CASE CX225SR CRAWLER EXCAVATOR Service Repair Manual

REPAIR MANUAL
CX225SR
9-40691 1 02/12/2004

Contents
INTRODUCTION
DISTRIBUTION SYSTEMS A
POWER PRODUCTION B
TRAVELLING D
BODY AND STRUCTURE E
FRAME POSITIONING F
WORKING ARM H
TOOLS AND COUPLERS J
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INTRODUCTION
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1

Contents
INTRODUCTION
Foreword ( - A.10.A.40)
CX225SR
3
Safety rules ( - A.50.A.10)
CX225SR
4
Basic instructions ( - A.90.A.05)
CX225SR
6
Torque ( - A.90.A.10)
CX225SR
7
Torque ( - A.90.A.10)
CX225SR
8
Dimension ( - A.92.A.30)
CX225SR
11
Weight ( - A.92.A.40)
CX225SR
12
Consumables ( - A.92.A.55)
CX225SR
13
Hydraulic contamination ( - A.92.A.60)
CX225SR
16
Product identication ( - A.80.A.10)
CX225SR WE
18
CX225SR NA
19
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INTRODUCTION
Foreword ( - A.10.A.40)
CX225SR
INTRODUCTION TO THE REPAIR MANUAL
This manual has been designed so that in the near future it can be made available on CD and in a database
via a computer network.
This will allow fast and targeted search and navigation between the various information modules.
Information search
CRIL03J033E01 1
This manual is organised according to types of function and information.
• The function and information types are codied and appear in parentheses after the title and separated by a dash:
(1) Function
(2) Information type.
• Only the rst letter (A) and the rst number (B) of the function need to be used for the information search.
The rst letter (A) corresponds to the sections of the repair manual.
The rst number (B) corresponds to the chapters of the repair manual.
The rst part of the (A.B) code is reected in the page numbering.
THE REST OF THE CODING IS NOT LISTED IN ALPHA-NUMERIC ORDER IN THIS MANUAL.
• You will nd a table of contents at the beginning and end of each section and chapter.
You will nd an alphabetical index at the end of each chapter.
• Therefore it is the rst part of the (A.B) coding, then the tables of contents and index (page numbers) which will allow you to
quickly nd the information you are looking for.
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INTRODUCTION
Safety rules ( - A.50.A.10)
CX225SR
CAUTION
M171C - THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL.
WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO
THE POSSIBILITY OF DEATH OR SERIOUS INJURY.
ATTENTION: To avoid injury, always observe the Safety Notices, CAUTION and ATTENTION, contained in this
section and throughout the manual.
Place a “Do not start the machine” warning notice on the starter switch key before all maintenance or repair
operations.
CAUTION
M489 - Read the operators manual to familiarize yourself with the correct control functions.
CAUTION
M490 - Operate the machine and equipment controls from the seat position only. Any other method could
result in serious injury.
CAUTION
M265A - A frequent cause of personal injury or death is persons falling off and being run over. Do not
permit anyone to ride on the machine.
CAUTION
SB055 - Before starting engine, study operators manual safety messages. Read all safety signs on machine.
Clear the area of other persons. Learn and practice safe use of controls before operation. It is your
responsibility to understand and follow manufacturers instructions on machine operation, service, and to
observe pertinent laws and regulation. Operators and service manuals can be obtained from your dealer.
ATTENTION: You risk injury if you wear loose clothing or if you do not use safety equipment for your work. Always
wear clothes which are unlikely to become caught in the machinery. Other safety equipment may be required, in
particular: hard hat, safety boots, ear protectors, safety goggles or mask, thick gloves and reective clothing.
CAUTION
M124A - Rotating machine parts, stay clear, keep shields installed to help protect from clothing
entanglement and injury. Wear close-tted clothing.
CAUTION
SB071 - Rotating fan and belts: Contact will cause injury. Keep clear.
ATTENTION: Follow the procedures exactly when carrying out checks or inspections on the vehicle’s hydraulic
systems. DO NOT CHANGE the procedures.
ATTENTION: Before running the hydraulic cylinders in this vehicle through the cycles necessary for checking their
functioning or for draining a circuit, warn people nearby to move away.
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INTRODUCTION
CAUTION
SM121A - Always wear heat protective gloves to prevent burning your hands when handling heated parts.
CAUTION
M132B - Lower or block elevated implements and other attachments before servicing or when leaving the
equipment.
CAUTION
R149C - Hydraulic oil or diesel fuel leaking under pressure can penetrate the skin and cause infection
or other injury. To Prevent Personal Injury: Relieve all pressure, before disconnecting uid lines or
performing work on the hydraulic system. Before applying pressure, make sure all connections are tight
and components are in good condition. Never use your hand to check for suspected leaks under pressure.
Use a piece of cardboard or wood for this purpose. If injured by leaking uid, see your doctor immediately.
ATTENTION: To remove a hardened pin, such as a pivot pin, or a hardened shaft, use a soft-headed hammer
(brass or bronze) or a brass or bronze peg and a steel-headed hammer.
CAUTION
M428 - Always wear safety glasses when using a drill, hammer, saw, or other tools that may cause chips
to y.
ATTENTION: Use suitable servicing jacks or a chain hoist for raising the wheels or tracks. Always chock the
vehicle in place with suitable safety supports.
ATTENTION: When carrying out maintenance or repair operations on the vehicle, keep the workshop oor, the
driving position and the steps free from oil, water, grease, tools, etc... Use an oil absorbent material and/or workshop
cloths as necessary. Always use sound methods.
ATTENTION: Some parts of this vehicle are very heavy. Use lifting devices or additional assistance recommended
in the Operator’s Manual.
CAUTION
M532 - Do not operate the engine in a closed building. Proper ventilation is required under all circumstances.
CAUTION
M503 - When the battery electrolyte is frozen, the battery can explode if (1), you try to charge the battery, or
(2), you try to jump start and run the engine. To prevent the battery electrolyte from freezing, try to keep the
battery at full charge. If you do not follow these instructions, you or others in the area can be injured.
CAUTION
M244A - BATTERIES CONTAIN ACID AND EXPLOSIVE GAS. EXPLOSION CAN RESULT FROM SPARKS,
FLAMES, OR WRONG CABLE CONNECTIONS. TO CONNECT JUMPER CABLES OR CHARGER, SEE
MANUAL(S) FOR THE CORRECT PROCEDURE. FAILURE TO FOLLOW THE ABOVE INSTRUCTIONS CAN
CAUSE SERIOUS PERSONAL INJURY OR DEATH.
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INTRODUCTION
Basic instructions ( - A.90.A.05)
CX225SR
GENERAL
Cleaning
Clean all metal parts except the bearings with white spirit or steam. Do not use caustic soda for steam cleaning.
After each cleaning, dry and oil all parts. Clean the oil ducts with compressed air. Clean the bearings with parafn,
then dry them completely and lubricate them.
Inspection
Check all the parts when they are disassembled. Replace all parts that show signs of wear or damage. Supercial
scratches and grooves can be removed with an oil stone or with a cloth dipped in red oxide. A complete visual
inspection is necessary to detect wear and pitting, and replacing parts as soon as it becomes necessary will help to
avoid premature breakdowns.
Bearings
Check that the bearings turn freely. Replace them if their adjustment is too free or if their functioning is irregular.
Wash the bearings with a good solvent or parafn and allow them to air dry.
DO NOT DRY THE BEARINGS WITH COMPRESSED AIR.
Needle bearings
Before pushing needle bearings into a cylinder bore, always remove all metallic projections from the bore and its
edges. Before pushing in bearings with a press, coat the inside and edges of the bearings with Vaseline.
Gears
Check all the gears and ensure that they do not show any signs of wear or damage. Replace the worn out
or damaged gears.
Gaskets, O-rings and at seals
Always install new gaskets, O-rings, and at seals. Coat the gaskets and O-rings with Vaseline.
Shaft
Check all shafts showing wear or damage. Enusre that the surface of a shaft carrying a bearing or gasket is
not damaged.
Spare parts
Always use CASE spare parts. To order these, refer to the Spare Parts Catalogue and indicate the correct reference
number of the CASE spare parts.
Breakdowns caused by the use of parts other than CASE spare parts are not covered by the warranty.
Lubrication
Use only the oils and lubricants specied in the Operator’s Manual or the Service Manual.
Breakdowns caused by the use of oils and lubricants not specically listed are not covered by the warranty.
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INTRODUCTION
Torque ( - A.90.A.10)
CX225SR
STANDARD TIGHTENING TORQUE
Order of tightening nuts and cap screws.
Tighten alternately so that torque remains uniform. Cap screws which are tted with Loctite (look for traces of a
white residue on the thread after removal), must be cleaned with a thin oil or a suitable solvent, then dried.
Add two or three drops of Loctite to the cap screw thread, then t the screw.
CRIL03H012E01 1
The numbers in the diagrams represent the order of tightening.
Tightening torque
Where there are no special instructions, tighten cap nuts screws to the torques given in the table below.
Standard torque setting table.
Designation of cap screws
(dimensions)
M6 M8 M10 M12 M14 M16 M18 M20
Spanner in mm 10 13 17 19 22 24 27 30Cap screw
Torque setting in
Nm
6.9 19.6 39.2 58.8 98.1 157.2 196 274
Wrench in mm 5 6 8 10 12 14 14 17Socket head
screw Torque setting in
Nm
8.8 21.6 42.1 78.4 117.6 176.4 245 343
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INTRODUCTION
Torque ( - A.90.A.10)
CX225SR
SPECIAL TORQUE SETTINGS
No. Component Screw
diameter
Wrench
in mm
Tightening torque
(1)* Travel motor and reduction gear assembly M16 24 267 - 312 Nm
(2)* Sprocket M16 24 267 - 312 Nm
(3)* Idler wheel M16 24 267 - 312 Nm
(4)* Upper roller M20 30 521 - 608 Nm
(5)* Lower roller M18 27 371 - 432 Nm
(6) Chain guide M18 27 380 - 443 Nm
(7) Track pad M20 30 300 Nm+120 °
(8) Counterweight M36 55 2750 - 2940 Nm
(9) Turntable (chassis) M20 30 468 - 545 Nm
(10) Turntable (upperstructure) M20 30 468 - 545 Nm
(11)* Swing motor and reduction gear assembly M20 30 521 - 608 Nm
(12)* Engine M16 24 265 - 313 Nm
(13)* Engine mounts M10 17 64 - 74 Nm
(14) Radiator M16 24 147 - 176 Nm
M10 17 64 - 74 Nm(15)* Hydraulic pump
M20 30 367 - 496 Nm
(16)* Hydraulic reservoir M20 30 412 - 471 Nm
(17)* Fuel tank M20 30 412 - 471 Nm
(18)* Control valve M16 24 267 - 312 Nm
(19)* Hydraulic swivel M12 19 109 - 127 Nm
(20) Cab M16 24 78 - 80 Nm
(21) Batteries M10 17 20 - 29 Nm
Use Loctite 262 or an equivalent on mounting screws marked with an asterisk (*).
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INTRODUCTION
CRIL04B072H01 1
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INTRODUCTION
CRIL04B073H01 2
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INTRODUCTION
Dimension ( - A.92.A.30)
CX225SR
Machine tted with monobloc boom 5.70 m
CRPH04B001F00 1
Dippers 1.90 m 2.40 m 3.00 m
(A) 3.08 m 3.14 m 2.90 m
(B) 2.97 m
(C) 8.97 m 8.93 m 8.85 m
(D) 6.74 m 6.70 m 6.62 m
(E) 2.80 m
(F) 1.40 m
(G) 1.68 m
(H) 4.46 m
(I) 3.66 m
(J) 2.39 m
(K) 0.60 m
(L) with track pads 600 mm 2.99 m
(M) 0.46 m
(N) 1.40 m
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INTRODUCTION
Weight ( - A.92.A.40)
CX225SR
Weight of machine
Conguration Weight Ground
pressure
With track pads 600 mm, monobloc boom 5.70 m, dipper 2.40 m, 760 kg
backhoe, driver and full fuel tank
22 700 kg 0.47 bar
Weight of components
Engine 487 kg
Hydraulic pump 125 kg
Attachment control valve 187 kg
Swing moto-reduction gear 223 kg
Travel moto-reduction gear 250 kg
Boom cylinder 200 kg
Dipper cylinder 257 kg
Bucket cylinder 151 kg
Counterweight 5880 kg
Cab kg
Turntable 244 kg
Upperstructure with equipment (counterweight and turntable) 11770 kg
Hydraulic swivel 27 kg
Undercarriage with equipment EUROPE
7020 kg
NA
7730 kg
Machine without equipment EUROPE
18840 kg
NA
19550 kg
Attachment 3870 kg
Boom with equipment 2200 kg
Dipper with equipment 3.00 m 910 kg
Dipper without equipment 3.00 m 599 kg
Radiator and oil-cooler assembly 55 kg
Fuel tank 160 kg
Hydraulic reservoir 145 kg
Idler wheel 82 kg
Upper roller 17 kg
Lower roller 35 kg
Tension shock absorber 142 kg
Track 600 mm 1350 kg
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INTRODUCTION
Consumables ( - A.92.A.55)
CX225SR
FLUIDS AND LUBRICANTS
Lubricants must have the correct properties for each application.
ATTENTION: You must respect the operating conditions for the different ingredients.
Hydraulic uid
CASE AKCELA hydraulic uid is specially designed for high pressure applications and for the CASE hydraulic
system.
The type of uid to be used depends on the ambient temperature.
• TEMPERATE COUNTRIES - 20 °C to + 40 °C
CASE AKCELA HYDRAULIC EXCAVATOR FLUID
(MS 1230. ISO VG 46. DIN 51524 PART 2 HV)
• HOT COUNTRIES 0 °C to + 60 °C
CASE AKCELA HYDRAULIC EXCAVATOR FLUID "HOT CLIMATE"
• COLD COUNTRIES - 40 °C to + 20 °C
CASE AKCELA HYDRAULIC EXCAVATOR FLUID "COLD CLIMATE"
• BIODEGRADABLE FLUID - 30 - +40 °C
This yellow uid can be mixed with standard uid.
If this liquid is used, it is advisable to completely drain the hydraulic circuit .
CASE AKCELA HYDRAULIC EXCAVATORS FLUID BIO
Transmission component oil
Extreme pressure oil used in transmission components inside sealed housings.
CASE AKCELA 135H EP GEAR LUBE SAE 80W-90
(SAE 80W-90. API GL 5. MIL-L-2105 D. MS 1316. ZF TE-ML 05A)
Grease
"Extreme Pressure" multi-purpose grease
• CASE AKCELA MOLY GREASE 241H EP-M (251H EP-M NLGI2)
with lithium and molybdenum bisulphide soap.
• CASE AKCELA 251H EP MULTI-PURPOSE GREASE (251H EP. NLGI 2)
with lithium and calcium soap.
• CASE AKCELA PREMIUM GREASE EP-2 (NLGI 2)
with lithium soap.
HYDRAULIC HAMMERS
Use only CASE AKCELA PREMIUM GREASE EP-2 (NLGI 2) grease with lithium soap.
Engine oil
CASE AKCELA NO. 1 ENGINE OIL is recommended for the engine.
This oil provides correct lubrication for your engine in all working conditions.
If CASE AKCELA NO. 1 ENGINE OIL Multigrade cannot be obtained, use oil corresponding to one of the following
categories: ACEA E5. MS 1121. API CH-4.
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INTRODUCTION
CRIL03H015F01 1
OIL USE RANGE
1. Mineral-based
2. Semi-synthetic based
3. Synthetic based
Fuel
Use fuel that is compliant with ASTM (American Society for Testing and Materials) standard D975.
• Use Grade No 2 fuel. The use of other types of fuel can result in a loss of power and may cause high fuel
consumption.
• When the temperature is very cold, the use of a mixture of No 1 and No 2 fuel is permitted. See your fuel
vendor for winter fuel requirements in your area.
• If the temperature falls below the fuel cloud point (point at which wax begins to form) the wax crystals will
cause power loss or will prevent the engine from starting.
IMPORTANT: In cold weather, ll the fuel tank at the end of the day’s work to prevent condensation from forming.
FUEL STORAGE
Long storage can lead to the accumulation of impurities and condensation in the fuel tank. Engine trouble can
often be traced to the presence of water in the fuel.
The storage tank must be placed outside and the temperature of the fuel should be kept as low as possible.
Drain off water and impurities regularly.
Anti-freeze/Anti-corrosion
Use anti-freeze in all seasons to protect the cooling system from corrosion and all risk of freezing.
CASE AKCELA PREMIUM ANTI-FREEZE LRD -25°C
For environments with temperatures falling to - 25 °C, do not mix with water.
CASE AKCELA PREMIUM ANTI-FREEZE (MS 1710)
For environments with temperatures falling to - 38 °C, use with water in a proportion of 50/50.
IMPORTANT: Do not mix products of a different origin or a different make.
The system must be topped up with the same product.
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INTRODUCTION
Environment
Before carrying out any servicing operation on this machine and before disposing of used uids or lubricants, always
think of the environment. Never throw uid or oil on the ground and never keep them in leaking receptacles.
Contact your local ecological recycling centre for information on appropriate ways to dispose of these substances.
Components made from plastic or resin
When cleaning plastic parts, (the console, the instrument panel, the indicators etc...) avoid using petrol, parafn,
paint solvents etc.
Use only water, soap and a soft cloth. The use of petrol, parafn, paint solvents, etc, will cause discoloration,
cracking or deformation of these components.
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INTRODUCTION
Hydraulic contamination ( - A.92.A.60)
CX225SR
CLEANING THE HYDRAULIC SYSTEM
General
Contamination of the hydraulic system is a major cause of incorrect operation of hydraulic components.
Contamination is indicated by the presence of foreign particles in the hydraulic uid.
Contamination of the hydraulic system can occur in any of the following situations:
1. When draining the uid or disconnecting a hydraulic line.
2. When disassembling a component.
3. Due to normal component wear.
4. Due to damaged or worn seals.
5. Due to a damaged component in the hydraulic system.
All hydraulic systems can function even if they are slightly contaminated. The components of the hydraulic system
are designed to support slight contamination. Any increase in the degree of contamination can cause serious
problems in the hydraulic system.
The following is an incomplete list of these problems:
1. The cylinder rod seals leak.
2. Control valve spools do not return to the neutral position.
3. Control valve spools do not move easily.
4. Hydraulic uid is too hot.
5. Hydraulic components wear quickly.
6. Safety valves or check valves do not close due to contamination.
7. Repaired components break down soon.
8. Cycles are slow; the machine does not have enough power.
If any of the above situations occurs, it is an indication of excessive contamination of the hydraulic system.
To eliminate contamination, effectively, refer to PRIMARY HYDRAULIC POWER SYSTEM - Decontaminating
(A.10.A - F.30.A.60).
Types of contamination
Contamination exists basically in two forms: microscopic or visible.
We speak of microscopic contamination when very small particles of foreign bodies are in suspension in the
hydraulic uid. These particles are too small to be seen or felt. Microscopic contamination can be detected by
identifying the problems relating to microscopic contamination or by laboratory tests.
The following are a few examples of problems caused by microscopic contamination:
• The cylinder rod seals leak.
• Control valve spools do not return to the neutral position.
• The operating temperature of the hydraulic system is too high.
• Components wear quickly.
We speak of visible contamination when the presence of foreign bodies can be detected visually, by touch or by
smell. Visible contamination can cause the sudden failure of a component.
The following are a few examples of problems caused by visible contamination:
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INTRODUCTION
• The uid contains metal or other fragments.
• The uid contains air. The uid is dark and thick.
• There is a smell of burning in the uid. The uid contains water.
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INTRODUCTION
CX225SR WE
NOTE: For all parts orders, requests for information or assistance, always specify the type and the serial number of
the machine to your CASE dealer.
Fill out the following lines with the required information: type, year of manufacture, serial number of the machine
(manufacturer’s plate), mark, type and serial number of the engine, and serial numbers of hydraulic components.
Manufacturer’s plate
CRIL03H001E01 1
(1) TYPE (2) YEAR OF MANUFACTURE (3) SERIAL NUMBER
Engine
MAKE TYPE SERIAL NUMBER
Serial numbers of hydraulic components
COMPONENTS SERIAL NUMBER
Hydraulic pump
Swing reduction gear
Travel reduction gear
Travel control valve
Attachment control valve
Swing control valve
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INTRODUCTION
CX225SR NA
NOTE: For all parts orders, requests for information or assistance, always specify the type and the serial number of
the machine to your CASE dealer.
Fill out the following lines with the required information: type, year of manufacture, serial number of the machine
(manufacturer’s plate), make, type and serial number of the engine and serial numbers of hydraulic components.
Manufacturer’s plate
CRIL03I175E01 1
(1)TYPE (2)YEAR OF MANUFACTURE (3)SERIAL NUMBER
Engine
MAKE TYPE SERIAL NUMBER
Serial numbers of hydraulic components
COMPONENTS SERIAL NUMBER
Hydraulic pump
Swing reduction gear
Travel reduction gear
Travel control valve
Attachment control valve
Swing control valve
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INTRODUCTION
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REPAIR MANUAL
DISTRIBUTION SYSTEMS
CX225SR
26019 1 02/12/2004
A

Contents
DISTRIBUTION SYSTEMS - A
PRIMARY HYDRAULIC POWER SYSTEM
CX225SR
A.10.A
HYDRAULIC COMMAND SYSTEM
CX225SR
A.14.A
ELECTRICAL POWER SYSTEM
CX225SR
A.30.A
LIGHTING SYSTEM
CX225SR
A.40.A
26019 1 02/12/2004
A

PRIMARY HYDRAULIC POWER SYSTEM - 10.A
CX225SR
26020 1 02/12/2004
A.10.A / 1

Contents
PRIMARY HYDRAULIC POWER SYSTEM - 10.A
TECHNICAL DATA
PRIMARY HYDRAULIC POWER SYSTEM - General specication (A.10.A - D.40.A.10)
CX225SR
5
PRIMARY HYDRAULIC POWER SYSTEM - General specication (A.10.A - D.40.A.10)
CX225SR
7
PRIMARY HYDRAULIC POWER SYSTEM - Special tools (A.10.A - D.20.A.40)
CX225SR WE
9
PRIMARY HYDRAULIC POWER SYSTEM - Special tools (A.10.A - D.20.A.40)
CX225SR NA
11
PRIMARY HYDRAULIC POWER SYSTEM - Seed rates (A.10.A - D.50.A.60)
CX225SR
13
Hydraulic pump
Hydraulic pump - Special tools (A.10.A.20 - D.20.A.40)
CX225SR
15
Hydraulic pump - Service limits (A.10.A.20 - D.20.A.20)
CX225SR
18
FUNCTIONAL DATA
PRIMARY HYDRAULIC POWER SYSTEM - Static description (A.10.A - C.30.A.20)
CX225SR
19
PRIMARY HYDRAULIC POWER SYSTEM - Dynamic description (A.10.A - C.30.A.10)
CX225SR
20
Stack valve
Stack valve - External view (A.10.A.18 - C.10.A.40)
CX225SR
23
Stack valve - Sectional view (A.10.A.18 - C.10.A.30)
CX225SR
26
Stack valve Inlet section - Sectional view (A.10.A.18.10 - C.10.A.30)
CX225SR
31
Stack valve Outlet section - Sectional view (A.10.A.18.20 - C.10.A.30)
CX225SR
32
Hydraulic pump
Hydraulic pump - Sectional view (A.10.A.20 - C.10.A.30)
CX225SR
33
Compensator
Compensator - Sectional view (A.10.A.23 - C.10.A.30)
CX225SR
37
Sensing system
Sensing system Temperature sensor - Electronic schema (A.10.A.95.90 - C.20.A.50)
CX225SR
38
Powerboost system
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A.10.A / 2

Powerboost system - Electronic schema (A.10.A.10 - C.20.A.50)
CX225SR
39
SERVICE
PRIMARY HYDRAULIC POWER SYSTEM - Warm up (A.10.A - F.35.A.40)
CX225SR
40
PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A - F.35.A.51)
CX225SR
41
PRIMARY HYDRAULIC POWER SYSTEM - Drain uid (A.10.A - F.35.A.20)
CX225SR
42
PRIMARY HYDRAULIC POWER SYSTEM - Bleed (A.10.A - F.35.A.25)
CX225SR
43
PRIMARY HYDRAULIC POWER SYSTEM - Pressure test (A.10.A - F.40.A.30)
CX225SR
44
PRIMARY HYDRAULIC POWER SYSTEM - Decontaminating (A.10.A - F.30.A.60)
CX225SR
46
Stack valve
Stack valve - Remove (A.10.A.18 - F.10.A.10)
CX225SR
48
Stack valve - Overhaul (A.10.A.18 - F.10.A.40)
CX225SR
49
Stack valve Outlet section - Disassemble (A.10.A.18.20 - F.10.A.25)
CX225SR
50
Stack valve Inlet section - Disassemble (A.10.A.18.10 - F.10.A.25)
CX225SR
51
Stack valve - Visual inspection (A.10.A.18 - F.40.A.10)
CX225SR
52
Stack valve Inlet section - Assemble (A.10.A.18.10 - F.10.A.20)
CX225SR
53
Stack valve Outlet section - Assemble (A.10.A.18.20 - F.10.A.20)
CX225SR
54
Stack valve - Install (A.10.A.18 - F.10.A.15)
CX225SR
55
Relief valve
Relief valve - Disassemble (A.10.A.16 - F.10.A.25)
CX225SR
56
Relief valve - Assemble (A.10.A.16 - F.10.A.20)
CX225SR
57
Relief valve - Pressure test (A.10.A.16 - F.40.A.30)
CX225SR
58
Relief valve - Pressure setting (A.10.A.16 - F.45.A.70)
CX225SR
59
Powerboost system
Powerboost system Electrovalve - Electrical test (A.10.A.10.15 - F.40.A.50)
CX225SR
60
Hydraulic pump
Hydraulic pump - Remove (A.10.A.20 - F.10.A.10)
CX225SR
61
Hydraulic pump - Disassemble (A.10.A.20 - F.10.A.25)
CX225SR
63
Hydraulic pump - Assemble (A.10.A.20 - F.10.A.20)
CX225SR
70
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Hydraulic pump - Install (A.10.A.20 - F.10.A.15)
CX225SR
80
Hydraulic pump - Bleed (A.10.A.20 - F.35.A.25)
CX225SR
82
Hydraulic pump - Pressure test (A.10.A.20 - F.40.A.30)
CX225SR
83
Reservoir
Reservoir - Remove (A.10.A.22 - F.10.A.10)
CX225SR
84
Reservoir - Install (A.10.A.22 - F.10.A.15)
CX225SR
85
Compensator
Compensator - Disassemble (A.10.A.23 - F.10.A.25)
CX225SR
86
Compensator - Assemble (A.10.A.23 - F.10.A.20)
CX225SR
87
Oil lter
Oil lter - Remove (A.10.A.24 - F.10.A.10)
CX225SR
89
Oil lter - Install (A.10.A.24 - F.10.A.15)
CX225SR
90
Sensing system
Sensing system Temperature sensor - Electrical test (A.10.A.95.90 - F.40.A.50)
CX225SR
91
DIAGNOSTIC
PRIMARY HYDRAULIC POWER SYSTEM - Troubleshooting (A.10.A - G.40.A.10)
CX225SR
92
Stack valve
Stack valve - Troubleshooting (A.10.A.18 - G.40.A.10)
CX225SR
92
Relief valve
Relief valve - Troubleshooting (A.10.A.16 - G.40.A.10)
CX225SR
93
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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
PRIMARY HYDRAULIC POWER SYSTEM - General specication
(A.10.A - D.40.A.10)
CX225SR
Capacities
Total hydraulic circuit 206 L
Hydraulic uid reservoir 120 L
Coolant only 6.1 L
Main hydraulic pump
Variable ow twin pump, with axial pistons.
Maximum ow 2 x 190 L/min
Displacement 2 x 96.7 cm³
Hydraulic control pump
Fixed ow pump
Maximum ow 22 L/min
Displacement 11 cm³
Calibration pressure
Pilot circuit main relief valve (± 1 bar) 39 bar
Main relief valve (standard) (± 3 bar) 343 bar
Main relief valve (power boost) (± 5 bar) 373 bar
Secondary relief valve (boom, dipper and bucket) ( ± 5 bar) 392 bar
Secondary relief valve (swing) (± 4 bar) 304 bar
Secondary relief valve (travel) (± 5 bar) 343 bar
Secondary relief valve (boom and dipper) (± 5 bar) 392 bar
Boom cylinder
Barrel diameter 125 mm
Rod diameter 90 mm
Stroke 1284 mm
Dipper cylinder
Rod diameter 95 mm
Stroke 1474 mm
Bucket cylinder
Rod diameter 80 mm
Stroke 1012 mm
Cylinder leakage - attachment lowering (without load)
Boom cylinders (rod retraction) 5 mm/5 mn
Dipper cylinder (rod extension) 5 mm/5 mn
Bucket cylinder (rod extension) 7 mm/5 mn
Full (at the end of the attachment) 200 mm/10 mn
Cylinder speed
Boom raising (bucket open and on the ground) 3.5+/-0.6 s
Boom lowering (bucket open) 2.9+/-0.6 s
Arm opening 2.7+/-0.6 s
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Arm closing 3.7+/-0.6 s
Bucket opening 2.3+/-0.6 s
Bucket closing 4+/-0.6 s
Control valve
Five-section control valve for dipper, boom acceleration, swing, option and right travel.
Four-section control valve for dipper acceleration, bucket, boom and left travel.
Load holding relief valve for boom and dipper.
Swing motor
Fixed ow motor with axial pistons.
Automatic disk brakes.
Chassis upperstructure swing speed 11.2 RPM
Displacement 151 cm³
Working ow 155 L/min
Reduction ratio 16.757
Braking torque 857 Nm
Minimum brake release pressure 32 bar
Acceptable motor leakage 16 L/min
Travel motor
Two-speed motor with axial pistons.
Automatic disk brakes.
Slow speed 3.1 km/h
High speed 5 km/h
Gradeability 70 % (35°)
Tractive effort 19 100 daN
Displacement 168.9 cm³
100.3 cm³
Working ow 212 L/min
Reduction ratio 43.246
Braking torque (excluding reduction gear) 483 Nm
Permissible deviation in travel over a distance of 20 m (full speed) 1 m
Acceptable motor leakage 13 L/min
Attachment
Breakout force 13000 daN
Breakout force (dipper 3 m) 9530 daN
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PRIMARY HYDRAULIC POWER SYSTEM - General specication
(A.10.A - D.40.A.10)
CX225SR
CRIL04B040H01 1
Location of secondary relief valves
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Calibration pressure
Item Description Secondary
relief
pressure
setting
Nominal
pressure
read on the
machine
Pressure
with one
turn of the
screw
(* or for a
shim)
For pressure setting
procedures,
refer to:
Main relief valve(standard
pressure)
343 bar to
120 L/min
346 bar 217 bar Relief valve - Pressure setting
(A.10.A.16 - F.45.A.70)
(A)
Main relief valve (power boosted
pressure)
373 bar to
108 L/min
373 bar 290 bar Relief valve - Pressure setting
(A.10.A.16 - F.45.A.70)
(B) Boom raising port secondary
relief
392 bar to
20 L/min
405 bar 212 bar Relief valve - Pressure test
(H.20.B.16 - F.40.A.30)
(B1)
(B2)
Boom cylinder safety valves
secondary relief
392 bar to
20 L/min
405 bar - Safety valve - Pressure
setting (H.20.B.15 - F.45.A.70)
(C) Boom lowering port secondary
relief
392 bar to
20 L/min
(H.20.B.16 - F.40.A.30)
(D) Dipper out port secondary relief 392 bar to
20 L/min
(H.25.B.16 - F.40.A.30)
(D1) Dipper cylinder safety valves
secondary relief
392 bar to
20 L/min
400 bar - Safety valve - Pressure
setting (H.25.B.15 - F.45.A.70)
(E) Dipper in port secondary relief 392 bar to
20 L/min
(H.25.B.16 - F.40.A.30)
(F) Bucket open port secondary
relief
392 bar to
20 L/min
(H.30.C.16 - F.40.A.30)
(G) Bucket close port secondary
relief
392 bar to
20 L/min
(H.30.C.16 - F.40.A.30)
(H) Pilot circuit main relief 39 bar 43 bar 30 bar Relief valve - Pressure test
(A.14.A.16 - F.40.A.30)
(I) RH swing port secondary relief 304 bar to
122 L/min
325 bar 5 bar* Relief valve - Pressure test
(F.40.C.16 - F.40.A.30)
(J) LH swing port secondary relief 304 bar to
122 L/min
325 bar 5 bar* Relief valve - Pressure test
(F.40.C.16 - F.40.A.30)
(K) Forward travel secondary relief 343 bar 343 bar 60 bar Relief valve - Pressure test
(F.10.F.16 - F.40.A.30)
(L) Reverse travel secondary relief 343 bar 343 bar 60 bar Relief valve - Pressure test
(F.10.F.16 - F.40.A.30)
(N1)
(N2)
Negative pressure of pump
bodies (P1) and (P2)
25.5 bar Hydraulic pump - Pressure
test (A.10.A.20 - F.40.A.30)
Pilot accumulator check Accumulator - Check
(A.14.A.30 - F.40.A.11)
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PRIMARY HYDRAULIC POWER SYSTEM - Special tools (A.10.A -
D.20.A.40)
CX225SR WE
Digital tester assembly
CRIL03G253E00 1
DESCRIPTION QUANTITY CODE
Tester assembly for Multi-Handy 2051 - E54444449
Multi-Handy 2051 tester 1 D5444448
Pressure sensor (0 bar to 600 bar) 2 V5344460
Straight union for sensor 2 W5344461
Elbow union for sensor 1 X5344462
Engine speed sensor 1 Z5344463
Cable (length 5 m) 3 E3144472
Electric plug 220 volts 50 Hz 1 D5344467
Cigarette lighter cable 1 E5344468
Instruction Sheet 1 -
Carrying case 1 N5344476
The Multi-Handy tester is used to:
Check pressure (two pressure scales)
Check differential pressure (delta P)
Check temperature
Check engine rpm
Check the ow
600 litre turbine
CRIL03G254E00 2
DESCRIPTION QUANTITY CODE
Turbine 1 RE3 Z5344486
Plates M45x2 2 D4323359
Flange diameter 24 mm 2 B8230183
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Semi-ange 4 D4024267
Screw M12 length 75 mm 8 Z1232983
Union assembly for testing pressure and ow
CRIL03G258E00 3
DESCRIPTION CODE
Union assembly for testing pressure and ow CAS30038
Set of high pressure hoses
CRIL03G259E00 4
DESCRIPTION CODE
Set of high pressure hoses CAS30036
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PRIMARY HYDRAULIC POWER SYSTEM - Special tools (A.10.A -
D.20.A.40)
CX225SR NA
Digital tester assembly for pressure measurement
CRIL03G255E00 1
DESCRIPTION CODE
Digital tester assembly for pressure measurement OEM1652
Digital tester assembly for pressure and temperature measurement
CRIL03G256E00 2
DESCRIPTION CODE
Digital tester assembly for pressure and temperature measurement OEM1653
Flowmeter
CRIL03G257E00 3
DESCRIPTION CODE
Flowmeter for a ow of < 75 GPM CAS10280
Flowmeter for a ow of > 75 GPM OEM1240
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Union assembly for testing pressure and ow
CRIL03G258E00 4
DESCRIPTION CODE
Union assembly for testing pressure and ow CAS40023A + CAS40035
Set of high pressure hoses
CRIL03G259E00 5
DESCRIPTION CODE
Set of high pressure hoses CAS30036
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Main pumps ow curve and pilot pressure
"Negative ow control" diagram
• Engine speed 2000 RPM
• Maximum displacement 96.7 cm³.
Hydraulic pump - Special tools (A.10.A.20 - D.20.A.40)
CX225SR
NOTE: The tools listed below are to be manufactured locally.
NOTE: Numbers in parentheses refer to Hydraulic pump - Sectional view (A.10.A.20 - C.10.A.30)
CRIL04B006E01 1
Used to install piston (69) and (70).
(A) 20 mm
(B) G1
(C) diameter 23 mm
(D) 56 mm
(E) diameter 4 mm
(F) Number of coils: 7
CRIL04B007E01 2
Used to install pusher bracket (47).
(A) 50 mm
(B) M12
(C) M12
(D) G3/4
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CRIL04B008E01 3
Used to install outer ring of taper roller bearing (4) on take-off shaft (3).
(A) 125 mm
(B) 105 mm
(C) diameter 46 mm
(D) diameter 56 mm
CRIL04B009E01 4
Used to protect seal (37) when reinstalling on seal holder (45).
(A) M8
(B) 95 mm
(C) 70 mm
(D) diameter 44 mm
(E) diameter 46 mm
(F) 69 mm
(G) 18 °
CRIL04B010E01 5
Used to install seal (37) on seal holder (45).
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(A) 53 mm
(B) 10 mm
(C) 12 mm
(D) 2 mm
(E) diameter 30 mm
(F) diameter 45 mm
(G) diameter 82 mm
(H) 30 °
CRIL04B011E01 6
Bushing (1)
Used to calculate the thickness of shims (2).
(A) diameter 11 mm
(B) diameter 116.5 mm
(C) 120 °
(D) 18 mm
(E) diameter 101 mm
(F) diameter 134.5 mm
CRIL04B012E01 7
Bushing (2)
Used to calculate the thickness of shims (2).
(A) 20.5 mm
(B) diameter 84 mm
(C) diameter 99.4 mm
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Hydraulic pump - Service limits (A.10.A.20 - D.20.A.20)
CX225SR
Description of parts Wear Limit Control
instrument
Action
Clearance between the piston and
the cylinder bore
0.04 mm or less Micrometer Replace the cylinder assembly
Valve plate (sliding contact surface
roughness)
0.8 Ra Gauge Polish the surface with a stone
Cylidner barrel (sliding contact
surface roughness)
0.4 Ra Gauge Polish the surface with a stone
Swash plate (roughness) 0.8 Ra Gauge Polish the surface with a stone
Piston assembly (roughness on
contact surface of shoes)
0.8 Ra Gauge Polish the surface
Clearance between pistons and
shoes
0.4 mm or less Gauge Replace the parts
Scratches on the sliding surface of
the shoes
0.4 mm or more Gauge Replace the parts
Inspection of barrel, pistons and bearings
Cylinder bores Replace the cylinder barrel if the bores show signs of
scratches or seizing.
Pistons Replace any pistons showing signs of scratches or
seizing.
Taper roller bearings and needle bearings Replace any interior or exterior bearing rings showing
signs of scratching.
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PRIMARY HYDRAULIC POWER SYSTEM - Static description (A.10.A
- C.30.A.20)
CX225SR
The hydraulic diagram is available as a poster at the end of this manual.
For easier understanding, the same legend is used for components appearing in the hydraulic sections and on
the poster.
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PRIMARY HYDRAULIC POWER SYSTEM - Dynamic description
(A.10.A - C.30.A.10)
CX225SR
TRAVEL
Functions Description Refer to
HIGH SPEED High speed is obtained by changing the travel motors
from large displacement to small displacement.
When the pressure increases too much, the motors
automatically change to low speed.
When the pressure drops below 39 bar, the motors
automatically change to high speed.
TRAVELLING Travel - Hydraulic
schema (F.10.F - C.20.A.20)
LOW SPEED Low speed is obtained when the travel motors are
changed to high displacement.
schema (F.10.F - C.20.A.20)
STRAIGHT-LINE
TRAVEL
If you want to use the attachment or the swing during
travel, the machine will continue in a straight line without
zig-zagging.
schema (F.10.F - C.20.A.20)
SWING
BRAKING When the swing control is in the neutral position, the
motor and reduction gear assembly is braked.
When the swing is operated, the motor and reduction
gear assembly brake is released.
The swing is braked 5 seconds after putting the control
into neutral or when the attachment is no longer
operated.
SWINGING Circular swing -
Hydraulic schema (F.40.C -
C.20.A.20)
PRIORITY The swing torque is maintained by the priority valve
incorporated in the control valve.
When working in a trench, the swing variable priority
valve is activated to provide sufcient ow to the dipper.
C.20.A.20)
ANTI-REBOUND This function reduces the number of rebounds when the
swing is stopped.
A protective valve is mounted on the swing motor.
C.20.A.20)
ATTACHMENT
BOOM LIFTING An internal spool is used to provide two ows when
raising the boom.
BOOM Lift - Hydraulic schema
(H.20.B - C.20.A.20)
BOOM LOWERING,
LOAD HOLDING
Boom lowering is made possible by unlocking the load
holding system which is incorporated in the control valve.
(H.20.B - C.20.A.20)
BOOM LOWERING,
ADDITIONAL
SUPPLY
Acceleration and ow reduction pressure information
are controlled via the fuel return circuit in the boom
valve spool and the continuous connection between the
supply and the return.
(H.20.B - C.20.A.20)
BOOM LOWERING,
VIBRATION
PREVENTION
The pressure points are controlled by the circuit which
keeps part of the supply ow for the free passage. This
is used to reduce vibration.
(H.20.B - C.20.A.20)
DIPPER OUT An internal spool provides two ows for the dipper. DIPPER Lift - Hydraulic schema
(H.25.B - C.20.A.20)
DIPPER IN, LOAD
HOLDING
Dipper in is made possible by unlocking the load holding
system that is incorporated in the control valve.
DIPPER Lift - Hydraulic schema
(H.25.B - C.20.A.20)
DIPPER IN,
ADDITIONAL
SUPPLY
The additional supply cancellation valve makes
combined movements quicker.
DIPPER Lift - Hydraulic schema
(H.25.B - C.20.A.20)
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Stack valve - External view (A.10.A.18 - C.10.A.40)
CX225SR
CRIL04A071G01b 1
Control valve block - Identication of ports
Port Description Port Description
(A1) RH forward travel (A2) Option circuit
(A3) Swing left (A5) Arm opening
(A6) LH forward travel (A7) Bucket closing
(A8) Boom raising (B1) RH reverse travel
(B2) Option circuit (B3) Swing right
(B5) Arm closing (B6) LH reverse travel
(B7) Bucket opening (B8) Boom lowering
(Dr) Leak-off return (P1-P2) Main pump pressure
(P3-P3) Flow reinjection (option) (PA) Attachment and swing pressure switch
(PT) Travel pressure switch (PP) Pilot pump pressure
(Pbu) Swing priority cancellation (Pc1) Dipper load holding
(Pc2) Boom load holding (Pc3) Priority to swing
(Ph) Main relief valve power boost (Ps1-Ps2) Negative pressure
(T1-T2) Return (T3) Swing return
(T4) By-pass return (T5) Towards cushion valve - heating
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CRIL04A88H01 2
Control valve block - description
Description of control valve block
(1) Control valve block (P1) (13) Control valve block (P2)
(32) Valve (33) Spring
(37) Flange (43) Flange
(52) Flange (57) Spacer
(68) Main safety valve (69) Secondary relief valve
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(72) Plug (74) Spool cap screw
(75) Screw (76) Load holding valve xing screws
(77) Control valve block xing screws (78) Swing priority cap xing screws
(81) Washer (87) Plug
(88) Cap (89) Seal
(92) Plug (93) Plug
(96) Plug (A-A) Refer to Stack valve - Sectional view
(A.10.A.18 - C.10.A.30)
(B-B) Refer to Stack valve - Sectional view (A.10.A.18 -
C.10.A.30)
(M-M) Refer to Stack valve - Sectional view
(A.10.A.18 - C.10.A.30)
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Stack valve - Sectional view (A.10.A.18 - C.10.A.30)
CX225SR
CRIL04A089G01 1
Section A-A - Control valve block (P1)
(5R) Spool assembly - RH travel (7) Seal
(8) Large cap with pilot port (9) Large cap
(10) Small cap (12) Small cap with pilot port
(14) Spool assembly - dipper 1 (15) Spool assembly - boom 2
(16) Spool assembly - swing (17) Spool assembly option (grab/hammer)
(41) Load holding valve watertight seal (42) Load holding valve watertight seal
(63) Port plug (70) Negative pressure valve
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CRIL04A090G01 2
Section B-B - Control valve block (P2)
(1) Control valve block (P2) (2) Spool assembly - dipper 2
(3) Spool assembly - boom 1 (4) Spool assembly - bucket
(5L) Spool assembly - LH travel (6) Straight-line travel spool assembly
(7) Seal (8) Large cap with pilot orice
(9) Large cap (10) Small cap
(12) Small cap with pilot orice (41) Load holding valve watertight seal
(42) Load holding valve watertight seal (70) Negative pressure valve
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CRIL04A103G01 3
Section M-M - Watertight seal between the two control valve blocks
(65) Seal (66) Seal
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CRIL04A102G01 4
Other sections
Section Description Refer to
(C-C) Output section with swing priority spool and dipper
recycling valve
Stack valve Outlet section - Sectional view
(A.10.A.18.20 - C.10.A.30)
(D-D) Dipper section 1 and 2 Control valve - Sectional view (H.25.B.14 -
C.10.A.30)
(E-E) Boom 1 and 2 section Control valve - Sectional view (H.20.B.14 -
C.10.A.30)
(F-F) Swing and bucket section Control valve - Sectional view (F.40.C.14 -
C.10.A.30)
Control valve - Sectional view (H.30.C.13 -
C.10.A.30)
(G-G) Option and LH travel section Control valve - Sectional view (J.20.E.14 -
C.10.A.30)
Control valve - Sectional view (F.10.F.14 -
C.10.A.30)
(H-H) RH travel and straight-line spool section Control valve - Sectional view (F.10.F.14 -
C.10.A.30)
(I-I) Inlet section with main relief valve and check valves Stack valve Inlet section - Sectional view
(A.10.A.18.10 - C.10.A.30)
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(J-J) Restrictor bridge (60) on port (PP) (pilot pressure)
and port (PT) (upper pilot pressure switch)
CRIL04A104A01 5
(K-K) Union (61) on port (PA) (travel pilot pressure switch)
CRIL04A105A01 6
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Stack valve Inlet section - Sectional view (A.10.A.18.10 - C.10.A.30)
CX225SR
CRIL04A109G01 1
Section I-I
(34) Valve
(35) Spring
(53) Spacer
(54) Seal
(55) Back-up ring
(68) Main relief valve
(92) Plug
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Stack valve Outlet section - Sectional view (A.10.A.18.20 - C.10.A.30)
CX225SR
CRIL04A110G01 1
Section C-C - Swing priority spool and dipper recycling valve.
(18) Cap (19) Swing priority spool
(20) Spring seat (21) Spring
(22) Spool end (23) Seal
(24) Plug (25) Seal
(26) Spring (27) Recycling spool
(30) Seal (31) Back-up ring
(32) Valve (33) Spring
(72) Plug
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Hydraulic pump - Sectional view (A.10.A.20 - C.10.A.30)
CX225SR
CRIL04A181H01 1
(1) Support (2) Shim
(3) Take-off shaft (4) Taper roller bearing
(5) Screw (6) Support
(7) Body (8) Swash plate
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(9) Retaining plate (10) Piston
(11) Snap ring (12) Pinion
(13) Seal (14) Cylinder barrel
(15) Valve plate (16) Centring stud
(17) Screw (18) Needle roller bearing
(19) Screw (20) Seal
(21) Coupling (22) Control pump
(23) Spring (24) Bushing
(25) Ring (26) Screw
(27) Seal (28) Plate
(29) Seal (30) Cover
(31) Seal (32) Valve plate
(33) Centring stud (34) Spring
(35) Spherical bushing (36) Seal
(37) Seal (38) Screw
(39) Driving shaft (40) Regulator block
(41) Regulator cartridge (42) Safety valve
(43) Safety block (44) Regulator cartridge
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CRIL04A182H01a 2
(45) Seal carrier (46) Pusher bracket
(47) Pusher (48) Piston
(49) Spring seat (50) Spring
(51) Stop (52) Seal
(55) Body (56) Screw
(57) Nut (58) Spring
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(59) Bushing (60) Seal
(61) Body (62) Screw
(63) Nut (64) Stop
(67) Spring (68) Seal
(69) Piston (70) Piston
(71) Sleeve (72) Regulator block
(73) Pusher (74) Swash plate
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Compensator - Sectional view (A.10.A.23 - C.10.A.30)
CX225SR
CRIL04A100G01 1
(1) Control lever (2) Spring
(3) Centring stud (4) Spring
(5) Nut (6) Washer
(7) Stop (8) Spring guide
(9) Cover (10) Seal
(11) Spring seat (12) Liner
(13) Spool (14) Piston
(15) Body (16) Seal
(17) Cover (18) Screw
(19) Piston
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Sensing system Temperature sensor - Electronic schema
(A.10.A.95.90 - C.20.A.50)
CX225SR
CRIL03K145F01 1
Circuit layout
(1) Coolant temperature indicator (2) Coolant or hydraulic oil overheating indicator
lamp
(3) Audible alarm device (A2) Engine electronic control box
(B1) Coolant solution temperature sensor (B9) Coolant solution temperature sensor
(B10) Hydraulic oil temperature thermo-switch (P1) Instrument panel
CRIL03G094E03 2
Timing diagram
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Powerboost system - Electronic schema (A.10.A.10 - C.20.A.50)
CX225SR
CRIL04B074F01 1
Circuit layout
(K28) Power boost solenoid valve relay
(P1) Instrument panel
(S29) Power boost switch
(Y5) Power-up solenoid valve (yellow band)
CRIL04B075F01 2
Timing diagram
(1) Operational power boost
OPERATION
• When the power boost switch (S29) is operated, a signal is sent to instrument panel (P1). This activates
relay (K28) and thus also power boost solenoid valve (Y5) for about 8 seconds. During these 8 seconds,
the main relief valve is overcalibrated.
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PRIMARY HYDRAULIC POWER SYSTEM - Warm up (A.10.A -
F.35.A.40)
CX225SR
1. Start the engine. The engine takes 10 to 15 minutes
to warm up.
2. With the engine running at full speed, operate the
bucket and dipper controls in one direction (against
the cylinder stops) for 30 seconds.
3. Actuate the bucket and dipper control in the other
direction (against the cylinder stops) for 30 seconds.
4. Repeat steps 2 and 3 until the hydraulic temperature
reaches 44 - 55 °C.
5. Operate the boom, swing and travel controls in both
directions to warm up all the circuits to 44 - 55 °C.
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A.10.A / 40

PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A -
F.35.A.51)
CX225SR
DANGER
M252A - Hydraulic uid escaping under pressure can have enough force to penetrate the skin. Hydraulic
uid may also infect a minor cut or opening in the skin. If injured by escaping uid, see a doctor at
once. Serious infection or reaction can result if medical treatment is not given immediately. Make sure
all connections are tight and that hoses and lines are in good condition before applying pressure to the
system. Relieve all pressure before disconnecting the lines or performing other work on the hydraulic
system. To nd a leak under pressure use a small piece of cardboard or wood. Never use hands.
IMPORTANT: This operation must be carried out before any work is done on the hydraulic circuit.
1. Park the machine on hard, at ground.
2. Open the bucket until the cylinder rod is completely
retracted.
3. Extend the dipper until the cylinder rod is completely
retracted.
Lower the boom so that the end of the dipper is
resting on the ground.
Lower the tool to the ground.
4. Slow the engine speed to idle for 30 seconds, then
switch off the engine.
5. Turn the starter switch key to "ON" without starting
the engine.
6. Lower the pilot control cancellation lever.
7. Operate each control more than 10 times in both
directions to release all pressure in the circuits.
8. Press button (1) located on the hydraulic reservoir
breather to release pressure in the reservoir.
CRIL04B099A01 1
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A.10.A / 41

PRIMARY HYDRAULIC POWER SYSTEM - Drain uid (A.10.A -
F.35.A.20)
CX225SR
Prior operation: PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A - F.35.A.51)
Prior operation: Fuel ller aid - Remove (B.20.A.20 - F.10.A.10)
NOTE: It is recommended to install the vacuum pump before carrying out any work on the hydraulic circuit which
requires opening the circuit.
Installing this pump prevents uid loss when the circuit is opened.
This chapter describes the procedure for installing vacuum pump CAS-10193.
1. Remove plate (A) from the top of the hydraulic
reservoir.
Do not remove the reservoir seal.
CRIL04B100A01 1
2. To install the adapter plate with elbow union, refer
to PRIMARY HYDRAULIC POWER SYSTEM -
Special tools (A.10.A - D.20.A.40).
3. Connect the vacuum pump to the adapter plate
elbow union.
Connect the vacuum pump harness to the batteries.
4. Start the pump before carrying out any work on the
circuit.
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PRIMARY HYDRAULIC POWER SYSTEM - Bleed (A.10.A - F.35.A.25)
CX225SR
IMPORTANT: A hydraulic component and the circuit must be bled after the component has been replaced.
It is essential to ll the pump and motor housings and hydraulic components with oil before starting the machine.
Failure to comply with these two recommendations may damage the component (overheating and seizing).
IMPORTANT: Having bled the components, stop the engine for ve minutes and check for air bubbles in the
hydraulic uid in the reservoir.
1. To ll the housing and drain the hydraulic pump,
refer to Hydraulic pump - Bleed (A.10.A.20 -
F.35.A.25)
2. To bleed the attachment cylinders, extend and
retract each cylinder rod four or ve times without
bringing them up against the stops.
Repeat the operation three or four times, this time
bringing all the cylinder rods up against the stops.
3. To ll the housing and bleed the hydraulic swing
motor, refer to Hydraulic motor - Bleed (F.40.C.28
- F.35.A.25)
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A.10.A / 43

PRIMARY HYDRAULIC POWER SYSTEM - Pressure test (A.10.A -
F.40.A.30)
CX225SR
CRIL04B065G01 1
Port identication marks
Description of ports and insertion diameters, adjusting screws
Port
Screw
Description Location
(D1) Pump output (P2) SAE 6000 psi 1"
(D2) Pump output (P1) SAE 6000 psi 1"
(D3) Pilot pump output to Din3 G 1/2
(D4) Option pump output G 1/4
(S1) Main pump and pilot pump suction SAE 2000 psi 3"
(S2) Option pump intake G 3/4
(Pp) Pilot pump output G 1/2
(Din3) Pilot pump output from D3 G 1/2
(Dr) Leak-off circuit G 3/4
(Pd1) Plugged - Pressure test point G 1/4
(Pi1) Negative pressure G 1/4
(Pi2) Negative pressure G 1/4
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A.10.A / 44

Port
Screw
Description Location
(H) Pilot pressure adjusting screw (main relief valve)
(2) Pump bleed screw
(3) Adjusting screw on large pump adjustment spring
(4) Adjusting screw on small pump adjustment spring
(5) Adjusting screw on large pump adjustment spring
(6) Adjusting screw on small pump adjustment spring
(7) Adjusting screw on retaining spring for maximum plate tilt on pump 1
(8) Adjusting screw on retaining spring for maximum plate tilt on pump 2
(9) Maximum stop adjusting screw pumps P1 and P2
(M1) Working pressure (port (Pd1) on main pump (D1))
• LH travel
• Boom
• Bucket
(M2) Working pressure (port (Pd2) on main pump (D2))
• R.H. travel
• Swing
• Dipper
(M3) Pilot pressure (port (Pd3) on pilot pump (D3) or port (P2) on the pilot circuit lter)
For pressure setting values, refer to PRIMARY HYDRAULIC POWER SYSTEM - General specication (A.10.A -
D.40.A.10)
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PRIMARY HYDRAULIC POWER SYSTEM - Decontaminating (A.10.A
- F.30.A.60)
CX225SR
Prior operation: PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A - F.35.A.51)
Prior operation: To remove the electric pump for lling with fuel, refer to Fuel ller aid - Remove (B.20.A.20
- F.10.A.10)
Prior operation: To remove the protective panel from the hydraulic reservoir, refer to Upper shield - Remove
(E.20.A.71 - F.10.A.10)
Prior operation: To remove the lower access panel to the hydraulic reservoir, refer to Protective shield - Remove
(E.20.A.73 - F.10.A.10)
1. Prepare portable lter CAS10162A as follows:
Expel all hydraulic uid from the portable lter inlet
and outlet hoses.
Remove the portable lter cartridge.
Expel all hydraulic uid from the portable lter.
Clean the interior of the cartridge housing.
Install a new lter cartridge.
CRIL03I082A 1
2. Drain the hydraulic uid from the reservoir and clean
the reservoir, see the Operator’s Manual.
NOTE: Do not re-install the drain plug on the hydraulic
reservoir.
3. Replace the breather element and the return lter
and clean the intake lter, see the Operator’s
Manual.
NOTE: Do not install the plate and the breather.
4. Replace the pilot circuit lter, see the Operator’s
Manual.
5. Replace the Ultra Clean lter, see the Operator’s
Manual.
6. Install the valve from union kit (CAS 10508) on the
reservoir drain port.
Make sure that the valve is closed.
CAS10508-3 2
7. Fill the hydraulic reservoir with clean hydraulic uid,
see the Operator’s Manual.
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8. Install the inlet hose from the portable lter on the
valve under the hydraulic reservoir.
9. Install the long pipe from union kit (CAS 10508) on
the portable lter return hose.
10. Pass the long pipe into the hydraulic reservoir via
the breather port.
Move the intake lter long pipe as far away as
possible.
11. Open the valve under the hydraulic reservoir.
12. Install the portable lter on the upperstructure so
that the machine can be operated.
Attach the portable lter securely to the machine.
13. Connect the portable lter electric cable to the
battery.
Make sure that the electric cable is away from all
moving parts.
14. Start the portable lter.
15. Start the engine, run it at half speed for 10 minutes.
During those ten minutes, stir the hydraulic uid in
the hydraulic reservoir with the long pipe.
16. Bring the hydraulic uid to its operating temperature,
refer to PRIMARY HYDRAULIC POWER SYSTEM
- Warm up (A.10.A - F.35.A.40)
17. With the engine idling, stir the hydraulic uid in the
hydraulic reservoir for 10 minutes with the long pipe.
18. Shut down the portable lter and the engine.
19. Close the valve under the hydraulic reservoir.
20. Remove the inlet pipe from the valve under the
hydraulic reservoir.
21. Remove the long pipe from the hydraulic reservoir.
22. Disconnect the portable lter’s electric cable from
the battery.
Remove the portable lter from the machine.
23. Install a vacuum pump on the hydraulic reservoir,
refer to PRIMARY HYDRAULIC POWER SYSTEM
- Drain uid (A.10.A - F.35.A.20)
Start the vacuum pump.
24. Remove the valve from underneath the reservoir
and install the drain plug.
25. Stop and remove the vacuum pump.
26. Replace the return lter and clean the intake lter,
see the Operator’s Manual.
27. Replace the pilot circuit lter, see the Operator’s
Manual.
28. Replace the Ultra-Clean lter, see the Operator’s
Manual.
29. Check the hydraulic uid level.
Top up as necessary, see the Operator’s Manual.
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Stack valve - Remove (A.10.A.18 - F.10.A.10)
CX225SR
Prior operation: To remove the side protection panels from the hydraulic control valve, refer to Side shield -
Remove (E.20.A.70 - F.10.A.10)
Prior operation: To remove the valve bank hood, the front protection panels from the hydraulic control valve and
the valve bank hood bracket, refer to Upper shield - Remove (E.20.A.71 - F.10.A.10)
Prior operation: PRIMARY HYDRAULIC POWER SYSTEM - Drain uid (A.10.A - F.35.A.20)
1. Remove bracket xtures (5), then remove the
bracket.
2. Mark the position of the hoses (1) and electrical
connectors (2) on control valve block (3).
CRIL04C134B01 1
3. Disconnect the electrical connectors (2) from the
pressure switches.
4. Disconnect and plug hoses (1).
5. Plug the unions on control valve block (3).
6. Attach a suitable lifting device to the control valve
block (3).
7. Remove screws and (4) control valve block (3).
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Stack valve - Overhaul (A.10.A.18 - F.10.A.40)
CX225SR
NOTE: This section relates only to the control valve components not dealt with under functionalities. To nd the
functionalities, refer to Stack valve - Sectional view (A.10.A.18 - C.10.A.30) Other sections
IMPORTANT: Clean and check parts before assembling, refer to Stack valve - Visual inspection (A.10.A.18 -
F.40.A.10).
1. To separate components (1) and (13), remove
screws (77) and washers (81).
Replace seals (65) and (66), refer to Stack valve
- Sectional view (A.10.A.18 - C.10.A.30) section
(M-M).
When reassembling, tighten screws (77) to a torque
of 167 - 177 Nm.
2. Negative pressure valves (70) are not removable.
Only the seals should be replaced.
When reassembling, tighten valves (70) to a torque
of 103 - 113 Nm.
3. Tightening torques for the other components:
Restrictor bridge (60) - 103 - 113 Nm.
Plug (61) - 39 - 44 Nm.
Plug (63) - 14 - 18 Nm.
Plug (72) - 73 - 79 Nm.
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Stack valve Outlet section - Disassemble (A.10.A.18.20 - F.10.A.25)
CX225SR
1. SWING PRIORITY SPOOL
Remove plug (72) and discard the seal.
Remove spring (33) and valve (32).
Remove screws (78) and cap (18). Discard seal
(23).
Remove complete spool (19).
Remove screws from spool (22).
Remove springs (21) and seats (20).
NOTE: To avoid abrasion of the spoolvsurface during
dismantling of the spool assembly, use a soft-jawed vice
and clamp the spool as closely as possible to the head
in order to avoid any deformation. If the threaded part
of the screw is coated with locking uid, heat the screw
head with an industrial drier until it can be removed easily
(usually the temperature should be 200 - 250 °C). If the
spring is damaged (impaired functioning) during this
operation, replace the spring.
CRIL04B004A01 1
2. DIPPER RECYCLING VALVE
Remove plug (24) and discard seal (25).
Remove spring (26) and spool/liner assembly (27).
Discard seals (30) and back-up rings (31).
CRIL04B005A01 2
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Stack valve Inlet section - Disassemble (A.10.A.18.10 - F.10.A.25)
CX225SR
CRIL04A109G02 1
Input section - cross-sectional view
1. Remove plugs (72) and (92). Discard seals.
2. Remove screws (75) and anges (52).
Extract spacers (53), springs (35) and valves (34).
Discard seals (54) and back-up rings (55).
3. Remove main relief valve (68).
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Stack valve - Visual inspection (A.10.A.18 - F.40.A.10)
CX225SR
NOTE: Clean all parts with a suitable light oil based product. Allow to air dry and place each part on a clean sheet
of paper or vinyl for inspection.
NOTE: Inspect the surface of each part for scratches, abrasion and other damage.
1. Check for scratches and dents on the check valve
seats in the control valve body and for traces of rust
and foreign matter.
2. Check for scratches and dents on the outer surface
of the spool. Remove small scratches with a piece
of cloth soaked in an abrasive product.
3. Check that all sliding surfaces move freely. Check
for the absence of foreign matter in passages and
grooves.
4. Check for deformed or worn springs.
5. Replace all seals and backup rings with new original
parts.
6. After removing the caps and plugs, make sure that
there is no trace of paint on the body ports or the
plug rims. (any trace of residual paint might lead
to contamination, which could cause the system to
malfunction and result in possible leaks).
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Stack valve Inlet section - Assemble (A.10.A.18.10 - F.10.A.20)
CX225SR
Prior operation: To clean and check parts before assembling, refer to Stack valve - Visual inspection (A.10.A.18
- F.40.A.10).
CRIL04A109G02 1
Input section - cross-sectional view
Torque settings
Valve (68) 78 - 88 Nm
Plug (72) 73 - 79 Nm
Screw (75) 39 - 44 Nm
Plug (92) 206 - 226 Nm
1. Install plugs (72) and (92) with new seals.
Tighten the plugs to the specied torque.
2. Install valves (34) and springs (35).
Install spacers (53) tted with seals (54) and new
back-up rings (55).
Install anges (52) with screws (75). Tighten the
screws to the required torque.
3. Install main relief valve (68) tted with a new seal.
Tighten the valve to the required torque.
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Stack valve Outlet section - Assemble (A.10.A.18.20 - F.10.A.20)
CX225SR
Prior operation: To clean and check parts before assembling, refer to Stack valve - Visual inspection (A.10.A.18
- F.40.A.10).
1. SWING PRIORITY SPOOL
Install spring (33) and check valve (32).
Install plug (72) with a new seal.
Tighten the plug (72) to a torque of 73 - 79 Nm.
Coat the threaded parts of spool (19) with thread
locking uid.
Clamp the end of the spool (spring side) in a
soft-jawed vice.
Install spring (21) and seats (20) on screw (22).
Install and tighten screws (22) to a torque of 19 -
22 Nm.
Fit complete spool (19) in the control valve.
Fit a new seal (23) on cap (18).
Install cap (18) with screws (78).
Tighten screws (78) to a torque of 8.8 - 10.8 Nm.
CRIL04B004A01 1
2. DIPPER RECYCLING VALVE
Fit new seals (30) and (31) on liner (27B).
Install piston (27C) and spool (27A) on liner (27B).
CRIL03L049A02 2
3. Fit spring (26) and spool/liner assembly (27).
Install the plug (24) tted with a new seal (25).
Tighten the plug to a torque of 103 - 113 Nm.
CRIL04B005A01 3
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Stack valve - Install (A.10.A.18 - F.10.A.15)
CX225SR
1. Using a lifting device, position control valve block
(3) on its bracket.
CRIL04C134B01 1
2. Coat xing screws (4) with thread locking uid and
tighten them to a torque of 267 - 312 Nm.
Remove the lifting device.
3. Install and tighten supply and pilot hoses (1) on
control valve block (3) following the marks made
during removal.
4. Attach electrical connectors (2) to the pressure
switches following the marks made during removal.
5. Mount bracket (5).
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Relief valve - Disassemble (A.10.A.16 - F.10.A.25)
CX225SR
CRIL04A200F01 1
Main relief valve
(1) Nut (2) Adjusting screw for standard pressure
(3) Seal (4) Piston
(5) Spring (6) Awl
(7) Nut (8) Adjusting screw for power boost pressure
(9) Seal (10) Valve body
(11) Seal (12) Check valve seat
(15) Valve tip (16) Spring
(17) Valve
1. The valve is removed in the order of the marks on
the parts.
NOTE: Valve seat (12) should not be removed. It is
crimped to body (10).
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Relief valve - Assemble (A.10.A.16 - F.10.A.20)
CX225SR
CRIL04A200F01 1
Main relief valve
Refer to the disassembly process for a description of the parts.
1. Clean the parts, coat the threads with hydraulic oil
and replace the seals during assembly.
The valve is re-assembled in the reverse order of
the marks on the parts.
When installing body (10) on the control valve,
tighten it to a torque of 78 - 88 Nm.
Next operation: Relief valve - Pressure setting (A.10.A.16 - F.45.A.70)
26020 1 02/12/2004
A.10.A / 57

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CASE CX225SR CRAWLER EXCAVATOR Service Repair Manual