling, replace all seals with new seals.

1 INLET PLATE
2 O-RING
3 O-RING
4 PLUG
5 O-RING
6 PLUG

7031-8
Stabilizer/dozer blade control valve section disassembly and assembly
7
12 17 Nm 1
5
6
40 Nm 9 10 Nm
28 8 + Loctite 270
85 Nm 10 11 130 Nm
12 Nm
A 18
29
3 27 19
4 2 Nm
20
2
17 Nm
17 24
4 2 Nm
27 20
3 10 Nm
12 Nm 19
+ Loctite 270
29
9 25 100 Nm
28
40 Nm 8 21
85 Nm
6 13
15 26
5 14 22
16
23
CS97G025
NOTE: When assembling, replace all seals with new seals. Install the screws (9) using Loctite 270.
1 BALANCE SPOOL 8 O-RING 15 SPOOL ADJUSTMENT 24 BALANCE SPRING

CONTROL SPOOL 9 SPOOL PLUG SCREW 25 ADJUSTMENT
CONTROL VALVE SECTION 10 SEAL 16 NUT ASSEMBLY GUIDE
2 SAFETY VALVE 11 SPOOL RETURN 17 PLUG 26 BACK-UP RING
3 BACK-UP RING ASSEMBLY 18 BALANCE VALVE PLUG 27 CALIBRATED ORIFICE
4 O-RING 12 CAP SCREW 19 BACK-UP RING 0.4 MM
5 BACK-UP RING 13 SPOOL SMALL CAP 20 O-RING 28 PLUG
6 O-RING 14 CAP SCREW 21 O-RING 29 HOLLOW SCREW*
7 LARGE SPOOL CAP 22 PUSH ROD/
ADJUSTMENT SCREW * (Non-hollow screw to be
23 SHIELD used with beam level 1)

7031-9
Cross-sectional drawing of the stabilizer/dozer blade control valve section
5 13 12 1 12 13 5
11 2
10
9
3
8
5
7 6
CS97G026
1 CONTROL VALVE SECTION BODY 7 CONTROL SPOOL

2 SAFETY VALVE ON STABILIZER AND DOZER BLADE 8 CUPS
LOWERING SUPPLY 9 LARGE SPOOL CAP
3 SPOOL SMALL CAP 10 SPOOL RETURN SPRING
4 STABILIZER AND DOZER BLADE RAISING FLOW 11 STABILIZER AND DOZER BLADE RAISING SAFETY
ADJUSTMENT SCREW VALVE
5 PLUG 12 CALIBRATED ORIFICE 0.4 MM
6 FLOW REGULATOR ASSEMBLY (BALANCE VALVE) 13 HOLLOW SCREW*
* (Non-hollow screw to be used with beam level 1)

7031-10
Travel control valve section disassembly and assembly
1
6
5 17 Nm
10 Nm
+ Loctite 270 7 8
130 Nm
85 Nm 9
17
18 10
19 20
21
21
20 4
2
3
16
15
14
10 Nm 22
+ Loctite 270 8
21
7 20
23 100 Nm
12
26
13 11
17 Nm 24
25
PDH0133
NOTE: When assembling, replace all seals with new seals. Install the screws (8) using Loctite 270.
1 BALANCE SPOOL 7 O-RING 15 PRESSURE SELECTOR 24 PUSH ROD/

CONTROL SPOOL 8 SPOOL PLUG 16 O-RING ADJUSTMENT SCREW
CONTROL VALVE SECTION 9 SEAL 17 BALANCE VALVE PLUG 25 SHIELD
2 O-RING 10 SPOOL RETURN 18 PLUG 26 BACK-UP RING
3 BACK-UP RING ASSEMBLY 19 FORCED-FEED CHECK
4 O-RING 11 BACK-UP RING VALVE
5 CAP SCREW 12 SPOOL SMALL CAP 20 BACK-UP RING
6 LARGE SPOOL CAP 13 CAP SCREW 21 O-RING
14 PRESSURE SELECTOR 22 BALANCE SPRING
PLUG 23 ADJUSTMENT
ASSEMBLY GUIDE

7031-11
Cross-sectional drawing of the travel control valve section
10 1
9
2
8
7
5
PDG0342
1 CONTROL VALVE SECTION BODY
2 PLUG WITH FORCED-FEED VALVE
3 CONTROL SPOOL
4 SPOOL SMALL CAP
5 PRESSURE SELECTOR ON "LOAD-SENSING" SYSTEM
6 FLOW REGULATOR ASSEMBLY (BALANCE VALVE)
7 CUPS
8 SPOOL RETURN SPRING
9 LARGE SPOOL CAP
10 PLUG WITH FORCED-FEED VALVE

7031-12

Cross-sectional drawing of the flow control (balance) valve assembly

1 2 3 4 5 6 7 8 9 11 12 13 14

10

15

16

17

18

19
PDG0251
1 PLUG 11 O-RING
2 BACK-UP RING 12 BACK-UP RING
3 O-RING 13 O-RING
4 RETAINING RING 14 BACK-UP RING
5 THRUST WASHER 15 LOCKING RING
6 NON-RETURN VALVE SPRING 16 PLUG WASHER
7 NON-RETURN VALVE 17 ADJUSTMENT SCREW
8 BALANCE VALVE SPOOL 18 PUSH ROD
9 BALANCE SPRING 19 PRESSURE SELECTOR
10 ADJUSTMENT ASSEMBLY GUIDE

7031-13
Cross-sectional drawing of the secondary relief valve
11 10 9 8 7 6 5 4 3 2 1

12

13

14
PDG0252
1 FORCED-FEED CHECK VALVE 8 PRESSURE SETTING SPRING

2 RETURN SPRING 9 VALVE BODY
3 RETAINING RING 10 PUSH ROD
4 SEAT 11 LOCKING RING
5 CHECK VALVE 12 PLUG WASHER
6 SPRING GUIDE 13 ADJUSTMENT SCREW
7 O-RING AND BACK-UP RING 14 O-RING AND BACK-UP RING
1 2 3 5 4

PDG0253
1 SEAT INSERT 4 SEAL

2 BALL 5 PLUG
3 SEAL

7031-14

7031
Section
7031
ONE-PIECE CONTROL VALVE FOR TRAVEL,

STABILIZERS AND DOZER BLADE

Printed in France
7031-2
TABLE OF CONTENTS
SPECIFICATIONS.....................................................................................................................................................3
SPECIAL TORQUES................................................................................................................................................. 3
TOOLS REQUIRED .................................................................................................................................................. 3
CONTROL VALVE FOR TRAVEL, STABILIZERS AND DOZER BLADE................................................................. 4
Removing and installing the travel, stabilizer/dozer blade control valve sections .................................................6
Cross-sectional drawing of the travel control valve section .................................................................................. 8
Cross-sectional view of the stabilizer/dozer blade control valve section............................................................... 9
Cross-sectional view of the flow regulator assembly (balance) .......................................................................... 10
Cross-sectional drawing of the secondary relief valve ........................................................................................ 11
Cross-sectional view of pressure selector........................................................................................................... 11

7031-3
SPECIFICATIONS
Calibre .................................................................................................................................................................... 22
Spool stroke .................................................................................................................................................... 10 mm
Spool pilot pressure .................................................................................................................................. 8 to 22 bar
Stabilizer secondary relief pressure setting,
dozer blade ......................................................................375 to 378.5 bar at 10 L/min without counter-pressure
Adjusting the travel motor control valve........................................................................................... see section 8001
SPECIAL TORQUES
Control valve retaining screws for travel, stabilizers and dozer blade ....................................................70 to 85 Nm
Travel control valve section
Forward/reverse travel adjusting screw........................................................................................................15 Nm
Balance adjusting screw ..............................................................................................................................40 Nm
Balance cap ...............................................................................................................................................250 Nm
Balance plug ..............................................................................................................................................400 Nm
Bleed screw .................................................................................................................................................15 Nm
Non-return check valve plug ......................................................................................................................150 Nm
Spool end cap retaining screws ....................................................................................................................9 Nm
Spool plug ....................................................................................................................................................10 Nm
Spool spring guide .......................................................................................................................................30 Nm
Pressure selector plug .................................................................................................................................30 Nm
Stabilizer/dozer blade control valve section
Secondary relief ..........................................................................................................................................90 Nm
Bleed screw .................................................................................................................................................10 Nm
Spool spring guide .......................................................................................................................................30 Nm
Spool end cap retaining screws ....................................................................................................................9 Nm
Non-return check valve plug ......................................................................................................................150 Nm
Spool plug ....................................................................................................................................................10 Nm
Lock-nut .......................................................................................................................................................15 Nm
Balance cap ...............................................................................................................................................400 Nm
Balance plug ..............................................................................................................................................250 Nm
TOOLS REQUIRED
2 Loctite 270

7031-4
CONTROL VALVE FOR TRAVEL, STABILIZERS AND DOZER BLADE
Za
Za
7 Zb2 A2 10 B2 7 8 Za2 9
Zb2
8 LS
3
Za2
5 4
2 6
Za1 Zb1
1 Zb1 B1 Za1
4 M A1 T P
P M Y
10
CS95K023
Identification of ports: Location of components:

P Flow inlet from the variable flow pump 1 Inlet plate
T Return to the reservoir by passing through P10 2 Travel control valve section
LS "Load Sensing" information circuit from the 3 Stabilizer or dozer blade control valve section
variable flow pump 4 Plug
M Plug 5 Plug with stop
Za1 Forward travel spool pilot 6 Flow regulator assembly (balance) for travel
Zb1 Reverse travel spool pilot control valve section
A1 Forward travel hydraulic motor supply 7 Stabilizer and dozer blade raising safety valve
B1 Reverse travel hydraulic motor supply 8 Stabilizer and dozer blade lowering secondary
Za2 Stabilizer and dozer blade lowering pilot relief
Zb2 Stabilizer and dozer blade raising pilot 9 Flow regulator assembly (balance) for stabilizer
A2 Stabilizer/dozer blade lowering circuit supply and dozer blade section
B2 Stabilizer/dozer blade raising circuit supply 10 Anti-return check valve assembly
Y Hydraulic travel motor displacement change
pilot

7031-5

- Stop the engine.
STEP 1 STEP 4
Remove the control valve block housing. 4
STEP 2
Place identification tags on all the control valve block 3
pipes. Plug the control valve block orifices.
1
STEP 3
Attach a suitable lifting device to the travel control 2
valve.
5 PH01020
Remove the two screws (1) with the washers (2), then
remove the selector valve (3). Remove the three
screws (4) with their washers, then remove the travel
control valve (5).
- Start the engine.
- Check the level of hydraulic fluid in the reservoir and top up if necessary.
- Set the correct pressures for the secondary reliefs, the balance valve flows on the travel control valve, the speed

7031-6
Removing and installing the travel, stabilizer/dozer blade control valve

sections
9 Nm
2 3
6 9 Nm 52 9 Nm 54 9 Nm
7
55
53 56
8 57
4
9 58
15 Nm 5
10
250 Nm 59
40 Nm 11
26 27
28 12 60
29 13
30 84
31 150 Nm
32
90 91
33 92
86 85
93
30 Nm 97 87 94
14 15 95
96
30 Nm 62 16 89
61 63
88
79
25 24 69 10 Nm
250 Nm
80 23
22
81 21 9 Nm
30 Nm 65
82 83 70
69 20
68 19
67 18 17
38 78
77 64 9 Nm
76
75 66
51
50 37 74
48 73
49 46 72 400 Nm
47 36
90 Nm 44 71
45 35
43 42 41 34
15 Nm
40 39 400 Nm
1 CS95K017

7031-7
1 Travel, stabilizer and dozer blade control valve 49 Secondary relief bodies
2 Bleed screw 50 Back-up ring
3 O-ring 51 O-rings
4 Adjusting nut 52 Bleed screw
5 Adjusting screw 53 O-ring
6 Screw 54 Screw
7 Large spool cap 55 Large spool cap
8 O-ring 56 O-ring
9 Cup 57 Cup
10 Inner spring 58 Inner spring
11 Outer spring 59 Outer spring
12 Washer 60 Cup
13 Cup 61 Spring guide
14 Spring guide 62 O-ring
15 O-ring 63 Control spool
16 Control spool 64 Bleed screw
17 Bleed screw 65 O-ring
18 O-ring 66 Screw
19 Adjusting screw 67 Spool small cap
20 Adjusting nut 68 O-ring
21 Screw 69 Spool plug
22 Spool small cap 70 O-ring
23 O-ring 71 Adjusting nut
24 Spool plug 72 Balance cap
25 O-ring 73 O-ring
27 Adjusting screw 75 Adjusting screw
28 Balance cap 76 Snap ring
29 O-ring 77 Nut
30 O-ring 78 Spring
31 Seat 79 Balance valve plug
32 Spring 80 O-ring
33 Balance valve spool 81 Balance valve spool
34 Balance valve plug 82 Pressure selector
35 O-ring 83 O-rings
36 Stop 84 Non-return check valve plug
37 Spring 85 Spring
38 Secondary relief valve 86 Non-return valve
39 Protection 87 O-ring
40 Adjusting screw 88 Plug
41 Adjusting nut 89 O-rings
42 Pressure setting spring 90 Plug
43 Check valve 91 O-rings
44 Seat 92 Plug
45 O-rings 93 O-rings
46 Return spring 94 Plug
47 Spring guide 95 O-rings
48 Check valve 96 Plug
97 Travel and stabilizer/dozer blade control valve body

7031-8
Cross-sectional drawing of the travel control valve section
6 7 6
8 5
4
4
3
10 1 2
CS95K019
1 Travel control valve section 6 Plug

2 Cross-sectional drawing of the flow control 7 Anti-return check valve assembly
(balance) valve assembly 8 Reverse travel flow adjusting screw
3 Control spool 9 Plug
4 Spool end cap 10 Pressure selector
5 Forward travel flow adjusting screw

7031-9
Cross-sectional view of the stabilizer/dozer blade control valve section
5 6 5
4
7
CS95K018
1 Stabilizer/dozer blade control valve section 5 Secondary relief valve

2 Plug 6 Anti-return check valve assembly
3 Control spool 7 Flow regulator assembly (balance)
4 Spool end cap

7031-10
Cross-sectional view of the flow regulator assembly (balance)
1 2 3 4 5 6 7 8 9 10 11 12 13
14
CS95K020
1 Balance valve plug 8 O-ring

2 O-ring 9 O-ring
3 Washer 10 Push rod
4 Stop 11 Balance cap
5 Spring 12 Adjusting nut
6 Balance valve spool 13 Adjusting screw
7 Spring 14 Pressure selector

7031-11

1 2 3 4 5 6 7 8 9 10 11

16 15 14 13 12
CM95K022
1 O-ring 9 Secondary check valve

2 Back-up ring 10 Adjusting screw
3 Main check valve 11 Adjusting nut
4 Return spring 12 Shield
5 O-ring 13 O-ring
6 Valve body 14 Back-up ring
7 Pressure setting spring 15 O-ring
8 Secondary check valve seat 16 Spring guide and calibrated orifice
Cross-sectional view of pressure selector
6

1

2

3

4
5

CM95K002
1 O-ring 4 O-ring
2 Shuttle ball 5 Pressure selector plug
3 O-ring 6 Pressure selector seat

7031-12

Section
7080
CYLINDERS FOR STEERING, STABILIZERS,

DOZER BLADE AND FRONT AXLE LOCKING
7080

Printed in France
7080-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................................... 3
Dozer blade cylinder ............................................................................................................................................ 3
Stabilizer cylinder ................................................................................................................................................. 4
Mobile beam cylinder ........................................................................................................................................... 5
Mobile beam stabilizer cylinder ............................................................................................................................ 6
CYLINDER IDENTIFICATION.................................................................................................................................. 8
Year coding .......................................................................................................................................................... 8
TOOLS REQUIRED ................................................................................................................................................. 8
STABILIZER CYLINDER .......................................................................................................................................... 9
MOBILE BEAM STABILIZER CYLINDER .............................................................................................................. 10
DOZER BLADE CYLINDER ................................................................................................................................... 11
Cross-sectional view of blade cylinder ............................................................................................................... 12
Cross-sectional view of piloted check valves ..................................................................................................... 12
FRONT AXLE BEAM LOCKING CYLINDER ......................................................................................................... 14
STEERING CYLINDER .......................................................................................................................................... 16
Removal and installation .................................................................................................................................... 16
Adjustment of front axle wheel alignment .......................................................................................................... 18
SPECIAL INSTRUCTIONS .................................................................................................................................... 19
Preventing the rotation of screw-in type cylinder gland...................................................................................... 19
Removing and installing the wiper ring .............................................................................................................. 19
Replacing bushings ............................................................................................................................................ 20
Checking cylinder rod deflection ........................................................................................................................ 20

7080-3
SPECIFICATIONS
Dozer blade cylinder
LS-LR
D2 ØA ØB F
C
PDH0352
Dozer blade cylinder
WX150 WX170
Type .................................................................................. 140/100 C233 140/100 C210
Part number ..................................................................... A7646764 W9046702
Weight................................................................... kg 108 99
Usable stroke .................................................. (mm) C 233 210
Permitted deflection of the rod ..................... (mm) F 0.2 0.2
Internal barrel diameter.................................. (mm) B 140 140
Rod diameter................................................... (mm) A 100 100
Between centres (rod extended) ................... (mm) LS 788 788
Between centres (rod retracted) ................... (mm) LR 555 578
Cylinder bore diameter (top) ......................... (mm) D2 60.3 +0.10

+0
60.3 +0.10
+0

7080-4
Stabilizer cylinder
LS-LR

Ø D1
ØA ØB F Ø D2
C
PDH0340
Stabilizer cylinder
WX150 WX170
Type ................................................................................... 125/95 C520 125/95 C520
Part number ...................................................................... N8746705 E8846793
Weight .................................................................. kg 93.5 96.9
Usable stroke ...................................................(mm) C 520 520
Permitted deflection of the rod ......................(mm) F 0.25 0.25
Internal barrel diameter ..................................(mm) B 125 125
Rod diameter ...................................................(mm) A 95 95
Between centres (rod extended) ....................(mm) LS 1440 1440
Between centres (rod retracted) ....................(mm) LR 920 920
Cylinder bore diameter (top) ..........................(mm) D1 60 +0.155

+0.65
60 +0.155
+0.65
Cylinder bore diameter (top) ..........................(mm) D2 75 +0.045
+0
60 +0.84
+0.060

7080-5
Mobile beam cylinder
LS-LR
D2 ØA ØB F
C
PDH0352
Mobile beam cylinder

WX150
Type ........................................................................................................ 140/100 C233
Part number ........................................................................................... W8846717
Weight.................................................................................... kg 108
Usable stroke ....................................................................(mm) C 233
Permitted deflection of the rod .......................................(mm) F 0.2
Internal barrel diameter....................................................(mm) B 140
Rod diameter.....................................................................(mm) A 100
Between centres (rod extended) .....................................(mm) LS 788
Between centres (rod retracted) .....................................(mm) LR 555
Cylinder bore diameter (top) ...........................................(mm) D2 60.3 +0.155

+0.65

7080-6
Mobile beam stabilizer cylinder

LS-LR
F ØA ØB
C
CS97A008
Mobile beam stabilizer cylinder

WX150
Type ........................................................................................................ 63/40 C690
Part number ........................................................................................... D7746794
Weight ................................................................................... kg 32.6
Usable stroke ....................................................................(mm) C 690
Permitted deflection of the rod .......................................(mm) F 0.2
Internal barrel diameter ...................................................(mm) B 125
Rod diameter ....................................................................(mm) A 95
Between centres (rod extended) .....................................(mm) LS 2170
Between centres (rod retracted) .....................................(mm) LR 1480

7080-7

Stabilizer cylinder (WX150 - WX170)
Cylinder bearing .............................................................................................................................. 400 to 500 Nm
Piloted check valve.......................................................................................................................... 300 to 400 Nm
Dozer blade cylinder (WX150 - WX170)
Piloted check valve.......................................................................................................................... 300 to 400 Nm
Front axle locking cylinder (WX150 - WX170)
Pressure limiter check valve cap ..................................................................................................... 108 to 132 Nm
Pressure limiter check valve seat ........................................................................................................ 50 to 70 Nm
Check valve .................................................................................................................................................. 15 Nm
Screw .................................................................................................................................................. 45 to 50 Nm
Steering cylinder (WX150 - WX170)
Cylinder retaining screw ............................................................................................................................. 240 Nm
Grease fitting ................................................................................................................................................ 10 Nm
Spool locking nuts ...................................................................................................................................... 300 Nm
Mobile beam stabilizer cylinder (WX150)
Upperstructure retaining screws ..................................................................................................... 500 to 610 Nm

7080-8
CYLINDER IDENTIFICATION
2
1 R 76 / 56 A 3
01 B
4 5
PDH0290
1 Control letter
2 Cylinder Part Number
3 (467, the cylinder "family" code is replaced by an oblique stroke. In the example, read 7646756)
4 Cylinder drawing index number
5 Cylinder week of manufacture number
6 Cylinder year of manufacture code (B = 1981)
Year coding
A 1980 E 1984 J 1988 N 1992 S 1996 W 2000
B 1981 F 1985 K 1989 O 1993 T 1997 X 2001
C 1982 G 1986 L 1990 Q 1994 U 1998 Y 2002
D 1983 H 1987 M 1991 R 1995 V 1999 Z 2003
TOOLS REQUIRED
1. TORQUE WRENCH
2. HYDRAULIC CYLINDER TEST BENCH CAS 10492
PDF0247
3. GLAND TIGHTENING WRENCH OEM 6203

Opening capacity: 120 mm to 323 mm

7080-9
STABILIZER CYLINDER
NOTE: Components are numbered in order of disassembly. For assembly, follow the same order in reverse.

9 8 7 6

PDH0343
10 4
21
5

18 PDH0342
20
17
400-500 Nm
19 16-19 Nm 1
2
16
15
14 13
12
11
300-400 Nm
PDH0341
NOTE: Screw (17) is prevented from rotating by two blows from a punch.
1 CYLINDER GLAND 10 COMPOSITE SEAL 19 GREASE FITTING

2 CYLINDER ROD 11 PILOTED VALVE CARTRIDGE 20 STEEL BUSHING
3 O-RING 12 O-RING 21 CYLINDER BARREL
4 O-RING 13 O-RING
6 WIPER SEAL 15 PISTON
7 BEARER RING 16 O-RING
8 COMPOSITE SEAL 17 SCREW
9 BEARER RING 18 BALL

7080-10
MOBILE BEAM STABILIZER CYLINDER

14
13
500-610 Nm 12
15
11
9
10
8 1 500-610 Nm
7 2
500-610 Nm
3
5
4
250-350 Nm
CS97A009
1 SCREW 10 SEAL
2 WASHER 11 CYLINDER ROD
3 JOURNAL 12 SCREW
4 CYLINDER GLAND 13 WASHER
5 WIPER SEAL 14 JOURNAL
6 SEALS 15 CYLINDER BARREL
7 SCREW
8 WASHER
9 PISTON

7080-11
DOZER BLADE CYLINDER

300-400 Nm 17 13
18
14
19
15
20
21
10
16 1
11
12
8
2
7
450-550 Nm
3
4
5
6
CS97H002
1 GREASE FITTING 10 O-RING 19 O-RING

2 CYLINDER GLAND 11 CYLINDER ROD 20 BACK-UP RING
3 O-RING 12 COMPOSITE SEAL 21 PISTON
4 BACK-UP RING 13 PLUG 22 CYLINDER BARREL
5 O-RING 14 SPRING
6 SEAL 15 CHECK VALVE
7 BEARER PISTON RING 16 PLUG
8 BEARER PISTON RING 17 PILOTED VALVE CAP
9 SEAL 18 O-RING

7080-12
Cross-sectional view of blade cylinder

3 8 9
4 10
6
2
24
1
5
450-550 Nm 7
CS99H507
Cross-sectional view of piloted

check valves
21 22 23
20
12
16
300-400 Nm
17 18 19 15 14 13
CS99H508

7080-13
1 CYLINDER GLAND
2 CYLINDER ROD
3 WIPER SEAL
4 O-RING
5 BACK-UP RING
6 O-RING
7 BEARER RING
8 COMPOSITE SEAL
9 O-RING
10 COMPOSITE SEAL
11 PILOTED VALVE CAP
12 O-RING
13 O-RING
14 BACK-UP RING
15 PISTON
16 PILOTED VALVE CAP
17 O-RING
18 O-RING
19 BACK-UP RING
20 PLUG
21 SPRING
22 CHECK VALVE
23 PLUG
24 CYLINDER BARREL

7080-14
FRONT AXLE BEAM LOCKING CYLINDER

108-132 Nm
2
15 Nm
1 14
15
45-55 Nm
13
3
* 6
50-70 Nm
7
*8
10
*
9
*11
*12
CS99J526
NOTE: To remove the pressure check valve (5) from the cylinder barrel (15), use the two extraction holes. The parts
marked with an asterisk must be systematically replaced.
1 CHECK VALVE 7 PRESSURE LIMITER VALVE SEAT 12 WIPER SEAL
2 CAP * 8 O-RING 13 SCREW
3 ADJUSTMENT WASHER 9 CYLINDER ROD 14 BALL
4 SPRING 10 O-RING 15 CYLINDER BARREL
5 PRESSURE LIMITER VALVE 11 BACK-UP RING
6 O-RING * Installed with O-ring on new-type
assembly

7080-15
15 Nm 1 3
2 108-132 Nm
16
15
14 5
13 7
45-55 Nm 50-70 Nm
10 9
12
11
CS99H504
1 CHECK VALVE 10 O-RING
2 CAP * 11 BACK-UP RING
3 ADJUSTMENT WASHER 12 WIPER SEAL
4 SPRING 13 SCREW
5 PRESSURE LIMITER VALVE 14 BALL
6 O-RING 15 CYLINDER BARREL
7 PRESSURE LIMITER VALVE SEAT 16 O-RING
8 O-RING
9 CYLINDER ROD
* Installed with O-ring on new-type assembly

7080-16
STEERING CYLINDER
10 Nm
8
6
7
10
A
13
5
3 10 Nm
9
2
1
11 A
240 Nm
12
PDH0347
NOTE: Remove the two steering cylinder feed hoses. Remove the steering cylinder using the two extraction holes (A).
1 PIN 8 GREASE FITTING
2 ROD 9 WASHER
3 GREASE FITTING 10 WASHER
4 WASHER 11 RETAINING SCREW
5 WASHER 12 WASHER
6 ROLL PIN 13 CYLINDER ASSEMBLY
7 ROD

7080-17

3
2 300 Nm
1
8
7
*10
*13
11
*12
*9 16
300 Nm
4
6
*15
14
5
PDH0348
NOTE: Before removing the two rods (2) and (5), count and make a note of the number of threads between the nut
and the rod eye. Parts marked with an asterisk must be changed.
1 NUT 9 O-RING
2 ROD 10 O-RING
3 BUSHING 11 CYLINDER ROD
4 NUT 12 O-RING
5 ROD 13 O-RING
6 BUSHING 14 WIPER SEAL
7 CYLINDER GLAND 15 O-RING
8 WIPER SEAL 16 CYLINDER BARREL

7080-18
Adjustment of front axle wheel alignment

Adjustment of steering cylinder tie-rod STEP 3
protruding length Dimensions X and Y must be identical.
STEP 1 If not, take up the difference between the two
dimensions by adjusting the protruding length of the
1 tie-rods in the direction necessary to obtain X = Y.
Wheel alignment adjustment
STEP 4
2
= = X
B
PDH0349 A
1 CYLINDER CENTRE LINE
2 STEERING CYLINDER
Turn the right-hand wheel to full lock. Measure and

note the dimension X (distance between the cylinder
gland and the connecting link centre line). PDH0351
1 REAR
STEP 2 2 FRONT
1 Turn the front wheels in line with the rear wheels.

Measure and note distance (A) between the two
wheels. Measure and note distance (B) between the
two wheels. Distance B should be equal to:
B = A ± 1 mm
If not, slacken the tie-rod lock nuts and turn the
cylinder rod in the direction necessary to obtain
Y = = 2 distance (B). When the adjustment is correct, re-
tighten the tie-rod lock nuts to a torque of 300 Nm.
PDH0350
1 CYLINDER CENTRE LINE
2 STEERING CYLINDER
Turn the left-hand wheel to full lock. Measure and

note the dimension Y (distance between the cylinder
gland and the connecting link centre line).

7080-19
SPECIAL INSTRUCTIONS
Preventing the rotation of screw-in Removing and installing the wiper
type cylinder gland ring
1
1
PDH0312 PDH0314
Unlock the screw-in type gland bearing (1) using a Unstick the wiper ring (1) using a hammer and a drift,
hammer and a drift as shown on the drawing. then remove it.
2
1
2
PDH0313 PDH0315
Lock the screw-in cylinder gland (1) by peening the Fit a new wiper ring (1) using the old wiper ring (2) to
barrel (2) into one of the slots by means of a hammer assist, as shown in the drawing.
and drift.

7080-20
Replacing bushings Checking cylinder rod deflection

STEP 1
Extract the old bushing.
STEP 2 = = = =

1 2 3 4 5

This check is carried out using a surface plate and a
PDH0319
øD2 dial gauge to 1/100 mm accuracy, proceeding

as follows:
PDH0317
- Centre the rod plumb in the axis of the checking
Check the diameter (D2) of the bushing bore. Refer to brackets 3.
the specifications for the dimension. - Carry out 5 checks at equal distances from each
STEP 3 other. Turn the rod very slowly at each check point.

Note the maximum and minimum variations.
Maximum value - minimum value

Boom =
2

See specifications for maximum acceptable
deflection.

NOTE: Straightening the rod is not acceptable. Any
rod with a deflection greater than the maximum
tolerance must be changed.
øD1
PDH0318
Fit the bushing (1) on the cylinder barrel using liquid

nitrogen. Check diameter (D1). Refer to the
specifications for this dimension.

8011
Section
8011
HYDRAULIC SWIVEL

Printed in France
8011-2
TABLE OF CONTENTS
SPECIFICATIONS..................................................................................................................................................... 3
SPECIAL TORQUES................................................................................................................................................. 3
WORKSHOP TOOLS ................................................................................................................................................ 3
HYDRAULIC SWIVEL ............................................................................................................................................... 3
Position of swivel housing in relation to swivel body ............................................................................................. 3
Description ............................................................................................................................................................ 4
Assembly of composite seals ................................................................................................................................ 7
Cross-sectional view .............................................................................................................................................8

8011-3
SPECIFICATIONS
Weight of hydraulic swivel ................................................................................................................................... 134 kg
Type..........................................................................................................................................H25 H10 2B25 12B10
SPECIAL TORQUES
Plate retaining screw ................................................................................................................................. 36 to 44 Nm
Hydraulic swivel support retaining screw........................................................................................................ 520 Nm
WORKSHOP TOOLS
1 OEM 6472 Torque wrench
HYDRAULIC SWIVEL
Position of swivel housing in relation to swivel body
55°±2°
CS95K014
NOTE: The swivel housing (1) must be fixed at 55±0.2° in relation to the swivel body fixing point (2).

8011-4
Description
05 02 09 03 08 010 011 012
04 07
01 016
013 015
2
014
3
06
4 1/2
4 2/2
1 1/2
1 2/2
7 1/3
6 7 3/3
8 2/3 9
10 2/2
8 1/3
11
7 2/3
12 1/2
10 1/2 5 1/2
12 2/2 13
14
8 3/3 15 2/2 15 1/2 5 2/2 16
CS95K013
Identification of ports
Swivel housing Swivel body

01 Travel or stabiliser/dozer blade LS informa- 1 1/2 LS information circuit from travel/stabiliser/dozer
tion circuit blade control valve
1 2/2 Not used (plugged)
02 Stabiliser and/or dozer blade raising pilot 2 Stabiliser and/or dozer blade raising control valve
spool pilot
03 Stabiliser and/or dozer blade lowering pilot 3 Stabiliser and/or dozer blade lowering control valve
spool pilot
04 Reverse travel pilot 4 1/2 Reverse travel control valve spool pilot
4 2/2 Transmission safety selector circuit
05 Forward travel pilot 5 1/2 Forward travel control valve spool pilot
5 2/2 Transmission safety selector circuit
06 Travel/stabiliser/dozer blade control valve 6 Supply to travel/stabiliser/dozer blade control
supply valve

8011-5
Swivel housing Swivel body

07 Return to reservoir via P10 7 1/3 Return to reservoir via P10
7 2/3 Hydraulic travel motor clutch release block
return to reservoir
7 3/3 Hydraulic travel motor return to reservoir
08 Hydraulic travel motor leak return 8 1/3 Leak return and flow from secondary relief
valve opening from the hydraulic travel motor
09 Front axle unlocking circuit 9 Front axle unlocking circuit
010 Service and working brake circuit on rear 10 1/2 Service and working brake circuit on the axle
axle
10 2/2 Hydraulic travel motor and transmission
safety selector clutch release block pilot
011 Service and working brake circuit on rear 11 Service and working brake circuit on front
axle axle
012 Parking brake circuit on transmission 12 1/2 Parking brake circuit on transmission
013 Steering circuit (LH) 13 Steering circuit (LH)
014 Steering circuit (RH) 14 Steering circuit (RH)
015 Transmission dog cylinder large chamber 15 1/2 Supply to transmission dog cylinder large
supply chamber
016 Transmission dog cylinder small chamber 16 Transmission dog cylinder small chamber
supply supply

8011-6

NOTE: The parts are numbered in order of disassembly. For assembly, follow the procedure in the reverse order.
NOTE: Parts marked with an asterisk must be replaced.
NOTE: For assembly of composite seals, see page 7.
**
6
7
*
*
4
3 *
2
1
CS95K012
1 SCREW 5 SWIVEL HOUSING
2 PLATE 6 COMPOSITE SEAL
3 LOWER O-RING 7 UPPER O-RING
4 LOWER O-RING 8 SWIVEL BODY

8011-7
Assembly of composite seals
1 2
CS95K010
Place the nylon ring (1) flat in an oven at 80°C for 8 hours.
The seals must be installed 48 hours maximum after the drying operation to prevent them absorbing humidity again
and increasing diameter.
When assembling, there must be no oil between the nitrile ring (2) and the nylon ring (1) to ensure that the parts
adhere directly to each other.

8011-8
Cross-sectional view
6
3 2
4 2/2
1 2/2 4 1/2
1 1/2
7 2/3 7 3/3 2
7 7 1/3
8 2/3
8 1/3 8 3/3 9
10 1/2 10 2/2
11
12 12 1/2
5 2/2 5 1/2 13
15 1/2 14
15 2/2 16
3 4 7
CS95K015
1 SWIVEL HOUSING 5 UPPER O-RING
2 SWIVEL BODY 6 COMPOSITE SEAL
3 PLATE 7 LOWER O-RINGS
4 SCREW

Section
8020
HIGH PRESSURE AND SWING PUMP
8020

Printed in France
8020-2
TABLE OF CONTENTS
SPECIFICATIONS..................................................................................................................................................... 3
TOOLS REQUIRED .................................................................................................................................................. 3
PORT AND ADJUSTMENT POINT IDENTIFICATION ............................................................................................. 4
HYDRAULIC PUMP .................................................................................................................................................. 5
Cross-sectional view of the hydraulic pump and the regulator..............................................................................8
REGULATOR ............................................................................................................................................................ 9
Disassembly and assembly ................................................................................................................................10
Cross-sectional view of the regulator ..................................................................................................................11
PILOT VALVE..........................................................................................................................................................12
Disassembly and assembly ................................................................................................................................12
Cross-sectional view of the pilot valve ................................................................................................................13
HYDRAULIC PUMP ................................................................................................................................................14
Disassembly and assembly.................................................................................................................................14
Cross-sectional view of the hydraulic pump ........................................................................................................16
EXPLODED AND CROSS-SECTIONAL VIEW OF THE VARIABLE FLOW PUMP ROTOR ASSEMBLY.............17
EXPLODED AND CROSS-SECTIONAL VIEW OF THE FIXED FLOW PUMP ROTOR ASSEMBLY....................18
this symbol, carefully read the message that follows, as there is a risk of serious injury.

8020-3
SPECIFICATIONS
Hydraulic pump drive speed under load ...............................................................................................................≥ 2000 rpm
Hydraulic pumps
(with axial pistons and external tooth gears)
Variable displacement pump maximum displacement ................................................................................. 107 cc
Displacement of the fixed flow swing pump (16 cc x 1.337).................................................................... 21.392 cc
Variable displacement pump maximum flow ................................................................................ 205 to 208 L/min
Fixed flow swing pump maximum flow ............................................................................................. 41 to 43 L/min
Rated pressure of attachment and travel function ...........................................................................355 to 365 bar
Rated pressure of the heavy lift function .....................................................................................................450 bar
Adjusting the Load-Sensing valve (LS): ∆P between M1 and M3:
static.................................................................................................................................................20 to 22 bar
dynamic............................................................................................................................................19 to 22 bar
Adjusting the torque regulating valve
Pressure in bucket or dipper cylinder large chamber..............................................................................300 bar
Engine speed ...................................................................................................................................................≥ 2000 rpm
Variable displacement pump flow ................................................................................................................ ≥ 145 L/min
Hydraulic fluid capacity ............................................................................................................................ 105 litres
Type of hydraulic fluid ............................................................................................................ CASE hydraulic fluid
Weight
Hydraulic pump ............................................................................................................................................ 106 kg
Upper hood .................................................................................................................................................... 26 kg
Hydraulic reservoir, empty............................................................................................................................ 170 kg

Engine/hydraulic pump retaining screws .......................................................................................................... 44 Nm
Engine/pump coupling splined sleeve retaining screws ................................................................................. 100 Nm
Engine/pump coupling centring stud retaining screws ................................................................................... 220 Nm
Hydraulic reservoir drain plug........................................................................................................................... 30 Nm
Load-Sensing valve cap ................................................................................................................................... 70 Nm
Pilot valve jets.................................................................................................................................................. 6.5 Nm
Positioning pin .................................................................................................................................................. 49 Nm
Retaining plate retaining screws...................................................................................................................... 9.6 Nm
Mechanical zero stop screw ............................................................................................................................. 69 Nm
TOOLS REQUIRED
2 Receptacle (130 litres)
3 Loctite 241
4 Loctite 649

8020-4
PORT AND ADJUSTMENT POINT IDENTIFICATION
RC
S
2
A
A1
B S1
CS02J520
LS
AD
X4
X8
X3
R1
1
CS02J521
Identification of ports: Adjusting points:

A Output from attachment, travel and option pump
RC Adjusting the torque regulating valve
A1 Working pressure measurement port
AD Adjusting the flow cancellation and 365 b
B Swing pump output
pressure holding valve
M Load pressure measurement port
LS Adjusting the Load-Sensing valve
R1 Anti-surge block leak-off return
S Variable displacement pump input
S1 Swing pump input IMPORTANT: Never perform any adjustment of the
X3 Swing pressure information circuit to the torque screw:
regulating valve 1 Pump maximum displacement stop screw
X4 35 b information input (for 400 b boost pressure) 2 Mechanical zero stop screw
X8 Information input from the 360 b Load-Sensing
valve

8020-5
HYDRAULIC PUMP
The following steps must be carried out before performing any servicing operation on the machine:
- Operate the foot-operated emergency pump while at the same time operating the control levers to release
pressure in all the hydraulic circuits.
- Close the hydraulic reservoir shut-off valve.
- Unscrew the hydraulic reservoir cap two or three turns to release the pressure and re-tighten the cap.
WARNING: When the machine is operating, the components of the hydraulic pump heat up to a high
temperature. To avoid being burnt by hot metal or scalded by oil or water, allow the machine to cool down
before carrying out any servicing operation.

STEP 1 Disconnect the oil filter restriction wire. Remove the
cable attached to the hydraulic reservoir.
Remove the nuts from the exhaust silencer outlet
pipe clamp, then remove the U-bolt. STEP 5
STEP 2 Disconnect and plug the return from the attachment
and the hydraulic hammer return hose (if fitted) on
Remove the engine side panel. Install suitable lifting the oil filter manifold.
equipment on the engine upper hood and remove the
hood. Remove the access panels under the engine. STEP 6
STEP 3 Disconnect and plug the return hose from the oil-
cooler.
STEP 7
Disconnect and plug the attachment leak-off return
hose on the magnetic filter.
STEP 8
Remove the cable clips from the hydraulic reservoir.
STEP 9
Untighten the hydraulic pump inlet hose clamps and
remove the hose.
PG02904
Place a clean receptacle of a capacity of 130 litres

STEP 10
under the hydraulic reservoir. Remove one of the Disconnect and plug the inlet hoses on the pilot
drain plugs and drain the hydraulic fluid into the pumps.
receptacle. Install the plug and tighten it to a torque of
30 Nm.
NOTE: When assembling, fill the hydraulic reservoir
with clean hydraulic fluid. Total capacity of hydraulic
reservoir (see section 1002).

8020-6
STEP 11 STEP 16
Install suitable lifting equipment on the hydraulic
reservoir. Remove the hydraulic reservoir retaining
screws and remove the hydraulic reservoir.
Weight of reservoir (see section 1002).
STEP 12
2
Attach identification labels to all the main hydraulic
pump hoses. Disconnect and plug the hoses.
STEP 13
Remove the exhaust silencer retaining screws and 1
remove the exhaust silencer. B20404
STEP 14 Remove the screws (1) then remove the centring

studs (2). Check the centring studs for wear and
Install suitable lifting equipment on the hydraulic condition and replace them if necessary.
pump assembly. Remove the hydraulic pump
retaining screws and remove the hydraulic pump. NOTE:
Place the hydraulic pump on a clean bench.
STEP 15

1

INCORRECT CORRECT
PDG0419
When installing, apply Loctite 638 to the screws,

B20402 position the centring studs correctly and tighten the
Remove the flexible coupling (1), check it visually for
wear and condition and replace it if necessary. NOTE: If wear on the flexible coupling and centring
studs necessitates their replacement, change the
splined sleeve at the same time.
PE08517
Remove the two retaining screws (1) from the splined

sleeve (2) and remove the splined sleeve.

8020-7
NOTE: When installing, assemble the splined sleeve Before running the machine, carry out the following
on the pump shaft. The splined sleeve must butt up steps:
against the pump shaft shoulder. Tighten the
- Start the engine.
NOTE: When installing the hydraulic pump, carry out - Operate the swing, travel and attachment for five
the same operations in the reverse order. Replace all minutes, with the engine at idle speed.
seals with new seals. - Check the hydraulic circuit for leaks.
- Check the level of hydraulic fluid in the hydraulic
IMPORTANT: Open the hydraulic reservoir shut-off
reservoir and add fluid if necessary.
valve. Check the level of hydraulic fluid in the
- Adjust the regulator block. Refer to section 8001.
hydraulic reservoir and top up if necessary.
R1
CS02J522
Before starting the machine, remove the hose at R1

on the pump. Fill the pump housing with clean oil via
port R1. Install and tighten the hose.

8020-8
Cross-sectional view of the hydraulic pump and the regulator
4 2
6 3
CS96F067
1 INLET FLANGE 4 REGULATOR RETAINING SCREWS

2 STOP PLUG 5 REGULATOR RETAINING SCREWS
3 REGULATOR 6 DISTRIBUTION PLATE

8020-9
REGULATOR
STEP 1 3
Remove the inlet flange (1) from the variable flow
pump and scrap the O-ring.
STEP 2
6
2 C18535
Mark the position of the distribution plate (6) on the

regulator (3) and remove the plate.
to that of removal.
3
C18404
Remove the stop plug (2) from the regulator (3), scrap
the O-ring.
STEP 3
4 3
5
C18408
Remove the retaining screw (4) located inside the

regulator (3). Remove the remaining retaining screws
(5) from the regulator and remove the regulator (3).
Scrap the seal.

8020-10

NOTE: The parts are numbered in order of disassembly. When assembling, follow the same procedure in the
reverse order.
3
5
4
2 12
16
13
49 Nm
15
20 37
21 28
27
14 17 26
18
19 24
36 23
22
25
36
31
32 11
1 30 10 9
29 8
7
35
Loctite 649
34
33
6
69 Nm CS02J523
NOTE: Do not remove the nut, the adjusting screw or the block stop (7). Do not remove the torque regulating valve
cap nut or adjusting screw (22).
1 DISTRIBUTION PLATE 11 SPRING CUP 19 SEAL 29 CONTROL PIN

2 SCREW 12 PLUG 20 RING 30 TORQUE REGULATING
3 COVER 13 POSITIONING PIN 21 PISTON RING LEVER
4 O-RING 14 PIVOT PIN 22 CAP ASSEMBLY 31 RING
5 O-RING 15 SLEEVE 23 O-RING 32 BEARING
6 SCREW 16 PISTON ASSEMBLY 24 SPRING CUP 33 SCREW
7 COVER ASSEMBLY 17 SERVO-CONTROL 25 SPRING 34 PILOT VALVE
8 O-RING SPOOL 26 LINER 35 O-RING
9 SMALL SPRING 18 RING 27 CONTROL SPOOL 36 CENTRING STUD
10 LARGE SPRING 28 CONTROL ROD 37 REGULATOR

8020-11
Cross-sectional view of the regulator
13 18
A-A
21 19 11 8
14 1 10 7
5 4 9 6
CS02J531
15 16 30 31 29 28 26 23 22
33
12
25
24
A A
32
27 2
CS02J525
1 DISTRIBUTION PLATE 13 RING FOR PISTON 24 SPRING

2 MEASUREMENT PISTON 14 PIVOT PIN 25 SPRING CUP
3 COVER 15 SLEEVE 26 LINER
4 O-RING 16 PISTON ASSEMBLY 27 SETSCREW
5 O-RING 17 SERVO-CONTROL SPOOL 28 CONTROL ROD
6 SCREW 18 RING 29 CONTROL PIN
7 COVER ASSEMBLY 19 SEAL 30 TORQUE REGULATING LEVER
8 O-RING 20 RING 31 BEARING
9 CONTROL PISTON 21 PISTON 32 PILOT VALVE
10 LARGE SPRING 22 CAP ASSEMBLY 33 REGULATOR
11 SPRING CUP 23 O-RING
12 PLUG

8020-12
PILOT VALVE
reverse order.
B
16
16
17
1 20
22
12 23 18
A 11 19
10 15
5 B
6
4 24
8 25
29 26
7
9
27
28
12
13
2
3
29
CS02J526
NOTE: Do not remove the nut (7) or the adjusting screw (8) from the valve Load-Sensing cap (4). Do not remove
the nut (18) or the adjusting screw (19) from the flow cancellation valve cap (15).
A Load-Sensing valve
B Flow cancellation valve
1 RETAINING SCREW 11 SMALL SPRING 21 SMALL SPRING

2 BLOCK 12 SPRING CUP 22 LARGE SPRING
3 SEAL 13 LINER 23 SPRING CUP
4 CAP 14 SPOOL 24 SPRING
5 O-RING 15 CAP 25 SPRING CUP
6 BACK-UP RING 16 BACK-UP RING 26 SPOOL
7 NUT 17 O-RING 27 PLUG
8 ADJUSTING SCREW 18 NUT 28 JET
9 SPRING CUP 19 ADJUSTING SCREW 29 PLUG
10 LARGE SPRING 20 SPRING CUP

8020-13
Cross-sectional view of the pilot valve
29
B-B
B 3 2 7 25 18 8 4 20
9
B
CS02J529 6 24 19 1 5 6 17 CS02J527
A-A
11 23 28 14 12 20 16 A
27 10 13 21 22 15
CS02J528 CS02J530
A Load-Sensing valve
B Flow cancellation valve
1 HOUSING 11 CONTROL PISTON 21 O-RING

2 CONTROL LINER 12 THREADED PLUG 22 TEFLON PRESSURE BUSHING
3 CONTROL PISTON 13 SPRING CUP 23 RING FOR PISTON
4 THREADED PLUG 14 PRESSURE SPRING 24 O-RING
5 SPRING CUP 15 SPRING CUP 25 THREADED PLUG
6 PRESSURE SPRING 16 SETSCREW 26 THREADED PLUG
7 PRESSURE SPRING 17 O-RING 27 JET
8 SPRING CUP 18 TEFLON PRESSURE BUSHING 28 DOUBLE BREAKING PLUG
9 SETSCREW 19 JET 29 CYLINDRICAL SCREW
10 CONTROL LINER 20 FLANGE NUT

8020-14
HYDRAULIC PUMP
reverse order.
11
19 21
20
18
17 22
6
5
3 23
7 16
4
12 8
10
9
14 15 13 16
CS96F061
NOTE: Do not remove the maximum displacement stop nut and screw from the rear housing assembly (12) of the
pump.
2 O-RING 14 BARREL
3 SCREW 15 SWING PUMP ROTOR ASSEMBLY
4 COVER 16 PLUG
5 O-RING 17 SNAP RING
6 O-RING 18 SEAL CARRIER
7 CENTRING STUD 19 O-RING
8 PLUG 20 LIP SEAL
9 DISTRIBUTION PLATE 21 VARIABLE FLOW PUMP ROTOR ASSEMBLY
10 SCREW 22 CENTRING STUD
11 SCREW 23 PUMP HOUSING
12 REAR HOUSING ASSEMBLY
13 SEAL

8020-15
STEP 1 STEP 6
15
12
2 1
C18424 C18527
Remove the retaining screws from the low pressure Using a hydraulic press, remove the rotor assembly
pump (1) then remove the pump. Remove the O-ring (15) from the rear housing assembly (12). Retain the
(2) and scrap it. adjusting shim for future use.
STEP 2 STEP 7
Remove retaining screws (3) from the fixed flow Remove the snap ring (17) and the seal-carrier (18)
pump cover (4) and remove the cover. Scrap the two from the pump housing (23). Remove the O-ring (19)
O-rings (5) and (6). Remove the centring stud (7) and the lip seal (20) from the seal-carrier. Scrap the
from the cover (4). O-ring and lip seal. Remove the centring stud (22)
from the pump housing (23).
STEP 3
STEP 8
21
23
9
C18435
C18320
Mark the position of the distribution plate (9) and
remove the plate. Using a hydraulic press, remove the rotor assembly
(21) from the pump housing (23).
STEP 4
STEP 9
Remove the retaining screws (10) and (11) from the
rear housing assembly (12) and remove the Clean all the parts using cleaning solvent and dry
assembly. Scrap the seal (13). with compressed air. Do not use cloths. Check that
no parts are worn or damaged.
STEP 5
NOTE: When assembling, proceed in the reverse
Carefully remove the barrel (14) from the fixed flow order from disassembly.
pump. Do not remove the Belleville washers located
in the central bore of the barrel.

8020-16
Cross-sectional view of the hydraulic pump
2
6
7
3
8
4
10
11
CS96F068
1 PUMP HOUSING 7 SEAL CARRIER

2 PUMP REAR HOUSING 8 VARIABLE FLOW PUMP ROTOR ASSEMBLY
3 VARIABLE FLOW PUMP BARREL 9 LIP SEAL
4 FIXED FLOW PUMP ROTOR ASSEMBLY 10 FIXED FLOW PUMP BARREL
5 O-RING 11 FIXED FLOW PUMP COVER
6 SNAP RING

8020-17
EXPLODED AND CROSS-SECTIONAL VIEW OF VARIABLE FLOW PUMP

ROTOR ASSEMBLY
NOTE: Individual components of the rotor are not supplied separately. If any of its components are worn or
damaged, the entire assembly must be replaced.
4
1 CASTELLATED NUT
2 BEARING
3
3 SHIM WASHER 2 6 7
4 BEARING ASSEMBLIES Loctite 241
5 SHAFT
6 PISTONS 1
7 PISTON RINGS
8 GUIDE PISTON
10 BELLEVILLE WASHER GUIDE
11 RETAINING PLATE
12 SCREW
13 BARREL
14 DISTRIBUTION PLATE 5
9 14
8 13
12
10 11 9.6 Nm
PDH0280
Loctite 241
14 13 8 12 4 3
10
5
9 7 6 11 2
PDH0281

8020-18
EXPLODED AND CROSS-SECTIONAL VIEW OF THE FIXED FLOW PUMP

ROTOR ASSEMBLY
NOTE: Individual components of the rotor are not supplied separately. If any of its components are worn or
damaged, the entire assembly must be replaced.
1 SHAFT
2 BEARING ASSEMBLIES
3 ADJUSTMENT SHIM 3
4 CASTELLATED NUT
5 PISTON RINGS 2 4
6 PISTONS Loctite 241
7 BELLEVILLE WASHER GUIDE 1
9 GUIDE PISTON
10 SCREW
11 RETAINING PLATE
12 DISTRIBUTION PLATE 9.6 Nm
13 BARREL
10 Loctite 241
6 11
9
5 8
7
13
12
PDH0282
2
13 9 10
4
12
7
1
8 5 6 11
PDH0283

8031
Section
8031
ATTACHMENT CONTROL VALVE

«MARREL»

Printed in France
CNH Cre 7-80822GB September 2002
8031-2
TABLE OF CONTENTS
SPECIFICATIONS .................................................................................................................................................. 3
SPECIAL TORQUE SETTINGS ............................................................................................................................. 3
TOOLS REQUIRED ............................................................................................................................................... 3
ATTACHMENT CONTROL VALVE ........................................................................................................................ 4
Disassembly and assembly of P10 pressure limiter ............................................................................................ 8
Cross-sectional drawing ...................................................................................................................................... 8
Disassembly and assembly of inlet plate ............................................................................................................ 9
Cross-sectional drawing of inlet plate ............................................................................................................... 10
Cross-sectional drawing of main relief valve ..................................................................................................... 10
Disassembly and assembly of boom, bucket and dipper control valve section ................................................ 11
Cross-sectional drawing of a control valve section ........................................................................................... 12
Cross-sectional drawing of the flow control (balance) valve assembly ............................................................. 13
Cross-sectional drawing of secondary relief valve ............................................................................................ 14
Cross-sectional drawing of pressure selector ................................................................................................... 14

8031-3
SPECIFICATIONS
Bore .........................................................................................................................................................................20
Spool stroke .................................................................................................................................................................. 10 mm
Spool pilot circuit pressure ..................................................................................................................................... 8 to 22 bar
Attachment control valve adjustment...........................................................................................................see section 8001

Control valve section assembly nut .................................................................................................................. 90 Nm
Control valve section assembly lock nut.......................................................................................................................50 Nm
P10 pressure limiter retaining screws...........................................................................................................................50 Nm
Inlet plate
M27x2 plugs ................................................................................................................................................. 90 Nm
M16 x 1.5 plug.............................................................................................................................................. 35 Nm
Main relief valve .................................................................................................................................. 75 to 95 Nm
Control valve sections
Secondary relief valve ......................................................................................................................... 75 to 95 Nm
Balance adjustment assembly guide................................................................................................. 90 to 110 Nm
Balance valve plug .......................................................................................................................... 120 to 140 Nm
Spool plug ...............................................................................................................................9 to 11 Nm + Loctite
Spool cap retaining screw ................................................................................................................... 12 to 22 Nm
Pressure selector plug ........................................................................................................................ 12 to 22 Nm
TOOLS REQUIRED
2 Loctite 270

8031-4

Location of components
1 PRESSURE LIMITER (P10)
2 INLET PLATE
3 BOOM CONTROL VALVE SECTION
4 BUCKET CONTROL VALVE SECTION
5 DIPPER CONTROL VALVE SECTION
6 SECONDARY RELIEF VALVES ON EACH SECTION
7 MAIN RELIEF VALVE
8 PRESSURE SELECTOR ON LS CIRCUIT BETWEEN BOOM AND BUCKET/DIPPER
9 PRESSURE SELECTOR ON LS CIRCUIT BETWEEN BUCKET AND DIPPER
10 PLUG
11 BOOM FLOW SELECTOR (BALANCE)
12 BUCKET FLOW SELECTOR (BALANCE)
13 DIPPER FLOW SELECTOR (BALANCE)
Zb3 Zb2 Zb1 T4

7 P1
B1
2
B2 F1
B3 T2 F4
A2
1
A3
4
F3
5
Za3 Za2 Za1 3 T3 A1 T1 P
13 10 12 9 11 8 LS

P2

P2 F2
F6

F5
6 T5 P3 6 T4 M1 T
CS96B026

8031-5
Identification of ports On boom control valve section
P1 OULET TO TRAVEL CONTROL VALVE ZA1 LARGE CHAMBER FEED SPOOL PILOT
P2 VARIABLE FLOW PUMP INLET ZB1 SMALL CHAMBER FEED SPOOL PILOT
P3 OUTLET TO OPTIONS CONTROL VALVE A1 LARGE CHAMBER FEED
T1 TRAVEL CONTROL VALVE RETURN B1 SMALL CHAMBER FEED
T2 RETURN TO RESERVOIR PASSING THROUGH P10
PRESSURE LIMITER On bucket control valve section
T3 SWING INLET PLATE 0.5 BAR CHECK VALVE RETURN ZA2 LARGE CHAMBER FEED SPOOL PILOT
T4 OPTION CONTROL VALVE RETURN ZB2 SMALL CHAMBER FEED SPOOL PILOT
T5 OUTLET TO OPTIONS CONTROL VALVE A2 LARGE CHAMBER FEED
M1 PRESSURE GAUGE TEST POINT B2 SMALL CHAMBER FEED
LS INFORMATION FROM PUMP LOAD-SENSING VALVE
On dipper control valve section
On the P10 pressure limiter
ZA3 LARGE CHAMBER FEED SPOOL PILOT
P RETURN FROM ATTACHMENT RECEIVING COMPO- ZB3 SMALL CHAMBER FEED SPOOL PILOT
NENTS, TRAVEL AND OPTION A3 LARGE CHAMBER FEED
T RETURN TO RESERVOIR B3 SMALL CHAMBER FEED
F1-F6 OPERATING LEAKAGE RETURN

8031-6

- Stop the engine.
- Loosen the hydraulic reservoir pressure release cap two turns. Tighten the pressure release cap.
- Operate the emergency pump and the control levers simultaneously to release all pressure in the hydraulic sys-
tem.
STEP 1 STEP 4
Remove the control valve hood.
STEP 2 2
Attach identification labels to all attachment control
3
valve hoses and pipes. Disconnect and plug the
hoses and pipes. Plug the control valve block orifices.
STEP 3
Install a suitable lifting device on the attachment con-
trol valve.
CS96B012
Remove the three retaining screws (2) with their wash-

ers (3) from the attachment control valve (1) and
remove the attachment control valve.
- Start the engine.
- Check the level of hydraulic oil in the reservoir and top up if necessary.
- Check the secondary relief valve pressure settings and the flow from the balance valves on the travel control
valve, the speed limiter and the anti-excess flow valve. See Section 8001.

8031-7

NOTE: The parts are numbered in order of disassembly. Assembly is carried out in the reverse order.
2 50 Nm 3 90 Nm
7
50 Nm
CS96B013
1 P10 PRESSURE LIMITER BLOCK 6 BUCKET OR CLAMSHELL CONTROL VALVE SECTION
2 LOCK-NUT 7 BOOM CONTROL VALVE SECTION
3 NUT 8 INLET PLATE
4 TIE-ROD
5 DIPPER CONTROL VALVE SECTION

8031-8
Disassembly and assembly of P10 pressure limiter
8 2
1
3
4
7 6 5
PDH0080
1 P10 PRESSURE LIMITER BLOCK SPOOL
2 PLUG
3 RETAINING RING
4 PRE-SET SPRING
5 PLUG
6 O-RING
7 SCREW
8 O-RING 1 2 3 4 5
1 SPOOL
2 RETAINING RING
3 PRE-SET SPRING
4 O-RING
5 PLUG
PDG0028

8031-9
Disassembly and assembly of inlet plate
9
10
11 8
85 Nm
12
13
14
15
16
6
5
CS96B014

4 INLET PLATE 11 SEAL
5 O-RING 12 SEAL
7 O-RING 14 O-RING
8 MAIN RELIEF VALVE 15 BACK-UP RING
9 BACK-UP RING 16 O-RING
10 O-RING

8031-10
Cross-sectional drawing of inlet plate

1
2

PDG0236
1 INLET PLATE
2 SECONDARY RELIEF VALVE
Cross-sectional drawing of main relief valve
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

PDG0237
1 SEAL AND BACK-UP RING 11 SEAL AND BACK-UP RING

2 PRIMARY VALVE SEAT 12 CARTRIDGE
3 PRIMARY VALVE 13 PUSH ROD/SPRING PRESSURE SETTING NUT
4 RETURN SPRING 14 BRAKE
5 SECONDARY VALVE SEAT 15 SHIELD
6 SEAL AND BACK-UP RING
7 SEAL
8 SECONDARY VALVE
9 PRESSURE SETTING SPRING
10 SEAL

8031-11
Disassembly and assembly of boom, bucket and dipper control valve section
6 25
25
5
21 17 Nm 26
7
27
22 8 10 Nm
85 Nm + loctite 270 28
10 9
17 Nm
23 A 15 29
17
19 30 13
14 18
4
20 2
24
3
4
20
19 10 Nm
+ loctite 270 18
85 Nm
23 8 17
30
7 16 130 Nm
22
12
21
11 1
17 Nm
PDH0079
NOTE: When assembling, replace all seals with new seals. Assemble the spool plugs (8) using oil-proof Loctite.
1 CONTROL VALVE SECTION 10 SPOOL RETURN ASSEM- 16 BALANCE VALVE PLUG 26 ADJUSTING SCREW
2 O-RING BLY 17 BACK-UP RING 27 BACK-UP RING
3 BACK-UP RING 11 CAP SCREW 18 O-RING 28 O-RING
4 O-RING 12 SPOOL SMALL CAP 19 BACK-UP RING 29 ADJUSTMENT ASSEM-
5 CAP SCREW 13 PRESSURE SELECTOR 20 O-RING BLY GUIDE
6 LARGE SPOOL CAP (EXCEPT FOR DIPPER) 21 BACK-UP RING 30 HEATING CALIBRATED
7 O-RING 14 O-RING 22 O-RING ORIFICE
8 SPOOL PLUG 15 PRESSURE SELECTOR 23 SECONDARY RELIEF VALVE
9 SEAL PLUG 24 BALANCE SPRING
25 SHIELD

8031-12
Cross-sectional drawing of a control valve section

4 5

9

14
10
7

8

12

8
3

13

11

6
2 1
PDG0225
1 CONTROL VALVE SECTION BODY

2 FLOW REGULATOR ASSEMBLY (BALANCE)
3 CONTROL SPOOL ASSEMBLY
4 LARGE CHAMBER FEED SECONDARY RELIEF VALVE
5 SMALL CHAMBER FEED SECONDARY RELIEF VALVE
6 PRESSURE SELECTOR ON “LOAD-SENSING” CIRCUIT (ON BOOM AND DIPPER SECTION ONLY)
7 SMALL CAP
8 SPOOL PLUG
9 CAP SEAL
10 LARGE CAP
11 SPOOL RETURN SPRING
12 CUP
13 WASHER
14 HEATING CALIBRATED ORIFICE

8031-13

Cross-sectional drawing of the flow control (balance) valve assembly

1

2
3 4 5 6 7 8 9 11 12 13 14

10

15

16

17

18

PDG0251
1 PLUG 10 ADJUSTMENT ASSEMBLY GUIDE
2 BACK-UP RING 11 O-RING
3 O-RING 12 BACK-UP RING
4 RETAINING RING 13 O-RING
5 THRUST WASHER 14 BACK-UP RING
6 CHECK VALVE SPRING 15 LOCKING RING
7 CHECK VALVE 16 PLUG WASHER
8 BALANCE VALVE SPOOL 17 ADJUSTING SCREW
9 BALANCE SPRING 18 PUSH ROD

8031-14
Cross-sectional drawing of secondary relief valve

11 10 9 8 7 6 5 4 3 2 1

12

13

14
PDG0252
1 FORCED-FEED POPPET 8 PRESSURE SETTING SPRING
2 RETURN SPRING 9 VALVE BODY
3 RETAINING RING 10 PUSH ROD
4 SEAT 11 LOCKING RING
5 POPPET 12 PLUG WASHER
6 SPRING GUIDE 13 ADJUSTING SCREW
7 O-RING AND BACK-UP RING 14 O-RING AND BACK-UP RING
Cross-sectional drawing of pressure selector
1 2 3 5 4

PDG0253
1 SEAT INSERT 3 SEAL
2 BALL 4 SEAL
5 PLUG

8031
Section
8031
"REXROTH" ATTACHMENT
CONTROL VALVE

Printed in France
8031-2
TABLE OF CONTENTS
SPECIFICATIONS .................................................................................................................................................. 3
SPECIAL TORQUES .............................................................................................................................................. 3
TOOLS REQUIRED ............................................................................................................................................... 3
ATTACHMENT CONTROL VALVE ........................................................................................................................ 4
Disassembly and reassembly of the boom, bucket and dipper control valve sections ....................................... 6
Cross-sectional drawing of a control valve section ............................................................................................. 8
Cross-sectional view of the flow regulator assembly (balance) .......................................................................... 9
Cross-sectional drawing of the secondary relief valve ...................................................................................... 10
Cross-sectional view of pressure selector ......................................................................................................... 10

8031-3
SPECIFICATIONS
Calibre .................................................................................................................................................................... 22
Spool stroke..................................................................................................................................................... 10 mm
Spool pilot pressure...................................................................................................................................8 to 22 bar
Setting pressures on the main relief valves .........................................................................................395 to 415 bar
Setting pressures on the boom cylinder small chamber secondary reliefs .........................................395 to 425 bar
Setting pressures with spacers on the control lever pushrods:
Boom cylinder large chamber secondary relief ..............................................................................395 to 425 bar
Bucket cylinder small chamber secondary relief ............................................................................395 to 425 bar
Bucket cylinder large chamber secondary relief .............................................................................395 to 425 bar
Dipper cylinder small chamber secondary relief ............................................................................395 to 425 bar
Dipper cylinder large chamber secondary relief .............................................................................395 to 425 bar
Adjustment of the attachment control valve.................................................................................... see Section 8001
SPECIAL TORQUES
Inlet plate
Plug M22 x 1.5 .......................................................................................................................................... 100 Nm
Control valve sections
Balance plug ............................................................................................................................................. 400 Nm
Balance cap .............................................................................................................................................. 250 Nm
Spool plug ................................................................................................................................................... 10 Nm
Non-return check valve plug...................................................................................................................... 150 Nm
Balance adjusting nut .................................................................................................................................. 40 Nm
Bleed screw................................................................................................................................................... 9 Nm
Spool caps retaining screw ........................................................................................................................... 9 Nm
Pressure selector plug (on bucket and dipper sections only) ...................................................................... 30 Nm
Spool spring guide ...................................................................................................................................... 30 Nm
TOOLS REQUIRED
1 Torque spanner, OEM 6481
2 Loctite 270

8031-4
T2 P3
P4
Zb3 6 15 16 B3 B2 4 3 Za3
A3 11
12
5 9
10 B1
A2
14
Zb2 Za2
16
7 2
13
Zb1 M A1 T1 16 P1 1 P2 Za1 T3 8
LS
cs95k028
Location of components: M1 Pressure test point for pressure checks on:

attachment, travel, options and Load Sensing of
1 Main relief valve the pump
2 Boom supply control valve section T1 Return from travel control valve
3 Bucket control valve section T2 Return to reservoir, passing via the pressure
4 Dipper control valve section limiters (2P10)
5 Load Sensing circuit pressure selector, between T3 Plug or return from the low flow option control
boom and bucket functions valve
6 Load Sensing circuit pressure selector, between LS Outlet to the "Load Sensing" valve on the
boom/bucket and dipper functions variable flow pump
7 Boom large chambers secondary relief
8 Boom small chambers secondary relief On boom control valve section:
9 Bucket large chamber secondary relief
Za1 Large chamber supply spool piloting
10 Bucket small chamber secondary relief
Zb1 Small chamber supply spool piloting
11 Dipper large chamber secondary relief
A1 Large chamber supply
12 Dipper small chamber secondary relief
B1 Small chamber supply
13 Adjustment of boom balance valve
14 Adjustment of bucket balance valve On bucket control valve section:
15 Adjustment of dipper balance valve
16 Non-return check valve assembly Za2 Large chamber supply spool piloting
Zb2 Small chamber supply spool piloting
Identification of ports: A2 Large chamber supply
P1 Outlet to travel control valve
P2 Inlet of flow from one body of the variable flow On dipper control valve section:
pump
P3 Outlet to the low flow option control valve Za3 Large chamber supply spool piloting
P4 Inlet of flow from the other body of the variable Zb3 Small chamber supply spool piloting
flow pump A3 Large chamber supply

8031-5
- Stop the engine.
STEP 1 STEP 5
STEP 2
Place identification tags on all the attachment control 3
valve block hoses and pipes. Disconnect and plug the 2
hoses and pipes. Plug the control valve block orifices.
STEP 3 1
Attach a suitable lifting device on the attachment
control valve.
STEP 4
4
3 2 cs95k021
Remove the two retaining screws (1) from the

manifold block (2) then remove it from the attachment
control valve (4). Discard the O-ring (5).
Before using the machine, all the following operations
- Start the engine.
- Check the circuit for leaks.
- Check the level of hydraulic fluid in the reservoir and
top up if necessary.
- Set the correct pressures for the safety valves, the
balance valve flows on the travel control valve, the
speed limiter and the anti-excess flow valve. Refer to
Section 8001.
1
cs95k001
Remove the three retaining screws (2) with their

washers (3) from the attachment control valve (1),
then remove the attachment control valve.

8031-6
Disassembly and reassembly of the boom, bucket and dipper control valve
sections
16 9 Nm 18 9 Nm
1
19
20
21
17 22
23
24
25 51 150 Nm
52
30 Nm
53
26 55 100 Nm
54 56
27
58 57
28
40 Nm
10 Nm
36
37 250 Nm 34
38 32 31 9 Nm
39
40
41
42 35
48
43 33
47
15 30
14 29 9 Nm
12 50
11 49
10 30 Nm
8 46
7
13 6 45
5
90 Nm 4 44
9
2 400 Nm
3
cs95k022

8031-7
NOTE: When assembling, replace all seals with new seals. Install the screw (26) using oil-proof Loctite 270.
1 Attachment control valve 31 Screw

2 Secondary relief valve 32 Small cap
3 Protection 33 O-ring
4 Adjusting screw 34 Spool plug
6 Pressure setting spring 36 Balance adjustment nut
7 Check valve 37 Balance adjustment screw
8 Check valve seat 38 Balance cap
9 O-rings 39 O-ring
10 Return spring 40 O-ring
11 Spring guide 41 Seat
12 Check valve 42 Spring
13 Valve body 43 Balance valve spool
14 Back-up ring 44 Balance valve plug
15 O-rings 45 O-ring
16 Large chamber bleed screw 46 Stop
17 O-ring 47 Washer
18 Screw 48 Spring
19 Large cap 49 Flow selector
20 O-ring 50 O-rings
21 Cup 51 Non-return check valve plug
22 Inner spring 52 Spring
23 Outer spring 53 Non-return valve
24 Washer 54 O-ring
25 Cup 55 Plug
26 Spool spring guide 56 Plug
27 O-ring 57 Plug
28 Control spool 58 Attachment control valve body
29 Small cap bleed screw
30 O-ring

8031-8
Cross-sectional drawing of a control valve section
5 6 5
8 3
9 2
10 1
cs95k025
1 Control valve section body 8 Small cap

2 Flow regulator assembly (balance) 9 Balance valve plug
3 Control spool assembly 10 Pressure selector on "Load Sensing" circuit (on
4 Large cap control valve sections for bucket dipper only)
5 Secondary relief valve
6 Non-return check valve assembly
7 Spool plug

8031-9
Cross-sectional view of the flow regulator assembly (balance)
1 2 3 4 5 6 7 8 9 10 11 12 13
14
cs95k020
1 Balance valve plug 8 O-ring

2 O-ring 9 O-ring
3 Washer 10 Push rod
4 Stop 11 Balance cap
5 Spring 12 Adjusting nut
6 Balance valve spool 13 Adjusting screw
7 Spring 14 Pressure selector

8031-10

1 2 3 4 5 6 7 8 9 10 11

16 15 14 13 12
cm95k022
1 O-ring 9 Secondary check valve
2 Back-up ring 10 Adjusting screw
3 Main check valve 11 Adjusting nut
4 Return spring 12 Shield
5 O-ring 13 O-ring
6 Valve body 14 Spring guide and calibrated orifice
7 Pressure setting spring 15 O-ring and back-up ring
8 Secondary check valve seat
Cross-sectional view of pressure selector
6

1

2

3

4
5

cm95k002
1 O-ring 4 O-ring
2 Shuttle ball 5 Pressure selector plug
3 O-ring 6 Pressure selector seat

Section
8033
8033
TWO-PIECE
SWING CONTROL VALVE

Printed in France
8033-2
TABLE OF CONTENTS
SPECIFICATIONS ................................................................................................................................................... 3
SPECIAL TORQUES ............................................................................................................................................... 3
TOOLS REQUIRED ................................................................................................................................................ 3
SWING CONTROL VALVE ..................................................................................................................................... 4
Identification of port and location of major components ...................................................................................... 4
Cross-sectional view of the control valve section ................................................................................................ 7
Cross-sectional view of the relief valve ............................................................................................................... 7

8033-3
SPECIFICATIONS
Weight................................................................................................................................................................... 7 kg
Calibre...................................................................................................................................................................................12
Spool stroke .................................................................................................................................................................... 7 mm
Spool pilot pressure................................................................................................................................................ 8 to 22 bar
Adjusting the swing motor control valve.......................................................................................................see section 8001
SPECIAL TORQUES
Control valve assembly nut............................................................................................................................... 26 Nm
Relief valve.....................................................................................................................................................................90 Nm
Plug ................................................................................................................................................................................90 Nm
Non-return check valve plug..........................................................................................................................................70 Nm
Spool caps retaining screw .............................................................................................................................................6 Nm
End ...........................................................................................................................................................10 Nm + Loctite 242
TOOLS REQUIRED
2 Loctite 242

8033-4
SWING CONTROL VALVE

Identification of port and location of major components
Za
2 A 1
T1
3
T3
T2 B
M
Zb
PDG0233
A LEFT SWING HYDRAULIC MOTOR SUPPLY 1 SWING MAIN DISCHARGE VALVE
B RIGHT SWING HYDRAULIC MOTOR SUPPLY 2 OUTLET PLATE
M PRESSURE GAUGE POINT M2 3 CONTROL VALVE SECTION
P INLET FROM FIXED FLOW PUMP
T1 PLUGGED
T2 RETURN TO P10
T3 PLUGGED
ZA SWING PILOTING FOR THE LH SWING
ZB SWING PILOTING FOR THE RH SWING

8033-5

- Stop the engine.
STEP 1 STEP 3
Remove the control valve hood. 1
STEP 2
Place identification tags on all the control valve hoses 2
and pipes. Disconnect and plug the hoses and pipes.
Plug the control valve block orifices.
PH08406
Remove the retaining screws (2) from the swing control

valve (1), then remove it.
- Start the engine.

8033-6
6 Nm 3
2
4 10 Nm + Loctite 242
90 Nm
5
6
26 Nm 13 7
19
18 1
6 90 Nm
5
8
15
16 17 14
12 2
~
1
12
70 Nm
8
11
10 6
9
14
13 6
90 Nm
2
6 Nm 3
PDH0129

1 CONTROL VALVE SECTION - CONTROL 8 O-RING 16 OUTLET PLATE
SPOOL 9 6 COIL SPRING 17 PLUG
2 SPOOL CAP 10 NON-RETURN VALVE 18 THREADED ROD
3 CAP SCREW 11 O-RING 19 NUT
4 END 12 O-RING
5 SHIM 13 PLUG
6 CUP 14 SEAL AND BACK UP RING
7 5 COIL SPRING 15 RELIEF VALVE

8033-7
Cross-sectional view of the control valve section
2 1 2
3 8 4 3
A B
6 7 6 5 7
PDG0246
1 NON-RETURN VALVE 5 CONTROL SPOOL
2 PLUGS 6 SHIM
3 SPOOL CAP 7 END
4 6 COIL SPOOL RETURN SPRING 8 5 COIL SPOOL RETURN SPRING
Cross-sectional view of the relief valve

2 3 1 5 4 6

PDG0247
1 VALVE SEAT
2 CHECK VALVE
4 ADJUSTMENT SCREW AND SPRING GUIDE
5 LOCK NUT
6 SHIELD

8033-8

Section
8033
8033
ONE-PIECE
SWING CONTROL VALVE

Printed in France
8033-2
TABLE OF CONTENTS
SPECIFICATIONS ................................................................................................................................................... 2
SPECIAL TORQUES ............................................................................................................................................... 2
WORKSHOP TOOLS .............................................................................................................................................. 2
Identification of ports and location of major components .................................................................................... 3
SPECIFICATIONS
Calibre .................................................................................................................................................................... 16
Spool pilot pressure...................................................................................................................................8 to 22 bar
Pressure setting the main relief valves ................................................................................................310 to 325 bar
Adjusting the travel control valve .....................................................................................................see section 8001
SPECIAL TORQUES
Bleed screw ..................................................................................................................................................... 30 Nm
Main relief valve............................................................................................................................................... 50 Nm
Plug for control valve spool non-return check valve ........................................................................................ 70 Nm
Plug ........................................................................................................................................................ 85 to 90 Nm
Spool cap retaining screw ............................................................................................................................... 12 Nm
End .............................................................................................................................................30 Nm + Loctite 242
WORKSHOP TOOLS
2 Loctite 270

8033-3
SWING CONTROL VALVE

Identification of ports and location of major components
Zb 1
P T1 M
A
6
Za
4
5
CS95M010
Identification of ports: Location of components:

A Left hand hydraulic swing motor supply 1 Main relief valve
B Right hand swing hydraulic motor supply 2 Upper cap
P Inlet from hydraulic swing motor 3 Upper cap bleed screw
T1 Return to counter-pressure valves (2P10) 4 Lower cap
Za Piloting of left hand swing spool 5 Lower cap bleed screw
Zb Piloting of right hand swing spool 6 Swing control valve section
M Pressure test point M2

8033-4

- Stop the engine.
STEP 1 STEP 3
STEP 2 3
Place identification tags on all the control valve block
pipes. Plug the control valve block orifices.
2 1
CS95M008
Remove the four retaining screws (2) with the nuts (3)
from the swing control valve (1), then remove it.
- Start the engine.
- Bleed the control valve.
- Check the level of hydraulic fluid in the reservoir and top up if necessary.
- Adjust the pressure setting of the main relief valve, refer to section 8001.

8033-5

12 Nm
30 Nm 1 3
2 4
30 Nm 6 21
7 22
8
23 20
9 50 Nm
24
10 25
11
12
13
85 to 90 Nm
27 26
19
18 17
15
16
30 Nm 14
12 Nm
CS95M009
1 Large chamber bleed screw 10 Jacket 19 O-ring

2 Seal 11 Cup 20 Main relief valve
3 Screw 12 O-ring 21 Protection
4 Washer 13 Control valve spool with non- 22 O-ring
5 Large cap return check valve 23 Back-up ring
6 End 14 Small cap bleed screw 24 O-ring
7 Washer 15 Seal 25 Back-up ring
8 Cup 16 Screw 26 Plug
9 Spring 17 Washer 27 Swing control valve body
18 Small cap

8033-6
1 2 3 4 5 6 7 8 9 10 11 12 13 14

19 18 17 16 15
CM95M003
1 Small cap bleed screw 10 Spring

2 Control valve spool plug 11 Spool spring guide
3 Small cap 12 Cup
4 Spring 13 Washer
5 Seal and back up ring 14 End
6 Non-return valve 15 Large chamber bleed screw
7 Control valve spool 16 Large cap
8 Cup 17 Main relief valve
9 Jacket 18 Plug
19 Body

8033-7
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

19 18 17 16
CM95M002
1 Back-up ring 10 Pressure setting spring

2 O-ring 11 O-ring
3 Back-up ring 12 O-ring
4 Primary check valve seat 13 Pressure setting screw
5 Primary check valve return spring 14 Lock nut
6 O-ring 15 Spring guide
7 Primary check valve 16 Protection
8 Secondary check valve seat 17 Back-up ring
9 Secondary check valve 18 O-ring
19 Back-up ring

8033-8

Section
8033
8033
TWO-PIECE
SWING CONTROL VALVE

Printed in France
8033-2
TABLE OF CONTENTS
SPECIFICATIONS ................................................................................................................................................... 3
SPECIAL TORQUES ............................................................................................................................................... 3
TOOLS REQUIRED ................................................................................................................................................ 3
Identification of port and location of major components ...................................................................................... 4

8033-3
SPECIFICATIONS
Weight................................................................................................................................................................... 7 kg
Calibre...................................................................................................................................................................................12
Spool stroke .................................................................................................................................................................... 7 mm
Spool pilot pressure................................................................................................................................................ 8 to 22 bar
Adjusting the swing motor control valve.......................................................................................................see section 8001
SPECIAL TORQUES
Control valve assembly nut............................................................................................................................... 26 Nm
Relief valve.....................................................................................................................................................................90 Nm
Plug ................................................................................................................................................................................90 Nm
Non-return check valve plug..........................................................................................................................................70 Nm
Spool caps retaining screw .............................................................................................................................................6 Nm
End ...........................................................................................................................................................10 Nm + Loctite 242
TOOLS REQUIRED
2 Loctite 242

8033-4
SWING CONTROL VALVE

Identification of port and location of major components
Za
2 A 1
T1
3
T3
T2 B
M
Zb
PDG0233
A LEFT SWING HYDRAULIC MOTOR SUPPLY 1 SWING MAIN DISCHARGE VALVE
B RIGHT SWING HYDRAULIC MOTOR SUPPLY 2 OUTLET PLATE
M PRESSURE GAUGE POINT M2 3 CONTROL VALVE SECTION
P INLET FROM FIXED FLOW PUMP
T1 PLUGGED
T2 RETURN TO P10
T3 PLUGGED
ZA SWING PILOTING FOR THE LH SWING
ZB SWING PILOTING FOR THE RH SWING

8033-5

- Stop the engine.
STEP 1 STEP 3
Remove the control valve hood. 1
STEP 2
Place identification tags on all the control valve hoses 2
and pipes. Disconnect and plug the hoses and pipes.
Plug the control valve block orifices.
PH08406
Remove the retaining screws (2) from the swing control

valve (1), then remove it.
- Start the engine.

8033-6
6 Nm 3
2
90 Nm
5
6
26 Nm 13 7
19
18 1
6 90 Nm
5
8
15
16 17 14
12 2
~
1
12
70 Nm
8
11
10 6
9
14
13 6
90 Nm
2
6 Nm 3
PDH0129

1 CONTROL VALVE SECTION - CONTROL 8 O-RING 16 OUTLET PLATE
SPOOL 9 6 COIL SPRING 17 PLUG
2 SPOOL CAP 10 NON-RETURN VALVE 18 THREADED ROD
3 CAP SCREW 11 O-RING 19 NUT
4 END 12 O-RING
5 SHIM 13 PLUG
6 CUP 14 SEAL AND BACK UP RING
7 5 COIL SPRING 15 RELIEF VALVE

8033-7
2 1 2
3 8 4 3
A B
6 7 6 5 7
PDG0246
1 NON-RETURN VALVE 5 CONTROL SPOOL
2 PLUGS 6 SHIM
3 SPOOL CAP 7 END
4 6 COIL SPOOL RETURN SPRING 8 5 COIL SPOOL RETURN SPRING

2 3 1 5 4 6

PDG0247
1 VALVE SEAT
2 CHECK VALVE
4 ADJUSTMENT SCREW AND SPRING GUIDE
5 LOCK NUT
6 SHIELD

8033-8

Section
8037
ROTARY CONTROL VALVE

(Orbitrol)
8037

Printed in France
8037-2
TABLE OF CONTENTS
SPECIFICATIONS................................................................................................................................................... 3
SPECIAL TORQUE SETTINGS .............................................................................................................................. 3
TOOLS REQUIRED................................................................................................................................................. 3
rotary control valve .............................................................................................................................................. 4
Removal and Installation ..................................................................................................................................... 4
Perspective view ................................................................................................................................................. 6
Disassembly ........................................................................................................................................................ 7
Assembly............................................................................................................................................................. 8
Cross-sectional drawing .................................................................................................................................... 10

8037-3
SPECIFICATIONS
Type............................................................................................................................................................ OSPC ON
Main relief valve pressure setting .........................................................................................................140 to 145 bar
Secondary relief valve pressure setting................................................................................................200 to 220 bar

Rotary control valve retaining screws...................................................................................................... 25 to 35 Nm
Main relief valve plug............................................................................................................................... 49 to 51 Nm
Secondary relief valve plug .............................................................................................................................. 30 Nm
TOOLS REQUIRED
T11013
1 O-ring and Kin ring assembly tool CAS 1238A

2 Torque wrench, OEM 6472

8037-4
ROTARY CONTROL VALVE

11
10
25-35 Nm
5
6
4
9 3
1
L
8
T R
7 P
PDH0386
1 ROTARY CONTROL VALVE FEED HOSE 7 ROTARY CONTROL VALVE
2 RETURN HOSE 8 STEERING COLUMN
3 LEFT-HAND STEERING FEED HOSE 9 BRAKE MODULE
4 RIGHT-HAND STEERING FEED HOSE 10 HYDRAULIC SWIVEL
5 SCREW 11 ATTACHMENT CONTROL VALVE
6 WASHER

8037-5
- Stop the engine.
hydraulic system.
- Untighten the hydraulic reservoir cap two or three full turns, then re-tighten the cap.
WARNING : When the machine is operating the components attain high temperatures. To avoid being
burnt by hot metal or scalded by high temperature fluid, let the machine cool down completely before start-
! ing work.
STEP 1 STEP 3
Remove the lower tray under the cab floor. Immobilize the steering colunm (8). Support the
rotary control valve (7).
STEP 2
STEP 4
Place identification marks on the rotary control valve
(7) hoses. Disconnect and plug the rotary control Remove the four retaining screws (5) and remove the
valve (7) hoses (1),(2),(3) and (4). rotary control valve (7).
NOTE: STEP 5
Remove the four retaining screws (5) and remove the
rotary control valve.
T L NOTE: When installing, tighten the screws to a
to that of removal.
P R
PDH0387
When installing, reconnect the hoses on the rotary

control valve in accordance with the drawing.
P Rotary control valve feed
T Return to attachment control valve
L Right-hand steering feed
R Left-hand steering feed
Before using the machine, all the following operations must be carried out in the order shown :
- Start the engine.
- Check the steering hydraulic system for leaks.
- Check the level of hydraulic oil in the reservoir and top up if necessary.
- Make adjustments to the rotary control valve, refer to Section 8001.

8037-6
Perspective view
NOTE: The parts are numbered in order of disassembly.
*35
31
* 32 33 16
15
14
*
29
30 21 22
23
*
25
27
24
26
20 18 17
19
11
10
*
13 28
12
9 2
*8 1
7 34
*
6
5
4
3
CS99J527
NOTE: Parts marked "*" must be replaced by new parts.

1 SCREW 20 BALL
2 WASHER 21 THRUST WASHER
3 SPECIAL SCREW 22 NEEDLE ROLLER BEARING
4 WASHER 23 THRUST WASHER
5 COVER 24 SHAFT
6 O-RING 25 RETAINING BUSHING
7 STATOR 26 SLEEVE
8 O-RING 27 SPOOL
9 ROTOR 28 SPRINGS
10 STOP 29 KING RING
11 UNIVERSEL JOINT SHAFT 30 MAIN RELIEF VALVE
12 DISTRIBUTION PLATE 31 SECONDARY RELIEF VALVE
13 O-RING 32 DUST SHIELD
14 STOP ROD 33 BODY
15 SPRINGS 34 PLATE
16 BALL 35 KING RING
17 STOP ROD
18 BALL
19 THREADED BUSHING

8037-7
Disassembly
STEP 1 STEP 6
Place the rotary control valve on a clean bench. Mark Remove parts (26) to (29). Push the spool (27) out of
and remove the hydraulic unions from the rotary con- the sleeve (26). Remove the springs (28).
trol valve.
NOTE: Spool (27) and sleeve (26) have identification
STEP 2 marks close to the slots intended for the springs (28).
If these identification marks are not visible, it will be
Paint identification marks on the sections of the rotary necessary to make a mark on the spool and on the
control valve body to facilitate assembly. Remove sleeve before disassembly.
parts (1) to (4). Remove the cover (5).
STEP 7
NOTE: Note the position of the special screw (3).
Remove parts (30) to (34).
STEP 3
STEP 8
Check all the parts.
STEP 4
If parts are worn or damaged, replace them.
NOTE: Do not use a magnet for taking out part (14).
STEP 5
Remove parts (21) to (25), as an assembly.
NOTE: Shaft (24) must be maintained in a horizontal
position during the removal of the spool/sleeve
assembly.

8037-8
Assembly
NOTE: Lubricate all parts with clean hydraulic fluid. STEP 12
STEP 9
Install parts (30) to (34) and the check valve in port
“P” of the rotary control valve.
STEP 10
29 PDG0022
Install new springs (28) in spool (27). Install the two flat
springs first of all and then insert the two curved springs
between the two flat springs.
CAS 1238-A
STEP 13
Introduce spool (27) into sleeve (26) making sure that
the marks on the spool and the sleeve are aligned.
Install the retaining bushing (25) and the shaft (24).
STEP 14
PDG0021
Install parts (21) to (25) on spool (27) with a slight
Install a Kin ring (29) complete with its new O-ring on rotating movement. Introduce the spool/sleeve
the guide on the end of special tool CAS 1238A. assembly into the rotary control valve body. The
spool/sleeve assembly will push the end guide of
STEP 11 special tool CAS 1238A out of the rotary control
valve.
NOTE: Install the assembly with shaft (24) in a hori-
zontal position at 90° to the rotary control valve
unions. Install the thrust washer (23) with the cham-
fered side towards the retaining bushing (25).
STEP 15
Install parts (14) to (20).
T11027
Introduce the external part of CAS 1238A special tool

into the body of the rotary control valve and then intro-
duce the internal part with the end guide as far as it will
go. Turn the internal part of the tool to position the Kin
ring and the O-ring in the rotary control valve body.
Remove the external and internal parts of the special
tool from the body of the rotary control valve, leaving the
end guide in the rotary control valve body.

8037-9
STEP 16
A
9 11
24
PDG0023
Install parts (7) and (13) so that they are aligned as

shown.
NOTE: Shaft (24) should be at 90° to the unions (A).
STEP 17
Install parts (1) to (6). Tighten screws (1) to a torque
setting between 24 and 36 Nm.
STEP 18
Install the dust shield (32) in the body of the rotary
control valve.

8037-10
1 2 3 4 5 6 7 8
23
10
11
22
12
13
21
14
20
19
15
17 18 16
PDH0389
1 MAIN RELIEF VALVE 16 SCREW

2 SECONDARY RELIEF VALVE 17 ROTOR
3 KIN RING 18 UNIVERSAL JOINT SHAFT
4 DUST SHIELD 19 COVER
5 NEEDLE ROLLER BEARING 20 STATOR
6 SPRINGS 21 DISTRIBUTION PLATE
7 SHAFT 22 MAIN RELIEF VALVE SEAT
8 BALL 23 SECONDARY RELIEF VALVE SEATS
9 BALL
10 SLEEVE
11 SPOOL
12 STOP ROD
13 CHECK VALVE
14 THREADED BUSHING
15 SPECIAL SCREW
Section
8040
HYDRAULIC SWING MOTOR AND SAFETY

AND FORCE-FEEDING BLOCK
8040

Printed in France
8040-2
TABLE OF CONTENTS
SPECIFICATIONS..................................................................................................................................................... 2
SPECIAL TORQUES................................................................................................................................................. 2
TOOLS REQUIRED ................................................................................................................................................. 2
HYDRAULIC SWING MOTOR AND SAFETY AND FORCE-FEEDING BLOCK ..................................................... 3
MEASUREMENT OF SWING MOTOR LEAK-OFF FLOW ON THE MACHINE ....................................................13
SAFETY AND FORCE-FEEDING BLOCK (WX150-WX170) .................................................................................14
SAFETY AND FORCE-FEEDING BLOCK (WX200) ..............................................................................................16
this symbol, carefully read the message that follows, as there is a risk of serious injury.
SPECIFICATIONS
WX150 WX170 WX200
Make and type ......................................................VOLVO F12-40......... VOLVO F12-40 ......... VOLVO F12-60
Capacity...................................................................... 40.0 cc ...................... 40.0 cc ..................... 59.8 cc
Theoretical speed ......................................................1145 rpm .................. 1505 rpm...................1563 rpm
Pinion back-lash .................................................. 0.05 to 0.25 mm ........0.05 to 0.25 mm ....... 0.05 to 0.25 mm
Clearance between bearing and snap ring........... 0.0 to 0.01 mm ..........0.0 to 0.01 mm ......... 0.0 to 0.01 mm
Weight ........................................................................ 17.3 kg ......................17.3 kg ..................... 20.2 kg
Reduction gear housing oil capacity............................. 2.5 L ..........................5.0 L ......................... 5.0 L
Reduction gear housing oil type TRANSELF EP 80W90 API GL5
SPECIAL TORQUES
WX150 WX170 WX200
Upper housing retaining screws ............................. 73 to 87 Nm .............. 73 to 87 Nm ............. 50 to 70 Nm
Motor retaining screws on reduction gear ..................215 Nm..................... 815 Nm ..................... 215 Nm
Drainage port plug .................................................. 27 to 43 Nm .............. 27 to 43 Nm ............. 27 to 43 Nm
Check valve guide ................................................. 90 to 110 Nm
Plug M22x1.5....................................................................................................... .......................90 to 110 Nm
Plug M22x2.......................................................................................................... ..................... 190 to 220 Nm
TOOLS REQUIRED
1 One soft-jawed vice
2 One bronze drift Ø 15 max
3 One torque wrench (10 to 50 Nm)
4 One torque wrench (20 to 100 Nm)
5 One sling (500 to 1000 kg)
6 One set of precision feeler gauges

8040-3
HYDRAULIC SWING MOTOR AND SAFETY AND FORCE-FEEDING BLOCK

- Shut down the engine and allow it to cool down.
- Turn the battery master switch to the "OFF" position and withdraw the key.
- Actuate the emergency pump while simultaneously actuating the control levers to release pressure in the
hydraulic circuits.
- Loosen the pressure release plug on the hydraulic reservoir two or three turns to release pressure in the hydraulic
circuit, then retighten the plug.
WARNING: When the machine is operating, the engine and hydraulic pump reach high temperatures. To
avoid being burnt by hot metal or scalded by high temperature oil or water, allow the machine to cool down
before starting any servicing operation.

STEP 1 STEP 2
1
4
3
1
3
2
CP95G048
Label, remove and plug the hydraulic hoses (1) on 2

the safety and force-feeding block (2) and on the
swing motor (3). Remove the safety and force-feeding
block (2) and discard the O-rings.
1
CS95G046
Label and disconnect the connector (1) from the

electrical harness (2). Remove the speed detector (3)
from the hydraulic swing motor (4).
NOTE: For re-assembly and adjustment, see section
4002.

8040-4
STEP 3
Remove the two retaining screws from the hydraulic
swing motor, then using a suitable sling, remove the
hydraulic swing motor from the machine.
NOTE: When installing, tighten the swing motor
retaining screws to torque.
NOTE: When installing, use the same procedure in
the reverse order.
- Start the engine.
- Check the level of hydraulic fluid in the reservoir
and top up if necessary.

8040-5
10 11
12
13
14
9
15
16
7
17
6
27-43 Nm
18
5
19
4 20
21
3
2
1 J
22
PDG0035A
1 SHAFT 16 CROWN WHEEL
2 BEARING INNER RACE 17 BEARING CUP
3 SEAL CARRIER 18 BEARING CAGE
4 BEARING 19 BEARING
5 LOWER HOUSING 20 BEARING WASHER
6 DRAIN PORT PLUG 21 SHIM
7 PISTON 22 SNAP RING
8 UPPER HOUSING J 0.0 TO 0.1 MM
9 CENTRING STUD
10 DISTRIBUTION PLATE
11 NEEDLE ROLLER BEARING
12 BARREL
13 BARREL SUPPORT ASSEMBLY
14 CYLINDRICAL PIN
15 SHIM (0.2 - 0.4 - 0.6 - 0.8 AND 1 MM)

8040-6
Three-quarter view
1
50 to 70 Nm (WX200)
3 73 to 87 Nm (WX150-170)
8 2
3
23
4
22
24 7
6 20
14
5 19
13
21
18
11
17
12
10 16
15
9
PDG0448
1 SCREW 16 TAPER BEARING
2 UPPER HOUSING 17 CYLINDRICAL BEARING
3 SHIM (0.2 - 0.4 - 0.6 - 0.8 AND 1 MM) 18 CROWN WHEEL
4 BARREL SUPPORT 19 CYLINDRICAL PIN
5 PISTON 20 SHAFT
6 BARREL 21 O-RING
7 NEEDLE ROLLER BEARING 22 LOWER HOUSING
8 DISTRIBUTION PLATE 23 O-RING
9 SNAP RING 24 DRAIN PORT PLUG
10 SEAL CARRIER
11 LIP SEAL
12 O-RING
13 SNAP RING
14 SHIM
15 BEARING WASHER

8040-7
Disassembly
STEP 1 STEP 3
PDG0437 PDG0489
Place the hydraulic travel motor in a soft-jawed vice. Extract the two needle roller bearings (1) and (2) from
Remove the four retaining screws from the upper the barrel, if necessary.
housing.
STEP 4
STEP 2
1
3
1
PDG0497
PDG0438
Mark identification marks (1) on the upper housing

(2) and the lower housing (3). Carefully remove the
housing, lifting it upwards as shown. Remove the
barrel. Remove the adjusting shims (4).
E03519
Remove the barrel support assembly (1). Place the

pistons in a position vertical to the axis and remove
them, pulling them out of their housings.

8040-8
STEP 5 STEP 8
PDG0439 PDG0442
Turn the lower housing the other way up. Remove the Push the shaft using a workshop press or a plastic-
snap ring (1). headed mallet.
STEP 6 STEP 9
PDG0440 PDG0035C
Using two screwdrivers, remove the seal-carrier. Remove and scrap the seals (1) and (2). Using a
Remove the lip-seal from the seal carrier and discard bronze drift, extract the taper bearing cup (3) and the
it. cylindrical bearing (4).
STEP 7 STEP 10
1
4 1
3 5
3
2 2
PDG0441 PDG0491
Remove and discard the O-ring (1), the snap ring (2), Remove the following from the shaft (1): the
the shims (3), then remove the bearing washer (4). cylindrical bearing inner race (2), the taper bearing
(3), the crown wheel (4) and the cylindrical pin (5).

8040-9
STEP 11 STEP 14
PDG00463 PDG0464A
Note the position of the distribution plate in the

housing. Remove the distribution plate by tapping the
housing on a wood block.
Inspection
STEP 12
After removing them from the hydraulic travel motor,
all parts must be carefully cleaned with a degreasing
product.
STEP 13
PDG00465A
Check the friction surface of the barrel and the

distribution plate. If they are scratched or damaged,
change them.
STEP 15
PDG0492
Check the condition and the wear of the piston rings. 1

If they show any scratches or other damage, replace
the pistons.
PDG0495
Check the taper and cylindrical bearings and the

crown wheel. Check that the part (1) of the shaft (2)
in contact with the seal (marked by the lip), is not
damaged. If it is damaged, the shaft must be
replaced.

8040-10
Assembly
STEP 1 STEP 4
2 3
C01317 E03535
Assemble the distribution plate in the upper housing Assemble the shaft assembly (1) in the lower housing
in the position noted at disassembly. (2). Remove the drain port plug (3).
STEP 2 STEP 5
1 2
4
1
5
PDG0491
Assemble the following on the shaft (1): the

cylindrical pin (2), the crown wheel (3), the taper
bearing (4) and the inner race of the cylindrical PDG0035D
bearing (5).
B 3
STEP 3
4 2
5
2
0.0 to 0.1 mm
3
6
1
PDG0490
Assemble the following in the housing (1): the bearing

PDG0035B washer (2) with the rounded end (B) on the bearing
Assemble the following in the lower housing (1): the (3) and the shaft (4). Assemble the shims (5) and the
taper bearing cup (2) and the cylindrical bearing (3). snap ring (6). Measure the clearance (A), it should be
between 0.0 mm and 0.1 mm. Otherwise, remove or
add shims (5) until the clearance is correct.
8040-11
STEP 6
2
PDG0497
PDG0439
Assemble the pistons (1) as shown. Assemble the
barrel support assembly (2). Lubricate the piston
1 3 rings with clean hydraulic oil.
STEP 8
B A 2
4 5 2
PDG0496
Assemble the O-ring (1) in the lower housing (2).

Assemble the lip seal (3) in the seal carrier (4) as
shown. Install the seal carrier (4) in the lower housing
PDG0489
(2) and assemble the snap ring (5).
Assemble the two needle roller bearings (1) in the
STEP 7 barrel as shown.
Position A ....................................10.75 to 11.25 mm
1 Position B (WX150-170)............ 29.75 to 30.25 mm
Position B (WX200) ................... 37.75 to 38.25 mm
E03523

8040-12
STEP 9 STEP 11
1
2 3
1 4
3
2
4
5 5
PDG0444 E03634
Lubricate the bore of each barrel piston (1) with clean Check the pinion back-lash via the drain port (1). It
oil. Present the barrel (1) so that the tooth marked on should be between 0.05 and 0.25 mm. If the back-
it is in alignment with the tooth hollow marked on the lash is not correct, add or remove shims (2) between
shaft (2). Carefully insert the pistons into the barrel the upper housing (3) and the lower housing (4).
(1) and push them down until they are resting on the Reassemble the drain port plug (1) and tighten to
shaft (2) teeth. The marked tooth of the barrel (1) torque. Assemble a new O-ring (5) on the lower
must be facing the marked tooth hollow on the shaft housing (4).
(2) to ensure correct alignment of the pistons in their
NOTE: The shims are available in the following
housing. Then place a new O-ring (3) on the lower
dimensions: 0.2 - 0.4 - 0.6 - 0.8 and 1 mm.
housing (4). Install the adjusting shims (5).
STEP 10
PDG0437
Assemble the upper housing (1) and tighten the four

retaining screws (2) to torque.

8040-13
MEASUREMENT OF SWING MOTOR LEAK-OFF FLOW ON THE MACHINE

Measurement must be performed:
- With the hydraulic oil at 50°C.
- With the engine at full speed.
- With the wheels locked.
- With the swing motor secondary relief valve set to 200 bar.
Disconnect the leak-off return hose and measure the leak-off for one minute. The motor must be changed when the
leaks are in excess of 5.0 litres/min (WX150-170) and 6 litres/min (WX200).

8040-14
SAFETY AND FORCE-FEEDING BLOCK (WX150-WX170)

NOTE: The parts are numbered in order of disassembly, assembly is carried out in the reverse order from
disassembly. Change all O-rings.
1
4
5
7
6 90 - 110 Nm
8 2
3
4
90 - 110 Nm 8
6
7
5
90 - 110 Nm
9 63 - 77 Nm
190 - 210 Nm
12
10 13
14
15
70 - 90 Nm
11 16
17
CS95G047
1 SAFETY BLOCK 10 PLUG
2 O-RING 11 SECONDARY RELIEF VALVE
3 PLUG 12 SEAL
4 FORCE-FEEDING VALVE 13 BACK-UP RING
5 GUIDE 14 SEAL
6 FORCE-FEEDING CHECK VALVE 15 O-RING
7 RETURN SPRING 16 SPRING
8 O-RING 17 SEAL
9 PLUG
NOTE: See section 8001 for checking and adjusting the secondary relief valves (11).
8040-15
A B 1
2
2
G
4
5 A1 B1
3
6
7 L
8
9
10
11
12
13 14
CS95K096
1 SAFETY AND FORCE-FEEDING BLOCK Identification of ports
2 FORCE-FEEDING VALVE
3 SECONDARY RELIEF VALVE A-B PORTS IN CONTACT WITH THE MOTOR SUPPLY
4 PRIMARY CHECK VALVE SEAT FACE
5 SEAL AND SEAL CARRIER A1-B1 HYDRAULIC MOTOR OIL SUPPLY OR RETURN
6 PRIMARY CHECK VALVE L FLOW FROM SECONDARY RELIEF VALVES TO
7 RETURN SPRING RESERVOIR
8 SECONDARY CHECK VALVE G FORCE-FEEDING SUPPLIED BY THE 2P10 BLOCK
9 SECONDARY CHECK VALVE SEAT
10 SEAL
12 ADJUSTING SCREW
13 ADJUSTING NUT
14 PROTECTION

8040-16
SAFETY AND FORCE-FEEDING BLOCK (WX200)

NOTE: The parts are numbered in order of disassembly. Re-assembly is performed in the reverse order from
disassembly. Change all O-rings.
1
4
5
7
6 90 to 110 Nm
8
2
3
4
90 to 110 Nm 8
6
7
5
10
90 to 110 Nm
190 to 210 Nm 9
12
11
13
14
15
70 to 90 Nm
16
17
1 SAFETY BLOCK 10 PLUG

2 O-RING 11 SECONDARY RELIEF VALVE
3 PLUG 12 SEAL
4 FORCE-FEEDING VALVE 13 BACK-UP RING
5 GUIDE 14 SEAL
6 FORCE-FEEDING CHECK VALVE 15 O-RING
7 RETURN SPRING 16 SPRING
8 O-RING 17 SEAL
9 PLUG
NOTE: See section 8001 for checking and adjusting the secondary relief valves (11).

8040-17
A B 1
2 2
G
4
5 A1 B1
3
6
7 L
8
9
10
11
12
13 14
CS95K096
1 SAFETY AND FORCE-FEEDING BLOCK Identification of ports
2 FORCE-FEEDING VALVE
3 SECONDARY RELIEF VALVE A-B PORTS IN CONTACT WITH THE MOTOR SUPPLY
4 PRIMARY CHECK VALVE SEAT FACE
5 SEAL AND SEAL CARRIER A1-B1 HYDRAULIC MOTOR OIL SUPPLY OR RETURN
6 PRIMARY CHECK VALVE L FLOW FROM SECONDARY RELIEF VALVES TO
7 RETURN SPRING RESERVOIR
8 SECONDARY CHECK VALVE G FORCE-FEEDING SUPPLIED BY THE 2P10 BLOCK
9 SECONDARY CHECK VALVE SEAT
10 SEAL
11 PRESSURE ADJUSTING SPRING
12 ADJUSTING SCREW
13 ADJUSTING NUT
14 PROTECTION

8040-18

8041
Section
8041
HYDRAULIC FAN MOTOR

Printed in France
8041-2
TABLE OF CONTENTS
SPECIFICATIONS ....................................................................................................................................................2
TORQUE SETTING .................................................................................................................................................. 2
HYDRAULIC FAN MOTOR ...................................................................................................................................... 3
Adjusting the fan speed detector.......................................................................................................................... 3
EXPLODED VIEW OF THE HYDRAULIC FAN MOTOR ......................................................................................... 4
Description ........................................................................................................................................................... 4
Cross-sectional view of the pressure limiter......................................................................................................... 5
SPECIFICATIONS
Type.......................................................................................................................................... Hydraulic motor 16 cc
Weight ............................................................................................................................................................. 5.08 kg
TORQUE SETTING
Fan retaining screws ....................................................................................................................................... 20 Nm
Detector lock-nut .............................................................................................................................................. 10 Nm
Nut for proportional pressure limiter element ................................................................................................... 12 Nm

8041-3
HYDRAULIC FAN MOTOR
- Stop the engine.
- Loosen the hydraulic reservoir cap 2 or 3 turns to release pressure.
NOTE: For removal and installation of the radiator, Adjusting the fan speed detector
refer to section 2003.
STEP 1
Remove the air deflector.
STEP 2
Remove the fan protective grille. 2
STEP 3
Remove the pulley with the fan blades.
STEP 4
1 CD02H009
Label and disconnect the electrical connectors from
the fan blade speed detector and the proportional STEP 1
pressure limiter.
Put the detector (1) in contact with one of the 6 fan
STEP 5 retaining screws (2).
Label and disconnect the hoses, then plug them. STEP 2
STEP 6 Unscrew the detector one turn and tighten the lock-
nut to torque.
Remove the fan motor.
NOTE: Check that none of the 6 screws is interfering
NOTE: When re-installing, use the same procedure
with the detector.
in the reverse order from disassembly.
- Check the oil level in the hydraulic reservoir. Top up
if necessary.
- Fill the cooling system (see the operator’s manual).
- Bleed the cooling system (see the operator’s manual).
- Start the engine and check the circuits for leaks. Top
up if necessary.

8041-4
EXPLODED VIEW OF THE HYDRAULIC FAN MOTOR
13
15 1 10 11 12 2 9 8 7 3
CS02K504
14
A 4
CS02K506
CS 02K505
Description
1 Front flange 9 Seal
2 Socket head screw 10 Seal
3 Closing cover 11 Seal
4 Nut 12 Seal
5 Proportional pressure limiter element 13 Seal
6 Allen screw 14 Seal
7 Seal 15 Bearing
8 Seal

8041-5
Cross-sectional view of the pressure limiter
T 6
P 1
CS02K557
P MOTOR DRIVE PRESSURE 3 SEAL

T RETURN 4 SEAL
1 PROPORTIONAL PRESSURE LIMITER ELEMENT 5 SEAL
2 SEAL 6 SEAL

8041-6
Disassembling and re-assembling the
hydraulic fan motor
STEP 1
Make identification marks on the motor body, the front
flange and the cover (1), (2), (3).
STEP 2
Install the flange (1) of the hydraulic motor in a soft-
jawed vice.
STEP 3
Loosen the nut (4) and remove the element (5) from
the proportional pressure limiter.
STEP 4
Unscrew and remove the 4 Allen screws (6) from the
motor cover, discard the seals (1 and 7 to 13).
Remove the bearing (15) from the flange (1).
STEP 5
Clean all the parts in a cleaning solvent and dry using
compressed air. Do not use cloths. Check that none
of the parts is worn or damaged.
When re-assembling, use the same procedure in the
reverse order from removal. Replace all seals by new
seals. Tighten the proportional pressure limiter
element nut (4) to a torque of 124 Nm.

Section
8050
ATTACHMENT AND SWING CONTROL BLOCK
8050

Printed in France
8050-2
TABLE OF CONTENTS
SPECIFICATIONS.....................................................................................................................................................2
SPECIAL TORQUES................................................................................................................................................. 2
TOOLS REQUIRED .................................................................................................................................................. 2
HOSE CONNECTIONS............................................................................................................................................. 3
Cross-sectional view of the control block .............................................................................................................. 5
Pressure setting for manual control block spool ...................................................................................................6
SPECIFICATIONS
HAND CONTROL BLOCK
Weight ................................................................................................................................................................. 3 kg
Theoretical output pressure depending on tilting angle of lever
from 0° to 1°3-3°5................................................................................................................................. 6.2 to 7 bar
from 0° to 16°-19°5........................................................................................................................18.4 to 21.6 bar
from 0° to 19°3-21°1............................................................................................................................ 28 to 34 bar
Push-rod stroke ............................................................................................................................................ 7.55 mm
Maximum permissible torque on the control lever ........................................................................................... 80 Nm
SPECIAL TORQUES
Control block retaining screw........................................................................................................................... 30 Nm
Control block universal joint............................................................................................................................. 30 Nm
Control block lever ........................................................................................................................................... 25 Nm
TOOLS REQUIRED
2 Loctite 271

8050-3
HOSE CONNECTIONS
1 4
2 3
PDH0192
P Supply
T Return to tank
Right-hand control block (boom and bucket) Left-hand control block (dipper and swing)
1 CLOSING THE BUCKET OR THE CLAMSHELL 1 UPPERSTRUCTURE SWING
2 LOWERING THE BOOM 2 RETRACTING THE DIPPER
3 OPENING THE BUCKET OR THE CLAMSHELL 3 UPPERSTRUCTURE SWING
4 RAISING THE BOOM 4 EXTENDING THE DIPPER

8050-4

NOTE: The parts marked with an asterisk must be systematically replaced. Components are numbered in order of
disassembly. For assembly, follow the same order in reverse.
.
4 7 11
15
30 Nm
12 16*
17*
8
13
18
6 3
14
5 19
2
20
1 33 21
10 * 32 22
25 Nm *31
23
30
24
9 *29
25
28
26
Use Loctite 271
27
CI97E026
1 PIN 10 CONTROL LEVER 19 ADJUSTMENT SHIM 27 SPOOL

2 SCREW 11 CAM 20 SPRING 28 SCREW
3 HARNESS 12 UNIVERSAL JOINT 21 STOP 29 O-RING
4 SWITCH 13 RETAINING PLATE 22 HALF CUP 30 LOWER BODY
5 GROMMET 14 SPACER 23 CUP 31 O-RING
6 SEAL 15 PUSH ROD GUIDE 24 RETURN SPRING 32 O-RING
7 TRIM 16 O-RING 25 PRE-SET SPRING 33 UPPER BODY
8 HANDLE 17 O-RING 26 SHIMS
9 BELLOWS 18 PUSH ROD

8050-5
Cross-sectional view of the control block
5
7
8
15
9
11 10
13
12
16
14
CS97J008
1 CONTROL LEVER 9 HALF CUP

2 UNIVERSAL JOINT 10 CUP
3 CAM 11 PRE-SET SPRING
4 PUSH ROD 12 RETURN SPRING
5 RETAINING PLATE 13 SHIM
6 SPRING 14 SCREW
7 STOP 15 ADJUSTMENT SHIM
8 PUSH ROD GUIDE 16 SPOOL

8050-6
Pressure setting for manual control block spool

Minimum pressure setting

The number of shims (1) determines the minimum U

pilot pressure P1 from the moment a connection with
P is made. The pressure should be lower than the

pilot pressure required for the starting supply of the
receptor.

The "Rated" setting (6.2 to 7 bar) is obtained with
shimming of 0.8 mm. However, if after testing, it is

found that the starting supply of the receiver is too
fast or too slow, the shimming must be increased or

reduced as much as required to obtain a normal
starting supply.
Maximum pressure setting

The number of shims (2) determines the maximum
pilot pressure P2 at U (with the spool up against the

stop). Pressure P2 is between 28 and 34 bar. The
"Rated" setting is obtained with a shimming of

0.5 mm. By increasing or reducing the shimming one

can obtain higher or lower pressure.
NOTE: The shimming values given above (0.8 mm in

(1) and 0.5 mm in (2)) allow one to obtain a "Rated"
setting on about 90% of the spools.

Pressure (bar)
P2
18.4-21.6
P1
0°-1°3-3°5 16°-19°5
19°3-21°1
Lever angle
CS96M021

8051
Section
8051
OPTION CONTROL BLOCK

Printed in France
8051-2
TABLE OF CONTENTS
SPECIFICATIONS.....................................................................................................................................................2
TOOLS REQUIRED .................................................................................................................................................. 2
OPTION CONTROL BLOCK ..................................................................................................................................... 3
Connecting the hoses ........................................................................................................................................... 3
Cross-sectional view of the control block .............................................................................................................. 5
Setting the option control block pressure .............................................................................................................. 6
SPECIFICATIONS
Weight ............................................................................................................................................................... 3.5 kg
Theoretical outlet pressure depending on tilt of pedal
from 0° to 1°-3°......................................................................................................................................7.2 to 8 bar
from 0° to 9°-11°...................................................................................................................................22 to 26 bar
from 0° to 11°-12°..........................................................................................................................................35 bar
Thruster stroke...................................................................................................................................................... 0 to 5.8 mm
TOOLS REQUIRED
1 Torque spanner (40 to 200 Nm)

8051-3
OPTION CONTROL BLOCK

Connecting the hoses
1 2
PDH0193
Option control block

P ARRIVAL OF SERVO CIRCUIT PRESSURE
T RESERVOIR RETURN
1 OPTION PILOTING
2 OPTION PILOTING

8051-4

NOTE: Components are numbered in order of disassembly. For assembly, follow the same order in reverse. The
parts marked with an asterisk must be systematically replaced.
1 PIN 4
1 LINKAGE PIN
2 RING
3 PEDAL 3
4 ADJUSTMENT SCREW
5 PROTECTION
6 SCREW 1
7 RETAINING PLATE
8 WASHER
9 THRUSTER GUIDE 5
10 O-RING 2
11 O-RING
12 PUSH ROD
13 HALF CUP 7
14 CUP
15 RETURN SPRING 6
16 PRE-SET SPRING
17 SHIMS
18 SPOOL
19 BODY
10
*11
*12 14
13 15
16
17
18
19
20
PDH0194

8051-5
Cross-sectional view of the control block
1 2 3
5
6
7
9
8
10
PDH0195
1 PEDAL 6 HALF CUP

2 RETAINING SCREW 7 SPRING GUIDE
3 ADJUSTMENT SCREW 8 SPOOL
4 THRUSTER GUIDE 9 PRE-SET SPRING
5 PUSH ROD 10 ADJUSTMENT SHIM

8051-6
Setting the option control block pressure


The number of shims (1) determines the minimum U

pilot pressure P1 from the moment a connection with
P is made. The P1 pressure should be lower than the

pilot pressure required for starting the supply to the
receptor.

Adjustment in made by adding or subtracting adjust-
ment shims (1).

1

P
Minimum pressure P1 = 7.2 to 8 bar

Maximum pressure P2 (spool against the stop) =
Servo circuit pressure 35 bar

Pressure (bar)
U
P2
22-26
P1
1°-3° 9°-11° 11°-12°

Pedal angle
PDH0196

Section
8053
8053
DIRECTION OF TRAVEL INVERTER CONTROL BLOCK

Printed in France
8053-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................................... 2
TOOLS REQUIRED.................................................................................................................................................. 2
HOSE CONNECTIONS............................................................................................................................................ 2
FORWARD/REVERSE TRAVEL CONTROL BLOCK
Disassembly and Assembly ................................................................................................................................. 3
Cross-sectional drawing of the control block........................................................................................................ 4
Pressure setting the forward/reverse travel control block .................................................................................... 5
SPECIFICATIONS
Weight ................................................................................................................................................................. 3 kg
Theoretical output pressure depending on tilting angle of lever
from 0° to 2°-4°...............................................................................................................................................8 bar
from 0° to 20° ...............................................................................................................................................24 bar
from 0° to 25° ...............................................................................................................................................24 bar
Lever movement friction torque.............................................................................................................................. 9 to 11 Nm
Push rod stroke............................................................................................................................................................ 7.5 mm
TOOLS REQUIRED
1 Torque Wrench (47 to 200 Nm)
HOSE CONNECTIONS
P SUPPLY FROM TRAVEL CONTROL PEDAL

T RETURN TO RESERVOIR
A PILOT CIRCUIT TO REVERSE TRAVEL CONTROL VALVE
B PILOT CIRCUIT TO FORWARD TRAVEL CONTROL
VALVE
C TRAVEL PILOT CIRCUIT PRESSURE SWITCH HOUSING
P
C
A B
PDH0201

8053-3

NOTE : Components are numbered in order of disassembly. For assembly, follow the same order in reverse. Com-
ponents marked with an asterisk must be systematically replaced.
During assembly, tighten the harness control screw (9) until a certain resistance is felt when operating the lever
(12). (Lever movement friction torque 9 to 11 Nm).
18
19
12
*
20
11
21
*
1
22
13
23
2
4 24
3
6 25
5
14 26
10 10 27
9
15
16 29 28
7
8
30
17
PDH0202
1 BOOT 10 BELLEVILLE WASHER 19 PUSH ROD GUIDE 29 SPOOL

2 SCREW 11 SPLIT PIN 20 O-RING 30 BLOCK HOUSING
3 BALL 12 LEVER 21 O-RING
4 SPRING 13 INDEXING BLOCK 22 PUSH ROD
5 SCREW 14 SCREW 23 HALF-CUP
6 NOTCHED CAM 15 LEVER ADJUSTING 24 CUP
7 SPLIT PIN SCREW 25 RETURN SPRING
8 CAM 16 SCREW 26 PRE-SET SPRING
9 STIFFNESS ADJUSTMENT 17 SPACER 27 ADJUSTING SHIMS
ASSEMBLY 18 MOUNTING PLATE 28 SPOOL
Cre 7-80290GB Issued 11-99.

8053-4
Cross-sectional drawing of the forward/reverse travel control block
3 5
16 8
9
15
10
14
11
13 12
PDH0203
1 CONTROL LEVER 10 REGULATOR SPRING

2 INDEXING BLOCK 11 SPOOL
3 NOTCHED CAM 12 BLOCK HOUSING
4 CAM 13 PRESSURE SELECTOR
5 LEVER STIFFNESS ADJUSTING SCREW 14 ADJUSTING SHIMS
6 SPACER 15 HALF-CUPS
7 PUSH ROD GUIDE 16 PUSH ROD
8 CUPS
9 RETURN SPRING

8053-5
Pressure setting the forward/reverse travel control block


The number of shims (1) determines the minimum P1

pilot pressure at U as soon as contact is established
with P. The P1 pressure must be lower than the pilot

pressure which is necessary for supply oil to begin to
move under pressure towards the hydraulic compo-

nent in question.
Adjustment is obtained by adding or removing adjust-

ment shims (1).

P1 Minimum Pressure = 8 bar
P2 Maximum Pressure (spool up against the stop)

= 24 bar

1

Pressure
P2
24 bar
P1
25°
2°-4° 20°
Tilting angle of lever
PDH0204

Section
8054
8054
TRAVEL CONTROL BLOCK

Printed in France
8054-2
TABLE OF CONTENTS
SPECIFICATIONS .................................................................................................................................................. 2
HOSE CONNECTIONS .......................................................................................................................................... 2
TRAVEL CONTROL BLOCK .................................................................................................................................. 3
Cross-sectional view of the travel control ............................................................................................................ 4
SPECIFICATIONS
Type........................................................................................................................................... Bloc RP5 8-27MPM2
Weight .........................................................................................................................................................................1.350 kg
Minimum pressure ........................................................................................................................................................... 8 bar
Maximum pressure........................................................................................................................................................ 27 bar
Spool stroke .................................................................................................................................................................. 15 mm
HOSE CONNECTIONS
A HAND CONTROL BLOCK SUPPLY

P SERVO-CIRCUIT PRESSURE INLET, COMING FROM
MANIFOLD
T RETURN TO RESERVOIR VIA MANIFOLD
T P
CS95N002

8054-3
TRAVEL CONTROL BLOCK

NOTE: Components are numbered in order of disassembly. For assembly, follow the same order in reverse. Com-
ponents marked with an asterisk must be systematically replaced.
The cartridge assembly item (3) has its pressure pre-set and must in no circumstances be disassembled. For any
adjustments, it is essential to use a test bench.
2
*
3 30 Nm
10
11
12
*
14 13
6 8
7
5
CS97H012
1 BOOT 10 SNAP RING
2 SCRAPER RING 11 BRASS WASHER
3 CARTRIDGE ASSEMBLY 12 LIP SEAL
4 WAHSER 13 CONNECTOR
5 CONNECTOR 14 BLOCK
6 SNAP RING
7 WASHER
8 SPRING
9 SPOOL

8054-4
Cross-sectional view of the travel control
19 1
18 2
17 5
4 30 Nm
16
6
15
7
14
8
13 9
10
12
11
CM97H003
1 LOCK-NUT 10 RETURN SPRING
2 PUSH ROD 11 SNAP RING
3 SPRING GUIDE RETAINING SCREW (DO NOT DISTURB) 12 WASHER
4 BUSHING 13 BLOCK
5 BOOT 14 WASHER
6 SNAP RING 15 SPRING GUIDE
7 BRASS WASHER 16 PUSH ROD RETURN SPRING
8 LIP SEAL 17 REGULATOR SPRING
9 SPOOL 18 SCRAPER RING
19 ADJUSTMENT SCREW (DO NOT DISTURB)

Section
8060
8060
BRAKE UNIT

Printed in France
8060-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................................... 2
SPECIAL TORQUES................................................................................................................................................ 2
TOOLS REQUIRED ................................................................................................................................................. 2
DESCRIPTION ......................................................................................................................................................... 3
Identification of ports ............................................................................................................................................ 3
Features of the various pressure switches........................................................................................................... 3
BRAKE UNIT ............................................................................................................................................................ 4
WARNING: This symbol is used in this manual to indicate important safety messages. When ever you see
SPECIFICATIONS
Brake unit
Type.............................................................................................................................................................. 2CB24
Engagement - disengagement
Engagement pressure ......................................................................................................................125 to 140 bar
Disengagement pressure .................................................................................................................150 to 165 bar
Service brake maximum pressure........................................................................................................45 to 60 bar
Parking brake maximum pressure....................................................................................................125 to 165 bar
Pressure switch
Brake circuit minimum pressure ..................................................................................................................105 bar
Steering circuit minimum pressure ..................................................................................................................5 bar
Brake light .......................................................................................................................................................5 bar
Parking brake pressure ...............................................................................................................................105 bar
Brake unit engagement and disengagement pressure................................................................ See section 8001
Parking brake pressure ............................................................................................................... See section 8001
SPECIAL TORQUES
Pressure switch ................................................................................................................................................ 20 Nm
Shut-off valve........................................................................................................................................... 18 to 22 Nm
Flow divider plugs............................................................................................................................................. 20 Nm
TOOLS REQUIRED
1 Torque wrench CAS-10033
2 Loctite 270

8060-3
DESCRIPTION
R
S
P
A2 A1
F1 F2 A3
P1
P2
P3
CS00A502
P
S
INLET FROM GEAR PUMP
OUTLET TO STEERING BOX
Features of the various pressure
switches
NOTE: Legislation in certain countries requires a
separate supply to the braking and steering circuits. P1 It closes at a pressure lower than 105 bar and
In this case, the supply to the steering circuit is the service brake warning lamp on the
provided independently from another gear pump and instrument panel comes on.
the return line S from the brake unit returns to the P2 It closes at a pressure higher than 5 bar, when
reservoir via the P10. the service brake is operated, to light up the
R RETURN TO TANK brake lights.
A1 TO THE FIRST SERVICE BRAKE CIRCUIT REAR AXLE P3 It closes at a pressure lower than 5 bar and the
ACCUMULATOR steering warning lamp on the instrument panel
A2 TO THE SECOND FRONT AXLE SERVICE BRAKE CIRCUIT comes on.
ACCUMULATOR
A3 TO THE PARKING BRAKE ELECTRO-CONTROL VALVE
F1 TO THE REAR AXLE SERVICE BRAKE CIRCUIT
F2 TO THE FRONT AXLE SERVICE BRAKE CIRCUIT
P1 SERVICE BRAKE MINIMUM PRESSURE SWITCH
CONNECTION
P2 BRAKE LIGHT PRESSURE SWITCH CONNECTION
P3 STEERING MINIMUM PRESSURE SWITCH CONNECTION

8060-4
BRAKE UNIT
NOTE: Before performing any service work on the machine, the following steps must be carried out in the order
shown:
- Stop the engine.
- Turn the battery master switch key to the "OFF" position and remove the key.
- Remove the lower access panel located under the engine to gain access to the hydraulic oil reservoir shut-off
valve. Remove the locking pin and lower the shut-off valve handle to close the shut-off valve.
hydraulic systems.
WARNING: When the machine is operating, the components attain high temperatures. To avoid being
! burnt by high temperature oil, allow the machine to cool down completely before starting work.

STEP 1 STEP 6
Open the windscreen. Remove the lower front glass
by pulling on the two catches located on the side. 1
STEP 2
1
Lift up the floor mat to gain access to the pedal
supports.
STEP 3
Remove the floor screws and washers which retain
the pedal support. 1
STEP 4
For better visibility, remove the carpet from the pedal CS96M003
support. Label and disconnect the hoses (1) at the brake module
end and plug them.
STEP 5
STEP 7
1
1
CD96A001
Tilt the bracket towards the rear. Keep it in this raised CS96M004
position using a wooden block (1). Label and disconnect the electrical connectors (1). See
Section 4001.

8060-5
STEP 8
CS96M005
Remove the three retaining screws (1) from the brake

module and place it on a clean bench.
to that of removal.
- Start the engine.
- Check the hydraulic oil level in the reservoir. Top up
if necessary.
- Carry out the adjustments, refer to Section 8001.
NOTE: It is essential that braking tests are carried out
in an area with no obstacles.

8060-6

The parts marked with an asterisk must be systematically replaced.
The box assembly, item (41), is pre-set and must under no circumstances be disassembled. It is essential that a test
bench is used for any new adjustment.
1
42
43
35 60 Nm
41 * *
44 36* 32 30 Nm
37 *
33
38
34
39
40 30 Nm
45
46 *
* * 25
47 * 26
2 27
24
28 *
* 29 46
* 30
31 *47
*
4
*
48
47 20
47 23 3
46 40 Nm
22 *
9*
21 30 Nm
8
19
7 14 *
18 *
6 13
5 17 60 Nm
12
20 Nm 16 *
11
15 40 Nm
10
40 Nm
CI97G114

8060-7
1 BRAKE UNIT 29 O-RING
2 NON-RETURN VALVE 30 O-RING
3 STEERING MINIMUM PRESSURE SWITCH 31 O-RING
4 WASHER/SEAL 32 PLUG
5 PLUG 33 O-RING
6 SPACER 34 SPOOL
7 SPRING 35 PLUG
8 SPOOL 36 O-RING
9 O-RING 37 GUIDE
10 BRAKE LIGHT PRESSURE SWITCH 38 SPRING
11 SPACER 39 SPRING
12 SPRING 40 GUIDE
13 SPOOL 41 CONTROL
14 SEAL 42 NUT
15 SERVICE BRAKE MINIMUM PRESSURE SWITCH 43 BOOT
16 SEAL 44 SEAL
17 PLUG 45 BRAKE MODULE BODY
18 SEAL 46 UNION
19 SPOOL 47 O-RING
20 NON-RETURN VALVE
21 PLUG
22 O-RING
23 SPRING
24 BLOCKING VALVE
25 O-RING
26 O-RING
27 O-RING
28 BLOCKING VALVE

8060-8
Cross-sectional drawing Blocking valve

Service brake control CROSS-SECTION A-A

CROSS-SECTION B-B
B

9
10

11

12

13 15

16 14 B
CS96M008

4

8

1 C
3

7

6
2 A
5 A

CS96M007
1 SERVICE BRAKE CONTROL SPOOLS
2
3
PLUG
SPRING
4 O-RING
5 BRAKE LIGHT PRESSURE SWITCH C
6 SPACER
7 SPRING
8 O-RING
9 CONTROL BLOCK CS96M009
10 NUT
11 SEAL
12 BOOT
13 BLOCKING VALVE ASSEMBLY
14 O-RING
15 O-RING
16 BRAKE MODULE BODY

8060-9
Engagement/disengagement/Flow divider
CROSS-SECTION C-C
1 PLUG
2 GUIDE
3 SPRING
4 O-RING
5 SPRING
6 GUIDE
7 SPOOL
8 NON-RETURN VALVE
9 SEAL
10 PLUG
1 11 SEAL
12 SERVICE BRAKE MINIMUM PRESSURE SWITCH
13 O-RING
2 13 14 PLUG

15 SPOOL
16 SPRING

14 17 PLUG
3 18 O-RING

15
4

5

16
6

17
7
8
18
11
9

10 12
CS96M010

8060-10

8061
Section
8061
PARKING BRAKE ELECTRO-CONTROL VALVE

Printed in France
8061-2
TABLE OF CONTENTS
SPECIFICATIONS................................................................................................................................................... 2
SPECIAL TORQUES............................................................................................................................................... 2
TOOLS REQUIRED ............................................................................................................................................... 2
DESCRIPTION ....................................................................................................................................................... 3
Identification of ports ........................................................................................................................................... 3
PARKING BRAKE ELECTRO-CONTROL VALVE ................................................................................................. 4
symbol, read the following message carefully. Your safety depends on it.
SPECIFICATIONS
Type .............................................................................................................................................. 3V 2P IZE FR P
Parking brake pressure ....................................................................................................................125 to 140 bar
PRESSURE SWITCH
Parking brake pressure ............................................................................................................... See section 8001
SPECIAL TORQUES
Pressure switch ................................................................................................................................................ 20 Nm
Solenoid valve .................................................................................................................................................. 25 Nm
Non-return check valve..................................................................................................................................... 60 Nm
TOOLS REQUIRED
1 Torque wrench CAS-10033

8061-3
DESCRIPTION
3 4
2
DS
1
PP
CS02J540
1 INLET FROM GEAR PUMP PRESSURE SWITCH
2 OUTLET TO PARKING BRAKE
3 RETURN TO RESERVOIR VIA THE SERVO MANIFOLD Specifications: It closes at a pressure less than
4 PARKING BRAKE RELEASE SAFETY PILOT SYSTEM 105 bar and the parking brake warning light comes
WHEN TRAVELLING on in the instrument panel.
5 PARKING BRAKE SOLENOID VALVE
DS PARKING BRAKE SOLENOID VALVE PRESSURE
SWITCH CONNECTION
PP PRESSURE TEST POINT M8

8061-4

- Stop the engine.
- Remove the lower access panel located on the engine to gain access to the hydraulic oil reservoir valve. Remove
the pin and lower the valve handle to shut it.
- Operate the emergency pump while simultaneously operating the control levers to release pressure in the
hydraulic circuits.
WARNING: The components reach high temperatures when the machine is working. To avoid being
scalded by high temperature oil, allow the machine to cool down completely before starting any work.

STEP 1 STEP 3
3
1 2
1
2
1
CS02J515 CS96M015
Label and disconnect the pipes (1) and hoses (2), then Remove the retaining screws (1), washers (2) and nuts
plug them. (3) from the selector block and place it on a clean
bench.
STEP 2
to that of removal.
NOTE: Before using the machine, all the following
operations must be carried out in the order shown:
- Start the engine.
- Check the level of hydraulic oil in the reservoir and
- Carry out the adjustments, refer to section 8001.
1
CS96M014
Label and disconnect the electrical connectors (1). See

section 4001.

8061-5
6
20 Nm
4
PP
DS
1
4
60 Nm
2
25 Nm
CS96M016
1 ELECTRO-CONTROL VALVE BLOCK
2 PARKING BRAKE SOLENOID VALVE
3 NON-RETURN CHECK VALVE
4 PARKING BRAKE PRESSURE SWITCH
5 O-RING
6 PRESSURE TEST POINT M8
7 O-RING

8061-6

8071
Section
8071
SOLENOID VALVE BLOCK

Printed in France
8071-2
TABLE OF CONTENTS
SOLENOID VALVE BLOCK ...................................................................................................................................... 3
PRESSURE LIMITER (P35)...................................................................................................................................... 6
Cross-sectional drawing ........................................................................................................................................ 7

8071-3
SOLENOID VALVE BLOCK

1 1 9
9
P F P F
T T
2 2
8 7 6 4 3 8 7 6 5 4 3
MF
Y27 Y11 Y27 Y11
B3 B2 B1 B3 B2 B1
B6 B5 B4 B7 B6 B5 B4
A6 A5 A4 A3 A2 A1 T
A5 A4 A3 A2 A1
Y13 Y26 Y14 Y5 Y2 Y13 Y26 Y14 Y16 Y5 Y2
MP
WX150 - WX170 WX200

CS02J559
Identification of ports B5 WX200 - Supply to the two-speed gearbox

cylinder small chamber
P Inlet from pilot system pump
WX150, WX170 - Pilots the stabilizer/dozer
F Return to reservoir
blade control valve to supply the stabilizer and
T Limiter return P35 (35 bar)
dozer blade cylinder large chambers
A1 Plugged
A6 WX200 - Pilots the stabilizer/dozer blade control
B1 Supply to the pilot circuits manifold
valve to supply the stabilizer and dozer blade
A2 Pressure test point M7 to check swing brake
cylinder small chambers
release pressure
B6 WX200 - Pilots the stabilizer/dozer blade control
B2 Swing brake release circuit
valve to supply the stabilizer and dozer blade
A3 Plugged (FR) (travel control pedal supply) (IT)
cylinder large chambers
B3 WX200 - Plugged
WX150, WX170 - Axle locking-unlocking
WX150, WX170 - Working brake and option
B7 WX200 - Axle locking-unlocking
leak return
MP Plugged
A4 WX200 - Plugged
MF Return
WX150, WX170 - Supply to the two-speed
gearbox cylinder small chamber Description
B4 WX200 - Working brake supply 1 BASE
WX150, WX170 - Supply to the two-speed 2 CONTROL ARM RAISING SAFETY SOLENOID VALVE (Y2)
gearbox cylinder large chamber 3 AUTOMATIC SWING BRAKING AND BRAKE RELEASE
SOLENOID VALVE (Y5)
A5 WX200 - Supply to the two-speed gearbox 4 PRESSURE LIMITER (P35)
cylinder large chamber 5 WORKING BRAKE SOLENOID VALVE (Y16)
WX150, WX170 - Pilots the stabilizer/dozer 6 TRAVEL SPEED CHANGE SOLENOID VALVE, (Y11) JOB
blade control valve to supply the stabilizer and SITE SPEED, (Y14) ROAD SPEED
dozer blade cylinder small chambers 7 STABILIZER AND DOZER BLADE RAISING (Y26) AND
LOWERING (Y27) SOLENOID VALVE
8 AXLE LOCKING AND UNLOCKING SOLENOID VALVE (Y13)
9 PRESSURE TEST POINT M7

8071-4

NOTE: The parts are numbered in order of disassembly. When assembling, follow the procedure in the reverse
order. Parts marked with an asterisk must be changed.
35
36 32
33 31
* 34
37
30 27 28
38
25
* 29 23
* 26 22
*24 21
20 *
17 *
14 12 *
18
19
9 *
11
15
16 8
6 *
13 5
10 3*
7
2
4
1
CI00C500

8071-5
1 SCREW
2 AXLE LOCKING-UNLOCKING SOLENOID VALVE
3 O-RING
4 SCREW
5 STABILIZER SOLENOID VALVE
6 O-RING
7 SCREW
8 TRAVEL SPEED CHANGE SOLENOID VALVE
9 O-RING
10 SCREW (WX200 ONLY)
11 WORKING BRAKE (WX200 ONLY)
12 O-RING (WX200 ONLY)
13 SCREW
14 P35 PRESSURE LIMITER
15 SCREW
16 SWING BRAKE SOLENOID VALVE
17 O-RING
18 SCREW
19 CONTROL ARM SAFETY SOLENOID VALVE
20 SEAL
21 SCREW
22 PLUG
23 BASE
24 O-RING
25 BASE
26 O-RING (WX200 ONLY)
27 BASE (WX200 ONLY)
28 PLUG
29 O-RING
30 BASE
31 PRESSURE TEST POINT
32 PLUG
33 PLUG
34 O-RING
35 SPRING CUP
36 SPRING
37 SPRING CUP
38 SPOOL
On some models, bases 23 and 25 are in one piece. The same applies to bases 27 and 30.

8071-6
PRESSURE LIMITER (P35)

NOTE: The parts are numbered in order of disassembly. When assembling, follow the procedure in the reverse
order. Parts marked with an asterisk must be changed.
h
$$$
2
6 kjkll
l$
5 * $$ioiu
1 *
7
9* 8
CS96A070
1 O-RING 7 BODY
2 CAP 8 PLUG
3 SPRING 9 SEAL
4 GUIDE
5 SEAL
6 SPOOL

8071-7
2
5 4 3
6 F P
1
CM97K004
1 BODY Identification of ports
2 SPOOL
3 SEAL T Return to attachment control valve
4 PRE-SET SPRING F Leak-off return to reservoir
5 ADJUSTMENT SHIMS P 35 bar supply
6 CAP

8071-8

8072
Section
8072
FLOW CANCELLATION OVER-PRESSURE

SELECTOR BLOCK

Printed in France
8072-2
TABLE OF CONTENTS
SPECIFICATIONS .................................................................................................................................................... 2
TORQUE SETTING .................................................................................................................................................. 2
SELECTOR BLOCK ................................................................................................................................................. 3
Identification ......................................................................................................................................................... 3
Description ........................................................................................................................................................... 3
Removal and installation of the selector .............................................................................................................. 4
SPECIFICATIONS
Selector block
Type .......................................................................................................................................... IZE 3U 2P LS 2AD
TORQUE SETTING
+5
Plug .............................................................................................................................................................20 Nm
+0
+5
Cartridge......................................................................................................................................................25 Nm
+0

8072-3
SELECTOR BLOCK
3
T 1
A
CS99H523
Identification Description
P Pressure P3 1. SELECTOR BLOCK
2. CARTRIDGE
A Outlet going to the flow cancellation valve 3. COIL
4. PLUG (LOCKING SCREW)
T Leak return

8072-4
Removal and installation of the selector

- Unscrew the hydraulic reservoir cap 3 turns.
STEP 1 NOTE: Before using the machine, all the following

operations must be carried out in the order shown:
B A
- Close the hydraulic reservoir cap.
- Start the engine.
- Check the level of hydraulic fluid in the reservoir
and top up if necessary.
E F
D
C
CD99J004
Attach identification labels, then disconnect and plug

the selector block hydraulic hoses (A, B, C).
STEP 2
Disconnect the connector (D).
STEP 3
Remove the retaining screws (E), the washers (F)
and the nuts from the selector block.
to that of removal.

8073
Section
8073
ELECTRO HYDRAULIC PROPORTIONAL VALVE

(DRE4)

Printed in France
8073-2
TABLE OF CONTENTS
SPECIFICATIONS ....................................................................................................................................................2
Identification of ports ................................................................................................................................................. 3
Operating principles................................................................................................................................................... 3
Removal and installation ........................................................................................................................................... 4
SPECIFICATIONS
Type........................................................................................................................................................... REXROTH
Weight ............................................................................................................................................................... 0.6 kg
Rated voltage ...................................................................................................................................................... 24 V
Control current.............................................................................................................................................max 1.0 A
Coil resistance at 20°C .................................................................................................................................. 12 ohms
Coil resistance at 80°C ............................................................................................................................. 18.42 ohms

8073-3
A Torque regulation spool pilot pressure

L
P Inlet pressure
L Return
A L
CS02J558
Operating principles
Pressure stage 30 bar The proportional pressure valve reduces the

pressure at port A in proportion to the current at the
solenoid. It functions independently from the
pressure at port P.
The hydraulic pressure at port A is applied on a spool
against the force of the solenoid. When the
Pressure setting P in A in bar
proportional solenoid is not excited, a return spring

placed on the spool makes the connection between A
and L.
Instruction in % (100 % = 1.0 A)

CS02K511

8073-4

- Stop the engine.
- Operate the emergency pump and the control levers simultaneously to release pressure in the hydraulic circuits.
- Loosen the hydraulic reservoir pressure release plug two or three turns to release the pressure.
STEP 1
Open the engine hood and remove the side panel.
STEP 2
CD02J006
Attach identification labels to all the solenoid valve block
hoses. Cap or plug all the hoses. Disconnect the
electrical connection from the electro-control valve bock.
STEP 3
Remove the 2 retaining screws and remove the
electro-control valve block.
NOTE: When installing, use the same procedure in
the reverse order.
- Start the engine.

Section
8080
ATTACHMENT CYLINDERS
Wheeled excavators
8080

Printed in France
8080-2
TABLE OF CONTENTS
SPECIFICATIONS.....................................................................................................................................................4
SPECIAL TORQUES................................................................................................................................................. 6
CYLINDER IDENTIFICATION................................................................................................................................... 7
TOOLS REQUIRED .................................................................................................................................................. 7
CYLINDER H8546761 / L8846799 / Q9046742 / B8546755 / A8546754 ................................................................. 8

CYLINDER F8746790 ............................................................................................................................................... 9

CYLINDER T7346723 ............................................................................................................................................. 10

CYLINDER E8746789 / F8746790 * ....................................................................................................................... 11

CYLINDER E8846701 / M8746796 / R9046743 / S9046744 / F8846702 / X8746783 / Q8746799........................ 12

CYLINDER U8746780 / P8746798 ......................................................................................................................... 13

CYLINDER S8846736 / Z8846788.......................................................................................................................... 14

CYLINDER V8846739 *........................................................................................................................................... 15

CYLINDER S8846759 / R8846758 ......................................................................................................................... 16

CYLINDER J546787................................................................................................................................................ 17
CYLINDER D46785................................................................................................................................................. 18
CYLINDER Q546701............................................................................................................................................... 19
CYLINDER E46786 ................................................................................................................................................. 20

CYLINDER C8846768............................................................................................................................................. 21
CYLINDER D8846769............................................................................................................................................. 22
CYLINDER E8846770 D (SCRAP IRON), F8846771 * (STONE) ........................................................................... 23


8080-3
CYLINDER U3446706 / U546774 ........................................................................................................................... 24
Disassembly and assembly.................................................................................................................................24
SPECIAL INSTRUCTIONS ..................................................................................................................................... 25

Removing and installing a cylinder piston ........................................................................................................... 25
Preventing the rotation of screw-in type cylinder gland....................................................................................... 28
Removing and installing the wiper ring ............................................................................................................... 28
Assembling the dash-pot..................................................................................................................................... 29
Replacing bushings .............................................................................................................................................29
Checking cylinder rod deflection ......................................................................................................................... 30

8080-4
SPECIFICATIONS
LS-LR

E
ØD2 ØD1 ØA ØB F
C
PDH0289
Disassembly Reassembly
Allowable deflection (F)
top/bottom machining
Bushing position (E)
Centre distance (LR)
Centre distance (LS)
Usable stroke (C)
Tube inner Ø (B)
bushing bore
rod extended
rod retracted
Part number
Description
Weight (kg)
Ø Max (D1)
Ø Max (D2)
Rod Ø (A)
See page
Machine
Type
Boom
cylinder
WX150 Q9046742 105/70
C850
100 850 0.40 105 70 2140 1290 10 + 0.7
+ 0.3
70 + 0.155 85 +0.045
+ 0.055 0
8
Boom 110/80
10 + 0.7 70 + 0.155 85 +0.045
cylinder
WX170 L8846799 C1030
132 1030 0.50 110 80 2515 1485
+ 0.3 + 0.055 0
8
Boom 115/80
WX200 E8746789 C1100 155 1100 0.63 115 80 2715 1615 10 +- 0.3
0.7
70 ++ 0.155 85 +0.054 11
cylinder 0.055 0
Adjustable
WX150 100/55 10 + 0.7 60 + 0.155 75 +0.054
boom
WX170
T7346723 C1050
66 1050 0.50 100 55 2370 1320
+ 0.3 + 0.055 0
10
cylinder
Articulated
110/70
boom WX200 F8746790 C983,5 136 983.5 0.63 110 80 2470 1487 10 +- 0.3
0.7
70 ++ 0.155
0.055
85 +0.054
0
9/11
cylinder
Dipper 100/70 10 + 0.7 60 + 0.155 75 +0.045
cylinder
WX150 R9046743 C1030
118 1030 0.50 100 70 2515 1485
+ 0.3 + 0.055 0
12
Dipper 110/80
10 + 0.7 70 + 0.155 85 +0.045
cylinder
WX170 S9046744 C1320
169 1320 0.63 110 80 3155 1835
+ 0.3 0 0
12
Dipper
cylinder
WX200 M8746796 125/90
C1370 224 1370 0.6 125 90 3285 1915 10 +- 0.3
0.7
80 ++ 0.165
0.006
95 +0.054
0
12
Dipper
cylinder on 100/70 10 + 0.7 60 + 0.155 75 +0.045
handling
WX170 X8746783 C850
100 850 0.40 100 70 2140 1290
+ 0.3 + 0.055 0
12
boom
Dipper
cylinder on 110/80
WX200 P8746798 C1320 169 1320 0.63 110 80 3155 1835 10 +- 0.3
0.7
70 ++ 0.155 85 +0.054 13
handling 0.055 0
boom
Dipper
cylinder on 100/70
WX150 S8846736 134 1030 0.49 100 70 2484 1454 10 ++ 0.7 60 ++ 0.155 75 +0.046 14
backhoe C1030 0.3 0.055 0
offset boom
Dipper
cylinder on T8546748 110/80 10 + 0.7 70 + 0.155 85 +0.054
WX170 C850
135 1320 0.63 110 80 3114 1794 14
backhoe Z8846788 + 0.3 + 0.055 0
offset boom

8080-5
Disassembly Reassembly
Allowable deflection (F)
top/bottom machining
Bushing position (E)
Centre distance (LR)
Centre distance (LS)
Usable stroke (C)
Tube inner Ø (B)
bushing bore
rod extended
rod retracted
Part number
Description
Weight (kg)
Ø Max (D1)
Ø Max (D2)
Rod Ø (A)
See page
Machine
Type
Bucket
cylinder
WX150 Q8746799 100/70
C700
93 700 0.33 100 70 1855 1155 10 + 0.7
+ 0.3
60 + 0.155 75 +0.045
+ 0.055 0
12
Bucket 100/70
WX170 E8846701 C1030 118 1030 0.50 100 70 2515 1485 10 ++ 0.7 60 ++ 0.155 75 +0.045 12
cylinder 0.3 0.055 0
Bucket 110/80 10 + 0.7 70 + 0.155 85 +0.054

cylinder
WX200 F8846702 C1100
149 1100 0.63 110 80 2715 1615
- 0.3 + 0.055 0
12
Offset 100/70
10 + 0.7 60 + 0.155 75 +0.045
cylinder
WX150 S8846759 C350
62 350 0.17 100 70 1115 765
+ 0.3 + 0.055 0
16
Offset 110/80
WX170 R8846758 C480 92 480 0.23 110 80 1415 935 10 ++ 0.7 70 ++ 0.155 85 +0.054 16
cylinder 0.3 0.055 0
Jib 100/70 10 + 0.7 60 + 0.155 75 +0.054

cylinder
WX150 A8546754 C700
107 700 0.33 110 70 1870 1170
+ 0.3 + 0.055 0
8
Jib 110/70
10 + 0.7 60 + 0.155 75 +0.054
cylinder
WX170 B8546755 C775
111 775 0.37 110 70 2020 1245
+ 0.3 + 0.055 0
8
Jib 140/80
WX200 V8846739 C824 178 824 0.63 140 80 2219 1395 10 +- 0.3
0.7
90 ++ 0.16 105 +0.05 15
cylinder 0.06 0
Clamshell 90/110/
WX150 D46785 75 108 415 0.20 110 90/75 1552 1137.5 - 30.2 + 0.10 - 18
cylinder C415
0
Clamshell 100/
100/
cylinder
WX170 Q546701 145/120 199 360 0.17 145 120 - 19
C360
Clamshell 105/155
cylinder
WX200 J546787 C480
288 480 0.23 155 105 1333 1835 - - - 17
Sugar beet WX150 100/70

clamshell H8546761 63 350 0.17 100 70 1115 765 10 + 0.7 60 + 0.155 75 +0.045 8
WX170 C350 + 0.3 + 0.055 0
cylinder
5-tine grab 50/40
WX150 E46786 C230 17 230 0.11 50 40 830 600 - 30.5 + 0.1 - 20
cylinder 0
5-tine iron
65/52
grab WX170 C8846768 21 255 0.12 65 52 805 550 - 30 + 0.149 - 21
C255 + 0.065
cylinder
5-tine stone
65/52
grab WX170 D8846769 C255 21 255 0.12 65 52 805 550 - 30 ++ 0.149
0.065
- 22
cylinder
5-tine iron
75/60
grab WX200 E8846770 30 280 0.13 75 60 904 624 - 40 + 0.180 - 23
C280 + 0.080
cylinder
5-tine stone
75/60
grab WX200 F8846771 C280 30 280 0.13 75 60 904 624 - 40 ++ 0.180
0.080
- 23
cylinder
Timber grab 95/65 40.2+ 0.10
cylinder
WX150 U3446706 C300
49 300 0.14 95 65 1047 747 -
0
- 24
Timber grab 95/52

WX170 U546774 51 400 0.14 95 52 1247 847 - 40.2 + 00.10 - 24
cylinder C400

8080-6
SPECIAL TORQUES
Part Screw in Bearing Retaining Locking Grease Piston
Piston
number bearing screw screw pins fitting nut
A8546754 400-500 Nm - 400-500 Nm 10 Nm - 16-19 Nm -
B8546755 400-500 Nm - 400-500 Nm 10 Nm - 16-19 Nm -
C8846768 - - - - - - 50 Nm
D46785 400-500 Nm - - - - -
D8846769 - - 50 Nm - - - -
E46786 - 300 Nm - 10 Nm - - 200 Nm
E8746789 - 160-180 Nm 250 Nm - 15 Nm 16-19 Nm -
E8846701 - 110-130 Nm 250 Nm - 15 Nm 16-19 Nm -
E8846770 - 320-340 Nm Minimum 100 Nm - - 16-19 Nm -
F8846702 - 160-180 Nm 250 Nm - 15 Nm 16-19 Nm -
F8846771 - 320-340 Nm Minimum 101 Nm - - 16-19 Nm -
H8546761 350-400 Nm - 350-400 Nm 10 Nm - 16-19 Nm -
J546787 - 350-500 Nm - - - 16-19 Nm -
J8546762 350-450 Nm - 350-450 Nm 10 Nm - 16-19 Nm -
L8846799 400-500 Nm - 250 Nm 10 Nm - 16-19 Nm -
M8746796 - 255-275 Nm 250 Nm - 15 Nm 16-19 Nm -
P8746798 - 255-275 Nm 250 Nm - 15 Nm 16-19 Nm -
Q546701 450 Nm - - - - -
Q8746799 - 110-130 Nm 250 Nm - 15 Nm 16-19 Nm -
Q9046742 400 Nm - 250 Nm - 16-19 Nm -
R8846758 400-500 Nm - - 15 Nm - 16-19 Nm -
R9046743 - 250 Nm - 16-19 Nm -
S8846736 - 16-19 Nm -
S8846759 - 350-450 Nm - 16-19 Nm -
S9046744 - 160-180 Nm 250 Nm - 15 Nm 16-19 Nm -
T7346723 200-300 Nm - - - - 16-19 Nm -
T8546748 400-500 Nm 400-500 Nm 15 Nm - 16-19 Nm -
U3446706 50 Nm - 50 Nm 15 Nm - 16-19 Nm -
U546774 -
U8546749 400-500 Nm - 400-500 Nm 15 Nm - 16-19 Nm -
V8846739 - 330-410 Nm Minimum 100 Nm - 15 Nm 16-19 Nm -
X8746783 - 110-130 Nm 250 Nm - 15 Nm 16-19 Nm -
Z8846788 - 160-180 Nm 150 Nm 15 Nm - 16-19 Nm -
NOTE: All threads must be lubricated before assembly, except retaining screws and locking pins.

8080-7
CYLINDER IDENTIFICATION
2
1 R76 / 56 A 3
01 B
4 5
PDH0290
1 CONTROL LETTER
2 CYLINDER PART NUMBER (467. THE CYLINDER GROUP CODE NUMBER IS REPLACED BY AN OBLIQUE STROKE. IN THE
EXAMPLE, READ 7646756)
3 CYLINDER DRAWING INDEX
4 CYLINDER WEEK OF MANUFACTURE NUMBER
5 CYLINDER YEAR OF MANUFACTURE NUMBER (B = 1981)
Year coding
A 1980 E 1984 J 1988 N 1992 S 1996 W 2000
B 1981 F 1985 K 1989 P 1993 T 1997 X 2001
C 1982 G 1986 L 1990 Q 1994 U 1998 Y 2002
D 1983 H 1987 M 1991 R 1995 V 1999 Z 2003
TOOLS REQUIRED
1. TORQUE WRENCH, OEM 6481
2. HYDRAULIC CYLINDER TEST BENCH CAS 10492
PDF0247
4. BEARING TIGHTENING WRENCH OEM 6203

PDF0248
Opening capacity: 120 mm to 323 mm
3. ADJUSTABLE PIN WRENCH CAS 1618 5. BEARING TIGHTENING WRENCH OEM 6206
Opening capacity: up to 178 mm Opening capacity: 38 mm to 101 mm

8080-8
CYLINDER H8546761 / L8846799 / Q9046742 / B8546755 / A8546754

17 18 16 14
D Nm
21
D Nm
1 2
3
20
PDH0291 D Nm
21
D Nm
19 15
6 7 9
8
5 D Nm
D Nm
4
13 12 11 10
PDH0293
CS95M032
NOTE: Install new, lubricated seals. To assemble the bushings (4) and (20), refer to page 29. To remove and install the
cylinder piston, refer to page 25.
∆ Nm. See Tightening torques, page 6
1 CYLINDER GLAND 10 O-RING 18 O-RING

2 CYLINDER ROD 11 BEARER RING 19 WIPER SEAL
3 CYLINDER BARREL 12 DOUBLE ACTING SEAL 20 BRONZE BUSHING
4 BRONZE BUSHING 13 BEARER RING 21 GREASE FITTING
5 GREASE FITTING 14 GTL SEAL
6 RETAINING SCREW 15 BEARER RING
7 LOCKING PIN 16 ANTI-HAMMERING SEAL
8 PISTON 17 SINGLE ACTING SEAL
9 BACK-UP RING

8080-9
CYLINDER F8746790
20 19 18 16
D Nm 22
3
21
15
D Nm
4
1
CS95M084
D Nm
2
8
9
17
6
14
D Nm
D Nm 10
7
6
D Nm 5
13
12 11
PDH0295BIS
CS95M025
1 SCREW 10 O-RING 18 ANTI-HAMMERING SEAL
2 WASHER 11 SEAL 19 SINGLE ACTING SEAL
3 CYLINDER ROD 12 DOUBLE ACTING SEAL 20 WIPER SEAL
4 CYLINDER BARREL 13 SEAL 21 BRONZE BUSHING
5 BRONZE BUSHING 14 BEARER RING 22 GREASE FITTING
6 GREASE FITTING 15 CYLINDER GLAND
7 LOCKING PIN 16 SEAL
8 PISTON 17 BEARER RING
9 BACK-UP RING

8080-10
CYLINDER T7346723
D Nm
*
14 1 13 12 15 16 6 8 7

2 10 11 9 5 4 3
D Nm
PDH0299
NOTE: Install new, lubricated seals.

* To remove and install the bearing (1) use tool OEM 6203.
1 CYLINDER GLAND 8 SEAL
2 CYLINDER ROD 9 O-RING
3 CYLINDER BARREL 10 BEARER RING
4 SCREW 11 ANTI-HAMMERING SEAL
5 WASHER 12 SINGLE ACTING SEAL
6 PISTON 13 O-RING
7 BEARER RING 14 WIPER SEAL

8080-11
CYLINDER E8746789 / F8746790 *

21 20 19 17
D Nm 23 3
*
22
16
D Nm
4 1
CS95M034
D Nm
2
8
10
18
6
15
D Nm
D Nm 11
7
5
6
D Nm 14
13 12 PDH0295
CS95M018
NOTE: Install new, lubricated seals. To remove and install the cylinder piston, refer to page 25.
1 SCREW 13 DOUBLE ACTING SEAL 23 GREASE FITTING
2 WASHER 14 SEAL
3 CYLINDER ROD 15 BEARER RING
4 CYLINDER BARREL 16 CYLINDER GLAND
5 BRONZE BUSHING 17 SEAL
6 GREASE FITTING 18 BEARER RING
7 PISTON LOCK 19 ANTI-HAMMERING SEAL
8 PISTON 20 SINGLE ACTING SEAL
9 DASH-POT 21 WIPER SEAL
10 BACK-UP RING 22 BRONZE BUSHING
11 O-RING
12 SEAL

8080-12
CYLINDER E8846701 / M8746796 / R9046743 / S9046744 / F8846702 /

X8746783 / Q8746799
21 20 19 17
D Nm 23 3
22
16
D Nm
4 1
9
CS95M067
D Nm
2
8
10
18
6
15
D Nm
D Nm 11
7
5
6
D Nm 14
13 12 PDH0295BIS
CS95M023
NOTE: Install new, lubricated seals. To assemble the dash-pot (9) refer to page 29. To remove and install the cylinder
piston, refer to page 25. To assemble the bronze bushes (5) and (22) refer to page 29.
1 SCREW 10 BACK-UP RING 18 BEARER RING
2 WASHER 11 O-RING 19 ANTI-HAMMERING SEAL
3 CYLINDER ROD 12 SEAL 20 SINGLE ACTING SEAL
4 CYLINDER BARREL 13 DOUBLE ACTING SEAL 21 WIPER SEAL
5 BRONZE BUSHING 14 SEAL 22 STEEL BUSHING
6 GREASE FITTING 15 BEARER RING 23 GREASE FITTING
7 PISTON LOCK 16 CYLINDER GLAND
8 PISTON 17 GTL SEAL
9 DASH-POT
8080-13
CYLINDER U8746780 / P8746798

21 20 19 17
3 22
D Nm
23
16 D Nm
4 1
9
PDH0294
D Nm
8
18 2 10
6
15
D Nm 11
D Nm
7
5
6
D Nm
14
13 12 PDH0295BIS
CS95M057
NOTE: Install new, lubricated seals. To assemble the dash-pot (9) refer to page 29. To remove and install the cylinder
piston, refer to page 25. To assemble the bronze bushes (5) and (22) refer to page 29.
1 SCREW 10 BACK-UP RING 18 BEARER RING
2 WASHER 11 O-RING 19 ANTI-HAMMERING SEAL
3 CYLINDER ROD 12 SEAL 20 SINGLE ACTING SEAL
4 CYLINDER BARREL 13 DOUBLE ACTING SEAL 21 WIPER SEAL
5 BRONZE BUSHING 14 SEAL 22 BRONZE BUSHING
6 GREASE FITTING 15 BEARER RING 23 GREASE FITTING
7 LOCKING PIN 16 CYLINDER GLAND
8 PISTON 17 SEAL Y3
9 DASH-POT

8080-14
CYLINDER S8846736 / Z8846788


D Nm 4 10 7 D Nm

19 20

2

8
13
CS97A001
1
12 11 9 D Nm
18 16 17 14

6

*
D Nm
5

3

15 PDH0294BIS
CS96N057
NOTE: Install new, lubricated seals. To assemble the dash-pot (6), refer to page 29. To assemble the bushing (19), refer
to page 29. To remove and install the cylinder piston, refer to page 25.
* Use tool CAS 1618
1 SCREW 11 DOUBLE ACTING SEAL
2 CYLINDER ROD 12 BEARER RING
3 CYLINDER BARREL 13 CYLINDER GLAND
4 BALL JOINT BLOCKING SCREW 14 SEAL
5 CYLINDER PISTON 15 BEARER RING
6 DASH-POT 16 SINGLE ACTING SEAL
7 BACK-UP RING 17 ANTI-HAMMERING SEAL
8 O-RING 18 WIPER SEAL
9 BEARER RING 19 BRONZE BUSHING
10 BEARER RING 20 GREASE FITTING

8080-15
CYLINDER V8846739 *
18 17 16 14 D Nm
* 19 6
3
13
4
CS95M042
15 D Nm
8
1
D Nm
11 2 9
6
10
D Nm
7
CS95M043
D Nm
12
CS95M031
1 SCREW 11 CARRIER SEAL
2 WASHER 12 SEAL
3 CYLINDER ROD 13 CYLINDER GLAND
4 CYLINDER BARREL 14 WIPER SEAL
5 BRONZE BUSHING 15 CARRIER SEAL
6 GREASE FITTING 16 SEAL
7 PISTON LOCK 17 O-RING
8 PISTON 18 GTL SEAL
9 BACK-UP RING 19 BRONZE BUSHING
10 O-RING

8080-16
CYLINDER S8846759 / R8846758

19 20 18 17
3
5
21
D Nm
4
PDH0291
16
* 10 23
D Nm D Nm
D Nm
8 9
7
6
∆
1
11
D Nm
2
22
PDH0293
15 14 13 12
CS99J516
∗ Use tool CAS 1618
∆ Use tool OEM 6203
1 CYLINDER GLAND 10 PISTON 18 ANTI-HAMMERING SEAL
2 CYLINDER ROD 11 BACK-UP RING 19 SINGLE ACTING SEAL
3 CYLINDER BARREL 12 O-RING 20 O-RING
4 BRONZE BUSHING 13 BEARER RING 21 WIPER SEAL
5 GREASE FITTING 14 DOUBLE ACTING SEAL 22 BRONZE BUSHING
6 SCREW 15 BEARER RING 23 GREASE FITTING
7 WASHER 16 BEARER RING
8 RETAINING SCREW 17 SEAL
9 LOCKING PIN
8080-17
CYLINDER J546787
12 11 9
D Nm 2 10
1 14
20
13
D Nm CS95M040
26
28
27 8 D Nm
7
23
24
22
5 6 17 16 19
25
21
28
3 D Nm
18
CS95M041
4 15
CS95M035

1 CYLINDER GLAND 16 BRONZE BUSHING
2 WASHER 17 SEAL
3 WIPER SEAL 18 PISTON RING
4 O-RING 19 LOCK WASHER
5 BEARER RING 20 CYLINDER BARREL
6 SEAL 21 RING
7 CYLINDER GLAND 22 BRONZE BUSHING
8 WASHER 23 O-RING
9 WIPER SEAL 24 PLUG
10 O-RING 25 PLUG
11 BEARER RING 26 SCREW
12 SEAL 27 WASHER
13 CYLINDER ROD 28 GREASE FITTING
14 LOCKING RING
15 LOCK WASHER

8080-18
CYLINDER D46785
8

25 2
26

* 3
D Nm 1

4

23
5
24

6
10

11
7

22
9

14

13 16

12
15

21
* 17
20

19

D Nm

18
PDH0301

* Use tool OEM 6203
1 CYLINDER GLAND 15 LOCKING RING
2 WIPER SEAL 16 WASHER
3 SEAL 17 CYLINDER GLAND
5 BACK-UP RING 19 SEAL
6 O-RING 20 O-RING
7 BACK-UP RING 21 COMPOSITE SEAL
8 CYLINDER ROD 22 CYLINDER BARREL
9 HOOP 23 GREASE FITTING
10 NIPPLE 24 RING
11 SPRING 25 PLUG
12 RING 26 SEALING DISC
13 RING
14 COMPOSITE SEAL
8080-19
CYLINDER Q546701
9 14 21 19
27 10
28
29

1 12

11

PDH0303
25
2 22 20
26

16 D Nm

24
13

17
15
3

23

18
D Nm
8

7
5

PDH0304
6
PDH0302

1 LOCKING RING 16 SCREW
2 CYLINDER GLAND 17 BRAKE
3 WIPER SEAL 18 CYLINDER GLAND
5 BEARER RING 20 BEARER RING
6 SEAL 21 SEAL
7 O-RING 22 O-RING
8 CYLINDER ROD 23 CYLINDER BARREL
9 HOOP 24 RING
10 NIPPLE 25 RING
11 SPRING 26 GREASE FITTING
12 RING 27 PLUG
13 RING 28 PLUG
14 COMPOSITE SEAL 29 O-RING
15 WASHER
8080-20
CYLINDER E46786

3
D Nm 2

∆
1

17

D Nm
18

16

14

13 15

4 12
8

11
7

10
6

* 5
D Nm

9

19 PDH305D
20

21
22
PDH305G

* To disassemble the nut (5) use tool OEM 6206
∆ To disassemble the nut (2) use tool OEM 6203
1 SCREW 14 CYLINDER GLAND
2 NUT 15 SEAL
3 CYLINDER ROD 16 COMPOSITE SEAL
4 CYLINDER BARREL 17 WIPER SEAL
5 NUT 18 SEALING DISC
6 LOCK WASHER 19 SPLIT PIN
7 WASHER 20 SHAFT
8 PISTON 21 HEAD
9 O-RING 22 RING
10 O-RING
11 O-RING
12 WASHER
13 WASHER

8080-21
CYLINDER C8846768
17

16

2
1

12

15
3

14

13

10

11
7

9
6

8
D Nm
A

A

A-A 4
18

21

19

20

5
PDH0309

When assembling the screw (6), tighten to a higher torque setting if necessary to be able to insert the dowel (5). Never
untighten.
1 LOCKING RING 13 COMPOSITE SEAL
2 CYLINDER ROD 14 O-RING AND BACK-UP RING
3 CYLINDER BARREL 15 COMPOSITE SEAL
4 LOCKING RING 16 WIPER SEAL
5 DOWEL 17 RING
6 NUT 18 SNAP RING
7 PISTON 19 RING
8 COMPOSITE SEAL 20 SNAP RING
9 O-RING 21 PLUG
10 COMPOSITE SEAL
11 WASHER
12 CYLINDER GLAND
8080-22
CYLINDER D8846769

15 14 13 12 17
3

7
10

5
16
PDH0306
4
6 2
D Nm
19 8

11

18

9
PDH0308
PDH0307

untighten.
1 LOCKING RING 13 BACK-UP RING
2 CYLINDER ROD 14 O-RING
3 CYLINDER BARREL 15 COMPOSITE SEAL
4 LOCKING RING 16 SEAL CARRIER
5 DOWEL 17 WIPER SEAL
6 NUT 18 RING
7 PISTON 19 PLUG
8 COMPOSITE SEAL
9 O-RING
10 WASHER
11 CYLINDER GLAND
12 COMPOSITE SEAL
8080-23
CYLINDER E8846770 ∆ (SCRAP IRON), F8846771 * (STONE)

19
*
20 18 ∆
∆ D Nm
17
7 * D Nm
8
11
13
1
6
5
4
9
10
12
14
+2
∆ 34 -0 mm
15
2
* 34 +2 mm
-0
16 3
CI00C507
NOTE: Install new, lubricated seals. When tightening the piston (7), tighten it to a higher torque setting if necessary, so
as to be able to insert the locking dowel (5).
1 SCREW 11 SEAL
2 CYLINDER BEARING 12 RING SEAL
3 CYLINDER ROD 13 SEAL
4 LOCKING RING 14 SEAL
5 STOP DOWEL 15 WIPER SEAL
6 CYLINDER BARREL 16 RING
7 PISTON 17 GREASE FITTING
8 SEAL 18 SNAP RING
9 SEAL 19 BALL-JOINT BUSHING
10 BACK-UP RING 20 RING
* Bushing specific to cylinder F8846771

8080-24
CYLINDER U3446706 / U546774

22
D Nm 23
6
8 7

9 D Nm
11

13
12
PDH0310A
10
14
*
18 5 D Nm
15
3
16
17
D Nm 1
2
4
19
D Nm 21
PDH0310 20

untighten.
* To disassemble and assemble the bearing (3), use tool OEM 6203
1 SCREW 13 COMPOSITE SEAL
2 NUT 14 SPACER
3 LOCK WASHER 15 O-RING
4 CYLINDER ROD 16 SHELL BEARING
5 CYLINDER GLAND 17 LINING
6 CYLINDER BARREL 18 SHELL BEARING
7 LOCKING RING 19 WIPER SEAL
8 DOWEL 20 RING
9 NUT 21 GREASE FITTING
10 RING 22 RING
11 O-RING 23 GREASE FITTING
12 O-RING

8080-25
SPECIAL INSTRUCTIONS
Removing and installing a cylinder piston
1) Piston with rotation locked by a Installation
locking pin involving a drilling out STEP 1
operation
Lubricate the internal thread of the piston and the
Removal
cylinder rod thread. Install the piston on the rod and
STEP 1 tighten to torque using special tool CAS 1618.
STEP 2
1
5 1
1A
PDF0241
Remove the retaining screw (1), using a hexagonal
PDH0338
8 mm Allen key.
STEP 2
3 6 øA
3 2 4
5
PDF0241B
Drill out one of the blind holes at (5) or (1A) at the
PDF0241A intersection of the piston (3) and the cylinder rod (6)
Extract the locking pin (2) using a screw (4) HM5 x using diameter (A) and depth (B). See table on page 27.
100. Remove the piston (3) using the special tool
CAS 1618.
NOTE: Make a visual inspection of the seal grooves
and the threads (piston and cylinder rod).

8080-26
STEP 3 Installation
STEP 1
2 1 3 Lubricate the piston threads and the cylinder rod
thread. Assemble the piston onto the cylinder rod
using special tool CAS 1618. Tighten the piston to
torque (see specifications).
5
STEP 2
PDF0241C
Remove the piston (3) again to clean all traces of iron
filings or chips from inside the orifice (5). Install the
piston (3) again and tighten it to torque using the spe-
cial tool CAS 1618. Insert the locking pin (2) into its
housing. Install the retaining screw (1) and tighten to
torque (See specifications).
NOTE: Do not lubricate the retainer screw (1). PDH0311
Insert the locking pin (1) in its housing and tighten to
2) Piston with rotation lock using locking
torque (see specifications). If the locking pin will not
pin not involving a drilling out operation go in, tighten to a higher torque. Never untighten.
Removal
NOTE: Do not lubricate the locking pin (1).
PDH0311
Remove the locking pin (1) using an 8 mm hexagonal
Allen key.
Remove piston (2) using special tool CAS 1618.
NOTE: Make a visual inspection of the seal grooves,
threads, the piston and the threads of the cylinder
rod.

8080-27
Drilling out the blind holes WX200
Cylinders Diameter A (mm) Depth B (mm)
Dipper
+0.10 +0.20
Offset 8 51
00 00
Dipper for offset backhoe boom
+0.10 +0.20
Jib cylinder 8 48
00 00
Drilling out the blind holes WX150 and WX170
Cylinders Diameter A (mm) Depth B (mm)
Boom
Lifting boom
+0.10 +0.20
Dipper 8 45
00 00
Bucket
Sugarbeet clamshell
Dipper
+0.10 +0.20
Offset 8 51
00 00
Dipper for offset backhoe boom
+0.10 +0.20
Jib cylinder 8 48
00 00

8080-28
Preventing the rotation of screw-in Removing and installing the wiper

type cylinder gland ring
1 1
PDH0312 PDH0314
Unlock the screw-in type gland bearing (1) using a Unstick the wiper ring (1) using a hammer and a drift,
hammer and a drift as shown on the drawing. then remove it.
1 2
2
PDH0313 PDH0315
Lock the screw-in cylinder gland (1) by peening the Fit a new wiper ring (1) using the old wiper ring (2) to
barrel (2) into one of the slots by means of a hammer assist, as shown in the drawing.
and drift.

8080-29
Assembling the dash-pot
+0.1
J: 0.3 0
3 1
PDH0316
After tightening the piston (1) onto the cylinder rod (2), to the specified torque, check the clearance between the
cylinder rod (2) and the dash-pot (3). The clearance should be 0.3 +0.1
0 .
Replacing bushings
STEP 1 STEP 3
Extract the old bushings.
STEP 2
1
+0.7
10 -0.3 ø D1
PDH0318
ø D2 Using liquid nitrogen, install the bushings (1) on the

cylinder barrel and on the cylinder rod, taking care to
PDH0317
position them correctly. Check the diameter (D1).
Check the diameter (D2) of the bushing bores. Refer Refer to the specifications for the dimensions.
to the specifications for the dimensions.

8080-30
Checking cylinder rod deflection
= = = =
1 2 3 4 5
PDH0319
This check is carried out on a surface plate and using
a dial gauge to 1/100 mm accuracy, proceeding
as follows:
- Centre the dial gauge feeler to zero at the centre of
the rod and plumb with the axis of the brackets at
check point 3.
- Carry out 5 checks at equal distances from each
other. Turn the rod very slowly at each check point.
Note the maximum and minimum variations.
Maximum value - minimum value

Boom =
2
See specifications for maximum acceptable deflec-

tion.
NOTE: Straightening the rod is not acceptable. Any
rod with a deflection greater than the maximum
tolerance must be changed.

8081
Section
8081
SAFETY VALVES

Printed in France
8081-2
TABLE OF CONTENTS
SPECIFICATIONS .................................................................................................................................................... 2
TORQUE SETTINGS ............................................................................................................................................... 2
BOOM SAFETY VALVE ........................................................................................................................................... 3
Description ........................................................................................................................................................... 3
Identifications ....................................................................................................................................................... 4
SAFETY VALVE .......................................................................................................................................................5
Description ........................................................................................................................................................... 5
SPECIFICATIONS
Type ............................................................................................................................ Flange ARQP RBA 34 FLDEQ
Weight ............................................................................................................................................................... 7.8 kg
Pressure .....................................................................................................................415 bar maximum at leak point
TORQUE SETTINGS
Cross-over valve ............................................................................................................................................... 45 Nm
Pressure limiter............................................................................................................................................... 100 Nm
Return plug (T) ............................................................................................................................................... 130 Nm
Cross-over valve plug ....................................................................................................................................... 45 Nm
Plug (A)............................................................................................................................................................. 90 Nm
Plug (X) (MR).................................................................................................................................................... 45 Nm
Non-return valve plug (17) .............................................................................................................................. 120 Nm

8081-3
BOOM SAFETY VALVE
1
6
2
1 3
CS99J529
Description
1 Hydraulic clamp
2 Pressure limiter
3 Cross-over valve
4 Load holding valve
5 Opening stop
6 Non-return valve

8081-4
B C
A D
CS99H521
Identifications
A Leak return
B Supply to block
C Piloting for boom locking
D Cross-over to right hand block

8081-5
SAFETY VALVE
20
1 2 3 4 14 15 16 4 18 17 4
1 2 3 4 5 6 7 8 4 5 6 9 10 11 12 13 2 19
21 22
CS99J530
Description
1 Cap 12 Spool
2 Socket head screw 13 Valve body (opening stop)
3 Nut 14 Limiter body
4 O-ring 15 Cups
5 Spring guide 16 Check valve
6 Ball 17 Plug
7 Valve body 18 Non-return valve
8 Spring 19 Guard
9 Valve end (opening stop) 20 Limiter
10 Seals 21 Safety check valve
11 Spool 22 Opening stop valve

8081-6
- Loosen the hydraulic reservoir pressure release plug two turns to release the pressure.
STEP 1 NOTE: When reassembling, use the same procedure
in the reverse order, not forgetting to change the seal
Turn the upperstructure a quarter of a turn to get between the valve and the cylinder.
easier access to the valves.
STEP 2 must be carried out in the order shown:
- Start the engine.
- To adjust the valves, refer to section 8001.
CD99J005
Attach identification labels to all the valve hoses that
have to be removed. Plug or cap all the hoses (for the
RH valve, disconnect the overload indicator detector
harness).
STEP 3
Place a clean receptacle under the valve concerned
to recover the oil from the cylinder. Remove the
4 valve retaining screws. Remove the valve.

9002
Section
9002
UPPERSTRUCTURE AND TURNTABLE

Printed in France
9002-2
TABLE OF CONTENTS
SPECIFICATIONS.....................................................................................................................................................3
TOOLS REQUIRED .................................................................................................................................................. 3
CHECKING TURNTABLE BEARING WEAR ............................................................................................................ 4
UPPERSTRUCTURE ................................................................................................................................................5
Cab........................................................................................................................................................................ 6
Cab floor................................................................................................................................................................ 7
Counterweight .......................................................................................................................................................8
Control valve bank partition................................................................................................................................... 9
Swing motor-reduction gear ..................................................................................................................................9
Upperstructure ...................................................................................................................................................... 9
TURNTABLE BEARING .......................................................................................................................................... 11
Removal .............................................................................................................................................................. 11
Installation ........................................................................................................................................................... 12

9002-3
SPECIFICATIONS
See Section 1002.

Counterweight retaining screws.................................................................................................................... 1000 Nm
Turntable retaining screws .............................................................................................................................. 450 Nm
TOOLS REQUIRED
1 Torque wrench (169 to 779 Nm and 34 to 197 Nm)
2 Torque wrench extension CAS 2318
3 One dial gauge CAS 10066-1A
4 One magnetic base CAS 10149
5 One 10 tonne lifting device
6 Two slings (400 to 600 kg)
7 Two slings (150 to 200 kg)
8 Four slings (3000 kg)
9 Loctite 495

9002-4
CHECKING TURNTABLE BEARING WEAR

STEP 1 STEP 3
CS02H500 CS02H501
Place weight in the bucket and park the machine on Start the engine and slowly lower the machine to the
hard level ground. Lower the bucket to the ground ground. Slowly lift the boom with the dipper extended
and use the attachment to lift the machine to the until the bucket is one metre from the ground and
position indicated. Stop the engine. note down the reading on the dial gauge. Lower the
bucket to the ground and check that the dial gauge
STEP 2 comes back to 0. Repeat the procedure and calculate
the average between the two results.
STEP 4
1 Remove the dial gauge from the turntable. Turn the
upperstructure 90° and repeat Step 3.
NOTE: If one of the results is greater than 7 mm, the
turntable must be replaced.
PDH0393
Clean the area around the opening in the

upperstructure and the turntable bearing teeth. Install
a dial gauge (1) on the teeth (2) of the turntable
bearing. Adjust the dial gauge to 0.

9002-5
UPPERSTRUCTURE
Before performing any service work on the machine, the following operations must be performed:
- Stop the engine.
- Operate the emergency pump and the control levers simultaneously to release pressure in the hydraulic circuits.
- Slacken the plug on the hydraulic reservoir 2 or 3 turns to release pressure, then retighten the plug.
WARNING: When the machine is operating, the hydraulic components heat up to a high temperature. To
avoid risk of burning by hot metal or boiling fluid, let the machine cool down completely before performing
! any service work.
NOTE: For weights of components, see section 1002.

STEP 1
Remove the boom, dipper and bucket.
STEP 2 1
Raise the engine upper hood. Remove the engine
side panel.
STEP 3
4
1
2 PG03613
Disconnect the negative (-) cable (1) first, then

disconnect the other cables. Remove the battery
retaining screws and remove the batteries.
NOTE: When installing, check that all the electrical
connections are correct and then connect and tighten
2 the positive terminal (+) first.
3
PDH0394
Disconnect the engine lighting electrical harness (if

equipped). Remove the screws (1), spacers (2) and
nuts (3) which retain the engine hood. Raise and
remove the hoods.

9002-6
STEP 5 Cab
Remove the walkway retaining screws then remove STEP 10
the walkway.
Remove the trimming located behind the seat.
STEP 6 Remove the cab power point and the windshield
Remove all the access panels under the upperstruc- washer hose.
ture. STEP 11
STEP 7 Install a suitable lifting device on the roof of the cab.
Remove the control valve hood retention screws and STEP 12
remove the hood.
STEP 8
PH00533
PG02904
Place a clean receptacle with a capacity of 180 litres

under the hydraulic reservoir. Remove the drain plug
and drain the hydraulic fluid. Install the drain plug and
tighten it to a torque of 30 Nm.
STEP 9
Place a clean receptacle under the fuel tank. Remove
the drain plug and drain the fuel. After draining, install
the drain plug.
PH00305
Remove the four cab retaining screws. Raise the cab

carefully until it is completely separated from he
machine. Lower the cab to the ground, resting on
wooden blocks.
NOTE: The floor carpet must be lifted to gain access
to the screws at the front of the cab.
NOTE: When installing, tighten the cab retaining
screws to a torque of 120 Nm. Make sure that the
seal located at the rear of the cab is correctly in
place.

9002-7
Cab floor STEP 15

STEP 13
Remove the lower tray retaining screws and remove
the drawer.
1
STEP 14
2 2
1 4
6
PE07509
Turn the cab heater lever to the "Hot" position. Place 9

a receptacle of about 30 litres capacity under the
heater radiator. Disconnect the heater hose (1) and 8
drain the radiator. Disconnect the hose (2) from the 5
radiator. Plug both hoses. 7
NOTE: When installing, bleed air from the heating
PDH0395
system (see Operator's Manual).
Lower the printed circuit card in the electrical cabinet.
Place identification labels on the connectors for
harnesses 1, 2, 3, 4 and 5 and the electronic circuit
harnesses, all the option harnesses and disconnect
them. Remove the cable clamp (6). Disconnect the
55 way connector (7) from the electronic box (8) and
also disconnect the connector from the control panel
(9) (see section 4002).
STEP 16
Place identification labels on the front right-hand
lighting cables and disconnect them.
STEP 17
Label and disconnect all the hoses connecting the
cab floor to the excavator components. Remove the
engine accelerator cable form the control lever.

9002-8
STEP 18 Counterweight
STEP 19
CS97G031
Remove the four cab floor retaining screws. Using a

suitable lifting device, remove the cab floor.
NOTE: Before removing the cab floor from the
excavator, make sure that all the electrical cables and 3
hydraulic hoses are disconnected.
3
2
PDH0397
Install a suitable lifting device on the counterweight.

Remove the four screws (1), the nuts (2) and the
washers (3). Remove the counterweight.
NOTE: When installing, tighten the counterweight

9002-9
Control valve bank partition Swing motor-reduction gear

STEP 20 STEP 21
Remove the swing motor-reduction gear assembly.
Refer to Section 6003.
Upperstructure
3 STEP 22
Place identification labels on the rotating part of the
hydraulic swivel then disconnect and plug the hoses.
STEP 23
3 Remove and plug all the turntable bearing lubrication
pipes.
2
1
1
2
2
2
2
1 3
CS96B053
Attach identification labels to the hydraulic hoses,

then disconnect and plug the attachment control
valve hoses and the hoses for the swing control valve,
the option control valve (if equipped) the solenoid
valve block and the brake unit filter. Attach identifica-
tion labels to the solenoid valve block electrical
cables and the electrical socket, then disconnect
them. Install a suitable lifting device at point (A) on
the control valve partition. Remove the nuts (1), the
washers (2) and the screws (3) retaining the partition
and remove the partition.
NOTE: Before removing the valve bank partition from
the excavator, make sure that all the hydraulic hoses
and electrical cables are disconnected.

9002-10
STEP 24
PDH0399
Install a suitable lifting device on the upperstructure NOTE: When installing, follow the same procedure in
frame (1) so that it is equally balanced between the the reverse order. Make sure that all hydraulic hoses
lifting points (A) and (B). Remove the turntable/upper- are correctly connected and are tightened to the
structure frame retaining screws. Slowly and carefully correct torque. Make sure that all electrical cables are
raise the upperstructure frame (1) until it is separated connected correctly.
from the undercarriage (2), then lower it onto
4 blocks.

9002-11
Before using the machine, carry out all the following operations:
- Fill the hydraulic reservoir with 180 litres of hydraulic fluid (see Operator’s Manual).
- Fill the fuel tank.
- Fill the cooling system (see Operator’s Manual).
- Lubricate the turntable (see Operator's Manual).
- Calibrate the engine servo-motor, refer to Section 4002.
- Bleed and prime the fuel system (see Operator's Manual).
- Bleed all the control valve spool caps.
- Bleed the brake circuit.
- Check all the indicator and warning lamps on the instrument panel.
- Check the hydraulic system, fuel system and cooling system for leaks.
- Stop the engine and check all levels. Top up if necessary.
- Check that the machine operates normally.
TURNTABLE BEARING
Removal
STEP 1 Fasten identification labels to all the hoses on the
hydraulic swivel (1). Disconnect the hoses from the
8 hydraulic swivel and plug them. Install two lifting eyes
on the hydraulic swivel. Attach slings to the hydraulic
swivel. Remove the hydraulic swivel retaining screws
(2) and washers (3). Slowly lift the hydraulic swivel
and lower it onto a suitable support. Install two lifting
4 eyes on the turntable bearing. Attach slings to the
turntable (4). Remove the turntable bearing retaining
screws (5) and washers (6). Slowly lift the turntable
bearing and lower it onto a suitable support.
Remove and discard the seals (7) and (8).
7
6
1
2
3
CS99J543

9002-12
Installation STEP 4
STEP 2
1
3 2
CM97G023
Carefully clean the turntable bearing seal grooves. CS99J541

Do not use a degreasing agent. Install new seals (1) A Front of the machine
and (2) on the turntable bearing (3). B Plug (heat treatment meeting point on outer
NOTE: The seals, upper and lower, are stuck to the ring)
turntable bearing at regular intervals with Loctite 495. C Lubrication orifices
D Heat treatment meeting point on inner ring
STEP 3 (paint mark)
X-X’ Machine axis
Clean the mating surfaces of the turntable bearing,
on both the undercarriage and upperstructure sides. Assemble the turntable on the undercarriage,
Make sure that the surfaces are flat. orienting the plug (B) and the paint mark (D) at 90° to
the X-X’ axis of the machine.
STEP 5
1
7 5
4 3
6 8
2
PDH0404
Tighten the turntable retaining screws to a torque of

450 Nm in the order shown, using the extension
piece CAS 2318.
STEP 6
Install the hydraulic swivel. Tighten the hydraulic
swivel bracket screws to a torque of 500 Nm.

Section
9004
9004
CAB

Printed in France
9004-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................................... 3
Identification of cab windows (sliding window) ..................................................................................................... 3
Identification of cab windows (fixed window) ....................................................................................................... 4
SPECIAL TORQUES................................................................................................................................................ 5
TOOLS REQUIRED ................................................................................................................................................. 5
TOOLS TO BE MADE .............................................................................................................................................. 5
CAB .......................................................................................................................................................................... 6
Removal ............................................................................................................................................................... 6
Installation ............................................................................................................................................................7
SLIDING DOOR WINDOW....................................................................................................................................... 9
Changing the sliding window .............................................................................................................................. 10
Changing the fixed window ................................................................................................................................ 12
Changing glued windows ................................................................................................................................... 14

9004-3
SPECIFICATIONS
Cab weight........................................................................................................................................................ 275 kg
Cab glass manufacturer.......................................................................................................... Saint Gobain/WÖLFLE
Identification of cab windows (sliding window)
CS02H507
A LEFT HAND WINDOW MANUFACTURER WÖLFLE
B LEFT HAND WINDOW MANUFACTURER SAINT GOBAIN

9004-4
Identification of cab windows (fixed window)
CS02H506

9004-5
SPECIAL TORQUES
Cab retaining screws ..................................................................................................................................... 120 Nm
TOOLS REQUIRED
1 Torque wrench CAS10033
2 Loctite 401
3 Silicomet (transparent)
4 Grease
5 Protective gloves
TOOLS TO BE MADE
IMPORTANT: The welds needed for the fabrication of this tool must be carried out by a competent welder.
830 mm
415 mm
45 mm
12 mm
15 mm
700 mm
45 mm
90 mm
65 mm 760 mm
PDH1028
1 CAB LIFTING BRACKET
Material: wood
Length: 150 mm
Diameter: 20 mm
End: sharpened to a point
PDH1061
1 WOODEN TOOL (USED FOR THE FIRST TIME ON
PAGE 10)

9004-6
CAB
Removal
STEP 1 STEP 4
Place the machine on flat and horizontal ground.
STEP 2
C09126
Remove the two plastic plugs from the roof of the cab
and install the cab lifting bracket (see tool to be
PG03502 made).
Remove the trimming located behind the seat.
STEP 5
STEP 3
PH00533
PE10834M
Turn the base to remove it, remove the cab power

socket and remove the windscreen washer hose and
the antenna wire.
PH00305
Remove the four cab retaining screws.

NOTE: The floor carpet must be lifted to gain access
to the screws at the front of the cab.

9004-7
STEP 6 STEP 3
Using a suitable lifting device, carefully lift the cab
until it is completely disengaged from the machine.
STEP 7
Lower the cab to the ground, resting on wooden
blocks.
STEP 8
PH00533
PH00629
Remove the lifting equipment and replace the two

plastic plugs.
Installation
STEP 1
PH00305
Install and tighten the four cab retaining screws to a

torque of 120 Nm. Then install correctly the floor mat
at the front of the operator’s compartment.
STEP 4
C09126
Remove the two plastic plugs from the roof of the cab
and install the cab lifting bracket (see tool to be
made).
STEP 2 PE10834M
Using a suitable lifting device, carefully lift the cab Install the cab power socket, the windshield washer
and install it correctly on the floor of the cab. hose and the antenna wire.
IMPORTANT: Make sure that the seal located at the
rear of the cab is correctly in place.

9004-8
STEP 5
PG03502
Install the guard.

STEP 6
PH00629
Remove the lifting equipment and install the two

plastic plugs in the cab roof.

9004-9
SLIDING DOOR WINDOW

1
A

2 4

7
3

8

5
A
9 10 6
PDH1060
1 LH WINDOW FRAME 6 BEAD OF SILICOMET
2 SLIDING WINDOW SLIDER 7 SLIDING WINDOW LOCK
3 SLIDING WINDOW 8 GUARD
4 FIXED WINDOW 9 SEAL
5 SLIDER 10 STRIP

9004-10
Changing the sliding window

STEP 1 STEP 4
Retain the lock with its LH sliding (broken) window
bracket.
STEP 2
A 1
A
2
3

4 Cross-section AA 3
PDH1035

Remove the seal (1) and the bar (2) from the fixed
window and remove the guard (3) from the LH win- 1

dow. Using a screwdriver, remove the slider (4) from
the LH window frame. B
WARNING: Use protective gloves when 2

! replacing a window.
STEP 3
PDH1040
Carefully clean the LH window frame, remove all Cut the slider into two equal parts. Grease one of the
pieces of broken glass. sliders (1) at B and put it in place on the lower frame
of the LH window (2); as shown in the drawing. Apply
a bead of silicomet (3) inside the slider (1).
NOTE: The slider (1) is supplied as one single part.
When fitting, it is necessary to cut it into two equal
parts.

9004-11
STEP 5 STEP 7
Cross-section AA

A 1

A

A

A

2

3

1 2 Cross-section AA

PDH1043 1

Put the sliding window (1) in place on the LH window
frame (2) starting by offering up the bottom. Hold the B

sliding window (1) in place.
2
STEP 6
PDH1051
1 Grease the second slider (1) at B and put it in place

on the inside frame of the LH window (2); as shown in
the drawing. Apply a bead of silicomet (3) inside the
second slider (1).
3 2 A
PDH1047
Simultaneously, lift the sliding window (1) and push

the first slider (2) using the wooden tool (3) (to be
made, see page 4), under the sliding window (1). The
slider (2) must come flush with the end A of the slid-
ing window (1).

9004-12
STEP 8 Changing the fixed window
4 STEP 1
3 1 A 2
PDH1054
Push the second slider (1) and the first slider (2)
using the wooden tool (3) (to be made, see page 4),
under the sliding window (4). The second slider (1) 2
must come flush with the end A of the sliding window
(4).
STEP 9
A 2
3
3
PDH1032
Remove the seal (1) from the bar (2) on the fixed
window and then remove the guard (3) from the LH
window.
WARNING: Use protective gloves when

! replacing a window.
1
STEP 2
Carefully clean the LH window frame, remove all
pieces of broken glass.
B
5
4
PDH1057
Place the bar (1) on the fixed window (2), with the
seal (3) on the bar (1) and the guard (4) on the LH
window frame (5). Apply silicomet on the ends (A and
B) of the seal (3).

9004-13
STEP 3 STEP 4
Cross-section AA

1

A
D
D

B
C
A

A

PDH1041
Place the fixed window (1) in the LH window frame,

Cross-section DD
starting by offering up the top, as shown in the
drawing. Hold the fixed window in place.
E
STEP 5
1
PDH1036
Apply a bead of silicomet E at A, B and C inside the

LH window frame. The length of the beads of
silicomet A, B and C will be correspond to the
dimensions of the fixed window.
2
PDH1044
Put the fixed window (1) in place, pushing it and lifting

it to avoid the shims (2) in place in the LH window
frame.

9004-14
STEP 6 Changing glued windows
STEP 1
When changing a glass which was installed using an
adhesive seal, the following must be ordered as well
2 as the glass:
3 A
- Q02031-04 (1): seal repair, comprising: the seal cut
to a length of 6000 and rolled up, two bottles of
adhesive primer and two rubber shims.
Remove the window stops. Clean out any remaining
debris.
STEP 2
Remove the old seal, using a spatula.
STEP 3
1 Clean the two surfaces to be assembled and make
sure that they are completely dry.
WARNING: Do not repaint the seal carrier

B on the cab. Good adhesion can only be
! obtained on stoved paint (factory paint).
STEP 4
Apply a thin coat of adhesive primer on the two sur-
4 faces (cab and window) using the piece of polyethane
supplied with the kit. Wait five minutes for the adhe-
PDH1048
sive to dry.
Reposition the bar (1) on the fixed window (2), with
the seal (3) on the bar (1) and the guard (4) on the LH STEP 5
window frame. Apply a bead of silicomet on the ends
Place the seal on the cab so that the connection is
(A and B) of the seal (3).
made on the upper portion.
STEP 6
Cut the seal, bevelled correctly, to the correct length
and connect the two ends. Put the rubber shims in
place.
STEP 7
Offer up the window. Apply and push to assemble the
glass, there must be no white marks between the
glass and the seal (air bubbles). It must be between 3
and 5 mm thick.

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