Case WX145, WX165 & WX185 Hydraulic Excavator Repair Service Manual

-
This complete service repair workshop manual PDF download for the WX145, WX165 & WX185 Case Hydraulic Excavator has easy-to-read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes.


APPLICABLE MODELS :

Case Hydraulic Excavator WX145 
Case Hydraulic Excavator WX165 
Case Hydraulic Excavator WX185 


TABLE OF CONTENTS :

- SAFETY INSTRUCTIONS SECTION 
- TECHNICAL DATA AND SPECIAL TOOLS SECTION 
- MACHINE STRUCTURE SECTION 
- ELECTRICAL SYSTEM SECTION 
- ELECTRONICS SECTION 
- HYDRAULICS SECTION 
- TROUBLESHOOTING AND REPAIR SECTION 
- REPAIR INSTRUCTIONS SECTION 


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Print No. : 9-91221 English
Total Pages : 746


This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

-

Section 1: Safety Instructions
    PREFACE
        To the reader
            Handling
            Repair
            Further information material
        Warnings and symbols
        Risks resulting from failure to observe the safety instructions
    SAFETY INSTRUCTIONS
        Personal safety instructions
            Observe the safety instructions
            Protection from noise
            Preparing for emergencies
            Wearing protective clothing
        Safety instructions before starting work
            Checking the machine
            Keeping the working area clean
            Using grab handles and steps
            Adjusting the operator’s seat
            Applying the safety belt
        Working from the operator’s seat only
        Never take passengers on the machine
        Safety instructions for machine operation
            Before setting off
            Note the position of the working equipment
        Taking care during operation
            Taking care when trenching
        Distance from overhead power lines
            Accident Prevention when reversing and slewing
            Rules for driving on the road
            Recovering and towing the machine
            Travelling uphill and downhill
            Preventing the machine from overturning
            Inspecting the deployment location
            Parking the machine safely
            Preventing accidents when the machine is moving
            Confirming the direction of machine travel
            Avoid caving out high banks
            Protection from rockfall and landslides
            Caving prevention
            Never move the bucket above persons
        Safety instructions, maintenance/servicing
            Safety during transport
            Safety during servicing operations
            Warning instructions for servicing work
            Correct machine support
            Working at greater heights
            Keeping clear of moving parts
            Prestressed units
            Never remove lead seals
            Safety instructions for accumulators
            Dismantling components
            After repair work
            Correct waste disposal
            Welding operations
            Starting the engine with starter batteries
            Prevention of acid-induced burns
            Prevention of scalding
            Safe handling of fluids
            Fire prevention
            Evacuation in case of fire
            Risks from exhaust gases
            Risks from fluids in pressure systems
            Preventing heat build-up close to pressure systems
            Preventing heat build-up in lines carrying combustible fluids
            Removing paint before welding
            Risks from breaking-away components
            Use appropriate tools
        Warning and instruction signs (mono-boom)
        Warning and instruction signs (boom adjusting equipment)
        Warning and instruction signs (mono-boom)
        Warning and instruction signs (boom adjusting equipment)
        Organizational measures
            Safety instructions governing specific operational phases
                Standard operation
            Warning of special dangers
                Electric energy
                Gas, dust, steam and smoke
                Hydraulic and pneumatic equipment
                Noise
                Oil, grease and other chemical substances
                Transporting and towing; recommissioning
                
Section 2: Technical Data and Special Tools
    Service Data General
        Foreword
        Data sheet for cylinders WX145
        Data sheet for cylinders WX165
        Data sheet for cylinders WX185
        Bucket-induced protrusion
        SI- and Additional Units
            Quantities of Space and Mass
            Time related Quantities
            Quantities of force, energy and power
        Conversions Tables Part 1
            Conversion for units of legth
            Conversion for units of area
            Conversion from foot and inch to metric mesures
        Conversions Tables Part 2
            Conversion table for units of pressure in gases, steam and fluids
            Conversion table for units of power, energy and heat quantity
            Conversion table for units of mechanical stress
            Practically equivalent units for pressure and mechanical stress (stregth)
            Units of temperature and conversion formulars
            Power, Energy and heat flow
            Speed
            Units of mass (weight)
            Units of volume, flow rates
            Fuel consumption
        Tightening Torques
            General information
            Units of measurement
            Bolts with standard thread DIN 13 – 13
            Bolts with metric fine thread DIN 13 – 13
            Tightening torques for SAE flange – system
            Tightening angles
        Calculation Examples
            Angles of Slope
            Travel Speed
            Hydraulic outputs (pumps/motors)
            Stroking times of cylinders
            Speeds of hydraulic motors
        Special tools for cylinders
            Screwed hex insert for piston nut
            Sealing kit – Assembly
            Scraper ring – Assembly
            Bushes - Dismantling
            Rod guide assembly
            Piston nut loosening and tightening
        Special tools for axles and gearboxes
            Axial stress meter
            Bearing friction moment adjusting device
            Driving tool for bushing
            Driving tool for bushing
            Assembly aid for shaft seals
            Master shaft
            Master shaft
            Extraction device
            Driving tool
            Driving tool
            Driving tool
            Assembly aid
            Assembly aid
            Brake centering device
            Tool handle
            Hydraulic pump
            Measuring device
            Threaded studs
            Driving tool for shaft seals
            Driving tool
            Driving tool
        Spacers
        
Section 3: Machine Structure
    MACHINE CONSTRUCTION
        Description of the machine (boom adjusting equipment)
            Machine layout
            Undercarriage
            Superstructure
            Hydraulic system
            Steering
            Service brake
            Parking brake
            Floating axle
            Electrical system
            Working equipment
        Description of the machine (monoblock boom)
            Machine layout
            Undercarriage
            Superstructure
            Hydraulic system
            Steering
            Service brake
            Parking brake
            Floating axle
            Electrical system
            Working equipment
        Description of the machine (boom adjusting equipment)
            Machine layout
            Undercarriage
            Superstructure
            Hydraulic system
            Steering
            Service brake
            Parking brake
            Floating axle
            Electrical system
            Working equipment
        Description of the machine (monoblock boom)
            Machine layout
            Undercarriage
            Superstructure
            Hydraulic system
            Steering
            Service brake
            Parking brake
            Floating axle
            Electrical system
            Working equipment
            Switches / keys
            Control elements
            Multifunction display
        Superstructure components, overview
        Engine assembly components, overview
        Drive unit components, overview
            WX145
            WX165/185
        Undercarriage components, overview
        
Section 4: Electrical System
    The electrical system
        Fundamental notions
        Automotive electrical systems
        Cable harnesses
        Fuses WX145, WX165 / WX185
        Fuses
            Checking / replacing the fuses
            Table of fuses
        Fuses
            Checking / replacing the fuses
            Fuse table
    ELECTRICAL CIRCUIT DIAGRAMS, WX165, WX185, 8916247
        Table of contents, page 1, WX145
        Table of contents, page 2, WX145
        Power supply, starter/engine, WX145
        Grid Heater / Filter Heater, WX145
        Sensor power supply, WX145
        Tank sensor / refuelling system, WX145
        Pilot control shutoff, WX145
        PCS, WX145
        Switches, WX145
        Speed adjusting motor, WX145
        Engine power supply – CU, WX145
        Driver's cab, voltage converter, WX145
        Driver's cab, wiper and washer, WX145
        Driver's cab, WX145
        Driver's cab, WX145
        Driver's cab, WX145
        Driver's cab, WX145
        Steering column lever switch, WX145
        Inching Function, WX145
        Lighting, WX145
        Lighting, WX145
        Lighting, WX145
        Speedometer – creep speed, WX145
        Valves – air filter control, WX145
        Service and parking brakes, WX145
        Floating axle brake, WX145
        Blower and air conditioner, WX145
        Auxiliary heating (option) , WX145
        Hammer / shears frequency (option) , WX145
        Stabilizers / levelling blade, WX145
        ESX power supply, WX145
        ESX CAN1 CAN2 diagnosis, WX145
        ESX coding, WX145
        ESX valve control, WX145
        ESX PCS valve control, WX145
        ESX valve stacking , WX145
        ESX valve control, WX145
        ESX slewing initiator, WX145
        ESX pressure sensors, WX145
        CAN BUS power supply, overview, WX145
        Fuses, overview, WX145
        Ground points on the machine, overview, WX145
    ELECTRICAL CIRCUIT DIAGRAMS, WX165, WX185, 8916248
        Table of contents, page 1, WX165/185
        Table of contents, page 2, WX165/185
        Power supply, starter/engine, WX165/185
        Grid Heater / Filter Heater, WX165/185
        Sensor power supply, WX165/185
        Tank sensor / refuelling system, WX165/185
        Pilot control shutoff, WX165/185
        PCS, WX165/185
        Switches, WX165/185
        Speed adjusting motor, WX165/185
        Engine power supply – CU, WX165/185
        Driver's cab, voltage converter, WX165/185
        Driver's cab, wiper and washer, WX165/185
        Driver's cab, WX165/185
        Driver's cab, WX165/185
        Driver's cab, WX165/185
        Driver's cab, WX165/185
        Steering column lever switch, WX165/185
        Inching Function, WX165/185
        Lighting, WX165/185
        Lighting, WX165/185
        Lighting, WX165/185
        Speedometer – creep speed, WX165/185
        Valves – air filter control, WX165/185
        Service and parking brakes, WX165/185
        Floating axle brake, WX165/185
        Blower and air conditioner, WX165/185
        Auxiliary heating (option) , WX165/185
        Hammer / shears frequency (option) , WX165/185
        Stabilizers / levelling blade, WX165/185
        ESX power supply, WX165/185
        ESX CAN1 CAN2 diagnosis, WX165/185
        ESX coding, WX165/185
        ESX valve control, WX165/185
        ESX PCS valve control, WX165/185
        ESX valve stacking , WX165/185
        ESX valve control, WX165/185
        ESX slewing initiator, WX165/185
        ESX pressure sensors, WX165/185
        CAN BUS power supply, overview, WX165/185
        Fuses, overview, WX165/185
        Ground points on the machine, overview, WX165/185
    ELECTRICAL CIRCUIT DIAGRAMS FOR SUPPLEMENTARY FUNCTIONS
        Electrical circuit diagram, hammer equipment
        Electrical circuit diagram, shears equipment
        Electrical circuit diagram, cutter equipment
        Electrical circuit diagram, hammer / shears equipment
        Electrical circuit diagram, hammer / cutter equipment
        Electrical circuit diagram, shears / cutter equipment
        Electrical circuit diagram, hammer / shears / cutter equipment
        Layout of electrical components
        Electrical system – central electronics \(behind
        Electrical system for electro-hydraulic pilot control
        Electrical system of pilot control-unit,solenoid valves, sensors and switches
        Electrical system in engine compartment
        Electrical system for undercarriage control block
        Electrical system for undercarriage stabilization, the fig. shows individual stabilization variant A4
        Electrical components by code numbers
        Connector pin assignment table for connector X33A
        Connector pin assignment table for connector X33B
        Connector pin assignment table for connector X33B
        Connector pin assignment table for connector X33C
        Connector pin assignment table for connector X33D
        Connector pin assignment table for connector X33E
        Connector pin assignment table for connector X33P
        
Section 5: Electronics
    CONTROL
        Introduction
    ELECTRONIC CONTROL UNIT
        Introduction
            ESX controller
            Central electronic system / Central Unit
            PCS
        CAN bus (digital technique)
            CAN bus, definition
                Was is CAN capable of ?
            How does CAN work ?
                Tasks
                Advantages
                Disadvantages
        Electronic control diagram
            Description
        CAN bus wiring
            Description
            Wiring
    POWER SUPPLY
        Electrical circuit diagram CAN-bus power supply
        Power supply and CAN bus in acc. with diagram P/N 8900298, sheet 37
            Power supply, description
            Grounding
    COMPONENTS AT CAN BUS 1
        Central electronics A100, Central Unit (CU)
            Description
        Multi-function display C4 / A400
            Description
        Key-board modules C5.1/A501, C5.2/A502, C5.3/A503
        PCS, Power Control System with load-limit regulator A10
            Description
        Diagnosis socket A10X4
            Description
        ESX controller A7.3
            Description
                Technical data
            Pin assignment ESX controller
    COMPONENTS AT CAN 2 BUS
        Right joystick A56 for boom and bucket cylinder
            Right joystick, description
        Left joystick A57 for stick cylinder and slewing mechanism
            Left joystick, description
            Left joystick
            Right joystick
            Description
        Functioning principle of joysticks and pedals
            Description
                Joystick/pedal position detection and evaluation
                Temperature compensation
                Power supply
                Reverse voltage protection
        Driving pedal (master) A61
            
                CAN plug assignment:
                Slave plug assignment:
            Characteristic
        Double pedal (slave) A61.1 for adjusting cylinder or hammer/shears
            Description
                Slave plug assignment:
    ESX CODING
        Schematic
            Description
    PCS: POWER  CONTROL  SYSTEM
        Function chart and location diagram of components
            Function listing, description
        Fundamental principle of pump control
            Description
        Regulating circuit
            Speed characteristics of the engine under load
            Detection of the load status
            Regulating process
                PCS in neutral
            PCS when driving on the public highway
                PCS when driving on terrain
                PCS when working
        PCS performance diagram
    PCS COMPONENTS
        Load-limit regulator
        Speed actuator M10
            Decription
        Speed sensing
            Description
            Speed sensor (pickup) B10.1
        Coolant temperature sensing
            Description
            Temperature sensor B13.1
        Charge-air temperature sensing
            Description
            Temperature sensor R10.3
        Hydraulic oil temperature sensing
            Description
            Temperature sensor R14
        Proportional valve Y10
            Description
        A8V with measuring point X3 for control pressure
            Description
                Sectional drawing
        Fan control with proportional valve Y131
            
                Description
            Valve cartridge
        Hammer / shears control with boom adjusting equipment (7-spool control block)
            Description
            
Section 6: Hydraulics
    CONTROL
        Introduction
    HYDRAULIC SYSTEM
        Overview
        Schematic of working, slewing and pilot-control circuits
            Oil flow through control block
            Working, slewing and pilot control circuits in the superstructure
        Working, travel and pilot-control circuits in the undercarriage
            Working, travel and pilot-control circuits in the undercarriage
        Hydraulic circuit diagram upper carriage
            Hydraulic circuit diagram WX145 boom adjusting equipment
            Hydraulic circuit diagram WX145 monoblock boom
            Hydraulic circuit diagram WX165 boom adjusting equipment
            Hydraulic circuit diagram WX165 monoblock boom
            Hydraulic circuit diagram WX185 boom adjusting equipment
            Hydraulic circuit diagram WX185 monoblock boom
        Hydraulic circuit diagram, undercarriage
            Legend
            Undercarriage axle
            Undercarriage with A2 stabilization with individual control
            Undercarriage levelling blade A2 stabilization
            Undercarriage A4 stabilization
            Undercarriage levelling blade A2 stabilization individual control
            Undercarriage A4 stabilization individual control
    drive unit
        Drive unit, circuit diagram
            Elements, description
        Multi-circuit pump unit (No. 2)
            Multi-circuit pump unit, description
        Variable displacement twin pump A8VO, (No. 3)
            Variable displacement twin pump A8VO, description
                Port designations
                Symbol
        Drive unit, variable displacement twin pump – out
            Drive unit, variable displacement twin pump - output regulator, No.3
            Output regulation by load-sensing pressure
                Output regulation by load-sensing pressure, description
            Output regulation by pump high pressure
                Regulation by pump high pressure, description
            Output regulation by load-limit control
                Description
        Pilot-control pump, No. 3
            Pilot-control pump, description
        Gear pump (No. 6)
            Gear pump
            Gear pump, description
            Twin gear pump, description
            Twin gear pump, 4 cylinders
            Twin gear pump, 6 cylinders
        Hydraulic reservoir with attachments, Nos. 20-24
            Hydraulic reservoir, description
    CONTROL BLOCK
        Control block, rear view
        Control block, front view
        Control block for monoblock boom equipment with hammer / shears
            Description
                Oil flow from pump 1
                Oil flow from pump 2
        Control block for boom adjusting equipment with hammer / shears
            Description
                Oil flow from pump 1
                Oil flow from pump 2
        Control block valves
            Primary pressure-limiting valves with pressure sequence stage (1)
                Description
            Tank channel – preloading valves
                Description
            Secondary pressure-limiting valves with replenishing stage (SV)
                Description
            Proportional valves for control spool adjustment
                Description
            Pressure sensors
                Description
                Pin assignment
                Diagram
    Pilot-control system
        Pilot-control system, description
            Pilot-control circuit in neutral position
        Pilot control unit (nos. 60, 61, 63 and 64)
            Pilot control unit, schematic diagram
            Pilot control unit, description
        Solenoid valves and their functions
            Proportional valve Y10 of the load-limit regulator
                Proportional valve Y10, description
                Emergency control
            Solenoids Y35 and Y113
            Solenoid valve Y35 for the superstructure holding brake in the slewing gearbox
                Solenoid valve Y35, description
            Solenoid valve Y113 for pilot pressure activation and de-activation
                Solenoid valve Y113, description
            Solenoid valve Y290 for pilot-control activation and deactivation
                Solenoid valve Y290, description
            Solenoid valve Y63 for POWER BOOST and power assist functions
                Solenoid valve Y63, description
            Solenoid valve unit Y241 and Y242 for pump control
                Solenoid valve unit Y241 and Y242, description
                Emergency control
    TRAVEL CIRCUIT
        Travel circuit, schematic diagram
        Travel circuit, description
            Neutral
            Before travelling
            Forward travel
            Reverse travel
            Setting off on slopes
        Pressure compensator for travel circuit
            Function
            Operation
            Travel forward or backward
        Travel control spool
        Hydraulic and electric rotor (Nos. 75 and 76)
            Hydraulic rotor, description
            Electric rotor, description
        Travel drive (Nos. 100, 101 and 102)
            Travel drive, description
        B7
        Travel oil motor type A 6 VM (20 km/h) (No. 102)
            Travel oil motor, regulator, No. 102
                Travel oil motor, description
                Automatic regulation
                Creep speed:
                Secondary relief
                Schematic diagram of travel drive
        Travel oil motor, travel brake valve (No. 102)
            Travel brake valve, description
        Undercarriage solenoid valves (Nos. 104, 105 and 106)
            Undercarriage solenoid valves, description
        Steered axle (No. 110)
            Steered axle, description
        Floating-axle cylinder (No. 111)
            Description
    BRAKING, STEERING AND FAN CIRCUIT
        Schematic diagram
            Braking, steering and fan circuit, description
        Brake system
            Superstructure
            Undercarriage
        Steering system
            Priority valve (No. 44)
                Description
            Steering valve (No. 40)
                Description
                Neutral
                Steering to the left
                Steering to the right
                Emergency steering capability
        Fan system
            Schematic
            Fan motor
            Combined radiator with controlled fan drive (No.7)
            Combined radiator, description
    Undercarriage, Stabilizers
        Schematic diagram
            Stabilizers, description
                Neutral
                Starting a movement
                Lowering
                Raising
        Stabilizer control spool
        Levelling blade cylinder (No. 115)
            Levelling blade cylinder, description
        Outrigger cylinder 116
            Outrigger cylinder, description
        Stabilization variants
            Description
                Stabilization A2, No. 107
                Stabilization PL/A2 Pos. 107
                Stabilization A4, No. 107
                Individual stabilization PL/A2, No. 108
                Individual stabilization A4, No. 109
    boom cylinder circuit
        Schematic diagram without regeneration circuit
            Boom cylinder circuit without regeneration circuit, description
                Neutral
                Activation of a function
                Boom raising:
                Boom lowering:
        Control spool
    boom cylinder circuit
        Schematic diagram with regeneration circuit
            Boom cylinder circuit with regeneration circuit, description
                Neutral
                Activation of a function
                Boom raising
                Boom lowering
        Boom cylinder circuit with regeneration circuit, control spool details
            Description
                Boom lowering with regeneration function (with load pressure on the piston sides)
                Boom lowering with pressure, bucket touching or penetrating into the soil:
        Boom cylinder control spool with regeneration circuit
    BUCKET CYLINDER CIRCUIT
        Schematic diagram
            Bucket cylinder circuit, description
                Neutral
                Activation of a function
                Bucket cylinder extension
                Bucket cylinder retraction
        Bucket cylinder control spool
        Bucket parallel connection circuit
            Bucket parallel connection circuit, description
        Restrictor non-return valve (No. 206)
            Description
        Umschaltung von Löffel auf Greifer, \(Pos. 207
            Description
    stick cylinder circuit with regeneration function
        Schematic diagram
            Stick cylinder circuit with regeneration function, description:
                Neutral
                Activation of a function
                Extending the stick
                General lowering of stick
                Pressureless lowering of stick
                Lowering the stick with pressure, excavating tool penetrates into the ground
        Stick cylinder control spool
    ADJUSTING CYLINDER CIRCUIT
        with pressure compensa
        or and relief valve
            Adjusting cylinder circuit with pressure compensator and relief valve, description
                Neutral
                Activation of a function
                Retracting the boom adjusting cylinder, extending the upper boom section
                Extending the boom adjusting cylinder, lowering the upper boom section:
        Boom adjusting cylinder (neck cylinder) control spool
            Boom adjusting cylinder control spool with compensator
            Boom adjusting cylinder control spool with pressure relief valve
        Pressure compensator for adjusting cylinder
            Function
            Operation
            Adjusting cylinder activated
        Pressure compensator, relief valve and LS pressure limiting valve
            Relief valve
                Description
        Pipe break protection valves (Nos. 202 and 210)
            Description
            Pipe break protection valve
    COMBINED FUNCTIONS
        Parallel actuation of boom, bucket, adjusting and stick cylinder
            Description
    HYDRAULIC HAMMER CIRCUIT WITH BOOM ADJUSTING EQUIPMENT
        Schematic diagram
            Hydraulic hammer circuit with boom adjusting equipment, description
                Neutral
                Switching on the hammer
                Activating the hammer with the joystick button or the pedal
                Performance setting
        Hydraulic hammer control spool
    HAMMER circuit with auxiliary function (Boom adjusting Equipment)
        Schematic diagram
            Hammer circuit with auxiliary function like shears or crusher, description
                Neutral
                Activating the hammer
                Starting hammer operation with the joystick pushbutton or the pedal
                Performance setting
                Oil flows
                Activating the shears
                Pedal operation of the shears
                Oil flow during closing of the shears:
                Oil flow during opening of the shears
        Hammer/shears control spool
            Control block
            Hammer by-pass valve
    SHEARS / CRUSHER CIRCUIT (BOOM ADJUSTING EQUIPMENT)
        Schematic diagram
            Shears or crusher circuit with boom adjusting equipment, description
                Neutral
                Activating the shears
                Starting shears operation by means of the pedal
                Oil flow during closing of the shears
                Oil flow during opening of the shears
    HYDRAULIC HAMMER CIRCUIT (MONOBLOCK BOOM EQUIPMENT)
        Schematic diagram
            Hydraulic hammer circuit with monoblock boom equipment, description
                Neutral
                Activating the hammer
                Starting the hammer operation with the joystick pushbutton or the pedal
                Performance setting
                Oil flows:
    HAMMER circuit and auxiliary function, MONOBLOCK Equipment
        Schematic diagram
            Hammer circuit with auxiliary function like shears or crusher with monoblock boom equipment, description
                Neutral
                Activating the hammer
                Starting hammer operation with the joystick pushbutton or the pedal:
                Performance setting
                Oil flows
                Activating the shears
                Pedal operation of the shears
                Oil flow during closing of the shears:
                Oil flow during opening of the shears
            Control block
    SHEARS / CRUSHER CIRCUIT, MONO BOOM EQUIPMENT
        Schematic diagram
            Shears or crusher circuit with monoblock boom equipment, description
                Neutral
                Activating the shears
                Starting shears operation by means of the pedal
                Oil flow during closing of the shears
                Oil flow during opening of the shears
    SLEWING SYSTEM
        Schematic diagram
            Slewing system, description
        Slewing pump
            A 4 VG 71 DE4D, (No. 4)
            Slewing pump
                Slewing direction
            Slewing pump type A 4 VG, No.4, description
        Slewing pump valves
            Feed-pressure limiting valve (No. 15)
                Description
            Secondary valve
                Description
            Pressure cut-off valve (18)
                Description
        Slewing pump valves
            Feed-pressure limiting valve (No. 15)
                Description
            Sekundärventil
                Description
            Pressure cut-off valve (18)
                Description
        Slewing pump control unit
            Slewing pump control unit, description
                Neutral
                Slewing
                Braking
        Pressure-control valve
            Description
        Slewing gearbox (No. 15)
            Description
        Oil motor
        Integrated holding brake
            
                Brake applied
                Brake permanently released
                Brake in automatic mode of operation
        Speed sensor B35.2
            Description
                Timing diagram
        GRAB ROTATION MECHANISM
        Schematic diagram
            Description
        Solenoid valve for grab rotation (No. 231)
            Description
            Description
            
Section 7: Troubleshooting and Repair
    Fault codes
        General information on fault codes
    Fault codes
    Fault codes PCS unit
    Fault codes, Central Unit
    
Section 8 Repair Instructions
    REPAIR INSTRUCTIONS
        Foreword
        Introduction
        Sicherheitshinweise
            Gefahren bei Nichtbeachtung der Sicherheitshinweise
        Welding operations
            Welding operations, safety instructions
            General welding instructions
            Protecting electronic modules during welding operations
                Removing electronic modules and disconnecting plug and grounding connections
                1st point (PCS)
                2nd point (CU)
                3rd point (ESX)
            Effect of electromagnetic fields and electrostatic discharges
        Handling of oils and greases
        Securing the Machine
        Depressurizing the hydraulic system / brake system
            Pilot control
            Service brake
            Depressurizing the hydraulic system
        Bearings and bushings
            Removal of bearings and bushings
                Figure 1
                Figure 2
            Fitting of bearings and bushings
                Figure 3
                Figure 4
                Figure 5
    Superstructure components
        Replacing the buffers under the cab baseplate
            Preparations
            Front buffers
            Rear buffers
        Removing and refitting the cab
            Preparations
            Unplugging the electrical connectors
            Dismantling the cab
            Refitting the cab
        Driver's seat
            Preparations
            Removing the driver's seat
            Installing the driver's seat
        Steering column, steering valve
            Preparations
            Removing the steering column with the steering valve
            Refitting the steering column and the steering valve
            Removing the steering column
            Refitting the steering column
        Control levers
            Preparations
            Replacing the control lever
        Display
            Preparations
            Removing the display unit
            Refitting the display unit
        ESX Box
            Preparations
            Removing the ESX Box
            Refitting the ESX Box
        Load-limit regulator
            Preparations
            Removing the load-limit regulator
            Refitting the load-limit regulator
        Removing and installing the battery
        Combined radiator
            Preparations
            Removing the combined radiator
            Refitting the combined radiator
        Battery box
            Preparations
            Battery box, removing the hood
            Battery box, refitting the hood
        Fan door
            Preparations
            Removing the fan door
            Refitting the fan door
        Battery box panelling
            Removing the metal panel
            Refitting the metal panel
    LINK BETWEEN SUPERSTRUCTURE AND UNDERCARRIAGE COMPONENTS
        Rotor
            Preparations
            Removing the rotor
            Refitting the rotor
        Slewing gearbox
            Preparations
            Removing the slewing gearbox
            Slewing gearbox, fitting
            Dismantling and assembling the slewing gearbox
        Ball-bearing slewing ring
            Preparations
            Removing the ball-bearing slewing ring
            Fitting the ball-bearing slewing ring
    undercarriage components
        Axles and gearboxes
            Instructions for the repair of gearboxes and axles
            Testing procedures
                Running noises
                Leaks
        Service brake
            Brake disks, checking the lining thickness
        Service brake
            Brake disks, checking the lining thickness
        Bleeding the multiple-disk brake
        Cardan shaft
            Removing the cardan shaft
            Refitting the cardan shaft
        Rigid axle
            Removing the rigid axle
            ASP100 tightening torques
            Refitting the rigid axle
        Rigid axle, hydraulic motor and flanges
            Removal and fitting of hydraulic motor and flanges
        Rigid axle, gearbox housing
            Removing and fitting the gearbox housing
        Ridid axle, differential unit
            Removing and fitting the differential unit
        Rigid axle, pinion unit
            Removing and fitting the pinion group
        Steered axle
            Removing the steered axle
            Tightening torques ALPP100
            Refitting the steered axle
        Steered axle, steering cylinder
            Removal and fitting of the steering cylinder
        Steered axle, reducer gear
            Removal and fitting of the reducer gear
        Steered axle, articulated joint housing
            Removal and fitting of the articulated joint housing
        Steered axle, differential unit
            Removal and fitting of the differential unit
        Floating-axle cylinder
            Removing the cylinders
            Replacing the rod seal
            Repairing the check valve
            Recommissioning and bleeding
        Tyres and wheels
            Tyres and wheels, safety instructions
            Tyre pressure, checking and topping up
            Tyres – sizes / pressures / travelling speeds
                For excavators with monoboom equipment
                For excavators with boom adjusting equipment
            Tyres – sizes / pressures / travelling speeds
                For excavators with monoboom equipment
                For excavators with boom adjusting equipment
            Changing a wheel
                Wheels, tread position
            Table of tightening torques
        Fastening of wheels
        Wheels
        Steps, left side
            Preparation
            Removing the steps on the left side
            Installing the steps on the left side
        Steps, right side, tool-box
            Preparation
            Removing the steps on the right side
            Fitting the steps on the right side
            Dismantling the tool-box
        Stabilizers
            Safety instructions
            Outriggers
            Levelling blade
        Outriggers
            Preparations
            Removing the outriggers
            Refitting the outriggers
        Boom cylinders for monoblock booms
            Preparations
        Boom cylinders for boom shift equipment
            Preparations
        Boom cylinder
            Removing the boom cylinder
            Refitting the boom cylinder
            Boom cylinder, components
            Dismantling the boom cylinder
            Tightening torques
            Assembling the boom cylinder
        Stick cylinder
            Preparations
            Removing the stick cylinder
            Refitting the stick cylinder
            Stick cylinder, components
            Dismantling the stick cylinder
            Tightening torques
            Assembling the stick cylinder
        Bucket cylinder
            Preparations
            Removing the bucket cylinder
            Refitting the bucket cylinder
            Bucket cylinder, components
            Dismantling the bucket cylinder
            Tightening torques
            Assembling the bucket cylinder
        Adjusting cylinder
            Preparations
            Removing the adjusting cylinder
            Refitting the adjusting cylinder
        Slip-on tooth
            Safety instructions
            Replacing the slip-on teeth
        Trenching grab, wear limits
            Reworking the stops
        Fuses
            Checking / replacing the fuses
            Table of fuses
        Fuses
            Checking / replacing the fuses
            Fuse table
        Lamp bulbs
            Replacing the lamp bulbs, instructions
            Lamp bulbs - Table
            Replacing the lamp bulb of the cab interior lamp
            Replacing the lamp bulb of the cab floodlamp
            Replacing the lamp bulb of the boom floodlamp
            Replacing the headlamp bulb
            Replacing the lamp bulb in the front turn signal lamp
            Replacing the lamp bulb of the tail-light
            
            -