Model Mejor Maq PDF

MODEL ________________
SERIES ________________
BOOK NO. ________________
SERIAL NO.________________
210LX
LX Series
1032
MACHINE SERIAL NUMBER
The machine serial number is stamped on the serial number plate which is
located at the front of the machine on the right side of the operator’s cab
platform. The serial number should always be furnished when ordering parts
for the machine or when corresponding with the distributor or factory
concerning the machine. Providing the serial number is the only way of
ensuring the correct parts and/or information can be furnished.
In the event the serial plate is not readable a number is stamped on the
upper revolving frame which can be used to identify the machine. The
number is stamped just below the boom and between the boom hoist
cylinder mounting lugs.
LBX Company, LLC Shop Manual
BLANK
jws0903K
Copyright 2001 Link-Belt
Printed in U.S.A. Link-Belt Cre 7-28151LX November 2001

210LX Crawler Excavators
Table of Contents
DIVISION/SECTION SECTION NREFERENCE N
1 GENERAL INFORMATION
Safety, general information and standard torque data .....................................1001 7-27690LX
General specifications and special torque setting............................................1002 7-29360-21LX
2 ENGINE
Removal and installation of the engine ............................................................2000 7-28230LX
Radiator and oil-cooler.....................................................................................2001 7-28050LX
3 FUEL SYSTEM
Removal and installation of the fuel tank .........................................................3001 7-27970LX
4 ELECTRICAL SYSTEM
Electrical system, electrical and electronic troubleshooting.............................4001 7-28250-21LX
Inspection and maintenance of batteries and connecting a booster battery....4002 7-27921LX
Main and engine electronic control boxes........................................................4003 7-27931-21LX
5 UNDERCARRIAGE
Removal and installation of the tracks set ......................................................5001 7-27750LX
Upper and lower rollers....................................................................................5003 7-27770-21LX
Sprocket...........................................................................................................5004 7-27781LX
Idler wheel and tension shock absorber ..........................................................5005 7-27801-21LX
6 DRIVE TRAIN
Drive motor and final drive transmission removal and installation ...................6001 7-27841LX
Drive motor and final drive transmission disassembly and assembly ..............6002 7-28090LX
Swing reduction gear, removal and installation................................................6003 7-27820LX
Swing reduction gear, disassembly and assembly ..........................................6004 7-28370LX
7 UNDERCARRIAGE HYDRAULICS
8 UPPERSTRUCTURE HYDRAULICS
Depressurising and decontaminating the hydraulic system, use of the
vacuum pump and bleeding the components ..............................................8000 7-27951-21LX
Specifications, troubleshooting, checks and hydraulic pressure settings ........8001 7-28270-21LX
Hydraulic sump tank removal and installation..................................................8002 7-27990LX
Main and pilot pumps, removal and installation ...............................................8003 7-27860LX
Main hydraulic control valve, removal and installation.....................................8004 7-27890LX
Attachment cylinders, removal and installation................................................8005 7-27791LX
Rotating joint, removal and installation ............................................................8006 7-27811LX
Pilot blocs, removal and installation.................................................................8007 9-35590LX
Swing motor, removal and installation .............................................................8008 7-28070LX
Free swing disassembly and assembly ...........................................................8009 9-35530LX
Main hydraulic pump, disassembly and assembly...........................................8010 7-35490LX
Main hydraulic control valve, disassembly and assembly................................8011 9-36270LX
Attachment cylinders, disassembly and assembly...........................................8012 7-27900-21LX
Hand joystick control, disassembly and assembly...........................................8013 7-28110LX
Foot joystick control, disassembly and assembly ............................................8014 7-28210LX
Six stack solenoid valve, disassembly and assembly......................................8015 7-27910LX
Cushion control, disassembly and assembly ...................................................8016 7-27940LX
Hose burst check valve....................................................................................8017 7-29630-21LX
Rotating joint, disassembly and assembly .......................................................8018 7-28080LX
Swing motor, disassembly and assembly ........................................................8019 7-28010LX
Hydraulic functions...........................................................................................8020 7-28420-21LX
Cre 7-28151LX Issued 11-01
DIVISION/SECTION SECTION N° REFERENCE N°
9 UPPERSTRUCTURE
Upperstructure, turntable and counterweight...................................................9002 7-27981-21LX
Boom, arm and bucket.....................................................................................9003 7-27961-21LX
Seat and safety belt .........................................................................................9004 7-28120LX
Cab and cab equipment...................................................................................9005 7-28021-21LX
Air conditioning troubleshooting.......................................................................9006
Air conditioning unit disassembly and assembly..............................................9007 7-29910LX
Air conditioning servicing .................................................................................9008
Air conditioning components............................................................................9009
Large format hydraulic and electrical schematics .........................................Pocket 7-28521
* Consult the Engine Service Manual
Sections to be distributed at a later date
NOTE: Link-Belt Company reserves the right to make changes in the
specification and design of the machine without prior notice and without
incurring any obligation to modify units previously sold.
The description of the models shown in this manual has been made in
accordance with the technical specifications known as of the date of
design of this document.
Link-Belt
Printed in U.S.A.
Cre 7-27690LX November 2001
1001
SAFETY, GENERAL INFORMATION
Section
1001
1001-2
TABLE OF CONTENTS
GENERAL INFORMATION
.......................................................................................................................................3
SAFETY.................................................................................................................................................
....................4
STANDARD TORQUE DATA FOR CAP SCREWS AND
NUTS...............................................................................6
1001-3
GENERAL INFORMATION
Cleaning
Clean all metal parts except bearings, in a suitable
cleaning solvent or by steam cleaning. Do not use
caustic soda for steam cleaning. After cleaning, dry
and put oil on all parts. Clean oil passages with
compressed air. Clean bearings in a suitable cleaning
solvent. Dry the bearings completely and put oil on
the bearings.
Inspection
Check all parts when the parts are disassembled.
Replace all parts that have wear or damage. Small
scoring or grooves can be removed with a hone or
crocus cloth. Complete a visual inspection for
indications of wear, pitting and the replacement of
parts necessary to prevent early failures.
Bearings
Check bearings for easy action. If bearings have a
loose fit or rough action, replace the bearing. Wash
bearings with a suitable cleaning solvent and permit
to air dry. DO NOT DRY BEARINGS WITH
COMPRESSED AIR.
Needle Bearings
Before you press needle bearings in a bore always
remove any metal protrusions in the bore or edge of
the bore. Before you press bearings into position, put
petroleum jelly on the inside and outside diameter of
the bearings.
Gears
Check all gears for wear and damage. Replace gears
that have wear or damage.
Oil Seals, O-rings and Gaskets
Always install new oil seals, O-rings and gaskets. Put
petroleum jelly on seals and O-rings.
Shafts
Check all shafts that have wear or damage. Check
the bearing and oil seal surfaces of the shafts for
damage.
Service Parts
Always install genuine Link-Belt service parts. When
ordering refer to the Parts Catalog for the correct part
number of the genuine Link-Belt replacement items.
Failures due to the use of other than genuine Link-
Belt replacement parts are not covered by warranty.
Lubrication
Only use the oils and lubricants specified in the
Operator’s or Service Manuals. Failures due to the
use of non-specified oils and lubricants are not
covered by warranty.
1001-4
SAFETY
This symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED. The message that follows the
symbol contains important information about safety. Carefully
read the message. Make sure you fully understand the
causes of possible injury or death.
!
To prevent injury always follow the Warning, Caution
and Danger notes in this section and throughout the
manual.
Place a “Do not operate“ tag on the starter switch key
before carrying out any service or repair work on the
machine.
.
WARNING: Read the operator’s manual to
familiarize yourself with the correct control
functions.
!
WARNING: Operate the machine and
equipment controls from the seat position
only. Any other method could result in
serious injury.
!
WARNING: This is a one man machine, no
! riders allowed.
WARNING: Before starting engine, study
Operator’s Manual safety messages. Read
all safety signs on machine. Clear the area of
other persons. Learn and practice safe use
of controls before operating.
It is your responsibility to understand and
follow manufacturers instructions on
machine operation, service and to observe
pertinent laws and regulations. Operator’s
and Service Manuals may be obtained from
your Link-Belt dealer.
!
WARNING: If you wear clothing that is too
loose or do not use the correct safety
equipment for your job, you can be injured.
Always wear clothing that will not catch on
objects. Extra safety equipment that can be
required includes hard hat, safety shoes, ear
protection, eye or face protection, heavy
gloves and reflector clothing.
!
WARNING: When working in the area of the
fan belt with the engine running, avoid loose
clothing if possible, and use extreme caution.
!
WARNING: When doing checks and tests
on the equipment hydraulics, follow the
procedures as they are written. DO NOT
change the procedure.
!
WARNING: When putting the hydraulic
cylinders on this machine through the
necessary cycles to check operation or to
remove air from a circuit, make sure all
people are out of the way.
!
1001-5
WARNING: Use insulated gloves or mittens
! when working with hot parts.
WARNING: Lower all attachments to the
ground or use stands to safely support the
attachments before you do any maintenance
or service.
!
WARNING: Pin sized and smaller streams
of hydraulic oil under pressure can penetrate
the skin and result in serious infection. If
hydraulic oil under pressure does penetrate
the skin, seek medical treatment
immediately. Maintain all hoses and tubes in
good condition. Make sure all connections
are tight. Make a replacement of any tube or
hose that is damaged or thought to be
damaged. DO NOT use your hand to check
for leaks, use a piece of cardboard or wood.
!
WARNING: When removing hardened pins
such as a pivot pin, or a hardened shaft, use
a soft head (brass or bronze) hammer or use
a driver made from brass or bronze and a
steel head hammer.
!
WARNING: When using a hammer to
remove and install pivot pins or separate
parts using compressed air or using a
grinder, wear eye protection that completely
encloses the eyes (approved goggles or
other approved eye protectors).
!
WARNING: Use suitable floor (service)
jacks or chain hoist to raise wheels or tracks
off the floor. Always block machine in place
with suitable safety stands.
!
WARNING: When servicing or repairing the
machine, keep the shop floor and operator’s
compartment and steps free of oil, water,
grease, tools, etc. Use an oil absorbing
material and/or shop cloths as required. Use
safe practices at all times.
!
WARNING: Some components of this
machine are very heavy. Use suitable lifting
equipment or additional help as instructed in
this Service Manual.
!
WARNING: Engine exhaust fumes can
cause death. If it is necessary to start the
engine in a closed place, remove the exhaust
fumes from the area with an exhaust pipe
extension. Open the doors and get outside
air into the area.
!
WARNING: 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.
!
1001-6
STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS
Tightening of Cap Screws and Nuts
Tighten alternately so that tightening torque can be applied evenly. The numbers in the figure below
indicate the
order of tightening.
JS00481B
Cap screws which have had Loctite used (white residue remains after removal) should be cleaned
with light oil or
suitable cleaning solvent and dried. Apply 2-3 drops of Loctite to the thread portion of the cap screw
and then
tighten.
1001-7
Torque Table
Tighten cap screws and nuts according to the table below if there are no other special instructions.
Cap Screw Name Size (Size) M6 M8 M10 M12 M14 M16 M18 M20
Cap Screw
Spanner
[in.] 0.39 0.51 0.67 0.75 0.87 0.95 1.06 1.18
[mm] 10 13 17 19 22 24 27 30
Tightening
torque
[lb-ft] 5.1 14.5 29.0 43.4 72.5 116.0 144.6 202.4
[Nm] 6.9 19.6 39.2 58.8 98.1 157.2 196.0 274.0
Socket
Head Cap
Screw
Spanner
[in.] 0.20 0.24 0.32 0.39 0.47 0.55 0.55 0.67
[mm] 5 6 8 10 12 14 14 17
Tightening
torque
[lb-ft] 6.5 15.9 31.1 57.8 86.8 130.1 180.8 253.1
[Nm] 8.8 21.6 42.1 78.4 117.6 176.4 245.0 343.0
1001-8
NOTES
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
Link-Belt
Printed in U.S.A.
Cre 7-29360-21LX November 2001
1002
GENERAL SPECIFICATIONS
AND SPECIAL TORQUE SETTINGS
Section
1002
1002-2
Cre 7-29360-21LX Issued 11-01
TABLE OF CONTENTS
TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE OF THE
MACHINE....................................................3
Machine.................................................................................................................................................
................3
Engine
...............................................................................................................................................................
....3
Component serial numbers
...................................................................................................................................3
FLUIDS AND LUBRICANTS
.....................................................................................................................................4
Hydraulic
fluid.......................................................................................................................................................
4
Transmission component oil
................................................................................................................................ 4
Grease
...............................................................................................................................................................
.. 4
Engine oil
..............................................................................................................................................................
5
Oil viscosity/Oil
range............................................................................................................................................5
Fuel
...............................................................................................................................................................
....... 6
Anti-freeze/Anti-
corrosion..................................................................................................................................... 6
Environment
......................................................................................................................................................... 6
Components made from plastic or resin
.............................................................................................................. 6
SPECIFICATIONS.................................................................................................................................
....................7
Engine
...............................................................................................................................................................
....7
Capacities
.............................................................................................................................................................7
Electrical system
...................................................................................................................................................7
Hydraulic
system...................................................................................................................................................
8
Cylinder
...............................................................................................................................................................
..8
Main control valve
.................................................................................................................................................9
Swing
...............................................................................................................................................................
.....9
Travel
...............................................................................................................................................................
.....9
Undercarriage
.......................................................................................................................................................9
Attachment
............................................................................................................................................................9
Weight of components
........................................................................................................................................10
DIMENSIONS AND LIMIT OF WEAR AND TEAR OF THE TRACKS SET
............................................................11
Toothed
wheel.....................................................................................................................................................
11
Idler
wheel.....................................................................................................................................................
......12
Upper roller
.........................................................................................................................................................13
Lower roller
.........................................................................................................................................................14
Track
...............................................................................................................................................................
....15
DIMENSIONS AND LIMIT OF WEAR AND TEAR OF THE MOBILE JOINTS OF THE
ATTACHMENT................16
Boom foot/Undercarriage
....................................................................................................................................16
Boom cylinder
foot/Undercarriage.......................................................................................................................17
Boom cylinder
head/Boom..................................................................................................................................17
Arm cylinder
foot/Boom.......................................................................................................................................18
Boom/Arm..............................................................................................................................................
.............18
Arm cylinder
head/Arm........................................................................................................................................18
Bucket cylinder foot/Arm
.....................................................................................................................................19
Connecting rod/Arm
............................................................................................................................................19
Compensator/Bucket.............................................................................................................................
..............19
Connecting rod/Compensator/Bucket cylinder
head...........................................................................................20
Arm/Bucket............................................................................................................................................
..............20
SPECIAL TORQUE
SETTINGS..............................................................................................................................21
MACHINE OVERALL
DIMENSIONS.......................................................................................................................24
WARNING: This symbol is used in this manual to indicate important safety messages. Whenever
you see
this symbol, carefully read the message that follows, ! as there is a risk of serious injury.
1002-3
Cre 7-29360-21LX Issued 11-01
TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE OF THE
MACHINE
When placing a parts order or making a request for information or assistance, always give you Link-
Belt Dealer the
type and serial number of the machine concerned.
Enter the required information on the lines below: Type, serial number, year of manufacture of the
machine and the
serial numbers of hydraulic and mechanical components
Machine
PA11003 PA11004
(1) Type.............................................................................
(2) Serial number..............................................................
(3) Year of manufacture....................................................
Engine
Make and type
.............................................................................................................................................................
Serial number
..............................................................................................................................................................
Component serial numbers
Hydraulic
pump......................................................................................................................................................
......
Swing reduction
gear...................................................................................................................................................
Travel reduction
gears.................................................................................................................................................
Travel main control
valve.............................................................................................................................................
Attachment main control valve
....................................................................................................................................
Swing main control
valve.............................................................................................................................................
12
3
1002-4
Cre 7-29360-21LX Issued 11-01
FLUIDS AND LUBRICANTS
Lubricants must have the correct properties for each application.
Hydraulic fluid
Hydraulic fluid is specially designed for high pressure
applications and for the hydraulic system. The type of
fluid to be used depends on the ambient temperature.
Temperate climates
-4F to +104F (-20°C to +40°C)
Fluid type ISO VG 46
Hot climates
32F to +140F (0°C to +60°C)
Cold climates
-40F to +68F (-40°C to +20°C)
Transmission component oil
Extreme pressure oil used for transmission components
inside sealed housings.
Extreme pressure oil TYPE API GL - 4 90.
Grease
The type of grease to use depends on ambient temperature.
Temperate and hot climates
-4F to +140F (-20°C to +60°C)
Extreme pressure grease EP NLGI grade 2 with molybdenum
disulphide.
Cold climates
-40F to +68F (-40°C to +20°C)
Extreme pressure grease EP NLGI grade 0.
WARNING: The conditions of use for individual fluids and lubricants ! must be respected.
1002-5
Cre 7-29360-21LX Issued 11-01
Engine oil
Multiperformance or Performance engine oil is recommended
for your engine. This oil ensures correct
lubrication of your engine in all working conditions.
If Multiperformance or Performance engine oil is not
available, use oil corresponding to category API/CG/
CF.
NOTE: Do not put any Performance Additive or other
additive in the sump. Oil change intervals shown in
this manual are based on tests carried out on lubricants.
Oil viscosity/Oil range
CS01M507
(A) FAHRENHEIT TEMPERATURE (2) WINTER
(B) CELSIUS TEMPERATURE (3) TROPICAL
(1) ALL SEASONS (4) ARCTIC
(*) SHOWS THAT AN ENGINE OIL HEATER OR ENGINE COOLANT SOLUTION HEATER MUST BE USED
B
A
3
1
2
4
1002-6
Cre 7-29360-21LX Issued 11-01
Fuel
Use fuel that is to ASTM (American Society for Testing
and Materials) D975 standard.
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.
In cold weather, the use of a mixture of fuels No. 1
and No. 2 is temporarily permitted. Consult your fuel
supplier.
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, fill the fuel tank at the
end of the day’s work, in order to prevent the formation
of condensation.
Fuel storage
Long storage can lead to the accumulation of impurities
and condensation in the fuel. 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.
In environments with a temperature higher than -33F
(-36°C), use a mixture of 50% ethylene-glycol based
anti-freeze.
For areas where the temperature is below -33F (-36°C), it
is advisable to use a blend of 40% water and 60% antifreeze.
Environment
Before carrying out any servicing operation on this
machine and before disposing of used fluids or lubricants,
always think of the environment. Never throw
fluid or oil on the ground and never keep them in leaking
receptacles.
Consult your local ecological recycling centre to
obtain information on the appropriate means of disposing
of these substances.
Components made from plastic or
resin
When cleaning plastic parts, the console, the instrument
panel, the gauges, etc., do not use petrol (gasoline),
paraffin (kerosene), paint solvents, etc. Use
only water, soap and a soft cloth.
The use of petrol (gasoline), paraffin (kerosene),
paint solvents, etc, will cause discoloration, cracking
or deformation of these components.
1002-7
Cre 7-29360-21LX Issued 11-01
SPECIFICATIONS
Engine
Make......................................................................................................................................................
............. Isuzu
Model.....................................................................................................................................................
.....BB-6BG1T
Type: Four stroke, water-cooled, overhead valve, direct injection (electronically controlled), in-line
engine with turbocharger.
Number of
cylinders................................................................................................................................................
...6
Bore and stroke
....................................................................................................................................... 4.13x4.92 in
Displacement.........................................................................................................................................
....... 396 cu in
Operating conditions
Idling......................................................................................................................................................
.......1000 rpm
Max speed
....................................................................................................................................................1950
rpm
SAE net horse
power........................................................................................................................................138HP
Max torque...................................................................................................................................392lb-
ft at 1600 rpm
Capacities
Engine oil
capacity............................................................................................................................................
6.3 gal
Engine cooling
system...................................................................................................................................... 7.1 gal
Capacity of the radiator
only............................................................................................................................. 3.1 gal
Fuel
tank........................................................................................................................................................
.... 90 gal
Hydraulic fluid reservoir
capacity....................................................................................................................... 32 gal
Total hydraulic system capacity
......................................................................................................................... 54 gal
Capacity of the cooler only
............................................................................................................................... 1.4 gal
Travel reduction gear housing capacity
............................................................................................................ 1.2 gal
Swing drive housing capacity
........................................................................................................................... 1.2 gal
Idler wheel capacity
........................................................................................................................................ 11 cu in
Upper roller
capacity............................................................................................................................... 3 to 3.3 cu
in
Lower roller
capacity.................................................................................................................................... 12.8 cu
in
NOTE: These capacities are only provided in an indicative manner. To check fluid levels, always
use the oil dipstick,
sight glasses or the filler cap.
Electrical system
Type of system ........................................................................................................................24 volts
negative earth
Alternator
amperage............................................................................................................................................
40 A
Battery
Number of batteries required
................................................................................................................................2
Voltage of each battery
.............................................................................................................................. 12 volts
Capacity
...................................................................................................................................................... 140
Ah
Reserve.................................................................................................................................................
.....160 min
Cold starting capacity at 1.4°F (-
17°C).......................................................................................................... 800 A
Load for load checking
.................................................................................................................................. 400 A
Starter motor
Voltage
....................................................................................................................................................... 24
volts
Power
...........................................................................................................................................................4.
5 kW
Voltage regulator ................................................................................................................ integrated,
not adjustable
1002-8
Cre 7-29360-21LX Issued 11-01
Hydraulic system
Main hydraulic pump
Double, axial piston, variable flow pump.
Max flow
................................................................................................................................................... 2x53.1
gpm
Displacement.........................................................................................................................................
.... 2x6.2 cu in
Hydraulic pilot pump
Fixed flow pump.
Max flow
.........................................................................................................................................................5.3
gpm
Displacement.........................................................................................................................................
........ 0.6 cu in
Pressure settings
Pilot circuit secondary relief valve
............................................................................................................. 566±14 psi
Main relief valve (standard)
..................................................................................................................... 4975±44 psi
Main relief valve (higher pressure - 2-stage relief)
.................................................................................. 5410±73 psi
Relief valves (boom, arm and bucket)
..................................................................................................... 5685±73 psi
Relief valves
(swing)................................................................................................................................ 4046±58
psi
Relief valves (travel)
................................................................................................................................ 5120±73 psi
Safety valve (boom and arm)
.................................................................................................................. 5685±73 psi
Cylinder
Boom cylinder
Bore diameter
..................................................................................................................................................... 4.7 in
Rod diameter
...................................................................................................................................................... 3.3
in
Stroke
...............................................................................................................................................................
49.4 in
Arm cylinder
Bore diameter
..................................................................................................................................................... 5.3 in
Rod diameter
...................................................................................................................................................... 3.7
in
Stroke
...............................................................................................................................................................
... 58 in
Bucket cylinder
Bore diameter
..................................................................................................................................................... 4.5 in
Rod diameter
...................................................................................................................................................... 3.1
in
Stroke
...............................................................................................................................................................
39.8 in
Leaks on the cylinder - attachment lowering (without load)
Boom cylinders (rod retracting)
0.19 in/5 min
Arm cylinder (rod
extending)0.19 in/5 min
Bucket cylinder (rod extending)
0.27 in/5 min
Full (at the end of the attachment)
7.87 in/10 min
Cylinder speeds (in mode S)
Boom raising (open bucket on the
floor).................................................................................................. 3.5±0.6 sec.
Boom lowering (open
bucket).................................................................................................................. 2.9±0.6 sec.
Arm
extension..........................................................................................................................................
2.7±0.6 sec.
Arm
retraction..........................................................................................................................................
3.7±0.6 sec.
Bucket
opening........................................................................................................................................
2.3±0.6 sec.
Bucket closing
............................................................................................................................................ 4±0.6 sec.
1002-9
Cre 7-29360-21LX Issued 11-01
Main control valve
Five section main control valve for arm, boom acceleration, swing, option and RH travel.
Four section main control valve for arm acceleration, bucket, boom and LH travel.
Load holding valve for boom and arm.
Swing
Fixed flow, axial piston motor.
Automatic disc brake.
Upperstructure swing
speed.............................................................................................................................12 rpm
Swing
torque.............................................................................................................................................
44840 ft.lbs
Tail swing
......................................................................................................................................................... 9 ft
0 in
Displacement.........................................................................................................................................
........ 9.2 cu in
Work output
.....................................................................................................................................................41
gpm
Reduction ratio
.................................................................................................................................................16.757
Braking
torque543.
4 lb-ft
Minimum brake pressure
................................................................................................................................. 421 psi
Travel
Two-speed, axial piston motor.
Automatic disc brake.
Slow speed
.....................................................................................................................................................2.1
mph
Fast
speed.....................................................................................................................................................
.3.4 mph
Gradeability
.................................................................................................................................................70%
(35°)
Tractive
force...............................................................................................................................................
41230 lbs
Displacement.........................................................................................................................................
.. 9.9/5.8 cu in
Work output
.....................................................................................................................................................53
gpm
Reduction ratio
.................................................................................................................................................43.246
Braking torque (including reducer)
.............................................................................................................15368 lb-ft
Number of turns at the sprockets (10 turns)
Mode "S", fast speed.........................................................................................................................
14.2±0.6 sec.
Mode "S", slow speed .......................................................................................................................
23.4±0.7 sec.
Permitted deviation in travel over a distance of 20 m
Mode "H", full
speed..................................................................................................................................... 39.4 in
Undercarriage
One-piece undercarriage with welded components.
Lubricated rollers and idler wheels.
Grease type track tension.
Ground pressure
with 23.6 in track pads
............................................................................................................................... 5.94 psi
............................................................................................................................... 5.22 psi
............................................................................................................................... 4.78 psi
Track tension
.....................................................................................................................................11.02 to 11.81
in
Attachment
Break-out bucket (standard)
......................................................................................................................... 29200 lbf
Break-out bucket (higher pressure)
..............................................................................................................31720 lbf
Penetration force
Crowd force
(standard)................................................................................................................................. 21420
lbf
Crowd force (higher
pressure)...................................................................................................................... 23380 lbf
1002-10
Cre 7-29360-21LX Issued 11-01
Weight of components
Engine
............................................................................................................................................................1
129 lbs
Hydraulic
pump................................................................................................................................................
346 lbs
Attachment main control valve
........................................................................................................................ 439 lbs
Swing motor/reduction gear assembly
............................................................................................................ 491 lbs
Travel motor/reduction gear assembly
............................................................................................................ 679 lbs
Boom
cylinder..................................................................................................................................................
372 lbs
Arm
cylinder..................................................................................................................................................
... 566 lbs
Bucket cylinder
................................................................................................................................................ 333 lbs
Counterweight
............................................................................................................................................... 8818 lbs
Cab........................................................................................................................................................
.......... 560 lbs
Turnable bearing
............................................................................................................................................. 580 lbs
Upperstructure attachment
...........................................................................................................................19114 lbs
Rotating
joint......................................................................................................................................................
68 lbs
Undercarriage attachment
........................................................................................................................... 14484 lbs
Machine without
attachment........................................................................................................................ 34017 lbs
Attachment
.....................................................................................................................................................8113
lbs
Boom attachment
.......................................................................................................................................... 4652 lbs
Arm attachment
............................................................................................................................................. 2046 lbs
Radiator and cooler set
................................................................................................................................... 167 lbs
Fuel
tank........................................................................................................................................................
.. 192 lbs
Hydraulic
tank..................................................................................................................................................
280 lbs
Idler wheel
....................................................................................................................................................... 181
lbs
Upper
roller.......................................................................................................................................................
. 38 lbs
Lower
roller.......................................................................................................................................................
. 79 lbs
Shock absorber
............................................................................................................................................... 278 lbs
Track 23.6
in.................................................................................................................................................. 2784
lbs
Track 27.5
in.................................................................................................................................................. 3241
lbs
Track 31.4
in.................................................................................................................................................. 3525
lbs
1002-11
Cre 7-29360-21LX Issued 11-01
DIMENSIONS AND LIMIT OF WEAR AND TEAR OF THE TRACKS
SET
Toothed wheel
Dimensions
CS01B512
Gauge
CS01G577
Marking Dimension (in)
a
Standard 2.59
Limit 2.36
Øb
Standard 22.9
Limit 22.6
Øc
Standard 25.9
Limit 25.7
Ød
Standard 25.3
Limit ---
P
Standard 7.48
Limit ---
P
ØbØcØd
a
1002-12
Cre 7-29360-21LX Issued 11-01
Idler wheel
Dimensions
CS01B514
Gauge
CS01G578
Øa
b
c
ef
Ød
Marking
Dimension
(in)
Ø a Standard 19.4
Limit 19.2
b Standard 0.74
Limit ---
c Standard 3.30
Limit 3.14
Ø d (pin) Standard 2.55
Limit 2.53
Ø d (ring) Standard 2.55
Limit 2.59
e
Standard 2.71
Limit 2.70
f
Standard 0.48
Limit 0.46
1002-13
Cre 7-29360-21LX Issued 11-01
Upper roller
Dimensions
CS01B516
Gauge
CS01G579
ge
Øa
b
fc
Ød
Marking Dimension (in)
Ø a Standard 4.72
Limit 4.40
b Standard 0.39
Limit ---
c Standard 3.34
Limit 3.11
Limit 1.79
Limit 1.84
e Standard 3.26
Limit 3.25
f
Standard 0.21
Limit 0.19
g
Standard 0.88
Limit 0.86
1002-14
Cre 7-29360-21LX Issued 11-01
Lower roller
Dimensions
CS01B518
Gauge
CS01G580
Øa
b
d
fg
Øe
Marking
Dimension
(in)
Marking
Dimension
(in)
Øa
Standard 5.90
Ø e (ring)
Standard 2.55
Limit 5.59 Limit 2.59
b
Standard 0.59
f
Standard 2.71
Limit --- Limit 2.70
d
Standard 6.81
g
Standard 0.91
Ø e (pin)
Standard 2.55
Limit 2.53
1002-15
Cre 7-29360-21LX Issued 11-01
Track
CS01B520
Marking
Dimension
(in)
Marking
Dimension
(in)
a Standard 1.35 Ø e (ring) Standard 2.31
b Standard 4.17 Ø f (ring) Standard 1.46
c Standard 1.49 Ø g (pin) Standard 1.42
d Standard 0.78 h Standard 7.48
c
d
Øe
Øf
Øg Øg
Øf
Øe
hh
b
a
1002-16
Cre 7-29360-21LX Issued 11-01
DIMENSIONS AND LIMIT OF WEAR AND TEAR OF
THE MOBILE JOINTS OF THE ATTACHMENT
CS01B521
1. Boom foot/Undercarriage
CS01B522
34
5
6
10 8 7
11
9
2
1
a
b
c
Ød
Marking
Dimension
(in)
a
Standard 26.8
Limit 27.2
b
Standard 26.8
Limit 26.7
c (a - b)
Standard 0.01 to 0.11
Limit Shims
Ø d (pin)
Standard 3.54
Limit 3.50
Ø d (ring)
Standard 3.54
Limit 3.60
1002-17
Cre 7-29360-21LX Issued 11-01
2. Boom cylinder foot/Undercarriage
CS01B523
3. Boom cylinder head/Boom

CS01B524
Marking
Dimension
(in)
a
Standard 4.17
Limit 4.40
b
Standard 4.13
Limit 4.05
c (play)
Limit Shims
Ø d (pin)
Standard 3.14
Limit 3.11
Ø d (ring)
Standard 3.14
Limit 3.20
Marking
Dimension
(in)
a Standard 3.93
Limit 3.85
b Standard 20.6
Limit 20.1
c (play) Standard 0.03 to 0.09
Limit Shims
Limit 3.30
Limit 3.40
Ød
a
b
c
Ød
abac
1002-18
Cre 7-29360-21LX Issued 11-01
4. Arm cylinder foot/Boom
CS01B525
5. Boom/Arm
CS01B526
6. Arm cylinder head/Arm

CS01B527
a
b
Ød
c
Marking
Dimension
(in)
a
Standard 4.76
Limit 4.99
b
Standard 4.72
Limit 4.64
c (a - b)
Limit Shims
Ø d (pin)
Standard 3.14
Limit 3.11
Ø d (ring)
Standard 3.14
Limit 3.20
Ød
abc
Marking
Dimension
(in)
a
Standard 12.2
Limit 12.3
b
Standard 12.1
Limit 12.1
c (play)
Limit Shims
Ø d (pin)
Standard 3.54
Limit 3.50
Ø d (dipper)
Standard 3.54
Limit 3.60
Ø d (boom)
Standard 3.54
Limit 3.60
a
b
Ød
c
Marking
Dimension
(in)
a
Standard 4.76
Limit 4.99
b
Standard 4.72
Limit 4.64
c (a - b)
Limit Shims
Ø d (pin)
Standard 3.14
Limit 3.11
Ø d (ring)
Standard 3.14
Limit 3.20
1002-19
Cre 7-29360-21LX Issued 11-01
7. Bucket cylinder foot/Arm
CS01B528
8. Connecting rod/Arm
CS01B529
9. Compensator/Bucket
CS01B530
a
b
Ød
c Marking
Dimension
(in)
a
Standard 3.97
Limit 4.21
b
Standard 3.93
Limit 3.85
c (a - b)
Limit Shims
Ø d (pin)
Standard 2.95
Limit 2.91
Ø d (ring)
Standard 2.95
Limit 3.01
a
b
Ød
c
Marking
Dimension
(in)
a
Standard 1.25
Limit 1.18
b
Standard 11.6
Limit 11.5
c (play)
Limit Shims
Ø d (pin)
Standard 2.95
Limit 2.91
Ø d (ring)
Standard 2.95
Limit 3.01
ba
Ød
c
Marking
Dimension
(in)
a
Standard 12
Limit 12.3
b
Standard 12.04
Limit 119
c (play)
Limit Shims
Ø d (pin)
Standard 3.14
Limit 3.11
Ø d (ring)
Standard 3.14
Limit 3.20
1002-20
Cre 7-29360-21LX Issued 11-01
10. Connecting rod/Compensator/Bucket cylinder head
CS01B531
11. Arm/Bucket
CS01B532
a
b
Øg
c
ed
f
Marking
Dimension
(in)
a
Standard 1.25
Limit 1.18
b
Standard 11.6
Limit 11.5
c (play)
Limit Shims
d
Standard 3.77
Limit 3.85
e
Standard 3.74
Limit 3.66
f (d - e)
Limit Shims
Ø g (pin)
Standard 3.14
Limit 3.11
Øg
(compensator)
Standard 3.14
Limit 3.20
Ø g (cylinder)
Standard 3.14
Limit 3.20
ab
Øe
c
d
Marking
Dimension
(in)
a Standard 12.08
Limit 12.3
b Standard 12.04
Limit 11.9
c (a - b) Standard 0.03 to 0.13
Limit Shims
d Standard 0.62
Limit 0.31
Ø e (pin) Standard 3.14
Limit 3.11
Ø e (dipper) Standard 3.14
Limit 3.20
Ø e (bucket) Standard 3.14
Limit 3.20
1002-21
Cre 7-29360-21LX Issued 11-01
SPECIAL TORQUE SETTINGS
NOTE: Use Loctite 262 or an equivalent on retaining screws of components marked with an
asterisk (*).
No. Component
Screw
(Ø)
Key
(mm)
Torque setting
(lb-ft)
1 * Travel motor/reduction gear assembly M16 24 197-230
2 * Sprocket M16 24 197-230
3 * Idler wheel M16 24 197-230
4 * Upper roller M20 30 384-448
5 * Lower roller M18 27 274-318
6 Chain guide M18 27 280-327
7 Track pad M20 30 221 + 120°
8 Counterweight
M27 41 780-911
M30 46 983-1142
9 Turntable (undercarriage)
M20 30 345-402
M24 36 578-673
10 Turntable (upperstructure)
M20 30 345-402
M24 36 578-673
11 * Swing motor/reduction gear assembly
M20 30 384-448
M24 36 578-673
12 * Engine M16 24 195-231
13 * Engine support M10 17 47-54
14 Radiator M16 24 108-130
15 * Hydraulic pump
M10 17 47-54
M20 30 271-366
16 * Hydraulic sump tank M16 24 171-203
17 * Fuel tank M16 24 171-203
18 * Main control valve M16 24 195-231
19 * Rotating joint M12 19 80-94
20 Cab M16 24 57-59
21 Battery M10 17 15-21
1002-22
Cre 7-29360-21LX Issued 11-01
CS00E507
CS00E508
CS00E510
CS00E509
CS00E511
16 18 15 12 13
14 8
21
7
12
5
6
34
20
9 10
19
17
11
1
2
7
4
5
6
3
6
8
1002-23
Cre 7-29360-21LX Issued 11-01
CS00E512 CS00E514
CS00E515
CS00E517
CS00E518
CS00E519
CS00E521
CS00E522 CS00E523 CS00E525
11
9 9 10
13
12
14
15
15
16 17 18
19
20
21
Link-Belt
Printed in U.S.A
2000
REMOVAL AND INSTALLATION OF THE ENGINE
Section
2000
2000-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................
................... 2
SPECIAL TORQUE
SETTINGS............................................................................................................................... 2
ENGINE.................................................................................................................................................
................... 3
Removal and installation
...................................................................................................................................... 3
SPECIFICATIONS
Weight of engine.............................................................................................................................
See Section 1002
Engine retaining screws .................................................................................................................
See Section 1002
WARNING: The components of the engine and the hydraulic pump reach high temperatures when
the
machine is operating. To avoid being burnt by hot metal or scalded by high temperature water or oil,
allow the
machine to cool down before starting any servicing operation. !
2000-3
ENGINE
STEP 1
JS00163A1
Park the machine on hard, flat ground. Lower the
attachment to the ground.
STEP 2
Release pressure in the hydraulic system and in the
hydraulic sump tank (see Section 8000).
STEP 3
CD00F091
Disconnect the ground cable from the battery (1) (-).
STEP 4
Refer to Section 8003 and remove the hydraulic
pump.
STEP 5
Refer to Section 2001 and remove the radiator and
oil-cooler assembly.
STEP 6
CD00J037
Remove the engine throttle control.
STEP 7
CD00J038
Disconnect the fuel supply pipe (1) and the fuel return
pipe (2) and plug them.
STEP 8
CD00J039
Remove the hoses (1) and (2) from the heater system
and plug them.
12
1
1
2
2000-4
STEP 9
CD00J044
Label and disconnect the electrical connections from
the water temperature sensor (1).
STEP 10
CD00J045
the fuel temperature sensor (1).
STEP 11
CD00J046
the oil pressure detector (1) and the engine speed
detector (2).
STEP 12
CD00J047
Label and disconnect the electrical supply (1) to the
pre-heating plugs.
STEP 13
CD00J048
Label and disconnect the electrical connections to
the starter motor. Remove the ground cable (1) at the
engine end.
1
1
1
2
1
1
2000-5
STEP 14
CD00J040
Label and disconnect the connectors to the electronic
regulator and disconnect the fuel flow regulation
resistance.
STEP 15
CD00J041
Remove the hose connecting the turbo-charger to the
air filter.
STEP 16
CD00J042
Label and disconnect the electrical connections to
the alternator.
NOTE: If the machine is equipped with air
conditioning, remove the compressor mounting
hardware and move the compressor away from the
engine.
STEP 17
Remove all the clips, etc, which fasten the electrical
harnesses to the engine and move the harnesses out
of the way.
STEP 18
CD00J043
Install a suitable lifting device on the engine lifting
eyes (for the weight of the engine, see Section 1002).
2000-6
STEP 19
Remove the engine retaining hardware.
NOTE: When installing, make a visual inspection of the
condition of the rubber flexible mountings and change
them if necessary. Tighten the engine retaining screws
to the torque specified in Section 1002.
STEP 20
When there is nothing interfering with the removal of
the engine, raise the engine carefully and install it on
a suitable repair bench.
NOTE: When installing the engine in the machine,
proceed in the reverse order from removal.
Before operating the machine, carry out the following operations:
- Bleed and prime the fuel system (see Operator’s Manual).
- Fill and bleed the engine cooling system (see Operator’s Manual).
- Check the hydraulic, fuel and cooling systems for leaks.
- Check the oil level in the hydraulic sump tank. Top up if necessary.
Link-Belt
Printed in U.S.A.
2001
RADIATOR AND OIL-COOLER
Section
2001
2001-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................
................... 2
............................................................................................................................... 3
Removing the oil-cooler
....................................................................................................................................... 3
Installing the oil-cooler
......................................................................................................................................... 3
Removing the
radiator.......................................................................................................................................... 4
Installing the
radiator............................................................................................................................................ 6
CHANGING THE RADIATOR OR THE OIL-
COOLER............................................................................................. 7
Disassembly and
assembly.................................................................................................................................. 7
SPECIFICATIONS
Coolant solution and total capacity.................................................................................................
See Section 1002
Thermostat opening range
Starts to
open.....................................................................................................................................180°F
(82°C)
Completely open
................................................................................................................................203°F (95°C)
Hydraulic fluid .................................................................................................................................
See Section 1002
you see
this symbol, carefully read the message which follows. ! Your safety depends on it.
2001-3
Before carrying out any operation on the machine, perform the following operations in the order
shown:
- Park the machine on hard, flat ground.
- Lower the attachment to the ground.
- Shut down the engine.
- Remove the starter switch key.
- Make sure that pressure in the hydraulic system has been completely released (see Operator’s
Manual).
Removing the oil-cooler
STEP 1
CD00G009
Remove the upper grille (1), then remove the air
conditioning heat exchanger (2) without disconnecting it.
STEP 2
Release pressure in the hydraulic sump tank to allow
the vacuum pump to be mounted (see Section 8000).
STEP 3
CD00G010
Disconnect and plug the hoses (1) and (2). Drain the
oil from the oil-cooler (3) into a clean receptacle.
Disassemble the four screws (4) from the oil-cooler
bracket (3).
STEP 4
CD00G013
Disassemble the four retaining screws (1) from the
oil-cooler (2) and remove the oil-cooler.
Installing the oil-cooler
When installing, proceed in the reverse order from
that of removal.
Before using the machine, check the level of oil in the
hydraulic sump tank. Top up if necessary. Check the
hydraulic fluid cooling circuit for leaks.
WARNING: When the machine is working, the engine components and the hydraulic pump reach a
high
temperature. To avoid being burnt by hot metal or scalded by high temperature water or oil, allow
the
machine to cool down before starting any servicing operation. !
1
2
1
2
3
4
2
1
1
2001-4
Removing the radiator
STEP 1
CD00G009
Remove the upper grille (1).
STEP 2
CD00G012
Disassemble the four retaining screws (1) from the
oil-cooler bracket (2).
STEP 3
CD00G152
Pivot the oil-cooler bracket assembly (1) to the
maximum opened position. Wedge the assembly (1)
into position.
STEP 4
CD00G014
Disassemble the retaining screws (1) from the hinges
(2) of the oil-cooler bracket (3) at the radiator bracket
end (4). The oil-cooler bracket (3) is then separated
from the radiator bracket (4).
STEP 5
Remove the cap from the expansion tank.
IMPORTANT: Do not remove the cap when the
engine is hot, since the system would still be under
pressure and you could be scalded.
STEP 6
Drain the cooling system (see Operator’s Manual).
STEP 7
CD00G015
Disconnect the expansion tank hose (2) and the
return hose (3) from the radiator (1).
1
1
2
1
4
3
1
1
2
1
2
3
2001-5
STEP 8
CD00G016
Disconnect the water pump intake hose (4) from the
radiator (1).
STEP 9
CD00G017
Loosen the retaining band (1) as far as possible, then
slide the retaining band (1) and the rubber skirt (2)
onto the shroud (3).
STEP 10
CD00G018
Remove the lower retaining screws (1) from the
radiator bracket.
STEP 11
CD00G019
Disassemble the two retaining screws (1) and remove
the rear tie-rod (2).
STEP 12
CD00G020
Disassemble the two retaining screws (1) and remove
the front mounting angle bracket (2).
STEP 13
CS00G513
Pass a suitable sling right around the radiator and
support assembly and, using a suitable lifting device,
remove the radiator and support assembly.
1
4
1
3
2
1
1
1
21
1
2
2001-6
Installing the radiator
When installing, proceed in the reverse order from
that of removal.
Before operating the machine, fill and bleed the
engine cooling system (see Operator’s Manual) and
check the engine cooling system for leaks.
2001-7
CHANGING THE RADIATOR OR THE OIL-COOLER
Disassembly and assembly
NOTE: The parts are numbered in order of disassembly. Assembly is carried out in the reverse
order from that of
disassembly.
CI00G506
1 INTAKE SHROUD RETAINING SCREWS
2 INTAKE SHROUD
3 RADIATOR UPPER RETAINING SCREWS
4 RADIATOR LOWER RETAINING SCREWS
5 RADIATOR
6 OIL-COOLER BRACKET RETAINING SCREWS
7 OIL-COOLER
8 OIL-COOLER BRACKET
9 FILTER RETAINING SCREWS
10 FILTER
11 GUARD RETAINING HARDWARE
12 GUARD
13 RADIATOR SUPPORT
3
4
5
37
9
6
8
10
11
12
1
2
13
2001-8
Link-Belt
Printed in USA
3001
REMOVAL AND INSTALLATION
OF THE FUEL TANK
Section
3001
3001-2
TABLE OF CONTENTS
SPECIFICATIONS
.................................................................................................................................................. 2
FUEL TANK
............................................................................................................................................................ 3
Removal
..............................................................................................................................................................
3
Installation
........................................................................................................................................................... 4
Description
.......................................................................................................................................................... 5
SPECIFICATIONS
See Section 1002
3001-3
FUEL TANK
Removal
STEP 1
JS00163A1
STEP 2
Reduce the engine speed to idle for 30 seconds, then
shut down the engine.
STEP 3
Turn the ignition key to "ON" without starting the
engine.
STEP 4
Attach a "DO NOT OPERATE" tag to the ignition key
in the cab.
STEP 5
NOTE: The numbers in brackets refer to the figures
on pages 5 and 6.
Remove the access panel under the fuel tank (1).
STEP 6
Open the filling plug of the tank (2). Empty the tank
using the valve (3) then remove the latter.
STEP 7
Lift the hood of the front boot. Remove the retaining
screw (4) of the access ramp (5). Remove the access
ramp (5).
STEP 8
Remove the screws (6) on top and then inside the
front boot, then remove the protective housing (7).
STEP 9
Remove the screws (8) and the protective plate (9)
from on top of the fuel tank (1).
STEP 10
Loosen the two screws (10) located underneath the
machine. Open the side portion of the machine and
remove the two screws (11) located on the RH side of
the fuel tank (1). Remove the protective plate of the
tank (12).
STEP 11
Remove the two screws (13) that hold the fuel oil filter
(14). Attach tags to the two hoses (15) and (16).
Remove the fuel oil filter (14) by removing the two
hoses (15) and (16) and the circlips (17) and (18).
STEP 12
Shift the plastic protection (19) from the fuel probe
(20). Remove the retaining screws (21) then the fuel
probe (20) as well as the seal (22).
STEP 13
Remove the four screws (23) from the fuel tank (1),
as well as the shims (24).
STEP 14
Remove the fuel tank (1) using a hoist.
STEP 15
See the operator’s manual for removing the fuel filter.
3001-4
Installation
NOTE: The numbers in brackets refer to the figures
on pages 5 and 6.
STEP 1
Using a hoist, position the fuel tank (1) on the
machine.
STEP 2
Install the shims (24) as well as the four screws (23),
tighten the screws to a torque, see specifications.
Install the valve (3) and tighten the valve (3) to a
torque of 14.7 Nm.
STEP 3
Install a new seal (22), then the fuel probe (20) using
the five screws (21), reposition the plastic protection
correctly (19).
STEP 4
Install the fuel oil filter (14) on the tank using screws
(13). Install the two hoses (15) and (16) taking help of
the tags installed during removal. Tighten using
circlips (18) and (17).
STEP 5
Install the tank protection (12) using screws (10) and
(11). Tighten the screws (10) and (11).
STEP 6
Install the protective plate (9) on top of the fuel tank
(1). Tighten the screws (8).
STEP 7
Install the protective housing (7) on top of the front
boot using the screws (6) then put back the screw
mask.
STEP 8
Install the access ramp (5) using screws (4). Close
the front boot.
STEP 9
Fill the fuel tank (see the operator’s manual) and
make sure that there are no leaks.
STEP 10
Reinstall the protective plate on top of the machine.
3001-5
Description
Location
CS00F539
CS00F540
4 SCREW
5 ACCESS RAMP
6 SCREW
7 PROTECTIVE HOUSING
8 SCREW
9 FUEL TANK PROTECTIVE PLATE
10 SCREW
11 SCREW
12 TANK PROTECTIVE PLATE
12 10
11
4
7
5
4
6
9
6
4
84
3001-6
Fuel tank
CI00F506
1 FUEL TANK
2 PLUG
3 VALVE
13 SCREW
14 FUEL OIL FILTER
15 HOSE
16 HOSE
17 CIRCLIP
18 CIRCLIP
20 FUEL PROBE
21 SCREW
22 SEAL
23 SCREW
24 SCREW
20
21
19
22
16
24
23
3
17 18
14
15
18
17
2 13 1
Link-Belt
Printed in U.S.A
4001
ELECTRICAL SYSTEM,
ELECTRICAL AND ELECTRONIC
TROUBLESHOOTING
Section
4001
4001-2
Cre 7-28250-21LX Issued 11-01
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................
................... 4
SPECIAL TOOLS
..................................................................................................................................................... 4
LOCATION OF COMPONENTS
.............................................................................................................................. 6
General Location of Components (Outside the Cab)
........................................................................................... 6
Relays and Main Fuses (Battery Compartment)
.................................................................................................. 8
General Location of Components (Inside the Cab)
..............................................................................................9
Fuse Box
............................................................................................................................................................1
1
Instrument Panel
................................................................................................................................................12
BASIC OPERATING PRINCIPLES
........................................................................................................................ 13
Engine Control
...................................................................................................................................................13
Working Mode Selection
....................................................................................................................................15
H/S/L Mode Control
............................................................................................................................................17
Automatic Mode Control
.....................................................................................................................................18
Acceleration Control
...........................................................................................................................................19
Control of Engine Return to Idle
(Automatic/Manual)......................................................................................... 20
Auxiliary Mode Control
.......................................................................................................................................21
Automatic Engine Pre-heat
................................................................................................................................22
Automatic Engine Warm-up
...............................................................................................................................25
3) Diagram showing times
..................................................................................................................................26
Idle Control by Battery Voltage and Coolant Temperature
................................................................................ 27
Engine Emergency Stop
.................................................................................................................................... 29
Emergency Mode
............................................................................................................................................... 31
Lockout Functions
..............................................................................................................................................33
Power Up
...........................................................................................................................................................34
Swing Brake
....................................................................................................................................................... 35
Cushion (On/Off)
................................................................................................................................................37
Free swing
..........................................................................................................................................................38
Travel
Speed....................................................................................................................................................
.. 39
Travel Alarm
.......................................................................................................................................................42
Supply Cut-Off Delayed
.....................................................................................................................................43
Protection by Power Transistor
..........................................................................................................................44
Water Temperature Gauge
................................................................................................................................44
Hydraulic Oil Temperature Gauge
.....................................................................................................................46
Fuel Level
...........................................................................................................................................................47
Engine Fuel Injection Pump Electronic Regulator
..............................................................................................48
ACCESS AND CONTENTS OF CONTROL SCREENS (Diagnostic Mode)
.......................................................... 50
Access to Control Screens
.................................................................................................................................50
Machine Condition
.............................................................................................................................................51
Diagnostic Code
.................................................................................................................................................55
Machine History
................................................................................................................................................. 58
Reset.....................................................................................................................................................
............. 61
4001-3
Cre 7-28250-21LX Issued 11-01
WARNING
MESSAGES.........................................................................................................................................
64
Message
Display................................................................................................................................................
64
EXCAVATOR MODEL SELECTION PROCEDURE
.............................................................................................. 65
Changing the Language Code
...........................................................................................................................66
ACTIVATING THE ANTI-THEFT
SYSTEM............................................................................................................ 67
TROUBLESHOOTING
........................................................................................................................................... 68
Prior Inspections
................................................................................................................................................ 68
Reading the Organization Charts
.......................................................................................................................69
Procedures
.........................................................................................................................................................70
Fuel
...............................................................................................................................................................
..... 71
Add Coolant Solution
......................................................................................................................................... 72
Low Engine Oil Pressure
....................................................................................................................................73
Overheating
........................................................................................................................................................74
Battery Charge Circuit
Defective........................................................................................................................ 77
Electrical System Troubleshooting
.....................................................................................................................79
Translation
.........................................................................................................................................................83
ELECTRICAL INSPECTION OF
COMPONENTS.................................................................................................. 84
Inspection Equipment
.........................................................................................................................................84
Proportioning Valve
............................................................................................................................................86
Engine Emergency Stop Motor
..........................................................................................................................86
Block of 6 Solenoid Valves
.................................................................................................................................87
Engine Speed Detector
......................................................................................................................................88
Engine Coolant and Hydraulic Oil Temperature Detectors
................................................................................89
Pressure Detector
..............................................................................................................................................90
4001-4
Cre 7-28250-21LX Issued 11-01
SPECIFICATIONS
Electrical system........................................................ 2 x 12 volt batteries connected in series with
negative ground
Electrical system
voltage.................................................................................................................................. 24 volt
Battery
.............................................................................................................................................................
140 Ah
Alternator ..........................................................................................................................................
24 volt, 40 amps
Voltage regulator ................................................................................................................ integrated,
not adjustable
Starter motor......................................................................................................... 24 volt/4.5 kW,
solenoid controlled
SPECIAL TOOLS
BS98G045
1 Service connector kit HKP1574
CS96K068
2 Multimeter
4001-5
Cre 7-28250-21LX Issued 11-01
This page is intentionally left blank
4001-6
Cre 7-28250-21LX Issued 11-01
LOCATION OF COMPONENTS
General Location of Components (Outside the Cab)
CM00K002
1
3
2
568
9
10
11
7
13
14
16
17
19
15
29 28 27 26 25 24 23 22 18 21
34
33
32
31
30
35
36
37
4
12
20
4001-7
Cre 7-28250-21LX Issued 11-01
1. Free swing valve solenoid
2. Alarm travel
3. Attachment working light
4. Swing pilot pressure switch
5. Horn
6. Horn
7. Pilot pressure switch (yellow ring)
8. Working light (upperstructure)
9. Windshield washer motor
10. Fuel filler pump connector (not used)
11. Fuel level sending unit
12. Travel pilot pressure switch
13. Engine speed sending unit
14. Engine oil pressure
15. Proportioning valve
16. Engine emergency stop motor
17. 6 solenoid valve block
18. Negative pressure detector (N)
19. P2 pressure transducer (yellow ring)
20. P1 pressure transducer
21. Hydraulic oil temperature sending unit
22. Starter motor
23. Electronic regulator
24. Fuel flow regulating resistor
25. Pre-heater plugs
26. Air conditioning compressor magnetic clutch
27. Alternator
28. Engine water temperature sending unit
29. Fuel temperature sending unit
30. Battery relay
31. Main protective fuse for circuits F11 and F12
32. Main protective fuse for circuits F3 to F10 and F13 to F20
33. Main protective fuse for circuit F2
34. Main protective fuse for circuit F1
35. Batteries
36. Coolant sending unit level
37. Air conditioning compressor magnetic clutch contact switch
4001-8
Cre 7-28250-21LX Issued 11-01
Relays and Main Fuses (Battery Compartment)
CI00E502
1. Battery relay
2. Fuse 65A: protection of circuits F3 to F10 and F13 to F20A
3. Fuse 20A: protection of circuits F11 and F12 (before contact)
4. Fuse 20A: protection of circuits F1
5. Fuse 20A: protection of circuits F2
6. Battery cables
6
1
235
4
4001-9
Cre 7-28250-21LX Issued 11-01
General Location of Components (Inside the Cab)
CS00K508
1
2
3
4
5
6
7
8
9 10 11 12
13
14
15
16
25
17
18
19
20
21
22
23 24
4001-10
Cre 7-28250-21LX Issued 11-01
1. Horn switch
2. Gatelock lever (Controls cancellation lever contact switch)
3. Switch for auxiliary hydraulics
4. Door contact switch
5. Air conditioner
6. Fuse box
7. Main electronic control box
8. Engine electronic control box
9. Engine emergency stop relay
10. Working lights relay
11. Horn relay
12. Pre-heat plug relay
13. DC-DC converter (24 V - 12 V)
14. Solar radiation sensor
15. Radio
16. Cigarette lighter
17. Air conditioning control
18. Starting contact switch
19. Throttle control
20. Instrument panel
21. Engine idle control
22. Windshield contact switch
23. Windshield wiper motor electronic control box
24. Windshield wiper motor
25. Cab interior lighting
4001-11
Cre 7-28250-21LX Issued 11-01
Fuse Box
CM00E005
F1 Fuse 20A: Engine electronic control box
F2 Fuse 20A: Electronic box control
F3 Fuse 20A: Power for electronic control box
F4 Fuse 10A: Hydraulic control cancellation
F5 Fuse 15A: (Not used)
F8 Fuse 15A: Engine emergency stop motor
F9 Fuse 30A: Pre-heater plug
F10 Fuse 10A: Option
F11 Fuse 10A: Memory
F12 Fuse 10A: Starting, radio and cab light switch
F13 Fuse 20A: Air conditioning, heating
F14 Fuse 5A: Air conditioning compressor
F15 Fuse 15A: Working lights
F17 Fuse 10A: DC converter (24 V - 12 V)
F18 Fuse 15A: Windshield wiper and washer
F19 Fuse 10A: Horn
F20 Fuse 15A: Cigar lighter
4001-12
Cre 7-28250-21LX Issued 11-01
Instrument Panel
CM00K003
1. Travel mode switch
2. Working mode switch
3. Automatic mode switch
4. Buzzer stop switch
5. Swing brake switch
6. Engine emergency stop switch
7. Hourmeter
8. Attachment cushion (Hard/soft) switch
9. Free swing switch
10. Working light switch
11. Windshield wiper switch
12. Windshield washer switch
13. Control screen
CS00K502
14. Travel speed indicator
15. Working mode indicator
16. Idle mode indicator
17. Water temperature indicator
18. Hydraulic oil temperature indicator
19. Fuel level indicator
13 1 2 3 4 5 6 7
8 9 10 11 12
14 15 16 13
17 18 19
4001-13
Cre 7-28250-21LX Issued 11-01
BASIC OPERATING PRINCIPLES
Engine Control
1) Circuit configuration
CS00F507
CS00K501
1. Starter motor switch
2. Emergency stop switch
3. Throttle control
4. Instrument panel
7. Electronic acceleration
8. Engine speed detector
10. Engine water temperature detector
11. Fuel temperature detector
12. Engine
13. Rack detector
14. Control circuit
15. Linear motor control circuit
16. Linear motor driver circuit
1
42
5
3
6 12
7
8
9
10
11
Emergency
mode
67
13
15 16
14
Existing position
signal
PWM signal
Emergency mode
Stop signal
Existing
value
Target
value
4001-14
Cre 7-28250-21LX Issued 11-01
2) Fuel consumption control
1. The engine electronic control box (6) calculates
the target speed based on:
- working mode data sent via CAN
communications from the main electronic
control box (5),
- voltage signals from the acceleration control (3),
- voltage signals from the water temperature
detector (10),
- voltage signals (starter motor switch 1) which
feed the engine electronic control box.
2. The engine electronic control box calculates the fuel
flow from the difference between the target speed
(electronic acceleration tachometric sender) and the
real speed (engine speed detector 8).
3. The engine electronic control box converts the fuel
flow at the target position of the electronic
acceleration rack (7) and corrects that target
position in accordance with the regulating resistance
(9).
3) Engine starting control
1. When the contact switch (1) is in the starting
position the starting signal is sent simultaneously
to the starter motor and the engine electronic
control box.
2. The engine electronic control box determines the
fuel injection flow. This flow is determined from the
water temperature data and the real number of
revolutions of the engine.
3. Once the starting signal is extinguished, the engine
electronic control box changes from starting fuel
control to normal fuel injection flow control.
4) Engine stop control
When the engine stop signal is received (when the
ignition switch is turned off or the emergency stop
control (2) is operated), the engine electronic control
box transmits the rack position signal "no injection" to
the electronic acceleration and activates the engine
stop signal.
5) Electronic acceleration assistance
error and emergency mode
1. The rack detector signal reaches the engine
electronic control box.
2. The engine electronic control box compares the
target position and the real position of the rack.
3. If the engine electronic control box determines that
the rack is not in the correct target position, it will
consider it to be an assistance error and will stop the
engine.
4. If the emergency mode is activated when an
electronic acceleration assistance error occurs, the
engine operates in emergency mode (See
"Emergency Mode" Section).
4001-15
Cre 7-28250-21LX Issued 11-01
Working Mode Selection
CS00F505
2) Timing diagram
1. Working mode switch
2. Automatic mode switch
3. Instrument panel
8. Engine
9. SERIES communication
1
2
3
9
45
6
8
7
H L H AUTO H AUTO H
24V
0V
1
2
a
Contact
switch
Working
mode S
b
d
c
4001-16
Cre 7-28250-21LX Issued 11-01
3) Mode selector switch
a) When the ignition is switched on, "H" is selected
by default.
b) Every time the work mode switch (1) is pressed,
the mode changes:
H L S H
c) If the auto mode switch (2) is operated, the
mode changes to auto mode. If the auto mode
switch is pressed again, the mode changes to
"H" mode.
d) When auto mode is running, if the work mode
switch (1) is pressed, the mode does not
change.
4) Operation
1. The mode switch signal (1 and 2) is managed by
the main electronic control box (4) which changes
the mode in accordance with the input signal.
2. The electronic control box (4) transmits the selected
mode to the control screen (LCD) via series
communications (9). The control screen shows the
mode selected.
3. The main electronic control box (4) transmits the
selected mode to the engine electronic control box
(6) via CAN communications which controls the
electronic acceleration (7).
4. The engine electronic control box (6) transmits the
mode and the data concerning the number of
revolutions to the main electronic control box (4) via
CAN communications.
5. The main electronic control box (4) calculates the
proportioning valve current (5) based on the mode
selected and the data concerning the real number of
revolutions of the engine and the target number of
revolutions.
6. The main electronic control box (4) transmits the
new data to the display screen (LCD) via series
communications.
4001-17
Cre 7-28250-21LX Issued 11-01
H/S/L Mode Control
CS00F509
2. Power up solenoid valve
5. Engine
2) Values set for each mode
NOTE: The shown above are for normal conditions; the following are exceptions:
1. If the target number of engine revolutions is less
than the maximum torque number of revolutions,
the pump is controlled by the value of "L" mode
current (even in H/S modes).
2. In "L" mode, if travel operation only is actuated, the
pump is controlled by the value of "S" mode current.
3. In "L" mode, if a hydraulic hammer is used, the
pump is controlled by the value of "S" mode current.
4. If the engine coolant solution temperature is too low,
or the voltage arriving at the engine electronic
control box is too low, the idle speed increases to
prevent the engine becoming too cool or the battery
being discharged.
1
2
345
6
Hydraulic
power up
Mode
H
Number of engine revolutions
(Maxi)
rpm 2000 ± 10
Automatic
Current (variable control
amperage)
(Max) mA 407
(Min) mA 292
Mode
S
(Max -200)
rpm 1800 ± 10
Automatic
Fixed current amperage control
(90% of torque)
mA 292
Mode
L
(Max -300)
rpm 1700 ± 10
Constant
Fixed current amperage
(70% of torque)
mA <50
Idle Number of engine revolutions rpm 900 ± 10 -----
Number of engine revolutions at maximum
torque
rpm 1600 -----
4001-18
Cre 7-28250-21LX Issued 11-01
Automatic Mode Control
CS00F510
4. Hydraulic oil temperature sender
5. Pressure transducer P1
7. Negative pressure transducer (N)
10. Engine
12. Water temperature transducer
2) Description
1. If auto mode is selected, 2 modes, SA and LA, are
available.
2. When auto mode is selected, LA mode is engaged,
which then automatically changes to SA or LA
depending on working conditions.
3. If the engine coolant solution temperature is below
122°F or the oil temperature below 77°F, auto mode
control does not operate and LA mode is selected.
When the water temperature is above 122°F and
the oil temperature above 77°F, auto mode starts
and continues operating even if the water and oil
temperatures fall.
4. When auto mode control is operating, if the travel
pressure switch (8) is operated, the mode change
does not take place. (If the travel pressure switch is
operated in SA mode, the system stays in SA mode
and if the pressure switch is operated in LA mode,
the system stays in LA mode).
1
2
34
5
6
7
8
9
10
11
12
SA mode
Number of engine revolutions (MAX) rpm 1800±10
Current (equal to S mode + 40 mA) mA 332
Hydraulic power up --- Automatic
LA mode
Number of engine revolutions (MAX) rpm 1700±10
Current (equal to S mode) mA 292
Hydraulic power up --- Automatic
4001-19
Cre 7-28250-21LX Issued 11-01
Acceleration Control
CS00F511
4. Throttle control
5. Engine
2) Operation
1. The electronic control box (1) transmits the
selected work mode to the engine electronic
control box (3) via the CAN communications.
2. The engine electronic control box (3) calculates the
number of revolutions based on engine output
(depending on the mode selected) and the analog
signal (volume) from the throttle control (4).
3. The engine electronic control box calculates the
target position of the rack, using the target number
of revolutions and the data from each detector (real
number of engine revolutions, real position of the
rack, fuel flow regulating resistance), and it sends
the signal to the electronic acceleration.
4. The electronic acceleration calculates the target
position of the rack and its real position (value
measured by the rack detector) and moves the rack
by turning the electronic motor to adjust the quantity
of fuel injected.
5. By repeating this process, the engine electronic
control box controls the electronic acceleration to
obtain: real number of revolutions = target number
of revolutions.
6. If the number of engine revolutions have become
less than the number of revolutions resulting from
the torque set by the throttle control, the value of
current delivered by the proportioning valve (2)
becomes that of mode "L".
3) Relation between the throttle control and the number of engine revolutions
1
2
3
4
5
6
0 100
5.0
Input voltage (Volt)
Throttle control (%)
0 100
NH Speed (
rpm)
Throttle control (%)
NS
NL
NI
Mode H
Mode S
Mode L
4001-20
Cre 7-28250-21LX Issued 11-01
Control of Engine Return to Idle (Automatic/Manual)
CS00F512
1. Instrument panel
2. Audible warning device
3. Return to idle control
5. Pilot pressure switch
8. Engine
2) Changing from automatic idle to manual idle
1. The idle mode is changed by pressing the idle
control button (3) for 3 seconds. The audible
warning device (2) sounds for 3 seconds. The
mode, "ON" or "OFF" is displayed on the control
screen (LCD).
- "ON" = automatic return to idle
- "OFF" = manual return to idle by pressing the
idle control button.
2. When the machine is started, it will be in the
previous idle mode.
3. If no function is operated and idle mode is "ON", the
engine speed automatically returns to idle after
5 seconds. (This timing can be changed to between
1 and 30 seconds).
4. If automatic idle is on and the engine is at idle, the
engine speed automatically returns to the original
speed when one of the machine functions is
operated.
5. If the automatic idle is on, the engine can be
returned to idle by pressing the return to idle control
button (3). But if automatic idle is not on, the only
way to return to idle is to press the control button (3).
6. When automatic or manual idle mode is engaged,
the "ENG. IDLING" message appears on the control
screen (LCD).
1
2
3
4
5
6
7
8
9
4001-21
Cre 7-28250-21LX Issued 11-01
Auxiliary Mode Control
CS00F513
1. Auxiliary hydraulic switch
2. Hammer pilot switch
5. Throttle control
7. Engine
2) Operation
When the auxiliary hydraulic switch (1) is turned to hammer function (when the option is installed)
and the option
pedal is pressed, the pressure switch (2) is on and the engine speed drops to the pre-set hammer
speed (see
engine speed setting for hammer option).
When the option pedal returns to the neutral position, the pressure switch (2) is deactivated and the
engine speed
returns to the throttle control setting.
For the pre-set hammer engine speed to function, the throttle control (5) has to be set at a higher
speed than the
pre-set hammer engine speed.
When the pressure switch (2) is on, the value of current delivered by the proportioning valve (4)
becomes that of
mode "S".
3) Time diagram
1
2
3
45
6
7
8
Pre-set hammer speed
(5V)
(0V)
(5V)
(0V)
Engine speed
Auxiliary switch
Pilot pressure
switch
Throttle control lower than
pre-set hammer speed
4001-22
Cre 7-28250-21LX Issued 11-01
Automatic Engine Pre-heat
CS00F514
1. Instrument panel
5. Pre-heat glow-plug relay
6. Engine
7. Pre-heater plugs
8. Engine coolant temperature sending unit
2) Operation
1. When the ignition switch is turned on (IN1 = ON),
the main electronic control box (2) calculates the
pre-heating time (Tp) by means of the engine
coolant temperature (see figure).
2. The engine electronic control box (4) activates the
pre-heat relay (5) for the pre-heating time (Tp)
previously calculated and transmits a signal to the
main electronic control box (2).
3. At the end of pre-heating time (Tp), the pre-heat
relay (5) stays on for 2 seconds more.
4. When the ignition switch is turned (3) to "START"
(ST, IN2 = ON), the engine electronic control box (4)
reactivates the pre-heat relay (5) but does not
transmit a signal to the main electronic control box
(2).
5. The engine electronic control box (4) calculates the
time after pre-heat (Ta) by means of the engine
coolant temperature (see figure).
6. When the ignition key (3) is turned back from
"START" to "ON" (IN1 = ON; IN2 = OFF), the engine
electronic control box (4) activates the pre-heat
relay (5) for the time after pre-heat (Ta).
7. During the time after pre-heat (Ta), the message
"ENG. PRE HEAT" appears on the control screen
(LCD).
8. The control system mentioned above immediately
starts, with the ignition on, the message "ENG. PRE
HEAT" appears on the control screen (LCD) only if
the pre-heating time exceeds 3 seconds (engine
coolant solution temperature below -23°F).
NOTE: When the ignition is switched on, the "LBX"
logo appears on the control screen (LCD) for
3 seconds.
123
45
7
8
9
6
4001-23
Cre 7-28250-21LX Issued 11-01
3) Figure showing pre-heating time (Tp) and after pre-heat (Ta)
4) Organization diagram
-4.4 5 14 23 32 41 50
0
2
4
6
8
10
12
14
16
Pre-heating time (Tp) in seconds
Engine coolant solution temperature (°F)
-4.4 5 14 23 32 41 50
0
10
20
30
40
50
60
70
80
Time after pre-heat (Ta) in seconds
Engine coolant solution temperature (°F)
Beginning
Switch on
Water
temp.
Calculated time
Glow-plug on
Elapsed time
Glow-plug
activated
Glow-plug
deactivated
Signal
deactivated
Signal active
Time calculation
pre-heat
Glow-plug on
Engine started
Time calculation
after pre-heat
Calculated time
Glow-plug on
Elapsed time
Glow-plug
deactivated
End
Water
temp.
4001-24
Cre 7-28250-21LX Issued 11-01
a) If the engine is started during the 2 seconds following the display "ENG. PRE HEAT"
b) If the engine is started after the 2 seconds following the display "ENG. PRE HEAT"
c) If the engine is started while "ENG. PRE HEAT" is displayed
A. Pre-heating time Tp
B. 2 seconds of additional pre-heat
C. Pre-heating time when engine is being started
D. Time after pre-heat Ta
OFF
ON
OFF
ST
ON
OFF
Control screen
Pre-heat
LBX logo
ABCD
3 sec.
Starter motor
switch
Pre-heat
glow-plug
3 sec.
ABCD
OFF
ON
OFF
ST
ON
OFF
Control screen
Pre-heat
LBX logo
Starter motor
switch
Pre-heat
glow-plug
3 sec.
ABD
OFF
ON
OFF
ST
ON
OFF
Control screen
Pre-heat
LBX logo
Starter motor
switch
Pre-heat
glow-plug
4001-25
Cre 7-28250-21LX Issued 11-01
Automatic Engine Warm-up
CS00F515
1. Instrument panel
2. Return to idle control
6. Engine throttle control
8. Engine
2) Operation
1. When the engine is started, if the coolant solution
temperature is equal to or lower than 122°F, the
main electronic control box (3) transmits an
automatic engine warm-up signal to the engine
electronic control box (7).
2. The engine electronic control box (7) manages the
automatic engine warm-up.
3. Automatic engine warm-up conditions:
- Coolant solution temperature (9) equal to or
lower than 122°F.
- Pilot pressure switch (4) and travel pilot
pressure switch (5) not on.
- Return to idle control (2), not on.
- Position of engine throttle control (6),
unchanged.
- Engine speed not higher than 1800 rpm for
3 minutes.
4. If one of the above conditions is not present, the
automatic engine warm-up does not operate. To
perform the engine warm-up again, the engine has
to be shut down and re-started.
5. When automatic engine warm-up is operating,
"AUTO WARM UP" is displayed on the control
screen (LCD).
1
2
3
4
5
6
78
9
10
4001-26
Cre 7-28250-21LX Issued 11-01
Throttle control position below 1200 rpm
Throttle control position above 1200 rpm
1200
1500
1800
5333
Engine speed
(rpm)
Floating
engine throttle
control
Warm-up time in minutes
1200
1500
1800
Engine speed
(rpm)
533
Floating
engine throttle
control
Warm-up time in minutes
4001-27
Cre 7-28250-21LX Issued 11-01
Idle Control by Battery Voltage and Coolant Temperature
The purpose of this function is to prevent the battery from becoming discharged or the coolant
solution temperature
becoming too low.
CS00F516
2. Engine
2) Operation
When the idle time is too long and the voltage supplied to the engine electronic control box (1)
drops or the coolant
temperature (3) is low, the idle speed automatically increases (see figure below).
Adjusting the speed in accordance with battery voltage
1
2
3
4
18 22 26 28
700
800
900
1000
1100
1200
Speed (rpm)
Voltage supplied to the engine
electronic control box (volt)
4001-28
Cre 7-28250-21LX Issued 11-01
Adjusting the idle speed in accordance with the coolant temperature
-22 -5 50 68
700
800
900
1000
1100
1200
Speed (rpm)
Coolant temperature (°F)
4001-29
Cre 7-28250-21LX Issued 11-01
Engine Emergency Stop
CS00F517
1. Instrument panel
2. Engine emergency stop switch
3. Engine emergency stop relay
5. Emergency stop motor
6. Engine
2) Operation
1. If the emergency stop switch (2) is pressed, the
transistor output OUT 1 = 0 volt and the LED on
the switch flash.
2. Since OUT 1 is at 0 volt, the emergency stop relay
(3) is activated, along with the emergency stop
motor (5).
3. The stop signal input (IN1) on the engine electronic
control box (4) falls to 0 volt, the engine electronic
control box (4) accepts that as the emergency stop
status and transmits the "stop engine" signal
OUT 2 = 0 volt.
4. The electronic acceleration starts to control the
engine shut down when it received the signal
(position of the rack = 0 mm).
5. The emergency stop status is maintained even after
the ignition switch is turned off. To deactivate the
emergency stop, the emergency stop switch has to
be pressed again, with the LED off.
1
2
3
4
5
76
4001-30
Cre 7-28250-21LX Issued 11-01
3) Timing diagram
24 V
0V
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
Supply
OUT1/IN1
LED
OUT2
Emergency stop
switch
Emergency stop
relay
Emergency stop
motor
4001-31
Cre 7-28250-21LX Issued 11-01
Emergency Mode
CS00F518
1. Instrument panel
4. Engine throttle control
6. Engine
2) Electronic acceleration regulator assistance control
The electronic acceleration regulator checks the engine speed by checking the position of the
electronic
acceleration rack.
- The engine electronic control box sends the target position of the rack to the electronic
acceleration regulator,
by means of a PWM signal. The regulator compares the value of the real position to the target
position informed
by the rack position detector incorporated in the regulator. Using the result of the calculation, the
electronic motor
incorporated in the electronic acceleration is actuated to check the position of the rack. The real
value of the rack
position is then transmitted to the engine electronic control box.
- The engine electronic control box checks if the electronic acceleration regulator is operating
correctly by
comparing the target position sent with the real value of the rack.
- If there is a difference of 2 mm or more between the real position and the target value of the rack,
variations in
engine speed will occur (see table below). The engine electronic control box considers that this is
an electronic
acceleration regulator assistance error.
- If the regulator assistance error is confirmed, the electronic control box stops the engine to prevent
it running
out of control.
The engine electronic control box transmits the problem codes to the main electronic control box
when a
regulator assistance error occurs and the error code "ELEC. PROBLEM" is displayed on the control
screen
(LCD).
12
3
4
5
6
8
7
When starting the engine Machine operation
Variation in engine speed 500 rpm for 1 second Variation in engine speed 1000 rpm for 1
second
Variation in engine speed < 500 rpm for 10 seconds Variation in engine speed < 1000 rpm for 10
seconds
4001-32
Cre 7-28250-21LX Issued 11-01
3) Checking the emergency mode
1. The engine electronic control box stops the
engine by cutting off the fuel injection if an
assistance error is detected at the electronic
acceleration regulator during operation or when
starting the engine.
2. After stopping the engine due to a regulator
assistance error, the engine can be re-started in
emergency mode (IN3 = ON = GND).
3. When operating in emergency mode, the engine
electronic control box only checks the position of the
rack against the engine speed obtained by the
engine speed detector. Therefore normal engine
performance cannot be obtained, since the engine
emergency mode has taken over.
4) Timing diagram
1a. Normal
1b. Off
1c. Emergency mode
5) Engine control when the emergency
mode has taken over
The engine electronic control box determines the
target engine speed from the position of the engine
throttle control.
The engine electronic control box checks the position
of the electronic acceleration rack by the difference
between the real engine speed obtained by a signal
from a speed detector incorporated in the electronic
acceleration (or by the engine speed detector located
in the engine bell-housing) and the target speed.
In emergency mode, the engine speed is controlled
only by the engine throttle control. Control by the
engine throttle control is different from control under
normal conditions.
1d. Off
1e. Emergency mode
ST
ON
OFF
1a 1b 1c 1d 1e
10 sec
24 V
0V
5V
0V
ON
OFF
ON
OFF
5V
0V
Supply
Emergency mode
Motor status
Starter motor
switch
OUT (IN4)
emergency mode
Regulator
assistance error
(IN3)
Engine control
mode
0 100
900
1600
Engine throttle control (%)
Engine
speed
(rpm)
4001-33
Cre 7-28250-21LX Issued 11-01
Lockout Functions
CS00F501
1. Battery
2. Battery relay
3. Main protective fuse
4. Fuse box
5. Control cancellation lever switch
6. Pilot pressure control solenoid valve
2) Timing diagram
3) Operation
When the engine is started and the control
cancellation lever is in the work position, the pilot
pressure solenoid valve is activated.
When the pilot pressure solenoid valve is activated,
the pilot pressure is supplied to the pilot systems and
the machine is ready to operate.
1
2
3
4
5
6
3 sec 3 sec
Starter motor switch 24 V
ON
ON
0V
OFF
OFF
ON
OFF
Supply
Control cancellation lever
position
Pilot pressure solenoid
valve
4001-34
Cre 7-28250-21LX Issued 11-01
Power Up
CS00F502
5. Option pilot pressure switch
7. Main valve
8. Power Up solenoid valve
2) Pressure increase in each work mode
* When the travel or option pressure switch is activated, the power up is deactivated.
3) Operation
When operating in mode H or S, the main electronic
control box (1) registers the ratio between:
- The load on the engine transmitted by the
engine electronic control box (6).
- The load on the hydraulic system transmitted by
the pressure detectors P1/P2 (2 and 3).
If pressure P1 or P2 is higher than 4351 psi and the
load ratio remains within a range of ± 5% for 2
seconds, the main electronic control box (1) activates
the power up solenoid valve (8) for 8 seconds which
increases the main pressure.
When the travel (4) or option (5) pressure switch is
activated, the main electronic control box deactivates
the power up solenoid valve.
2
5
6
3
4
7
8
1
Mode H
(Pressure)
Automatic power up (*)
(4975 5409 psi)
Mode S
(Pressure)
Automatic power up (*)
(4975 5409 psi)
Mode L
(Pressure)
Constant power up (*)
(5409 psi)
4001-35
Cre 7-28250-21LX Issued 11-01
Swing Brake
CS00F503
1. Instrument panel
2. Swing brake switch
5. Swing pilot pressure switch
7. Travel pressure switch
10. Swing brake
11. Swing brake solenoid valve
2) Swing brake control operation
When the swing brake switch (2) is operated, the red
LED comes on and the swing brake locks.
When the swing brake switch is operated again, the
red LED goes out, the swing brake unlocks and
changes to automatic control (see paragraph 4).
While the swing is locked, the transistor OUT 2
output is activated and the swing brake (10) is
locked.
The swing brake remains in the previous state even
when the ignition is switched off.
2
1
3
4
5
6
7
8
9
10
11
4001-36
Cre 7-28250-21LX Issued 11-01
3) Timing diagram
4) Automatic swing brake control
Automatic brake control operates when the swing
brake red LED is off.
When the swing and an attachment function are
operated simultaneously, the mechanical swing brake
is automatically disengaged. When the operation
stops, the mechanical swing brake is automatically
activated by the main electronic control box.
The swing brake is automatically deactivated when:
- The swing pilot pressure switch (5) is activated.
- When the pressure at the pressure transducer
P1 (8) or P2 (9) is higher than 2175 psi.
The swing brake is automatically activated when:
- The pilot pressure switch (6) is deactivated for
more than 5 seconds.
- The starter switch (3) is in the = OFF position.
When the pressure supplied by the pump (P1 or P2)
exceeds 2175 psi during one single travel, the
mechanical swing brake is deactivated for 5 seconds,
then reactivated.
ON
OFF
24 V
0V
ON
OFF
5 V (OFF)
0 V (ON)
5V
0V
ON
OFF
OFF ON ON OFF ON ON
Supply
Brake
LED
OUT
(N1)
Starter motor
switch
Swing brake switch
Swing pilot
pressure switch
4001-37
Cre 7-28250-21LX Issued 11-01
Cushion (On/Off)
CS01G511
1. Instrument panel
2. Cushion switch
4. Cushion valve
5. Cushion solenoid valve
6. RPM sensor
2) Operation
1. Controls the pilot oil of the boom and arm spools.
2. This feature can be turned off by the operator.
3. Each time the machine is started, it will be in
cushion ON.
NOTE: The main electronic control box needs a RPM
signal for cushion OFF.
Output to the cushion solenoid valve is OFF when the
key switch is ON. This is cushioned status.
To turn the cushion feature OFF the cushion switch is
pressed. The main electronic control box will sent
24V to the cushion solenoid valve.
The solenoid valve shifts and sends pressure to the
cushion valve and shifts the valve to the non-cushion
position.
1
2
3
5
4
6
4001-38
Cre 7-28250-21LX Issued 11-01
Free swing
CS00N514
1. Free swing switch
3. Free swing solenoid valve
4. Orifice Ø 2.5
5. Swing motor
2) Operation
When a free swing switch (1) is turned on, electrical
signal is sent through a main electronic control box
(2) to a solenoid valve (3) and then solenoid valve is
switches.
The solenoid valve (3) inside is changed to connect
GA and GB line and thus, it make free swing
operation.
The free swing line has an orifice Ø 2.5 (4) so that
swing speed and swing inertia are reduced.
When the free swing is at on, swing mechanical
brake is released.
1
2
3
5
4
4001-39
Cre 7-28250-21LX Issued 11-01
Travel Speed
CS00F504
1. Instrument panel
2. Travel speed switch
6. Negative pressure transducer (N)
8. Travel 2nd speed solenoid valve
2) Timing diagram
1
2
3
4
5
6
7
8
I II I II I II I I II
Supply 24 V
0V
ON
OFF
5V
IN1 0 V
Speed
Travel speed
switch
4001-40
Cre 7-28250-21LX Issued 11-01
3) Operation
When the starter motor switch is positioned in the
“ON” position, 1st speed is selected by default.
Each time the speed switch is pressed (2), the
electronic control box (3) registers a signal
(IN1: 0 volt).
The electronic control box changes travel speed in
the following way I II, II I and transmits the
modifications to the control screen (LCD).
Travel speed I selected
The output from the travel speed change solenoid
valve (8) electronic control box (OUT) is deactivated
(1st speed).
Travel speed II selected
1. When pressure P1 or P2 is lower than 580 psi at
the electronic control box output (OUT), the travel
change speed solenoid valve is deactivated (1st
speed).
2. When pressure P1 or P2 is higher than 580 psi at
the electronic control box output (OUT), the travel
change speed solenoid valve is activated (2nd
speed).
3. When the attachment controls are operated, the
electronic control box output (OUT) from the travel
speed change solenoid valve cannot be activated or
deactivated.
4. When the travel pressure is higher than 3771 psi,
travel motor displacement change spool is pushed
back and the swash plate angle is in high
displacement (1st speed).
5. Travel speed II can be forced (for cleaning tracks)
by holding the speed control switch pressed for over
2 seconds (IN1 = 0 volt).
4001-41
Cre 7-28250-21LX Issued 11-01
4) Organization chart
Ignition switch
ON
Speed change
control
YES
< 2 seconds
Travel pressure
sensor
YES
Pilot pressure
sensor
YES
2nd speed
selected
NO
P1 < 580 psi
YES
P2 < 580 psi
NO
2ND SPEED
SOLENOID VALVE
ACTIVATED
NO
SOLENOID VALVE
CANNOT BE ACTIVATED
OR DEACTIVATED
1ST SPEED
SOLENOID VALVE
DEACTIVATED
2 seconds
YES
NO
YES
YES
NO
NO
Engine
4001-42
Cre 7-28250-21LX Issued 11-01
Travel Alarm
CS00J504
3. Buzzer
2) Timing diagram
2
13
24 V
Alimentation 0 V
ON (1 HZ)
OFF
24 V
0V
IN
Buzzer
OUT
10 sec 10 sec
5V
0V
4001-43
Cre 7-28250-21LX Issued 11-01
Supply Cut-Off Delayed
CS00F506
1. Batteries
2. Battery relay
4. Main fuses
5. Fuse box
7. Engine
8. Alternator
2) Timing diagram
3
1
2
45
6
8
7
0.5 sec 3 sec 0.5 sec 3 sec
ON
OFF
24 V
0V
24 V
0V
ON (24 V)
OFF (0 V)
ON
OFF
Starter motor switch
Main electronic control
box supply (IN1)
Batter relay coil excited
(OUT)
Start engine (IN2)
Supply to battery
relay
4001-44
Cre 7-28250-21LX Issued 11-01
Protection by Power Transistor
To protect the circuits of the main electronic control
box in the event of a short-circuit of a solenoid valve
or a relay, the power transistors cut off the electrical
supply and the message “ELEC. PROBLEM”
appears on the instrument panel control screen. Use
the diagnostic mode to locate the short-circuit.
Check the wiring and the components of the affected
circuit.
Water Temperature Gauge
CM00F007
1. Instrument panel
4. Engine
5. Water temperature sending unit
6. Water temperature gauge
7. Series connection
8. CAN connection
Connector
Path Functions
CN5 8 Power up solenoid valve
CN6 31 Swing cancellation solenoid valve
CN6 20 Battery relay
CN6 27 Swing brake solenoid valve
CN6 28 Travel speed solenoid valve
CN6 29 Shock absorbing solenoid valve
1
6
7
2
8
34
5
4001-45
Cre 7-28250-21LX Issued 11-01
2) Operation
A. The engine water temperature sending unit (5)
sends a signal to the engine electronic control box
(3).
B. The engine electronic control box (3) sends the
converted signal to the main electronic control box
(2) via the CAN connection (8).
C. The main electronic control box (2) calculates the
number of bars to display and transmits the
information to the water temperature gauge (6) via
the Series connection (7).
D. When the 8th bar on the water temperature gauge is
displayed, the message “OVER HEAT” appears on
the instrument panel control screen (1) and the
audible warning device sounds.
8
7
6
5
4
3
2
1
104 122 140 158 176 194 212 230
221
ON
OFF
217.4
ON
OFF
212
ON
OFF
206.6
ON
OFF
179.6
ON
OFF
170.6
ON
OFF
122
ON
OFF
Water temperature (°F)
Water temperature
gauge bar
4001-46
Cre 7-28250-21LX Issued 11-01
Hydraulic Oil Temperature Gauge
CM00F008
1. Instrument panel
4. Hydraulic oil temperature gauge
2) Operation
A. The hydraulic oil temperature sending unit (3)
attached to the inlet pipe sends a signal to the main
B. The main electronic control box (2) calculates the
number of bars to be displayed and sends the
information to the oil temperature gauge (4) via the
series connection (5).
C. When the 8th bar is displayed on the hydraulic oil
temperature gauge, the message “OVER HEAT”
appears on the instrument panel control screen (1)
and the audible warning device sounds.
1
4
5
2
3
8
7
6
5
4
3
2
1
68 86 104 122 140 158 176 194 212
208.4
ON
OFF
203
ON
OFF
190.4
ON
OFF
176
ON
OFF
140
ON
OFF
113
ON
OFF
77
ON
OFF
Hydraulic oil temperature (°F)
Hydraulic oil temperature
gauge bar
4001-47
Cre 7-28250-21LX Issued 11-01
Fuel Level
CM00F009
1. Instrument panel
3. Fuel level sending unit
4. Fuel level indicator
2) Operation
A. The fuel level sender (3) sends a signal to the main
B. The main electronic control box (2) calculates the
number of bars to be displayed and sends the
information to the fuel level gauge (4) via the Series
connection (5).
C. When only one bar is displayed on the fuel level
gauge (4), the message “LOW FUEL” appears on
the instrument panel control screen (1) and the
audible warning device sounds.
Remaining fuel
(gal)
Fuel level sender
resistor ()
Input voltage (V) Bars displayed
69.1- 10.0 - 18.1 0.455 - 0.766 8
61.5 - 69.1 18.1 - 23.9 0.766 - 0.964 7
50.2 - 61.5 23.9 - 29.6 0.964 - 1.142 6
38.8 - 50.2 29.6 - 36.5 1.142 - 1.337 5
27.5 - 38.8 36.5 - 46.3 1.337 - 1.582 4
13.5 - 27.5 46.3 - 60.8 1.582 - 1.891 3
6.7 - 13.5 60.8 - 74.7 1.891 - 2.138 2
- 6.7 74.7 - 80.0 2.138 - 2.222 1
4
1
5
2
3
4001-48
Cre 7-28250-21LX Issued 11-01
Engine Fuel Injection Pump Electronic Regulator
CM00F010
1. Engine
2. Hydraulic system
5. Fuel injection pump
9. Throttle control
11. CAN connection
12. Detector and sender information input
13. Engine speed signal
14. Rack position detector signal
15. Rack control signal
16. Engine speed detector signal
1
6
5
7
8
2
12
4
3 11
16
15
14
13
9
10
4001-49
Cre 7-28250-21LX Issued 11-01
2) Electronic regulator
CS00F532
17. Linear motor
18. Rack
19. Linear motor control section
20. Rack position detector
3) Operation
A. To ensure low fuel consumption and optimum
productivity, the engine electronic control box (3) is
programmed for the various work modes (M, S and
L) and selects the optimum work mode in
accordance with the signal that it receives from the
main electronic control box (4) via the CAN
connection (11).
B. The electronic regulator (7) has an input section, a
calculating section and a linear motor control section
(17).
C. The input section receives the signals coming from
the detectors and senders (12) and transmits them
after processing to the calculation section.
D. The calculation section compares the information
received with the programmed data, and then
transmits a control signal to the linear motor (17)
control section (19).
E. The control section (19) sends a signal to the
regulator (7) linear motor (17) to actuate the fuel
injection pump (5) rack control (18).
18
19
20
17
4001-50
Cre 7-28250-21LX Issued 11-01
ACCESS AND CONTENTS OF CONTROL SCREENS (Diagnostic
Mode)
Access to Control Screens
A. Press the travel mode and work mode switches
simultaneously for a minimum of 3 seconds.
B. Press the automatic mode switch.
C. Press the audible warning device stop switch.
D. To erase the data, press the work mode switch for a
minimum of 10 seconds and the audible warning
device sounds.
E. To reset the system, press the audible warning
device stop switch.To program the system, press the
travel speed switch.To erase the data, press the
work mode switch for 10 seconds and the audible
warning device sounds.
F. To detect overloads on the electrical circuit, press
the travel speed switch.
G. To detect short-circuits, operate the return to idle
switch and the starter motor switch simultaneously,
but do not start the engine.
Starter motor switch "ON"
Normal display (Water temperature, hydraulic oil temperature, fuel level, travel mode,
work mode, idle mode)
Machine
condition
A
B Diagnostic
code
B Machine
history
B Reinitialization
CHK1
C
CHK2
C
CHK3
C
CHK4
C
CHK5
D
CHK6
DIAG
C
DIAG
C
DIAG
C
DIAG
C
DIAG
C
DIAG
C
HR12
C
HR11
C
HR10
C
HR9
C
HR8
C
HR7
HR1
C
HR2
C
HR3
C
HR4
C
HR5
C
HR6
C
C
RST1 G
E
F
F
F
C BRK
C
C
OUT L/M
C
C
HLD AI
C
C
AU C PA
F
4001-51
Cre 7-28250-21LX Issued 11-01
Machine Condition
1. Machine condition CHK1
2a. Machine condition CHK2
Transistor output: 0 = OFF, 1 = ON
X: Not used
CHK MODE II H ENG 2000 rpm
1
P1 4351,1 psi I 0300 mA
P2 4351,1 psi WT 0176 °F
N 435,1 psi OT 0131 °F
MODE: Travel - work
P1: Main pump pressure
P2: Main pump pressure
N: Negative pressure (N)
ENG: Engine speed
I: Proportioning valve current
WT: Engine water temperature
OT: Hydraulic oil temperature
CHK MODE II H TR1 0000
2
R 0080 % TR2 0000
FT 0040 °F TR3 0000
TV 0100 % TR4 0000
R: Engine load rate
FT: Fuel temperature
TV: Rate of acceleration
TR1 to TR3: Electronic control box transistor
outputs
TR4: Not used
TR1 0 0 0 0 TR2 0 0 0 0 TR3 0 0 0 0
Swing brake Battery relay Free swing
Travel 2nd speed Attachment cushion X
Travel alarm Swing pilot cancellation X
Power up Swing priority X
4001-52
Cre 7-28250-21LX Issued 11-01
Pressure switch and electronic control box switch inputs: 0 = OFF, 1 = ON
X = Not used
CHK MODE II H SW4 0000
3
SW1 0000 SW5 0000
SW2 0000 SW6 0000
SW3 0100 SW7 0000
SW1 to SW3 Electronic control box pressure
switch inputs
SW4 to SW7 Electronic control box switch
inputs
SW1 0 0 0 0 SW2 0 0 0 0 SW3 0 0 0 0
Pilot pressure Engine oil pressure Battery charge
Travel pilot pressure Coolant solution level X
Swing pilot pressure Safety valve pressure X
Auxiliary pilot pressure X X
SW4 0 0 0 0 SW5 0 0 0 0 SW6 0 0 0 0
Attachment cushion Swing brake Windshield washer
Free swing Emergency stop Travel alarm
Swing priority Working lights Auxiliary
Engine idle Windshield wiper
Material handling
(L/M) mode switch
SW7 0 0 0 0
Anti-theft
Starter motor switch
X
X
4001-53
Cre 7-28250-21LX Issued 11-01
In screen CHK2 when the travel mode switch is
pressed, the CHK5 screen appears and windows
TR1 and TR2 show any overloads in the
corresponding electrical circuits.
No overload = 0, Overload = 1
Example: In the screen opposite, windows TR1 and
TR2 show an overload on the swing brake and
battery relay circuit.
NOTE: In diagnostic mode, if an error code is
changed to zero, the data is also erased.
CHK MODE I H TG 0000
4
FS 0080 BP 0000
AC 0005 SP1 0000
TR5 0010 SP2 0000
FS: Fuel gauge
AC: A/C control temperature
TR5: Electronic control box transistor
output (Not used)
TG: Engine speed
BP: Not used
SP1 and SP2: Not used
AC 0 0 0 0
1: below 86°F
2: between 86°F and 113°F
5
R 0080 % TR2 0001
FT 0104 °F TR3 0000
TV 0100 % TR4 0000
4001-54
Cre 7-28250-21LX Issued 11-01
1) When the return to idle switch and the starter
motor switch are both actuated simultaneously,
without starting the engine, automatic checking for
short-circuits in output transistors is initialized.
2) If the message "ELEC. PROBLEM" is displayed on
the control screen, return to screen CHK2 and press
the travel mode switch for 10 seconds. The CHK6
screen will be displayed and the windows TR1 and
TR2 will show any short-circuits on the corresponding
lines.
NOTE: If there is no message and the audible
warning device sounds 6 times, that means that there
is no defect.
Example: In the screen opposite, window TR1 shows
a short-circuit at the high speed travel control
transistor output.
3) When the starter motor switch is in the OFF
position, the results are erased.
No short-circuit = 0, short-circuit = 1
6
R 0080 % TR2 0000
FT 0104 °F TR3 0000
TV 0100 % TR4 0000
4001-55
Cre 7-28250-21LX Issued 11-01
Diagnostic Code
1. Detection of engine failures DIAG1
Failure code
Example: In the screen above, there is a defect in the engine water temperature sender.
2. Previous failures in the engine DIAG2
Example: The screen above shows that there is a defect in the electronic regulator rack position
detector (0032)
and in the fuel temperature detector (0016).
DIAG MODE II H E 0000
1
E 0015 E 0000
E 0000 E 0000
E 0000 E 0000
E: Failure code
E0000: No defect
E0015: Engine water temperature sending unit
E0016: Fuel temperature sending unit
E0025: Fuel flow regulating resistance
E0031: Linear motor control circuit in electronic regulator
E0032: Electronic regulator rack position detector
E0041: Electronic regulator engine speed receiver
E0042: Engine speed detector
2
E 0032 E 0000
E 0016 E 0000
E 0000 E 0000
E: Failure code
4001-56
Cre 7-28250-21LX Issued 11-01
3. Previous failures in the engine DIAG3
This screen is connected to the previous screen (DIAG2) as concerns failures involving the
hourmeter.
Example:
The screen above shows that the failure code 0032 (electronic regulator rack position detector)
occurred at 1200 H
and that failure code 0016 (fuel temperature sender) occurred at 1000 H.
A. The number of hours shown indicates the time at which the failures occurred for the first time since the
data was reinitialized.
B. If you wish to erase the failure codes and the number of hours, press the work mode switch for 10
seconds.
C. When data is erased from screens DIAG2 and DIAG3. It is recorded in the electronic control box
memory (this data is
only visible using an external computer).
4. Excavator failure detection DIAG4
Failure code
Example:
The screen above shows a failure in the hydraulic oil temperature sending unit (0020).
3
E 1200 E 0000
E 1000 E 0000
E 0000 E 0000
E: Failure code
DIAG MODE II H M 0000
4
M 0020 M 0000
M 0000 M 0000
M 0000 M 0000
M: Failure code
M0000: No defect
M0010: Transistor output short-circuit
M0020: Hydraulic oil temperature sending unit
M0030: Fuel level sending unit
M0040: Pressure transducer P1
M0050: Pressure transducer P2
M0060: Negative pressure transducer
M0070: Starter motor switch
M0080: Attachment or travel pilot pressure switch
M0090: CAN communication circuit
M00A0: Electronic control box re-initialization
M00B0: Engine electronic control box
4001-57
Cre 7-28250-21LX Issued 11-01
5. Previous failures on the excavator DIAG5
Example:
The screen above shows that there is a failure in the hydraulic oil temperature sending unit and in
the fuel level
sending unit.
6. Previous failures on the excavator DIAG6
This screen is connected to the previous screen (DIAG5) as regards failures involving the
hourmeter.
Example:
The screen above shows that failure code 0020 (hydraulic oil temperature sending unit) occurred at
1200 H and
that failure code 0030 occurred at 1000 H.
A. The numbers of hours shown indicate the time at which the failures occurred for the first time since the
data was reinitialized.
B. To erase the failure codes and the number of hours, press the work mode switch for 10 seconds.
C. When data is erased from screens DIAG5 and DIAG6, it is recorded in the electronic control box
memory (this data is
only visible using an external computer).
5
M 0020 M 0000
M 0030 M 0000
M 0000 M 0000
M: Failure code
3
M 1200 M 0000
M 1000 M 0000
M 0000 M 0000
M: Failure code
4001-58
Cre 7-28250-21LX Issued 11-01
Machine History
1. Screen HR1
2. Screen HR2
3. Screen HR3
4. Screen HR4, operating time of the various P1 pressures
HR MODE II H T 0000 HR
1
ENG 0000 HR S 0000 HR
WRK 0000 HR PU 0000 HR
U 0000 HR BRK 0000 HR
ENG: Hourmeter
WRK: Length of time that excavator has been
used (with attachment or travel operating)
U: Length of time that attachment has been
used
T: Length of time that travel has been used
S: Length of time that swing has been used
PU: Length of time that power up has been used
BRK: Length of time that hammer has been used
HR MODE II H A 0000 HR
2
H 0000 HR WT 0000 °F
S 0000 HR OT 0000 °F
L 0000 HR FT 0000 °F
H: Length of time excavator was used in mode
H
S: Length of time excavator was used in mode
S
L: Length of time excavator was used in mode
L
A: Length of time excavator was used in
AUTO mode
WT: Maximum engine temperature
OT: Maximum hydraulic oil temperature
FT: Maximum fuel temperature
HR MODE II H 4 0000
3
1 0000 5 0000
2 0000 6 0000
3 0000 7 0000
1: Length of time the electronic control box
was used
2: Length of time slow travel was used
3: Length of time fast travel was used
4: Length of time travel alone was used
5: Maintenance intervals
6: Not used
7: Not used
HR MODE II H 4 0000
4
1 0000 5 0000
2 0000 6 0000
3 0000 7 0000
1: 1450 psi or less
2: Between 1450 psi and 2176 psi
7: 5076 psi or more
4001-59
Cre 7-28250-21LX Issued 11-01
5. Screen HR5, operating time of the various P2 pressures
6. Screen HR6, operating time of the various engine speeds
7. Screen HR7, operating time of the various engine water temperatures
8. Screen HR8, operating time of the various hydraulic oil temperatures
HR MODE II H 4 0000
5
1 0000 5 0000
2 0000 6 0000
3 0000 7 0000
1: 1450 psi or less
7: 5076 psi or more
HR MODE II H 4 0000
6
1 0000 5 0000
2 0000 6 0000
3 0000 7 0000
1: 1200 rpm or less
2: Between 1200 rpm and 1400 rpm
7: 2200 rpm or more
HR MODE II H 4 0000
7
1 0000 5 0000
2 0000 6 0000
3 0000 7 0000
1: 171°F or lower (1st and 2nd bar)
2: 171°F to 180°F (3rd bar)
3: 180°F to 207°F (4th bar)
4: 207°F to 212°F (5th bar)
5: 212°F to 217°F (6th bar)
6: 217°F to 221°F (7th bar)
7: 221°F or more (8th bar)
HR MODE II H 4 0000
8
1 0000 5 0000
2 0000 6 0000
3 0000 7 0000
1: 113°F or less (1st and 2nd bar)
2: 113°F to 140°F (3rd bar)
3: 140°F to 176°F (4th bar)
4: 176°F to 190°F (5th bar)
5: 190°F to 203°F (6th bar)
6: 203°F to 208°F (7th bar)
7: 208°F or more (8th bar)
4001-60
Cre 7-28250-21LX Issued 11-01
9. Screen HR9, operating time of the various fuel temperatures
10. Screen HR10, operating time of the various engine load rates
11. Screen HR11, operating time of the various engine load rates in mode "H"
(maximum speed)
HR MODE II H 4 0000
9
1 0000 5 0000
2 0000 6 0000
3 0000 7 0000
1: 86°F or less
2: 86°F to 104°F
3: 104°F to 122°F
4: 122°F to 140°F
5: 140°F to 158°F
6: 158°F to 176°F
7: 176°F or more
HR MODE II H 4 0000
10
1 0000 5 0000
2 0000 6 0000
3 0000 7 0000
1: 30% or less
2: 30% to 40%
3: 40% to 50%
4: 50% to 60%
5: 60% to 70%
6: 70% to 80%
7: 80% or more
HR MODE II H 4 0000
11
1 0000 5 0000
2 0000 6 0000
3 0000 7 0000
1: 30% or less
2: 30% to 40%
3: 40% to 50%
4: 50% to 60%
5: 60% to 70%
6: 70% to 80%
7: 80% or more
4001-61
Cre 7-28250-21LX Issued 11-01
12. Screen HR12, operating time of the various engine load rates in mode "S"
(maximum speed)
To erase all data from the machine history mode (screens HR1 to HR12), press the work mode
switch for
10 seconds or more.
Reset
1. Reset RST1
PA = Adjusting fuel injection pump 0 = OFF, 1 = ON
AU = Automatic power up0 = ON, 1 = OFF
NOTE: To select the various adjustment windows, press as many times as necessary on the
audible warning
device stop switch (a window is selected when the item concerned changes from negative
appearance to positive
appearance).
HR MODE II H 4 0000
12
1 0000 5 0000
2 0000 6 0000
3 0000 7 0000
1: 30% or less
2: 30% to 40%
3: 40% to 50%
4: 50% to 60%
5: 60% to 70%
6: 70% to 80%
7: 80% or more
RST MODE II H PA 0000
1
BRK 0000 rpm AU 0000
L/M 0000 rpm HLD 0000
AI 0000 sec OUT 0000
MODE: Travel mode - work mode
BRK: Setting engine speed for hammer option
L/M: Not used
AI: Adjusting timing of automatic return to
idle (from 1 to 30 seconds)
PA: Adjusting fuel injection pump
AU: Automatic power up
HLD: Data management
OUT: Not used
HLD 0 0 0 0
Mode auto (0 = Maintain previous data / 1 = Up-date data)
Work mode (0 = Maintain previous data / 1 = Up-date data)
Travel mode (0 = Maintain previous data / 1 = Up-date data)
Hourmeter maintenance (0 = ON, 1 = OFF)
4001-62
Cre 7-28250-21LX Issued 11-01
2. Setting engine speed for hammer option
A. Select window BRK (see NOTE on page 61).
B. Start the engine, then, using the throttle control, set
the required engine speed which is displayed in the
BRK window on screen RST 1.
C. To save the engine speed, press the work mode
switch for 10 seconds. The audible warning device
sounds when saving is completed.
D. Turn the starter key switch to the OFF position.
E. Check the engine speed on screen CHK1.
Example:
In the above screen, the engine speed for the hammer option is set at 1800 rpm.
3. Setting the automatic return to idle timing
A. Select window AI (see NOTE on page 61).
B. Press the travel mode switch as many times as
necessary to obtain the required time delay. The
setting must be between 1 and 30 seconds.
C. To save the time delay, press the work mode switch
for 10 seconds. The audible warning device sounds
when saving is completed.
Example:
In the above screen, the automatic return to idle time delay is set at 10 seconds.
4. Selecting the type of supply to the fuel injection pump
Mode 1 should be selected when the fuel used does
not meet normal specifications.
A. Select window PA (see NOTE on page 61).
B. To select the type of supply to the fuel injection
pump, press the travel mode switch (the right-hand
figure changes alternately from 0 to 1 with each
press of the travel mode switch).
C. To save the selection, press the work mode switch
Example:
In the above screen, the type of supply to the fuel injection pump is in low power mode.
RST MODE 2 H PA 0000
1
L/M 0000 rpm HLD 0000
1
L/M 0000 rpm HLD 0000
1
L/M 0000 rpm HLD 0000
0 = Normal mode
1 = Low power mode
4001-63
Cre 7-28250-21LX Issued 11-01
5. Selecting automatic power up
A. Select window AU (see NOTE on page 61).
B. To activate or de-activate automatic power up, press
the travel mode switch (the right-hand figure
changes alternately from 0 to 1 with each press of
the travel mode switch).
C. To save the selection, press the work mode switch
6. Data management
A. Select window HLD (see NOTE on page 61).
B. To set data management, to maintain or reset data, press the travel mode switch until the required
figure appears
(each time the travel mode switch is pressed the figures scroll down in the following order: 0000, 0001,
0010, 0011,
0100, 0101 ... up to 1100, 1101, 1110, 1111, 0000).
C. To save the settings, press the work mode switch for 10 seconds. The audible warning device sounds
when saving is
completed.
1
L/M 0000 rpm HLD 0000
0 = With power up
1 = Without power up
1
L/M 0000 rpm HLD 0000
0 = Maintain previous data
1 = Re-initialization of data
HLD 0 0 0 0
Auto mode
Work mode
Travel mode
Hourmeter maintenance (0 = ON, 1 = OFF)
4001-64
Cre 7-28250-21LX Issued 11-01
WARNING MESSAGES
Message Display
Starter key switch ON Engine running
ELEC. PROBLEM. ALTERNATOR
LOW FUEL LOW OIL PRESS
LOW COOLANT ENG. IDLING
OVER HEAT AUTO WARM UP
ENG. PRE HEAT POWER UP
SERVICE DUE
MESSAGES
AUDIBLE
WARNING
ENG. PRE HEAT Yes
This message shows that the engine must be pre-heated before starting. The audible warning
device will sound once the correct temperature is reached. The engine can then be started.
AUTO WARM UP
This message shows that the engine is automatically warming up. The message will
disappear when the engine reaches its operating temperature or when the acceleration
rotating knob or a control lever is operated.
ENG. IDLING
This message shows that the engine has been set at idle speed by means of the return to idle
control.
POWER UP This message shows that maximum power is automatically provided for the attachment.
SERVICE DUE
This message shows that the 500 hours service interval is due. The message is displayed five
times when the engine is started up.
LOW FUEL Yes
This message shows that the level of fuel in the fuel tank is low and that more fuel should be
added.
LOW COOLANT Yes
This message shows that the coolant solution level is low. Shut down the engine and remove
the starter switch key to allow the system to cool down. Then check the level of coolant
solution in the expansion reservoir and the radiator.
LOW OIL PRESS Yes
This message shows that the engine oil pressure is too low. Stop the engine, remove the
starter switch key, and check the level.
OVER HEAT Yes
This message shows that the coolant solution or hydraulic fluid temperature is too high.
Reduce engine speed. If the temperature does not decrease, shut down the engine, remove
the starter switch key and find the reason for the problem.
ALTERNATOR Yes
This message shows that there is a defect in the alternator. Shut down the engine, remove the
starter switch key, and check the alternator.
ELEC. PROBLEM Yes
This message shows that there is a defect in the electrical system. Shut down the engine,
remove the starter switch key, then find the reason for the problem.
4001-65
Cre 7-28250-21LX Issued 11-01
EXCAVATOR MODEL SELECTION PROCEDURE
The model of excavator is selected after reinitializing
the machine code or replacing an electronic control
box.
1. Starter key switch ON, the screen below appears
and "?" for machine is selected:
2. Press the travel mode switch until the required
machine code is displayed.
3. Press the work mode switch. The screen below
appears and "?" for territory is selected.
4. Press the travel mode switch until the required
destination code is displayed.
5. Press the work mode switch. The screen below
appears and "?" for language is selected.
6. Press the travel mode switch to display the required
language:
0 = Japanese
1 = English
2 = Thai
3 = Chinese
4 = German
5 = French
6 = Italian
7 = Spanish
8 = Portuguese
9 = Dutch
10 = Danish
11 = Norwegian
12 = Swedish
13 = Finnish
14 = Icons
Example:
The screen above corresponds to a 130LX model
excavator for North America in English.
MACHINE CODE MACHINE MODEL
SH0120 130LX
SH0150 160LX
SH0180 Not used
SH0200 210LX
SH0220 240LX
SH0250 Not used
SH0300 Not used
SH0400 Not used
SH0800 Not used
MACHINE : SH ? - 3
TERRITORY : ? LANGUAGE : ?
CONT. P / N KHR2668
MACHINE : SH0120- 3
CONT. P / N KHR2668
MACHINE : SH0120- 3
CONT. P / N KHR2668
Destination
code
destination
Pressure
unit
T° unit
1
North
America
psi °F
MACHINE : SH0120- 3
TERRITORY : 1 LANGUAGE : ?
CONT. P / N KHR2668
MACHINE : SH0120- 3
TERRITORY : 1 LANGUAGE : 1
CONT. P / N KHR2668
4001-66
Cre 7-28250-21LX Issued 11-01
7. After selecting the machine code, the destination
code and the language code, press the auto mode
switch and the screen below will appear:
CS00J508
Then the work screen is displayed:
CS00K502
8. If the machine code does not correspond to the
engine electronic control box installed, the error
code: "E. CONT. ERROR" appears on the screen
and the audible warning device sounds.
9. Check that the machine code corresponds to the
electronic control box installed on the excavator.
- If the machine code is wrong, start the procedure
again from the beginning.
- If the engine electronic control box installed is not
correct, change it.
10. To confirm the excavator model selection, press the
auto mode switch for 10 seconds:
The screen below will appear
11. Press the auto mode switch again and the work
screen will appear:
CS00K502
12. Re-initializing the data
In the excavator model selection screen, if the auto
mode switch is pressed for 10 seconds, all the data
will be erased and the audible warning device will
sound.
13. If the starter key switch is turned OFF and then ON,
the screen below will appear and the procedure
starts again from the beginning.
Changing the Language Code
Display the excavator model confirmation screen
(press the auto mode switch for 10 seconds).
To change the language code, press the travel
mode switch to display the required code.
To confirm the language code, press the work mode
switch and the audible warning device sounds.
Turn the starter key switch to OFF. See previous
page for language codes.
MACHINE : SH0120- 3
CONT. P / N KHR2668
E. CONT. ERROR
MACHINE : SH0120- 3
CONT. P / N KHR2668
MACHINE : SH ? - 3
CONT. P / N KHR2668
4001-67
Cre 7-28250-21LX Issued 11-01
Example:
In the screen opposite, the language code has
changed from 1 (English) to 5 (French).
ACTIVATING THE ANTI-THEFT SYSTEM
1. Remove the hood (A) located behind the
operator’s seat.
CD00F011
A. Hood
2. Disconnect the two wires (A) (B) covering the antitheft
system.
CD00F012
A. Violet wire marked 469 female plug
B. Black wire marked 621 male plug
C. Radio connector
3. Turn the starter key switch to ON and then OFF.
4. Reconnect the two wires (A) (B) covering the antitheft
system (see paragraph 2).
5. To save the new access code, consult the anti-theft
protection section in the operator’s manual.
MACHINE : SH0120- 3
CONT. P / N KHR2668
A
AB
C
4001-68
Cre 7-28250-21LX Issued 11-01
TROUBLESHOOTING
Prior Inspections
Item Value Action
POINTS TO BE CHECKED WHEN STARTING
Lubricants - Coolants
1. Check the quantity of fuel
2. Check that fuel is not contaminated
3. Check the quantity of hydraulic fluid
4. Inspect the hydraulic fluid filter
5. Check the quantity of oil in each reduction gear
6. Check the quantity of engine oil
7. Check the quantity of coolant
8. Check the filter restriction indicator (dust)
---
---
---
---
---
---
---
---
Add fuel
Clean, drain
Fill with fluid
Drain, clean
Fill with oil
Fill with oil
Fill with water
Clean or change
Electrical equipment
9. Check the battery terminals and wiring for tightness and corrosion
10. Check the alternator terminals and wiring for tightness and corrosion
11. Check the starter motor terminals and wiring for tightness and
corrosion
---
---
---
Tighten or change
Tighten or change
Tighten or change
OTHER POINTS TO CHECK
Hydraulic system - Mechanical equipment
12. Abnormal noise or smell
13. Check for oil leaks
14. Air in the system
---
---
---
Repair
Repair
Bleed the air
Electrical system - Electrical equipment
15. Check the battery voltage (with engine shut down)
16. Check the quantity of fluid in the battery
17. Make sure that the cables are not discolored, burnt or stripped
18. Check for missing or loose cable retaining clips
19. Check for dampness on cables (especially on connectors and
terminals)
20. Check fuses for condition and corrosion
21. Check the alternator voltage (with engine speed above the throttle
control mid-point) (when battery charge is insufficient, there can be
25 V only at start up)
22. Noise from battery relay (with starter motor ON or OFF)
23-26 V
---
---
---
---
---
27.5-29.5 V
---
Change
Add or change
Change
Repair
Disconnect and dry
if damp
Change
Change
Change
4001-69
Cre 7-28250-21LX Issued 11-01
Reading the Organization Charts
Error code and description of problem
The error code and the description of the problem are shown in the organization charts
Prior checks
Before identifying the cause of the problem, always
make prior checks.
Procedure method
After checking or measuring the items described in
Step 1, depending on the results, choose YES or NO
and pass on to the next step.
The description in the YES or NO refers directly to
the cause of the problem as the result of checks or
measurements made. Refer to the description of the
cause and carry out the repair procedures described
on the right-hand side.
The inspection methods/measurements are
described in Step 1. YES should be chosen if the
criteria or questions meet the situation; NO if they do
not meet it.
The necessary preparation work, operating method
and the criteria are described under Step 1. This
should be carefully read before starting the
inspection and the measurements and the
procedures should be followed, starting by Step (1)
since negligent preparation work or incorrect
operating methods can cause damage to the
machine.
Wire color
When troubleshooting, refer to the table below for the
wire colors. (For connector numbers, refer to the
following pages).
Table showing wire colors
BR indicates color B striped with R.
Example: BR indicates a black wire with red stripes
IMPORTANT: Before removing or installing a
connector, always turn the ignition key to OFF.
Error code Description of problem
1 The message is still displayed even after refuelling
2 The message is still displayed even after adding coolant solution
Symbol Wire Symbol Wire
B Black R Red
W White Y Yellow
Br Brown Lg Light green
P Pink Sb Sky blue
V Violet L Blue
G Green Gr Grey
O Orange
4001-70
Cre 7-28250-21LX Issued 11-01
Procedures
1. This is what to do to detect defects when the message is still displayed after all necessary
measures have been
taken to correct the error.
2. This is what to do if the problem is not indicated by a message but machine operation is not
correct.
A. Engine
3. Problem without message.
Message displayed Description of the problem Problem No.
Low fuel The message is still displayed even after refilling the fuel tank. 1
Low coolant The message is still displayed even after refilling with coolant
solution.
2
Low oil pressure The message is still displayed even after adjusting the engine
oil pressure.
3
Over heat The message is still displayed even when the hydraulic oil
temperature is 183°F or less and the engine coolant
temperature is 197°F or less.
4
Alternator The message is still displayed. 5
Elec. problem The message is still displayed. 6
Description of the problem Problem No.
6
7
Description of the problem Problem No.
8
The engine does
not start.
"ELEC. PROBLEM" is shown on the monitor.
YES
NO
Impossible to change travel speed
4001-71
Cre 7-28250-21LX Issued 11-01
Fuel
Description of the problem No. 1
- The message is still displayed even after refilling the fuel tank.
CM00F001
1. Main electronic control box 2. Fuel level sender
Resistance between GL and BG
12
Troubleshooting Cause Action
Starter key switch ON
Measure the
resistance of the fuel
level sender using
maintenance support
CHK4. (Refer to the
table below for the
resistance).
YES Defective main
electronic
control box
Change the
main
electronic
control box
NO
Starter key switch OFF
Disconnect the coupler
from the fuel level
sender to measure the
resistance of the
coupler at the fuel level
sender end. (Refer to
the table below for the
resistance).
NO
Defective fuel
level sender
Change or
check the fuel
level sender
YES
Disconnect the CN24
connector to measure
the resistance between
GL female and the GND
earth. (Refer to the
table below for the
resistance).
NO Bad
connection on
fuel level
sender
Clean the
connection
terminal
YES
Disconnect connector
CN1 to measure the
resistance between
female GL and the GND
earth. (Refer to the
table below for the
resistance).
NO Bad
connection on
CN24
Clean CN24
connection
terminal
YES
Defective main
electronic
control box or
incorrect CN1
connection
Change the
main
electronic
control box or
clean the
CN1
connection
terminal
Note: All the bar graph indicators have disappeared when the circuit is open
Monitor 1. Refill the tank 2 3 4 5 6 7 8
Resistance (OHM) 80-75 75-61 61-47 47-37 37-30 30-24 24-19 19-10
4001-72
Cre 7-28250-21LX Issued 11-01
Add Coolant Solution
Description of problem No. 2
- The message is still displayed even after adding coolant solution.
CM00F002
1. Main electronic control box 2. Coolant solution level switch
1
2
Disconnect the reserve tank
level pressure switch
connector to see if the
message disappears
YES Reserve tank
level pressure
switch is
defective
Change the
reserve tank
NO Disconnect connector CN24 to
see if the message disappears
YES
Short-circuit on
wire GrG
between the
reserve tank
level pressure
switch and CN24
Repair wire
GrG
NO Disconnect the connector CN4
to see if the message
disappears
YES
Short-circuit on
wire GrG
between CN24
and CN4
Repair wire
GrG
NO Main electronic
control box
defective
Change the
main electronic
control box
4001-73
Cre 7-28250-21LX Issued 11-01
Low Engine Oil Pressure
- The message is still displayed even when the engine oil level is satisfactory.
CM00F003
1. Main electronic control box 2. Engine oil pressure switch
1
2
Check the following points during the 12 seconds following starting the engine
Disconnect the oil pressure
switch connector to see if the
message disappears
YES
Oil pressure
switch defective
Change
YES
Short-circuit on
wire LgY
between the oil
pressure switch
and CN24
Repair wire
LgY
YES Short-circuit on
wire LgY
between CN24
and CN4
Repair wire
LgY
NO Main electronic
control box
defective
Change the
main electronic
control box
4001-74
Cre 7-28250-21LX Issued 11-01
Overheating
- The message is still displayed even when the real temperature is less than the following:
Hydraulic oil temperature 183°F, engine coolant temperature 197°F.
Prior check:
1. Make sure that 8 bars are displayed on the hydraulic oil and engine coolant temperature gauge
bar-graphs.
CM00F004
1
2
3
4
4001-75
Cre 7-28250-21LX Issued 11-01
1. The 8 bars on the coolant temperature bar-graph are displayed.
The temperature of the
temperature sending
unit (coolant) is
abnormal compared to
maintenance
assistance CHK1
(comparison between
the real temperature
and the indicated
temperature).
See coolant
temperature on CHK1
WT. Measure the real
temperature
YES
Check problem code
E0015 for the coolant
temperature sending
unit with the
maintenance diagnostic
(DIAG 1)
YES
Disconnect the coolant
temperature sending
unit connector to
measure the resistance
NO Coolant
temperature
sending unit
defective
Change the
temperature
sending unit
YES
Disconnect connectors
CN24 and CNAO to
between the female
terminals PL and BP.
(Refer to the table
below for the
resistances).
NO
Bad
connection
on the
temperature
sending unit
connector
(coolant)
Clean the
temperature
sending unit
connecting
terminal
YES
Disconnect connectors
CN7 and CNAO to
between the female
terminals PL and BP.
(Refer to the table
below for the
resistances).
NO Bad
connections
on CN24
Clean
connections
CN24
YES
Main
electronic
control box
defective or
bad CN7 and
CNAO
connections
Change main
electronic
control box or
clean the
connecting
terminals on
CN7 and
CNAO
Note: In the event of a short-circuit, the bar-graph disappears completely.
4001-76
Cre 7-28250-21LX Issued 11-01
Overheating (continued)
2. The hydraulic temperature bar-graph displays 8 bars.
The temperature
sending unit
temperature (oil) is
abnormal compared to
maintenance
assistance CHK1
(comparison between
the real temperature
and that indicated).
See coolant
temperature in CHK1
OT. Measure the real
temperature
YES
See problem code
M0020 for the oil
temperature sending
unit using maintenance
diagnostic (DIAG 4)
YES
Disconnect the
temperature sending
unit connector (oil) to
measure the resistance.
(Refer to the table
below for the
resistances).
NO Temperature
sending unit
(oil) defective
Change the
oil
temperature
sending unit
YES
CN24 to measure the
resistance between the
male terminals OL and
BO. (Refer to the table
below for the
resistances).
NO
Bad
connection
on the
thermal
sending unit
(oil)
connector
Clean the
sending unit
connecting
terminal
YES
CN1 to measure the
resistance between the
female terminals OL
and BO. (Refer to the
table below for the
resistances).
NO Bad
connections
on CN24
Clean the
connecting
terminal on
CN24
YES
Electronic
control box
defective or
bad
connection
on CN1
Change the
electronic
control box or
clean the
connecting
terminals on
CN1
Note: In the event of a short-circuit, the bar-graph disappears completely.
4001-77
Cre 7-28250-21LX Issued 11-01
Detector resistances
NOTE: The resistance varies with the temperature.
Battery Charge Circuit Defective
- The message is still displayed.
CM00F005
2. Hourmeter
3. Battery relay
4. Alternator
5. Starter motor
Coolant or oil temperature Coolant temperature detector Oil temperature detector
68°F 6.08 k2.45 k
86°F 4.24 k1.66 k
104°F 3.02 k1.15 k
122°F 2.18 k0.81 k
140°F 1.61 k0.58 k
158°F 1.20 k0.43 k
176°F 0.91 k0.32 k
1
2
63
4
5
4001-78
Cre 7-28250-21LX Issued 11-01
The hourmeter does not work
NO
Disconnect CN13 to
measure the voltage
between the female
terminal on wire BrW545
and earth. Over 10V.
YES
Bad connection
on CN13 or
defective
hourmeter
Clean the
connecting
terminal CN13 or
change the
hourmeter
NO
Disconnect CN26 to
measure the voltage
between the female
terminal on wire BrR544
and earth. Over 10V
YES
Bad connection
on CN26 or
short-circuit on
wire BrW545
between CN26
and CN13
Clean terminal on
CN26 or repair
wire BrW545
NO
Disconnect CN22 to
measure the voltage
between the female
terminal on wire BrR543
and earth. Over 10 V
YES
Bad connection
on CN22 or
short-circuit on
wire BrR543 or
BrR544 between
CN26 and CN22
Clean the terminal
on CN22 or repair
wire BrR543 or
BrR544
NO
Short-circuit on
wire BrR543
between CN22
and the
alternator or
defective
alternator
Repair wire
BrR543 or change
the alternator
Disconnect CN1 to
measure the voltage
between wire BrR543 at
the main electronic control
box end and earth. Over
10 V
YES Bad connection
on CN1 or main
electronic control
box defective
Clean the
connecting
terminal on CN1
or change the
main electronic
control box
NO
Short-circuit on
wire Br543
between CN1
and CN26
Repair wire
BRR543
Disconnect the connector from terminal R on the alternator to
measure the voltage between wire LgR at the alternator end
and earth. Over 10 V
NO
Alternator
defective
Change the
alternator
YES
Disconnect CN22 to measure
the voltage between the male
terminal on wire LgR and
earth. Over 10 V
NO
Bad connection
at terminal R on
the alternator or
short-circuit on
wire LgR
between CN22
and the
alternator
Clean the terminal
on CN22 or repair
wire LgR between
CN22 and the
alternator
YES
Short-circuit on
wire LgR540
between the
starting motor
switch and CN22
or starting motor
switch defective
Repair wire
LgR540 or change
the starting motor
switch
YES
4001-79
Cre 7-28250-21LX Issued 11-01
Electrical System Troubleshooting
- The message is still displayed
CS00J507
3. Engine
7. Battery relay
8. Fuse
9. Attachment cushion solenoid valve
10. Swing cancellation solenoid valve
11. Function locking solenoid valve
12. Swing brake solenoid valve
13. Travel 2nd speed solenoid valve
15. Free swing solenoid valve
11
12
13
14
9
10
5
4
3
6
2
7
8
1
15
4001-80
Cre 7-28250-21LX Issued 11-01
Troubleshooting using the diagnostic system
Starting motor switch ON
Failure code displayed in DIAG 1 NO To DIAG4
YES
Display E0031 YES Defective circuit in the regulator
Check the electronic
regulator
NO
Display E0032 YES Problem with rack detector signal
in regulator
Same as above
NO
Display E0041 YES Problem with TDC detector signal Same as above
Failure code displayed in DIAG 4
YES
M00B0 YES Faulty engine electronic control
box
Change the engine
electronic control
box
NO
M0010 Check that the transistor output is not short circuited
YES
To CHK2"
Self-detection finds the short circuit
YES
The failure code disappears after disconnecting the solenoid
valve connector
YES Defective solenoid valve
Change the solenoid
valve
NO
The failure code disappears after disconnecting connector
CN22
YES Short circuit on wire between
CN22 and the solenoid valve
Repair the wiring
NO
CN23
CN23 and the solenoid valve
Repair the wiring
NO
CN6
CN23 and CN6
Repair the wiring
NO
CN5
CN22 and CN5
Repair the wiring
NO
Electronic control box defective
Change the
electronic control
box
4001-81
Cre 7-28250-21LX Issued 11-01
The engine will not start even when the message "ELEC. PROBLEM" is no longer displayed.
Prior checks:
1- Make sure there are no problems with the engine and in the fuel system.
2- Make sure that the fuses are intact.
3- Make sure that the starter motor is working and turning the engine.
CM00F006
1. Fuse
2. Emergency stop switch
3. Emergency stop relay
4. Emergency stop motor
5. Stop position
6. Start position
7. Cab end
8. Service connector end
2
1
3
78
6
45
4001-82
Cre 7-28250-21LX Issued 11-01
Starting motor switch ON
The fuel inlet cut-off
lever is in the stop
position
NO Problem with
engine
system
Check the
engine
system
YES
Disconnect the connector
from the engine
emergency stop motor
CND6. Connect the
appropriate service
connector (6P) to
connector CND6 at the
engine harness end,
measure the voltage
between the earth (-) and
the (+) wire LR. The
voltage should be
between 20 V and 30 V
NO
Open circuit
on wire LR
between the
stop motor
connector
and CN or on
wire LR
between the
fuse and CN
Repair the
wire LR
YES
Using the same
configuration check for
continuity between
wires L and LW:
Starting motor switch
ON: continuity
Starting motor switch
OFF: no continuity
YES
Stop motor
defective
Change the
stop motor
NO
Measure the voltage at
the emergency stop
relay terminals,
between wire L (+) and
earth (-)
Emergency stop switch
ON = 0 V
Emergency stop switch
OFF = 20 V to 30 V
NO Emergency
stop relay
defective
Change the
emergency
stop relay
You can also check the
emergency stop relay
by replacing it
temporarily by one of
the relays from the
other functions
YES
Open circuit
between the
emergency
stop relay
and wire L
Change the
emergency
stop relay or
repair wire L
4001-83
Cre 7-28250-21LX Issued 11-01
Translation
- Not possible to change travel speed
No. Check Result Repair
1
Changing to second speed is not
shown on the checking screen
when pressing the speed
selection switch
Check the signal at connector
CN4 terminal 64 on the
electronic control box
0 Volt continuous, change the
electronic control box
Check the signal at connector
CN13 terminal 3 on the
instrument panel
0 Volt continuous, check the
connecting cable between
terminals 3 and 64
5 Volts continuous when
pressing the switch, change the
speed change switch
2
The travel mode changes when
the speed control switch is held
pressed down for over two
seconds
The electrical harness between
the electronic control box and the
2nd speed solenoid valve (red) is
defective
The voltage is equal to 24 V at
the output from the electronic
control box (CN6 terminal 30)
Check the solenoid valve and the
hydraulic system (see hydraulic
system troubleshooting)
The voltage is below 24 V at the
output from the electronic control
box (CN6 borne 30)
Change the harness
3
Using diagnostic mode CHK3,
the travel pressure switch does
not change to ON when the
travel function is operated
pressure switch is cut
Repair the harness
The pressure switch is defective Change the pressure switch
4
Using diagnostic mode CHK3,
the pilot pressure switch stays
ON
pressure switch is short circuited
Repair the harness
The pressure switch is defective Change the pressure switch
5
Check the pressure transducers
P1, P2 and the negative
pressure transducer (N) using
mode CHK1
One of the harnesses is
defective
Repair the harness
Voltage under 5 V, at input to one
of the transducers
Change the electronic control
box
Voltage under 5 V, at input to one
of the transducer
box
Voltage equal to 5 V, at input to
one of the transducer
Change the faulty transducer
6
The hydraulic oil temperature is
not displayed or is below 25°C
on the CHK1 check screen
the hydraulic oil temperature
sender and the electronic control
box (CN1 terminal 6 and 13) is
defective
Repair the electrical harness
Voltage below 5 V, at sender
input
box
Voltage equal to 5 V, at sender
input
Change the oil temperature
sender
4001-84
Cre 7-28250-21LX Issued 11-01
ELECTRICAL INSPECTION OF COMPONENTS
Inspection Equipment
Tool: See "Special Tools"
Details of service connector kit
BS98F222
1. Not used
BS98F223
2. Not used
BS98F224
3. For engine emergency stop motor (6P)
BS98F225
4. For harness end of engine emergency stop motor
(6P)
BS98F226
5. For solenoid valve and fuel gauge
BS98F227
6. 7. For proportioning valve
BS98F228
8. For pressure switch (2P)
BS98F229
9. For harness end of pressure switch
BS98F230
10. For air conditioning evaporator (2P)
BS98F231
11. Not used
4001-85
Cre 7-28250-21LX Issued 11-01
BS98F232
12. Not used
CD00N018
13. Not used
CD00N019
14. Not used
CS00E531
15. For hydraulic oil temperature and engine coolant
temperature senders
CS00E530
16. For engine speed detector
CS00E532
17. For pressure transducer
CS00J512
18. For engine governer (RED4)
CS00J513
CS00J514
4001-86
Cre 7-28250-21LX Issued 11-01
Proportioning Valve
CD00F022
1. Disconnect the proportioning valve connector (A)
from the hydraulic pump.
CS00E534
A. To hydraulic pump
B. To main harness
C. Meter
2. Connect the appropriate service connector (2P)
between the connector at the pump end and the
connector at the main harness end and install the
meter.
NOTE: The + terminal of the meter should be
connected to wire BrB (brown/black) on the service
connector coming from the main harness and the
- terminal to wire BrB (brown/black) on the service
connector coming from the hydraulic pump.
3. When the connections have been made, start the
engine and check the current in each work mode, at
maximum speed.
Current in mA
Engine Emergency Stop Motor
1. Disconnect connector (A) from the engine
emergency stop motor (B).
CS00E535
2. Connect the appropriate service connector (6P) to
the connector at the main harness end only.
CS99A846
A
AB
C
Mode H
SL
Auto
Max Min S L
407 292 292
50 or
less
332 292
B
A
4001-87
Cre 7-28250-21LX Issued 11-01
3. Make sure that wire LR (blue/red) on the service
connector is connected to wire LR on the main
harness and install the meter.
NOTE: The + terminal on the meter must be
connected to wire LR (blue/red) on the service
connector and the - terminal to the machine earth.
4. Turn the starter switch key to "ON", the meter
reading should be 24 V.
Block of 6 Solenoid Valves
1. Disconnect connector (A) from one of the
solenoids on the 6 solenoid valve block (B)
CD00F023
the connector on the disconnected solenoid only
and install the meter.
CS99A843
3. When the connection has been made, the solenoid
resistance reading should be 45 at 68°F.
NOTE: The resistance value varies with temperature.
Marking Function Ring color
1 Swing pilot cancellation Green
2 Power up Yellow
3 2nd travel speed Red
4 Attachment cushion Light green
5 Swing brake Pink
6 Pilot pressure Blue
123
4
5
6
B
A
4001-88
Cre 7-28250-21LX Issued 11-01
Engine Speed Detector
CD00F025
1. Disconnect connector (A) from the engine speed
detector.
the connector on the speed detector only and install
the meter.
BS98F255
3. When the connection has been made, the speed
detector resistance should be 0.7 kat 77°F.
NOTE: The resistance value varies with temperature.
A
4001-89
Cre 7-28250-21LX Issued 11-01
Engine Coolant and Hydraulic Oil
Temperature Detectors
CD00F027
CD00F028
A. Coolant temperature sender
B. Oil temperature sender
1. Remove the coolant temperature sender (A) or
the oil temperature sender (B) from the machine.
CS99A851
C. Service connector (2P)
D. Thermometer
E. Beaker
F. Temperature sender
G. Tripod
H. Spirit lamp
I. Meter
the temperature sender and install the meter.
3. When the connection has been made, place the
sender in the beaker and gradually increase the
temperature in the beaker using the spirit lamp and
check the resistance value.
A
B
Temperature
Coolant
temperature
sender
Oil temperature
sender
68°F 6.08 k 2.45 k 
86°F 4.24 k 1.66 k 
104°F 3.02 k 1.15 k 
122°F 2.18 k 0.81 k 
140°F 1.61 k 0.58 k 
158°F 1.20 k 0.43 k 
176°F 0.91 k 0.32 k 
D
E
C
I
F
G
H
4001-90
Cre 7-28250-21LX Issued 11-01
Pressure Detector
CD00E146
P1. Pressure transducer P1
P2. Pressure transducer P2
N. Negative pressure transducer (N)
1. Disconnect the pressure transducer connector
from the hydraulic pump.
2. Connect the appropriate service connector (3P)
between the connector at the pump end and the
connector on the main harness and install the
meter.
CS00E541
NOTE: The + terminal on the meter should be
connected to wire YL (yellow/blue) on the service
connector and the (–) terminal to the machine earth.
3. When the connection has been made, start the
engine and check the voltages in accordance with
the pressures.
Pressure transducer P1 and P2
Pressure transducer N
P1
P2
N
Pressure (psi) Voltage (V)
7252 4.5
6338 4
5439 3
3626 2
2538 1
0 0.5
Pressure (psi) Voltage (V)
725 4.5
634 4
544 3
362 2
181 1
0 0.5
Link-Belt
Printed in U.S.A
4002
INSPECTION AND MAINTENANCE OF BATTERIES
AND CONNECTING A BOOSTER BATTERY
Section
4002
4002-2
TABLE OF CONTENTS
SAFETY
INSTRUCTIONS....................................................................................................................................
.... 3
SPECIFICATIONS.................................................................................................................................
................... 3
MAINTENANCE
....................................................................................................................................................... 4
Electrolyte level
.................................................................................................................................................... 4
Inspecting and cleaning the battery
..................................................................................................................... 4
INSPECTING THE
BATTERY.................................................................................................................................. 5
Visual checks
....................................................................................................................................................... 5
Checking the specific
gravity................................................................................................................................ 5
Charge
test.........................................................................................................................................................
.. 6
CHARGING THE BATTERY
.................................................................................................................................... 7
BATTERY CHARGING GUIDE
................................................................................................................................ 8
PREPARING A DRY CHARGED BATTERY FOR
USE........................................................................................... 8
CONNECTING A BOOSTER
BATTERY.................................................................................................................. 9
you see
4002-3
SAFETY INSTRUCTIONS
SPECIFICATIONS
See Section 1002
WARNING: Never try to charge a battery
which has frozen electrolyte.
WARNING: Never cause sparks and never
smoke near batteries which are being
charged or which have recently been
charged.
WARNING: When disconnecting cables from
batteries, always disconnect the earth cable
first. When reconnecting cables to a battery,
always reconnect the earth cable last.
WARNING: Some batteries have a breather
tube. If the breather tube contains battery acid,
it could spill out when the battery is turned
round. When you turn the battery round,
always keep the end of the ventilation tube
away from yourself and persons in the vicinity.
Battery acid can cause very severe burns.
!
!
!
!
WARNING: Battery acid causes very severe
burns. Batteries contain sulphuric acid. Avoid
all contact with the skin, eyes and clothes.
Antidote:
EXTERNAL - Rinse copiously with plenty of
water.
INTERNAL - Drink large quantities of water or
milk. Follow this with milk of magnesia, a
beaten egg or vegetable oil.
Consult a doctor immediately.
EYES - Rinse copiously with plenty of water
for 15 minutes and obtain medical assistance
immediately.
Batteries produce explosive gases. Keep
sparks, flames and cigarettes well away. If
you use or charge a battery in a confined
space, make sure that it is well ventilated.
Always protect your eyes when you are
working near batteries.
Keep batteries and the acid they contain out
of the reach of children.
!
4002-4
MAINTENANCE
Electrolyte level
If the battery is a maintenance-free battery, check the
electrolyte level every 1000 hours of use or every six
months, whichever comes first. For all other batteries,
check the electrolyte level every 250 working hours.
Inspecting and cleaning the battery
If the battery is damaged and leaks, it must be
replaced. Regularly check for contamination, corrosion
and deterioration of the battery. If the top of the battery
is contaminated by impurities or electrolyte, the battery
may become discharged, since the current can pass
across the terminals.
If the battery has to be cleaned, remove the battery
from its retaining bracket and clean the battery, the
cable terminals and the battery retaining bracket. Use
bicarbonate of soda and water. MAKE SURE that you
do not allow the cleaning product to enter the battery
cells.
Reinstall the battery on the machine and check that
the retainers are fully tightened. Apply Link-Belt
Battery Saver and Cleaner or a urethane product to
the battery terminals to prevent corrosion. Refer to the
Parts Catalogue. Do not use grease.
WARNING: When disconnecting cables from
the battery, always disconnect the ground
cable first. When reconnecting cables to the
battery, always reconnect the ground cable
last.
!
4002-5
INSPECTING THE BATTERY
NOTE: To carry out a correct inspection of the
battery, carry out each step of the inspection; this will
enable you to find out the real condition of the battery.
Visual checks
- Check cable connections are clean and correctly
tightened. Remove all foreign bodies from the top of
the battery.
- Check there is no damage to the battery housing,
terminals and cables.
- Check the electrolyte level, see page 4.
- If you have added water to the battery, charge the
battery for 15 minutes at between 15 and 25 amps
to allow the water to mix correctly with the
electrolyte.
Checking the specific gravity
Use an acid hydrometer to check the specific gravity
of the electrolyte. The specific gravity shows the
charge level in each cell.
Acid hydrometers are designed to show the correct
specific gravity when the electrolyte is at a
temperature of 80°F (26.7°C).
Before checking the specific gravity, check the
temperature of the electrolyte. If the hydrometer
does not have a thermometer, use a thermometer to
measure the temperature of the electrolyte. The
thermometer must be graduated to at least 120°F
(52°C).
1. Remove enough electrolyte from each cell to
allow the float to move freely in the tube.
NOTE: If it is not possible to check the specific gravity
without first adding water to each cell, charge the
battery for 15 minutes at between 15 and 25 amps to
allow the water to mix correctly with the electrolyte.
Then check the specific gravity.
2. Read the float.
3. Read the thermometer if the reading is higher than
80°F (26.7°C), add specific gravity points to the
reading to obtain the specific gravity. If the reading is
lower than 80°F (26.7°C), subtract specific gravity
points from the reading to obtain the specific gravity.
See the illustration below and add or subtract
specific gravity points as required.
JS00532A
4. Record the corrected specific gravity for each cell.
5. If the difference between the high and low readings
is minimum 0.050, charge the battery and check the
specific gravity again. If, after charging, the
difference is still minimum 0.050, install a new
battery.
NOTE: When the battery is changed, do not install a
used battery with a new battery. That would reduce
the life-time of the new battery.
4002-6
6. The corrected specific gravity shows the charge
level for each cell. The charge level for each cell
should be 75% minimum. For maintenance-free
batteries, the charge level is 75% minimum when
the corrected specific gravity is 1.240 minimum. For
all other batteries the charge level is 75% minimum
when the corrected specific gravity is 1.230
minimum.
is lower than 0.050 and the charge level is 75%
minimum in each cell, carry out the charge test.
is lower than 0.050 but the charge level is lower than
75% in one of the cells, charge the battery and
check the specific gravity again. If after charging:
A. The charge level is lower than 75% in one of the
cells, replace the battery by a new battery.
B. The charge level is 75% minimum in each of the
cells, carry out the charge test.
Charge test
For this check, use a variable charge tester such as
the Sun Electric VAT-33 or an equivalent machine.
Connect the tester as per the manufacturer’s
instructions.
1. The charge level should be at least 75%. Carry
out the specific gravity check in this section.
2. Prepare the tester for the tests (the diagram shows
a Sun Electric VAT-33).
A. Select the voltmeter range between 1 and
18 volts.
B. Check that the charge control knob is in the
OFF position.
C. Select the ammeter range between 0 and
1000 amps.
D. Move the voltmeter switch to the INT position.
E.
JS00533A
1 CHARGE CONTROL KNOB
2 AMMETER CLAMP (WITH THE POINT OF THE ARROW
DIRECTED AWAY FROM THE BATTERY)
NOTE: Never apply the charge for more than
15 seconds. Every 15 seconds, turn the charge
control knob to OFF for at least 1 minute.
21
4002-7
3. Apply a charge of 15 amps to the battery for
15 seconds. Wait at least 3 minutes before
continuing the test.
4. Measure and note the temperature of the
electrolyte.
5. Refer to specifications for the correct charge for this
test.
6. The correct charge corresponds to half the value of
the cold start current 0°F (-17°C).
7. Turn the charge control knob until the ammeter
shows the current required. Maintain the charge for
15 seconds and read the voltmeter. Turn the charge
control knob to OFF.
8. Compare the reading and the electrolyte
temperature with the values shown below.
A. If the result of the test is higher than or equal to
the voltage shown, the battery is in good
condition.
B. If the result of the test is less than the voltage
shown, replace the battery with a new battery.
CHARGING THE BATTERY
Before charging the battery, check the electrolyte
level.
It is difficult to state an exact charging rate since the
following conditions are variable: (1) temperature of
the electrolyte, (2) charge level, and (3) condition of
the battery. Refer to the Charging Guide for correct
charging time.
Refer to Specifications on page 3 for the reserve
battery charge of this machine.
Reduce the rate of charge if:
1. The electrolyte spills out of the cells since they
are producing too much gas.
2. The temperature of the electrolyte exceeds 125°F
(52°C).
NOTE: For optimum charging, select slow charging
rates. The battery is fully charged when, after slow
charging for 3 hours, no cell is producing too much
gas and the specific gravity remains unchanged.
Electrolyte temperature Minimum voltage
70°F (21°C) minimum 9.6
60°F (16°C) 9.5
50°F (10°C) 9.4
40°F (4°C) 9.3
30°F (-1°C) 9.1
20°F (-7°C) 8.9
10°F (-12°C) 8.7
0°F (-18°C) 8.5
WARNING: Never try to charge a battery
! which has frozen electrolyte.
4002-8
BATTERY CHARGING GUIDE
Recommended rates* and duration for a completely discharged battery.
PREPARING A DRY CHARGED BATTERY FOR USE
1. Remove the plugs from the battery.
2. Fill each cell with electrolyte, up to the top of the
separators. This is because the electrolyte volume
can increase when it is heated by being on charge.
3. Install the plugs on the battery.
4. Connect the battery charger to the battery.
5. Charge the battery at 30 amps until the specific
gravity reaches 1.250 minimum and the
temperature of the electrolyte reaches at least 60°F
(15.5°C).
6. If necessary, add electrolyte to each cell until the
maximum level indicator is reached (uppers) which
corresponds to a value of 0.39 to 0.59 in (10 to 15
mm) above the battery polarity plates.
Capacity of the battery
See "Reserve" in the
specifications on page 3
Slow charging Quick charging
80 minutes maximum 10 hours at 5 amps
5 hours at 10 amps
2.5 hours at 20 amps
1.5 hour at 30 amps
Between 80 and 125 minutes 15 hours at 5 amps
1.5 hour at 50 amps
10 hours at 10 amps
5 hours at 20 amps
2 hours at 50 amps
15 hours at 10 amps
3 hours at 50 amps
In excess of 250 minutes 24 hours at 10 amps 6 hours at 40 amps
4 hours at 60 amps
* Initial rate for a standard charger.
4002-9
CONNECTING A BOOSTER BATTERY
1. Open the left-hand side access doors. Remove
the lid and the screws (1) from the batteries.
CD00F052
2. While seated in the operator’s seat, ask your
assistant to carry out the connections. Check that
the voltage of the booster batteries is indeed
24 volts.
3. If the connection is being made from another
machine, make sure that the two machines do not
touch each other.
4. Connect the positive jump lead (+) (1) to the positive
terminal (+) on the battery.
JD00531A
5. Connect the negative jump lead (-) (2) to a clean
ground, away from the battery.
WARNING: When a battery is frozen it may
explode if (1) you try to charge it or (2) you try
to start the engine using jump leads. To
prevent the electrolyte freezing, always keep
the battery fully charged. Non-observance of
these instructions can endanger your safety
and that of those around you.
WARNING: Batteries contain acid and
explosive gases. A spark, flame or incorrect
cable connection can cause the battery to
explode. The correct procedure for
connecting jump leads to the machine’s
battery is explained on this page. Nonobservance
of these instructions may lead to
serious or fatal injury.
WARNING: Batteries produce explosive
gases. Keep all cigarettes, sparks and flames
away from the area. If you charge or use a
battery in a confined space, make sure that it
is well ventilated. Always protect your eyes
when working near batteries.
WARNING: When connecting the jump leads,
do not allow the positive (+) and negative (-)
cables to touch each other.
WARNING: Incorrect connecting of jump
leads may cause an accident. Always
proceed with the greatest caution.
!
!
!
!
!
1
2
1
4002-10
6. If the connection is being made from another
machine, start the machine and run it at half of
maximum engine speed.
7. Start the engine of the machine requiring the
booster connection and ask your assistant to
disconnect the negative jump lead (-) first and the
positive jump lead (+) last.
8. Install the lid on the battery and close the left-hand
access doors.
9. Do not stop the engine for at least 20 minutes. This
is to allow the batteries to recharge correctly.
Printed in U.S.A.
4003
Link-Belt
MAIN ELECTRONIC CONTROL BOX
ENGINE ELECTRONIC CONTROL BOX
Section
4003
4003-2
Cre 7-27931-21LX Issued 11-01
TABLE OF CONTENTS
MAIN ELECTRONIC CONTROL BOX AND ENGINE ELECTRONIC CONTROL BOX
.......................................... 3
Removal
...............................................................................................................................................................
3
Main electronic control box
.................................................................................................................................. 4
Engine electronic control box
............................................................................................................................... 4
Installation
............................................................................................................................................................ 4
4003-3
Cre 7-27931-21LX Issued 11-01
MAIN ELECTRONIC CONTROL BOX AND ENGINE ELECTRONIC
CONTROL BOX
Removal
STEP 1
JS00001A
STEP 2
Shut down the engine and position the starter switch
on OFF.
STEP 3
CD00F045
Disconnect the main ground cable (-) (A) from the
battery.
STEP 4
CD00F011
Remove the panel (A) located behind the operator’s
seat, taking care to disconnect the connector from
the cigarette lighter (B) and the solar radiation
detector (C).
A
AC
B
4003-4
Cre 7-27931-21LX Issued 11-01
Main electronic control box
STEP 5
CD00F047
Disconnect the connectors CN1 to CN6 from the
main electronic control box (B).
STEP 6
Remove the 4 retaining screws (A) from the main
electronic control box (B).
STEP 7
Remove the main electronic control box (B).
Engine electronic control box
STEP 5
CD00F048A1
Identify and remove the engine stop relay (A).
STEP 6
Disconnect the connectors CNA0, CNA1, CN7 and
CN8 from the engine electronic control box (B).
STEP 7
Remove the 4 retaining screws (C) from the engine
electronic control box (B).
STEP 8
Remove the engine control unit (B).
Installation
To install, proceed in the reverse order from that of
removal.
NOTE: To reprogram the main and engine electronic
control boxes, see Section 4001.
B
A
C
B
A
Link-Belt
Printed in U-S-A
5001
OF THE TRACKS SET
Section
5001
5001-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................
................... 2
SPECIAL TORQUE
SETTINGS............................................................................................................................... 2
SPECIAL TOOLS
..................................................................................................................................................... 3
TRACKS
SET........................................................................................................................................................
... 4
Description
...........................................................................................................................................................4
Removal
...............................................................................................................................................................
5
Installation
............................................................................................................................................................8
Track tension adjustment
...................................................................................................................................10
Checking pin and bushing wear
.........................................................................................................................12
SPECIFICATIONS
See Section 1002
See Section 1002
WARNING: This symbol is used in this manual to indicate important safety messages. Every time
you see
this symbol, read carefully the message that follows, as it indicates t ! hat there is a risk of serious
injury.
5001-3
SPECIAL TOOLS
926407
1. Track removal hydraulic press K1P0013
2. Loctite 262
3. Hammer
4. Lifting jib
5. Impact wrench
6. Torque spanner
7. Supports 10 T
8. Roller pump
9. Angle wrench K1P0014
5001-4
TRACKS SET
Description
Lower mechanism
CI00E511
1 TRACK PAD
2 SCREW
3 NUT
4 END OF CHAIN PIN HALF-LINK
5 END OF CHAIN HALF-LINK
6 END OF CHAIN PIN
7 SHIM
8 END OF CHAIN PIN SPACER
9 RETAINER PIN
10 RH STANDARD TRACK PIN HALF-LINK
11 LH STANDARD TRACK PIN HALF-LINK
12 STANDARD TRACK PIN
13 STANDARD TRACK PIN SPACER
14 SEAL
12 6
5
7
8
7
4
9
14
3
10
13
14
11
1
2
5001-5
Removal
STEP 1
Park the machine on hard, flat ground. Rotate the
upperstructure of the machine so that the cab is over
the track to be removed.
STEP 2
JD00270A1
Lower the bucket or the tool to lift the track a few
centimeters off the ground.
NOTE: If the machine does not have a bucket or tool
installed, install wood blocks under the arm and lower
the arm onto the wood blocks. Then, lower the arm to
raise the machine.
STEP 3
JD00271A
The main axle (1) can be identified by flat surfaces on
one end and the pin (2) that fastens it at the other
end.
JD00272A
Operate the machine until the main axle is close to
the centre of the sprocket. Operate machine to lower
track to be removed to ground. Rotate the upper
structure of the machine so that the cab is facing the
front. Shut down the engine.
STEP 4
JD00273A
Do not remove the non-return check valve. The
grease in the track adjustment cylinder is under high
pressure. Slacken the track by gradually loosening
the non-return check valve by about two turns. The
grease will escape from a port on the check valve
thread.
KHP1014
1
2
5001-6
STEP 5
JD00274A
Remove the four screws (1) and the track pad nuts
on top of the end of chain axle. Remove the track
pad.
STEP 6
JD00275A
JD00276A
Straighten up one end of the pin (1) and remove the
pin from the end of chain axle.
STEP 7
JD00277A
Remove the four screws and the nuts from the track
pad under the end of chain axle. Remove the track
pad.
STEP 8
B504423M
Install a portable hydraulic press K1P0013 on the end
of chain axle. Using the portable hydraulic press,
force the end of chain axle out.
STEP 9
Remove the portable hydraulic press.
1
1
5001-7
STEP 10
JD00278A
Using a crowbar, separate the chain links. Remove
the two spacers (1) from the end of chain axle.
STEP 11
JD00279A
Start the engine. Using the attachment, lift the
upperstructure on the side of the track to be
removed. Install supports under the machine to hold
the machine in place and lower the machine onto the
supports. Shut down the engine.
STEP 12
JS00280A
Sling the lower end of the track. Start the engine.
Operate the machine backwards and move the arm
out at the same time. When the track is free from the
sprocket, stop reversing the machine. Continue
operating the arm out until the track is pulled from
beneath the machine. Stop the engine, move the
track to be replaced away from the machine.
1
5001-8
Installation
STEP 1
JD00279A
Lift the undercarriage. Install supports under the
machine to hold the machine in place.
STEP 2
JD00281A
Place and align the new track under the lower roller.
STEP 3
Lower the machine onto the track chain.
STEP 4
CD00F057A
Connect lifting equipment to the track. Lift the track
on the idler wheel.
STEP 5
JS00283A
Sling the track to the attachment. Start the engine,
operate the machine forward and move the arm out
at the same time to pull the track on the sprocket.
Keep the track engaged on the sprocket teeth.
5001-9
STEP 6
B5573689M
Connect suitable pulling equipment to both ends of
the track chain. Operate the pulling equipment to pull
both ends of the track chain together.
STEP 7
JD00278A
Install two spacers (1) in the two half links where the
end of chain axle is assembled.
STEP 8
B5491989M
Install the end of chain axle with the portable
hydraulic press K1P0013.
STEP 9
JD00284A
Remove the portable hydraulic press. Install a new
pin (1) in the end of chain axle. Bend the ends of the
pins to brake the end of chain axle.
STEP 10
Install the two track pads, the screws and the nuts.
STEP 11
B5171389M
Tighten the track pad screws to a torque (see the
specifications).
STEP 12
See "Track tension adjustment" in this section and
adjust the track tension.
1
1
5001-10
Track tension adjustment
Check the tension of the tracks as required. Adjust
the tension for the type of surface the machine will be
operating on. Tighten the track for operation on hard
surfaces and loosen the track for operation on soft
surfaces.
STEP 1
upper structure of the machine so that the cab is over
the track to be checked.
STEP 2
JD00270A1
Lower the attachment to lift the machine until the
track to be checked is lifted off the ground by a few
centimeters.
STEP 3
JD01074A
Measure the distance between the bottom surface of
the track frame and the top surface of the track shoe.
Compare the values with the specifications.
STEP 4
Do the following procedure to increase the track
tension:
1. Clean the grease fitting of the track adjustment
cylinder.
JD00273A
2. Check that the check valve is tight.
JD00287A
3. Inject grease into the track tension cylinder until
the required tension is obtained.
KHP1014
5001-11
STEP 5
Do the following procedure to decrease the track
tension:
JD00273A
1. Do not remove the non-return check valve.
Grease in the track tension cylinder is under high
pressure. Release the track by gradually
loosening the non-return check valve by about
two turns, the grease escapes from a port in the
check valve thread.
2. When the track tension is correct, tighten the
check valve.
3. Clean the grease from the check valve.
WARNING: Grease is under havy spring
pressure. Disassembly without releasing
pressure may result in serious injury or
death. Do not disassemble the track
compensating system before completely
releasing the grease pressure. Release
grease pressure by loosening check valve.
Do not remove the non-return check valve
or retaining bracket.
!
5001-12
Checking pin and bushing wear
The wear on the pins and bushings can be measured
with a micrometer or an outside calliper.
STEP 1
JS00288A
1 OUTSIDE CALLIPER
2 BUSHING
Measure the outer diameter of the bushing. Compare
the values with the specifications. Replace them if
necessary.
STEP 2
Measure the inside diameter of the bushing.
Compare the values with the specifications. Replace
them if necessary.
STEP 3
Measure the outer diameter of the track pin.
Compare the values with the specifications. Replace
them if necessary.
12
Link-Belt
Printed in U.S.A.
5003
UPPER AND LOWER ROLLERS
Section
5003
5003-2
Cre 7-27770-21LX Issued 11-01
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................
................... 3
SPECIAL TORQUE
SETTINGS............................................................................................................................... 3
SPECIAL TOOLS
..................................................................................................................................................... 3
LOWER
ROLLER................................................................................................................................................
..... 4
Description
...........................................................................................................................................................4
Removal
...............................................................................................................................................................
5
Reconditioning
.....................................................................................................................................................6
Disassembly
.........................................................................................................................................................6
Inspection
.............................................................................................................................................................7
Assembly
..............................................................................................................................................................
7
Installation
............................................................................................................................................................9
UPPER
ROLLER................................................................................................................................................
.... 10
Description
.........................................................................................................................................................10
Removal
.............................................................................................................................................................1
1
Reconditioning
...................................................................................................................................................12
Disassembly
.......................................................................................................................................................12
Inspection
...........................................................................................................................................................14
Assembly
............................................................................................................................................................1
5
Installation
..........................................................................................................................................................17
CHECKING FOR LEAKS
....................................................................................................................................... 18
you see
injury.
5003-3
Cre 7-27770-21LX Issued 11-01
SPECIFICATIONS
See Section 1002
See Section 1002
SPECIAL TOOLS
B407320M
Use K1P0015 and K1P0016 for the leak checks
shown below
1. 10 T capacity supports
2. Micrometer gauges
3. Torque spanner 700 Nm
4. Jack 5 T
5. Roller pump
6. Loctite 262
5003-4
Cre 7-27770-21LX Issued 11-01
LOWER ROLLER
Description
CS01B539
1 LOWER ROLLER
2 DRAIN PLUG
3 SNAP RING
4 END CAP
5 FACE SEAL
6 SHAFT
7 O-RING
8 BUSHING
A...............................................................................................................................................12.51 to
12.55 inches
B............................................................................................................................................................
.....9.6 inches
3
7
1854
2
6
A
B
5003-5
Cre 7-27770-21LX Issued 11-01
Removal
STEP 1
upperstructure of the machine so that the cab is over
the lower rollers to be removed.
STEP 2
JD00273A
pressure. Slacken the tracks by slowly loosening the
non-return check valve by about two turns, the
grease will escape from a port in the thread of the
check valve.
STEP 3
Lower the attachment to lift the machine until a
sufficient gap between the track frame and the trackis
obtained so that the lower roller can be removed.
STEP 4
JD01075A
Install the supports (1) of suitable capacity under the
machine.
STEP 5
JD01076A
At each end of the track, install wood blocks (1) under
the track.
STEP 6
JD00299A
Install a wood block under the lower roller to support
it. Remove the four screws and the retaining washers
and remove the lower roller.
WARNING: Grease is under heavy spring
pressure. Disassembly without releasing
pressure may result in serious injury or
death. Do not disassemble the track
compensating system before completely
releasing the grease pressure. Release
grease pressure by loosening check valve.
Do not remove the non-return check valve
or the retaining bracket.
!
KHP1040
1
1
5003-6
Cre 7-27770-21LX Issued 11-01
Reconditioning
When the roller is worn out or is leaking, it must be
reconditioned or replaced by a new one. See
Section 1002 for limits of wear.
Disassembly
STEP 1
JS00301A
Clean the lower roller (1) using a suitable solvent.
Remove the two drain plugs (2) and drain the oil.
STEP 2
JS00302A
Remove the retainer rings (3) and the end caps (4)
from the shaft (6). Discard the retainer rings.
STEP 3
JS00303A
Remove the face seals (5) from the end caps (4) with
a screwdriver or similar tool. Be careful not to
damage the seal bore in the end cap. Discard the
face seals.
STEP 4
JS00304A
Remove and discard the O-rings (7) from the shaft
(6). Take the shaft (6) out of the lower roller.
STEP 5
JS00305A
Remove and discard the face seals (5) from the lower
roller (1) or the shaft (6).
1
2
3
4
6
3
4
4
5
7
1
6
7
5
1
5
5003-7
Cre 7-27770-21LX Issued 11-01
STEP 6
JS00306A
NOTE: Carry out this step only if inspection reveals
that the bushings (8) need to be replaced.
Using a hammer and a brass punch, drive the
bushings (8) from the lower roller (1). Be careful not
to damage the seal bore in the lower roller. Discard
bushings.
Inspection
STEP 1
Clean all components with solvent.
STEP 2
Inspect the bushing surfaces on the shaft (6) for
scoring, pitting, and other damage. Measure the
diameter of the shaft at four opposing points.
Compare the values with the specifications, replace
them if necessary.
STEP 3
Inspect bushings (8) for wear and damage. Measure
the inner diameter and width of the bushing.
Compare the values with the specifications, replace
them if necessary.
STEP 4
Inspect the bore in each end cap and in the lower
roller for damage that will result in leakage. Use new
parts as required.
Assembly
STEP 1
JS00309A
If removed, install new bushings (8) in the lower roller
(1) using a hydraulic press and a proper size rod.
STEP 2
JS00310A
Install an O-ring and a face seal metal bushing (5) in
the seal bore on each side of the lower roller.
8
8
1
8
8
1
5
5
1
5003-8
Cre 7-27770-21LX Issued 11-01
STEP 3
JS00311A
Apply clean grease on the shaft surface (6) and
install the shaft in the lower roller (1), lubricate and
assemble the O-rings (7) on the shaft (6).
STEP 4
JS00312A
JS00313A
Install the O-ring and remaining face seal metal
bushings (5) in the seal bore of the end cap (4). Apply
clean oil copiously to the face seals (A).
STEP 5
JS00314A
Install the end caps (4) on the shaft (6) and install
new retainer rings (3). Install one drain plug (2).
NOTE: Check the adjustment settings of the face
seal covers as well as those of the retaining pitch
holes, see page 4.
STEP 6
See the chapter on leak checks, carry out an
inspection to ensure that the lower roller has been
correctly installed.
STEP 7
JS00315A
Fill the lower roller (1) with clean oil, see
specifications. Install the drain plug (2) in the end cap
(4).
7
6
1
7
4
5
A
5
4
34
1
3
4
2
4
2
5003-9
Cre 7-27770-21LX Issued 11-01
Installation
STEP 1
JD00316A
Align the lower roller in position under the lower
undercarriage.
STEP 2
JD00299A
Apply Loctite 262 to the threads of the four screws.
Assemble the four hardened washers and the
screws.
STEP 3
Tighten the four retaining screws of the lower roller
end caps to the torque (see specifications). Remove
the wood blocks.
STEP 4
At each end of the track, remove the wood blocks
from beneath the track. Remove the two supports
from beneath the machine.
STEP 5
Refer to "Adjusting track tension", see section 5001.
5003-10
Cre 7-27770-21LX Issued 11-01
UPPER ROLLER
Description
CS01B540
1 UPPER ROLLER
2 DRAIN PLUG
3 SNAP RING
4 COVER
5 O-RING
6 SCREW
7 THRUST PLATE
8 SHAFT
9 FACE SEAL
10 BUSHING
11 BUSHING
12 BRACKET
13 ROLL PIN
A.....................................................................................................................................................4.5
to 4.54 inches
B............................................................................................................................................................
...2.55 inches
C............................................................................................................................................................
...0.45 inches
5
3
2
13 7 10 8 11 9 1 12
6
4
ABC
5003-11
Cre 7-27770-21LX Issued 11-01
Removal
STEP 1
JS00163A1
Park the machine on hard, flat ground. Lower the tool
to the ground.
STEP 2
JD00273A
pressure. Slacken the track by slowly loosening the
non-return check valve by about two turns, the
grease will escape from a port in the check valve
thread.
STEP 3
JD00317A
Install a hydraulic jack on the side frame. Using the
jack, lift the track just enough to remove the upper
roller.
STEP 4
JD00318A
Place wooden shims between the track and the
undercarriage.
KHP1040
5003-12
Cre 7-27770-21LX Issued 11-01
STEP 5
JD00319A
Loosen the two screws (1) holding the upper roller to
the undercarriage. Using a soft peening hammer, tap
gently on the upper roller to separate it from the
undercarriage.
STEP 6
JD00320A
Support the upper roller. Remove the two screws
holding the upper roller to the undercarriage. Remove
the upper roller.
Reconditioning
When the upper roller is worn or is leaking, it must be
reconditioned or a new upper roller installed. See
Section 1002 for wear limits.
Disassembly
STEP 1
JS00322A
Clean the upper roller (1) using a suitable solvent.
Remove the drain plug (2) and drain the oil.
STEP 2
CS01B538
Remove the snap ring (3), the cover (4) and the roll
pin (13) from the upper roller (1). Remove and
discard the O-ring (5) from the cover.
2
1
3
4
5
1
13
5003-13
Cre 7-27770-21LX Issued 11-01
STEP 3
JS00324A
Secure the upper roller in a vice. Remove the two
screws (6) holding the thrust plate (7). Remove the
thrust plate (7).
STEP 4
JS00325A
Pull the upper roller (1) from the shaft (8).
NOTE: Carry out step 5 only if inspection reveals that
the shaft (8) needs to be replaced.
STEP 5
Using a press, remove the shaft (8) from the bracket
(12). Be careful not to damage the seal bore in the
bracket.
STEP 6
JS00326A
Remove and discard the face seal (9) from the upper
roller (1) using a screwdriver or other suitable tool. Be
careful not to damage the seal bore in the upper
roller. Discard the face seal.
STEP 7
JS00327A
Remove and discard the face seal (9) from the
bracket (12) using a screwdriver or other suitable tool.
Be careful not to damage the seal bore in the bracket.
6
7
1
1
8
12
9
1
9
8
12
89
12
5003-14
Cre 7-27770-21LX Issued 11-01
NOTE: Carry out step 8 only if inspection reveals that
the bushings (10 and 11) need to be replaced.
STEP 8
JS00328A
Using a hammer and a brass punch, drive the
bushings (10) and (11) from the upper roller (1). Be
careful not to damage the seal bore in the upper
roller.
Inspection
STEP 1
Clean all the components with cleaning solvent.
STEP 2
Inspect the bushing surfaces on the shaft (8) for
scoring, pitting, and other damage. Measure the
diameter of the shaft at four opposing points.
Compare the values with the specifications, replace if
necessary.
STEP 3
Check for wear and damage to the bushings.
Measure the inner diameter and width of the bushing.
Compare the values with the specifications, replace if
necessary.
STEP 4
Inspect the thrust plate for wear and damage.
Measure the thicknes of the thrust plate. Compare
the values with the specifications, replace if
necessary.
STEP 5
Inspect the bore in the bracket (12) and the upper
roller (1) for damage that could result in leakage. Use
new parts as required.
10
1
11
5003-15
Cre 7-27770-21LX Issued 11-01
Assembly
STEP 1
JS00331A
If the shaft (8) has been removed from the bracket
(12), install the shaft in the bracket using a press. Be
careful not to damage the seal bore in the bracket.
NOTE: The retaining ports of the thrust plate (7)
should be perpendicular to the retaining plane of the
bracket (12).
NOTE: Respect the recess dimension of the shaft in
the bracket, see page 10.
STEP 2
JS00332A
Install the bushings (11) and (10) in the upper roller
(1).
NOTE: The grooves of the bushings should be
rotated by 90°
STEP 3
JS00333A
Install an O-ring and a face seal (9) metal bushing in
the seal bore of the upper roller (1). Liberally apply
clean oil on the edge of the face seal.
STEP 4
JS00334A
Install the O-ring and the remaining face seal (9)
metal bushing in the seal bore of the bracket (12).
Apply clean oil copiously to the face seal.
STEP 5
JS00335A
Apply clean grease on the surface of the shaft (8) and
install the shaft in the upper roller (1).
12
8
11
1
10
10
11
1
1
9
9
8
12
89
12
1
8
5003-16
Cre 7-27770-21LX Issued 11-01
STEP 6
JS00336A
Apply grease on the inside of the thrust plate (7).
Position the thrust plate on the shaft (8) and install
the two screws (6). Apply brake thread fluid to the
screws and tighten to a torque of 46 to 53 lb-ft (63 to
72.5 Nm).
STEP 7
CS01B538
Apply grease on the O-ring (5) and install in the
groove of the cover (4). Install the cover (4) and the
roll pin (13) in the upper roller (1). Install the snap ring
(3) to secure the cover (4).
STEP 8
Check for leaks to ensure that the upper roller has
been correctly reassembled and check for any
damage which could give rise to leaks at seals and
other components.
STEP 9
JS00337A
Fill the upper roller (1) with synthetic oil (see the
specifications for quantity). Install the drain plug (2) in
the cover (4).
6
7
1
1
5
4
3
13
1
2
5003-17
Cre 7-27770-21LX Issued 11-01
Installation
STEP 1
JD00338A
Place the shims on the undercarriage, then install
and support the upper roller.
STEP 2
JD00319A
Apply Loctite 262 to the screw threads. Install two
tempered washers and screws to fasten the upper
roller bracket to the undercarriage. Tighten the
screws to torque (see specifications).
STEP 3
JD00317A
Remove the wood blocks between the track pad and
the undercarriage.
STEP 4
Operate the hydraulic jack to lower the track onto the
upper roller. Remove the jack.
STEP 5
Refer to "Track tension setting" in section 5001.
5003-18
Cre 7-27770-21LX Issued 11-01
CHECKING FOR LEAKS
Use K1P0015 and K1P0016 for the leak checks
shown below.
B407320M
STEP 1
Connect the shut-off valve (1) to the pressure
regulator (2). Connect a union for the air supply hose
to the shut-off valve.
STEP 2
Install the adaptor and a quick coupler to the oil filler
orifice. Use a seal washer with the adapter.
STEP 3
Turn the knob anti-clockwise to close the pressure
regulator (2).
STEP 4
Connect the pressure gauge pipe to the quick
coupler.
STEP 5
Make sure that the shut-off valve (1) is open.
STEP 6
Adjust the pressure regulator (2) until the pressure
gauge shows 27.5 psi (1.9 bar).
STEP 7
Turn the shaft of the unit under test four revolutions.
STEP 8
Adjust the regulator until the pressure gauge shows
14.5 psi (1 bar).
STEP 9
Close the shut-off valve. Maintain the air pressure of
step 8 for 10 seconds. A reduction in air pressure
during this period shows a defective component or
incorrect assembling.
2
1
Link-Belt
Printed in U.S.A.
5004
SPROCKET
Section
5004
5004-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................
................... 2
SPECIAL TORQUE
SETTINGS............................................................................................................................... 2
SPROCKET...........................................................................................................................................
................... 3
Removal
...............................................................................................................................................................
3
Installation
............................................................................................................................................................ 4
SPECIFICATIONS
See Section 1002
See Section 1002
5004-3
SPROCKET
Removal
STEP 1
See "Removing and installing a set of tracks"
(Section 5001) and disengage the sprocket from the
chain.
STEP 2
JD00290A
Move the machine so that the track is in the position
shown.
STEP 3
JD00291A
Swing the upperstructure so that the cab is over the
side of the machine from which the sprocket has to
be removed. Use the attachment to raise the side of
the machine until the sprocket teeth are disengaged
from the chain.
STEP 4
JD00292A
To facilitate reassembly, make alignment marks (1)
on the sprocket and the reduction gear.
STEP 5
JD00293A
Remove the screws (1) and the hardened washers
which attach the sprocket to the reduction gear.
STEP 6
JD00294A
Using a soft-faced hammer, drive the sprocket off the
reduction gear housing. Remove the sprocket from
the machine.
1
1
5004-4
Installation
STEP 1
JD00292A
Install the sprocket on the drive reduction gear,
ensuring that the alignment marks (1) are lined up
correctly.
STEP 2
JD00295A
If necessary, use a soft-faced hammer to seat the
sprocket correctly on the reduction gear flange.
STEP 3
JD00293A
Apply Loctite 262 to the screw threads (2). Assemble
the hardened washers and the screws.
STEP 4
JS00296A
Tighten the four screws in the order shown to the
specified torque, see "specifications". Then
progressively tighten the remaining screws to the
same torque setting.
STEP 5
See "Removing and installing a set of tracks" for
installing the tracks.
1
1
2
34
Printed in U.S.A.
5005
Link-Belt
IDLER WHEEL AND TENSION SHOCK ABSORBER
Section
5005
5005-2
Cre 7-27801-21LX Issued 11-01
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................
................... 3
SPECIAL TORQUE
SETTINGS............................................................................................................................... 3
SPECIAL TOOLS
..................................................................................................................................................... 3
REMOVAL AND INSTALLATION OF THE IDLER WHEEL AND THE TENSION SHOCK
ABSORBER................. 4
Removal
...............................................................................................................................................................
4
Installation
............................................................................................................................................................6
DISASSEMBLY AND ASSEMBLY OF THE IDLER
WHEEL.................................................................................... 8
Description
...........................................................................................................................................................8
Reconditioning
.....................................................................................................................................................8
Disassembly
.........................................................................................................................................................9
Inspection
...........................................................................................................................................................10
Assembly
............................................................................................................................................................1
1
Leakage test
.......................................................................................................................................................13
DISASSEMBLY AND ASSEMBLY OF THE TENSION SHOCK ABSORBER
....................................................... 14
Description
.........................................................................................................................................................14
Disassembly
.......................................................................................................................................................15
Assembly
............................................................................................................................................................1
5
TRACK TENSION CYLINDER
............................................................................................................................... 16
Description
.........................................................................................................................................................16
Removal
.............................................................................................................................................................1
6
Disassembly
.......................................................................................................................................................17
Inspection
...........................................................................................................................................................18
Assembly
............................................................................................................................................................1
8
Installation
..........................................................................................................................................................19
you see
injury.
5005-3
Cre 7-27801-21LX Issued 11-01
SPECIFICATIONS
Idler wheel ......................................................................................................................................
See section 1002
Shock absorber spring
Pre-stressed during assembly..............................................................................................................
17.9 inches
Shock absorber spring yoke screw* ........................................................................197 to 230 lb-ft
(267 to 312 Nm)
Tension cylinder screw* ...........................................................................................197 to 230 lb-ft
(267 to 312 Nm)
Tension cylinder non-return
valve.......................................................................................................43 lb-ft (59 Nm)
* Apply Loctite 262 to the threads
SPECIAL TOOLS
B407320M
Use CAS 1450 and CAS 1682 to check for leaks as
below
5005-4
Cre 7-27801-21LX Issued 11-01
REMOVAL AND INSTALLATION OF THE IDLER WHEEL
AND THE TENSION SHOCK ABSORBER
Removal
STEP 1
See "Removing and installing a set of tracks", Section
5001.
STEP 2
JD00339A1
Start the engine. Move the machine until the track
chain is disengaged from the idler wheel. Shut down
the engine.
STEP 3
JD00340A
Attach the nylon sling from the lifting equipment to the
idler wheel.
STEP 4
JD00341A
Using a crowbar, move the idler wheel and the shock
absorber spring assembly out of the housing in the
undercarriage.
STEP 5
JD00342A
Move the idler wheel and the shock absorber spring
assembly out of the housing in the undercarriage,
using a crowbar, until the nylon sling can be attached
to the shock absorber spring assembly.
5005-5
Cre 7-27801-21LX Issued 11-01
STEP 6
JD01077A
Raise and remove the idler wheel and the shock
absorber spring assembly.
NOTE: The tension cylinder is linked to the shock
absorber spring.
STEP 7
JD01078A
Place the idler wheel and the shock absorber spring
on wooden blocks. Remove the lifting equipment from
the shock absorber spring assembly.
STEP 8
JD00345A
Connect the lifting equipment to the idler wheel.
Remove the four screws and hardened washers
which attach the idler wheel to the yoke. Remove the
idler wheel from the yoke.
5005-6
Cre 7-27801-21LX Issued 11-01
Installation
STEP 1
JD00362A
Attach a suitable lifting device to the idler wheel and
bring it into position on the yoke. Apply Loctite 262 to
the threads of the idler wheel retaining screws. Install
four hardened washers and screws to fasten the idler
wheel to the tension shock absorber yoke. Tighten
the screws to torque (see specifications).
STEP 2
JD01078A
Attach the lifting device Nylon sling to the assembly.
STEP 3
JD00342A
Raise the idler wheel and the tension shock absorber
and install them in the undercarriage housing. Push
the idler wheel and the tension shock absorber into
the undercarriage. Remove the lifting device from the
idler wheel and from the back of the tension shock
absorber.
STEP 4
JD00363A
Insert the lifting device Nylon sling into the central
orifice of the tension shock absorber yoke.
5005-7
Cre 7-27801-21LX Issued 11-01
STEP 5
JD00365A
Raise the assembly and slide it into the
undercarriage, with the help of a crowbar. Remove
the lifting equipment.
STEP 6
See "Removing and installing a set of tracks",
(section 5001), for installing the track.
5005-8
Cre 7-27801-21LX Issued 11-01
DISASSEMBLY AND ASSEMBLY OF THE IDLER WHEEL
Description
CS01B544
1 DRAIN PLUG
2 IDLER WHEEL
3 SNAP RING
4 HUB
5 O-RING
6 SHAFT
7 FACE SEAL
8 BUSHING
A................................................................................................................................................ 11.16
to 11.24 inches
B........................................................................................................................................................
7.86 to 8 inches
Reconditioning
If the idler wheel is worn to the indicated limits or if it shows traces of leaks, it must be reconditioned
or changed.
See section 1002 for limits of wear.
2
87564
3
1
AB
5005-9
Cre 7-27801-21LX Issued 11-01
Disassembly
STEP 1
JS00348A
Clean the idler wheel (2) with a suitable solvent.
Install the idler wheel (2) on stands, with the drain
plug (1) at the bottom. Remove the drain plug (1)
from the hub (4) and drain the oil.
STEP 2
JS00349A
Remove and scrap the snap ring (3) at one end.
Remove the hub (4) from the shaft (6).
STEP 3
JS00350A
Remove and scrap the O-ring (5) from the shaft (6).
Remove the shaft (6) with the hub (4) from the idler
wheel (2).
STEP 4
JS00351A
Remove and scrap the other snap ring (3). Remove
the hub (4) from the shaft (6), remove and scrap the
O-ring (5) from the shaft (6).
STEP 5
JS00352A
Remove and scrap the face seal (7) from the hub (4)
using a screwdriver or equivalent tool. Make sure you
do not damage the hub seal bore. Scrap the face
seal.
2
1
4
2
6
43
1
5
2
64
6
54
3
4
7
7
4
5005-10
Cre 7-27801-21LX Issued 11-01
STEP 6
JS00353A
Remove and scrap the face seal (7) from the idler
wheel (2) using a screwdriver or suitable tool. Make
sure you do not damage the idler wheel seal bore.
STEP 7
JS00354A
NOTE: Carry out this step only if the inspection in
step 3 reveals that the bushings (8) have to be
changed.
Using a hammer and a brass drift, drive the bushings
(8) out of the idler wheel (2). Make sure you do not
damage the idler wheel seal bore.
Inspection
STEP 1
Clean all the components with cleaning solvent. Also
clean the cavity in the idler wheel. Dry all the
components with compressed air at low pressure and
apply clean oil to all the components.
STEP 2
Inspect the bushing surfaces on the shaft for scoring,
pitting, and other damage. Measure the diameter of
the shaft at four opposing points. Compare the values
with the specifications. Change them if necessary.
STEP 3
Check for wear and damage to the bushings.
Measure the inner diameter and width of the bushing.
Compare the values with the specifications. Change
them if necessary.
STEP 4
Check for damage which could give rise to leaks at
the hub seal and idler wheel bores. Replace the
components with new components as required.
Measure the depth of the hub seal bores. Compare
the values with the specifications. Change them if
necessary.
7
2
7
7
2
7
82
8
5005-11
Cre 7-27801-21LX Issued 11-01
Assembly
STEP 1
JS00356A
A. Clean the inside
Carefully install the bushings (8) in the idler wheel
using a press and a suitable rod.
STEP 2
JS00357A
Install an O-ring and a face seal metal bushing in the
idler wheel bore (2). Apply clean oil to the face seal
lips. Repeat this step to install the face seal on the
other side of the idler wheel.
STEP 3
JS00352A
Install the remaining O-rings and face seal (7) metal
bushing in the hub seal bore (4). Apply clean oil
copiously to the face seals.
STEP 4
JS00358A
Lubricate the O-rings (5) with clean grease. Install an
O-ring on the shaft (6), then install the shaft in the
hub (4). Fasten the hub and seal with a new snap ring
(3).
82
8
A
8
2
7
27
7
7
2
4
7
7
4
6
5
4
3
5005-12
Cre 7-27801-21LX Issued 11-01
STEP 5
JS00359A
Apply clean grease around the shaft (6). Install the
shaft and hub (4) assembly in the idler wheel (2).
STEP 6
JS00360A
Apply clean grease on the O-ring (5) if this has not
already been done and install the O-ring on the shaft
(6). Install the hub (4) on the shaft and install a new
snap ring (3) to fasten the hub and shaft. Install a
drain plug (1).
NOTE: Check the pitch of the retaining ports of the
tension shock absorber yoke, see page 8.
STEP 7
Check for leaks to ensure that the idler wheel has
been correctly reassembled and check for any
damage which could give rise to leaks at seals and
other components.
STEP 8
JS00361A
Fill the idler wheel (2) with clean oil (see
specifications). Install the drain plug (1) in the hub (4).
2
64
2
54
3
1
6
2
4
1
5005-13
Cre 7-27801-21LX Issued 11-01
Leakage test
Use CAS 1450 and CAS 1682 for the leak checks
shown below.
B407320M
STEP 1
Connect the shut-off valve (1) to the pressure
regulator (2). Connect a union for the air supply hose
to the shut-off valve.
STEP 2
Install the adaptor and a quick coupler to the oil filler
orifice. Install a seal with the adaptor.
STEP 3
Turn the knob anti-clockwise to close the pressure
regulator (2).
STEP 4
Connect the pressure gauge pipe to the quick
coupler.
STEP 5
Make sure that the shut-off valve (1) is open.
STEP 6
Open the pressure regulator (2) until the pressure
gauge shows 27.5 psi (1.9 bar).
STEP 7
The shaft being checked should now be rotated four
times.
STEP 8
Close the regulator until the pressure gauge shows
14.5 psi (1 bar).
STEP 9
Close the shut-off valve. Maintain the air pressure of
step 8 for 10 seconds. A reduction in air pressure
during this period shows a defective component or
incorrect assembling.
1
2
5005-14
Cre 7-27801-21LX Issued 11-01
DISASSEMBLY AND ASSEMBLY OF THE TENSION SHOCK
ABSORBER
Description
CS01B546B
1 SHOCK ABSORBER SPRING
2 ROLL PIN
3 SLOTTED NUT
4 YOKE
5 SPRING GUIDE
6 PRE-STRESS VALUE (SEE SPECIFICATIONS)
1
4
3
2
6
5
5005-15
Cre 7-27801-21LX Issued 11-01
Disassembly
STEP 1
Clean the shock absorber spring assembly.
STEP 2
Place the shock absorber spring in a hydraulic press.
Use the press to compress the shock absorber spring
(1).
STEP 3
Drive out the roll pin (2) from the slotted nut (3).
Remove the slotted nut from the spring guide (5).
STEP 4
Operate the hydraulic press to release tension in the
shock absorber spring (1).
STEP 5
Remove the yoke (4) and the shock absorber spring
(1) from the spring guide (5).
Assembly
STEP 1
Fix the spring guide (5) in a hydraulic press.
STEP 2
Place the shock absorber spring (1) and the yoke (4)
in the hydraulic press on the spring guide (5).
STEP 3
Operate the hydraulic press to compress the shock
absorber spring (see specifications for the value).
STEP 4
Install the slotted nut (3) and install a new roll pin (2)
in the slotted nut and the spring guide shaft (5).
STEP 5
Remove the shock absorber spring from the
hydraulic press.
WARNING: The shock absorber spring is
! highly compressed.
5005-16
Cre 7-27801-21LX Issued 11-01
TRACK TENSION CYLINDER
Description
5002-108
1 SCREW
2 LOCKING WASHER
3 BRACKET
4 NON-RETURN CHECK VALVE ASSEMBLY
5 POPPET
6 SPRING
7 BALL
8 BODY
9 GREASE FITTING
10 SCREW
11 CYLINDER ROD
12 WIPER SEAL
13 THRUST RING
14 O-RING
15 CYLINDER BARREL
Removal
STEP 1
Carry out the procedure for the removal of the idler
wheel and the tension shock absorber.
STEP 2
Carry out the procedure for the removal of the
tension shock absorber.
1
2
10
3
9
5
6
7
48
15
14
13
12
11
5005-17
Cre 7-27801-21LX Issued 11-01
Disassembly
STEP 1
5002-104
Clean the track adjustment cylinder rod and the
tension cylinder barrel. Remove the screws (1) and
the locking washers (2) which fasten the bracket (3)
to the cylinder rod (11). Remove the bracket. Remove
the non-return check valve assembly (4) with the
grease fitting (9). Remove the non-return check valve
grease fitting. Disassemble the non-return check
valve assembly by removing the check valve (5), the
spring (6), the ball (7), and the body (8).
STEP 2
5002-105
Remove the cylinder rod (11) from the tension
cylinder barrel (15).
STEP 3
5002-106
Using a screwdriver or a suitable tool, carefully
remove the wiper seal (12) from the tension cylinder
(15). Discard the wiper seal.
STEP 4
5002-107
Remove and discard the thrust ring (13) and the Oring
(14) from the tension cylinder (15).
11
1
2
15
3
4
9
15 11
12
15
13
14
15
5005-18
Cre 7-27801-21LX Issued 11-01
Inspection
STEP 1
Clean all the components with cleaning solvent.
STEP 2
Check for deep grooves, scratches or other damage
inside the cylinder. If necessary, use a lamp to look
inside the cylinder. Use medium abrasive emery
paper to eliminate grooves or scratches. If the
grooves or scratches are too deep or if there is other
damage, change the cylinder.
STEP 3
Check for deep grooves, scratches or other signs of
wear or damage on the cylinder rod. Use medium
abrasive emery paper to eliminate grooves or
scratches. If the cylinder rod is worn or damaged,
replace the cylinder rod.
STEP 4
Check for wear or damage on the non-return check
valve assembly. Check for signs of irreparable
seizure of the spring. Change all defective
components.
Assembly
STEP 1
5002-107
Apply clean grease to a new O-ring (14). Install the
O-ring and the thrust ring (13) in the tension cylinder
barrel (15).
STEP 2
5002-106
5002-109
Apply clean grease to a new wiper seal (12). Using a
sleeve and a hammer, drive the wiper seal into the
tension cylinder with the seal lip orientated towards
the outside of the tension cylinder.
STEP 3
5002-105
Apply clean grease around the cylinder rod (11).
Install the cylinder rod in the tension cylinder barrel
(15).
13
14
15
12
15
15
11
5005-19
Cre 7-27801-21LX Issued 11-01
STEP 4
5002-104
Install the screws (10) in the tension cylinder (15).
Install the ball (7), the spring (6) and the check valve
(5) in the body (8). Install the grease fitting (9) in the
body (8). Install the non-return check valve (4) on the
tension cylinder barrel (15). Tighten the non-return
check valve to torque, see specifications. Assemble
the bracket (3) on the tension cylinder. Assemble and
tighten the screws (1) and washers (2) to torque.
Installation
STEP 1
Carry out the procedure for installing the tension
shock absorber.
STEP 2
Carry out the procedure for installing the idler wheel
and the tension shock absorber.
1
2
10
11
3
4
9
5005-20
Cre 7-27801-21LX Issued 11-01
NOTES
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
Link-Belt
Printed in U.S.A.
6001
DRIVE MOTOR AND FINAL DRIVE TRANSMISSION
Section
6001
6001-2
TABLE OF CONTENTS
SPECIFICATIONS
.................................................................................................................................................. 2
SPECIAL TORQUES
.............................................................................................................................................. 2
.......................................................................................... 3
..................................................................................................................................... 3
SPECIFICATIONS
Hydraulic oil ....................................................................................................................................
See Section 1002
Reduction gear lubricant
Type ........................................................................................................................................... See
Section 1002
Quantity ...................................................................................................................................... See
Section 1002
Weight of the drive motor and final drive transmission...................................................................
See Section 1002
SPECIAL TORQUES
Cap screws securing drive motor and final drive transmission to the machine ..............................
See Section 1002
(Loctite 262 must be applied to the threads of the cap screws)
Oil level, fill plug and oil drain plug ...................................................................................... 3.6 to 8
lb-ft (5 to 11 Nm)
(Teflon tape must be wrapped on threads)
6001-3
STEP 1
JS00163A1
STEP 2
hydraulic sump tank(see Section 8000).
STEP 3
CD00F069
Remove the oil fill plug and oil lever plug (1) and oil
drain plug (2) and drain the oil.
NOTE: When installing, refer to Section 1002 for the
correct type and quantity of oil to use. Tighten the
plugs to a torque of 3.6 to 8 lb-ft (5 to 11 Nm).
STEP 4
Wrap Teflon tape on the oil drain plug and install it.
Install the fill plug.
STEP 5
To prevent fluid loss when disconnecting hydraulic
lines, connect a vacuum pump to the hydraulic sump
tank(see Section 8000).
STEP 6
CD00F067
Remove the four cap screws and washers (1) holding
the access cover to the drive motor.
STEP 7
CD00F068
Install indentification tags on the hoses connected to
the drive motor to aid in installation.
STEP 8
Start the vacuum pump.
1
2
1
1
1
6001-4
STEP 9
CD00F068
Disconnect the hoses (1) from the drive motor. Install
a plug in each hose and a cap on each fitting.
STEP 10
Stop the vacuum pump.
STEP 11
Refer to Section 5004 and carry out the sprocket
removal procedure.
STEP 12
JD00836A
Connect suitable lifting equipment to the drive motor
and final drive transmission.
NOTE: For the combined weight of the drive motor
and final drive transmission, see Section 1002.
STEP 13
CD00F068
Remove the screws and washers (1) that hold the
final drive transmission (2) to the track frame (3).
NOTE: When installing, tighten the screws to the
torque specified in Section 1002.
STEP 14
JD00838A
Remove the drive motor and final drive transmission
from the machine.
1
1
2
3
6001-5
STEP 15
6002-11
Place the drive motor and final drive transmission on
a flat surface with the final drive transmission pointing
upwards. Remove the lifting equipment.
NOTE: For installation, follow the same procedure in
reverse order. Systematically replace all O-rings with
new ones. Fill the final drive casing via the leak off
orifice with hydraulic oil. Before using the machine,
check there are no leaks from the circuit. Check the
oil level in the hydraulic sump tank and the final drive
casing. Add oil if necessary.
6001-6
NOTES
...............................................................................................................................................................
.....................
...............................................................................................................................................................
.....................
...............................................................................................................................................................
.....................
...............................................................................................................................................................
.....................
...............................................................................................................................................................
.....................
...............................................................................................................................................................
.....................
...............................................................................................................................................................
.....................
...............................................................................................................................................................
.....................
...............................................................................................................................................................
.....................
...............................................................................................................................................................
.....................
...............................................................................................................................................................
.....................
...............................................................................................................................................................
.....................
...............................................................................................................................................................
.....................
...............................................................................................................................................................
.....................
...............................................................................................................................................................
.....................
...............................................................................................................................................................
.....................
...............................................................................................................................................................
.....................
...............................................................................................................................................................
.....................
...............................................................................................................................................................
.....................
...............................................................................................................................................................
.....................
...............................................................................................................................................................
.....................
...............................................................................................................................................................
.....................
...............................................................................................................................................................
.....................
...............................................................................................................................................................
.....................
...............................................................................................................................................................
.....................
...............................................................................................................................................................
.....................
...............................................................................................................................................................
.....................
...............................................................................................................................................................
.....................
...............................................................................................................................................................
.....................
...............................................................................................................................................................
.....................
...............................................................................................................................................................
.....................
...............................................................................................................................................................
.....................
...............................................................................................................................................................
.....................
...............................................................................................................................................................
.....................
...............................................................................................................................................................
.....................
...............................................................................................................................................................
.....................
...............................................................................................................................................................
.....................
Link-Belt
Printed in U.S.A.
6002
DISASSEMBLY AND ASSEMBLY OF
THE TRAVEL MOTOR/REDUCTION GEAR
ASSEMBLY
Section
6002
6002-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................
................... 2
SPECIAL TORQUE
SETTINGS............................................................................................................................... 2
INTERCHANGEABLE
PRODUCTS......................................................................................................................... 2
TRAVEL MOTOR/REDUCTION GEAR ASSEMBLY
............................................................................................... 3
Description
........................................................................................................................................................... 3
HYDRAULIC MOTOR
.............................................................................................................................................. 4
Disassembly..........................................................................................................................................
............... 4
Inspection..............................................................................................................................................
............... 8
Assembly...............................................................................................................................................
............... 8
SPECIFICATIONS
Hydraulic motor
Manufacturer
................................................................................................................................................
KAYABA
Type...................................................................................................................................................M
SF-170VP-E2
Displacement.........................................................................................................................................
95/162.2 cm3
Braking torque
.......................................................................................................................................... 25 100 Nm
Reduction gear
Manufacturer
................................................................................................................................................
KAYABA
Type.............................................................................................................................................
RGC-170VP-43E-1
Reduction ratio
.............................................................................................................................................. 1/43246
Type of oil ...................................................................................................... API GL5 grade 80W90
or ISO VG 150
Capacity..........................................................................................................................................See
Section 1002
Weight of motor and reduction gear assembly ...............................................................................See
Section 1002
Hydraulic motor
Screw 1/16 NPTF ...................................................................................................................7±0.7 lb-
ft (10 ± 1 Nm)
Cover screw.....................................................................................................................151 ± 7 lb-ft
(205 ± 10 Nm)
Non-return check valve spool plugs ................................................................................103 ± 7 lb-ft
(140 ± 10 Nm)
Spool plugs.......................................................................................................................... 87 ± 4 lb-ft
(118 ± 6 Nm)
Secondary relief valve ...................................................................................................275 ± 15 lb-ft
(373 ± 20 Nm)
Non-return check valve spool cap screw...........................................................................80 ± 7 lb-ft
(108 ± 10 Nm)
Calibrated orifice screw 0.078 in (Ø 2 mm) ..........................................................1.80 ± 0.36 lb-ft
(2.45 ± 0.49 Nm)
Calibrated orifice screw 0.031 in (Ø 0.8 mm) ........................................................1.80 ± 0.36 lb-ft
(2.45 ± 0.49 Nm)
Reduction gear
Cover retaining screws................................................................................................ 54 ± 2.5 lb-ft
(73.5 ± 3.5 Nm)
Planetary carrier short retaining screws .....................................................................398 ± 18.4 lb-ft
(540 ± 25 Nm)
Planetary carrier long retaining screws ......................................................................398 ± 18.4 lb-ft
(540 ± 25 Nm)
Planetary pinion retaining screws..................................................................................43.5 ± 36.6 lb-
ft (59 ± 5 Nm)
Drain, level and filler plugs ................................................................................................ 116 ± 6 lb-
ft (157 ± 8 Nm)
INTERCHANGEABLE PRODUCTS
Thread lock fluid
....................................................................................................................................... Loctite 262
Liquid sealing
compound.......................................................................................................................... Loctite 504
Reduction gear oil.......................................................................................... API GL5 grade 80W90
or ISO VG 150
Hydraulic oil
...............................................................................................................................................ISO VG
46
6002-3
TRAVEL MOTOR/REDUCTION GEAR ASSEMBLY
Description
CI00G510
1 CONTROL COVER
2 BALL BEARING
3 CYLINDER BLOCK FACE
4 STOP STUD
5 STOP STUD
6 SCREW
7 BRAKE PISTON
8 CYLINDER BLOCK
9 STEEL BRAKE DISC
10 SINTERED BRAKE DISC
11 PISTON
12 THRUST PLATE
13 PAD
14 BALL BEARING
15 CONTROL PISTON FOR 1ST AND 2ND SPEED
16 BALL BEARING
17 SCREW
18 PLANETARY CARRIER
19 PLANETARY
20 PLANETARY CARRIER
21 PLANETARY
22 REDUCTION GEAR HUB
23 SCREW
24 REDUCTION GEAR COVER
25 THRUST PLATE
26 1ST STAGE SUN GEAR
27 SHIM
28 THRUST PLATE
29 2ND STAGE SUN GEAR
30 SCREW
31 STOP STUD
32 SHIM
33 LIP SEAL
34 FACE SEAL
35 PIVOT BALLS
36 PISTON FACE
37 BODY
38 SPRING STOP
39 SPRING
40 SPRING STOP
41 BRAKE SPRING
42 SNAP RING
1234567
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
29 28 27 26 25 24 23
30
31
32
33
34
35
36
37
38
39
41
40 42
6002-4
HYDRAULIC MOTOR
Disassembly
STEP 1
CI00G510
Install the motor/reduction gear assembly on a tripod,
with the reduction gear downwards. Make identification
marks between the reduction gear cover and housing.
Disassemble the screws (1), remove the cover (2) and
discard the O-ring (3).
STEP 2
CI00G512
Disassemble the two valves (1). Remove the seals and the back-up rings (2) and discard them.
Disassemble the seat
and the check valve (3). Remove the body of the valve (4) and the piston (5). Remove the spring
guides (6) and the
spring (7). Remove the plugs (8) from the spool valve (9) and discard the seals (10). Extract the
spring guide (11), the
shim (12) and the spring (13). Remove the spool (9) and the spool (14). Remove the piston (15) and
discard the seals
and back-up rings (16).
21
3
20
21 22
19
18
17
23
24
23
26
27
28
29
31
32
33 34
31
30 25 29
28
27
26 24
23
22
17
18
19
21
20
1
2
7
26
5
4
23
34
33
32
10 8
15
16
14 9
31
30
13
12
11
8 10
1
6002-5
Remove the plug (17) and discard the seal (18),
remove the screw (19). Disassemble the screws (20),
remove the covers (21) and discard the seals (22).
Remove the spring guides (23) and the spring (24).
Extract the spool (25). Disassemble the plugs (26),
discard the O-ring (27), remove the spring (28) and
the check valve (29). Disassemble the screws (30)
and the calibrated orifice screws (31). Remove the
seals (32), the springs (33) and the valves (34).
STEP 3
CI00G513
Remove the springs (1) and the distribution plate (2).
Extract the brake piston (3) and discard the seals (4).
Remove the steel discs (5) and the friction discs (6).
Compress the spring (9) to free up the snap ring (7).
Disassemble the snap ring (7), the thrust stop (8), the
spring (9) and the shim (10).
STEP 4
CI00G514
Extract the cylinder block (1). Label and remove the
pistons (2) complete with guide plate (3) from the
cylinder block. Remove the spherical bushing (4) and
the thrust rods (5). Remove the piston face plate (6).
STEP 5
CI00G515
Extract the shaft (1) complete with bearing (2).
Remove the pistons (3) and the springs (4). Remove
the balls (5). Extract the bearing (2) from the shaft (1).
127893
4
5
6
10
154326
5
1
2
3
4
6002-6
STEP 6
CI00G516
Disassemble the three plugs (1) and discard the
seals. Disassemble the retaining screws (2).
Separate and remove the cover (3). Remove the shim
(4).
STEP 7
CI00G517
Disassemble the screws (1). Remove the retaining
plate (2). Remove the plates (3).
STEP 8
CI00G518
Remove the planetary pinions (1) with the needle
roller bearings (2). Remove the washer (3). Remove
the planetary carrier (4).
STEP 9
CI00G519
Remove the sun gear (1), 1st stage, the sun gear (2)
2nd stage. Disassemble the retaining screws (3) for
the planetaries (5). Remove the thrust plates (4), the
planetaries (5) and the washers (6).
2341
213
21
3
4
3123
4
5
6
6002-7
STEP 10
CI00G520
Disassemble the screws (1). Extract the planetary
carrier (2). Remove the centring studs (3) and retain
the shims (4).
STEP 11
CI00G521
Install the housing under a press and on blocks so as
to allow the body to be driven out (1). Drive out the
body (1). Remove the face seal (2), taking care not to
damage the steel contact faces.
STEP 12
CIG00522
The following operation needs to be performed only if
the bearings are changed: Remove the two bearings
(1), driving them out using a bronze drift (arrow).
STEP 13
CI00G523
Disassemble and discard the lip seal (1) (arrows).
32
1
4
1
2
1
1
6002-8
Inspection
STEP 1
Check for cracks, breakage and pitting on the
planetary and sun gears, planetary carriers, hub, body,
cylinder block, pistons and pads.
STEP 2
Check for heavy wear, cracks, pitting, deep scratches,
rough areas on the distribution plate, piston face plate,
thrust rings, pistons, piston housings in the cylinder
block and control spools.
STEP 3
Turn the bearings, check that they do not have any
hard spots or places where they are too loose. Check
for flattened areas, corrosion, bursting, scaling or
indented, grazed or corroded paths on the bearings
and the inner and outer bushings.
STEP 4
If one of these conditions is present, change the
component.
Assembly
STEP 1
CI00G524
Assemble the lip seals (1). Position the half face seal
(2) on the body (3).
STEP 2
CI00G525
Assemble the bearings (1) hard up against the hub.
Position the half face seal (2) on the hub. Coat the
steel faces of the face seals with oil.
2
13
2
2
1
6002-9
STEP 3
CI00G526
CI00G527
Assemble the body (1) in the hub (2). Apply a load of
3 tonnes on the inner bearing cage (arrows). Read
and note the dimension (A) on the planetary carrier
(3). Read and note dimension (B).
Calculation of shims (X) to be placed between the
bearing and the planetary carrier: A - B = X
NOTE: Shims are available as spare parts in the
following thicknesses 0.0019 in (0.05 mm), 0.0039 in
(0.1 mm), 0.011 in (0.3 mm), 0.019 in (0.5 mm) and
0.039 in (1.0 mm).
STEP 4
CI00G520
Position the shims (X). Assemble the centring studs
(1). Position the planetary carrier (2). Assemble and
tighten the screws (3) to torque.
STEP 5
CI00G528
Assemble the thrust washers (1), with the rounded
part towards the planetary carrier. Assemble the
planetaries (3) complete with needle roller bearings
(2). Assemble the thrust washers (4), with the
rounded part towards the screw head. Assemble and
tighten the screws (5) to torque.
2
1
A
3
B
12
3
X
54
3
2
1
6002-10
STEP 6
CI00G519
Position the 2nd stage sun gear (1) with its spring
ring. Position the 1st stage sun gear shaft (2).
STEP 7
CI00G517
Position the 1st stage planetary carriers (1).
Assemble the plate (2) with the rounded end towards
the planetary carriers. Assemble the planetaries (3)
complete with needle roller bearings (4). Assemble
the plates (5) with their rounded ends towards the
planetary. Position the retaining plates (6). Assemble
and tighten the screws (7) to torque.
STEP 8
CI00G529
Measure the dimension (A) between the hub (1) and
the retaining plate (2).
Calculate the shims to be installed between the cover
and the 1st stage sun gear.
Dimension in inch
2
1
76
5
4
3
2
1
Value A Place the shim
between 0.047
and 0.026
0.090
between 0.025
and 0.0015
0.110
between 0.0011
and -0.0062
0.118
between -0.0066
and -0.0161
0.125
between -0.0165
and 0.0314
0.141
2
1
A
6002-11
STEP 9
CI00G516
Position the shim(s) (1) calculated in step 8. Coat the
face of the cover seal (2) with Loctite 504. Position
the cover (2) on the hub (3) in accordance with the
marks made on disassembly. Assemble and tighten
the screws (4) to torque. Assemble and tighten the
plugs (5) to torque. Turn the reduction gear the other
way up.
STEP 10
CI00G515
Oil the parts before assembling them. Assemble the
pistons (1) complete with springs (2). Assemble the
ball bearing (3) on the shaft (4) using a press.
Assemble the shaft (4) complete with bearing (3) in the
body (5) using a plastic mallet. Grease and position
the balls (6).
STEP 11
CI00G530
Position the spring stop (1) with the chamfer
orientated towards the barrel (2). Assemble the
spring (3), the shim (4) and the spring ring (5) using a
press. Oil and assemble the push-rods (6) in the
cylinder block (2). Assemble the spherical bushing (7)
on the cylinder block (2). Oil and assemble the
pistons (8) on the thrust plate (9). Assemble all the
pistons (8) and the plate (9) in the cylinder block
(identification marks made before disassembly).
STEP 12
CI00G511
Oil and assemble the piston face plate (1) on the balls
(2). Tilt the reduction gear (3). Hold the pistons (4) in
the barrel (5) and position the whole assembly on the
reduction gear (3) taking care not to drop the piston
face plate (1) or the balls (2).
4215
3
5
6431
2
8
9
7
6
2
1
3
4
5
5
4
3
1
2
6002-12
STEP 13
CI00G513
Assemble the brake discs, alternating one steel disc (1)
and one friction disc (2) and so on. Oil and assemble
new seals (3) on the brake piston (4). Assemble the
brake piston (4). Position the brake springs (5).
STEP 14
CI00G512
Oil and assemble the new seals and back-up rings (2). Assemble the seat and the check valve (3)
on the valve body
(4). Assemble the piston (5) on the valve body (4). Position the spring guides (6) and the spring (7).
Assemble the
valve body (4) in the plug (8). Assemble the adjusting screw (9) and its lock-nut (10). Assemble the
valves (1) and
tighten to torque. Assemble the seals and back-up ring (11) on the piston (12), oil and place the
whole assembly in
the spool (13).
543
2
1
33
32 31
34
35
36
29
30
29
27
26
25
24
37
41
40 39
37
38 28 24
25
26
27 30
29
31
36
35
34
32
33
8
2
7
26
5
4
23
39
40
41
18
12
11
14 13
37
38
19
20
21
22 23
1
16
17
10 9
15
6002-13
Assemble the spool (14) in the spool (13), assemble
the spool assembly (13) in the cover (15). Assemble
the seal (16) on the piston (12). Assemble the seal
(17) on the plug (18). Assemble the plug and tighten
to torque (18). Position the spring (19), the shim (20)
and the spring guide (21). Fit the seal (23) on the
plug (22), assemble the plug (22) and tighten to
torque. Assemble the check valves (24) and the
springs (25) in the spool (28). Fit seals (26) on the
plugs (27). Assemble and tighten the plugs (27) to
torque. Position the spring guides (29) and the
springs (30). Fit the plugs (32) on the cover (15) and
tighten the screws (33) to torque. Assemble the bleed
screw (34) and the seal (35) and tighten the plug (36)
to torque. Assemble the calibrated orifice screws
(37), tighten the plugs (38) au couple. Assemble the
valves (39), the springs (40) and the seals (41).
STEP 15
CI00G531
Assemble the four centring studs (1). Assemble the
distribution plate (3) positioning stud (2). Assemble
the ball bearing (4) in the control cover (5). Grease
the face of the distribution plate (3) which is in contact
with the cover (5).
STEP 16
CI00G510
Assemble one O-ring (1) on the reduction gear (2).
Assemble the cover (3) on the reduction gear (2) as
per the identification marks made during
disassembly. Make sure you align the stud (4) with
the face (5), the studs (6) in the brake piston (7), and
the bearing (8) on the reduction gear primary shaft.
Assemble and tighten the screws (9) to torque.
12345
9
38546
7
1
2
6002-14
Link-Belt
Printed in U.S.A.
6003
OF THE SWING REDUCTION GEAR
Section
6003
6003-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................
................... 2
SPECIAL TORQUE
SETTINGS............................................................................................................................... 2
TOOLS REQUIRED
................................................................................................................................................. 2
SWING REDUCTION
GEAR.................................................................................................................................... 3
Removal
...............................................................................................................................................................
3
Installation
............................................................................................................................................................ 4
SPECIFICATIONS
Swing motor and swing reduction gear
Weight ........................................................................................................................................ See
Section 1002
Swing reduction gear
Capacity ..................................................................................................................................... See
Section 1002
Type of oil................................................................................................................................... See
Section 1002
Retaining screws for upper panel and central frame ......................................................70 to 80 lb-ft
(88 to 107 Nm)
(apply Loctite 262 to the threads)
Screws which attach swing motor to swing reduction gear ............................................. 87 lb-ft
(117.7 Nm)
Screws which attach swing reduction gear to the upperstructure frame ........................................
See Section 1002
TOOLS REQUIRED
Hand pump K1P0017.
+15
-0
+20
-0
6003-3
SWING REDUCTION GEAR
Removal
STEP 1
Carry out steps 1 to 11 of "Removing the swing
motor" (see Section 8008).
STEP 2
Mark the position of the swing reduction gear on the
upperstructure frame by making alignment marks on
the swing reduction gear and the upperstructure
frame.
STEP 3
6003-110
Remove the eleven swing reduction gear retaining
screws (1) and the centring pin.
STEP 4
6003-084
Using a suitable lifting device, carefully raise the
swing motor/reduction gear assembly from the
upperstructure and move it away from the machine.
STEP 5
6003-014
Place a receptacle of 2 gal (7.5 litres) capacity under
the swing reduction gear drain plug (1). Remove the
drain plug (1) and drain the oil. Install the drain plug.
STEP 6
Lower the swing motor/reduction gear assembly to
the ground and place it on suitable stands.
NOTE: The stands must be high enough to prevent
the pinion touching the ground.
STEP 7
6003-018
To facilitate assembly, make an alignment mark on
the swing motor and the reduction gear. Remove the
sixteen swing motor retaining screws (1).
STEP 8
Carefully raise the swing motor and move it away
from the swing reduction gear. Place it in a clean
area.
1
1
1
6003-4
Installation
STEP 1
JD00446A
Connect a suitable lifting device to the swing motor
and move it into position above the reduction gear.
Carefully lower the swing motor onto the reduction
gear.
STEP 2
6003-018
Assemble the sixteen swing motor retaining screws
(1).
NOTE: Tighten the screws to a torque of 87 Nm
(117.7 Nm).
STEP 3
Clean the upperstructure mating surface.
STEP 4
6003-084
Raise the swing motor/reduction gear assembly off
the ground. Apply No. 2 EP lithium grease over the
pinion (A).
NOTE: Before installing the swing motor/reduction
gear assembly, check that the drain hose (B) is
installed on the side of the reduction gear housing.
STEP 5
6003-085
Raise the swing motor/reduction gear assembly and
bring it into position above the upperstructure mating
surface, ensuring that it is in line with the alignment
marks previously made.
1
+15
-0
+20
-0
B
A
6003-5
STEP 6
6003-109
Connect the hand pump K1P0017 to the swing motor
brake release orifice (A).
STEP 7
Check that the hand pump is filled with fluid.
STEP 8
Operate the hand pump until the pressure gauge
shows 281 psi (19.4 bar). The swing motor brake
should be released, thus allowing the reduction gear
output shaft to turn.
STEP 9
Lower the swing motor/reduction gear assembly onto
the upperstructure mating surface, using a centring
stud.
NOTE: Make sure that the reduction gear pinion is
correctly engaged with the upperstructure ring gear.
STEP 10
6003-110
Apply Loctite 262 to the screw threads and tighten
them to the torque specified in Section 1002.
STEP 11
6003-109
Release the hydraulic pressure in the hand pump
K1P0017 and disconnect it from the swing motor
brake release orifice (A). Remove the lifting
equipment from the swing motor.
A
A
A
6003-6
STEP 12
CD00E093
CD00E118
Check that the swing reduction gear oil drain plug (1)
is correctly tightened. Remove the oil level dipstick (2)
and the oil filler plug (3). Fill the swing reduction gear
with the quantity (capacity) and type of oil specified in
Section 1002. Install the oil dipstick and check the oil
level. The oil level should be on the lower part of the
dipstick. Add oil as required and install and tighten
the oil filler plug.
STEP 13
CD00E101
1 AIR BLEED PLUG
2 LUBRICATION ORIFICE
Remove the air bleed plug on the side of the swing
reduction gear. Pump No. 2 EP lithium grease into
the reduction gear until grease comes out of the air
bleed orifice. Install the air bleed plug.
STEP 14
Connect a vacuum pump to the hydraulic sump tank
(see Section 8000). Start the vacuum pump.
STEP 15
CD00F094
Remove the hose plugs and the union caps and
connect the hydraulic hoses to the swing motor, using
new O-rings.
2
3
1
1
2
6003-7
STEP 16
CP99A021
Remove the plug on the top of the swing motor. Fill
the swing motor with hydraulic fluid via the plug
orifice until the fluid starts to spill over. Then install
the plug.
STEP 17
Stop and disconnect the vacuum pump from the
STEP 18
CD00F091
Connect the ground cable (-) (A) to the battery.
STEP 19
See Section 8001 and adjust the swing motor safety
valves.
STEP 20
CD00F093
Install the central frame (1).
NOTE: Tighten the screws to a torque of between 70
and 80 lb-ft (88 and 107 Nm) (apply Loctite 262 to the
threads).
STEP 21
CD00F092
Install the upper access panel (1).
NOTE: Tighten the screws to a torque of between 70
and 80 lb-ft (88 and 107 Nm) (apply Loctite 262 to the
threads).
NOTE: Before operating the machine, start the
engine, check the system for leaks and check the
level of hydraulic fluid in the tank, top up if necessary.
A
6003-8
Link-Belt
Printed in U.S.A;
6004
Section
6004
6004-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................
................... 3
SPECIAL TORQUE
SETTINGS............................................................................................................................... 3
SWING REDUCTION
GEAR.................................................................................................................................... 4
Description
.......................................................................................................................................................... 4
Disassembly
........................................................................................................................................................ 5
Assembly
.............................................................................................................................................................
8
you see
6004-3
SPECIFICATIONS
See Section 1002
Motor retaining screw on the reduction gear ................................................................. 86 lb-ft (117.7
Nm) +15
-0
+20
-0
6004-4
Description
CI00K508
1 PINION SHAFT
2 STOP
3 SNAP RING
4 RETAINING PLATE
5 SPHERICAL ROLLER BEARING
6 HOUSING
7 LIP-SEAL
8 SPHERICAL ROLLER BEARING
9 DOWEL PIN
10 RING GEAR
11 SECOND STAGE SUN GEAR
12 FIRST STAGE SUN GEAR
13 PLANETARY GEAR
14 FIRST STAGE PLANET WHEEL CARRIER
15 PLANETARY GEAR
16 ROLL PIN
17 SECOND STAGE PLANET WHEEL CARRIER
18 SNAP RING
19 SPACER
1
2
3
4
5
6
7
8
9
10
11
12 13
14
15
16
17
18
19
6004-5
Disassembly
NOTE: The swing reduction gear is extremely heavy.
Use suitable lifting equipment to lift and move the
components.
STEP 1
Place the reduction gear in a clean working area.
STEP 2
JD00450A
Remove the first stage sun gear (1) and the thrust
ring (2).
STEP 3
JD00451A
Remove the first stage planet wheel carrier (1). If first
stage planetary gears are worn or have broken or
missing teeth replace the complete assembly.
STEP 4
JD00452A
Remove the second stage sun gear.
STEP 5
JD00453A
Remove the second stage planet wheel carrier (1).
NOTE: The planetary gear axles are assembled in
two ways: A = assembly by hubbing the axle; B =
assembly by blocking the axle (roll pin). Replace the
whole planet wheel carrier or the spare parts
separately.
2
1
1
1
6004-6
STEP 6
Place the planetary gear assembly on a suitable
workbench.
STEP 7
6003-103
Push the roll pins into the shafts so that the shafts
can be removed.
STEP 8
6003-104
Support the planetary gears and remove the planet
wheel carrier shafts. Remove the roll pins completely
from the shafts and discard them.
STEP 9
6003-105
Remove the planetary gears.
STEP 10
6003-106
Remove the thrust washers from under the planetary
gears.
STEP 11
JD00454A
To aid in assembly, put alignment marks on the ring
gear (1) and the gear housing (2). Remove the ring
gear from the gear housing by tapping lightly with a
plastic mallet.
1
2
6004-7
STEP 12
JD00455A
Remove the four dowel pins (1) from the ring gear (2).
STEP 13
JD00456A
(A) Gap
(B) Notch
Take the retaining ring out of its groove using the
notch in the housing for leverage. Remove the
retaining ring (1).
STEP 14
JD00457A
Use a puller or a press to remove the equipped shaft.
STEP 15
JD00458A
Remove the roller bearing (1) from the gear housing.
STEP 16
JD00459A
Using a suitable tool remove the lip seal (1) from the
gear housing. Discard the lip seal.
STEP 17
JD00460A
Remove the retaining ring (1) and the spacer (2).
1
2
1
A
B
1
1
2
1
6004-8
STEP 18
JD00461A
Press the bearing (1) from the shaft.
STEP 19
JD00462A
Remove the thrust plate (1) and the retaining plate (2)
from the shaft.
Assembly
STEP 1
JD00462A
Install the stop (1), the retaining plate (2) on the
pinion shaft.
STEP 2
JD00463A
Secure the pinion gear shaft in a press. Heat the
bearing (1) to 122°F (50°C) above the ambient
temperature before pushing it in the press on the
shaft.
NOTE: Do not heat the bearing to a temperature
greater than 212°F (100°C). Assemble the spacer (2)
and the snap ring (3).
1
2
1
WARNING: Take precautions (gloves), risk of
burns.
2
1
!
3
2
1
6004-9
STEP 3
JD00464A
Fill the roller bearings with 21 oz (600 cc) of No. 2 EP
lithium grease.
NOTE: The total grease capacity is 34 oz (1000 cc).
The remainder is added after assembly.
STEP 4
JD00465A
Remove the grease from the reduction gear housing
and apply Loctite 504. Fix the reduction gear housing
in a press, install the lip seal (1) in the reduction gear
housing. Lubricate the lip seal with No. 2 EP lithium
grease.
STEP 5
JD00466A
Install a M16 eyebolt into the pinion gear (1) and
reposition the housing under a press. Align the shaft
to keep it straight and plumb. Press the pinion gear
assembly into the reduction gear housing.
STEP 6
JD00467A
Install the retaining ring (1) with the gap
approximately 1.181 inch (30 mm) away from the
notch in the reduction gear housing.
1
1
1
6004-10
STEP 7
JD00468A
Oil and assemble the bearing (1) in the housing (2)
using a plastic mallet.
STEP 8
JD00469A
Degrease the mating surfaces of the gear housing,
ring gear, and the four dowel pins. Install the four
dowel pins (1) into the gear housing. Apply
Loctite 504 liquid packing to the mating surfaces.
STEP 9
JD00470A
Install the ring gear (1) ensuring the alignment marks
are aligned. Assemble four screws (2) in opposition to
hold the ring gear (1).
STEP 10
Place the first stage planet wheel carrier on a clean
workbench.
STEP 11
6003-106
Install the planetary gears and the thrust washers in
the planet wheel carrier, washers under the pinions
(boom).
STEP 12
6003-105
Align the ports of the pinions with the ports of the
planet wheel carrier and install the shafts.
1
2
1
1
1
2
6004-11
STEP 13
6003-107
With a suitable tool, install a new roll pin (A).
B = 0.039 inch (1 mm) , recess dimension
Brake using two awl strokes (booms).
STEP 14
JD00453A
Install the second stage planet wheel carrier so that it
meshes correctly with the internal teeth of the ring
gear. Turn the planetary assembly slightly to engage
the splines of the pinion shaft.
STEP 15
JD00452A
Install the second stage sun gear so that it meshes
with the planetary gears.
STEP 16
JD00451A
Install the first stage planet wheel carrier so that it
meshes with the internal teeth of the ring gear. Turn
the planetary assembly slightly to mesh the teeth of
the planetary gears with the teeth of the second
stage sun gear.
A
B
6004-12
STEP 17
JD00450A
Install the first stage sun gear (1) and the thrust ring
(2). Mesh the teeth of the sun gear with those of the
planetary gears. Turn the first stage planet wheel
carriers by hand to check that the output shaft rotates
smoothly.
STEP 18
CI00K509
Measure the dimension A
A = 0.098 inch (2.5 mm).
Adjust or change the shim (1) if necessary.
1
2
A
1
+0.066
-0.019
+1.7
-0.5
Link-Belt
Printed in U.S.A.
8000
DEPRESSURISING AND DECONTAMINATING THE
HYDRAULIC SYSTEM, USE OF THE VACUUM
PUMP
AND BLEEDING THE COMPONENTS
Section
8000
8000-2
Cre 7-27951-21LX Issued 11-01
TABLE OF CONTENTS
SPECIAL TOOLS
..................................................................................................................................................... 3
RELEASING PRESSURE IN THE HYDRAULIC
SYSTEM...................................................................................... 4
BLEEDING AIR FROM THE MAIN HYDRAULIC SYSTEM COMPONENTS
.......................................................... 5
Hydraulic pump
.................................................................................................................................................... 5
Attachment
cylinders............................................................................................................................................ 5
Hydraulic swing motor
.......................................................................................................................................... 5
VACUUM
PUMP....................................................................................................................................................
... 6
Installation
............................................................................................................................................................ 6
Removal
...............................................................................................................................................................
6
CLEANING THE HYDRAULIC SYSTEM
................................................................................................................. 7
General
...............................................................................................................................................................
.7
Types of contamination
........................................................................................................................................ 7
Decontamination of the hydraulic system
............................................................................................................ 8
8000-3
Cre 7-27951-21LX Issued 11-01
SPECIAL TOOLS
806127
CAS 10162A - Portable filter
CS99B532
CAS 30038 - Set of hydraulic flow and pressure test
unions
806128
CAS 10508 - Kit for unions
M1325
CAS 10193 - Kit for vacuum pump
8000-4
Cre 7-27951-21LX Issued 11-01
RELEASING PRESSURE IN THE HYDRAULIC SYSTEM
IMPORTANT: Before carrying out any operation on
the hydraulic system, pressure in all the hydraulic
circuits must first be at zero.
STEP 1
Place the machine on flat, level ground, with the
attachment lowered to the ground, then shut down
the engine.
STEP 2
CD00E060
Place the starter switch key in the "ON" position.
STEP 3
CD00E006
Lower the function cancellation control arm (exit
safety bar).
STEP 4
CD00E111
Operate the control levers ten times to right and left
and backwards and forwards.
STEP 5
CD00E080
Place the starter switch key in the "OFF" position.
STEP 6
CD00E112
Press the button located above the breather to
release any remaining pressure.
8000-5
Cre 7-27951-21LX Issued 11-01
BLEEDING AIR FROM THE MAIN HYDRAULIC SYSTEM
COMPONENTS
IMPORTANT: After having bled the air from the
components, shut down the engine for five minutes
and then check that no air bubbles appear in the
hydraulic fluid reservoir.
Hydraulic pump
CD00E134
Using a solvent, clean the upper surface of the pump
and the air bleed plug. Remove the air bleed plug.
Fill the pump with hydraulic fluid via that orifice. Install
and tighten the air bleed plug.
Start the engine and run it at idle speed. Loosen the
pump air bleed plug. Retighten the plug when fluid
flows out of the orifice with no air bubbles. Carefully
clean around the plug.
Attachment cylinders
Start the engine and run it at idle. Extend and retract
all the cylinder rods four or five times without bringing
them against the stops, then do the same again three
or four times, but this time bringing the cylinder rods
against the stops.
Hydraulic swing motor
CD00F056
Start the engine and run it at idle. Loosen the air
bleed plug and make sure that hydraulic fluid flows
out of that orifice. If necessary, shut down the engine
and top up via that orifice. Install the plug, without
tightening it, then start the engine and run it at idle.
Let it run until hydraulic fluid flows out of the orifice.
Completely retighten the air bleed plug. Perform at
least two complete swings of the upperstructure, both
to right and to left.
8000-6
Cre 7-27951-21LX Issued 11-01
VACUUM PUMP
Installation
STEP 1
Release pressure in the hydraulic system, see page 4.
STEP 2
CD00E112
Remove the plate (A) on top of the hydraulic sump
tank.
NOTE: Do not remove the O-ring from the reservoir.
STEP 3
JD00019A
Install the adaptor plate (B) from the kit CAS 30028
on the hydraulic sump tank.
STEP 4
JD00020A
Connect the vacuum pump CAS 10193 to the elbow
union of the adaptor plate. Connect the vacuum
pump harness to the batteries.
Removal
STEP 1
Disconnect the vacuum pump harness from the
batteries.
STEP 2
Disconnect the vacuum pump from the elbow union
of the adaptor plate (B).
STEP 3
Remove the adaptor plate (B) from the hydraulic
sump tank and scrap the O-ring.
STEP 4
Install a new O-ring on the hydraulic sump tank and
install the plate (A).
A
B
8000-7
Cre 7-27951-21LX Issued 11-01
CLEANING THE HYDRAULIC SYSTEM
General
Contamination of the hydraulic system is a major
cause of incorrect operation of hydraulic components.
Contamination manifests itself by the presence of
foreign bodies in the hydraulic fluid. Contamination of
the hydraulic system can occur in any of the following
situations:
1. When draining fluid 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 still operate even when
slightly contaminated. Components of the hydraulic
system are designed to withstand a slight degree of
contamination. Any increase in the degree of
contamination causes serious problems in the
hydraulic system.
Here is a non-exhaustive list of these problems:
1. Cylinder rod seals leak.
2. Control valve spools do not return to the neutral
position.
3. Control valve spools are hard to move.
4. Hydraulic fluid is too hot.
5. Hydraulic components wear quickly.
6. Safety valves or non-return check valves do not
close, due to contamination.
7. Repaired components soon fail again.
8. Cycles are slow; the machine does not have enough
power.
If one of the above situations occurs, it shows
excessive contamination of the hydraulic system. To
eliminate this contamination effectively, use the
portable filter CAS 10162A.
Types of contamination
Contamination exists basically in two forms:
microscopic or visible.
1. We speak of microscopic contamination when
very small particles of foreign bodies are in
suspension in the hydraulic fluid. These particles
are too small to be seen or felt. Microscopic
contamination can be identified by the problems
connected with microscopic contamination or by
tests in the laboratory. Here are a few examples of
the problems caused by microscopic
contamination:
A. Cylinder rod seals leak.
B. Control valve spools do not return to the neutral
position.
C. The hydraulic system working temperature is
high.
D. Components wear quickly.
2. We speak of visible contamination when the
presence of foreign bodies can be detected visually
or by touch or smell. Visible contamination can
cause a sudden failure of a component. Here are a
few examples of problems caused by visible
contamination:
A. The fluid contains metal or other debris.
B. The fluid contains air.
C. The fluid is dark and thick.
D. The fluid smells burnt.
E. The fluid contains water.
8000-8
Cre 7-27951-21LX Issued 11-01
Decontamination of the hydraulic
system
STEP 1
Prepare the portable filter CAS 10162A as follows:
1. Eliminate all hydraulic fluid from the inlet and
outlet hoses of the portable filter.
2. Remove the element from the portable filter.
3. Eliminate all the hydraulic fluid from the portable
filter.
4. Clean the inside of the element housing.
5. Install a new filter element.
STEP 2
Release the pressure in the hydraulic system, see
page 4.
STEP 3
Drain the hydraulic fluid from the reservoir and clean
the reservoir. See the Operator’s Manual.
NOTE: Do not install the access panel under the
hydraulic sump tank.
STEP 4
Change the breather element, the return filter and
clean the inlet filter.
NOTE: Do not install the plate complete with
breather.
STEP 5
Change the pilot circuit filter. See the Operator’s
Manual.
STEP 6
Change the Ultra Clean filter. See the Operator’s
Manual.
STEP 7
CD00E178
Remove the bleed lever valve (1) under the hydraulic
sump tank. Do not remove the adaptor (2).
STEP 8
Install the shut-off valve from the union kit CAS 10508
on the adaptor (2).
NOTE: Make sure that the shut-off valve is closed.
STEP 9
Fill the hydraulic sump tank with clean hydraulic fluid.
See the Operator’s Manual.
STEP 10
Install the inlet hose from the portable filter on the
shut-off valve under the hydraulic sump tank.
STEP 11
Install the long pipe from the union kit CAS 10508 on
the portable filter return hose.
STEP 12
Insert the long pipe in the hydraulic sump tank. Move
the inlet filter long pipe as far away as possible.
STEP 13
Open the shut-off valve under the hydraulic sump
tank.
1
2
8000-9
Cre 7-27951-21LX Issued 11-01
STEP 14
Install the portable filter on the upperstructure in such
a manner that the machine can be operated. Attach
the portable filter firmly to the machine.
STEP 15
Connect the electric cable from the portable filter to
the batteries. Make sure that the electric cable is
away from any moving components.
STEP 16
Start the portable filter running.
STEP 17
Start the engine, run it at half maximum speed for ten
minutes. During those ten minutes, stir the hydraulic
fluid in the hydraulic sump tank with the long pipe.
STEP 18
Set engine speed to maximum and bring the
hydraulic fluid up to its operating temperature by the
following procedure:
1. Operate the bucket and dipper controls in one
direction (against the cylinder stops) for
30 seconds.
2. Operate the bucket and dipper controls in the other
direction (against the cylinder stops) for 30 seconds.
3. Repeat steps 1 and 2 until the hydraulic fluid
temperature reaches 113 to 131°F (45 to 55°C)
(third bar on the hydraulic fluid temperature gauge
on the illuminated instrument panel control screen).
STEP 19
With the engine at full speed; operate each cylinder
(retract, extend) two times, one after another, for
45 minutes.
STEP 20
With the engine at full speed; operate the swing
control several times 180° to the left and then to the
right.
STEP 21
With the engine at full speed; position the attachment
at right angles to the undercarriage. Use the
attachment to raise the track off the ground. Operate
the travel pedal, in one direction for two minutes and
then in the other direction for two minutes. Repeat
this cycle for ten minutes.
STEP 22
Repeat Step 21 for the other track.
STEP 23
Reduce the engine speed to idle.
STEP 24
Stir the hydraulic fluid in the hydraulic sump tank for
10 minutes with the long pipe.
STEP 25
Stop the portable filter and the engine.
STEP 26
Close the shut-off valve under the hydraulic sump
tank.
STEP 27
Remove the inlet pipe from the shut-off valve under
the hydraulic sump tank.
STEP 28
Remove the long pipe from the hydraulic sump tank.
STEP 29
Disconnect the portable filter electric cable from the
batteries and remove the portable filter from the
machine.
STEP 30
Install a vacuum pump on the hydraulic sump tank.
See page 6.
STEP 31
8000-10
Cre 7-27951-21LX Issued 11-01
STEP 32
CD00E178
Remove the shut-off valve from the adaptor (2) and
install the bleed lever valve (1).
NOTE: Make sure that the bleed lever valve is closed.
STEP 33
Stop the vacuum pump and remove it from the
hydraulic sump tank. See page 6.
STEP 34
Install the access panel under the hydraulic sump
tank.
STEP 35
Change the return filter and clean the inlet filter. See
the Operator’s Manual.
STEP 36
Change the pilot system filter. See the Operator’s
Manual.
STEP 37
Change the Ultra-Clean filter. See the Operator’s
Manual.
STEP 38
Check the level of the hydraulic fluid. Top up as
necessary. See the Operator’s Manual.
1
2
Link-Belt
Printed in U.S.A.
8001
SPECIFICATIONS, TROUBLESHOOTING, CHECKS
AND HYDRAULIC PRESSURE SETTINGS
Section
8001
8001-2
Cre 7-28270-21LX Issued 11-01
TABLE OF CONTENTS
SPECIAL TOOLS
......................................................................................................................................................4
Tester
...............................................................................................................................................................
.....4
IDENTIFICATION OF HYDRAULIC COMPONENTS
...............................................................................................5
Pump.....................................................................................................................................................
............... 5
Main Control
Valve............................................................................................................................................... 6
6 Solenoid Valve
Manifold.................................................................................................................................... 7
Control pattern modification
................................................................................................................................. 7
PREPARATION BEFORE
INSPECTION..................................................................................................................8
Releasing Pressure In the Hydraulic
System....................................................................................................... 8
Installing the Pilot Pressure Test Point
.................................................................................................................9
Installing the Flowmeter
........................................................................................................................................9
Display on CHK1 Diagnostic
Screen...................................................................................................................10
Warming up the
Engine.......................................................................................................................................10
Warming up the Hydraulic Fluid
..........................................................................................................................10
CHECKING AND PRESSURE SETTING
PROCEDURE........................................................................................11
Pilot System Secondary Relief Valve (H)
............................................................................................................12
Checking the Pilot Accumulator
..........................................................................................................................12
Main Relief Valve (A)
..........................................................................................................................................13
Attachment Secondary Relief Valves (B, C, D, E, F and G)
...............................................................................14
Hammer relief valve (O)
.....................................................................................................................................16
Secondary relief valve of the boom safety valves (B1 and B2)
..........................................................................16
Secondary relief valves of the dipper safety valves (D1)
...................................................................................17
Swing Secondary Relief Valves
..........................................................................................................................18
Travel Secondary Relief
Valve............................................................................................................................19
Checking the Pressure Delivered by the Proportional Valve
..............................................................................20
Travel mistracking test
........................................................................................................................................20
Checking for Leaks on the Travel Motor
.............................................................................................................21
Checking the Swing Motor for Leaks
..................................................................................................................21
8001-3
Cre 7-28270-21LX Issued 11-01
TROUBLESHOOTING
............................................................................................................................................23
Travel
Drift........................................................................................................................................................
.. 23
Not Possible to Select 2nd Travel
Speed........................................................................................................... 24
No Swing or Slow Swing
.................................................................................................................................... 25
With the Excavator on a Slope, the Swing Brake Does Not Hold
...................................................................... 25
No Movement on Any
Function.......................................................................................................................... 26
Lack of Power or Speed on One of the Attachment Movements
....................................................................... 26
Not Possible to Select Cushion Attachment
System.......................................................................................... 27
The Boom or the Arm Does Not Lower
.............................................................................................................. 27
8001-4
Cre 7-28270-21LX Issued 11-01
SPECIAL TOOLS
Tester
B877558M
1. K1P0005 PRESSURE FITTING KIT
B785789R
2. K1P0006 FLOW METER
CS99B532
3. SET OF UNIONS FOR PRESSURE TEST AND
HYDRAULIC FLOW K1P0003.
CD99C002
4. SET OF HIGH PRESSURE HYDRAULIC
HOSES K1P0011 (INCLUDING TWO HIGH
PRESSURE HOSES).
8001-5
Cre 7-28270-21LX Issued 11-01
IDENTIFICATION OF HYDRAULIC COMPONENTS
Pump
CS00E547
A2 A1
a2 a1
A3
B3
Pi2
B1
a4
Pi1
Dr
PSv
Port Description Port size
A1-A2 Pump output (P1-P2) SAE 6000 3/4 "
B1 Main pump intake SAE 2500 2-1/2 "
Dr Filling and bleeding orifice G 3/4
PSv Accumulator pressure information G 1/4
Pi1 - Pi2 Pump pressure G 1/4
a1 - a2 P1 - P2 pressure detector G 1/4
a3 - a4 Plugged (proportional pressure valve) G 1/4
A3 Pilot pump output G 1/2
B3 Pilot pump intake G 3/4
8001-6
Cre 7-28270-21LX Issued 11-01
Main Control Valve
CS00E549CS00E548
T5
PS2
P3
P2
T2
Dr
PC2
PC3 PC1
PT
PH
P1 PP
T4
B1
B8
B7
B6
A8
A7
A6
PS1 A5
B5
B3
P4
A1 PA
A3
A2
T1 Pbu T3
B2
Port Description Port Description
B7 Bucket opening P3
P4 Option circuit
A7 Bucket closing T1 T2 Return
B8 Boom lowering Ps1
Ps2 Check negative signal
A8 Boom raising
A6 LH forward travel PT Travel pressure switch
B6 LH reverse travel PH
Relief valve forcing control (higher pressure - 2-
stage relief)
A5 Arm extending PA Attachment and swing pressure switch
B5 Arm retracting Dr Leak-off return
B3 RH swing Pc1 Arm load holding
A3 LH swing Pc2 Boom load holding
A2 Option circuit T4 By-pass return
B2 Option circuit T5 To attachment cushion (pre-heating)
A1 LH forward travel T3 Swing return
B1 LH reverse travel Pc3 Priority to swing
P1
P2 Pump pressure Pbu Cancel priority to swing
PP Pilot pressure
8001-7
Cre 7-28270-21LX Issued 11-01
6 Solenoid Valve Manifold
CD00E143
Control pattern modification

The modification consists of reversing the boom controls (raise/lower) on the right-hand control
lever with the arm
controls (extend/retract on the left-hand control arm).
CD01A002
Remove the mounting screws (see arrows) and move
the plate (1) to gain access to the hoses.
CD01A003
Invert the V2 hose with the A2 hose and the V1 hose
with the A1 hose. Put the plate back in place and
tighten the mounting screws.
Port Description
B Supply to pilot manifold
T Return to reservoir
C1 Select 2nd travel speed
C2 Swing brake control
C3 Higher pressure - 2-stage relief
C4 Cancel pilot system attachment cushion
C5 Cancel swing piloting
P Pilot pressure cancellation control
C5
C4 C2
C3 C1
T
B
P
1
A1
V1
A2
V2
8001-8
Cre 7-28270-21LX Issued 11-01
PREPARATION BEFORE INSPECTION
Releasing Pressure In the Hydraulic System
To be carried out before conducting any service work
on the hydraulic circuit.
1. Position the machine on hard, flat ground.
2. Open the bucket until the cylinder rod is
completely retracted.
3. Extend the arm until the cylinder rod is
completely retracted. Lower the boom so that the
end of the arm is resting on the ground. Lower
the tool to the ground.
4. Check in "S" mode on the diagnostic screen that
the following values are respected.
5. Lower the engine speed to idle for 30 seconds,
then shut down the engine.
6. Turn the starter key switch to "ON", without
starting the engine.
7. Lower the pilot control cancellation lever.
8. Operate each control 10 times in both directions
to release pressure in the circuits.
CS00E544
9. Press the button located on the hydraulic sump
tank breather to release pressure in the
reservoir.
WARNING: Hydraulic fluid output under pressure can penetrate the skin. Hydraulic fluid can also
cause or
infect a slight skin cut. In the event of being injured by hydraulic fluid under pressure, consult a
doctor
immediately. Any delay in obtaining treatment for an injury can cause a serious infection or reaction.
Before
pressurizing the circuits, make sure that all the outlets are correctly tightened and that the hoses
and pipes are
in good condition. Release pressure in the circuits completely before disconnecting pipes or
carrying out any
operation on the hydraulic system. Always use a small piece of cardboard or wood to detect leaks
of fluid under
pressure. Never use your hands.
!
WARNING: Any incorrect use or maintenance
of a construction machine can cause
accidents. Only persons who have read,
understood and who observe the instructions
in the operator’s manual are authorized to use
or maintain this machine.
!
WARNING: The accumulator of this machine
is charged with nitrogen under pressure. In the
event of incorrect operation of the circuit,
change the accumulator. Never try to repair it.
Non-observance of these instructions and the
procedure shown below can cause serious or
fatal injury.
!
CHK MODE II S ENG 1950 rpm
1
P1 4350 psi I 0450 mA
P2 4350 psi WT 0176 °F
No. 435 psi OT 0131 °F
Engine speed
1800
± 10 rpm
Amperage 292 mA
8001-9
Cre 7-28270-21LX Issued 11-01
Installing the Pilot Pressure Test
Point
CD00E191
Install a pressure test point (P3) on the pilot circuit
using the T-union and quick coupling supplied in kit
K1P0003.
Installing the Flowmeter
(Checking hydraulic pump flows)
CD00F004
1. Remove the hose (1) to the pump outlet to be
checked.
2. Install the flange (2) (supplied in the kit
K1P0003) on the hose (1).
3. Connect the elbow union (3) (supplied in the kit
K1P0003) on the pump outlet to be checked.
4. Install the hoses (4) (K1P0011) on the elbow
union (3) and on the flange (2).
5. Connect the hoses to the flow meter.
P3
4
1
3
4
2
8001-10
Cre 7-28270-21LX Issued 11-01
Display on CHK1 Diagnostic
Screen
To access this screen: Select work mode H or S
using the control (2).
CM00K003
Press simultaneously on the travel speed control (1)
and on the work mode selector control (2) as shown
above until the CHK1 diagnostic screen appears
(3 seconds).
P1 P1 pump pressure in psi
P2 P2 pump pressure in psi
N: Negative pressure of the pump in MPa. The
pressure transducer at this test point is
located on the pump port Pi1 on the hose. It is
used to check the pump negative pressure.
ENG: Engine speed in rpm.
I: Amperage in mA (Proportional valve).
WT: Engine water temperature in °F.
OT: Hydraulic oil temperature in °F.
Warming up the Engine
1. Start the engine. The engine will have warmed
up in 10-15 minutes.
2. Run the engine until the message "Automatic
pre-heating" disappears from the display
monitor.
Warming up the Hydraulic Fluid
1. Actuate the bucket and arm controls in one
30 seconds.
2. Actuate the bucket and arm controls in the other
30 seconds.
3. Repeat Steps 1 and 2 until the hydraulic fluid
temperature reached 113-131°F.
4. Actuate the boom, swing and travel controls in
both directions to warm up all the circuits to 113-
131°F.
CHK MODE II H ENG 2000 rpm
1
P1 4350 psi I 0300 mA
P2 4350 psi WT 0176 °F
No. 435 psi OT 0131 °F
Inspection orifice a1
Pressure checked
Arm
RH travel
Swing
Inspection orifice a2
Pressure checked
Boom
Bucket
LH travel
12
8001-11
Cre 7-28270-21LX Issued 11-01
CHECKING AND PRESSURE SETTING PROCEDURE
Location of secondary relief valves
CS00E552 CS00M501
JI
CS00E549
C
F
D
G
H
CS00E548
B
E
A
L
K
CS00E545
8001-12
Cre 7-28270-21LX Issued 11-01
Pilot System Secondary Relief
Valve (H)
Test
1. Connect a 0-1500 psi pressure gauge to
pressure test point P3. (See page 9)
2. With the engine at full speed, select "S" mode.
3. Move the pilot cancellation lever to its low
position.
4. With the swing and travel attachment controls in
neutral, read the value on the pressure gauge:
The value should be 565 ± 15 psi.
Adjustment
1. Loosen the lock nut and turn the valve adjusting
screw (H) until 565 ± 15 psi is reached.
2. Tighten the lock nut while holding the adjusting
screw in position.
3. When the adjusting screw has been tightened,
check the pressure again and make sure there
are no leaks.
Checking the Pilot Accumulator
1. Raise the boom completely and extend the arm.
2. Shut down the engine, with the starter key switch
on "ON".
3. Operate the boom lowering or arm retracting
control several times consecutively.
4. The pressure in the accumulator should enable
the boom lowering or arm retracting function to
be performed about six times.
Item Description
Approximately pressure
with 1/4 turn of the screw
(or with one shim*)
A
Main relief valve (standard
pressure)
775
Main relief valve (higher pressure
- 2-stage relief)
1030
B
Boom raising secondary relief
valve
770 psi
C
Boom lowering secondary relief
valve
770 psi
D
Arm extending secondary relief
valve
770 psi
E
Arm retracting secondary relief
valve
770 psi
F
Bucket opening secondary relief
valve
770 psi
G
Bucket closing secondary relief
valve
770 psi
H Pilot circuit secondary relief valve 73 psi
I RH swing secondary relief valve 70 psi *
J LH swing secondary relief valve 70 psi *
K
Reverse travel secondary relief
valve
215 psi *
L
Forward travel secondary relief
valve
215 psi *
8001-13
Cre 7-28270-21LX Issued 11-01
Main Relief Valve (A)
Testing
1. Display the CHK1 screen.
3. Operate and hold in position the arm retracting
control (against the cylinder stops).
4. Read the pressure on the diagnostic screen:
When the arm cylinder is against the stops, the
pressure is the standard value for 2 seconds,
then at the higher pressure - 2-stage relief value
for 8 seconds before falling back to standard
pressure.
NOTE: To read the higher pressure - 2-stage relief
level again, the control lever should be released, then
operated against up the cylinder stops.
Adjusting the higher pressure -
2-stage relief
CS00E550
1. Disconnect the higher pressure pilot line from the
main relief valve and plug the line.
2. Use a wrench to prevent the adjusting screw (3)
from moving and loosen the lock nut (4).
3. Fully tighten the adjusting screw (3).
4. Tighten the lock nut (4).
5. Start the engine, run it at full speed and select
“S” mode.
6. Operate the arm retracting control, bringing the
arm cylinder up to the stop and holding it in this
position.
7. Loosen the lock nut (2) and turn the adjusting
screw (1) until the higher pressure is obtained.
NOTE: Tighten the screw (1) to increase pressure.
Loosen the screw (1) to reduce pressure.
from turning and tighten the lock nut (2).
9. Check the pressure once again. If the required
pressure has not been obtained, repeat Steps 6
to 9.
10. Carry out the standard pressure setting
procedure (See Steps 2 to 9).
Pump
Standard
pressure
Higher
pressure level
P1 4975±45 psi 5415±70 psi
12
34
8001-14
Cre 7-28270-21LX Issued 11-01
Adjusting the standard pressure
NOTE: The procedure described hereunder is only
valid if the higher pressure is correct. If this is not the
case, start by adjusting the higher pressure.
CS00E550
from moving and loosen the lock nut (4).
“S” mode.
position.
5. Turn the adjusting screw (3) until the standard
pressure is obtained.
7. Check the pressure once again. If the required
to 6.
8. Stop the engine.
9. Reconnect the higher pressure pilot line to the
main relief valve.
Attachment Secondary Relief
Valves (B, C, D, E, F and G)
NOTE: Attachment secondary relief valve pressure
settings are higher than the main relief valve
pressure setting. Before checking or setting the
attachment secondary relief valve pressure, it is
therefore necessary to overset the main relief valve.
Pressure setting and checking
CS00E550
from turning and loosen the lock nut (2).
3. Tighten the adjusting screw 180°.
“S” mode.
7. Operate the control for the attachment function
being tested up to the (cylinder) stop and hold it
in this position.
34
12
8001-15
Cre 7-28270-21LX Issued 11-01
8. Read the pressure on the test screen. The
pressure should read:
9. Carry out Steps 10 to 14 only if one of the
attachment secondary relief valves needs its
pressure setting.
CI00E508
for the relief valve concerned from turning and
loosen the lock nut (3).
11. Operate the control for the attachment function to
be adjusted up to the (cylinder) stop and hold it in
this position.
12. Turn the adjusting screw (4) of the relief valve
concerned until the correct pressure is obtained.
14. Check the pressure once more. If the required
to 14.
15. Use a wrench to prevent the main relief valve
adjusting screw (1) from turning and loosen the
lock nut (2).
position.
17. Turn the adjusting screw (1) until the correct
standard pressure adjustment for the main relief
valve is obtained.
19. Check that the main relief valve standard
pressure setting is correct. If this is not the case,
repeat Steps 15 to 18.
20. Stop the engine.
21. Reconnect the higher pressure pilot line to the
main relief valve.
Function
Boom
raising
P2 5685 ± 70 psi
Boom
lowering
P2 5685 ± 70 psi
Arm
retracting
P1 5685 ± 70 psi
Arm
extending
P1 5685 ± 70 psi
Bucket
opening
P2 5685 ± 70 psi
Bucket
closing
P2 5685 ± 70 psi
34
8001-16
Cre 7-28270-21LX Issued 11-01
Hammer relief valve (O)
Checking and setting
CD01G101
1. If the machine is equipped with an optional
hammer/crusher:
Select the hammer position on the switch located
on the LH console.
The corresponding position of the selector block
(1) must be strictly observed when using the
hydraulic hammer, see the Operator’s Manual.
2. Make sure that the hammer filter and the
hydraulic fluid are clean.
3. The flow and pressure must be set to the levels
shown in the manufacturer’s specifications for
the hammer installed.
4. The flow can be set by adjusting the engine
speed (pre-set electronics), see section 4001.
Formula for calculating engine speed:
5. Close the shut-off valves at the end of the dipper.
6. With the engine at full speed.
7. Display "CHK1" on the diagnostic screen.
8. Operate and maintain the hammer control.
9. Read the pressure on the diagnostic screen.
10. If the desired value is not obtained, turn the
adjusting screw of the hammer relief valve (O)
until the correct pressure is obtained.
Secondary relief valve of the boom
safety valves (B1 and B2)
Checking and setting right-hand side
CD01B008
Disconnect the balancing hose (1). Assemble on the
hose a male coupling joint equipped with its union
(2). Plug the elbow union (3).Connect to the hose (1)
a female coupling joint equipped with a pressure
detector (4). Connect a 0-8000 psi pressure gauge
(5) to the pressure detector (4).
CD01B007
Disconnect and plug the pilot hose (6) corresponding
to the valve to be adjusted located behind the boom
foot. Put the hose (6) in a receptacle in order to
retrieve possible leaks. Plug the elbow union (7).
Start the engine. Set the rotational velocity to 1000
rpm using the potentiometer on the instrument panel.
Move the boom to half-height. Operate the boom
lowering control and raise pressure settings of the
valve (B+). Repeat the operation several times
raising the pressure each time.
Max engine speed (rpm)
x hammer flow (gpm)
Max flow of one pump body (gpm)
1
O
98
5
4
2
1
3
6
7
8001-17
Cre 7-28270-21LX Issued 11-01
If the value is not correct, loosen the lock nut (8) and
turn the screw (9) in order to adjust the pressure
while turning the boom lowering control. Tighten to
increase, loosen to decrease the pressure. Tighten
again the lock nut (8). Shut down the engine. To
decompress the large chamber cylinder, first
reconnect the pilot hose (6). Start the engine in order
to fill the accumulator. Shut down the engine.
Decompress the hydraulic system. Remove the union
plug (3). Disconnect the mail coupling joint and the
union (2). Reconnect the balancing hose (1).
Checking and setting the right-hand side
Carry out the same operations as those on the righthand
side. The difference between the two valves
should be less than 5 bar.
Secondary relief valves of the
dipper safety valves (D1)
Checking and setting
CD01B017
Disconnect and plug the pilot hose (1). Put a
receptacle under the union (2) to collect possible
leaks. Remove the plug (3) and install a pressure
detector union (4) (location 21G). Connect a 0-8000
psi pressure gauge to the pressure detector (4). Start
the engine. Set the rotational velocity to 1000 rpm
using the potentionmeter on the instrument panel.
Lower the boom to half-height. Operate the dipper
retracting control and raise the pressure settings of
the valve. Repeat the operation several times while
raingin the pressure each time.
CD01B016
If the value is not correct, loosen the lock nut (5) and
turn the setting screw (6) in order to adjust the
pressure. Tighten to increase, loosen to reduce the
pressure. While turning the dipper retracting control,
tighten the lock nut again (5). Shut down the engine.
To decompress the small chamber dipper cylinder,
first reconnect the pilot hose (1). Start the engine in
order to fill the accumulator. Shut down the engine.
Decompress the hydraulic system. Disconnect the
pressure detector union (4). Fit the plug again (3).
Pressure settings
5555 to 5630 psi
Pressure settings
5555 to 5630 psi
3
4
1
2
56
8001-18
Cre 7-28270-21LX Issued 11-01
Swing Secondary Relief Valves
(I, J)
Test
CD00E143
1. Disconnect the swing cancellation solenoid valve
connector (green).
2. Display the CHK1 diagnostic screen.
3. Start the engine and select "S" mode.
4. Make sure the free swing function is not
operational.
5. Operate the swing brake control on the
instrument panel (indicator lamp ON).
6. Slowly operate the swing lever to the right, then
gradually increase engine speed to full speed to
ensure that the swing is locked.
7. Repeat Step 6 for the LH swing, the pressures
should be:
Note down the pressures if they are not correct to find
the number of shims needed for adjustment. One
0.1 mm shim corresponds to 70 psi of pressure.
Adjustment
CS99B596
(I) RH swing secondary relief valve
(J) LH swing secondary relief valve
1. Remove the secondary relief valve concerned
from the swing motor. If both secondary relief
valves have to be removed, mark them ready for
reassembly.
CS99B598
2. Tighten the body of the valve in a vise and
remove the plug (1), guide (2), liner (3), spacer
(4), shims (5), spring (6) and the check valve (7).
3. Remove (to reduce pressure) or add (to increase
pressure) the number of shims (5) required to
reach the correct pressure.
4. Reassemble the parts (1 to 7) of the valve and
tighten the plug (1) to 116 lb-ft.
5. Reassemble the valve on the swing motor and
the tighten to 57.5 lb-ft.
6. Check the pressure of the valves again and
make sure there are no leaks.
Function
RH swing P1 4047 ± 60 psi
LH swing P1 4047 ± 60 psi
I
J
1237
456
8001-19
Cre 7-28270-21LX Issued 11-01
Travel Secondary Relief Valve
Tools required
CS99B579
- One locking pin to above dimensions
Checking and adjustment
1. Overset the main relief valve (See Steps 1 to 4
on page 14 in the chapter "Attachment
secondary relief valves").
2. Start the engine.
CS99B580
3. Lock the travel side to be checked mechanically
by carefully placing the locking pin (A) between
the drive sprocket and the undercarriage, as
shown above.
4. Run the engine at full speed and select “S”
mode.
6. Operate the corresponding travel control and
hold it in operating position (drive sprocket in
locked position).
7. Read the pressure on the test screen. The
pressure should read:
8. Go to Step 9 if the pressure of one of the
secondary relief valves needs setting. Otherwise,
reset the main relief valve pressure (see Steps
15 to 21 on page 15).
Pressure setting
6002-03
J. Reverse travel secondary relief valve
K. Forward travel secondary relief valve
of the secondary relief valve concerned from
turning and loosen the lock nut (4).
10. Operate the corresponding travel control and
hold it in operating position. (Drive sprocket in
locked position).
11. Turn the adjusting screw (3) of the secondary
relief valve concerned until the correct pressure
is obtained.
13. Check the pressure once more. If the required
to 13.
14. Reset the main relief valve (see Steps 15 to 21
on page 15).
A
Pressure
5120 ± 70 psi
J
K
3
4
8001-20
Cre 7-28270-21LX Issued 11-01
Checking the Pressure Delivered
by the Proportional Valve
CS00E552 CS00E554
1. Connect a pressure test point and a 0-1500 psi
pressure gauge to port a4 on the pump.
3. With the engine at full speed, select "H" mode.
Travel mistracking test
Make sure that track tension is correctly adjusted.
This test should be carried out with the hydraulic oil at
122°F on flat ground and over a distance of
approximately 100 ft.
Run the engine at full speed in “H” mode, press down
the travel pedals as far as they will go and hold them
in this position.
Drive the machine forwards for a distance of 82 ft.
Read the mistracking over the last 66 ft.
If the reading is more than 40 in.
1. Check the pilot pressure for the two travel spools
(it should be above 435 psi).
2. Check the leak-off losses from the travel motors.
a4
Pressure
255 to 300
psi
Amperage 407 mA
Pressure
355 to
420
Amperage 292 mA
8001-21
Cre 7-28270-21LX Issued 11-01
Checking for Leaks on the Travel
Motor
Tools required
CS99B579
1 locking pin of above dimensions
1 oil container
1 hydraulic hose
1 plug
Checking for leaks
(With the hydraulic oil between 113 and 131°F)
1. Press the breather to release pressure in the
2. Remove the travel motor protective shield.
CS00E546
3. Disconnect the drain hose from the hydraulic
motor and plug it.
4. Use a hose to connect the drain port to the
receptacle.
CS99B580
A: Locking pin
B: Forward
5. Lock the travel on the side to be checked by
carefully placing the locking pin (A) between the
drive sprocket and the undercarriage, as shown
above.
7. Operate the travel control of the hydraulic motor
to be checked and measure the quantity of oil
which leaves the drain during 1 min.
8. Repeat Steps 1 to 7 to check the other motor.
9. Compare the quantities of oil collected; if the
difference between the two motors is greater
than 0.26 gpm, repair or change the one which
has output of the greatest quantity of oil.
Checking the Swing Motor for
Leaks
Tools required
1 oil container 2.6 gal
1 hydraulic hose
1 plug
AB
8001-22
Cre 7-28270-21LX Issued 11-01
Checking for leaks
(With the hydraulic oil between 113 and 131°F)
CD00E143
1. Disconnect the swing solenoid valve connector
(green).
3. Start the engine and select the "S" mode.
4. Make sure the free swing function is not
operational.
5. Switch on the swing brake control on the
instrument panel (indicator lamp ON).
6. Slowly operate the swing control lever and
gradually increase the engine speed to full speed
to ensure that the swing is locked.
7. Shut down the engine.
8. Press the breather to release pressure in the
CD00E192
9. Disconnect the hydraulic motor drain hose and
plug it.
10. Use a hose to connect the drain port to the
receptacle.
11. Start and run the engine at full speed in "S"
mode. Operate the swing control to right or left
and measure the quantity of oil which flows out of
the drain hole during 1 min.
12. Since the quantity of oil can vary depending on
the test point used, repeat the measurement
(Step 10) with the upperstructure at 90°, then at
180°.
8001-23
Cre 7-28270-21LX Issued 11-01
TROUBLESHOOTING
Travel Drift
(Pressures P1 and P2 correct)
No. Tests Results Repairs
1 With the tracks lifted, check the
rotating speed at the drive sprockets
Difference in speed between the two
drive sprockets
Check travel motor leaks (No. 4)
2
Check pressures P1 and P2 during
travel
The pressure difference between P1
and P2 is greater than 435 psi
Check the negative pressure (N) of
the pump (No. 3)
3
Check the negative pressure (N) of
the pump
Pressure greater than 87 psi
Check the main relief valve:
Adjust or change
Check the pump regulator or body
which is at fault:
Adjust or change
Pressure below 87 psi
Check the travel spool pilot pressure
on the side which is at fault
Check the operation of the control
pedal spool, replace or repair
Check the travel spool (sticking,
scratched ...)
4 Check the travel motors for leaks
Above the authorized value Replace or repair the travel motor
Below the authorized value
Check the travel pressure without
load (with track raised)
Normal pressure:
Change the central seal
Higher than normal pressure:
Drain the reduction gear and check to
see if there is any contamination
(metal particles).
Replace or repair the travel reduction
gear
8001-24
Cre 7-28270-21LX Issued 11-01
Not Possible to Select 2nd Travel Speed
1
Press the travel speed control and
check that the speed changes from I
to II on the console screen
Speed II is not displayed
Refer to troubleshooting electrical
failures
2
Check on diagnostic screen CHK2 if
the information changes to "ON"
when the machine is traveling
Information stays on "OFF"
Check pressures P1 and P2 on
diagnostic screen CHK1 when the
machine is traveling
1) both pressures are less than
580 psi: refer to troubleshooting
electrical failures
2) both pressures are higher than
580 psi, refer to point No. 3
3 Check the pump negative pressure
(N)
Too high Adjust the pressure
4
Check the pilot pressure at the output
from solenoid valve (C1)
Pressure too low
Check the electrical supply and the
solenoid valve coil (No. 5 and 6)
Pressure correct (565 psi)
Check the pilot pressure at the travel
motor displacement change spool
(No. 7)
5
Check the voltage at the electrical
plug on the displacement change
solenoid valve
Voltage < 24 V Check the electrical harness
6
Check the displacement change
solenoid valve coil
Infinite or 0 Ohm Change the solenoid valve
About 40 Ohm Change the solenoid valve coil
7
Check the pilot pressure at the travel
motor displacement change spool
Pressure too low
Internal leak at hydraulic swivel,
repair or change the hydraulic swivel
Check the travel motor displacement
change spool.
Repair or change the travel motor
8001-25
Cre 7-28270-21LX Issued 11-01
No Swing or Slow Swing
(No problems with other functions)
With the Excavator on a Slope, the Swing Brake Does Not Hold
1 Check the swing pressure Pressure too low
Adjust or change the secondary relief
valves
2
Disconnect the swing brake solenoid
valve (pink connector) and operate
the swing
No swing or slow swing
Reconnect the solenoid valve and
check the swing brake release
pressure at the output from the
solenoid valve (No. 3)
The swing operates normally
Check the solenoid valve supply
electrical circuit
3
With the engine running and the
swing brake deactivated, check the
swing brake release pressure
Check or change the swing brake
solenoid valve
Check the swing motor for leaks
(No. 5)
4
Disconnect the swing cancellation
solenoid valve (green connector) and
operate the swing
No swing or slow swing
Check or change the swing
cancellation solenoid valve
The swing operates normally
Check the solenoid valve supply
electrical circuit
5
With the engine at full speed, and
hydraulic oil at 122°F, check for leaks
at the swing motor during the swing
Above the authorized value Change or repair the swing motor
Below the authorized value
Check the swing brake, repair or
change
1 Check the swing braking system Abrasion
Incident on the brake, repair or
change
2 Check the swing pressure Pressure too low
Adjust or change the secondary relief
valves
3
With the engine at full speed, and
hydraulic oil at 122°F, check for leaks
on the swing motor during the swing
Above the authorized value Change or repair the swing motor
4
Check the swing brake pilot pressure
at the solenoid valve output
Check electrical supply and the
solenoid valve coil (No. 5 and 6)
5
plug on the swing brake pilot solenoid
valve
6 Check the pilot solenoid valve coil
8001-26
Cre 7-28270-21LX Issued 11-01
No Movement on Any Function
(Control cancellation lever in the low position)
Lack of Power or Speed on One of the Attachment Movements
(No problems with the other movements)
1 Check the hydraulic oil level Lack of hydraulic oil Top up as required
2 Check the pilot pressure at P3 Pressure below 435 psi
Adjust the pilot circuit secondary relief
valve, change it if necessary
3
Check the pilot pressure at outlet
port B on the 6 solenoid valve block
Check electrical supply and the
solenoid valve coil (Nos. 4 and 5)
4
Check the voltage at the pilot solenoid
valve connector (blue)
Voltage < 24 V
Check the electrical supply and
mechanical adjustment of the controls
cancellation contact switch.
Check the harness between the
contact switch and the solenoid valve
5 Check the pilot solenoid valve coil
1 Check the P1 or P2 pressure Pressure too low
Incident on the secondary relief valve
of the faulty movement, adjust or
change
2
With the engine at full speed (in "H"
mode), and the hydraulic oil at 122°F,
check the speed of the movement
concerned
Below:
- Boom raising: 3.4 seconds
- Dipper retracting: 3.6 seconds
- Dipper extending: 2.6 seconds
- Bucket opening: 1.9 seconds
- Bucket closing: 2.4 seconds
Leak at the check valve, adjust or
change
3
With a load on the end of the
attachment and 39.5 in above the
ground, check the retracting and
extending of the cylinder rods
Rod retracting or extending over
10 mn greater than:
- Boom: 1.20 in
- Dipper: 2.40 in
- Bucket: 0.80 in
Leak at attachment cylinders, change
the piston seals or change the
cylinder
4
Manually check the movement of the
pilot spool in the control valve for
faulty movement
Difficult to move
Spool stuck or scratched, spring
broken
5
Check the pilot pressure of the control
valve spool
lever spool, change or repair
8001-27
Cre 7-28270-21LX Issued 11-01
Not Possible to Select Cushion Attachment System
The Boom or the Arm Does Not Lower
(No problems with other movements)
1
Check on diagnostic screen "CHK3" if
information displayed changes to
"ON" when cushion attachment is
selected/deselected
Information stays on "OFF"
Check the signal at the electronic box
input:
Below 5 volts: change the control box
5 volts: change the electronic box
2
Check the pilot pressure at the
cushion attachment solenoid valve
(C4)
Pressure too low
Check the electrical supply and the
solenoid valve coil (Nos. 3 and 4)
Repair or change the cushion
attachment valve
3
plug on the cushion attachment
solenoid valve
4
Check the cushion attachment
solenoid valve coil
1
Manually check the movement of the
pilot spool
Difficult to move Spool stuck or spring broken
2 Check the load holding operation Sticking
Repair or change the load holding
valve
3
Check the pilot pressure at the control
valve spool
lever spool, change or repair
Link-Belt
Printed in U.S.A.
8002
OF THE HYDRAULIC SUMP TANK
Section
8002
8002-2
TABLE OF CONTENTS
SPECIFICATIONS
.................................................................................................................................................. 2
HYDRAULIC SUMP TANK
..................................................................................................................................... 3
Removal
..............................................................................................................................................................
3
Installation
........................................................................................................................................................... 4
Description
.......................................................................................................................................................... 5
SPECIFICATIONS
See Section 1002
8002-3
HYDRAULIC SUMP TANK
Removal
STEP 1
JS00163A1
STEP 2
STEP 3
Attach a "DO NOT OPERATE" tag to the ignition key
in the cab.
STEP 4
NOTE: The numbers within brackets refer to the
figures on pages 5 and 6.
Remove the screws and the access panels under the
hydraulic sump tank (1).
STEP 5
Using a container of sufficient capacity, empty the
hydraulic sump tank (1) using the valve (2) and
remove the latter.
STEP 6
Remove the screws (4) on top and then inside the
front boot, then remove the protective housing (3).
STEP 7
on top of the hydraulic sump tank (1).
STEP 8
on top of the control valve.
STEP 9
Loosen the two screws (9) located under the
machine. Open the side door on the right of the
machine and remove the two screws (10). Remove
the screw (10) located on the right of the fuel tank.
Remove the protective plate of the hydraulic sump
tank (11).
STEP 10
Loosen the circlips (12) and disconnect the suction
hoses (13) under the hydraulic sump tank.
STEP 11
Attach identification tags to the output hoses.
Disconnect the hoses.
STEP 12
Remove the screws (14) and the retaining shims
(15).
STEP 13
Using a hoist, remove the hydraulic sump tank (1)
from the machine.
8002-4
Installation
STEP 1
NOTE: The numbers within brackets refer to the
figures on pages 5 and 6.
Using a hoist, position the hydraulic sump tank (1) on
the machine.
STEP 2
Install the screws (14) and the retaining shims (15) to
hold the hydraulic sump tank (1) to the machine
undercarriage, tighten the screws to a torque, see the
specifications. Install the oil change valve (2).
STEP 3
Connect the suction hose (13) using two circlips (12).
Tighten the nut.
STEP 4
Connect the output hoses taking help of the tags
installed during removal.
STEP 5
Install the hydraulic sump tank protective plate (11)
using screws (9) and (10).
STEP 6
Install the protective plate (6) under the hydraulic
sump tank using retaining screws (5).
STEP 7
Install the protective plate (8) under the main control
valve using screws (7).
STEP 8
Install the protective housing (3) using screws (4),
then install the screw mask inside the front boot.
STEP 9
Fill the hydraulic sump tank, see the section "Filling
the hydraulic sump tank" in the operator’s manual
and check for leaks.
STEP 10
Start the engine. Pressurize the hydraulic sump tank
then stop the engine. Check again for leaks.
STEP 11
Install the protective plate under the machine using
screws and flat washers.
8002-5
Description
Location
CS00F539
CS00F540
3 PROTECTIVE HOUSING
4 SCREW
5 SCREW
6 HYDRAULIC SUMP TANK PROTECTIVE PLATE
7 SCREW
8 CONTROL VALVE PROTECTIVE PLATE
9 SCREW
10 SCREW
11 HYDRAULIC SUMP TANK PROTECTIVE PLATE
3
10
10
11 9
4
8
4
3
7
4
5
65
8002-6
Hydraulic sump tank
CI00F507
1 HYDRAULIC SUMP TANK
2 VALVE
12 BAND CLAMP
13 HOSE
14 SCREW
15 SHIM
1
13
12
2
15
14
Link-Belt
Printed in U.S.A.
8003
REMOVAL AND INSTALLATION OF THE MAIN
HYDRAULIC PUMP AND THE PILOT PUMP
Section
8003
8003-2
TABLE OF CONTENTS
SPECIFICATIONS
................................................................................................................................................... 3
.............................................................................................................................. 3
MAIN HYDRAULIC PUMP
...................................................................................................................................... 4
..................................................................................................................................... 4
PILOT PUMP
........................................................................................................................................................... 9
..................................................................................................................................... 9
HYDRAULIC PUMP COUPLING
........................................................................................................................... 10
Description
........................................................................................................................................................ 10
................................................................................................................................... 11
8003-3
SPECIFICATIONS
Filling capacity of the hydraulic sump tank .....................................................................................See
Section 1002
Total capacity of the hydraulic system............................................................................................See
Section 1002
Hydraulic oil ....................................................................................................................................See
Section 1002
Weight ............................................................................................................................................See
Section 1002
Screw for fixing the hydraulic pump flange to the engine hand-wheel crankcase ..........................See
Section 1002
Screw for fixing the hydraulic sump tank cover ..............................................................2 to 3.6 lb-ft
(2.9 to 4.9 Nm)
Nuts for tightening the silencer retaining collars................................................................................29
lb-ft (39 Nm)
Screw for fixing the silencer bracket to the motor............................................................ 47 to 55 lb-ft
(64 to 74 Nm)
Dowel blocks retaining screw ..................................................................................151 to 166 lb-ft
(205 to 225 Nm)
Splined sleeve locking screw........................................................................................... 71 to 72 lb-ft
(96 to 98 Nm)
8003-4
MAIN HYDRAULIC PUMP
STEP 1
JS00163A1
STEP 2
Release pressure in the hydraulic system and
release pressure in the hydraulic sump tank (see
section 8000).
STEP 3
CD00F091
Disconnect the ground cable (1) from the battery.
STEP 4
6003-011
Remove the access panel (1) retaining screws from
underneath the hydraulic sump tank, then remove the
panel.
STEP 5
Place a container of 53 gal (200 litres) capacity under
the oil change valve of the hydraulic sump tank.
Empty the hydraulic fluid and close the valve.
STEP 6
CD00F099
Unlock the two engine hood locking latches (1) and
raise the hood to the raised, locked position.
STEP 7
Attach suitable lifting slings to the hood.
1
1
1
8003-5
STEP 8
CD00F100
Remove the retaining hardware (1) from the retaining
bar (2) and remove the retaining bar.
STEP 9
CD00F101
Remove the split pin (1) and the flat washer (2) from
the engine hood safety side support bracket.
STEP 10
Remove the engine hood safety side support bracket.
Lower the hood.
NOTE: Have an assistant help you with this step.
STEP 11
Attach the lifting slings to the hoist.
STEP 12
CD00F102
Remove the six retaining screws (1) from the hinges
(2).
STEP 13
Lift the hood using the hoist, then move it away from
the machine.
STEP 14
CD00F103
Remove the six retaining screws (1) from the metal
plate (2), then remove the metal plate (2).
21
2
1
11
2
1
2
1
8003-6
STEP 15
CD00F104
Remove the two retaining screws (3) from the metal
plate (4).
STEP 16
CD00F105
Remove the four retaining screws (1) from the grille
(2), then remove the grille.
STEP 17
CD00F106
Loosen the nut (1) from its bracket, free the cable (2)
from the engine stop control lever (3).
STEP 18
CD00F107
Remove the engine stop control cable (1) from the
cable grommet (2). Remove the retaining screw (4)
from the metal plate (3), then remove the metal plate.
STEP 19
CD00F108
Loosen the circlip (1) fastening the silencer pipe to
the turbocompressor.
NOTE: Let the engine and the exhaust system cool
before trying to remove the silencer.
43
1
1
2
3
12
34
2
1
1
8003-7
STEP 20
CD00F110
Remove the four retaining nuts from the silencer
circlips, then remove the two circlips (1).
NOTE: When installing, tighten the nuts to the torque
specified on page 3.
STEP 21
CD00F111
Remove the silencer assembly from the machine.
STEP 22
CD00F112
Remove the three screws (1) and the retaining
washers from the silencer bracket, then remove the
silencer bracket.
torque specified on page 3.
STEP 23
CD00F113
To aid proper installation, attach identification tags to
all hoses and electrical connections of the main
hydraulic pump and the pilot pump.
STEP 24
Remove the pipes, the hydraulic hoses and the
electrical connections. Seal all hoses and union of
the main pump as well as those of the pilot pump.
STEP 25
Install suitable lifting apparatus on the lifting eyes of
the hydraulic pump. Do not leave any slack so that
the pump can be supported when the coupling
screws are removed.
STEP 26
Remove the screws that fasten the hydraulic pump
flange to the engine hand-wheel housing.
STEP 27
Remove the hydraulic pump from the motor and put it
away from the machine. Place the hydraulic pump on
a clean workbench using suitable brackets.
NOTE: Carry out the following step only if a new
hydraulic pump needs to be installed.
1
1
8003-8
STEP 28
Remove the connections of the hydraulic pump that
has just been removed and install them on the new
hydraulic pump. Remove and install the connections
one after another to avoid improper installation of the
connections on the new hydraulic pump.
NOTE: For installing the hydraulic pump, proceed in
the reverse order to that of removal. Replace all rings
with new rings.
STEP 29
CD00F176
Remove the four screws and washers (1). Remove
the cover (2) and the O-ring from on top of the
hydraulic sump tank. Discard the O-ring. Fill the
hydraulic sump tank with hydraulic fluid (see section
1002) up to a level in between the "high" and "low"
marks on the visual gauge. Install the cover with a
new O-ring, fasten it using four screws and washers
(1), tighten the screws to the torque specified on
page 3.
STEP 30
CD00F091
Connect the ground (-) cable (1) of the battery.
NOTE: Always drain the air out from the hydraulic
pump before starting the engine. If the air has not
been drained out, the pump can get damaged.
NOTE: Before working with the machine, operate the
swing, travel and attachment for five minutes with the
engine at idle. Check that there are no leaks in the
system, check the level of oil in the hydraulic sump
tank, add oil if necessary. Adjust the hydraulic pump,
refer to section 8001.
2
1
8003-9
PILOT PUMP
STEP 1
Refer to the removal of the hydraulic pump in this
section and carry out steps 1 to 3.
STEP 2
To prevent any fluid leaks when disconnecting
hydraulic hoses, connect a vacuum pump to the
hydraulic sump tank (see section 8000). Start the
vacuum pump.
STEP 3
CD00F114
Place a 2.6 gal (10 litres) container below the
hydraulic pump to recover any oil that might escape
from one of the hoses when it is disconnected or from
the pilot pump when the latter is removed. Label and
disconnect the hoses from the pilot pump (1), seal
the hoses and unions.
STEP 4
Remove the four retaining screws (and the flat
washers) from the pilot pump, then remove the pilot
pump.
STEP 5
Shut off the vacuum pump.
NOTE: When installing, proceed in the reverse order
to that of removal. Replace the O-rings with new
O-rings.
STEP 6
Remove the air bleed plug located on top of the pilot
pump. Fill the pump with clean hydraulic fluid. Install
the air bleed plug.
NOTE: Before working with the machine, operate the
swing, travel and attachment for five minutes with the
engine at idle. Check that there are no leaks in the
system, check the oil level in the hydraulic sump tank.
Add oil if necessary. Adjust the hydraulic pump, refer
to section 8001.
1
8003-10
HYDRAULIC PUMP COUPLING
Description
CS00M509
1 SCREW
2 ROLL PIN
3 LOCKING SCREW
4 HYDRAULIC PUMP SHAFT
5 DOWEL BLOCK
6 ELASTIC COUPLING
7 SPLINED SLEEVE
8 ENGINE HAND-WHEEL
9 HYDRAULIC PUMP
10 FLANGE
11 SCREW
11
10
9
8
4
2
3
15
6
7
8003-11
NOTE: The numbers in brackets refer to the
illustration on page 10.
STEP 1
Refer to the removal of the hydraulic pump in this
section and remove the hydraulic pump.
STEP 2
Remove the two locking screws (3), remove the
splined sleeve (7) from the hydraulic pump shaft (4).
NOTE: When installing, replace the splined sleeve if
necessary. Install the splined sleeve on the pump
shaft. The splined sleeve should be stopped against
the pump shaft shoulder. The depth between the face
of the end of shaft and the outer face of the splined
sleeve should be 0.236±0.118 in (6±3 mm) (see
illustration below).
CS00M510
Apply Loctite 262 on the threads and tighten the
locking screws (3) of the splined sleeve to the torque
STEP 3
Remove the elastic coupling (6), check visually the
elastic coupling for wear, replace if necessary.
STEP 4
Remove the screws (1), then remove the dowel
blocks (5). Visually check the state of the dowel
blocks for wear, replace them if necessary.
NOTE: If wear of the elastic coupling and dowel
blocks requires them to be replaced, replace the
splined sleeve as well. When installing, apply
Loctite 262 on the threads of the dowel block
retaining screws, position the dowel blocks correctly
and tighten to the torque specified on page 3.
STEP 5
Remove the four roll pins from the engine handwheel,
when installing, replace them if necessary.
NOTE: When installing the hydraulic pump coupling,
proceed in the reverse order to that of removal.
3
0.236±0.118 in
8003-12
NOTES
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
Link- Belt
Printed in U.S.A.
8004
OF THE MAIN HYDRAULIC CONTROL VALVE
Section
8004
8004-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................
................... 2
SPECIAL TORQUE
SETTINGS............................................................................................................................... 2
MAIN HYDRAULIC CONTROL
VALVE.................................................................................................................... 3
...................................................................................................................................... 3
SPECIFICATIONS
Weight of control valve ...................................................................................................................
See Section 1002
Retaining screws for central frame and upper access panel..........................................65 to 79 lb-ft
(88 to 107 Nm)
Control valve mounting on upperstructure frame ...........................................................................
See Section 1002
8004-3
MAIN HYDRAULIC CONTROL VALVE
STEP 1
JS00163A1
STEP 2
STEP 3
CD00F091
Disconnect the ground cable (1) (-) from the battery.
STEP 4
Connect a vacuum pump to the hydraulic sump tank
to prevent any fluid leaks when disconnecting
hydraulic lines (see Section 8000).
STEP 5
CD00F092
Remove the retaining screws for the upper access
panel (1) and remove the panel.
NOTE: When installing, tighten the screws to a
torque of between 65 to 79 lb-ft (88 and 107 Nm)
(apply Loctite 262 to the threads).
STEP 6
CD00F093
Remove the central frame (1) retaining screws and
remove the central frame.
1
1
1
8004-4
STEP 7
CD00F116
Remove the screws (1) then remove the flange (2).
STEP 8
STEP 9
CD00G182
Remove the two hose clips (1) from the hose (2) and
remove the hose from the manifold.
STEP 10
CD00G181
Remove the four retaining screws (1) from the flange (2).
STEP 11
CD00G180
Attach identification labels to all the main control
valve hoses, pipes and electric wires. Disconnect and
plug the hoses and pipes. Plug the main control valve
orifices. Disconnect the electrical connections.
STEP 12
STEP 13
Install lifting eyes in the threaded orifices on the top
of the main control valve.
STEP 14
Connect a suitable lifting device to the main control
valve. See Section 1002 for the weight of the main
control valve.
1
2
2
1
2
1
8004-5
STEP 15
CS00E521
Remove the retaining screws (1) and washers from
the main control valve.
STEP 16
Carefully raise and guide the main control valve out
of the upperstructure frame. Move all the hoses and
pipes out of the way. Remove the main control valve
from the machine and place it on suitable stands.
NOTE: The following step is to be performed only if
the main control valve has to be changed.
STEP 17
Remove the unions and manifolds from the main
control valve which has just been removed and mount
them on the new main control valve. Remove and
install the unions and manifolds one after another to
make sure that they are correctly installed on the new
main control valve.
NOTE: For the installation, follow the same procedure
in the reverse order. Replace all seals with new seals.
NOTE: Before carrying out any work with the
machine, operate the swing, travel and the
attachment for five minutes with the engine at idle
speed. Check that there are no leaks in the system,
check the oil level in the hydraulic sump tank. Add oil
if necessary. Adjust the valves in the control valve
(see Section 8001).
1
8004-6
NOTES
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
Link-Belt
Printed in U.S.A.
8005
OF THE ATTACHMENT CYLINDERS
Section
8005
8005-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................
................... 2
PREPARATION BEFORE
REMOVAL/INSTALLATION........................................................................................... 2
BOOM CYLINDER
................................................................................................................................................... 3
Description
........................................................................................................................................................... 3
Removal
...............................................................................................................................................................
4
Installation
............................................................................................................................................................ 6
ARM CYLINDER
...................................................................................................................................................... 9
Description
........................................................................................................................................................... 9
Removal
.............................................................................................................................................................
10
Installation
.......................................................................................................................................................... 12
BUCKET
CYLINDER............................................................................................................................................
.. 16
Description
......................................................................................................................................................... 16
Removal
.............................................................................................................................................................
17
Installation
.......................................................................................................................................................... 18
SPECIFICATIONS
See Section 1002
PREPARATION BEFORE REMOVAL/INSTALLATION
- Completely retract the bucket and arm cylinder rods and lower the attachment to the ground.
- Release pressure in the hydraulic system and install a vacuum pump on the hydraulic sump tank
(see Section 8000).
8005-3
BOOM CYLINDER
Description
JS00593
1 LUBRICATING HOSE
2 NUT
3 SCREW
4 LOCKING BUSHING
5 SHIM
6 HYDRAULIC HOSE
7 NUT
8 SCREW
9 PIN
10 BOOM CYLINDER
11 PIN
2
4
3
5
5
1
10
6
6
1
8
10
5
5
342
9
7
11
8005-4
Removal
NOTE: The number sin brackets in the following
steps refer to the boom cylinder illustration on page
3.
STEP 1
JS00577A
Disconnect the lubrication hose (1) from the boom
cylinder.
NOTE: Lift the cylinder carefully. The cylinder is
heavy, the weight should be carefully distributed on
the slings when lifting.
STEP 2
JS00578A
Attach a suitable lifting device to the boom cylinder.
Take up all the slack to ensure the boom cylinder is
fully supported before starting to remove the boom
cylinder.
STEP 3
JS00579A
Remove the nuts (2) from the screws (3). Remove
the screws from the pin (11) and the locking bushings
(4). Push the pin far enough to prevent it interfering
with the removal of the boom cylinder. Remove the
shims (5) and the locking bushings.
STEP 4
JS00580A
Place a stand (A) at the front of the boom cylinder.
Place the front of the boom cylinder on the stand.
STEP 5
JS00581A
Attach a strap (B) to hold the cylinder rod to the
cylinder barrel.
1
3
5
2
2
11
3
4
A
B
8005-5
STEP 6
STEP 7
JS00582A
Disconnect the hydraulic supply hoses (6) from the
boom cylinder.
STEP 8
(Only if the machine is equipped with cylinder
safety valves)
CS00G501
Disconnect the safety valve piloting hydraulic hoses
and disconnect the harness from the pressure
detector.
STEP 9
Plug the hoses with plugs and the unions with caps.
STEP 10
JS00583A
Remove the nuts (7) from the screw (8). Remove the
screw from the pin (9). Install a suitable screw (C) in
the threaded orifice in the pin. Use a suitable sliding
hammer fastened to the screw to remove the pin.
Unscrew the screw from the pin.
STEP 11
JS00584A
Carefully raise the boom cylinder and move it away
from the machine. Place the boom cylinder on
suitable stands. Remove the strap which was holding
the cylinder rod to the cylinder barrel.
6
7
B
8
9
AC
8005-6
STEP 12
hose burst check valves)
CS00G502
Disconnect the pipe (A) from the safety valve (B).
Remove the screws (C), the base (D) and the hose
burst check valve (B) from the boom cylinder. Scrap
the O-ring (E).
STEP 13
Repeat steps 1 to 13 to remove the other cylinder.
Installation
STEP 1
JS00586A
Attach a suitable strap (B) to the boom cylinder to
hold the cylinder rod to the cylinder barrel.
STEP 2
CS00G502
Install a new O-ring (E) on the boom cylinder and
install the hose burst check valve (B) and the base
(D) with the screws (C). Connect the pipe (A).
NOTE: Carefully raise the cylinder. The cylinder is
heavy, the weight must be carefully distributed over
the slings during lifting.
STEP 3
JS00587A
Using a suitable lifting device, raise the boom
cylinder. Align the boom cylinder with the chassis
mounting brackets. Place a suitable stand under the
boom cylinder to support it.
ABC
D
E
B
ABC
D
E
8005-7
STEP 4
JS00588A
Install the pin (9) and the screw (8). Using a feeler
gauge, check that there is a clearance of 0.039 to
0.098 inch (1 to 2.5 mm) between the mounting
bracket and the cylinder barrel mounting eye. If
necessary, remove the screw and the pin and add
one or more shims as required to obtain the correct
clearance. Install the pin and the screw. Install the
first nut (7) on the screw and tighten until the nut
touches the mounting bracket boss. Loosen the nut a
quarter turn and, using two wrenches, install the
second nut (7) to lock the first one in position.
STEP 5
JS00589A
Start the vacuum pump. Remove the plugs from the
hydraulic hoses (6) and the caps from the unions.
Connect the two hydraulic supply hoses to the boom
cylinder.
STEP 6
CS00G501
Connect the hydraulic piloting hoses to the hose burst
check valves and connect the harness to the pressure
detector. Stop the vacuum pump. Remove the strap
which is holding the cylinder rod to the cylinder barrel.
STEP 7
JS00590A
Raise the boom cylinder and align the cylinder rod
end with the boom mounting orifice.
STEP 8
Repeat steps 1 to 7 to install the second boom cylinder.
7
B
8
9
AC
6
8005-8
STEP 9
JS00591A
Install the pin (11) and the shims (5).
STEP 10
JS00592A
Install the locking bushings (4). Install the screws (3)
through the locking bushings and the pin. Using a set
of feeler gauges, check that there is a clearance of
0.039 to 0.098 inch (1 to 2.5 mm) between the
mounting bracket and the cylinder rod mounting eye.
If necessary, remove the screws and the pin and add
or remove one or more shim(s) as required to obtain
the correct clearance. Install the pin and the screws.
Install the first nut (2) on the screw and tighten until
the nut touches the locking bushing. Loosen the nut a
quarter of a turn and, using two wrenches, install the
second nut (2) to lock the first nut in position.
Remove the sling from the boom cylinder.
STEP 11
JS00656A
Connect the lubricating hoses (1) to the boom
cylinders.
STEP 12
Remove the vacuum pump and bleed air from the
boom cylinders (see Section 8000).
STEP 13
Check the level of hydraulic fluid in the hydraulic
sump tank. Add oil as necessary.
STEP 14
Lubricate the linkages.
11
3
2
4
1
8005-9
ARM CYLINDER
Description
JS00603A
1 NUT
2 SCREW
3 PIN
4 HYDRAULIC HOSE
5 LUBRICATION HOSE
6 NUT
7 SCREW
8 PIN
9 ARM CYLINDER
10 SHIM
3
9
10
8
45
10
2
1
6
7
8005-10
Removal
NOTE: The numbers in brackets in the following steps
refer to the arm cylinder illustration on page 9.
STEP 1
JS00594A
Place a wooden block (A) under the arm cylinder (9).
STEP 2
JS00595A
Remove the nuts (1) and the screw (2) at the cylinder
rod end.
STEP 3
JS00596A
Carefully remove the pin (3).
STEP 4
JS00586A
Attach a suitable strap (B) to hold the cylinder rod to
the cylinder barrel.
STEP 5
STEP 6
JS00598A
Disconnect both hydraulic supply hoses (4) from the
arm cylinder.
A
9
2
1
3
B
4
8005-11
STEP 7
CS00G503
Disconnect the hydraulic piloting hoses from the
cylinder hose burst check valves.
STEP 8
Plug the hydraulic hoses with plugs and the unions
with caps. Stop the vacuum pump.
STEP 9
JS00599A
Disconnect the lubrication hose (5) from the arm
cylinder.
NOTE: Raise the cylinder carefully, the cylinder is
heavy and the weight must be carefully distributed
over the slings when lifting.
STEP 10
JS00600A
Attach a suitable lifting device to the arm cylinder. Take
up all the slack in the lifting equipment so as to support
the arm cylinder before starting to remove it.
STEP 11
JS00601A
Remove the nuts (6) and the screw (7) from the pin
(8) at the cylinder barrel end and carefully remove the
pin (8).
5
A
8
7
6
8005-12
STEP 12
JS00602A
Carefully raise the arm cylinder and move it away
from the arm. Remove the shims (10). Place the arm
cylinder on suitable stands.
STEP 13
JS00586A
Remove the strap (B) which holds the cylinder rod to
STEP 14
CS00G504
Disconnect the pipe (A) from the cylinder safety valve
(B). Remove the screws (C), the base (D) and the
cylinder hose burst check valves (B) from the arm
cylinder. Scrap the O-ring (E).
Installation
STEP 1
JS00586A
Attach a suitable strap (B) to the arm cylinder to hold
the cylinder rod to the cylinder barrel.
10
B
A
E
D
C
B
B
8005-13
STEP 2
CS00G504
Install a new O-ring (E) on the arm cylinder and install
the cylinder hose burst check valves (B) and the base
(D) with the screws (C). Connect the pipe (A).
heavy and the weight must be carefully distributed
over the slings when lifting.
STEP 3
JS00602A
Attach a suitable lifting device to the arm cylinder, lift
the arm cylinder and bring it into position. Align the
arm cylinder mounting orifices with the boom
brackets and install the shims (10).
STEP 4
JS00601A
Install the pin (8) and fasten the pin with the screw
(7). Using a set of feeler gauges, check that there is a
clearance of 0.019 to 0.118 inch (0.5 to 3 mm)
between the mounting bracket and the cylinder barrel
mounting eye. If necessary, remove the screw and
the pin and add or remove one or more shims (10) as
required to obtain the correct clearance. Install the
pin and the screw. Install the first nut (6) on the screw
and tighten until the nut touches the bracket boss.
Loosen the nut a quarter of a turn and, using two
wrenches, install the second nut (6) to lock the first
nut in position.
STEP 5
JS00604A
Connect the lubrication hose (5) to the arm cylinder.
A
E
D
C
B
10
8
7
6
5
8005-14
STEP 6
JS00605A
Connect the hydraulic supply hoses to the arm
cylinder.
STEP 7
CS00G503
Connect the hydraulic piloting hoses on the cylinder
hose burst check valves. Stop the vacuum pump.
STEP 8
JS00586A
Remove the sling (B) which holds the cylinder rod to
STEP 9
JS00606A
Align the arm cylinder mounting orifices with the arm
orifices.
4
B
8005-15
STEP 10
JS00607A
Install the pin (3) and the screw (2). Using a set of
feeler gauges, check that there is a clearance of
0.019 to 0.118 inch (0.5 to 3 mm) between the
mounting bracket and the cylinder rod mounting eye.
If necessary, remove the screw and the pin and add
one or more shims as required to obtain the correct
touches the boss. Loosen the nut a quarter of a turn
and, using two wrenches, install the second nut (1) to
lock the first nut in position. Remove the sling from
the arm cylinder.
STEP 11
Remove the vacuum pump and bleed the air from the
arm cylinder (see Section 8000).
STEP 12
sump tank. Add oil as required.
STEP 13
32
1
8005-16
BUCKET CYLINDER
Description
CS00F534
1 NUT
2 SCREW
3 PIN
4 SHIM
5 HYDRAULIC HOSE
6 NUT
7 SCREW
8 PIN
9 SHIM
10 BUCKET CYLINDER
11 CONNECTING ROD
3
11
4
4
1
11
2
10
5
6
8
7
9
9
8005-17
Removal
refer to the bucket cylinder illustration on page 16.
STEP 1
JS00597A
Place a wooden block (A) under the bucket cylinder
(10).
heavy and its weight must be distributed over the
slings when lifting.
STEP 2
JS00608A
Attach a suitable lifting device to the bucket cylinder.
Take up any slack so that the cylinder is fully
supported when removed.
STEP 3
JS00609A
Remove the nuts (1) from the screw (2) and remove
the screw from the connecting rod (11).
STEP 4
JS00610A
Carefully remove the pin (3).
STEP 5
JS00611A
Lift the bucket cylinder, at the same time moving it
away from the connecting rods. Attach a suitable
sling (B) to the bucket cylinder to hold the cylinder rod
onto the cylinder barrel. Remove the shims (4).
NOTE: Remove the wooden block once the bucket
cylinder is lifted.
A
10
2
1
11
3
B
4
8005-18
STEP 6
JS00612A
Start the vacuum pump. Disconnect the two hydraulic
hoses (5) from the bucket cylinder. Plug the hydraulic
hoses with plugs and the unions with caps. Stop the
vacuum pump.
STEP 7
JS00613A
Remove the nuts (6) and the screw (7). Remove the
arm pin (8).
STEP 8
JS00614A
Carefully raise the bucket cylinder and move it away
from the arm. Remove the shims (9). Place the
bucket cylinder on suitable stands.
STEP 9
JS00586A
Remove the sling (B) which was holding the cylinder
rod onto the cylinder barrel.
Installation
STEP 1
JS00586A
Attach a suitable strap (B) to the bucket cylinder to
hold the cylinder rod onto the cylinder barrel.
heavy and its weight must be distributed over the
slings when lifting.
STEP 2
JS00614A
Install the bucket cylinder on the arm and install the
shims (9).
5
5
8
7
6
9
B
B
B
9
8005-19
STEP 3
JS00616A
With the cylinder and the shims in position, install the
pin (8) and the screw (7). Using a set of feeler
gauges, check that there is a clearance of 0.019 to
0.118 inch (0.5 to 3 mm) between the mounting
bracket and the cylinder barrel. If necessary, remove
the screw and the pin and add or remove one or
more shims (9) as required to obtain the correct
touches the boss. Unscrew a quarter of a turn and,
using two wrenches, install the second nut to lock the
first nut in position.
STEP 4
JS00617A
Connect the hydraulic hoses to the unions on the
bucket cylinder. Stop the vacuum pump.
STEP 5
JS00586A
Remove the sling (B) which was holding the cylinder
rod onto the cylinder barrel.
STEP 6
JS00618A
Raise the bucket cylinder (10) to align the cylinder
rod and the connecting rods (11). Install the shims
(4).
8
7
6
5
5
B
10
11
8005-20
STEP 7
JS00619A
Install the pin (3) and the screw (2). Using a set of
feeler gauges, check that there is a clearance of
0.039 to 0.078 inch (1 to 2 mm) between the
connecting rod and the mounting eye on the cylinder
rod. If necessary, remove the screw and the pin and
add or remove one or more shims as required to
obtain the correct clearance. Install the pin and the
screw. Install the first nut (4) on the screw and tighten
until the nut touches the boss. Loosen the nut a
quarter of a turn and, using two wrenches, install the
second nut (4) to lock the first nut in position.
STEP 8
Remove the vacuum pump and bleed the air from the
bucket cylinder (see Section 8000).
STEP 9
sump tank. Add oil as required.
STEP 10
3
2
4
Link-Belt
Printed in U.S.A.
8006
OF THE ROTATING JOINT
Section
8006
8006-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................
................... 2
SPECIAL TORQUE
SETTINGS............................................................................................................................... 2
ROTATING
JOINT....................................................................................................................................................
3
...................................................................................................................................... 3
SPECIFICATIONS
Weight ............................................................................................................................................
See Section 1002
Capscrews for retaining locking bar ...............................................................................................
See Section 1002
Capscrews for retaining rotating joint outer sleeve on upperstructure ...........................................
See Section 1002
8006-3
ROTATING JOINT
STEP 1
JS00163A1
Park the machine on flat, hard ground. Lower the
attachment to the floor.
STEP 2
Release pressure in the hydraulic system and
release pressure in the hydraulic sump tank (see
Section 8000).
STEP 3
Disconnect the ground cable from the battery.
STEP 4
To prevent any fluid loss when disconnecting hydraulic
lines, connect a vacuum pump to the hydraulic sump
tank (see Section 8000).
STEP 5
CI00F500
Remove the retaining hardware (1) from the lower
plates (2) then remove the plates.
8006-4
STEP 6
CD00F058
CD00F059
To facilitate installation, attach identification labels to
all the rotating joint hoses (outer and inner).
STEP 7
STEP 8
Disconnect the hoses from the rotating joint. Plug the
rotating joint hoses and orifices.
STEP 9
STEP 10
Connect suitable lifting equipment to the rotating
joint. Do not leave any slack since the rotating joint
has to be supported once the retaining screws are
removed.
STEP 11
CD00F060
Remove the retaining hardware (1), the locking bar
(2) and the retaining hardware (3) from the rotating
joint outer component.
NOTE: When installing, tighten to the torque
specified in Section 1002.
STEP 12
Raise the rotating joint sufficiently to free it from its
bracket, so that it can be pivoted 90°. Place the
rotating joint on the ground.
NOTE: When installing, use the same procedure in
the reverse order. Replace all O-rings with new
O-rings. Before operating the machine, operate the
travel, stop the engine and check that there are no
leaks. If there is a leak, tighten the hose connections,
check the level of hydraulic oil in the hydraulic sump
tank and top up if necessary.
3
2
1
Link-Belt
Printed in U.S.A.
Cre 9-35590-LX November 2001
8007
OF THE PILOT FUNCTION BLOCKS
Section
8007
8007-2
Cre 9-35590-LX Issued 11-01
TABLE OF CONTENTS
............................................................................................................................. 2
PILOT FUNCTION BLOCKS
.................................................................................................................................. 3
Travel pedal block
............................................................................................................................................... 3
LH control lever
................................................................................................................................................... 4
RH control lever
.................................................................................................................................................. 8
Swing shuttle block
........................................................................................................................................... 11
Cushion control valve
........................................................................................................................................ 12
Servo control and return manifold block
............................................................................................................ 13
6 solenoid valve block
....................................................................................................................................... 14
Free swing solenoide valve
............................................................................................................................... 15
Manipulator block control lever locknut
..............................................................................................30 lb-ft (41 Nm)
8007-3
PILOT FUNCTION BLOCKS
Travel pedal block
STEP 1
JS00163B
STEP 2
hydraulic sump tank(see Section 8000).
STEP 3
CD00F091
Disconnect the ground (-) cable (1) from the battery.
STEP 4
hydraulic lines, connect a vacuum pump to the
STEP 5
Attach identification tags on all hoses of the control
pedal block.
STEP 6
STEP 7
Provide for a container to recover any possible
hydraulic fluid leaks.
STEP 8
CD00G165
Remove and seal the hydraulic hoses (1). Remove
the junction joints (2), put plugs on the ports of the
control pedal, then discard the O-rings.
NOTE: When installing, replace all O-rings with new
O-rings.
STEP 9
1
8007-4
STEP 10
CD00G047
Remove the retainers (1), then remove the lever (4).
Remove the retainers (2), then remove the pedal (5).
Remove the retainers (3), then remove the bracket
(6). Proceed in the same manner for the second
pedal.
STEP 11
CD00E046
Put the floor carpet away from the pedals. Remove
the four screws (1) that fasten the control pedal block
to the cab floor, then remove the control pedal block.
to that of removal. Start the engine and operate the
control levers. Stop the engine, check the circuit for
leaks and the hydraulic oil level in the reservoir, add
oil if necessary.
LH control lever
NOTE: Refer to page 3 and carry out steps 1 to 4.
STEP 1
CD00G048
Lift the grommet. Loosen and remove the four
retaining screws from the front upper portion of the
control arm.
STEP 2
CD00G049
Loosen and remove the retaining screw (1) from the
function cancellation lever (2), then remove the lever.
4
3
1
6
2
5
1
2
1
8007-5
STEP 3
CD00G050
Loosen and remove the three retaining screws from
the inner cab access bar, then remove the access
bar.
STEP 4
CD00G051
Label and disconnect the electrical connections (1),
remove the compartment control casing assembly
(2).
STEP 5
CD00G052
Loosen and remove the four retaining screws from
the rear upper portion of the control arm.
STEP 6
CD00G053
Loosen and remove the two retaining screws from
the arm angle adjustment and function cancellation
lever, then remove the lever.
STEP 7
CD00G054
Lift the upper portion of the control arm, label and
disconnect the electrical connections.
STEP 8
CD00G055
Loosen the locknut, unscrew the control lever and
remove the upper portion of the control arm.
NOTE: When installing, tighten the locknut to a
torque of 30 lb-ft (41 Nm).
1
2
8007-6
STEP 9
JD00764A
1 CLIP
2 NUT
3 HANDLE
4 GROMMET
5 CONNECTOR
6 LEVER
Cut the clip (1) and discard it. Loosen the nut (2).
Unscrew and remove the handle (3) and the
connector (5) from the lever (6). Remove the nut (2)
to remove the grommet (4).
NOTE: Replace the grommet if it is damaged. The
grommet protects the unions from all types of
contamination.
STEP 10
CD00G056
Loosen and remove the two upper screws as well as
the two lower retaining screws from the front portion
of the control arm.
STEP 11
CD00G057
Loosen and remove the retaining screws from the
left-hand side of the control arm.
STEP 12
CD00G058
Remove from the safety bar side, the rod (1) that
links the function cancellation lever to the safety bar.
STEP 13
CD00G059
the plate (1).
3
5
2
261
4
1
1
2
8007-7
STEP 14
CD00G060
Loosen and remove the four screws that fasten the
retaining plate of the control lever (1) to the bracket
(2).
STEP 15
CD00G061
Take the control lever block (1) out from the bracket
(2).
STEP 16
STEP 17
STEP 18
CD00G062
Attach identification tags to all hoses of the control
lever block. Remove and seal the hydraulic hoses.
Remove the junction unions, put plugs on the ports of
the control lever block, then discard the O-rings.
Loosen and remove the two retaining screws (1) from
the plate (2).
O-rings.
STEP 19
oil if necessary.
1
2
1
2
2
1
8007-8
RH control lever
STEP 1
CD00G065
CD00G066
Remove the trim panel (1) then remove the retaining
screws from the air-conditioning control box.
STEP 2
CD00G067
Label and disconnect the electrical connection (1)
then remove the air-conditioning control box (2).
STEP 3
CD00G068
Loosen and remove the two retaining screws from
the arm angle adjustment lever.
STEP 4
CD00G069
Lift the grommet. Loosen and remove the four
retaining screws from the front upper portion of the
control arm.
STEP 5
CD00G070
the rear upper portion of the control arm.
1
1
2
8007-9
STEP 6
CD00G071
Lift the upper portion of the control arm, label and
disconnect the electrical connections.
STEP 7
CD00G072
Loosen the locknut, unscrew the control lever and
remove the upper portion of the control arm.
NOTE: When installing, tighten the locknut to a
torque of 30 lb-ft (41 Nm).
STEP 8
JD00764A
1 CLIP
2 NUT
3 HANDLE
4 GROMMET
5 CONNECTOR
6 LEVER
Cut the clip (1) and discard it. Loosen the nut (2).
Unscrew and remove the handle (3) and the
connector (5) from the lever (6). Remove the nut (2)
to remove the grommet (4).
NOTE: Replace the grommet if it is damaged. The
grommet protects the unions from all types of
contamination.
STEP 9
CD00G073
Loosen and remove the two upper retaining screws
as well as the two lower retaining screws from the
front portion of the control arm.
3
5
2
261
4
8007-10
STEP 10
CD00G074
the plate (1).
STEP 11
CD00G075
retaining plate of the control valve (1) to the bracket
(2).
STEP 12
CD00G076
Take the control lever block (1) out from the bracket
(2).
STEP 13
STEP 14
STEP 15
CD00G07
Attach identification tags to all hoses of the control
lever block. Remove and seal the hydraulic hoses.
Remove the junction unions, put plugs on the ports of
the control lever block, then discard the O-rings.
Loosen and remove the two retaining screws (1) from
the plate (2).
O-rings.
STEP 16
oil if necessary.
1
1
2
2
1
2
1
8007-11
Swing shuttle block
STEP 1
To make installation easier, attach identification tags
to all hydraulic hoses and electrical connections of
the shuttle block.
STEP 2
STEP 3
STEP 4
CD00G166
Remove and seal the hydraulic hoses (1), remove the
pressure detector (2), remove the junction unions (3),
put plugs on the ports of the shuttle block, then
discard the O-rings.
O-rings.
STEP 5
STEP 6
CD00G064
Remove the screws (1), then remove the shuttle
block (2) from its bracket.
to that of removal. Start the engine, operate the
control levers, stop the engine, check the circuit for
oil if necessary.
1
2
8007-12
Cushion control valve
STEP 1
Open the left-hand side doors.
STEP 2
CD00G008
To aid installation, put identification tags on the
hydraulic hoses. Seal the ports of the cushion control
valve and the ends of the hydraulic hoses.
STEP 3
STEP 4
Disconnect the hydraulic hoses from the cushion
valve. Seal the hydraulic hoses and the ports of the
cushion control valve.
STEP 5
STEP 6
CD00G164
Remove the four retaining screws (1) from the access
panel (2), then remove the access panel.
STEP 7
Loosen the cushion control valve retaining screws
behind the partition. Remove the cushion valve (raise
it until the screws and the flat washers are clear of
the key hole slots in the bracket then pull it from the
bracket).
STEP 8
Install the cushion control valve in a vice with
protective jaws. Loosen then remove the adaptors
and the elbow union.
oil if necessary.
1
2
8007-13
Servo control and return manifold
block
STEP 1
To aid installation, put identification tags on all the
hydraulic hoses.
STEP 2
STEP 3
STEP 4
CD00G162
Remove and seal the hydraulic hoses.
STEP 5
STEP 6
CD00G163
Remove the screws (1) then remove the block (2).
Remove the junction unions (3), discard the O-rings,
put plugs on the ports of the block.
O-rings.
oil,if necessary.
2
1
3
8007-14
6 solenoid valve block
STEP 1
Open the right-hand side door of the machine.
STEP 2
CD00F049
Remove the two screws and the washers from the
protective housing.
STEP 3
Put the protective housing away to make it easier to
disconnect the connectors from the protective
housing.
STEP 4
CD00F050
Disconnect the connectors by pressing on the tongue
fastener then by pulling to separate them (the
connectors are identified by rings of different
colours).
STEP 5
To aid installation, put identification tags on the
hydraulic hoses.
STEP 6
STEP 7
CD00F051
Disconnect the hydraulic hoses connected to the
solenoid valve block. Seal the ports with caps and the
hoses with plugs.
STEP 8
STEP 9
Loosen the retaining screws from the solenoid valve
block. While supporting the solenoid valve block,
remove the screws and the washers. Remove the
solenoid valve block from its bracket.
STEP 10
For proper installation of the connections, mark the
locations of the elbow unions. Hold the solenoid valve
in a vice. Remove the elbow unions and the straight
unions from the ports of the solenoid valve. Seal the
ports of the solenoid valve with plugs to avoid any
penetration of foreign bodies into the block.
to that of removal. Start the engine. Activate several
times the solenoid valves (selection of the second
speed, swing brake control, power boost, cushion
pilot cancellation, swing pilot cancellation, pilot
pressure cancellation control). Stop the engine,
check the circuit for leaks and the hydraulic oil level in
the reservoir, add oil if necessary.
8007-15
Free swing solenoide valve
NOTE: Refer to page 3 and carry out Steps 1 to 4.
STEP 1
Remove the protective plate on top of the control
valve.
STEP 2
CS01G517
To aid installation, put identification tags on all the
hydraulic hoses (1), (2) and (3).
STEP 3
STEP 4
Disconnect the hydraulic hoses (1), (2) and (3) from
the free swing solenoide valve (4). Seal the hydraulic
hoses and the ports of the free swing solenoide
valve.
STEP 5
STEP 6
Disconnect the electrical connectors.
STEP 7
Support the free swing solenoide valve. Remove the
screws (5) and washers (6) then remove the free
swing solenoide valve (4).
STEP 8
If the free swing solenoide valve is being replaced,
remove the jonction unions (7), (8) and (9). Discard
the O-ring (10), (11) and (12), put plugs on the ports
of the block.
O-rings.
NOTE: When installing, proced in the reverse order
to that of removal.
271
10 8
5
6
93
12
4
11
8007-16
NOTES
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
Link-Belt
Printed in U.S.A.
8008
OF THE SWING MOTOR
Section
8008
8008-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................
................... 2
SPECIAL TORQUE
SETTINGS............................................................................................................................... 2
SWING
MOTOR.................................................................................................................................................
...... 3
...................................................................................................................................... 3
SPECIFICATIONS
Weight ............................................................................................................................................
See Section 1002
Upper panel and central frame retaining screws............................................................70 to 79 lb-ft
(88 to 107 Nm)
(apply Loctite 262 to the threads)
Swing motor retaining screws......................................................................................... 87 lb-ft
(117.7 Nm)
+15
-0
+20
-0
8008-3
SWING MOTOR
STEP 1
JS00163A1
Park the machine on flat, hard ground. Lower the
STEP 2
STEP 3
JD00375A
Disconnect the ground cable (1) (-) from the battery.
STEP 4
hydraulic lines, connect a vacuum pump to the
STEP 5
CD00F061
Remove the upper panel (1) retaining screws, then
remove the panel.
STEP 6
CD00F093
Remove the retaining screws from the central frame
(1) then remove the central frame.
STEP 7
To facilitate installation, attach labels to all the hoses
and hydraulic unions which are disconnected during
removal.
1
1
1
8008-4
STEP 8
STEP 9
CD00F094
Disconnect all the hoses from the swing motor. Plug
the hoses with a plug and the unions with a cap.
O-rings.
STEP 10
STEP 11
6003-085
Connect a suitable lifting device to the swing motor.
STEP 12
6003-018
To facilitate reassembly, make an alignment mark on
the swing motor and on the reduction gear. Remove
the sixteen retaining screws (1) from the hydraulic
swing motor.
torque of 87 lb-ft (117.7 Nm).
STEP 13
Carefully raise the swing motor and move it away
from the reduction gear. Move the swing motor away
from the machine and place it on a clean bench.
NOTE: When installing, apply Loctite 504 to the
mating surfaces between the reduction gear and the
swing motor.
STEP 14
To prevent any contamination of the gear oil, cover
the reduction gear with a cloth or a suitable
protection.
NOTE: When installing, follow the same procedure in
the reverse order.
1
+15
-0
+20
-0
8008-5
STEP 15
CP93A021
Remove the plug from the top of the swing motor. Fill
the swing motor with hydraulic fluid via the plug
orifice until the fluid starts to overflow. Then install the
plug.
STEP 16
See Section 8001 and adjust the swing motor
secondary relief valves.
NOTE: Before operating the machine, start the
engine, check the system for leaks and check the
fluid level in the hydraulic sump tank, add oil if
necessary.
8008-6
NOTES
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
Link-Belt
Printed in U.S.A.
Cre 9-35530-LX November 2001
8009
DISASSEMBLY AND ASSEMBLY
OF THE FREE SWING VALVE
Section
8009
8009-2
TABLE OF CONTENTS
FREE SWING SOLENOIDE VALVE
.........................................................................................................................2
Section
...............................................................................................................................................................
..2
Disassembly
.........................................................................................................................................................3
Inspection
.............................................................................................................................................................4
FREE SWING SOLENOIDE VALVE
Section
JS00739A
1. Housing
2. Spool
3. Spring
4. O-ring
5. Plug
6. Rivet
7. Name plate
8. Electrical connector
9. Solenoid
10. Socket head cap screw
11. O-ring
8
76
5
4
3 2 1 11 10 9
8009-3
Disassembly
STEP 1
JD00733A
Remove the two socket head cap screws (10) holding
the solenoid (9) to the valve body.
STEP 2
JD00734A
Remove the solenoid. Be careful not to drop or loose
the actuating pin (A).
STEP 3
JD00735A
Remove and discard the O-ring (11).
STEP 4
JD00736A
Remove the plug (5). Remove and discard the O-ring
(4) from the plug. Remove the spring (3) from the valve
bore.
STEP 5
JD00737A
Using a suitable tool push the spool (2) through the
valve body and remove from bore.
A
4
3
8009-4
Inspection
STEP 1
Clean all parts except the solenoid using suitable
cleaning solvent. Wipe exterior of solenoid clean
using clean cloth moistened with suitable cleaning
solvent.
STEP 2
Inspect the spool for damage to the finish, bent
condition, or other damage. Check that spool slides
easily in the bore of the valve body. Replace the
complete valve if any defects are observed.
STEP 3
Check plugs and cap screws for damaged threads
and corrosion. Replace the part if threads are
damaged or if the part is corroded.
STEP 4
Inspect the solenoid connector for cracks and
missing or broken contacts. Replace the complete
valve if any of these conditions are seen. Check
wires for damaged insulation; if insulation is
damaged, repair using electrical tape. Connect an
ohmmeter across the contacts of the connector;
check that ohmmeter indicates continuity. If
ohmmeter does not indicate continuity, replace the
complete valve.
STEP 5
Check valve body for damaged bores, internal thread
damage, and signs of internal wear. If any defects are
seen, replace the valve as a complete assembly.
8009-5
STEP 1
JD00738A
Install the spool (2) in valve body bore.
STEP 2
JD00736A
Install a new O-ring (4) on the plug. Install the spring (3)
in the valve housing bore then install the plug. Tighten
the plug securely.
STEP 3
JD00735A
Reposition the valve body in the vise. Install a new Oring
(11) in the valve body.
STEP 4
JD00734A
Install the actuating pin (A) in the solenoid. Install the
solenoid on the valve body.
STEP 5
JD00733A
Install two socket head cap screws (10) to secure the
solenoid (9) to valve body. Tighten the cap screws
securely.
4
3
A
8009-6
NOTES
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
Link-Belt
Printed in U.S.A.
8010
MAIN HYDRAULIC PUMP
Section
8010
8010-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................
................... 2
SPECIAL TORQUE
SETTINGS............................................................................................................................... 3
WEAR
INSPECTION.........................................................................................................................................
....... 3
IDENTIFYING THE
COMPONENTS........................................................................................................................ 4
Description
............................................................................................................................................................5
DISASSEMBLY
........................................................................................................................................................ 6
ASSEMBLY
............................................................................................................................................................
10
SPECIFICATIONS
See Section 1002.
8010-3
Cover retaining
screws....................................................................................................................21.5 lb-ft (29 Nm)
Body retaining screws ....................................................................................................................318
lb-ft (431 Nm)
Power take-off housing retaining screws......................................................................................24.5
lb-ft (33.3 Nm)
Control unit retaining screws ........................................................................................................21.5
lb-ft (29.4 Nm)
WEAR INSPECTION
Description of parts
Pump K3V112 DTP
Standard dimension/
maximum dimension (in)
Action
Play between the piston and the
cylinder bore
0.0015 / 0.0026 Replace the cylinder assembly
Play at the shoe piston and the guide 0-0.0039 / 0.011
Replace the piston or the plate
assembly
Shoe thickness 0.19 / 0.18 Replace the pistons
Free height of cylinder springs 1.61 / 1.59 Replace the springs
Height of the base plate and the
spherical bushing
0.47 / 0.43
Replace the base plate and the
spherical bushing
Overhaul dimension of the cylinder, the distribution machined plate and the swash plate
(machined surface)
Distribution machined plate (sliding contact surface)
Swash plate (at the plate)
Cylinder (sliding contact surface)
Irregularity of each surface
Standard roughness
after grinding (in)
0.0039 RA or less
Roughness of the surface
at the wear limit (in)
0.031 RA
8010-4
IDENTIFYING THE COMPONENTS
CI01G501
40
41
A
B
35
37
36
38 39
23
4567
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
26 25 24 23
27
28
29
30
31
32
33
34
1
8010-5
Description
1 DRIVING SHAFT
2 LIP-SEAL
3 COVER
4 SHIM
5 BEARING
6 FLANGE - FRONT BRACKET
7 ROLL PIN
8 STOP SCREW
9 FRONT HOUSING
10 CONTROL PISTON
11 SWASH PLATE
12 PLATE
13 PISTON
14 CONTROL PIVOT
15 CYLINDER PLATE
16 NEEDLE BEARINGS
17 INTERMEDIATE HOUSING
18 STOP SCREW
19 MAIN PINION
20 SEAL PLATE
21 REAR HOUSING
22 SEAL PLATE
23 REAR FLANGE
24 COVER
25 BEARING
26 SNAP RING
27 REAR CYLINDER BLOCK
28 STOP DOWEL
29 FRONT CYLINDER BLOCK
30 SPRING
31 SPHERICAL BUSHING
32 BASE PLATE
33 SNAP RING
34 SHIM
35 LP PUMP POWER TAKE-OFF HOUSING
36 BEARING
37 SECONDARY PINION
38 SHAFT
39 INTERMEDIATE PINION
40 REGULATOR BLOCK
41 SOLENOID VALVE BLOCK
8010-6
DISASSEMBLY
STEP 1
NOTE: Always keep the components from different
pumps separate from one another. During
disassembly of the pump, place the components on a
rubber mat. Handle the components carefully, always
mark the position of the parts.
CD01G103
Remove the oil drain plug located in the low pressure
pump gear housing and drain the pump. Remove the
retaining screws (1) and remove the regulator block (2).
STEP 2
CD01G104
Place the pump on a table, with the regulators facing
downwards. Remove the retaining screws and
remove the front pump housing (1). Retain the
cylinder plate. Remove the main pinion.
STEP 3
CD01G105
Remove the cylinder assembly (1), the spherical
bushing, the thrust springs, the piston plate.
NOTE: Do not loosen the stop screws of the control
piston, the front and rear flanges and the
intermediate housing, as doing so will alter the flow.
STEP 4
CD01G106
Remove the retaining screws (1) from the cover (2).
Install two screws in the extraction holes (3). Protect
the shaft splines (4) with adhesive tape. Remove the
cover (2), remove and discard the O-ring and the lip
seal.
1
2
1
1
12
4
3
8010-7
STEP 5
CD01G107
Remove the front flange (1) by gently tapping it with a
plastic mallet. Discard the seal.
STEP 6
CD01G108
Remove the swash plate (1) from the pump housing (2).
STEP 7
CD01G109
Remove the shaft (1) from the flange (2) using a
plastic mallet.
STEP 8
NOTE: Operation to be carried out in case of wear of
the piston or the control pivot.
CI01G502
Remove the seal plates (1) and (2), discard the seals
(3) and (4). Drive out the control pivot (6) blocking pin
(5). Remove the control pivot (6).
NOTE: The control pivot is installed using Loctite.
Extract the control piston (7).
STEP 9
CI01G503
Remove the snap ring (1). Remove the shim (2),
drive out the shaft (3). Remove the bearing (4) and
the shim (5). Proceed in the same manner when
removing the other pump body.
1
2
1
2
1
14
5
6
7
3
2
3
1
2
4
5
8010-8
STEP 10
CD01G110
Remove the low pressure pump. Remove the
retaining screws and extract the power take-off
housing (1) from the low pressure pump.
STEP 11
CD01G111
Remove the snap ring, drive out the shaft and
remove the intermediate pinion (1). Remove the two
shims.
STEP 12
CD01G112
Remove the snap ring, drive out the bearing
assembly and the secondary pinion (1).
1
1
1
8010-9
STEP 13
CI01G560
Removing the regulator

In order to avoid changing the pump settings, the
cover (1) is equipped with adjusting screws (2) and
(3), a push-rod (4), a lock nut (5), an adjusting screw
(6) and a nut (7).
Do not loosen these screws and nuts, failure to
comply with this instruction will cause maladjustment
of pressure and flow.
Compensation section
Remove the cover (1) by removing the screws (15).
Remove the outer spring (8), the inner spring (9) and
the spring seat (10).
Pilot section
Remove the spring guide (11), the spring (12) and the
spring seat (13).
Remove the screws (14) and (15) and remove the
cover (16) and the spring (17). Extract the snap ring
(18), the spring seat (19), the spring (20) and the
sleeve (21) and remove the outer snap ring (22) from
the sleeve (21).
Extract the snap rings (23) and (24), the support plug
(25) and the adjustment plug (26).
Remove the side lever (27) without removing the axle
(28).
Remove the shaft (29) and remove the control lever
(30).
Remove the side lever (31) without removing the
shaft (32).
Remove the pilot piston (33) and the spool (34).
Remove the sleeve (35) by pushing the
compensating rod (37) to the opposite side.
Remove and discard the seals.
Replace all defective parts.
4
9
8
D1 10
37 B1
36
35
41
42
18
20
19
17
22
21
34
32
A1
F1 31
30 29
40
33
27
G1 C1
E1
13
12
11
67
15 5
1
7
3
2
D
E
F
25
23
26 24
A
BC
15
14
15
28
43
G
39
8010-10
ASSEMBLY
STEP 1
CI01H504
Regulator assembly instructions

Assembly is done in the reverse order of
disassembly, taking into account the following
instructions:
- Clean the components with detergent and dry them
with compressed air.
- Tighten the screws and plugs to the recommended
torque.
- Coat the moving parts with clean oil before
assembling them.
- Install new seals and O-rings.
Assembly
Press the shaft (28) into the housing (38).
Press the shaft (32) into the lever (31).
Install the compensating rod (37) in the housing (38).
Install the lever (31) on the shaft (28) by engaging the
gear (32) in the groove of the compensating rod (37).
Install the snap ring (22) on the sleeve (21), grease
and install the spool (34) in the sleeve (21), install the
assembly in the housing (38) at port (A) by adjusting
the spool (34). Check that the sleeve and the spool
are sliding freely.
Install the control lever (30) complete with its shaft
(40), maintaining the orientation (reference mark
made during disassembly), align the bores of the
lever (30) and the spool (34) and install the shaft (29).
15
16
14
38 33 13 12 11 15
16
7
1
B-B
4
7
3
2
5
8 1 20 17 22 21 34 38 10 9
19
18
16
42
41
35
36
37
A-A
37
32
31
28
29
40
39
25
33
26
24
27
33
43
30
C
8010-11
Install the pilot spool (33) at (C) in the housing (38).
Install the lever (27), engaging the shaft (28) in the
groove on the spool (33).
Install the plug (25) complete with the shaft (39) in the
housing (38). Position the lever (27) correctly so that
the shaft (39) is engaged in the orifice on the lever
(27), then install the snap ring (23).
Install the plug (26) and the snap ring (24).
Install the spring (20), the spring seat (19) on the
spool (34) and install the snap ring (18).
Install the spring (17).
Install the compensating piston (36), the sleeve (35),
the spacer (41) and the piston (42) at orifice (B).
Install the cover (16) and tighten the screws (14).
Install the spring seat (13), the spring (12) and the
spring guide (11) in the housing at (E) (see
disassembly).
Install the spring seat (10), the inner spring (9), the
outer spring (8) in the housing at (D) (see
disassembly).
Install the cover (1) complete with adjusting screws
(2), (3) and (6), the push-rod (4), the lock nuts (5)
and (7).
Install and tighten the retaining screws (15).
Pump assembly instructions
Assembly is done in the reverse order of
disassembly, however, the following instructions need
to be followed:
- Respect the reference marks made during
disassembly.
- Lubricate the seals and the sliding parts.
- Do not mix the parts of the front and rear pumps.
- Use light Loctite when installing the control pivot.
STEP 2
CI01G502
Install the control piston (1) and the control pivot (2)
in the housing (3), coat with light Loctite that part of
the control piston that is in contact with the control
pivot (arrow). Position the pivot in such a way that the
locking pin (4) is installed, wipe off excess Loctite.
Lubricate the control piston (1) and its housing, fit
new seals on the seal plates (5), (6) and install them
in the housing (3).
STEP 3
CD01G113
Fit a new O-ring on the flange (1). Install the flange
(1) on the housing (2), respecting the reference
marks made during disassembly.
5
3
2
4
1
6
21
8010-12
STEP 4
CD01G114
Place the pump housing (1) with the regulator side
facing downwards. Coat the swash plate bearings (2)
with grease. Install the swash plate (2) by engaging
the housing of the plate in the control pivot. Check
that the swash plate (2) is fully home against the
housing bearings (1). Ensure that the swash plate (2)
is able to move freely by pressing on each side with
fingers of both hands.
STEP 5
CI01G504
Install the shim (1) on the shaft (2). Heat the bearing
(3) to176°F (80°C) in an oven.
NOTE: The bearing locking shim (4) is oriented
towards the shaft splines.
Adjust the bearing (3) properly. Install the bearing (3)
on the shaft (2) using heat protective gloves. Install
the shim (5). Install the snap ring (6).
STEP 6
CD01G115
Install the shaft assembly (1) in the flange (2) while
supporting the swash plate. Tap with a plastic mallet.
STEP 7
CD01G116
Grease the cover (1) lip seal. Install the cover (1)
taking care not to damage the lip seal on the splines
of the shaft (2). Install and tighten the screws (3) to a
torque of 21.5 lb-ft (29 Nm).
2
1
5
3
1
2
6
4
1
2
2
3
1
8010-13
STEP 8
CD01G117
Install the springs, the spherical bushing, the pistons
complete with the thrust ring on the cylinder block.
Install the piston plate on the swash plate. Install the
cylinder block assembly (1) in the housing (2) by
engaging the splines of the spherical bushing and the
cylinder block on the shaft (3).
STEP 9
CD01G118
Install new needle bearings (1) in the intermediate
housing (2). Use grease to stick the cylinder plate (3)
on the intermediate housing (2) by adjusting it so that
the retaining pin is engaged in the plate housing.
Install a new seal (4). Position the intermediate
housing on the pump body according to the reference
marks made during disassembly.
STEP 10
CD01G119
Install and tighten the screws (1) alternately to a
torque of 318 lb-ft (431 Nm). Install the coupling
pinion in the intermediate housing. Proceed in the
same manner to install the second pump body.
STEP 11
CD01G112
Position the pinion complete (1) with two bearings on
the power take-off housing, install the assembly
under a press and push in until stopped. Install the
snap ring.
3
1
2
1
2
3
4
1
1
1
8010-14
STEP 12
CD01G111
Install the intermediate pinion (1) complete with its
bearing (2). Install a shim on each side of the pinion.
Install the shaft (arrow). Install the snap ring.
STEP 13
CD01G110
Install a new seal on the intermediate housing. Install
the power take-off housing (1). Install and tighten the
screws to a torque of 24.5 lb-ft (33.3 Nm).
STEP 14
CD01G103
Install a new O-ring (1) on the regulator block (2).
Align the control lever (3) with the axle (4) of the
control pivot and install the regulator block (2). Install
and tighten the retaining screws to a torque of 21.5
lb-ft (29.4 Nm).
Proceed in the same manner when assembling the
second regulator block.
2
1
1
3
4
2
1
Link-Belt
Copyright 2001 Link- Belt
Printed in U.S.A.
8011
OF THE MAIN CONTROL VALVE
Section
8011
8011-2
TABLE OF CONTENTS
SPECIFICATIONS
.................................................................................................................................................. 2
TOOLS REQUIRED
............................................................................................................................................... 2
............................................................................................................................. 3
MAIN CONTROL VALVE
........................................................................................................................................ 4
Description
.......................................................................................................................................................... 4
Identifying the ports
..............................................................................................................................................9
Disassembly
.......................................................................................................................................................10
General instructions
...........................................................................................................................................10
Separating the sections
..................................................................................................................................... 10
Load holding block
............................................................................................................................................ 11
Cleaning
............................................................................................................................................................
14
Inspection
.......................................................................................................................................................... 14
Precautions before assembly
............................................................................................................................ 14
Assembly
...........................................................................................................................................................
14
SPECIFICATIONS
Weight of the main control valve ....................................................................................................
See Section 1002
Safety valve settings.......................................................................................................................
See Section 8001
8011-3
Spool assembly
Screws (D) for spools (2) to (6) and (14) to (17) ..........................................................15 to 16 lb-ft
(20 to 22 Nm)
Screws (22) for the spool (19) ......................................................................................14 to 16 lb-ft
(19 to 22 Nm)
Load holding valve (67)
Plug (N) and (B) ................................................................................................... 108 to 116 lb-ft
(147 to 157 Nm)
Plug (P) ........................................................................................................................10 to 13 lb-ft
(14 to 18 Nm)
Retaining screw (76) ....................................................................................................29 to 32 lb-f
t(39 to 44 Nm)
Control valve assembly
Relief valve (68) ...........................................................................................................57 to 65 lb-ft
(78 to 88 Nm)
Safety valves (69) .........................................................................................................57 to 65 lb-f
(78 to 88 Nm)
Safety valves (70) .................................................................................................... 76 to 83 lb-ft (103
to 113 Nm)
Retaining screws (77) of the control valve sections .............................................123 to 130 lb-ft (167
to 177 Nm)
Plugs (92) .............................................................................................................151 to 167 lb-ft (205
to 227 Nm)
Plug (46)................................................................................................................... 79 to 86 lb-ft (107
to 117 Nm)
Plugs (72) .....................................................................................................................54 to 58 lb-ft
(73 to 79 Nm)
Plugs (87) .....................................................................................................................57 to 65 lb-ft
(78 to 88 Nm)
Plugs (24) and (60) .................................................................................................. 76 to 83 lb-ft (103
to 113 Nm)
Plug (61).......................................................................................................................29 to 32 lb-ft
(39 to 44 Nm)
Plug (63).......................................................................................................................10 to 13 lb-ft
(14 to 18 Nm)
Plugs (72) .....................................................................................................................54 to 58 lb-ft
(73 to 79 Nm)
Cap retaining screws (37), (43) and (88) .....................................................................43 to 47 lb-ft
(58 to 64 Nm)
Cap retaining screws (10), (12), (8) and (9) .................................................................29 to 32 lb-ft
(39 to 44 Nm)
Cap retaining screw (18) ...........................................................................................6.5 to 8 lb-ft (8.8
to 10.8 Nm)
Plugs (73), (97) and (91) ..............................................................................................14 to 16 lb-ft
(19 to 22 Nm)
8011-4
MAIN CONTROL VALVE
Description
CI01K536
72
1
74 13
78
69 75
37
87
75
89 88
96 92
72 93
87
68
37 69
43
76 74
76
52
52 75
75
75
92
77 81
69
37
69
B
A
A
B
C
D
E
F
G
H
I
C
D
E
F
G
H
I
J
K
M
N
MN
N-N
L
72
72
77 81
8011-5
CI01K537
92
44 45
36
97
64
91
50
49
48 46
47
35
36 51
73 73
34 35 53 54
55
92 I - I 34 35 53 54 55
H-H
G-G
8011-6
CI01K538
67
35
36 34 38 39 40
34
36 35
34
35 36 72
73
67
40
39 38
36 35
34
35 36
34
36 35 34
D-D
E-E
F-F
8011-7
CI01K539
41
42
7
9
8
8
8
8
13 70
14
15
16
17
5
10
10
12
12
12
7
65
66
66
66
65
65 65
65
60
63
72
57
33
32
A1 A2
A - A A2 - A2
J-J
A1 - A1
M-ML-L
8011-8
CI01K540
1 70
7
2
12
3
10
4
12
5
12
6
12
7
8
9
8
8
8
42
41
72
18
22 21
23
19
20
33 32
31
30 27 26
24
25
61
62
B1
B1
B1 - B1 B - B
C-C
K-K
8011-9
NOTE: Refer to Section 8001.
Description
1. Main control valve housing
2. Arm spool 2
3. Boom spool 1
4. Bucket spool
5. Travel spool
6. Straight-line travel spool
7. O-ring
8. Cap
9. Cap
10. Cap
12. Cap
13. Main control valve housing
14. Arm spool 1
15. Boom spool 2
16. Swing spool
17. Option spool
18. Cap
19. Spool
20. Spring seat
21. Spring
22. Spool end screw
23. O-ring
24. Plug
25. O-ring
26. Spring
27. Spool
30. O-ring
31. Back up ring
32. Check valve
33. Spring
34. Check valve
35. Spring
36. O-ring
37. Flange
38. Check valve
39. Spring
40. Spacer assembly
41. O-ring
42. O-ring
43. Flange
44. Check valve
45. Spring
46. Plug
47. O-ring
48. Spring
49. Check valve
50. Steel ball
51. Check valve
52. Flange
53. Spacer
54. O-ring
55. Back up ring
57. Spacer
60. Plug assembly
61. Plug
62. O-ring
63. Port plug
64. O-ring
65. O-ring
66. O-ring
67. Load holding valve
68. Relief valve
69. Safety valves
70. Safety valves
72. Plug
73. Plug
74. Screw M10x1.5 L=28
75. Screw M10x1.5 L=40
76. Screw M10x1.5 L=70
77. Screw M16x2 L=130
78. Screw M6x1 L=20
81. Washer
87. Plug
88. Cap
89. O-ring
91. Plug
92. Plug
93. Plug
96. Screw
96. Plug
8011-10
Disassembly
NOTE: Remove the main control valve from the
machine, see Section 8004.
General instructions
- Clean around the component to be removed and
take care to ensure that no foreign matter enters the
main control valve.
- Label the parts removed and arrange them in a
manner that makes installation easier.
- Since the spool is an integral part of the main
control valve body and the sleeve, do not replace
the spool.
NOTE: The numbers in brackets refer to the views on
pages 4 to 8.
Separating the sections
NOTE: Remove the sections only if required. If
removal is required, place the main control valve
body in a horizontal plane.
STEP 1
Clean the outside of the main control valve with a
suitable cleaning solvent to eliminate all traces of
impurities, grease and other foreign bodies. Dry,
using low pressure compressed air.
STEP 2
CI01K541
Separate the two sections (1) and (13) from the main
control valve by removing the screws (77) and the
washers (81).
STEP 3
CI01K542
Remove the O-rings (65) and (66).
Spool assembly
STEP 1
Loosen and remove the twenty screws (74) that
fasten the caps (8) and (9) and remove the caps.
NOTE: If necessary, remove the plug assembly (73)
and the plug (91) complete with the O-ring (64).
STEP 2
Remove the ten O-rings (7) from sections (1) and
(13) of the main control valve.
STEP 3
Remove the spools (2) to (6) and (14) to (17) from the
main control valve body as sub-assemblies, taking
care not to damage them.
NOTE: Identify each spool so that they can be put
back in their respective housings during assembly.
STEP 4
Loosen and remove the twenty screws (74) that
fasten the caps (10) and (12) and remove the caps.
NOTE: If required, remove the plug assembly (73)
and the plug (97).
77 81
77 81
65
66
66
65
65
65
66
65
65
8011-11
STEP 5
Remove the O-rings (7) froms sections (1) and (13)
of the main control valve.
NOTE: To avoid abrasion of the spool surface during
removal of the spool assembly, use a vice with
protective jaws and tighten the spool as close as
possible to the head in order to avoid any deformity.
When the threaded portion of the screw is coated
with Loctite, heat the head of the screw using an
industrial drier until removal becomes easy (normally
the temperature should be in between 392 and
482°F). If this operation causes the spring to be
deformed and malfunction, replace the spring.
STEP 6
CS01K596
Remove the spool screws (D) on the spring side of
the spools (2) to (6) and (14) to (17). Remove the
spring seats (B) as well as the springs (C).
NOTE: In the spools (3) and (14), only remove the
check valves, the springs, the O-rings, the back up
rings and the plugs if it is necessary. If it is necessary
to remove them, heat the periphery of the spool in
order to make it easier to remove the plug.
Arm load holding valve decompression
spool 1
STEP 1
Loosen and remove the screws (78) that fasten the
cap (18) and remove the cap (18).
STEP 2
Remove the O-ring (23) from the cap (18).
STEP 3
Remove the spool (19) from the main control valve
body taking care not to damage it.
NOTE: For removal of the spool, refer to the
instructions previously cited for removal of spool
assemblies.
STEP 4
Loosen, then remove the end (22) of the spool (19),
then remove the spring seats (20) and the spring
(21).
Spool assembly (27)
NOTE: When removing the plug (24), make sure that
you do not drop parts which under pressure from the
springs.
STEP 1
Loosen and remove the plug (24) and remove the
O-ring (25).
STEP 2
Remove the spring (26).
STEP 3
CS01K597
Remove the spool (A) from the sleeve (B). Extract the
sleeve (B) from the main control valve body. Remove
the piston (C), the O-ring (30) and the back up rings
(31).
Load holding block
NOTE: Be careful when removing the components,
some parts are subject to spring pressure.
STEP 1
Loosen and remove the screws (75) and remove the
caps (37).
STEP 2
Remove the springs (35), the check valves (34) and
(51), the O-rings (36) from the main control valve
body.
NOTE: The straight-line travel valve does not have
springs or check valves (see section H-H).
STEP 3
caps (52).
BCBD
31 B
A
30 C
8011-12
STEP 4
Remove the spacer (53) from the main control valve
body, then remove the O-ring (54), the back-up ring
(55) from the spacer (53).
STEP 5
Remove the spring (35) and the check valve (34)
from the main control valve body.
STEP 6
Loosen and remove the plug (72) (see section C-C).
STEP 7
STEP 8
Loosen and remove the plug (72) (see section L-L).
STEP 9
Remove the spacer (57), the spring (33) and the
check valve (32) from the main control valve body.
STEP 10
Loosen and remove the plug (92) (see section G-G).
STEP 11
cap (43).
STEP 12
Remove the spring (45), the check valve (44) and the
O-ring (36) from the main control valve body.
STEP 13
Loosen and remove the plug (46) and the O-ring (47).
STEP 14
Spacer assembly (40)
NOTE: Be careful when removing components, some
parts are subject to spring pressure.
STEP 1
Loosen and remove the screws (76) from the load
holding valve (67) then remove the load holding
valve.
STEP 2
Remove the O-rings (41) and (42) from the main
control valve body.
STEP 3
CS01K598
Remove the O-ring (A).
STEP 4
Use the screw (78) M6 x 1 as an extracting screw to
remove the spacer (40).
STEP 5
Remove the O-ring (C) and the back-up ring (B).
STEP 6
CB
40
A
8011-13
CS01K599
NOTE: Be careful when removing components, some
parts are subject to spring pressure.
STEP 1
Loosen and remove the plug (N) and remove the
O-ring.
STEP 2
Remove the piston (C), the spool (D) and the spring
(F).
STEP 3
Loosen and remove the plug (B) and remove the
O-ring (M).
STEP 4
Remove the sleeve (E), the check valve (A) from the
load holding valve body (67). Remove the O-rings (H)
and (J), the back-up rings (K) and (L) from the
periphery of the sleeve (E).
STEP 5
Remove the spring seat (Q) and the spring (G).
STEP 6
Loosen and remove the plug (P), if this is required.
NOTE: The steel ball (R) is a press fit, do not remove
it.
Valves
NOTE: Do not operate on the components of the
safety valve, as this will affect the pressure.
STEP 1
Loosen and remove the six safety valves (69) from
the main control valve body.
STEP 2
Loosen and remove the relief valve (68) from the
main control valve body.
STEP 3
CS01K600
Loosen and remove the two safety valves (70) and
remove the O-rings (A) and (B).
Auxiliary assembly
STEP 1
Loosen and remove the screws (75) from the caps
(88) and remove the O-rings (89).
STEP 2
Loosen and remove the two plugs (87) and remove
the O-rings and the back up rings.
Plug assembly
STEP 1
O-ring (see section J-J).
STEP 2
O-ring (62) (see section K-K).
67 P
E
G
A
QLHJKRMFDCBN
A 70 B
8011-14
STEP 3
Loosen and remove the plug (63) from its port (see
section A1-A1).
STEP 4
O-ring (see section I-I).
STEP 5
Loosen and remove the plugs (72) and remove the
O-rings.
Cleaning
Clean all the parts removed with clean oil. Dry with
compressed air and place each part on a clean sheet
of paper or vinyl for inspection.
Inspection
Inspect the surface of each part for scratches,
abrasion and other damage.
1. Check that there are no scratches or dents on
the non-return load check valve seat in the main
control valve body and that there are no traces
of rust or contaminants.
2. Check that there are no scratches or dents on
the periphery of the spool. Remove small
scratches using a piece of cloth soaked in an
abrasive product.
3. Check that all sliding surfaces are moving
freely. Check for the absence of foreign matter
in holes and in grooves.
4. Replace the springs in case of damage,
deformity or wear and tear.
5. Replace all O-rings and back up rings with new
ones.
6. After removing the caps and plugs, ensure that
there is no trace of paint at the level of the port
of the body or on the rim of the plug. (Any trace
of residual paint is likely to cause contamination
that could cause the system to malfunction and
lead to possible leaks).
Precautions before assembly
Before beginning assembly, check the quantity of the
parts, be sure of their final position and get all the
required tools ready.
Assembly
Spool assembly
NOTE: Take care not to apply too much Loctite, it
could seep through inside the spool and cause it to
malfunction.
NOTE: If the spool (3) boom section 1 (opposite the
spring) and the spool (14) arm section 1 (spring side)
have been removed for assembly, proceed in the
following manner:
STEP 1
Install the check valve and the spring in the spool,
install the back up ring and the O-ring on the plug.
Apply Loctite 242 on the threaded portion of the plug.
Install the spool in a vice with protective jaws and
tighten the plug at the end of the spools (3) and (4).
STEP 2
Apply Loctite 242 on the spring side on the threaded
portions of the spools (2) to (6) and (14) to (17).
Install the spool in a vice with protective jaws.
STEP 3
CS01K596
Install the spring seat (B), the spring (C), the spring
seat (B) on the screw (D) and tighten it on the spool
to a torque of 15 to 16 lb-ft (20 to 22 Nm).
BCBD
8011-15
spool 1
STEP 1
Apply Loctite 242 on the threaded portions of the
spool (19) and install the spring seats (20), the spring
(21) and the spool end (22).
STEP 2
Install the spool in a vice with protective jaws. Tighten
the end of the spool to a torque of 14 to 16 lb-ft (19 to
22 Nm).
CS01K599
STEP 1
Install the O-rings (H) and (J) and the back up rings
(K) and (L) on the peripheral grooves of the sleeve
(E).
NOTE: Respect the position of the O-rings and the
back up rings. Any wrong installation will cause
lacerations to the O-rings and will encourage the
cylinder to drift.
STEP 2
Install the check valve (A) and the spool (D) in the
port of the sleeve (E).
STEP 3
Install the spring seat (Q) at the end of the check
valve (A), install the spring (G). Insert the assembly
into the load holding valve body (67).
NOTE: Apply grease on the spring seats to make
installation easier.
STEP 4
Install the spring (F) and the piston (C) in the plug
(B).
STEP 5
Install the plug (N) equipped with an O-ring on the
plug (B). Tighten to a torque of 108 to 116 lb-ft (147 to
157 Nm).
STEP 6
Install the plug (B) equipped with a new O-ring (M) on
the load holding valve body (67). Tighten to a torque
of 108 to 116 lb-ft (147 to 157 Nm).
STEP 7
Install the plug (P) equipped with a new O-ring on the
load holding valve body (67). Tighten to a torque of
10 to 13 lb-ft (14 to 18 Nm).
Valves
NOTE: Do not act on the components of the safety
valve, as this will affect the pressure.
STEP 1
Install the relief valve (68). Tighten to a torque of 57
to 65 lb-ft (78 to 88 Nm).
STEP 2
Install the six safety valves (69). Tighten to a torque
of 57 to 65 lb-ft (78 to 88 Nm).
STEP 3
CS01K600
Install the two safety valves (70) equipped with an
O-ring (A) and (B). Tighten to a torque of 76 to 83 lb-ft
(103 to 113 Nm).
67 P
E
G
A
QLHJKRMFDCBN
A 70 B
8011-16
Load holding block
STEP 1
Install the O-rings (36) in the main control valve
housing, arm sections 1 and 2 (see section D-D),
boom section 1 and 2 (see section E-E), swing and
bucket section (see section F-F), install the check
valves (34) and the springs (35).
STEP 2
Install the caps (37) and fasten them using screws
(75). Tighten to a torque of 43 to 47 lb-ft (58 to 64
Nm).
STEP 3
Install the O-rings (36) in the housing of the travel
control valve section (see section H-H), install the
check valves (51) and the springs (35).
STEP 4
Install the caps (37) and fasten them using screws
Nm).
STEP 5
Install the O-ring (36) in the housing of the straightline
travel control valve section (see section H-H).
NOTE: The straight-line travel valve is not equipped
with springs or check valves.
STEP 6
Install the cap (37) using screws (75). Tighten to a
torque of 43 to 47 lb-ft (58 to 64 Nm).
STEP 7
Install the check valve (34) and the spring (35) (see
section I-I), install the spacer (53) complete with an
O-ring (54) and a back up ring (55).
NOTE: Respect the position of the O-rings and back
up rings. Any wrong installation will cause lacerations
to the O-rings and will encourage the cylinder to drift.
STEP 8
Install the cap (52) using screws (75) and tighten to a
STEP 9
Install the O-ring in the option section (see section
G-G), install the check valve (44) and the spring (45).
Install the cap (43) and fasten it using screws (96).
Tighten to a torque of 43 to 47 lb-ft (58 to 64 Nm).
STEP 10
Install the plug assembly (92) equipped with an
O-ring. Tighten to a torque of 151 to 167 lb-ft (205 to
227 Nm).
STEP 11
Install the check valve (49) and the spring (48) on the
travel portion (see section G-G). Install the plug (46)
equipped with an O-ring (47). Tighten to a torque of
79 to 86 lb-ft (107 to 117 Nm).
STEP 12
Install the check valve (32) and the spring (33) on the
dipper portion 1 (see section C-C). Install the plug
(72) equipped with an O-ring. Tighten to a torque of
54 to 58 lb-ft (73 to 79 Nm).
STEP 13
Install the check valve (32), the spring (33) and the
spacer (57) on the dipper portion 2 (see section L-L).
Install the plug (72) equipped with an O-ring. Tighten
Load holding valve
STEP 1
Install the O-rings (41) and (42) on the arm control
valve body 1 (see sections D-D and A2-A2) and
boom 1 (see sections E-E and B1-B1).
STEP 2
Install the check valve (38) and the spring (39).
STEP 3
CS01K598
Install an O-ring (A) on the spacer (40), install the
O-ring (C) and the back up ring (B).
NOTE: Respect the positions of the O-rings and back
up rings. Any wrong installation will cause lacerations
and external leaks.
CB
40
A
8011-17
STEP 4
Install the spacer assembly (40).
STEP 5
Install the load holding valve (67) and fasten it using
screws (76). Tighten to a torque of 29 to 32 lb-ft (39 to
44 Nm).
Auxiliary assembly
STEP 1
Install the caps (88) equipped with an O-ring (89) and
fasten them using the screws (75). Tighten to a
STEP 2
Install the plugs (87) complete with an O-ring and a
back up ring. Tighten to a torque of 57 to 65 lb-ft (78
to 88 Nm).
Spool assembly (27)
STEP 1
CS01K597
Install the O-ring (30) and the back up rings (31) on
the sleeve (B). Install the piston (C) and the spool (A)
in the sleeve (B). Install the assembly in the main
control valve body.
STEP 2
Install the spring (26) inside the plug (24) equipped
with an O-ring (25). Screw the plug on the main
control valve body. Tighten to a torque of 76 to 83 lbft
(103 to 113 Nm).
spool 1
STEP 1
Install the spool assembly (19) in the control valve
body without forcing it.
NOTE: Ensure that it is functioning properly by
making it slide manually.
STEP 2
Install the cap (18) equipped with an O-ring (23) and
fasten it using screws (78). Tighten to a torque of 6.5
to 8 lb-ft (8.8 to 10.8 Nm).
Spool assemblies (2) to (6) and (14) to (17)
STEP 1
Install the O-rings (7) on the main control valve body.
STEP 2
Install the assembled spools (2) to (6) and (14) to
(17) in the ports of the main control valve body.
NOTE: Ensure that the spool is installed in its original
port, install it without pressing too hard. After
installing the spool, make it slide manually to check
its proper functioning.
STEP 3
Install the caps (10) and the caps (12) on the main
control valve body and fasten them using screws
Nm).
STEP 4
Install the caps (8) and the caps (9) on the main
control valve body and fasten them using screws
Nm).
NOTE: Check the proper positioning of the caps (9)
and (10).
STEP 5
Install the plugs (73) equipped with an O-ring on the
long cap of the boom section 2 (see section E-E), on
the long cap of the straight-line travel section (see
section H-H). Tighten to a torque of 14 to 16 lb-ft (19
to 22 Nm).
STEP 6
Install the plug (97) equipped with an O-ring on the
short cap of the option section (see section G-G).
STEP 7
Install the plug (73) equipped with an O-ring on the
short cap of the straight-line travel section (see
section H-H). Tighten to a torque of 14 to 16 lb-ft (19
to 22 Nm).
31 B
A
30 C
8011-18
STEP 8
Install the plug (91) equipped with an O-ring (64) on
the long cap of the option section (see section G-G).
Plug assembly
STEP 1
Install the plug (60) equipped with an O-ring. Tighten
to a torque of 76 to 83 lb-ft (103 to 113 Nm) (see
section J-J).
STEP 2
Install the plug (61) equipped with an O-ring (62).
Tighten to a torque of 29 to 32 lb-ft (39 to 44 Nm),
(see section K-K).
STEP 3
Install the plug (63) in its port. Tighten to a torque of
10 to 13 lb-ft (14 to 18 Nm), (see section A1-A1).
STEP 4
Install the plugs (92) equipped with an O-ring. Tighten
STEP 5
Install the plugs (72) equipped with an O-ring. Tighten
Assembling the sections
STEP 1
CI01K542
Install new O-rings (65) and (66).
STEP 2
CI01K541
Assemble the two sections (1) and (13) using screws
(77) and washers (81). Tighten to a torque of 123 to
130 lb-ft (167 to 177 Nm).
NOTE: For installation of the control valve, see
Section 8004.
65
66
66
65
65
65
66
65
65
77 81
77 81
Link-Belt
Printed in U.S.A.
8012
OF THE ATTACHMENT CYLINDERS
Section
8012
8012-2
Cre 7-27900-21LX Issued 11-01
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................
................... 2
SPECIAL TORQUE
SETTINGS............................................................................................................................... 3
CYLINDERS..........................................................................................................................................
................... 4
Boom cylinder description
....................................................................................................................................4
Arm cylinder description
.......................................................................................................................................6
Bucket cylinder description
..................................................................................................................................8
Disassembly
.......................................................................................................................................................10
Inspection
...........................................................................................................................................................18
Assembly
............................................................................................................................................................1
9
SPECIFICATIONS
See Section 1002.
8012-3
Cre 7-27900-21LX Issued 11-01
Boom cylinder
Piston nut ...............................................................................................................................3355 lb-ft
(4820 Nm)
Bearing retaining screw............................................................................................................. 197 lb-
ft (267 Nm)
Clamp screw (11) .......................................................................................................................... 24
lb-ft (32 Nm)
Clamp screw (9) ............................................................................................................................. 46
lb-ft (63 Nm)
Hydraulic pipes retaining screws (4) ..............................................................................................38
lb-ft (51 Nm)
Hydraulic pipes end plugs (2).....................................................................................................167 lb-
ft (226 Nm)
Piston nut screw (16) ..................................................................................................................... 42
lb-ft (57 Nm)
Arm cylinder
Piston nut ............................................................................................................................7597 lb-ft
(10 300 Nm)
Bearing retaining screw............................................................................................................. 271 lb-
ft (367 Nm)
Clamp screw (11) ...........................................................................................................................24
lb-ft (32 Nm)
Clamp screw (9) .............................................................................................................................30
lb-ft (40 Nm)
Hydraulic pipes retaining screws (4) ..............................................................................................68
lb-ft (92 Nm)
Barrel end plug.......................................................................................................................... 167 lb-
ft (226 Nm)
Piston nut screw (16) .................................................................................................................... 42
lb-ft (57 Nm)
Bucket cylinder
Piston nut .............................................................................................................................. 4905 lb-ft
(6650 Nm)
Bearing retaining screw.............................................................................................................. 197
lb-f (267 Nm)
Clamp screw (11) ...........................................................................................................................24
lb-ft (32 Nm)
Clamp screw (9) .............................................................................................................................30
lb-ft (40 Nm)
Hydraulic pipe retaining screw cylinder head side .........................................................................38
lb-ft (51 Nm)
Pipe retaining screw cylinder foot side...........................................................................................38
lb-ft (51 Nm)
Piston nut screw (16) .................................................................................................................... 42
lb-ft (57 Nm)
8012-4
Cre 7-27900-21LX Issued 11-01
CYLINDERS
Boom cylinder description
JS00664A
10 43
3 4 44
2
6
30
29
38 37
31 32 33
36
35
34
42 41
14
15
432
56
11
12
13
42
41
1
18
7
8
9
5
40
39
19
45
21
20
22
23
24
16
17
8012-5
Cre 7-27900-21LX Issued 11-01
1 LUBRICATION FITTING
2 PLUG
3 O-RING
4 SCREW
5 HYDRAULIC PIPE
6 O-RING
7 SCREW
8 WASHER
9 PIPE CLAMP
10 HYDRAULIC PIPE
11 SCREW
12 LOCKING WASHER
13 RETAINING CLIP
14 SCREW
15 BEARING
16 SCREW
17 STEEL BALL
18 PISTON NUT
19 PISTON
20 SEAL RING
21 BACK UP RING
22 WEAR RING
23 WEAR RING
24 SHIM
25 NOT USED
26 NOT USED
27 NOT USED
28 NOT USED
29 O-RING
30 BACK UP RING
31 WEAR RING
32 BACK UP RING
33 SQUARE SEAL
34 U-RING
35 BACK UP RING
36 WIPER SEAL
37 STOPPING RING
38 BUSHING
39 SEAL RING
40 CUSHION BUSHING
41 WIPER SEAL
42 BUSHING
43 CYLINDER ROD
44 CYLINDER BARREL
45 O-RING
8012-6
Cre 7-27900-21LX Issued 11-01
Arm cylinder description
JS00657A
36
35
34
31 32 33
38 37 29 30
2
3
4
6
5 44
43
42
1 41
14
15
4
5
6
789
42
41
12
13 11
40
39
19
22
21
20 23
16
17 27
26
28
25
45 24
18
8012-7
Cre 7-27900-21LX Issued 11-01
2 PLUG
3 O-RING
4 SCREW
5 HYDRAULIC PIPE
6 O-RING
7 SCREW
8 WASHER
9 PIPE CLAMP
10 NOT USED
11 SCREW
12 WASHER
13 RETAINING CLIP
14 SCREW
15 BEARING
16 SCREW
17 STEEL BALL
18 PISTON NUT
19 PISTON
20 SEAL RING
21 BACK UP RING
22 WEAR RING
23 WEAR RING
24 SHIM
25 RING
26 SNAP RING
27 CUSHION BUSHING
28 CUSHION SEAL
29 O-RING
30 BACK UP RING
31 WEAR RING
32 BACK UP RING
33 SQUARE SEAL
34 U-RING
35 BACK UP RING
36 WIPER SEAL
37 STOPPING RING
38 BUSHING
39 SEAL RING
40 CUSHION BUSHING
41 WIPER SEAL
42 BUSHING
43 CYLINDER ROD
44 CYLINDER BARREL
45 O-RING
8012-8
Cre 7-27900-21LX Issued 11-01
Bucket cylinder description
JS00658A
36
35
34
31 32 33
38
37 30
29
44
43
5
4
6
14
15
41
1
42
4
1
42
41
7
8
9
13
12
11
5
6
40
23
22
21 20 24 16 17
45
18
19
8012-9
Cre 7-27900-21LX Issued 11-01
2 NOT USED
3 NOT USED
4 SCREW
5 HYDRAULIC PIPE
6 O-RING
7 SCREW
8 WASHER
9 RETAINING CLIP
10 NOT USED
11 SCREW
12 WASHER
13 RETAINING CLIP
14 SCREW
15 BEARING
16 SCREW
17 STEEL BALL
18 PISTON NUT
19 PISTON
20 SEAL RING
21 BACK UP RING
22 WEAR RING
23 WEAR RING
24 SHIM
25 NOT USED
26 NOT USED
27 NOT USED
28 NOT USED
29 O-RING
30 BACK UP RING
31 WEAR RING
32 BACK UP RING
33 SQUARE SEAL
34 U-RING
35 BACK UP RING
36 WIPER SEAL
37 STOPPING RING
38 BUSHING
39 NOT USED
40 CUSHION BUSHING
41 WIPER SEAL
42 BUSHING
43 CYLINDER ROD
44 CYLINDER BARREL
45 O-RING
8012-10
Cre 7-27900-21LX Issued 11-01
Disassembly
NOTE: The boom, arm and bucket cylinders are
basically identical in construction. What changes is
the hydraulic tube connections. Before installing the
cylinder in the repair stand, remove the hydraulic
tubes.
STEP 1
Boom cylinder
refer to the boom cylinder illustration on page 4.
1. Remove the lubrication fitting (1) from the
cylinder.
2. Remove the two plugs (2). Remove and discard
the two O-rings (3).
3. Remove the screws (4) and disconnect the
hydraulic tubes (5) and (10) from the cylinder.
Remove and discard the two O-rings (6).
4. Remove the screw (7), the washer (8) and the
clamp (9) from the tubes. Remove the hydraulic
tubes (5) and (10) from the cylinder.
5. Remove the screws (11), the washers (12) and
the clamp (13) from the cylinder.
STEP 2
Arm cylinder
1. Remove the lubrication fitting (1) from the
cylinder.
2. Remove the plug (2) from the hydraulic tube.
Remove and discard the O-ring (3).
3. Remove the screws (4) and disconnect the
hydraulic tube (5) and the clamp from the cylinder.
Remove and discard the two O-rings (6).
clamp (9) from the cylinder.
5. Remove the screws (11), the washers (12).
Remove the clamp (13) from the cylinder.
Remove the hydraulic tube (5) from the cylinder.
STEP 3
Bucket cylinder
1. Remove the two lubrication fittings (1) from the
cylinder.
2. Remove the screws (4). Disconnect the hydraulic
tubes (5) from the cylinder. Remove and discard
the two O-rings (6).
clamp (9) from the cylinder.
4. Remove the screws (11), the washers (12) and
the clamp (13) from the cylinder. Remove the
hydraulic tube (5) from the cylinder.
STEP 4
JD00620A
Install suitable bushings on the cylinder head stock
chuck wings.
STEP 5
JD00621A
Tighten the bushing retaining screws.
8012-11
Cre 7-27900-21LX Issued 11-01
STEP 6
JD00623A
Install the stop pins on the boom tail stock.
STEP 7
JD00624A
Install suitable bushings on the cylinder tail stock
chuck wings. Tighten the retaining screws. Install the
chuck wings on the cylinder tail chuck. Tighten the
locking screws. Use the scale on the face of the
chuck to aid in centering the chuck wings.
STEP 8
JD00625A
Connect lifting equipment, if necessary, to the
cylinder. Position the cylinder in the repair stand with
the rod end of the cylinder at the head stock chuck.
Loosen the retaining screws of the tail stock chuck
wings. When positioning the cylinder rod end on the
head stock chuck wing, be sure that the chuck wing
bushings are centred in the rod bushing. Install the
screw and nuts to secure the cylinder rod end to the
repair stand.
STEP 9
JD00626A
On the cylinder repair stand, loosen the retaining
screws of the tail stock chuck wings. When
positioning the cylinder barrel end on the head stock
chuck wing, be sure that the bushings are centred in
the cylinder barrel bushing. Install the screw and nuts
to secure the cylinder barrel end to the repair stand.
8012-12
Cre 7-27900-21LX Issued 11-01
STEP 10
JD00627A
Check and ensure that the chuck wings are centred
on the repair stand centre line using scales scribed
on the head and tail stock chucks.
NOTE: The numbers in brackets in the following
steps refer to the boom cylinder, arm cylinder and
bucket cylinder illustrations on pages 4, 6 and 8.
STEP 11
JD00628A
Raise the cylinder rod (43) support to support the
cylinder rod. Tighten the nuts to lock the support in
position.
STEP 12
JD00629A
Raise the cylinder barrel (44) support to support the
cylinder barrel. Tighten the nuts to lock the support in
position. Remove the lifting equipment.
STEP 13
JD00630A
To make reassembly easier, draw alignment marks
on the cylinder barrel (44) and the bearing (15).
Remove the screws (14).
STEP 14
JD00631A
Place a container beneath the bearing and cylinder
barrel to catch any hydraulic oil that may still be
inside the cylinder. Start the hydraulic pump to
remove the rod from the cylinder barrel.
8012-13
Cre 7-27900-21LX Issued 11-01
STEP 15
Connect lifting equipment, if necessary, to the
cylinder barrel (44) and remove from the repair stand.
STEP 16
JD00632A
Move the bearing (15) away from the piston (19).
STEP 17
JD00633A
JD00634A
Remove the screws (16) from the piston nut (18).
Turn the cylinder rod and remove the ball (17).
STEP 18
JD00635A
Check that both stop bars (A) are installed to prevent
the head stock (B) chuck from turning. Remove the
tail stock chuck wings and install the wrench (C) on
the tail stock. Check that the wrench is centred on the
chuck and tighten the screws (D).
STEP 19
JD00636A
Push the head stock chuck towards the piston nut
(18) and, if necessary, remove the stop bars (A) and
turn the chuck until the wrench (E) engages the
piston nut.
B
A
A
D
C
18
E
8012-14
Cre 7-27900-21LX Issued 11-01
STEP 20
JD00637A
Loosen the tail stock chuck screws. Tighten the
wrench nuts on the piston nut (18). Check that the
wrench is centred by using the scale on the chuck.
STEP 21
JD00638A
Lower the toggle assembly (B) as far as possible on
the circular plate and install the stop bars (A).
STEP 22
JD00639A
Start the hydraulic pump by pressing on the pedal to
loosen the piston nut. At the end of the stroke,
remove the two stop bars; if necessary, depress the
rear of the pedal to retract the cylinder rod just
enough to enable removal of the stop bars. Depress
the rear of the pedal to retract the cylinder rod to
lower the toggle assembly as far as possible on the
circular plate then install the stop bars.
STEP 23
Repeat step 22, if necessary, until the piston nut has
been loosened.
STEP 24
JD00640A
Remove the piston nut (18) from the rod.
B
A
8012-15
Cre 7-27900-21LX Issued 11-01
STEP 25
JD00641A
Remove the shim (24) from the rod.
STEP 26
JD00642A
Remove the piston (19) then remove the bearing rod.
STEP 27
JD00643A
Remove the two outer wear rings (23) from the
piston.
STEP 28
JD00644A
Remove the two inner wear rings (22) from the
piston.
STEP 29
JS00645A
Install the piston (19) in a vice (A) with protective jaws
(B). Using a suitable tool, cut or break the seal ring
(20). Remove the seal ring and discard. Remove and
discard the two back up rings (21). Remove the
piston from the vice.
A
19
20 22 23
B
45 21
8012-16
Cre 7-27900-21LX Issued 11-01
STEP 30
JD00646A
JD00647A
Use a suitable tool to remove the O-ring (45). Discard
the O-ring.
NOTE: Step 31 applies only to the arm cylinder.
STEP 31
JS00648A
18 PISTON NUT
25 RING
26 STOPPER
27 CUSHION BUSHING
28 CUSHION RING
43 CYLINDER ROD
Remove the ring (25). Push the cushion bushing (27)
away from the stopper (26). Remove the stopper (26).
Remove the cushion bushing (27). Widen the slit of
the cushion ring (28) then remove and discard the
cushion ring (28).
18
27
26
28
25
43
8012-17
Cre 7-27900-21LX Issued 11-01
STEP 32
JS00649A
JD00650A
JD00651A
JD00652A
Remove and discard the O-ring (29) and back up ring
(30). Remove and discard the back up ring (35) and
U-ring (34). Remove and discard the buffer ring (A)
which consists of a wear ring (31), a back up ring
(32), and a square ring (33). Remove and discard the
wiper ring (36).
STEP 33
JS00653A
With a suitable tool, remove the stop ring (37) from
the bearing. Place the bearing on a press and with a
suitable driver, force the ring (38) out of the bearing.
36
35 34 A
38
37
30 29
38
37
8012-18
Cre 7-27900-21LX Issued 11-01
STEP 34
NOTE: The bucket cylinder does not incorporate a
seal on the cushion ring.
Remove the seal (39) from the cushion ring (40) and
discard the seal. Remove the cushion ring (40).
STEP 35
NOTE: Do the following step only if inspection
indicates that the bushings (42) require replacement.
JD00654A
JD00655A
Remove the four wipers (41) from the cylinder rod
and cylinder barrel. Use a suitable press and driver
and remove the two bushings (42) from the cylinder
rod and cylinder barrel.
Inspection
STEP 1
Inspect the seals, U-rings, back up rings, and O-rings
prior to installation for any imperfections, tears, or
other damage. If the seals or the bushings are worn
out or damaged, replace the component(s). Ensure
seals and bushings are installed correctly with no
twisting of the seal or bushing. Install all new seals
and rings wet with hydraulic oil.
STEP 2
Check the sliding parts for wear or damage such as
scratches, dents, or bent parts. Small scratches can
be removed with a hone or crocus cloth.
STEP 3
Check for cracks in the welding or other damage.
STEP 4
Measure the internal diameter of the bushings (42). If
the internal diameter of the bushings is greater than
the specifications, replace the bushing(s).
41
41
8012-19
Cre 7-27900-21LX Issued 11-01
Assembly
steps refer to boom cylinder, arm cylinder and bucket
cylinder illustrations in this section on pages 4, 6 and
8.
STEP 1
JD00655A
JD00654A
Using a suitable press and driver, install the two
bushings (42). Install the four new wipers (41) with
the lip side of the wipers facing out.
STEP 2
NOTE: The bucket cylinder does not incorporate a
seal in the cushion ring.
Install the cushion bushing (40) on the cylinder rod
(43). Install a new seal (39) in the cushion bushing.
STEP 3
JS00659A
Using a suitable press and driver, install the bushing
(38) in the bore of the bearing (15).
STEP 4
JS00653A
Install the stop ring (37) in the bearing groove (15).
41
41
38
15
38
15
8012-20
Cre 7-27900-21LX Issued 11-01
STEP 5
JD00652A
JD00651A
JD00650A
Install a new O-ring (29) and back up ring (30). Install
a new wiper ring (36). Install a new U-ring (34) and
back up ring (35). Install a new buffer ring (A) which
consists of a wear ring (31), a back up ring (32), and
a square ring (33).
JS00649A
36
35 34 A
38
37
30 29
8012-21
Cre 7-27900-21LX Issued 11-01
NOTE: Step 6 applies only to the arm cylinder.
STEP 6
JS00648A
18 PISTON NUT
25 RING
26 STOPPER
27 CUSHION BUSHING
28 CUSHION RING
43 CYLINDER ROD
Install a new cushion ring (28) on the cylinder rod
(43). Install the stopper (26) in the groove of the
cylinder rod (43). Install the cushion bushing (27) on
the cylinder rod (43) and install the ring (25) to hold
the cushion bushing (27).
18
27
26
25
28
43
8012-22
Cre 7-27900-21LX Issued 11-01
STEP 7
JD00647A
JD00646A
Coat a new O-ring (45) with clean hydraulic oil. Install
the O-ring in the center groove of the piston.
STEP 8
JS00645A
(A) VICE
(B) HARD WOOD
Place a tapered tool over the piston (19). Coat a new
seal ring (20) with clean hydraulic fluid. Slide the seal
onto the tool and install it in the groove of the piston
on top of the O-ring (45). Install two new back up
rings (21). Install four new wear rings (22) and (23) in
the grooves of the piston.
STEP 9
JD00642A
Install the bearing (15) then the piston (19) on the
cylinder rod.
STEP 10
JD00641A
Install the shim (24) on the piston rod behind the
piston.
STEP 11
JD00640A
Install the piston nut (18) on the cylinder rod and
hand tighten.
A
19
20 22 23
B
45 21
8012-23
Cre 7-27900-21LX Issued 11-01
STEP 12
Carry out steps 4 to 12 of disassembly to install the
cylinder rod in the repair stand.
STEP 13
JD00637A
JD00636A
Carry out steps 19 to 21 of disassembly to install
wrench (E) on the piston nut (18).
STEP 14
JD00660A
Remove the toggle assembly (A) and the cylinder (D)
on the RH side of the repair stand, by removing the
stop bars (B) and the pins (C). Install the toggle
assembly and cylinder (D) on the left side of the
repair stand. Operate the hydraulic pump by
depressing the foot pedal to extend the rod end of the
hydraulic cylinder to rotate the circular plate
clockwise to tighten the piston nut. At the end of the
stroke, remove the two stop bars; if necessary,
depress the rear of the pedal to retract the cylinder
rod just enough to enable removal of the stop bars.
Depress the rear of the pedal to retract the cylinder
rod to lower the toggle assembly as far as possible
then install the stop bars. Repeat this step as
required to tighten the piston nut to torque (see
"Specifications").
18
E
A
C
D
C
B
8012-24
Cre 7-27900-21LX Issued 11-01
STEP 15
JD00634A
JD00633A
Install the steel ball (17) in the piston nut (18). Install
the screw (16) in the nut. Tighten the screw to torque
(see "Specifications").
STEP 16
JS00661A
(A) AWL
After tightening the screw (16) to the required torque,
caulk the screw at two places.
STEP 17
JD00637A
Loosen the nuts to remove the wrench from the
piston nut (18). Move the repair stand support away
from the cylinder rod.
17
16
A
8012-25
Cre 7-27900-21LX Issued 11-01
STEP 18
JD00662A
Using suitable means of lifting, install the tube on the
repair stand in order to align the cylinder rod (43) and
the bearing. Install the tube and the bearing (15) by
aligning the markers.
STEP 19
JD00630A
JS00663A
Start the pump on the machine to bring the tube into
contact with the bearing. Install 12 screws (14) and
tighten the screws to torques (see "Specifications").
STEP 20
Attach a suitable lifting device to the cylinder.
Remove the screws and chuck wings to free the
cylinder from the repair stand.
STEP 21
Boom cylinder
refer to the boom cylinder illustration on page 4.
1. Install the clamp (13) on the cylinder, the washer
(12) and the screw (11). Tighten the screws to
torque (see "Specifications").
2. Install the two hydraulic pipes (5) and (10), the
clamp (9), the washer (8) and the screw (7).
Tighten the screw to torque (see "Specifications").
3. Install two new O-rings (6) on the cylinder.
Connect the hydraulic pipes (5) and (10) to the
cylinders. Fasten the pipes using screws (4).
Tighten the screws to torque (see
"Specifications").
4. Install two new O-rings (3) on the pipes. Install
two plugs (2) and tighten the plugs to torque (see
"Specifications").
5. Install the lubrication fitting (1) in the cylinder.
STEP 22
Arm cylinder
1. Install the clamp (13), the screw (11) and the
washer (12) on the cylinder. Tighten the screw to
torque (see "Specifications").
2. Install the hydraulic pipe (5), the clamp (9), the
washer (8) and the screw (7). Tighten the screw
to torque (see "Specifications").
3. Install two new O-rings (6) on the cylinder.
Connect the pipe (5) and the clamp to the cylinder
with screws (4). Tighten the screws to torque (see
"Specifications").
4. Install a new O-ring (3) on the pipe. Install the
plug (2). Tighten the plug to torque (see
"Specifications").
5. Install the lubrication fitting (1) in the cylinder.
8012-26
Cre 7-27900-21LX Issued 11-01
STEP 23
Bucket cylinder
1. Install the clamp (13) on the cylinder tube. Secure
the clamp with two washers (12) and screws (11).
Tighten the screws to torque (see
"Specifications").
2. Install the clamp (9) and tube (5) on the clamp
(13). Secure the clamp (9) with the washer (8)
and the screw (7). Tighten the screws to torque
(see "Specifications").
3. Install two new O-rings (6). Connect the hydraulic
pipe (5) to the cylinder and secure the pipes with
the screws (4). Tighten the screws to torque (see
"Specifications").
4. Install two lubrication fittings (1) on the cylinder.
Link-Belt
Printed in U.S.A.
8013
OF THE HAND JOYSTICK CONTROL
Section
8013
8013-2
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................
................... 2
JOYSTICK CONTROL
............................................................................................................................................. 3
Description
........................................................................................................................................................... 3
Disassembly..........................................................................................................................................
............... 4
Inspection..............................................................................................................................................
............... 7
Assembly...............................................................................................................................................
............... 8
SPECIFICATIONS
Torque settings
Orifice plate retaining screws .................................................................................21.6 ± 1.1 lb-ft
(29.4 ± 1.5 Nm)
Universal joint on joystick control ...........................................................................34.7 ± 2.1 lb-ft
(47.1 ± 2.9 Nm)
Lock-nut on universal joint .....................................................................................50.5 ± 3.6 lb-ft
(68.6 ± 4.9 Nm)
8013-3
JOYSTICK CONTROL
Description
CI00G508
1 LOCK-NUT
2 PROTECTIVE BOOT
3 DISC
4 PUSH-ROD
5 PLATE
6 PLUNGER ASSEMBLY
7 O-RING
8 SPRING SEAT
9 SPRING
10 SPRING
11 SPOOL
12 JOYSTICK CONTROL BODY
13 ORIFICE PLATE
14 HEXAGONAL ALLEN-TYPE SCREW
15 O-RING
16 BUSHING
17 SPOOL
18 SPRING
19 LIP-SEAL
20 UNIVERSAL JOINT
21 PLASTIC PIN
22 WASHER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
21
15
16
22
17
18
19
20
8013-4
Disassembly
steps refer to the illustration on page 3.
Always handle high precision parts with the greatest
care to prevent them being damaged by being
knocked or dropped. The components of the joystick
control may rust due to contamination and humidity if
they are left without protection after disassembly. If
work has to be stopped, the components must be
protected against contamination or corrosion.
STEP 1
CD00G087
Install the joystick control in a soft-jawed vice.
Remove the protective boot.
STEP 2
CD00G088
Remove the lock-nut from the joystick control.
STEP 3
CD00G089
Remove the disc from the joystick control.
STEP 4
JD00767A
Install two nuts on the universal joint and tighten
them fully. While holding the upper nut, turn the lower
nut anti-clockwise to unscrew the universal joint.
Remove the universal joint from the joystick control.
NOTE: Carefully remove the universal joint to
prevent the plate and the push-rods, which are under
pressure from the springs, from flying out too quickly.
8013-5
STEP 5
CD00G091
Remove the plate.
NOTE: Mark the components removed in the
following steps to facilitate their insertion in the
correct bore during assembly.
STEP 6
CD00G092
Depending on the condition of the return springs, the
friction of the O-rings can keep the plunger
assemblies in place in the body. In this case, use a
flat screwdriver to remove the plunger assemblies.
Slide the screwdriver into the external groove of the
plunger assembly, taking care not to damage the
plunger assembly. This must be done carefully, since
the plunger assembly can be thrown out suddenly,
due to the action of the return springs.
STEP 7
CD00G093
Remove the spool assembly from the joystick control.
STEP 8
CD00G094
Turn the control valve the other way up in the vice.
Unscrew and remove the six screws and the sealing
washers.
STEP 9
CD00G095
Remove the orifice plates and the O-ring from the
body. Discard the O-ring.
8013-6
STEP 10
JD00774A
Remove the bushing from the body of the joystick
control.
STEP 11
CD00G096
CD00G097
Press the spring down a few millimetres so as to free
the spool (11) from the spring seat (8). Separate the
spool (11) from the spring (10) and the washer (22).
Keep these components together for the reassembly
procedure.
STEP 12
CD00G098
Remove the spool (17) and the spring (18) from the
plunger assembly (6).
STEP 13
CD00G099
Remove the push-rod (4) from the plunger assembly
(6).
STEP 14
CD00G100
Remove and discard the plunger assembly O-ring.
8013-7
STEP 15
CD00G101
Remove and discard the plunger assembly seal.
STEP 16
Cleaning the components:
1. Soak them in a suitable cleaning solvent until
contamination and oil are removed. Components can
be damaged if they are washed while they are still
contaminated.
2. Final washing: Immerse the components in a
clean receptacle containing a suitable cleaning
solvent. Impart a rotary motion to the receptacle so
as to wash the inner surface of the components as
well. Dry the components with a clean cloth.
NOTE: Never dry them with compressed air. Dust
and water contained in the air will damage and
corrode their surfaces.
3. Corrosion prevention: Apply an anti-rust product
to all the components.
NOTE: Components can rust if left in the open air
after cleaning.
Inspection
Change all the seals and O-rings which have been
removed. Also change the washers on all screws
which have been removed.
STEP 1
Inspect the spools to ensure that the finish is not
damaged, that they are not bent or damaged in any
other manner. Make sure that the spool slides freely
in the control valve body bore. If defects are found,
change the entire control valve.
STEP 2
JS00784A
Inspecting the controls. Change the components if
wear on the shaft pin and seal create play in the
controls greater than 0.078 inch (2 mm) .
STEP 3
If it is impossible after inspection of the parts to
determine the cause of an abnormal noise or a
reduction in primary pressure, change the joystick
control.
8013-8
Assembly
Carry out the assembly with the very greatest care.
Do not hit or force the components, since that will
damage them and cause seizure or oil leaks which
would result in impaired performance of the machine.
Before reassembly, remove all traces of metal
particles or foreign bodies from all components.
Check that there are no burrs on the components and
remove them with an oil stone. Replace all O-rings
and thrust rings with new components. Lubricate the
O-rings and thrust rings to prevent any damage
during assembly. Tighten all cap screws to the
specified torque. Plug all orifices with plugs to
prevent any contamination of the joystick control by
dust after reassembly.
STEP 1
JD00774A
Install the joystick control body bushing.
STEP 2
CD00G102
Install the O-ring in the groove in the joystick control
body.
STEP 3
CD00G103
Install the orifice plate (13) with the plastic pin (21) in
the orifice (A) in the joystick control body.
STEP 4
CD00G104
Install the hexagonal Allen-type cap screws and the
sealing washers in the orifice plate (13). Tighten the
screws and retighten them alternately to a torque of
21.6 ± 1.1 lb-ft (29.4 ± 1.5 Nm).
STEP 5
CD00G105
Assemble the spool assembly by installing the
washer (22), the spring (10) and the spring seat (8)
on the spool (11).
A
8013-9
STEP 6
CD00G106
Turn the joystick control the other way up in the vice.
Install the return spring and the complete spool
assembly in the body, respecting the positions noted
during steps 5 to 7 (disassembly).
STEP 7
CD00G107
Install the O-ring on the plunger.
STEP 8
CD00G108
CI00G509
Install the lip seals (19) with their ends as shown
above.
STEP 9
CD00G109
Coat the surfaces of the push-rod (4) with hydraulic
fluid and install it in the plunger (6).
19
4
8013-10
STEP 10
CD00G110
Install the spool (17) and the spring (18) in the
plunger (6).
STEP 11
CD00G111
Install the plunger in the body. Depending on the
condition of the return springs, the friction of the
O-rings may keep the plungers in place in the body.
STEP 12
Repeat steps 5 to 11 for the other three bodies.
STEP 13
CD00G112
Install the plate and retain it by means of the
universal joint. Tighten the universal joint to a torque
of 34.7 ± 2.1 lb-ft (47.1 ± 2.9 Nm).
STEP 14
CD00G113
Install the disc on the universal joint. Tighten until the
disc touches the four push-rods equally.
STEP 15
CD00G114
Install the lock-nut and tighten it to a torque of 50.5
± 3.6 lb-ft (68.6 ± 4.9 Nm) while holding the flats on
the disc (3) with a flat wrench.
8013-11
STEP 16
CD00G115
Place a few spots of grease on the push-rods.
STEP 17
CD00G116
Install the protective boot (2) on the joystick control.
8013-12
NOTES
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
Link-Belt
Printed in U.S.A.
8014
OF THE TRAVEL PEDAL CONTROL
Section
8014
8014-2
TABLE OF CONTENTS
SPECIFICATIONS
................................................................................................................................................... 3
TORQUE SETTING
................................................................................................................................................. 3
SPECIAL TOOLS
.................................................................................................................................................... 3
TRAVEL PEDAL CONTROL
................................................................................................................................... 4
Description
.......................................................................................................................................................... 4
Disassembly
........................................................................................................................................................ 5
Inspection
............................................................................................................................................................ 9
Assembly
.............................................................................................................................................................
9
Troubleshooting
................................................................................................................................................ 15
8014-3
SPECIFICATIONS
Primary coolant pressure....................................................................................... Maximum 9.8 MPa
(100 kgf/cm2)
Secondary coolant pressure.........................................................0 ~ 4.4 MPa (Max end of stroke
control pressure)
Permissible return pressure........................................................................................................0.3
MPa (3 kgf/cm2)
Rated flow............................................................................................................................ 2.641
gal/min (10 L/min)
Operating angle
.............................................................................................................................................. ± 12.4°
Hydraulic fluid .......................................................................................................................... Mineral
hydraulic fluid
Working temperature range......................................................................................-4°C ~ +167°C (-
20°C ~ +75°C)
TORQUE SETTING
Cover retaining screws.................................................................................................... 58 to 60 lb-ft
(79 to 81 Nm)
Cam joint pin locking screw (apply Loctite 241) ...................................................................... 4 to 6
lb-ft (6 to 8 Nm)
Cam setting screw locking nut................................................................................... 23 to 28 lb-ft
(31.5 to 37.5 Nm)
SPECIAL TOOLS
CM99E005
Tool for removing the cover bushing.
CS01C525
Tool for installing the stopping ring.
Ø 1.57
2.75
1.14
0.35
Ø 0.98
Ø 1.25
8014-4
TRAVEL PEDAL CONTROL
Description
CI00J500
1 BODY
2 SPOOL
3 SHIM
4 SPRING SEAT
5 RECOIL SPRING
6 CALIBRATED SPRING
7 SPRING SEAT
8 LOCKING HALF-WASHER
9 STOPPING RING
10 BALL SEAT
11 BALL
12 SPRING SEAT
13 SPRING
14 SPRING
15 PISTON
16 COVER
17 O-RING
18 TAPPET GUIDE
19 BUSHING
20 WIPER SEAL
21 PUSH-ROD
22 NUT
23 SETTING SCREW
24 SCREW
25 GROMMET
26 CAM
27 CAM SHAFT
28 BUSHING
29 SCREW
1
2
3
7
8
9
13
14
20
21
24
25
26
28 29 27 23
22
19
18
17
16
15
12
11
10
6
5
4
8014-5
Disassembly
Always handle high precision parts with the greatest
care to prevent them being damaged by being
knocked or dropped. The components of the control
lever may rust due to contamination and humidity if
they are left without protection after disassembly. If
work has to be stopped, the components must be
protected against contamination or corrosion.
STEP 1
CI01B517
Tighten the travel pedal control in a vice with
protective jaws. Remove the grommet.
STEP 2
CI01B518
Remove the locking screw from the cam shaft.
STEP 3
CI01B519
Remove the cam shaft using a 0.31 in (8 mm)
diameter drift punch.
STEP 4
CI01B520
Mark the position of the cam with respect to the cover
and remove the cam assembly.
STEP 5
CI01B521
Remove the cover retaining screw.
8014-6
STEP 6
CI01B522
Mark the position of the cover with respect to the
travel pedal control body and remove the cover.
NOTE: Repeat the steps 2 to 6 for the second travel
pedal control body.
STEP 7
CI01B523
Mark the position of the push-rod with respect to the
guide and remove the push-rod.
STEP 8
CI01B524
Mark the position of the guide with respect to the
travel pedal control body and remove the guide
assembly.
STEP 9
CI01B525
Mark the position of the piston with respect to the port
of the travel pedal control body and remove the
piston.
STEP 10
CI01B526
Mark the position of the springs with respect to the
port of the travel pedal control body, then remove the
outer spring and the inner spring.
STEP 11
CI01B527
Mark the position of the spring seat with respect to
the port of the travel pedal control body and remove
the spring seat.
8014-7
STEP 12
CI01B528
Mark the location of the balls and remove the four
balls using a magnet.
STEP 13
CI01B529
Remove the stopping ring using pliers.
NOTE: Be careful not to scratch the inner part of the
body. When installing, make sure that the stopping
ring is put back in its original port.
STEP 14
CI01B530
Mark and remove the ball seat.
STEP 15
CI01B531
Mark and remove the spool assembly.
STEP 16
CI01B532
Mark and remove the spring.
STEP 17
CI01B535
Compress the spring with the seat so that the two
locking half-washers can be removed.
NOTE: Be careful not to damage the spool surface.
Do not compress the spring by more than 0.157 in
(4 mm).
8014-8
STEP 18
CI01B536
Mark and remove the spool, the spring seat, the
calibrated spring, the spring seat and the shim.
STEP 19
CI01B537
Mark and remove the bushing from the tappet guide.
STEP 20
CI01B538
Remove the wiper seal from the tappet guide.
NOTE: Make sure you do not damage the inner
portion of the tappet guide.
STEP 21
CI01B539
Remove the O-ring from the tappet guide.
NOTE: Repeat the steps 7 to 21 for the three other
travel pedal control ports.
STEP 22
CI01B533
Position each cover on a flat surface and remove the
bushings using a special tool and a hammer.
STEP 23
CI01B534
Fasten each cam assembly in a vice with protective
jaws, loosen and remove the nuts and the setting
screws.
8014-9
Inspection
STEP 1
Check for cracks, distortion or blocking of the springs.
If any one of the defects is found, replace the spring.
STEP 2
Check the spools to ensure that their finish is not
damaged, that they are not twisted, or chipped etc.
Ensure that the spools slide smoothly in the bore of
the travel pedal control body. If defects are found,
change the entire control pedal.
STEP 3
Check the sleeves and the clips to ensure that their
finish is not damaged, that they are not twisted,
cracked or chipped. If any one of the defects is found,
replace the damaged part.
STEP 4
Check the bores for damage, internal damage of
housings, or signs of internal wear at the level of the
travel pedal control. If the travel pedal control is
damaged, replace the entire assembly.
STEP 5
Discard all the O-rings and use new O-rings.
Assembly
NOTE: Immerse all parts in clean hydraulic fluid in
order to guarantee proper lubrication when installing
and restarting operation.
STEP 1
CI01B536
Assemble the shim, the spring seat, the calibrated
spring and the spring seat in their original positions
on the spool.
STEP 2
CI01B540
Compress the spring with the seat so that the two
locking half-washers can be engaged.
CS01C526
NOTE: Assemble the two locking half-washers with
the right angle side (A) directed towards the top.
A
8014-10
STEP 3
CI01B532
Assemble the recoil spring.
STEP 4
CI01B531
Assemble the spool assembly in the bore of the travel
pedal control body and ensure that it is positioned
correctly.
STEP 5
CI01B541
Assemble the ball seat.
STEP 6
CI01B529
Using pliers, insert the stopping ring in the port of the
travel pedal control body with the right angle directed
towards the top.
NOTE: Be careful not to damage the inside of the
body.
STEP 7
CI01B542
Using a special tool, position the stopping ring in its
groove by applying pressure on the recoil spring and
the ball seat.
NOTE: Be careful not to damage the inside of the
body.
8014-11
STEP 8
CI01B528
Install the four steel balls on their seats.
STEP 9
CI01B527
Assemble the spring seat.
STEP 10
CI01B526
Assemble the small diameter spring.
STEP 11
CI01B543
Assemble the large diameter spring.
STEP 12
CI01B544
Assemble the piston.
STEP 13
CI01B539
Assemble the O-ring on the tappet guide.
8014-12
STEP 14
CI01B538
Apply a thin coat of grease on the wiper seal and
install it in the tappet guide.
NOTE: Respect the position of the wiper seal (A)
according to the illustration below.
CS01C527
STEP 15
CI01B537
Assemble the bushing on the tappet guide.
STEP 16
CI01B545
Oil and install the push-rod in the guide.
NOTE: Make sure that the wiper seal does not get
damaged.
STEP 17
CI01B546
Assemble the tappet guide assembly.
NOTE: Repeat the steps 1 to 17 for the three other
ports of the travel pedal control.
A
8014-13
STEP 18
CI01B547
Place the cover on a flat surface and install the
bushings using the special tool and a hammer.
STEP 19
CI01B548
Assemble the cover on the travel pedal control body.
STEP 20
CI01B549
Tighten the cover retaining screw to the torque
NOTE: Check the proper positioning of the cover on
the travel pedal control body.
STEP 21
CI01B550
Assemble the nuts and the screws on the cam.
STEP 22
CI01B520
Position the cam on the cover; assemble the cam
shaft while holding it.
NOTE: Repeat the steps 18 to 22 for the other travel
pedal control body.
STEP 23
CI01B551
Apply Loctite 241 on the threads of the cam pin
locking screw and tighten it to the torque specified on
page 3.
8014-14
STEP 24
CI01B552
Adjust the height of the setting screws until the upper
surface of the cam is level. Check there is no play
between the screws and the push-rods by operating
the cam. Tighten the nuts to the torque specified on
page 3.
STEP 25
CI01B553
Tilt the cam and apply grease at the ends of the
push-rods and inject grease in the tappet guide
bushings.
STEP 26
CD01B554
Assemble the upper portion of the grommet on the
cam, apply a humidity inhibitor in the groove of the
cover in order to avoid oxidation, then assemble the
lower portion of the grommet on the cover.
8014-15
Troubleshooting
The following table draws up a list of common problems, reasons for them and action that needs to
be taken.
However, in most cases, the problems are not due to the malfunction of only a single component
but the malfunction
of this and other related components. It is important to note that this list of measures is not
exhaustive.
Problem Cause Action to be taken
The secondary coolant pressure
does not increase.
1. Insufficient primary coolant
pressure.
2. Secondary coolant pressure
control spring is worn or broken.
3. Excessive play between the spool
and the guides.
4. End play in working component.
1. Getting the correct primary
coolant pressure.
2. Use a new component.
3. Replace the spool or the guides
assembly.
4. Removal, installation and
replacement of parts.
The secondary coolant pressure is
unstable.
1. The sliding parts are jammed.
2. Variation in the line pressure at
the reservoir.
3. Mixture of air in the line.
1. Repair the jammed part.
2. Return directly to the reservoir.
3. Operate several times to drain the
air.
The secondary coolant pressure is
high.
1. Line pressure at the reservoir is
too high.
2. The sliding parts are jammed.
1. Return directly to the reservoir.
2. Repair the jammed part.
No discharge function. 1. Air trapped in the piston.
2. Sliding parts seized up.
3. The seat of the springs (13) and
(16) is defective (see section).
4. Gap between the discharge
spring and the housing is
abnormally large.
5. Malfunction of the non-return
check valve.
6. Calibrated port of the discharge
piston is abnormally large.
1. Operate several times and
release the air.
2. Repair or replace the defective
part.
3. Replace the part.
4. Replace the spring as well as the
housing.
5. Repair or replace the non-return
check valve.
6. Replace the discharge piston.
Discharge pressure is too high. 1. Sliding parts are seized up.
2. Calibrated port of the discharge
piston is blocked.
1. Repair or replace the defective
part.
2. Repair or replace the piston.
8014-16
NOTES
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
Link-Belt
Printed in U.S.A.
8015
OF THE SIX STACK SOLENOID VALVE
Section
8015
8015-2
TABLE OF CONTENTS
SIX STACK SOLENOID VALVE
............................................................................................................................. 3
Identifying the ports and the solenoid valves
...................................................................................................... 3
Section
...............................................................................................................................................................
.4
................................................................................................................................. 5
Inspection
............................................................................................................................................................ 6
8015-3
SIX STACK SOLENOID VALVE
Identifying the ports and the solenoid valves
CS01C519
C1 HIGH SPEED CONTROL
C2 SWING BRAKE CONTROL
C3 POWER BOOST CONTROL
C4 CUSHION CANCELLATION CONTROL
C5 SWING CANCELLATION CONTROL
P SIX STACK SOLENOID VALVE POWER SUPPLY
B MACHINE CONTROL POWER SUPPLY
T RETURN TO THE RESERVOIR
S1 HIGH SPEED TRAVEL SOLENOID VALVE (RED RING)
S2 SWING BRAKE SOLENOID VALVE (PINK RING)
S3 POWER BOOST SOLENOID VALVE (YELLOW RING)
S4 CUSHION CANCELLATION SOLENOID VALVE (LIGHT
GREEN RING)
S5 SWING CANCELLATION SOLENOID VALVE (GREEN
RING)
SP PILOT PRESSURE SOLENOID VALVE
BT
C5 C3 C1
S5 S3 S1
S4 S2 SP
C4 C2 P
8015-4
Section
CS01C521
1 NUT
2 COIL
3 CORE
4 O-RING
5 SPOOL
6 SPRING
1
2
3
4
56
8015-5
CS01C522
NOTE: During disassembly, identify each part of
every component in order to make assembly easier.
The spool of the component S2 is different from the
components S1, S3, S4, S5 and SP.
STEP 1
Remove the connections of the solenoid valve block.
STEP 2
Remove the retaining nut (1) from the coil (2) and
remove the coil from the core (3).
NOTE: During assembly, tighten the nut (1) to a
torque of 3.6 lb-ft (4.9 Nm).
STEP 3
Remove the core (3) from the solenoid valve housing.
Discard the O-ring (4).
NOTE: During assembly, install a new O-ring (4) on
the core (3), tighten the core (3) to a torque of 22 to
27 lb-ft (30 to 37 Nm).
STEP 4
Remove the spool (5) from the solenoid valve block
housing.
STEP 5
Remove the spring (6) from the solenoid valve block
housing.
STEP 6
Repeat steps 2 to 5 for the disassembly of the other
components.
STEP 7
Carry out inspection of the components.
NOTE: During assembly, proceed in the reverse
order to that of disassembly.
1
2
3
4
5
6
8015-6
Inspection
1. Clean all parts using suitable cleaning solvent.
Immerse the solenoid valve housing in a
cleaning solvent for several minutes to dissolve
dirt or other foreign matter inside the solenoid
valve housing. Use low pressure compressed air
to blow out any foreign matter from interior of
valve housing. Dry parts using clean cloths.
2. Inspect springs for cracks, distortion, or evidence
of permanent set. Replace a spring if any of
these defects are observed.
3. Check for cracks, holes, deformities and other
signs of wear on the spools. Check that the
spools slide easily into the grooves of the
solenoid valve block spools. If any of these
conditions are seen, replace the solenoid valve
block.
4. Check that the internal threading is not worn out
and that the solenoid valve block is not damaged
inside. If any of these conditions are seen,
replace the solenoid valve block.
5. Measure the play between the spool groove and
the spool. The play must be approximately
0.0003 inch (0.01 mm) 0.0003 inch. If this is not
the case, replace the solenoid valve block.
Link-Belt
Printed in U.S.A.
8016
OF THE CUSHION CONTROL
Section
8016
8016-2
TABLE OF CONTENTS
CUSHION CONTROL
............................................................................................................................................ 2
Description
.......................................................................................................................................................... 2
Disassembly
........................................................................................................................................................ 4
Inspection
............................................................................................................................................................ 6
Assembly
.............................................................................................................................................................
6
CUSHION CONTROL
Description
CS01C518
A ARM RETRACTION (TOWARDS JOYSTICK CONTROL)
B ARM EXTENSION (TOWARDS JOYSTICK CONTROL)
C ARM RETRACTION (TOWARD CONTROL VALVE)
D ARM EXTENSION (TOWARDS CONTROL VALVE)
E BOOM LIFTING (TOWARDS JOYSTICK CONTROL)
F BOOM LOWERING (TOWARDS JOYSTICK CONTROL)
G BOOM LIFTING (TOWARDS CONTROL VALVE)
H BOOM LOWERING (TOWARDS CONTROL VALVE)
R RETURN TO HYDRAULIC SUMP TANK
S CUSHION FUNCTION CANCELLATION
T LEAK RETURN
E
TGHR
F
B
A
CD
S
8016-3
Section
JS00567A
1 CONTROL VALVE HOUSING
2 SPRING
3 SPOOL
4 SPRING
5 SPACER
6 O-RING
7 FLOW RESTRICTION ADAPTOR
8 PLUNGER ASSEMBLY
9 O-RING
10 SPRING
11 SPRING GUIDE
12 O-RING
13 SPOOL
8
7
9
10 11 12 13
654321
8016-4
Disassembly
STEP 1
JD00549A
If the cushion control valve has to be replaced,
remove the adaptors and elbow unions and install
them on the new control valve. Do not remove the
four flow restriction adapters (7) installed in the sides
of the valve.
NOTE: Mark parts to ensure correct assembly in
same valve bore as removed from.
STEP 2
JD00550A
Remove the plug (8) with the O-ring (9) and the
spring (10).
STEP 3
JD00551A
Remove the spring (10) and the O-ring (9) of the
plug. Discard the O-ring.
STEP 4
JD00552A
Remove the spool (13) with the O-ring (12), the
spring guide (11) and the spring (10) of the control
valve.
STEP 5
JD00553A
Put the spool (13) in a vice using wooden shims to
protect the spool. Remove the spring guide (11) from
the spool (13).
7
7
8016-5
STEP 6
JD00554A
Remove the O-ring (12) from the spring guide (11).
Discard the O-ring.
STEP 7
Repeat steps 2 through 6 for the other spool.
STEP 8
JD00555A
Remove the flow restriction adaptor (7) and the
O-ring (6).
STEP 9
JD00556A
Remove and discard the O-ring (6) and the flow
restriction adaptor (7).
STEP 10
JD00557A
Remove the spring (4).
STEP 11
JD00558A
Install an M4 cap screw (A) in the tapped hole of the
spool (3). Remove the spool (3) with the spacer (5)
and the spring (2). Remove the M4 cap screw.
STEP 12
JD00559A
Remove the spring (2) and the spacer (5) from the
spool (3).
STEP 13
Repeat steps 9 through 12 for the remaining three
spools.
3
2
5
8016-6
Inspection
STEP 1
Clean all parts using suitable cleaning solvent.
Immerse valve housing in cleaning solvent for
several minutes to dissolve dirt or other foreign
matter inside valve housing. Use low pressure
compressed air to blow out any foreign matter from
interior of valve housing. Dry parts using clean cloths.
STEP 2
Inspect springs for cracks, distortion, or evidence of
permanent set. Replace a spring if any of these
defects are observed.
STEP 3
Check the spools for cracks, holes, distortion or other
damage. Check that the spools slide easily in the
groove of the control valve housing. If any defects are
observed replace the cushion valve.
STEP 4
Check the plugs, flow restriction adapters, and spring
guides for damaged threads. Check the ports in flow
restriction adapters for foreign matter, chipping, or
other damage. Check spring guides for bent
condition. Replace a defective part.
STEP 5
Check the spacer for chipping, wear and signs of
damage. If any of these conditions are seen replace
the spacer.
STEP 6
Check for damaged threads and signs of internal
wear on the control valve housing. If any defects are
seen, replace the cushion valve.
Assembly
NOTE: Lubricate all parts with clean hydraulic oil.
Ensure that parts are assembled in the same groove
as they were removed from.
STEP 1
JD00559A
Install the spacer (5) on the spool (3).
STEP 2
JD00560A
Install the spring (2), the spool (3) and the spacer (5)
in the control valve housing.
3
2
5
2
8016-7
STEP 3
JD00561A
Install the spring (4) in the spool (3).
STEP 4
JD00562A
Install a new O-ring (6) on the flow restriction adaptor
(7). Install the flow restriction adaptor in the control
valve housing.
STEP 5
Repeat steps 1 through 4 for remaining three spools.
STEP 6
JD00554A
Install the spring guide (11) using a new O-ring (12)
on the spool (13).
STEP 7
JD00563A
Install the spring (10) on the spool (13).
STEP 8
JD00564A
Install the spring (10), the spring guide (11) and the
spool (13) in the groove of the control valve housing.
STEP 9
JD00565A
Install the spring (10).
8016-8
STEP 10
JD00566A
Install a new O-ring (9) on the plug (8). Install the
plug and O-ring in the housing.
STEP 11
Repeat steps 6 through 10 for the other spool.
STEP 12
JD00549A
If removed, install the adapters and elbows on the
control valve.
Link-Belt
Printed in U.S.A.
8017
HOSE BURST CHECK VALVE
Section
8017
8017-2
Cre 7-29630-21LX Issued 11-01
TABLE OF CONTENTS
TORQUE SETTINGS
............................................................................................................................................. 2
BOOM RELIEF VALVE
.......................................................................................................................................... 3
Marking the ports
................................................................................................................................................ 3
Removal
..............................................................................................................................................................
3
Installation
........................................................................................................................................................... 3
Disassembly
........................................................................................................................................................ 4
Assembly
.............................................................................................................................................................
6
ARM RELIEF VALVE
............................................................................................................................................. 8
Marking the ports
................................................................................................................................................ 8
Removal
..............................................................................................................................................................
8
Installation
........................................................................................................................................................... 8
Disassembly
........................................................................................................................................................ 9
Assembly
...........................................................................................................................................................
11
TORQUE SETTINGS
Boom relief valve
Spool cap (3) ....................................................................................................202 lb-ft +/- 10%
(274.6 Nm +/- 10%)
Spool stop cap (1) ................................................................................................58 lb-ft +/- 10%
(78.5 Nm +/- 10%)
Plug (11) ...........................................................................................................159 lb-ft +/- 10%
(215.8 Nm +/- 10%)
Plug (15) ...............................................................................................................58 lb-ft +/- 10%
(78.5 Nm +/- 10%)
Safety valve (10)...................................................................................................43 lb-ft +/- 10%
(58.8 Nm +/- 10%)
Arm relief valve
Plug (1) and (5).................................................................................................159 lb-ft +/- 10%
(215.8 Nm +/- 10%)
Spool cap (9) and (11) retaining screws ...............................................................29 lb-ft +/- 10%
(39.2 Nm +/- 10%)
Safety valve (18)...................................................................................................43 lb-ft +/- 10%
(58.8 Nm +/- 10%)
8017-3
Cre 7-29630-21LX Issued 11-01
BOOM RELIEF VALVE
Marking the ports
CD00K000
1 PILOT SPOOL
2 LEAK RETURN
3 HIGH PRESSURE CIRCUIT BYPASS TOWARDS THE
OTHER VALVE
4 VALVE POWER SUPPLY
Removal
NOTE: Before performing any operation on the
machine, carry out the following operations in the
order shown.
- Depressurise the hydraulic circuit (see
Section 8000).
1. Remove the hoses (1), (2) and (3) and seal the
unions and the hoses.
2. Remove the tube (4) and seal the ports.
3. Remove the screws (5) and remove the relief
valve (6).
4. Seal the cylinder port.
Installation
When installing, use the same procedure in the
reverse order of removal by assembling new seal
rings.
For 1 valve adjustment, refer to section 8001.
2
3
6
45
8017-4
Cre 7-29630-21LX Issued 11-01
Disassembly
1. Remove the spool stop cap (1) and discard the
joint (2).
2. Remove the spool cap (3), discard the joint (4)
and remove the springs (5) and (6).
3. Remove the seat from the springs (7).
4. Remove the spool (9).
CI00K505
5. Remove the plug (11), discard the joint (12),
remove the spring (13) and the check valve (14)
by marking their positions.
6. Remove the plug (15), discard the joint (16),
remove the spring (17) and the check valve (18)
by marking their positions.
7. Remove the valve (10) and discard the joint (36).
1
2
974563
10
14 13 11 12 18 17 15 16 36
8017-5
Cre 7-29630-21LX Issued 11-01
CI00K504
8. Remove the locknut (19), the pressure setting
screw (20) and discard the joint (21).
9. Remove the spring (22) and the check valve (23).
10. Remove the valve cap (24) from the sheath (25)
and discard the joint (26).
11. Remove the valve nose (27) and remove the
spring (28).
12. Discard the joint (29) and the back up rings (30).
14. Remove the awl (33), discard the joint (34) and
the back up rings (35).
21 22 23 24 26 28 25 27
19
20
30 29 31 34 35 33
32
8017-6
Cre 7-29630-21LX Issued 11-01
Assembly
CI00K504
NOTE: When installing, install new seal rings.
1. Install a joint (34) and back up rings (35) on the
awl (33).
2. Oil and install the awl (33) in the valve nose (27).
3. Oil and install the valve nose (27) in the sheath
(25).
4. Install the check valve (32) and the spring (31).
5. Install a joint (29), the back up rings (30) and a
joint (26) on the cap (24).
6. Put the spring (28) in place.
7. Oil the cap (24) and the inside of the valve nose
(27).
8. Install the cap (24) taking care not to damage the
joints (29) and (30).
10. Install a joint (21) on the screw (20).
11. Install the screw (20) without tightening it too
much, the final tightening will be done with
pressure setting.
12. Install the blank nut (19).
21 22 23 24 26 28 25 27
19
20
30 29 31 34 35 33
32
8017-7
Cre 7-29630-21LX Issued 11-01
13. Install an O-ring (2) on the spool stop cap (1).
14. Install the cap (1) on the relief valve.
15. Oil and install the spool (9).
16. Install the springs (5) and (6).
17. Install an O-ring (4) on the spool cap (3).
18. Install the spool cap (3).
19. Install a joint (36) and install the valve (10).
CI00K505
NOTE: Take care in respecting the position of each
check valve assembly marked during removal.
20. Install an O-ring (16) on the plug (15).
21. Oil and install the check valve (18) and the spring
(17).
22. Install and tighten the plug (15).
23. Install an O-ring (12) on the plug (11).
(13).
25. Install and tighten the plug (11).
1
2
974563
10
14 13 11 12 18 17 15 16 36
8017-8
Cre 7-29630-21LX Issued 11-01
ARM RELIEF VALVE
Marking the ports
CD00K001
1 PILOT SPOOL
2 VALVE POWER SUPPLY
3 SPOOL LEAK RETURN
4 VALVE LEAK RETURN
Removal
NOTE: Before performing any operation on the
machine, carry out the following operations in the
order shown.
- Park the machine on the ground.
- Depressurise the hydraulic circuit (see
Section 8000).
1. Remove the hoses (1), (3) and (4) and seal the
unions and the hoses.
2. Remove the tube (2), seal the tube and the
union.
3. Remove the screws (5) and remove the relief
valve (6).
4. Seal the cylinder port.
Installation
When installing, use the same procedure in the
reverse order of removal, by assembling new seal
rings.
For valve adjustment, refer to section 8001.
23
4
1
6
5
8017-9
Cre 7-29630-21LX Issued 11-01
Disassembly
CI00K503
1. Remove the plug (1) and discard the joint (2).
2. Remove the spring (3) and the check valve (4)
after marking their positions.
3. Remove the plug (5) and discard the joint (6).
4. Remove the spring (7) and the check valve (8)
after marking their positions.
5. Remove the retaining screws from the spool stop
cap (9), remove it and discard the joint (10).
6. Remove the screws and remove the spool cap
(11), discard the joint (12).
7. Remove the springs (13) and (14).
8. Remove the seats from the spring (15) and (16).
9. Remove the spool (17).
10. Remove the valve (18) and discard the joint (36).
9
10
13 11 12 15 16 17
14
18
1
2345678
36
8017-10
Cre 7-29630-21LX Issued 11-01
CI00K504
11. Remove the locknut (19), and the pressure
setting screw (20) and discard the joint (21).
13. Remove the valve cap (24) from the sheath (25)
and discard the joint (26).
14. Remove the valve nose (27) and remove the
spring (28).
15. Discard the joint (29) and the back up rings (30).
17. Remove the awl (33), discard the joint (34) and
the back up rings (17).
22 23 24 26 28 25 27
21
19
20
30 29 31 34 35 33
32
8017-11
Cre 7-29630-21LX Issued 11-01
Assembly
CI00K504
NOTE: When installing, install new seal rings.
1. Install a joint (34) and back up rings (35) on the
awl (33).
2. Oil and install the awl (33) in the valve nose (27).
3. Oil and install the valve nose (27) in the sheath
(25).
5. Install a joint (29), back up rings (30) and a joint
(26) on the cap (24).
6. Install the spring (28).
7. Oil the cap (24) and the inside of the valve nose
(27).
8. Install the cap (24) taking care not to damage the
joints (29) and (30).
10. Install a joint (21) on the screw (20).
11. Install the screw (20) without tightening it too
much, the final tightening will be done with
pressure setting.
12. Install the blank nut (19).
22 23 24 26 28 25 27
21
19
20
30 29 31 34 35 33
32
8017-12
Cre 7-29630-21LX Issued 11-01
CI00K503
13. Install a joint (36) on the valve (18).
14. Install the valve (18).
(3) according to the markings made during
disassembly, install the plug (1) equipped with a
joint (2).
(7) according to the markings made during
disassembly, install the plug (5) equipped with a
joint (6).
17. Install a joint (10) and install the spool stop cap
(9) using four retaining screws.
18. Oil and install the spool (17).
19. Install the spring seats (16) and (15).
20. Install the springs (13) and (14).
21. Install a joint (12) on the spool cap (11).
22. Install and fasten the spool cap (11) using the
four screws.
9
10
13 11 12 15 16 17
18
1
2345678
36
14
Link-Belt
Printed in U.S.A.
8018
OF THE ROTATING JOINT
Section
8018
8018-2
TABLE OF CONTENTS
SPECIAL TORQUE
SETTINGS............................................................................................................................... 2
ROTATING
JOINT....................................................................................................................................................
3
Description
........................................................................................................................................................... 3
Disassembly..........................................................................................................................................
............... 4
Assembly...............................................................................................................................................
............... 6
Cover retaining screws.........................................................................................23.7 to 28.1 lb-ft
(32.2 to 38.2 Nm)
8018-3
ROTATING JOINT
Description
JS00031A
1 CAP SCREW
2 WASHER
3 LOCKING BAR
4 PIVOT
5 "V" SEAL
6 BUSHING
7 O-RING
8 SEALING RING
9 THRUST PLATE
10 HEXAGONAL ALLEN TYPE CAP SCREW
11 O-RING
12 COVER
14 CAP SCREW
15 WASHER
4
5
78
6
8
12
13
10
9
11
1
2
3
14
15
8018-4
NOTE: To remove the rotating joint, refer to Section
8006.
Disassembly
Always handle the components carefully. Never
force, hit or drop components. Prevent any
contamination from dust, water or foreign bodies.
Work in a clean area with clean tools. Always use a
press to disassemble the inner and outer
components of the rotating joint.
STEP 1
JS00025A
Remove the screws (13) and the cover (12).
STEP 2
JS00026A
Remove the O-ring (11) and discard it.
STEP 3
JS00027A
Remove the screws (10) and the thrust plate (9).
STEP 4
JS00028A
Using a press, separate the inner component (4) from
the outer component (6).
STEP 5
JS00029A
Remove the "V" seal (5) from the inner component
(4) and discard it.
13
12
6
11
6
10
9
4
6
6
4
5
4
8018-5
STEP 6
JS00030A
Remove the O-ring (7) and the sealing rings (8) from
inside the outer component (6). Discard the sealing
rings and the O-ring.
7
8
8
8
6
8018-6
Assembly
Clean all the components. Use an oil stone to polish
out scratches and rough areas. Use new seals,
O-rings and sealing rings. Take the same precautions
as during disassembly.
STEP 1
JS00032A
Clean the outer component in cleaning solvent or low
pressure compressed air.
STEP 2
JS00033A
A: 1 O-ring
B: 6 sealing rings
JS00034A
Coat the O-ring (7) with hydraulic fluid and insert it in
the upper groove in the outer component. Coat the
six sealing rings (8) with hydraulic fluid and insert
them, starting from the second groove down from the
top of the outer component.
STEP 3
JS00035A
Use a mirror to check that the O-ring and sealing
rings are correctly installed. Apply hydraulic fluid,
make sure that the components are not protruding,
twisted, etc.
7A
8
8
B8
6
7
8
8
8
8018-7
STEP 4
CS00G519
Install a new "V" seal (5) on the inner component (4)
and coat it with clean hydraulic fluid.
STEP 5
JS00037A
Insert the inner component (4) in the outer
component (6).
NOTE: Do not cut through the "V" seal, or graze it.
STEP 6
JS00038A
Install the thrust plate (9) and the screws (10).
STEP 7
JS00039A
Install the O-ring (11).
STEP 8
JS00040A
Install the cover (12) and the screws (13). Tighten the
screws to torque (see page 2).
5
4
6
4
10
9
4
11
6
13
12
6
8018-8
Link-Belt
Printed in U.S.A.
8019
OF THE HYDRAULIC SWING MOTOR
Section
8019
8019-2
TABLE OF CONTENTS
SPECIFICATIONS
................................................................................................................................................... 3
TORQUE SETTINGS
.............................................................................................................................................. 3
HYDRAULIC SWING MOTOR
................................................................................................................................ 4
Description
.......................................................................................................................................................... 4
Disassembly
........................................................................................................................................................ 6
Inspection
.......................................................................................................................................................... 13
Assembly
...........................................................................................................................................................
14
RELIEF VALVE
..................................................................................................................................................... 21
Disassembly
...................................................................................................................................................... 21
Inspection
.......................................................................................................................................................... 22
Assembly
...........................................................................................................................................................
22
8019-3
SPECIFICATIONS
See Section 1002
TORQUE SETTINGS
Cover plug ...................................................................................................................................17.5
lb-ft (23.8 Nm)
Bypass valve plug........................................................................................................................17.5
lb-ft (23.8 Nm)
Non return check valve plug ........................................................................................................17.5
lb-ft (23.8 Nm)
Cover screw................................................................................................................................... 115
lb-ft (157 Nm)
Safety valve
.......................................................................................................................................57 lb-ft (78
Nm)
8019-4
HYDRAULIC SWING MOTOR
Description
1 SLEEVE
2 SPY JOINT
3 BEARING
4 OIL GAUGE
5 SPRING
6 PISTON PLATE
7 BASE PLATE
8 PISTON ASSEMBLY
9 FRICTION PLATE
10 DISK PLATE
11 O-RING
12 BRAKE PISTON
13 O-RING
14 SPRING
15 RETAINING PIN
16 COVER
17 O-RING
18 PLUNGER ASSEMBLY
19 PISTON
20 SPRING
21 TEFLON RING
22 BUSHING
23 DISTRIBUTION PLATE
24 BEARING
25 CYLINDER
26 HOUSING
27 PLUNGER ASSEMBLY
28 SPRING
29 BY PASS VALVE
30 CHECK VALVE
31 SPRING
32 O-RING
33 BACKUP RING
34 O-RING
35 NON RETURN CHECK VALVE
36 SEAT
37 PLUNGER ASSEMBLY
38 CHECK VALVE
39 SPRING
40 O-RING
41 SHIM
42 SPACER
43 VALVE HOUSING
44 PISTON
45 O-RING
46 BACKUP RING
47 PLUNGER ASSEMBLY
48 SLEEVE
49 SAFETY VALVE ASSEMBLY
51 O-RING
52 BACKUP RING
53 PLUNGER ASSEMBLY
A SHOE
B BRAKE PILOT PORT
8019-5
CI00G504
31
15
30
28
29
32 33 34 35 36 38 39 40 42 41 43 45
46
47
44
48
37
49
50
53 52 51
16 19 18
17
20
21
22
23
B
24
25
26
27
45321
6
A
7
8
9
10
11
12
13
14
8019-6
Disassembly
STEP 1
JD00387A
Remove the oil level dipstick (4) and dipstick tube
(A).
NOTE: If the swing motor is being replaced, do steps
2 through 4 below. If the swing motor is not being
replaced, disregard steps 2 through 4.
NOTE: Install the plugs in the ports of the motor.
STEP 2
JD00388A
Remove the two elbow joints from the motor. Remove
and discard O-rings.
STEP 3
JD00390A
Remove the large joint on top of the motor. Remove
and discard O-rings.
STEP 4
JD00391A
To make reassembly easier, mark the location of the
safety valve assemblies (1) on the lid so that they can
be put back in their original place.
4
A
1
8019-7
STEP 5
JD00392A
Remove relief valve assemblies (1) from swing
motor. Remove and discard the O-rings (2).
STEP 6
JD00393A
To aid assembly, put alignment marks (A) on the
cover and motor housing. Remove the four cover
retaining screws (1).
STEP 7
JD00394A
Remove the cover from the motor housing.
STEP 8
JD00395A
Place the cover with the shaft on top and remove the
retaining ring (1) from the shaft (2).
STEP 9
JD00396A
Remove the internal needle bearing ring (1).
STEP 10
JD00397A
A ALIGNMENT MARK
Remove large O-ring (1) from cover. Discard the
O-ring.
NOTE: Mark the distribution plate and cover with an
indelible ink felt tip pen prior to removal to ensure
correct alignment when reassembling.
2
1
1
A
1
2
1
1
A
8019-8
STEP 11
JD00398A
Remove the cover distribution plate.
STEP 12
JD00399A
To aid assembly, mark the location of pistons (1) to
ensure installation in the same bore as removed
from. Remove the pistons from the balance plate.
STEP 13
JD00400A
Remove the four bushings (1) with teflon rings (2)
from the cover. Discard teflon rings.
STEP 14
JD00401A
Remove the four Belleville washers (1) from bushing
recesses in the cover.
STEP 15
JD00403A
Remove the plug (1) from cover.
1
1
1
2
1
1
8019-9
STEP 16
JD00403A
Remove the O-ring (1) and back-up ring (2) from the
plug (3). Discard the O-ring and back-up ring.
STEP 17
JD00404A
Remove the spring (1) from cover.
STEP 18
JD00405A
Remove the check valve (1) from the cover.
STEP 19
JD00407A
Remove the two O-rings (1) and (2) and the teflon
back-up ring (3) from the bypass valve plug. Discard
O-rings and back-up ring.
STEP 20
JD00408A
Remove the spring (1) and valve assembly (2) from
cover.
STEP 21
Rotate cover 180 degrees and repeat steps 15
through 20 to remove the other check valve and
bypass valve plug.
3
21
1
1
3
2
1
1
2
8019-10
STEP 22
JD00409A
JD00410A
Remove the plug (1) from cover. Remove O-ring from
plug. Discard the O-ring.
STEP 23
JD00411A
Remove the springs (1) from the brake piston (2).
STEP 24
NOTE: Protect the housing and the piston surfaces
with rags when you lever the piston out of the
housing.
JD00412A
JD00413A
Install two M6 screws (A) in tapped holes in piston.
Lever these screws and free the piston from the
housing.
1
2
1
A
A
8019-11
STEP 25
JD00414A
JD00415A
Remove the O-rings (1) and (2) from the swing motor
housing (3) and the brake piston (4). Discard O-rings.
Remove the two M6 screws from the brake piston.
STEP 26
JD00416A
Remove the three friction plates (1) and the three
disc plates (2) from the motor housing.
STEP 27
JD00417A
Remove the cylinder assembly from the motor
housing.
STEP 28
JD00418A
Remove the external bearing ring (1) from the motor
housing.
STEP 29
JD00419A
Position the motor housing in a press. With a sleeve
or a suitable guiding pin, force the lip seal out of the
housing. Discard the lip seal.
1
4
2
3
1
2
1
A
8019-12
STEP 30
JD00420A
Remove the retaining ring (1) from the fluted shaft
(2).
STEP 31
JD00421A
Remove the tapered roller bearing and the spacer
with an extractor separator.
STEP 32
JD00422A
Remove the tapered roller bearing (1) and the spacer
(2) from the shaft (3).
STEP 33
NOTE: Mark the location of the pistons on the base
plate and on the cylinder. Pistons must be installed in
same positions during assembly.
JD00423A
Remove the piston plate (1), the piston assembly (2)
and the base plate (3) from the cylinder.
STEP 34
JD00424A
Slip the piston plate (1) out of the sliding surfaces of
the piston assemblies (2), while ensuring that it does
not get damaged. Remove the pistons from the base
plate (3).
1
2
2
1
3
1
2
3
1
2
3
8019-13
STEP 35
JD00425A
Using an extractor, remove the spacer (1) from the
fluted shaft. Remove the spring (2) from the cylinder.
Inspection
STEP 1
Check the distribution plate sliding surfaces for signs
of seizing or wear. If there is evidence of seizing or
wear, the plate should be replaced.
STEP 2
Check for wear of the pistons. Replace the motor if
the depth of any shoe sliding surface is less than
0.0177 inch (0.45 mm), if the shoe surfaces are
seriously damaged or if a piston assembly shows any
sign of seizing. There should be no wear of the
external surfaces of the piston assemblies.
STEP 3
Check for signs of seizing or wear on the piston plate
sliding surface. The plate should be replaced if there
is evidence of seizing or wear.
STEP 4
Check for signs of seizing, wear or damage on the
cylinder piston bores. The motor should be replaced
if there is evidence of seizing or if the piston bores
are damaged.
Inspect the needle bearing and tapered roller bearing
for damage. The bearings should be replaced if any
damage is found, or after 3000 hours of operation.
1
2
8019-14
Assembly
STEP 1
JD00427A
Apply grease (No. 2 EP lithium grease) to the curved
part of the cylinder shaft that contacts the spring and
install the spring.
STEP 2
JD00428A
Apply clean hydraulic fluid to the cylinder (1) bores.
Install the piston assemblies (2) at the ports of the
base plate (3). Install the piston assemblies and the
base plate on the cylinders. Be sure that the pistons
are installed in the same bores as removed from.
STEP 3
JD00429A
Apply clean hydraulic fluid on the sliding surfaces of
the piston assemblies (A) and install the piston plate.
STEP 4
JD00432A
Install the spacer (1) and a new tapered roller bearing
(2) on the shaft. Using a proper size sleeve on the
inner race of the tapered roller bearing, press the
bearing and sleeve (3) on the shaft.
2
3
1
A
3
2
1
8019-15
STEP 5
JD00430A
Apply a thin coat of Loctite 515 or 518 where the
sleeve is installed on the cylinder shaft. Press the
sleeve on the shaft.
STEP 6
JD00420A
Install the retaining ring (1).
STEP 7
JD00431A
Before removal, apply grease to the lip of the lip seal.
Position housing in a press. Apply Loctite 504 to the
periphery of the lip seal. Install and centre the lip seal
in the housing bore. With a suitable sleeve (A), press
the lip seal in the bore of the housing.
STEP 8
JD00418A
Install the new external roller ring (1) in the motor
housing.
STEP 9
JD00417A
Carefully install the cylinder assembly in the housing.
Be careful when installing the cylinder assembly not
to damage the splines on the shaft.
STEP 10
JD00416A
Apply clean hydraulic fluid to both faces of the friction
plates (1) and the disc plates (2). Install a disc plate
first, then a friction plate, then a disc plate, then a
friction plate, then the last disc plate, then the last
friction plate.
1
A
1
1
2
8019-16
STEP 11
JD00415A
JD00414A
Apply grease to the new O-rings (1) and (2); install
the O-rings in the motor housing (3) and on the brake
piston (4). Install two M6 screws (A) in tapped holes
in piston to assist in installing the brake piston in the
motor housing.
STEP 12
JD00433A
Apply clean hydraulic fluid on the periphery of the
piston. Push the piston in the housing. Remove the
two M6 screws.
STEP 13
JD00411A
Install the springs (1) in the brake piston (2) in their
original locations.
STEP 14
JD00410A
JD00409A
Install a new O-ring on the plug (1). Install the plug
(1) on the cover. Tighten the plug to a torque of 17.5
lb-ft (23.8 Nm).
1
3
2
4
A
2
1
1
8019-17
STEP 15
JD00408A
Reposition the cover and install the spring (1) and
valve assembly (2) in bypass valve port of cover.
STEP 16
JD00407A
Install two new O-rings (1) and (2) and a new teflon
back-up ring (3) on bypass valve plug (4).
STEP 17
JD00406A
Install bypass valve plug (1) in cover. Tighten the plug
to a torque of 17.5 lb-ft (23.8 Nm).
STEP 18
Repeat steps 15 through 17 to install second bypass
valve on other side of cover.
STEP 19
JD00405A
Install the check valve (1) in the cover.
STEP 20
JD00404A
Install the spring (1) in the cover.
STEP 21
JD00403A
Install a new O-ring (1) and a new back-up ring (2) on
the plug (3).
1
2
3
4
2
1
1
1
1
3
2
1
8019-18
STEP 22
JD00403A
Install the plug (1) in cover. Tighten the plug to a
torque of 17.5 lb-ft (23.8 Nm).
STEP 23
Repeat steps 19 through 22 to install second make
up check valve.
STEP 24
JD00401A
Install the Belleville washers (1).
STEP 25
JD00400A
Apply No. 2 EP lithium grease to the bushings (1),
new teflon rings (2), and the pins (3) in the cover.
Install a teflon ring on each of the bushings. Install
the bushings with rings in the bushing ports on the
cover.
STEP 26
JD00399A
Apply No. 2 EP lithium grease to the pistons and
install the pistons (1) in the balance plate (2). Be sure
that the pistons are installed in same bore as
removed from. Install pistons and balance plate on
the cover ensuring that marks made in step 10 of
disassembly are aligned.
1
1
1
2
3
21
8019-19
STEP 27
JD00395A
Install the new needle bearing inner race (1) on the
shaft and install the retaining ring (2).
STEP 28
JD00397A
Install a new, greased O-ring (1) on the cover.
STEP 29
JD00434A
Apply Loctite 504 to the mating surfaces of the motor
housing and cover.
STEP 30
JD00394A
Install carefully the cover (1) and the distribution plate
(2) on the housing, by making sure that the
distribution plate and bushings do not fall off the
cover. Align the motor housing and cover alignment
marks.
STEP 31
JD00393A
Install the four retaining screws (1) on the cover and
tighten to a torque.
2
1
1
1
2
1
8019-20
STEP 32
JD00435A
JD00392A
Install a new O-ring (1) on the safety valve assembly
(2). Install the safety valve assemblies in the cover
and tighten to a torque.
STEP 33
JD00390A
Install a new O-ring on the large fitting and install the
fitting in the swing motor cover.
STEP 34
JD00388A
Install new O-rings on elbows. Install the elbow
unions in the motor cover.
STEP 35
JS00436A
Install the oil level gauge tube (A) L = 4.56 inch (116
mm), and the oil level gauge.
STEP 36
Apply a pilot pressure of 30 bar (435 psi) at the brake
port. Check that the drive shaft can be rotated
smoothly at least one full revolution by applying a
torque of approximately 28.7 lb-ft (39 Nm).
NOTE: If the shaft does not turn, the unit has not
been assembled correctly. Disassemble and repeat
assembly steps.
2
1
A
8019-21
RELIEF VALVE
Disassembly
STEP 1
JD00438A
Loosen the plug on the relief valve.
STEP 2
JD00439A
Remove the plug from the relief valve housing.
STEP 3
JD00440A
If necessary, remove the O-ring and back-up ring
from plug. Do not discard the rings; rings are not
available separately.
STEP 4
JD00441A
Remove the relief valve assembly from the housing.
STEP 5
JD00435A
Remove O-ring from housing, if not previously
removed. Discard the O-ring.
STEP 6
JD00442A
Remove the piston from the poppet.
8019-22
STEP 7
JD00443A
Remove the poppet sleeve.
STEP 8
JD00444A
Remove the spacer (A) and the shim (B) from the
poppet.
STEP 9
JD00445A
Remove the spring and the seat from the poppet.
Inspection
NOTE: Individual relief valve assembly parts cannot
be replaced. If a relief valve assembly fails to operate
properly for any reason other than dirt or foreign
matter, the entire assembly must be replaced.
STEP 1
Clean the disassembled components with clean
hydraulic fluid and dry them with compressed air at
low pressure.
Assembly
STEP 1
JD00445A
Install the seat and the spring on the poppet.
STEP 2
JD00444A
Install the spacer (A) and the shim (B) on the poppet.
AB
8019-23
STEP 3
JD00443A
Install the sleeve on the poppet.
STEP 4
JD00442A
Install the piston on the poppet.
STEP 5
JD00435A
Install new O-ring on the housing.
STEP 6
JD00441A
Install relief valve assembly in housing.
STEP 7
JD00440A
Install O-ring and back-up ring on plug if removed.
STEP 8
JD00439A
Assemble and tighten the plug in the relief valve
housing.
8019-24
Link-Belt
Copyright 2001 Link Belt
Printed in U.S.A.
8020
HYDRAULIC FUNCTIONS
Section
8020
8020-2
Cre 7-28420-21LX Issued 11-01
TABLE OF CONTENTS
HYDRAULIC
FUNCTIONS........................................................................................................................................3
Function
List.........................................................................................................................................................
.3
Controls in Neutral
................................................................................................................................................6
High Speed Travel Circuit
.....................................................................................................................................8
Low Speed Travel Circuit
....................................................................................................................................10
Straight Line Travel
Circuit..................................................................................................................................12
Swing Circuit
.......................................................................................................................................................14
Auto Swing Priority Valve
Circuit.........................................................................................................................16
Free swing
operation...........................................................................................................................................18
Boom Raising
Circuit...........................................................................................................................................18
Boom Lowering Circuit, Load Holding
Valve.......................................................................................................20
Boom Lowering Regeneration Circuit
.................................................................................................................20
Boom Lowering Anti-vibration Circuit
..................................................................................................................20
Arm Extending Circuit
.........................................................................................................................................22
Arm Retracting Circuit
.........................................................................................................................................24
Arm Retracting Regeneration Circuit
..................................................................................................................24
Bucket Opening Circuit
.......................................................................................................................................26
Bucket Closing Circuit
.........................................................................................................................................27
Crusher Circuit
....................................................................................................................................................28
Breaker Circuit
....................................................................................................................................................30
8020-3
Cre 7-28420-21LX Issued 11-01
HYDRAULIC FUNCTIONS
Function List
Operation Description of function
Description
of operation
Travel
High speed
High speed may be obtained by changing the displacement of the travel motors
from high to low.
When pressure becomes too high, the motors automatically change down to low
speed.
When pressure drops, the motors automatically change up to high speed.
The machine returns to 1st speed when travel pressure drops to below
570 psi, to prevent snatching when turning on the spot in 2nd speed.
Page 8
Low speed Low speed may be obtained by selecting high travel motor displacement. Page 10
Straight line
travel
If the attachment is used or swing operated during travel, the machine continues
traveling in a straight line.
Page 12
Swing
Braking
When the swing control is in neutral, swing is prevented by the brake.
When the swing control is operated, the moto-reduction gear brake is released.
The brake will be applied once more within 5 seconds of returning the swing
control to neutral or of halting all attachment movement.
When the swing locking control is operated, the brake will be applied.
Page 14
Priority Full swing power is maintained by a priority valve inside the control valve.
When digging trenches, the variable swing priority valve is actuated.
Page 16
Swing
cushion This function allows the swing movement to come to a smooth halt.
Free swing
operation
An orifice leak is opened between the A and B ports of the swing motor. This will
provide smoother starts and stops of the swing during hoisting operation
Page 18
Attachment
Boom raising An internal spool makes two flows to the boom possible. Page 20
Boom
lowering,
load holding
Boom can be lowered by releasing the load holding valve inside the control
valve.
Page 22
Boom
lowering
regeneration
By regeneration hydraulic oil via the boom spool and maintaining permanent
feed/return information feed back, higher speed and negative pressure
prevention are made possible.
Page 22
Boom
lowering -
vibration
prevention
Peak pressure is prevented by the bleed off circuit, thereby reducing extra
vibration.
Page 22
Arm
extension An internal spool makes two flows to the arm possible. Page 24
Arm
retraction -
load holding
Arm retraction is made possible by releasing the load holding valve inside the
control valve.
Page 26
Arm
retraction -
regeneration
The regeneration cancellation valve makes combined movements faster. Page 26
Cushion
valve
The shocks encountered at the end of attachment movements are reduced by
the cushion valve, which has a built-in pilot heating circuit.
8020-4
Cre 7-28420-21LX Issued 11-01
Attachment (continued)
Option An option section is included in the control valve and can be used for special
attachments such as a crusher or breaker.
Page 32
Other features
Auto
power-up
When the engine is under heavy load, the main relief valve automatically goes
into high setting for 8 seconds.
Neutral pump
de-stroke
This is designed to reduce power consumption by reducing flow from the pumps
when the machine is not under load.
8020-5
Cre 7-28420-21LX Issued 11-01
This page is intentionally left blank
8020-6
Cre 7-28420-21LX Issued 11-01
Controls in Neutral
When the controls are in neutral, with the engine running, a part of the flow coming from the low
pressure pump
arrives at PP and is divided by a battery of restrictors. Part of the flow goes through the travel
control valves and
the other part goes to the remaining control valves before returning to the tank. When the spools
are moved,
these circuits are closed, thereby closing the travel or upperstructure pressure switch contact points
and
transmitting the electronic information.
The two flows from the HP pumps cross the control valve via the free passages. They are controlled
by two
pressure limiters set at 370 psi for a flow of 13.2 gpm and two flow restrictors. Both pressures (PN)
are sent to
the Pi1 and Pi2 ports on the pumps to regulate them to deliver minimum flow.
8020-7
Cre 7-28420-21LX Issued 11-01
CM00K026
Pb9
Pa9
Pc2
Pb8
Pb8’
Pa8’
Pa8
Pb7
Pa7
Pb6
Pa6
__ PT __ __
P4
A3
B3
Pbu
A5
Pc1
Ps1 Dr T2 T1 Ps2
405 psi
28 bar
405 psi
28 bar
Pb5’
B5
PH
Pa1
Pb1
PA P3
A8
B8
A7
B7
A6
B6
Pb5
Pa5’
Pa5
Pc3’
Pc3
Pb4
Pb4’
Pb3
Pa3
A2
B2
Pb2
Pa2
A1
B1
T3 T5 T4
___ ___
A2
a2
A3
Dr B1 B3
A1 Psv a3
a1
3.92 MPa
568 psi
39.2 bar
a3
10μ
P3
P2
P0 P
P1
0.103 Mpa
14.5 psi
1 bar
0.02 MPa
8020-8
Cre 7-28420-21LX Issued 11-01
High Speed Travel Circuit
There are two flows of oil which supply the travel motors.
In high speed the travel motors are in low displacement position.
The travel motors have an internal circuit which enables them to change from low to high
displacement when
supply pressure exceeds a certain level. If the pressure drops once more, the motors automatically
revert to high
speed.
Oil from the A1 pump outlet enters the P1 port on the control valve, whereas oil from the A2 pump
outlet enters
P2. One flow goes directly to the left-hand travel spool and the other goes to the right-hand travel
spool.
The calculator sends a current to the cylinder displacement change electrovalve for high speed to
be selected.
The 565 psi pilot pressure coming from the high speed electrovalve passes through the hydraulic
swivel and
goes to pilot the travel motor cylinder displacement change spools.
C1. 2 stage travel (Red band)
C3. Power-up (Yellow band)
C5. Swing shut off (Green band)
Pa1/A1. RH forward travel
Pb1/B1. RH reverse travel
Pa6/A6. LH forward travel
Pb6/B6. LH reverse travel
2. Controller
3. Work mode switch
8020-9
Cre 7-28420-21LX Issued 11-01
CM00K013
Pb9
Pa9
Pc2
Pb8
Pb8’
Pa8’
Pa8
Pb7
Pa7
___
___
PT PP __ __
P4
A3
B3
Pbu
A5
Pc1
Ps1 Dr T2 T1 Ps2
405 psi
28 bar
405 psi
28 bar
Pb5’
B5
PH
___
___
PA P3
A8
B8
A7
B7
__
__
Pb5
Pa5’
Pa5
Pc3’
Pc3
Pb4
Pb4’
Pb3
Pa3
A2
B2
Pb2
Pa2
__
__
T3 T5 T4
C4
C2
P
_
_
BT
1,2
C
A
EF
B
D
P2
P1 P2
P1
Pm2
Pm1 __
T2
Pm1
Pm2 __
T1
__ __
1
2
3
8020-10
Cre 7-28420-21LX Issued 11-01
Low Speed Travel Circuit
Low speed is the normal speed for travel. Even if the machine is in high speed, if the starter switch
key is turned
OFF and then turned ON again, the speed setting will always return to low speed.
A1 pump flow enters port P1 of the control valve and A2 pump flow enters port P2. One flow goes
directly to the
left-hand travel spool and the other goes to the right-hand travel spool. The high speed travel
electrovalve is
switched OFF and the motor displacement change spools are in direct communication with the tank
return line.
C1. 2 Stage travel (Red band)
Pa1/A1. RH forward travel
Pb1/B1. RH reverse travel
Pa6/B6. LH forward travel
Pb6/B6. LH reverse travel
2. Controller
3. Work mode switch
8020-11
Cre 7-28420-21LX Issued 11-01
CM00K014
Pb9
Pa9
Pc2
Pb8
Pb8’
Pa8’
Pa8
Pb7
Pa7
___
___
__ PT PP __
P4
A3
B3
Pbu
A5
Pc1
Ps1 Dr T2 T1 Ps2
405 psi
28 bar
405 psi
28 bar
Pb5’
B5
PH
___
___
PA P3
A8
B8
A7
B7
__
__
Pb5
Pa5’
Pa5
Pc3’
Pc3
Pb4
Pb4’
Pb3
Pa3
A2
B2
Pb2
Pa2
__
__
T3 T5 T4
C4
C2
P
_
_
BT
1,2
C
A
EF
B
D
P2
P1 P2
P1
Pm2
Pm1 __
T2
Pm1
__ Pm2
T1
__ __
1
2
3
8020-12
Cre 7-28420-21LX Issued 11-01
Straight Line Travel Circuit
This situation applies to travel and boom raising operations carried out at the same time.
When the travel function is used, the low pressure circuit is closed and the pressure switch
transmits this
information to the control unit, which in turn powers the pressure booster electrovalve.
When boom spool 2 is piloted, the control circuit coming from PP and going through all the
attachment and swing
control valves is closed. The pressure in this circuit then rises to 565 psi and this pilots the straight
line travel
valve. When this occurs, pump P1 supplies oil to both travel motors and pump P2 supplies oil to the
attachment.
As oil is supplied to both travel motors in parallel the pressure is equal and the machine travels in a
straight line.
If all the flow to the attachment is not used, the surplus is sent to the travel function, thereby
keeping speed loss
to a minimum.
If other functions than the boom are used at the same time as the travel function, the operating
principle is the
same.
C1. 2 stage travel (Red band)
Pa1/A1. RH Forward travel
Pb1/B1. RH Reverse travel
Pa6/A6. LH Forward travel
Pb6/B6. LH Reverse travel
Pb4. Boom spool 2
Pa8/A8. Boom up
Pb8/B8. Boom down
2. Controller
3. Work mode switch
8020-13
Cre 7-28420-21LX Issued 11-01
CM00K015
Pb9
Pa9
Pc2
___
Pb8’
Pa8’
___
Pb7
Pa7
___
___
__ PT __ __
P4
A3
B3
Pbu
A5
Pc1
Ps1 Dr T2 T1 Ps2
405 psi
28 bar
405 psi
28 bar
Pb5’
B5
PH
___
___
PA P3
__
_
A7
B7
__
_
Pb5
Pa5’
Pa5
Pc3’
Pc3
__
Pb4’
Pb3
Pa3
A2
B2
Pb2
Pa2
__
_
T3 T5 T4
C4
C2
P
__
_
__
BT
1,2
C
A
EF
B
D
P2
P1 P2
P1
Pm2
Pm1 Ps
T2
Pm1
Ps Pm2
T1
__ __
1
2
3
8020-14
Cre 7-28420-21LX Issued 11-01
Swing Circuit
The swing function has one source of oil supply only.
When the engine is started and the swing control is in neutral, the swing brake electrovalve is
powered and the
brake is applied.
When the swing function is operated, the swing pressure switch closes. Current to the swing brake
electrovalve is
cut off and the swing brake is released. The upperstructure thereby becomes free to turn. When the
swing
control is in neutral and the attachment is operated, lateral forces are exerted on the attachment. To
prevent the
swing effect damaging the brake the swing brake is released.
When one of the HP pressure detectors situated on the pump outlets informs the calculator that
pressure is
equal to or greater than 2132 psi, current to the swing brake electrovalve is cut off and the swing
brake is
released.
When swing pressure switch or attachment pressure falls below 2932 psi, current flows to the swing
brake
electrovalve after five seconds and the swing brake is applied.
If swing locking is engaged, even if the swing pressure is closed and pressure at both pumps is
higher than
2132 psi, the swing brake will be applied. The swing spool is piloted on both sides. If the starter
switch key is
turned to OFF position, the swing locking will be memorized and when the key is turned to ON
position the swing
function will still be locked.
During travel, if pressure in one of the pumps rises to 2132 psi, the swing brake will be released for
5 seconds.
Pa3/A3. LH Swing
Pb3/B3. RH Swing
C2. Swing brake (Pink band)
Key switch
Swing pressure
switch
Outlet pressure on
A1 or A2 pump
outlets
Swing brake
electrovalve
Swing brake
OFF OFF 0 OFF Applied
ON OFF 0 ON Applied
ON ON > 0 OFF Released
ON OFF 2132 psi or more OFF Released
8020-15
Cre 7-28420-21LX Issued 11-01
CM00K016
P
Dr
AB
MU
GA GB
Pb9
Pa9
Pc2
Pb8
Pb8’
Pa8’
Pa8
Pb7
Pa7
Pb6
Pa6
__ PT PP __
P4
__
__
Pbu
A5
Pc1
Ps1 Dr T2 T1 Ps2
405 psi
28 bar
405 psi
28 bar
Pb5’
B5
PH
Pa1
Pb1
PA P3
A8
B8
A7
B7
A6
B6
Pb5
Pa5’
Pa5
Pc3’
Pc3
Pb4
Pb4’
___
___
A2
B2
Pb2
Pa2
A1
B1
T3 T5 T4
3S
S1
2S 1S
S2
S3
C4
_
P
BT
__ __
8020-16
Cre 7-28420-21LX Issued 11-01
Auto Swing Priority Valve Circuit
After going through the selector the swing pilot pressure arrives at Pc3 and pilots the variable
priority valve. This
makes it possible to have the maximum swing torque with high swing pressure, even if the arm is
being used at
the same time.
When the machine is digging, the boom raising pressure pilots the swing priority valve. Flow for the
swing
function is then in parallel with the arm via the priority valve and arm speed is improved. Digging
speed is more
constant, even if the free passage is closed by the boom (2) spool.
When the swing function and the arm retracting or boom raising functions are operated
simultaneously, parallel
working is reduced and swing pressure is maintained.
Pa5/A5. Arm out
Pb5/B5. Arm in
Pa9/Pb9. Arm spool 2
Pa3/A3. LH swing
Pb3/B3. RH swing
Pc3. Priority to swing
Pb4. Boom spool 2
8020-17
Cre 7-28420-21LX Issued 11-01
CM00K017
P
Dr
AB
MU
GA GB
__
__
Pc2
Pb8
Pb8’
Pa8’
Pa8
Pb7
Pa7
Pb6
Pa6
__ PT PP __
P4
__
__
Pbu
__
Pc1
Ps1 Dr T2 T1 Ps2
405 psi
28 bar
405 psi
28 bar
Pb5’
__
PH
Pa1
Pb1
PA P3
A8
B8
A7
B7
A6
B6
___
Pa5’
___
Pc3’
___
__
Pb4’
___
___
A2
B2
Pb2
Pa2
A1
B1
T3 T5 T4
3S
S1
2S 1S
S2
S3
__ __
8020-18
Cre 7-28420-21LX Issued 11-01
Free Swing Operation
An orifice leak is opened between the A and B ports of the swing motor. This will provide smoother
starts and
stops of the swing during hoisting operations
NOTE: The controller needs a RPM signal for Free Swing.
The Free Swing operation dampens the oil pressure and flow surges to the swing motor during
starting and
stopping. This provides for smoother starts and stops during swing operations.
When the Free Swing switch is ON, the controller sends a 24v signal to the Free Swing solenoid
valve. The valve
is shifted and allows oil to free flow, through an orifice, between both main ports of the swing motor.
The valve
creates a restricted by-pass of the swing motor when starting swing operations and a by-pass of the
swing motor
when stopping. When Free Swing is ON, the swing brake is released and does not come on. The
Free Swing
solenoid valve is located behind the cab.
8020-19
Cre 7-28420-21LX Issued 11-01
CM00K008
CONTROLLER
RPM Signal
Free Swing
Solenoid
24V
Hertz
OFF
Control Valve
Free Swing
orifice
Swing
Motor
Pilot Solenoid
550/600PSI
24V
Swing Brake
Solenoid
OV
Free Swing switch
10A Fuse
8020-20
Cre 7-28420-21LX Issued 11-01
Boom Raising Circuit
Two supply flows are used to raise the boom.
The P1 pump flow goes through the straight line travel valve or the right-hand travel spool, through
the parallel
working passage and the boom (2) spool, before emerging from the boom (1) spool outlet.
The P2 pump flow goes through the second parallel working passage and the boom (1) spool and
joins the flow
from pump P1 to go through the load holding valve and supply oil to the boom cylinders.
Pa8/A8. Boom up
Pb8/B8. Boom down
Pb4. Boom spool 2
8020-21
Cre 7-28420-21LX Issued 11-01
CM00K018
Pb9
Pa9
Pc2
___
Pb8’
Pa8’
___
Pb7
Pa7
Pb6
Pa6
__ PT PP __
P4
A3
B3
Pbu
A5
Pc1
Ps1 Dr T2 T1 Ps2
405 psi
28 bar
405 psi
28 bar
Pb5’
B5
PH
Pa1
Pb1
PA P3
__
__
A7
B7
A6
B6
Pb5
Pa5’
Pa5
Pc3’
Pc3
__
Pb4’
Pb3
Pa3
A2
B2
Pb2
Pa2
A1
B1
T3 T5 T4
__ __
8020-22
Cre 7-28420-21LX Issued 11-01
Boom Lowering Circuit, Load Holding Valve
A single supply flow is used to lower the boom.
When the boom lowering function is operated only the boom (1) spool is piloted.
At the same time, pilot pressure arrives at Pc2 and releases the load holding valve. This allows the
oil discharge
from the boom cylinder large chambers to flow to the return circuit.
Boom Lowering Regeneration Circuit
When the boom is lowered, boom (1) spool is piloted. The load holding valve is released and part of
the oil
discharged from the cylinder large chambers can go through a check valve and be reinjected in the
cylinder small
chambers. The lower the supply pressure to the cylinder small chambers, the higher the flow
reinjected in this
manner will be.
Even if the boom spool is completely closed, an orifice makes it possible for oil to reach the free
passage and
develop pressure (PN) to inform the pump that flow must be reduced. Flow reduction is
compensated for by the
regeneration circuit, thereby contributing towards a more efficient use of engine power.
Boom Lowering Anti-vibration Circuit
Due to the constant loss of oil from the supply source to the free passage, via the orifice, peak
pressures and
vibrations are avoided, even if the boom lowering control is operated roughly.
Pa8/A8. Boom up
Pb8/B8. Boom down
Pc2. Boom load holding
1. Holding valve
8020-23
Cre 7-28420-21LX Issued 11-01
CM00K019
Pb9
Pa9
___
___
____
Pa8’
___
Pb7
Pa7
Pb6
Pa6
__
Dr T2 T1 Ps2
405 psi
28 bar
P3 PH
__
__
A7
B7
A6
B6
ø3
T3 T5 T4
Pi1 Pi2
A2
a2
(AVANT) (ARRIERE)
A3
Dr B1 B3
A1 Psv a3
a1
M
3.92 MPa
568 psi
39.2 bar
a3
___
___
__
__
__
1
8020-24
Cre 7-28420-21LX Issued 11-01
Arm Extending Circuit
The arm uses two supply flows.
When the arm extends, flow from pump A1 arrives at the arm (1) spool, either via the free passage
or after
passing through the straight line travel valve via the parallel working passage.
Flow from pump A2 arrives at the arm (2) spool, either via the free passage or after passing through
the straight
line travel valve via the parallel working passage. It merges with the other flow just before the arm
(1) spool. In
this way, the two flows of oil go through the load holding valve and then on to the arm cylinder small
chamber.
Return to the large chamber is via the two arm spools, thereby improving efficiency.
Pa5/A5. Arm out
Pb5/B5. Arm in
Pa9/A9. Arm spool 2
8020-25
Cre 7-28420-21LX Issued 11-01
CM00K020
__
__
Pc2
Pb8
Pb8’
Pa8’
Pa8
Pb7
Pa7
Pb6
Pa6
__ PT PP __
P4
A3
B3
Pbu
__
Pc1
Ps1 Dr T2 T1 Ps2
405 psi
28 bar
405 psi
28 bar
Pb5’
__
PH
Pa1
Pb1
PA P3
A8
B8
A7
B7
A6
B6
___
Pa5’
___
Pc3’
Pc3
Pb4
Pb4’
Pb3
Pa3
A2
B2
Pb2
Pa2
A1
B1
ø3
T3 T5 T4
__ __
8020-26
Cre 7-28420-21LX Issued 11-01
Arm Retracting Circuit
The arm uses two supply flows.
When the arm retracts flow from pump A1 arrives at the arm (1) spool, either via the free passage
or after
passing through the straight line travel valve via the parallel working passage.
A2 pump flow arrives at the arm (2) spool, either via the free passage or after passing through the
straight line
travel valve via the parallel working passage. It merges with the other flow just before the arm (1)
spool. In this
way, the two flows of oil go through the load holding valve and then on to the arm cylinder large
chamber. Return
to the large chamber is via the two arm spools, thereby improving efficiency.
Arm Retracting Regeneration Circuit
Oil discharging from the small chamber is fed back into the large chamber. The return flow goes
through a
restrictor and a variable cancellation valve, which force the oil to re-enter the large chamber via a
check valve.
When pressure in the large chamber increases, the cancellation valve is piloted by this pressure
and
regeneration is progressively brought to a halt.
Pa5/A5. Arm out
Pb5/B5. Arm in
8020-27
Cre 7-28420-21LX Issued 11-01
CM00K021
__
__
Pc2
Pb8
Pb8’
Pa8’
Pa8
Pb7
Pa7
Pb6
Pa6
__ PT PP __
P4
A3
B3
Pbu
__
___
Ps1 Dr T2 T1 Ps2
405 psi
28 bar
405 psi
28 bar
Pb5’
__
PH
Pa1
Pb1
PA P3
A8
B8
A7
B7
A6
B6
___
Pa5’
___
Pc3’
Pc3
Pb4
Pb4’
Pb3
Pa3
A2
B2
Pb2
Pa2
A1
B1
ø3
T3 T5 T4
__ __
8020-28
Cre 7-28420-21LX Issued 11-01
Bucket Opening Circuit
The bucket uses one supply flow which arrives from pump A2 via the parallel working passage.
Pa7/A7. Bucket opening
Pb7/B7. Bucket closing
CM00K022
Pb9
Pa9
Pc2
Pb8
Pb8’
Pa8’
Pa8
___
___
Pb6
Pa6
__
Dr T2 T1 Ps2
405 psi
28 bar
P3 PH
A8
B8
__
__
A6
B6
ø3
T3 T5 T4
__
8020-29
Cre 7-28420-21LX Issued 11-01
Bucket Closing Circuit
The bucket uses one supply flow which arrives from pump A2 via the parallel working passage.
Pa7/A7. Bucket opening
Pb7/B7. Bucket closing
CM00K023
Pb9
Pa9
Pc2
Pb8
Pb8’
Pa8’
Pa8
___
___
Pb6
Pa6
__
Dr T2 T1 Ps2
405 psi
28 bar
P3 PH
A8
B8
__
__
A6
B6
ø3
T3 T5 T4
__
8020-30
Cre 7-28420-21LX Issued 11-01
Crusher Circuit
The crusher uses two supply flows.
One flow goes directly to the option, the other is forced into the reinjection valve and merges with
the first flow
just before the inlet for the option spool.
When the switch in the cab is tilted to crusher position, current is sent to the second flow
electrovalve.
When the option pedal is pressed, pilot pressure is sent through the selector and then the
electrovalve. The
reinjection valve is released. This pressure also moves the arm (2) spool and the latter seals off the
free
passage. As a result, flow from pump P2 may be reinjected at the inlet for the option pedal.
P1 pump flow arrives directly at the inlet of the option spool.
The pilot pressure also acts on the reinjection valve priority valve. Arm (2) spool pilot pressure
return oil goes
back to the tank via the priority valve. The crusher thereby takes priority but, for example, should
the arm be
extended at the same time, one flow goes to the arm and the other to the crusher.
Pa2/A2. Option circuit
Pb2/B2. Option circuit
8020-31
Cre 7-28420-21LX Issued 11-01
CM00K024
10μ
A
C
B
D
TT
___
___
Pc2
Pb8
Pb8'
Pa8'
Pa8
Pb7
Pa7
Pb6
Pa6
__ PT PP __
P4
A3
B3
Pbu
A5
Pc1
Ps1 Dr T2 T1 Ps2
405 psi
28 bar
405 psi
28 bar
Pb5'
B5
PH
Pa1
Pb1
PA P3
A8
B8
A7
B7
A6
B6
Pb5
Pa5'
Pa5
Pc3'
Pc3
Pb4
Pb4'
Pb3
Pa3
__
__
___
___
A1
B1
T3 T5 T4
A
B
T
P
C
E
D
12
P
T
A1 S1
B1 S2 B2
A2 P T
A
AB
__ __
8020-32
Cre 7-28420-21LX Issued 11-01
Breaker Circuit
The breaker uses one supply flow.
When the switch in the cab is in breaker position and the option pedal toed forward, the pressure
switch closes
and sends the information to the calculator, which sets the breaker running at the preselected
speed.
The option spool is piloted and pump A1 supplies the breaker with a flow of oil.
Pa2/A2. Option circuit
Pb2/B2. Option circuit
8020-33
Cre 7-28420-21LX Issued 11-01
CM00K025
10μ
A
C
B
D
TT
Pb9
Pa9
Pc2
Pb8
Pb8'
Pa8'
Pa8
Pb7
Pa7
Pb6
Pa6
__ PT PP __
P4
A3
B3
Pbu
A5
Pc1
Ps1 Dr T2 T1 Ps2
405 psi
28 bar
405 psi
28 bar
Pb5'
B5
PH
Pa1
Pb1
PA P3
A8
B8
A7
B7
A6
B6
Pb5
Pa5'
Pa5
Pc3'
Pc3
Pb4
Pb4'
Pb3
Pa3
__
__
___
___
A1
B1
T3 T5 T4
A
B
T
P
C
E
D
12
P
T
A1 S1
B1 S2 B2
A2 P T
A
AB
__ __
8020-34
Cre 7-28420-21LX Issued 11-01
NOTES
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
...............................................................................................................................................................
......................
Link-Belt
Copyright 2001 Link-belt
Printed in U.S.A.
9002
UPPERSTRUCTURE, TURNTABLE BEARING
AND COUNTERWEIGHT
Section
9002
9002-2
Cre 7-27981-21LX Issued 11-01
TABLE OF CONTENTS
SPECIAL TORQUE
SETTINGS............................................................................................................................... 2
SPECIFICATIONS.................................................................................................................................
................... 2
UPPERSTRUCTURE............................................................................................................................
................... 3
Inspection..............................................................................................................................................
............... 3
Removal
...............................................................................................................................................................
4
Installation
............................................................................................................................................................ 6
COUNTERWEIGHT
............................................................................................................................................... 10
Description
......................................................................................................................................................... 10
Removal
.............................................................................................................................................................
11
Installation
.......................................................................................................................................................... 13
See Section 1002
SPECIFICATIONS
Weight ............................................................................................................................................See
Section 1002
Quantity of grease to be applied
to the turntable bearing..................................................................................................................
13.52 oz (400 cc)
WARNING: This symbol is used in the manual to indicate important safety messages. Whenever
you see
this symbol, carefully read the message that follows. ! It concerns your safety.
9002-3
Cre 7-27981-21LX Issued 11-01
UPPERSTRUCTURE
Inspection
STEP 1
Inspecting the turntable bearing
If the upperstructure no longer swings regularly or
makes a creaking noise, this shows that the turntable
bearing is worn or damaged. If there is a time lapse
before the upperstructure starts to swing, this shows
that the ring gear of the turntable bearing is
damaged. When an operator works with a machine,
he must pay attention to any unusual noises which
could indicate turntable bearing wear. If the operator
hears unusual noises and if the upperstructure has a
time lapse before it starts swinging, he must carry out
the following inspection.
STEP 2
Park the machine on hard, level ground. Lower the
STEP 3
Reduce engine speed to idle for 30 seconds, then
STEP 4
CI00F500
Remove the screws (1) which fasten the lower housing
to the machine and remove the lower housing.
STEP 5
CI00F509
Remove the three screws (1) and lock washers (2)
which fasten the access panel (3) to the machine.
Remove the access panel (3). Remove and discard
the access panel seal (4).
STEP 6
Request help from an assistant to operate the swing
gear. Check for scratches, a missing tooth, scaling,
cracks or other damage to the ring gear, using a
pocket torch. In the event of damage, refer to
"Removing the upperstructure" and change the
upperstructure turntable bearing.
STEP 7
Install a new seal on the access panel and install the
access panel on the machine using screws and lock
washers.
1
WARNING: If you put your hand in the ring
gear access orifice when the upperstructure is
swinging, you could be serious injured. Before
applying grease by hand to the ring gear,
always make sure that the bucket or the tool
is on the ground and that the engine is shut
down.
1
2
3
4
!
9002-4
Cre 7-27981-21LX Issued 11-01
STEP 8
Install the lower housing on the machine using
screws and flat washers.
Removal
STEP 1
JS00163A1
Park the machine on hard, level ground. Lower the
STEP 2
Release pressure in hydraulic system in the hydraulic
sump tank (see Section 8000).
STEP 3
CD00G002
Open the left-hand side door. Disconnect the ground
cable (1) from the battery, then the positive cable (2).
Disconnect and remove the battery cable (3). Remove
the two screws (4), lock washers and the flat washers
that fasten the battery protective cover. Remove the
cover and remove the battery. Close the side doors.
STEP 4
CI00F508
1 FUEL TANK LOWER ACCESS PANEL
2 HYDRAULIC SUMP TANK LOWER ACCESS PANEL
Remove the lower access panel from the fuel tank (1)
located at the front and to the right. Place a
receptacle under the fuel tank drain valve. Open the
drain valve and drain the fuel.
2
13
4
1
2
1
2
9002-5
Cre 7-27981-21LX Issued 11-01
NOTE: See Section 1002 for the fuel tank capacity.
STEP 5
Remove the lower access panel from the hydraulic
sump tank (2). Place a receptacle under the hydraulic
sump tank drain valve. Open the drain valve and
drain the hydraulic fluid into the receptacle.
NOTE: See Section 1002 for the capacity of the
hydraulic sump tank and of the total system.
STEP 6
Refer to Section 8006 and remove the rotating joint.
STEP 7
Refer to Section 9003 and remove the bucket, the
arm and the boom.
STEP 8
Refer to the page 10 in this section and remove the
counterweight.
STEP 9
Install lifting eyes at the rear of the upperstructure.
Connect a suitable lifting device to these lifting eyes
and to the lifting eyes located at the front of the
upperstructure, above the boom brackets. Take up
any slack in the lifting equipment, to ensure the
upperstructure is fully supported before lifting starts.
NOTE: Refer to specifications on page 2 for the
weight of the upperstructure. Make sure that the
lifting device has sufficient lifting and support
capacity for the upperstructure.
STEP 10
CD00G043
Using paint or another marking product, make marks
on the upperstructure, turntable bearing (4) and the
undercarriage, to facilitate re-assembly of the
upperstructure and the turntable bearing.
STEP 11
Remove the cap screws (1) which fasten the
upperstructure to the turntable bearing (4).
STEP 12
Carefully lift the upperstructure while disengaging it
from the undercarriage. Place the upperstructure on
suitable stands to protect the swing pinion against
any damage.
STEP 13
Install lifting eyes on the turntable bearing (4).
Connect a suitable lifting device to the lifting eyes.
Take up any slack in the lifting equipment, to ensure
that the turntable bearing is fully supported before
lifting starts.
weight of the turntable bearing.
STEP 14
Remove the cap screws (2) and the flat washers (3)
which fasten the turntable bearing to the
undercarriage. Carefully lift the turntable bearing
while disengaging it from the undercarriage. Place
the turntable bearing on suitable stands to protect the
surfaces of the turntable bearing against any
damage. Remove the lifting equipment from the lifting
eyes and disassemble the lifting eyes from the
turntable bearing.
1
4
9002-6
Cre 7-27981-21LX Issued 11-01
Installation
Turntable bearing
CI00F510
1 CAP SCREW
2 CAP SCREW
3 FLAT WASHER
4 TURNTABLE BEARING
STEP 1
Clean the mating surfaces of the undercarriage and
the turntable bearing.
steps refer to the turntable bearing illustration.
STEP 2
Install lifting eyes on the turntable bearing (4) and
connect a suitable lifting device to these rings. Take
up any slack in the lifting equipment, to ensure that
the turntable bearing is fully supported before lifting
starts.
weight of the turntable bearing.
STEP 3
Position the turntable bearing (4) on the
undercarriage. Align the marks on the turntable
bearing (4) and on the undercarriage. Remove the
lifting equipment and disassemble the lifting eyes
from the turntable bearing.
1
41
2
2
3
9002-7
Cre 7-27981-21LX Issued 11-01
STEP 4
CD00G043
Coat the cap screw threads (2) with Loctite 262.
Install the cap screws (2) and flat washers (3) to
fasten the turntable bearing (4) to the undercarriage.
Tighten the cap screws (2) to the torques shown on
page 2.
STEP 5
Connect a suitable lifting device to the lifting eyes
located at the front of the upperstructure, above the
boom brackets, and to the rings mounted on the
frame at the rear of the upperstructure.
weight of the upperstructure. Make sure that the
lifting equipment has sufficient lifting and support
capacity for the upperstructure.
NOTE: When the upperstructure is lowered and
touches the turntable bearing and the ring gear, make
sure that the swing reduction gear pinion engages
perfectly with the teeth on the upperstructure ring
gear.
STEP 6
Carefully install the upperstructure in position on the
turntable bearing. Align the marks on the
upperstructure and on the turntable bearing. Check
that the mounting orifices of the upperstructure are
aligned with those of the turntable bearing.
STEP 7
Coat the cap screw threads (1) with Loctite 262.
Install the cap screws (1) in the turntable bearing and
the upperstructure to fasten the upperstructure en
position. Tighten the cap screws (1) to the torques
STEP 8
Remove the lifting equipment, then disassemble the
lifting eyes.
STEP 9
Refer to Section 8006 and reassemble the rotating
joint.
STEP 10
Refer to Section 9003 and reassemble the boom, the
arm and the bucket on the machine.
STEP 11
Make sure that the hydraulic sump tank drain valve is
closed. To fill the hydraulic sump tank, refer to the
Section "Filling the hydraulic sump tank" in the
Operator’s Manual.
NOTE: See Section 1002 for the capacity of the
hydraulic sump tank and the capacity of the total
system.
1
4
9002-8
Cre 7-27981-21LX Issued 11-01
STEP 12
CI00F508
1 FUEL TANK LOWER ACCESS PANEL
2 HYDRAULIC SUMP TANK LOWER ACCESS PANEL
Install the access panel (2) under the hydraulic sump
tank.
STEP 13
Make sure that the fuel tank drain valve is closed, fill
the tank (see the Operator’s Manual).
NOTE: See Section 1002 for the fuel tank capacity.
STEP 14
CCD00G002
Open the left-hand side door and install the batteries.
Install the battery protective cover (1), on the batterie
and fasten with the two screws (4), flat washers and
locking washers. Tighten the screws to the torque
specified o page 2. Install and reconnect the battery
cable (3). Connect the positive cable first (2) then the
negative cable (5). Close the left-hand side doors.
STEP 15
Refer to page 10, "Installing the counterweight" and
install the counterweight.
1
2
1
2
52
1
3
4
WARNING: If you put your hand in the ring
gear access orifice when the upperstructure is
swinging, you can be seriously injured. Before
applying grease by hand to the ring gear,
always check that the bucket or tool is on the
ground and that the engine is shut down.
!
9002-9
Cre 7-27981-21LX Issued 11-01
STEP 16
CI00F509
Remove the three screws (1) and the locking
washers (2) which fasten the access panel (3) to the
upperstructure. Remove the access panel (3).
Discard the seal (4).
STEP 17
Apply grease by hand to the ring gear.
STEP 18
Start the engine and swing the upperstructure an
eighth of a turn. Stop the engine.
STEP 19
Apply grease by hand to the ring gear again.
STEP 20
Repeat the operation until all the teeth of the ring
gear are perfectly greased.
quantity of grease to be applied.
STEP 21
CD00G043
Apply grease to the three grease fittings on the
turntable bearing bearing. Install a new seal.
STEP 22
Install the access panel with its seal, on the machine.
Fasten it in position with the three screws and the
locking washers.
STEP 23
CI00F500
Install the lower housing under the machine, using
screws and washers.
1
2
3
4
9002-10
Cre 7-27981-21LX Issued 11-01
COUNTERWEIGHT
Description
CS00F541
1 COUNTERWEIGHT
2 PLUG
3 CAP SCREW
4 WASHER
CI00F511
5 SHIM
6 INSULATING MATERIAL
2
1
6
5
4
3
2
1
6
5
4
3
9002-11
Cre 7-27981-21LX Issued 11-01
Removal
STEP 1
CD00F099
Unlock the two engine hood locking latches (1) and
raise the hood to the raised, locked position.
STEP 2
Attach suitable lifting slings to the hood.
STEP 3
CD00F100
Remove the retaining hardware (1) from the retaining
bar (2) and remove the retaining bar.
STEP 4
CD00F101
Remove the split pin (1) and the flat washer (2) from
the engine hood safety side support bracket.
STEP 5
Remove the hood support strut. Lower the hood.
STEP 6
Connect a suitable lifting device.
STEP 7
CD00F102
Remove the six screws (1) and the flat washers
which fasten the hinges (2).
1
1
1
2
1
2
11
22
9002-12
Cre 7-27981-21LX Issued 11-01
STEP 8
Install a lifting ring on the counterweight (1). Connect
suitable lifting equipment to the lifting eyes. Take up
any slack in the lifting equipment to ensure that the
counterweight is fully supported before releasing the
retaining cap screws.
weight of the counterweight.
STEP 9
Remove the four cap screws (3) and the flat washers
(4) which attach the counterweight (1) to the chassis
frame.
STEP 10
Raise the counterweight (1) and remove it from the
machine. Place it on flat ground. Remove the lifting
device.
STEP 11
Remove the shims (5) from the chassis frame
anchorage points.
NOTE: Count the number of shims (5), as you
remove them from each anchorage point. Keep each
set of shims (5) to facilitate reassembly.
STEP 12
Check the condition of the insulating material (6)
installed on the counterweight. Change the insulating
material if it is damaged.
9002-13
Cre 7-27981-21LX Issued 11-01
Installation
STEP 1
Connect a suitable lifting device to the lifting eyes
installed on the counterweight (1).
NOTE: Refer to the specifications on page 2 for the
weight of the counterweight.
STEP 2
Install the same number of shims (5) as were
removed during removal in step 11, at each
anchorage point of the counterweight on the chassis
frame.
STEP 3
Move the counterweight (1) into position on the
chassis frame. Align the orifices of the counterweight
with those on the chassis frame.
STEP 4
Install the four cap screws (3) and flat washers (4) to
attach the counterweight (1). Tighten to the torque
settings specified on page 2.
STEP 5
Disconnect the lifting equipment from the lifting eyes
on the counterweight (1), disassemble the lifting eyes
and re-install the plugs.
STEP 6
Connect a suitable lifting device to the engine hood.
Move the engine hood into position.
STEP 7
CD00F102
Install the six washers (1) and flat washers which
attach the hood hinges (2).
STEP 8
CD00F101
Install the hood support strut, install the split pin (1)
and the flat washer on the engine hood safety side
support bracket.
STEP 9
CD00F100
Install the retaining bar (2) using the retaining
hardware (1).
STEP 10
Remove the lifting equipment from the engine hood.
11
22
1
2
1
2
9002-14
Cre 7-27981-21LX Issued 11-01
STEP 11
CD00F099
Lock the two engine hood locking latches (1).
1
1
Link-Belt
Printed in U.S.A.
9003
BOOM, ARM AND BUCKET
Section
9003
9003-2
Cre 7-27961-21LX Issued 11-01
TABLE OF CONTENTS
SPECIFICATIONS.................................................................................................................................
................... 2
BUCKET................................................................................................................................................
................... 3
Description
........................................................................................................................................................... 3
Removal
...............................................................................................................................................................
4
Installation
............................................................................................................................................................ 4
Shimming the
bucket............................................................................................................................................ 6
ARM.......................................................................................................................................................
................... 7
Description
........................................................................................................................................................... 7
Removal
...............................................................................................................................................................
8
Installation
............................................................................................................................................................ 8
BOOM....................................................................................................................................................
................. 10
Description
......................................................................................................................................................... 10
Removal
.............................................................................................................................................................
11
Installation
.......................................................................................................................................................... 12
SPECIFICATIONS
See Section 1002
9003-3
Cre 7-27961-21LX Issued 11-01
BUCKET
Description
JS01273A
1 LOCKING PIN
2 PIN
3 BUCKET
4 BUCKET LINK
5 LINKAGE SEAL
6 LOCKING PIN
7 PIN
8 LINKAGE SEAL
9 DUST SEAL
10 GREASE FITTING
11 NUT
12 SCREW
13 PIN
14 SHIM
15 GUIDE LINK
16 GREASE FITTING
17 BUSHING
18 BUSHING
19 SHIM
20 DUST SEAL
21 DUST SEAL
16
13
15
14 21 17
10 17
19
8
9
18
4
18
9
19
5
20
8
21 14
15
12
11
20
5
6
7
312
9003-4
Cre 7-27961-21LX Issued 11-01
Removal
STEP 1
Place the bucket flat on flat, level ground. Operate the
attachment controls so that the arm/bucket
connecting pin is not under load from the weight of
the arm. Shut down the engine.
steps refer to the bucket drawing on page 3.
STEP 2
Remove the locking pins (1) and (6).
STEP 3
CD00E097
Remove the pins (2) and (7) and retain the shims
(19).
STEP 4
Start the engine. Disengage the attachment from the
bucket and retain the linkage seals (5) and (8).
STEP 5
Remove and discard the dust seals (9) and (20).
NOTE: Perform steps 6 to 9 only if the bucket link (4)
or the guide link (15) have to be changed.
STEP 6
Attach a suitable lifting device to the bucket link (4).
Disconnect the bucket cylinder rod from the bucket
link (4) and from the guide link (15), see Section
8005. Remove the grease fittings (10) if necessary.
STEP 7
Remove the nuts (11) and the screw (12). Remove
the pin (13) and the shims (14) from the arm.
STEP 8
Remove and discard the dust seals (21). Remove, if
necessary, the grease fitting (16) from the pin (13).
NOTE: Perform step 9 only if the bushings (17) and
(18) have to be changed. See Specifications.
STEP 9
Remove the bushings (17) and (18) from the bucket
link (4) using a hammer and a suitable drift on the
outer diameter of the bushing.
Installation
NOTE: Perform step 1 only if the bushings (17) and
(18) have been removed.
STEP 1
Using a suitable sleeve, install the bushings (17) and
(18) in the bucket link (4).
NOTE: Perform steps 2 to 6 only if the bucket link (4)
and the guide link (15) have been removed.
STEP 2
Install new dust seals (21) on the arm. Install the pin
(13) in a guide link (15) and install the pin on the arm.
Install the second guide link (15) on the pin and install
the screw (12).
STEP 3
Using a set of feeler gauges, check that the clearance
between the arm and the guide link (15) is 0.039 to
0.059 inch (1 to 1.5 mm). If necessary remove the
screw (12) and the pin (13) and add on or more shims
as required to arrive at the correct clearance. Install
the pin and the screw.
STEP 4
Install the first nut (11) on the screw and tighten until
the nut touches the boss on the guide link. Loosen a
quarter of a turn and use two wrenches to tighten the
second nut on the first.
STEP 5
Install the grease fitting (16) on the pin (13).
7
2
9003-5
Cre 7-27961-21LX Issued 11-01
STEP 6
Attach a suitable lifting device to the bucket link (4)
and place the bucket link in position on the arm.
Install the bucket cylinder rod on the bucket link (4)
and the guide link (15), see Section 8005. Install the
grease fittings (10).
STEP 7
Install new dust seals (9) on the bucket link (4).
STEP 8
Install new dust seals (20) on the arm.
STEP 9
B9240128
Install new linkage seals (5) and (8) on the bucket
bosses.
STEP 10
Start the engine and align the arm orifices with the
orifices in the bucket.
STEP 11
Install the pin (2) through the bucket and the arm.
Install the locking pin (1).
STEP 12
Align the orifices of the bucket link with the orifices in
the bucket and install the pin (7) through the bucket
and the bucket link. Install the locking pin (6).
STEP 13
Using a set of feeler gauges, check that the clearance
between the bucket link and the bucket is 1 to 0.137
inch (3.5 mm). If necessary remove the locking pin
(6) and the pin (7) and add or more shims (19) as
required to arrive at the correct clearance. Install the
pin (7) and the locking pin (6).
STEP 14
Push the linkage seals (5) and (8) into their housings.
STEP 15
Grease the linkages.
STEP 16
Carry out the shimming of the bucket, see page 6.
8
5
9003-6
Cre 7-27961-21LX Issued 11-01
Shimming the bucket
The machine is equipped with a bucket play adjusting
system which eliminates play that develops at the
bucket/arm linkage due to wear. This system delays
the effects of wear and gives longer life to bushings
and pins.
NOTE: Incorrect adjustment of the play can cause
friction, abnormal noises or excess play and damage
the O-rings.
Adjusting the play
Place the bucket flat, lying on the ground.
CD00E121
Check the play (J) between the arm and the bucket
lug.
If the play (J) is considerable, remove the four screws
and the cap (1), then the shims (2).
Use the shims (2) as a feeler gauge and calculate the
number of shims necessary to eliminate the play (J).
Install the necessary number of new shims.
Reinstall the cap (1) and the four screws.
NOTE: When the screws on the cap (1) are
tightened, the inner bushing moves towards the arm
and the play is eliminated.
IMPORTANT: The inner bushing has a stud which
prevents the bushing from turning. The cap (1) has
an orifice in its inner surface. Make sure that the stud
is inserted in that orifice when the cap is installed (1).
1
J
2
9003-7
Cre 7-27961-21LX Issued 11-01
ARM
Description
JS01274A
1 NUT
2 SCREW
3 PIN
4 ARM
5 BOOM
6 DUST SEAL
7 GREASE FITTING
8 BUSHING
9 BUSHING
10 BUSHING
11 BUSHING
3
11
1
11
2
5
6
8
8
6
7
94
7
10
9
10
9003-8
Cre 7-27961-21LX Issued 11-01
Removal
STEP 1
Remove the bucket, the guide link and the bucket
link, see page 4.
STEP 2
Start the engine, retract the arm cylinder rod and
lower the attachment to the ground. Shut down the
engine.
STEP 3
Remove the bucket cylinder and disconnect the arm
cylinder rod from the arm, see Section 8005. Attach
the arm cylinder rod to the boom.
NOTE: The numbers in the following steps refer to
the arm drawing on page 7.
STEP 4
Attach a suitable lifting device to the arm. Take up
any slack on the lifting slings, since the arm has to be
supported before lifting.
STEP 5
Remove the nuts (1), the screw (2) and remove the
pin (3).
STEP 6
Start the engine, move the machine backwards to
separate the arm from the boom. Lower the boom to
the ground and shut down the engine.
STEP 7
Lower the arm to the ground and remove the lifting
equipment from the arm.
STEP 8
Remove and discard the dust seals (6).
NOTE: Perform step 9 only if the bushings (8), (9),
(10) or (11) have to be changed, see Specifications.
STEP 9
Remove the bushings (8), (9), (10) or (11) from the
arm or from the boom, using a hammer and a
suitable drift on the outer diameter of the bushing.
Installation
NOTE: Perform step 1 only if the bushings (8), (9),
(10) or (11) have been removed.
STEP 1
Using a suitable sleeve, install the bushings (8), (9),
(10) or (11).
STEP 2
Install new dust seals (6) on the arm.
STEP 3
Attach a suitable lifting device to the arm. Move the
arm into position near the machine.
STEP 4
Start the engine and move the machine forwards so
that the boom is aligned with the arm. Check the
alignment of the pin bores on the boom and the arm.
Shut down the engine.
STEP 5
Install the pin (3).
STEP 6
Using a set of feeler gauges, check that the play
between the boom and the arm is 0.019 to 0.043 inch
(0.5 to 1.1 mm) . If necessary, remove the pin (3) and
add one or more shims as required to arrive at the
correct clearance. Install the pin (3).
9003-9
Cre 7-27961-21LX Issued 11-01
STEP 7
Install the screw (2), the first nut (1) and tighten the
nut until it touches the boss on the boom. Loosen the
nut a quarter of a turn and use two wrenches to lock
the second nut (1) onto the first.
STEP 8
Remove the lifting device from the arm.
STEP 9
Connect the arm cylinder rod to the arm and install
the bucket cylinder, see Section 8005.
STEP 10
Install the bucket, see page 4.
STEP 11
Bleed the cylinders, see Section 8000.
STEP 12
9003-10
Cre 7-27961-21LX Issued 11-01
BOOM
Description
JS01275A
1 NUT
2 CAP SCREW
3 PIN
4 BOOM
5 SHIM
6 DUST SEAL
7 GREASE FITTING
8 BUSHING
5
6
87
8
6
5
32
1
4
9003-11
Cre 7-27961-21LX Issued 11-01
Removal
STEP 1
Remove the arm, see page 8.
STEP 2
Start the engine and lower the boom to the ground.
Shut down the engine.
STEP 3
Remove the arm cylinder, see Section 8005. Do not
remove the vacuum pump from the hydraulic sump
tank.
STEP 4
CD00F117
Start the vacuum pump. Label and disconnect the
bucket (A) and arm (B) supply hoses at the bottom of
the boom. If equipped, disconnect the option hoses (E).
Plug the hoses. Stop the vacuum pump. If equipped,
disconnect and move the arm cylinder safety valve pilot
hoses (D) away from the boom. Disconnect the boom
working light electrical harness (C).
STEP 5
Disconnect the boom cylinder rods from the boom,
see Section 8005.
STEP 6
CS00F539
Remove the lid (A) on the front of the fuel tank.
steps refer to the drawing on page 10.
STEP 7
Remove the nuts (1) and the screw (2).
STEP 8
Attach a suitable lifting device to the boom, take up all
the slack on the lifting device.
STEP 9
CD00F118
Install a screw (A) in the pin threaded orifice (3).
Install a sliding hammer (B) on the screw and remove
the pin (3).
STEP 10
Raise the boom and retain the shims (5). Lower the
boom to the ground and remove the lifting device.
C
A
E
D
B
E
A
BA3
9003-12
Cre 7-27961-21LX Issued 11-01
STEP 11
Remove and discard the boom dust seals (6).
NOTE: Perform step 12 only if the bushings (8) have
to be changed, see specifications.
STEP 12
Remove the bushings (8) from the boom, using a
hammer and a suitable drift on the outer diameter of
the bushing.
Installation
NOTE: Perform step 1 only if the bushings (8) have
been removed.
STEP 1
Using a suitable sleeve, install the bushings (8) on
the boom.
STEP 2
Install new dust seals (6) on the boom.
STEP 3
Attach a suitable lifting device to the boom. Raise the
boom and move it into position, check the alignment
of the boom and chassis orifices.
STEP 4
Install the pin (3).
STEP 5
Using a set of feeler gauges, check that the play
between the boom and the chassis is 0.019 to 0.118
inch (0.5 to 3 mm). If necessary, remove the pin (3)
and add one or more shims (5) as required to arrive
at the correct clearance. Install the pin (3).
STEP 6
Install the screw (2), the first nut (1) and tighten the
nut until it touches the boss on the chassis. Loosen
the nut a quarter turn and use two wrenches to lock
the second nut (1) onto the first.
STEP 7
Connect the boom cylinder rods to the boom, see
Section 8005.
STEP 8
CD00F117
Start the vacuum pump and remove the plugs from
the hoses. Connect the bucket (A) and arm (B)
supply hoses at the bottom of the boom. If equipped,
connect the option hoses (E). Stop the vacuum
pump. If equipped, clip the arm cylinder hose burst
check valve pilot hoses to the boom. Connect the
boom working light electrical harness (C).
STEP 9
CS00F539
Install the lid (A) on the front of the fuel tank.
STEP 10
Install the arm cylinder on the boom, see Section
8005.
STEP 11
Install the arm and the bucket, see page 8.
STEP 12
Bleed the cylinders, see Section 8000.
STEP 13
C
A
E
D
B
E
A
Link-Belt
Printed in U.S.A.
9004
SEAT AND SAFETY BELT
Section
9004
9004-2
TABLE OF CONTENTS
SPECIFICATIONS
................................................................................................................................................... 2
OPERATOR’S SEAT
............................................................................................................................................... 3
Description
.......................................................................................................................................................... 3
Removal
..............................................................................................................................................................
4
Installation
........................................................................................................................................................... 7
SAFETY BELT
......................................................................................................................................................... 8
Removal
..............................................................................................................................................................
8
Installation
........................................................................................................................................................... 8
SPECIFICATIONS
Weight of the operator’s seat........................................................................................................101
pounds (46 kg)
9004-3
OPERATOR’S SEAT
Description
CI00G507
1 OPERATOR’S SEAT
2 MASK
3 GROMMET
4 RAIL
5 REAR CONTROL ARM BRACKET
6 SHOCK ABSORBER
7 BRACKET
8 FRONT CONTROL ARM BRACKET
1
4
6
5
7
8
3
2
9004-4
Removal
STEP 1
JS00163A1
to the ground.
STEP 2
STEP 3
Move the operator’s seat as far forward as possible.
STEP 4
CD00G048
Lift the grommet. Loosen and remove the four screws
(1) from the front portion of the control arm.
NOTE: Steps 5 to 7 are to be carried out only for the
LH control arm.
STEP 5
CD00G049
Loosen and remove the screw (1) that retains the
gate lock lever (2). Remove the lever.
STEP 6
CD00G050
Loosen and remove the three screws that hold the
inner cab access bar. Remove the access bar.
STEP 7
CD00G051
Label and disconnect the electrical connectors (1),
remove the compartment control casing assembly
(2).
1
2
1
1
2
9004-5
NOTE: For the LH control arm, do not carry out
step 8.
STEP 8
CD00G066
Remove the mask then remove the air-conditioning
box using the four screws. Remove the latter.
STEP 9
CD00G052
Loosen and remove the four screws (1) from the rear
portion of the control arm.
STEP 10
CD00G053
Loosen and remove the two screws (1) that hold the
arm angle adjustment lever, then remove the lever.
STEP 11
Lift the upper portion of the control arm and position it
on the side.
STEP 12
CD00G117
Loosen and remove the two upper screws as well as
the two lower screws that hold the front portion of the
control arm.
NOTE: For the RH control arm, do not carry out
steps 13 and 14.
STEP 13
CD00G118
Loosen and remove the screws that hold the LH side
portion of the control arm.
1
1
1
1
1
9004-6
STEP 14
CD00G058
Remove from the LH side, the rod (1) that links the
gate lock lever to the safety bar (2).
STEP 15
LH side
CD00G059
RH side
CD00G119
plate (1) to the bracket (2).
STEP 16
CD00G120
Loosen and remove the two front retaining screws (1)
of the control arm to the front seat bracket.
STEP 17
CD00G121
Loosen and remove the two rear retaining screws (1)
of the control arm to the rear seat bracket.
1
1
2
1
2
1
1
1
1
9004-7
STEP 18
CD00G127
Move the LH control arm (1) on the cab side, keep it
in this position using suitable lifting equipment.
NOTE: For the RH control arm, position it behind the
cab.
STEP 19
CD00G122
Remove the mask in front of the seat using the four
screws (1).
STEP 20
CD00G123
Remove the carpet, loosen then remove the eight
retaining screws from the seat. Remove the seat from
the cab, with the help of an assistant.
NOTE: The seat weighs 101 pounds (46 kg) .
Installation
removal.
1
1
1
1
1
9004-8
SAFETY BELT
Removal
STEP 1
JS00163A1
to the ground.
STEP 2
STEP 3
CD00G124
Loosen then remove the retaining screw (1) and the
washer. Remove the seat fastener.
STEP 4
CD00G125
Loosen then remove the screw (2) and the washer.
Remove the inertia-reel.
Installation
removal.
1
2
Link-Belt
Printed in U.S.A.
9005
CAB AND CAB EQUIPMENT
Section
9005
9005-2
Cre 7-28021-21LX Issued 11-01
TABLE OF CONTENTS
SPECIFICATIONS
................................................................................................................................................... 2
.............................................................................................................................. 2
CAB
...............................................................................................................................................................
.......... 3
Removal
..............................................................................................................................................................
3
Installation
........................................................................................................................................................... 5
HEATING BLOCK/AIR-CONDITIONING BLOCK
................................................................................................... 8
Description
.......................................................................................................................................................... 8
Removal
..............................................................................................................................................................
9
Installation
......................................................................................................................................................... 11
WINDSHIELD WIPER MOTOR
............................................................................................................................. 13
Description
........................................................................................................................................................ 13
Removal
............................................................................................................................................................
14
Installation
......................................................................................................................................................... 16
SPECIFICATIONS
Cab weight..................................................................................................................................560
pounds (254 kg)
Air-conditioning circuit capacity
...............................................................................................................1 kg +/- 0.05
Type of air-conditioning coolant............................................................................................................
HFC (R) 134a
Cab retaining screws........................................................................................................57 to 59 lb-ft
(78 to 80 Nm)
Battery housing retaining screws...................................................................................... 15 to 21 lb-ft
(20 to 29 Nm)
you see
9005-3
Cre 7-28021-21LX Issued 11-01
CAB
Removal
STEP 1
JS00163A1
to the ground.
STEP 2
STEP 3
CD00G002
Open the left-hand side doors. Disconnect the
ground cable (1) from the battery. Close the doors.
STEP 4
Fold the operator’s seat-back down and move the
seat as far as possible.
STEP 5
Remove the floor mat from the cab.
STEP 6
Remove the thrust bar on the left-hand side of the
cab.
STEP 7
Remove the radio, if fitted.
STEP 8
CD00G003
Remove the trim panel at the rear of the cab, taking
care to disconnect the connector for the cigarette
lighter and the solar radiation detector (only on air-
1 conditioned models).
9005-4
Cre 7-28021-21LX Issued 11-01
STEP 9
CD00G004
Remove the two electronic boxes (1) and (2) (see
Section 4003).
STEP 10
CI00G501
Remove the five relays and the relay retaining plate
(3).
STEP 11
Remove the electronic control box support brackets
(4) and (5).
STEP 12
CD00G005
Remove the screws (1) which fasten the rear
ventilation and remove the two conduits.
STEP 13
Remove the connectors (2) at the rear of the cab.
STEP 14
CD00G006
Disconnect the windshield washer pipe and remove
the retaining clip.
STEP 15
Remove the windshield wiper motor, see page 13 in
this Section.
STEP 16
Remove the upper right-hand side trim panel and
remove the display.
1
2
3
4
5
11
2
9005-5
Cre 7-28021-21LX Issued 11-01
STEP 17
CD00G007
Remove the pollen filter guard, remove the pollen
filter and remove the pollen filter conduit.
STEP 18
Remove the working light from the top of the cab.
Retract the radio aerial. Install suitable lifting rings on
the top of the cab. Install lifting equipment.
STEP 19
Remove the screws and washers which fasten the
cab to the upperstructure frame.
NOTE: Keep away from the cab while it is being
lowered. Make sure that the cab is not damaged
during lifting or lowering. Room for maneuver is very
limited at the rear, on the sides and inside the cab.
STEP 20
CI99G501
Using the lifting equipment, carefully raise the cab
until it is completely away from the machine, then
lower it to the ground.
NOTE: The cab weighs 560 pounds (254 kg).
Installation
NOTE: Keep away from the cab while it is being
lowered. Make sure that the cab is not damaged
during lifting or lowering. Room for maneuver is very
limited at the rear, on the sides and inside the cab.
9005-6
Cre 7-28021-21LX Issued 11-01
STEP 1
CI99G501
Install suitable lifting rings on the top of the cab.
Using suitable lifting equipment, raise the cab. Guide
the cab so that it is correctly aligned with the
mounting studs and orifices in the upperstructure
frame.
NOTE: The cab weighs 560 pounds (254 kg).
STEP 2
Install the screws and washers which fasten the cab
to the upperstructure frame. Tighten them to a torque
of 57 to 59 lb-ft (78 to 80 Nm).
STEP 3
Install the working light on the top of the cab.
STEP 4
Install the windshield wiper motor, see page 13 in this
Section.
STEP 5
Use the screws to install the display and connect it to
the electrical harness.
STEP 6
CD00G007
Install the pollen filter and the pollen filter conduit.
Using screws (1), fasten the pollen filter housing (2)
to the cab.
STEP 7
Reconnect the blower motor conduit to the ventilation
conduit at the front of the cab. Reconnect the
ventilation conduit at the rear of the cab.
STEP 8
CD00G006
Connect the windshield washer pipes together and
attach the circlip.
STEP 9
Install the electronic control box support brackets.
STEP 10
Connect the electrical harnesses.
2
1
1
9005-7
Cre 7-28021-21LX Issued 11-01
STEP 11
CD00G004
Install the five relays and the two electronic control
boxes, see Section 4003.
STEP 12
CD00G003
Install the trim panel at the rear of the cab, taking
care to reconnect the cigarette lighter connector and
the solar radiation detector (only on air-conditioned
models).
STEP 13
Install the radio, if fitted.
STEP 14
Install the access bar, using screws and washers.
STEP 15
Install the floor mat.
STEP 16
CD00G002
Open the left-hand side doors. Reconnect the battery
cable (1) to the battery. Close the doors.
1
9005-8
Cre 7-28021-21LX Issued 11-01
HEATING BLOCK/AIR-CONDITIONING BLOCK
Description
CI00G503
1 CAB REAR VENTILATION CONDUIT
2 CAB LOWER VENTILATION CONDUIT
3 CAB REAR VENTILATION CONDUIT
4 POLLEN FILTER
5 CONDUIT
6 SCREW
7 HEATER HOSE
8 RETAINING CLIP
9 UNION
10 UNION
11 HEATER ASSEMBLY
1
3
10
9
2
11
8
7
6
5
4
1
9005-9
Cre 7-28021-21LX Issued 11-01
Removal
STEP 1
JS00163A1
to the ground.
STEP 2
STEP 3
CD00G002
STEP 4
Raise the engine hood and lock it in the raised
position.
STEP 5
Make sure that the radiator has cooled down and
remove the radiator cap.
STEP 6
Use a container of suitable capacity and empty the
cooling system (see the operator’s manual).
STEP 7
Remove the operator's seat from the cab (see
Section 9004).
1
WARNING: Boiling cooling fluid can spurt out
when the radiator cap is removed. To remove
the cap, proceed as follows: Wait until the
system has cooled down and then turn the
cap slightly and wait for all the pressure to be
released. You can be seriously scalded if the
radiator cap or expansion reservoir cap is
removed too quickly. For checking and
maintenance of the cooling system, refer to
the maintenance instructions.
!
9005-10
Cre 7-28021-21LX Issued 11-01
STEP 8
CD00G003
Remove the trim panel at the rear of the cab, taking
care to disconnect the connector for the cigarette
lighter and the solar radiation detector (only on airconditioned
models).
STEP 9
Disconnect the electric blower supply harness.
STEP 10
CD00G044
Unscrew the hose clips (8) and disconnect the heater
hoses (7).
NOTE: Carry out Steps 11 and 12 only for airconditioned
machines.
STEP 11
Empty the air-conditioning system, contact an
authorised engineer.
STEP 12
CD00G006
Remove the screw (A) and remove the hoses (B)
from the air-conditioner. Discard the O-rings. Block
the air-conditioner and the hoses with plugs in order
to avoid any risk of contaminating the system.
STEP 13
Remove the ventilation conduits (1-2-3) from the cab.
STEP 14
CD00G007
Remove the pollen filter guard, remove the filter (4)
and remove the conduit (5).
STEP 15
Remove the screws (6) that secure the heating or airconditioning
block to the cab. Remove the block from
the cab.
8
8
77
B
A
9005-11
Cre 7-28021-21LX Issued 11-01
Installation
STEP 1
Install the heating or air-conditioning block in the cab
using screws (6), brake washers and flat washers.
STEP 2
CD00G007
Install the conduit (5), the pollen filter (4) and the
pollen filter guard.
STEP 3
Install the heater ventilation conduits (1), (2) and (3).
STEP 4
CD00G044
Install the heater hoses (7) and tighten the retaining
clips (8).
NOTE: Carry out Steps 5 and 6 only on
air-conditioned machines.
STEP 5
CD00G006
Remove the plugs from the air-conditioner and the
hoses (B), install new O-rings on the hoses (B) and
install the hoses (B) on the air-conditioner, tighten the
screw (A) to a torque of 7.8 to 11.8 Nm.
STEP 6
Fill the air-conditioning circuit, contact an authorized
engineer.
Type of coolant: HFC (R) 134a
Capacity of the circuit: 1 kg +/- 0.05
STEP 7
Connect the blower supply electrical harness.
STEP 8
CD00G003
Install the trim at the rear of the cab, taking care to
reconnect the connector for the cigarette lighter and
the solar radiation detector (only on air-conditioned
models).
8
8
77
B
A
9005-12
Cre 7-28021-21LX Issued 11-01
STEP 9
Install the operator’s seat in the cab (see
section 9004).
STEP 10
Pour suitable cooling fluid in the radiator (see the
operator’s manual).
STEP 11
CD00G002
Open the left-hand side doors. Reconnect the ground
cable (1). Close the doors.
STEP 12
Start the engine and run it at idle speed for one
minute. Shut down the engine.
STEP 13
Add cooling fluid according to requirement in the
expansion reservoir.
STEP 14
Start the engine and run it at maximum speed until it
reaches normal working temperature.
STEP 15
STEP 16
When the radiator feels cold, remove the caps from
the radiator and the expansion reservoir. Add oil if
necessary.
STEP 17
Close the left-hand side doors.
1
WARNING: Boiling cooling fluid can spurt out
when the radiator cap is removed. To remove
the cap, proceed as follows: Wait until the
system has cooled down and then turn the
cap slightly and wait for all the pressure to be
released. You can be seriously scalded if the
radiator cap or expansion reservoir cap is
removed too quickly. For checking and
maintenance of the cooling system, refer to
the maintenance instructions.
!
9005-13
Cre 7-28021-21LX Issued 11-01
WINDSHIELD WIPER MOTOR
Description
CI00G502
1 PROTECTIVE FLAP
2 WINDSHIELD WIPER ARM
3 NUT
4 WINDSHIELD WIPER MOTOR
5 RUBBER CAP
6 NUT
7 FLAT WASHER
8 PLASTIC SUPPORT
9 SCREW
10 ELECTRICAL HARNESS
11 SCREW
4
11
9
2
1
35
6
7
8 10
9005-14
Cre 7-28021-21LX Issued 11-01
Removal
STEP 1
JS00163A1
to the ground.
STEP 2
STEP 3
CD00G002
STEP 4
From the front of the cab, raise the protective flap (1)
located on the lower portion of the windshield wiper
arm (2).
STEP 5
Remove the nut (3).
STEP 6
Note the position of the windshield wiper arm (2).
Remove the windshield wiper arm (2) from the
windshield wiper motor (4) by pulling it off the
windshield wiper motor shaft.
STEP 7
Remove the rubber cap (5).
STEP 8
Remove the nuts (6), washer (7) and plastic support
(8) from the windshield wiper motor shaft.
STEP 9
CD00G133
Remove the upper right-hand trim.
1
9005-15
Cre 7-28021-21LX Issued 11-01
STEP 10
CD00G134
Remove the lower front trim inside the cab, by the
screw(s) (A).
STEP 11
Disconnect the electrical harness (10) from the
windshield wiper motor (4).
STEP 12
Remove the screws (9) and (11) from the windshield
wiper motor. Remove the windshield wiper motor.
A
A
A
9005-16
Cre 7-28021-21LX Issued 11-01
Installation
STEP 1
Place the windshield wiper motor (4) in position on
the cab bracket. Connect the windshield wiper motor
connector (4) to the electrical harness (10).
STEP 2
Install the windshield wiper motor (4) on the cab
pillar, using the screws (9) and (11).
STEP 3
CD00G134
Install the right-hand front trims in the cab using the
screws.
STEP 4
Install the support (8), washer (7) and the two nuts
(6). Tighten the nuts.
STEP 5
Install the rubber cap (5).
STEP 6
Install the windshield wiper arm (2) on the windshield
wiper motor shaft (4), positioning the windshield
wiper arm (2) in the same position as was noted at
disassembly.
STEP 7
Install the nut (3) on the windshield wiper motor shaft.
Tighten the nut.
STEP 8
Turn back the flap (1) located on the lower portion of
the windshield wiper arm (2).
STEP 9
CD00G002
Open the left-hand side doors. Connect the ground
cable (1). Close the doors.
STEP 10
Switch on the windshield wiper motor and check that
everything is working correctly.
1
F8 F16 F15 F18 F3 F13 F7 F9 F2 F1 F10 F19 F17 F14 F5 F6 F4 F20 F11 F12
15A 15A 15A 15A 20A 20A 20A 30A 20A 20A 10A 10A 10A 5A 15A 10A 10A 10A 10A 10A
1.25 YR 208
1.25 R 206
8R 207
1.25 WR 209
RW 220
206. 208. 209
206. 208. 209
BrR 230
R 221
0.85LR 381
0.85 BrR 360
1.25 LW 340
1.25 GrR 330
0.85 OR 375
0.85 VR 370
VR 240
1.25 W 312
1.25 GR 310
VW 280
GW 290
OW 300
0.85 LR 380
0.85 YR 260
0.85 YR 260
1.25 W 322
1.25 W 325
1.25 LgR 320
2WR 050
1.25 LgR 350
BP 690
BrR 530
0.85 YM 270
LR 250
B 703
LR 250
2
1
55
2A
2B
CN 29
12
CN 1 CN 6 CN 5
0.85 OR 375
29
2 STAGE TRAVEL LW 801
VARIABLE ISC
BATTERY RELAY
A/C CONT.
NOT USE
BrW 804
WR 541
WR 548
LgW 803
24
30
31
23
SWITCHED DROP 36
20
33
34
25
35
26
32
GY 566
SPARE 3 (PNP)
24VB
5V
CN 5
GW 810
VW 800
SPARE 1 (PNP)
PROTECT
PROTECT
PWM
D/A PWM
8 BIT
A/O
10 BIT
I/O
I/O
RAM - 2 K BYTE
E2PROM
8 K BYTE
FLASH
MEMORY
2 M BYTE
FREE SWING
SWING PRIORITY
SWING LOCK
SWING BRAKE
CUSHION
WARNING BUZZER
17
21
19
28
27
22
18
9 10 11
123
W 820
12 13 14 15 16
45678
CN 6
27 28 29
17 18 19
30 31 32 33 34
20 21 22 23 24 25 26
SPARE 2 (PNP)
IMMOBILIZER
5
YR 940
GND
NOT USED
PWM 2 OUT
2 STAGE RELIEF
PWM2 RET
BY 941
YW 802
13
14
15
8
7
16
6
GND
GND
GND
1.25 LgR 350
1.25 LgR 351
1.25 BG 600
1.25 BG 601
POWER 24V
PWM 2 OUT
GND
GND
CONTROL 24V
10
12
4
9
11
3
1
2
1.25 W 320
1.25 W 321
PWM 2 RET
CW / ISC2
ISC DECR.
ISC INCR.
CCW / ISC3
10
18
7
11
12
15
17
16
14
20
19
13
IGN
TRAVEL MODE
ILLUMINATION
WORK MODE
CUSHION
FREE SWING
SWING PRIORITY SWING PRIORITY
AUTO MODE
BZ STOP
B+
TXD
SWING LOCK
WORKING LAMP
ENG. STOP
WASHER
WIPER (INT)
WIPER (CNT)
WINDOW L/SW.
ALTERNATOR.
GND
RXD
1
4
3
6
9
8
5
2
22
21
CN 3
42
TEST
SPARE 19 (SW.)
LIMIT SWITCH (CW)
SPARE 24 (SW.)
CAN-H
WG 446
LY 444
29
37
43
44
47
40
48
46
30
39
45
P 580
PG 581
LgY 436
SPARE 16 (SW.)
BZ. STOP
0.85 VG 469
YG 443
IMMOBILIZER
OVER LOAD SW.
LIMIT SWITCH (CCW)
CUSHION
BREAKER MODE
CHECK
SPARE 25 (SW.)
31
34
33
36
41
38
35
32
G 464
BrG 460
SWING PRIORITY
2ND OPT. PILOT
SWING LOCK
NOT USED
CAN-L
CAN GROUND
35 36
11 12 13 CN P0
123
14 15 16 17 18
4 5 6 7 8 9 10
19 20 21 22
CN 13
CN 26
11 12 13
123
14 15 16 17 18
789
10
456
19 20
CN 14
CN 31
11 12 13
123
7 8 9 10 14
456
CN P3
CN 10
18
8
17 16 15 14 13
7654321
12 11 10 9
CN 25
CN 27
CN 63 CN 62
CN 61
456
1
78
23
456
1
78
23
CN 11
6
4
5
1
789
23
456
123
2
YV 414
1.25 BG 600 1.25 BG 600
430, 431, 432, 433, 435, 436,
437, 440, 464, 580, 581
A GND
OVER LOAD (SIG)
KEY SW.
BATT. CHARGE
SPARE 12 (CMP)
BY 426
YV 415
LgR 542
BrR 543
11
4
7
8
16
12
5
A Vcc
P2 SIG
P1 SIG
0.85 BO 425
0.85 OL 415
0.85 WY 400
YV 414
0.85 WL 410
THERMO SENSOR (0)
SPARE 9 (A/D)
NEG. CON SIG
AVcc
FUEL SENSOR
A GND
SPARE 11 (A/D)
6
15
14
1
10
9
3
13
0.85 GL 413
0.85 YL 411
0.85 L 412
0.85 BW 420
A GND
CN 2
GROUND 26
24
17
18
SW. TO ACCESS (FLASH)
SERIAL OUTPUT
PROTECT (FLASH)
PG 586
P 585
WR 571
PW 583
SPARE 13 (CMP)
GROUND
SERIAL IN (MONITOR)
SCI TXD
COUNTER
SCI
RXD
TA INPUT
Rx
Tx
SG
23
20
21
22
19
25
28
27
BP 587
LG 570
PL 584
TA GND
FILTER
CPU
1/4
RS 232 C
CAN
TXD
RXD
10V
5V
5V
5V
CN 4
57
BrY 432
COOLANT
SWING PILOT
UPPER PILOT
TRAVEL MODE
ONE-TOUCH IDLE
LG 430
BrG 441
G 450
WG 448
58
59
62
64
63
61
60
L/M MODE
BREAKER PILOT
AUTO MODE OG 442
ENGINE OIL PRESSURE
WARNING CHG.
WORK MODE
SPARE 22 (SW.)
TRAVEL PILOT
ONE-TOUCH POWER-UP
FREE SWING
49
52
51
54
56
55
53
50
YG 431
VG 447
LY 435
VY 440
GrG 437
SPARE 23 (SW.)
V REF
1K ½ 100 ½ 1K ½
5V
24 V
CN 1
9 10 11
123
12 13 14 15 16
45678
CN 4
57 58 59
49 50 51
60 61 62 63 64
52 53 54 55 56
CN 2
23 24 25
17 18 19
26 27 28
20 21 22
CN 3
39 40 41
29 30 31
42 43 44 45 46
32 33 34 35 36 37 38
47 48
2A1
2A2
2A3
2A4
2A5
GND
PWB
2B1
2B2
2B3
2B4
2B5
2B6
GND
2D
2E
16G
16F
16E
16B
2C
FPC
10
YG 443
VR 523
LY 444
GrR 520
PW 583
PL 584
BrR 501
WR 531
BrW 545
1.25 BG 602 602, 603, 604
18
7
11
12
15
17
16
14
20
19
13
LR 521
YR 522
R 221
OG 442
VG 447
BrG 441
1.25 W 322
VY 440
WG 446
YG
VR
LY
GrR
PW
PL
BrR (BrY)
WR
BrW (BrR)
1.25 BG
LR
YR
R
OG (GY)
VG
BrG
GrR
1.25 W
VY
WG (OG)
YG
VR
LY
GrR
PW
PL
BrR (BrY)
WR
BrW (BrR)
GND 1.25 BG
LR
YR
R
OG (GY)
VG
BrG
GrR
1.25 W
VY
WG (OG)
IGN
TRAVEL MODE
WORK MODE
CUSHION
FREE SWING
AUDIO MODE
BZ STOP
SWING LOCK
WORKING LAMP
ENG. STOP
WASHER
WIPER (INT)
WIPER (CNT)
WINDOW L/SW
ALTERNATOR
B+
TXD
RXD
1
4
3
6
9
8
5
2
WIPER SW. IN (INT) 11
VW
GrR
0.85 BrR
LR
YR
BW
WV
1.25 B
VW
GR
GW
VR
VR
GR
GW
7
12
13
1
9
10
3
4
8
2
1.25 B
6
5
1
VR
LW
WR
VW
BL
BG (B)
BG (B)
2
3
6
8
7
5
4
YN
BY
VR
LW (SPK: L+)
VW
BL (SPK: L-)
BG (B)
YN (SPK: R+)
BY (SPK: R-)
WR
WR
7
BG 620
BP 587
LG 570
P 585
PG 586
1.25 W 325
WR 571
1
4
3
6
8
5
2
1
8
4
9
2
7
6
3
1
3
VG 576 2
5
5V
4.7K
WG 448
BG 604
GY 467
LY 468
1.25BG 600
BrR 543
BG 622
575. 588
BrR 840
B 710
BP 632
BP 633
R 222
LW 972
BL 973
YW 970
BY 971
BP 690
BrG 460
8
54
53
56
52
1
2
123
CN P9
123
CN P7
321
CN P5
1
2
CN P6
CN P2
1
2
CN P4
1
2
CN 50
321 10 11
13
CN 12
11
9
10
123
12 13 14 15 16 17 18
45678
CN 28
123
45678
CN 51
21
10 9 8 7 6 5
CN 19
4356
7 8 9 10 11 12 13
1234
CN P1
12
CN P8
12
0.85 VG 469 0.85 BG 621
0.85 BrW 575
23
1
23
17
1
2
3
1
2
3
BrR 840 CN 62
BP 690
BrG 460
23
1
1
2
3
6
21
12
5
WR 391
OFF
ON
HEAT
ACC
START
OFF
HEAT
ACC
ON
ST
ST
CONNECTION
B G1 G2 Acc M
2
LW 532
B 713
1
VW 842
B 714
3
4
1234
0.85 L 480
0.85 BL 490
0.85 LY 470
LgR 540
WR 390
GrR 010
RW 220
0.85 L
0.85 B
3 0.85 Y
2
1
3
2
1
14
15
19
17
2
G 450
BG 603
1
CN 53
VR 841
B 711
3
4
1234
4
2
3
5
6
1
CN 52
123
456
M
9
0.85 GR 567
1.25 B 701
1.25 LW 340
18
14
8
1
11
13
12
10
2
0.85 YW 270
PL 562
WR 980
4
7
6
15
3
17
16
5
1
2
0.85 R PW 563
0.85 G
0.85 W
0.85 B
(LIMIT SW. DOOR) 0.85 O
(LIMIT SW. WINDOW) 0.85 YW
(RECIEVER DRYER) 0.85 WG
(COMP. POWER) 0.85 WG
(MAN POWER) 2 WG
(GND) 2 B
(ILLUMINATION) 0.85 RB
(WATER TEMP. SIG.) 0.85 BrW
VR 524
GY 566
VW 525
YR 560
BY 561
1
12
2
1
2
3 BG
VW
BG (B)
WG
BY
R YW
1
2
BL
L LW
24V
1
2
MMMM
BW 565
WL 564
16
7
5
4
12
13
9
14
1
10
8
15
16
18
3
11
6
2
17
15
0.85 BL 490
BG 603
14
6
17
18
11
13
12
10
9
B 711
WR 390
0.85 L 480
1
4
3
16
8
7
5
2
RW 220
VR 841
0.85 LY 470
G 450
GrR 010
LgR 540
0.85 BL 490
BG 603
B 711
WR 390
0.85 L 480
RW 220
VR 841
0.85 LY 470
G 450
GrR 010
LgR 540
6
BW 565
4
1
8
3
5
2
7
7
10
4
3
18
1
14
19
20
2
5
6
16
17
21
22
26
15
30
13
25
9
12
24
8
28
11
23
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
27
29
PW 563
WL 564
PL 562
BY 561
YR 560
BW 565
PW 563
WL 564
PL 562
BY 561
YR 560
10
7
1
4
3
6
9
8
5
YR 830 2
VR 240
GrR 448
LW 532
B 713
VW 842
BrR 840
BrG 460
YR 830
VR 240
GrR 448
WR 391
LgR 542
LgR 542
GrR 010
GrR 504
GrR 503
GrR 502
WR 390
LW 532
B 713
BP 690
BG 604
BP 690
BG 604
0.85 B
0.85 B
222, 391, 970, 971, 972, 973
WR 391
B 710
222, 970, 971, 972, 973
240, 448
830, 840. 842
VW 842
BrR 840
BrG 460
BP 690
603.604
BG.604
24V - 10W
51
50
49
16A
16C
16D
6
14
12
11
1
2
3
13
LR
0.85 GR
GrR
VR
YR
WR
VW
0.85 BrR
8
10
9
7
BL
LW
BY
YW
5
4
BW
WV
LR 521
VR 524
GrR 520
VR 523
VR 524
YR 522
WR 390
VW 525
0.85 BrR 360
BL 973
LW 972
BY 971
YW 970
BW 720
WV 930
WR 541
YR 830
LgR 540
BrR 543
GrR 010
VR 900
VW 800
1.25 R 206
1
2
3
BG (B)
VR
CN 70
456
1
7
23
CN 9
456
123
123456
6
2
5
4
7 SHUT OFF
3
GND
12 V OUT (BACKUP)
12 V OUT (MAIN)
GND
24 V IN (BACKUP)
24 V OUT (MAIN)
1
B 702
0.85 BY 729
R 223
0.85 RW 282
0.85 YR 281
VW 280
B 702
R 223
VW 280
B 702
R 223
VW 280
CN 30
321
1
2
3
1
3
6
5
2
4
WV 931
BW 721
WV 931
BW 721
12
2
1
B 713
B 715
B 702
1.25 B 700
B 710
BrR 230 B 715
W 820
0.85L 910
0.85LW 911
0.85LY 912
0.85LR 380
OR 506
2 LR 060
1.25 GR 312
BP 690
B 703 B 703
1.25 YR 208
1.25 BG 600
1.25 B 700
1.25 B 700
1.25 B 701
B 702
710, 711
713, 715
1.25 WR 209
1.25 GrR 330
1
2
3
6
5
4
BrW 545
BrW 545
1.25 BG 602
BG 603
BG 604
BrR 544
LgW 803
YW 802
GW 810
VW 842
BrW 804
WV 930
BW 720
0.85GR 890
0.85LgR 891
LR 901
WR 980
VR 841
BrR 840
LW 801
OW 300
YR 940
BY 941
BrG 461
LG 430
GrG 437
G 464
BrY 432
YG 431
LgY 436
0.85 OL 415
0.85 GL 413
0.85 BO 425
0.85 WL 410
LY 435
0.85 WY 400
0.85 L 412
0.85 BW 420
0.85 YL 411
P 580
PG 581
0.85 PL 484
CONNECTOR
LETTER LOCATED
(OUTSIDE CAB)
1
COLOR OF CONNECTOR
(IF NOT INDICATED COLOR IS WHITE)
TABLE OF COLOR SYMBOLS
CIRCUIT NUMBER
60 B 001
SYMBOL
B
W
Br
P
V
G
O
R
Y
Lg
Sb
L
Gr
COLOR
AREA
INDICATES CONSTANT POWER
INDICATES POWER WHEN KEY SWITCH IS ON
CONNECTOR (MALE)
CN12 (R)
CONNECTED
BOOT GROUND
CONNECTOR (FEMALE)
NOT CONNECTED
SINGLE WIRE CONNECTOR
CONNECTOR NUMBER
(IN CAB)
INSULATION AGAINST MAGNETISM
CABLE GROUND
HARNESS
NOTE :
1. "BR" INDICATES BLACK CABLE WITH RED STRIPE.
2. WATERPROOF CONNECTORS USED OUTSIDE OF CAB.
210 LX - 240 LX EXCAVATOR

ELECTRICAL SCHEMATIC
Part Number 7-28521
LEGEND
COLOR
BLACK
WHITE
BROWN
PINK
VIOLET
GREEN
ORANGE
RED
YELLOW
LIGHT GREEN
SKY BLUE
BLUE
GRAY
3
R 223
R 222
WIPER SW. IN (CNT)
WASHER SW. IN
WASHER CONT. (+)
WASHER CONT. (-)
POWER (24 V) IN
GND
WINDOW CONTROL
REV. SIG.
STOP SIG.
WINDOW LIMIT SW.
WIPER MOTOR (CW)
WIPER MOTOR (CCW)
CN Q0
1
2
CN Q1
2
1
0.85 GR
0.85 B
0.85 GR
0.85 B
2
1
2
1
1
2
3
6
5
4
CN S3
12
CN S7
12
34
CN S9
23
1
CN S8
1
2
CN S2
12
0.85 LY
0.85 LY
0.85 OB
0.85 GY
0.85 OB
0.85 GY
0.85 OB
0.85 LB
0.85 L
0.85 R
0.85 G
0.85 W
0.85 B
0.85 WR
0.85 WR
0.85 WG
0.85 GW
0.85 GW
0.85 YR
0.85 BR
0.85 BR
0.85 BR
0.85 WG
0.85 WG
0.85 BR
0.85 YB
0.85 Y
0.85 YW
0.85 BrW
0.85 RB
0.85 O
0.85 BrR
0.85 RG
0.85 WL
0.85 LgW
0.85 YL
0.85 Br
0.85 LW
0.85 LgB
0.85 YG
0.85 RY
0.85 LR
0.85 LgR
0.85 YR 0.85 GB
0.85 RG
0.85 WL
0.85 LgW
0.85 YL
0.85 YB
0.85 Br
0.85 LW
0.85 LgB
0.85 YG
0.85 Y
0.85 RY
0.85 LR
0.85 LgR
0.85 GB
CN S6
12345
CN S5
12345
CN S4
12345
1
4
3
2
2R
2R
2L
2L
2B
0.85 LB
0.85 BrR
0.85 WG
2 WG
9 10 11
123
12 13 14 15 16 17 18
45678
CN S0
CN S1
1 2 3 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
45678
CN 15
35
4
12
2
5
1
4
3
2WR 050
2WR 051
OR 506
2LR 060
CN 18
35
4
12
2
5
1
4
3
0.85L 910
0.85LR 381
BrR 530
060, 506, 910 ,911,912
050, 381, 530
0.85LW 911
0.85LW 912
CN 16 CN 17
22C 22D
22A 22B
35
4
12
2
5
1
4
3
0.85 VR 370
0.85 VR 371
WR 531
GW 290
GW 291
LW 532
LR 900
0.85 GR 890
0.85 LgR 891
0.85 GR 892
35
4
12
2
5
1
4
3
LR 901
531, 532, 567
890, 891, 900, 901
461, 470, 480, 490
501, 502, 503, 504
290, 370
G 438
BG 658
12
1
G 438 2
BG 658 1
2
CN N0
12
CN Y0
G 439
BG 659
12
1
2
CN N1
62
4
301, 842, 843
1
2
1
2
CN B7
1
3
2
OW 301
VR 841
VW 842
123
CN L0 CN L1
1
2
OW 301
OW 301
VR 841
VW 842
OW 302
VW 842
VR 841
1
2
28A
28B
CN 32
BrR 547
12
2
1
BrR 548
BrR 547
BrR 547
BrR 544
CN 60
9 12
YR 830 2
VR 240 1
BrG 460
BrG 461
1
2
61
BG 657
G 465
1
2
12
CN M0
12
CN M1
BG 656
G 464
BG 656
G 464
43
42
1
1
WR 980 2
W 981
12
CN B9
W 981
CN C8
1
5 B 796
M6 M6
30A 30
31A
31B
31C
31D
31E
41F
31G
31H
31J
24A
24B 24C 24D
30B
30C
30D
30E
30F
8R 207 8R 207
CN 20
1
2
CN C1
1
2
CN C3
1
2
CN C4
1
2
CN C2
1
2
CN C0
1
1
2
CN 22
11 12 13
123
7 8 9 10 14
456
1
2
3
6
8
7
5
4
10
12
11
9
14
13
WR 541
YR 830
LgR 540
BrR 543
GrR 010
VR 900
VW 800
1.25 R 206
OR 505
W 820
0.85 LW 911
0.85 L 910
0.85 LR 380
0.85 LY 912
CN 21
6
4
578
123
CN D6
0.85 L 913
0.85 B 751
12
2
1
1
2
1
2
1
2
1
2
1
2
1
2
1
2
3
6
8
7
5
4
2 LR 060
BP 690
1.25 YR 208
1.25 GR 312
1.25 B 731
1.25 B 730
1.25 GrR 330
2 BG 600
2 B 700
1.25 WR 209
B 765
BrW 804
B 761
LW 801
YW 802
B 763
B 764
LgW 803
B 762
B 765
B 761
B 763
B 764
B 762
YR 830
B 760
2 LR 050
BP 690
B 760
0.85 BG 660
BG 641
BG 652
BG 640
B 763
GND
(G2)
OW 301
B 760
VW 800
60 R 001
BR 207
1
2
3
6
8
7
5
4
10
12
11
9
14
13
16
15
18
17
LgW 803
BrR 840
YW 802
WV 930
BrW 804
LW 801
B 763
B 760
M6
BW 720
0.85 LgR 891
0.85 GR 890
WR 980
LR 901
OW 300
BY 941
YR 940
VW 842
VR 841
GW 810
1
2
3
6
8
7
5
4
10
12
11
9
14
13
16
15
18
17
20
19
22
21
BrY 432
0.85 WY 400
YG 431
0.85 L 412
LY 435
0.85 YL 411
0.85 WL 410
LG 430
0.85 W 420
GrG 437
LgY 436
BrG 461
G 464
0.85 OL 415
0.85 GL 413
0.85 BO 425
0.85 PL 484
PG 581
P 580
1.25 R 206
60 R 200
M10
60 B 799
M10
-
12V
24V
M10
+
60 R 201
2 B 700
BG 650
B 779
B 779
B 779
2 BG 800
2 B 700
2 BG 800
BP 690
BW 630
8 R 100
301, 841, 842
8 R 100
WV 930
1.25 RW 202
-
M10
MB
NB
M8
M8 GND
(GI)
M4
+
1.25 LR 204
BR 203
1.25 GR 205
LgR 540
WR 541
1.25 YR 208
1.25 LR 204
1.25 WR 209
1.25 GR 205
12V
M
2
1
25
26
29
27
1
1
2
1
2
1
2
1
2
BG 651
BG 658
CN B4
CN E0 CN E2 CN E1 CN E3 CN E4 CN E5
1
2
GrG 437
BG 641
0.85 GL 413
0.85 BG 660
0.85 OL 415
0.85 BO 425 t C
12
CN B8
12
CN B3
12
CN D3
12
CN A8
12
CN A7
12
CN A6
12
CN A5
12
CN D7
12
CN C9
CN D6
456
123
0.85 LY 912
0.85 LW 911
0.85 B 750
0.85 B 751
0.85 LR 380
0.85 L 910
B
LW
LR
LY
1L
2
5
3
6
4
CN A3
CN A4
456
123
12
M
2 BG 600
B 779
2 B 700
VCC
POWER GND
SIG GND
PWM
VB
0.85 WG 473
0.85 LG 507 LIMP HOME
60 B 798
1.25 GrB 953
0.85 BW 492
0.85 BG 465
1.25 LG 952 1
4
2
6
5
3
32
31
1
2
1
2
3
0.85 L 412
0.85 LY 402
0.85 BL 422
2
3
1
0.85 YL 411
0.85 Y 401
0.85 BY 421
2
3
1
0.85 WL 410
0.85 WY 400
0.85 BW 420
48
47
46B
46A
45
44
CN D2
3
12
CN D1
3
1
2
CN D0
3
12
O 487
W 497
YL 488
BY 498
0.85 BY 495
0.85 YL 465
0.85 BP 494
0.85 PL 484
LgY 438
BG 640
tC
M10
M4
tC
CN A2
6
4
578
123
1
2
3
6
8
7
5
4
0.85 GR 465
L 496
1.25 BrB 951
0.85 WY 472
0.85 WL 482
0.85 YG 508
Y 486
1.25 RG 950
PWM
TACHO SENSOR (GND)
POWER GND
VCC
RACK 1ST
PULL DOWN
TACHO SENSOR (SIG)
VB
2 LR 060
B 719
BrR 030
LgR 020 1
2
R
L
B
E
M5
M5
SG
M
24V 40A
140
60 R 001
030
010, 543
WR 541
LgR 540
0.85 BrR 543
0.85 GrR 010
B
S
R
M10
½
1
2
1
2
1
2
1
2
1
2
1
2
3
123
RED
4
650, 651, 652 641, 650, 651, 652
010, 540, 541, 543
CN 24
11 12 13
123
14 15 16 17 18
4 5 6 7 8 9 10
19 20 21 22
CN 23
11 12 13
123
14 15 16 17 18
78
9 10
456
CN B5
1
2
LG 430
BG 651
YG 431
G 438
WR 980
BG 650
BrY 432
BrY 432
BG 652
BG 652
40
41
39
12
12
12
1
2
1
2
1
2
1
G 464 2
BG 656
G 464
BG 656 1
2
CN B0
12
CN G2
CN C5
CN C6
1
2
1
2
1
2
1
2
37
36
35
34 34
12
CN D4
12
CN B2
BY 941
YR 940
BY 941
YR 940
0.85 GR 890
LR 900
B 753
0.85 B 740
0.85 GR 890
1.25 B 740
1.25 B 740
B 767
0.85 B 741
0.85 LgR 891
24V
70W
70W
24V
GW 810
2 B 700
2 BG 600
2 BG 600
LR 901
2 B 700
B 753
B 754
2 B 700
2 BG 600
B 779
2 B 700
LR 901
B 754
24V. 370 HZ. 111dB
24V. 370 HZ. 111dB
650, 651 650, 651, 652
1.25 B 740
B 779
CN B1
456
123
1
1
2
2
60
59
28C
38
12
CN G1
12
CN G0
1
2
3
6
5
4
BG 655
BrR 840
LY 435
BrG 461
BG 655
LY 435
BG 655
LY 435
BG 656
BG 655
BG 655
LY 435
BrG 461
G 464
G 464
G 464
OW 300
BG 655
BrR 840
LY 435
BrG 461
OW 300
BG 655
BrR 840
G 464
LY 435
OW 300
BrR 840
OW 300
1
2
1
2
12
CN K0
12
CN B6
B 767
GW 810
B 767
GW 810
G 464
BG 656
G 464
1
2
3
6
5
4
G 464
B 752
W 820 W 820
CN C7
12
2
1
33
1.25 GrR 330 58
CN A0
16
18
19
24
26
25
23
21
2
7
6
12
14
13
8
3
31
L 496
TF SENSOR (SIG)
LIMP HOME (RED 4)
PS (GE) PWR GND
GND (TW & TF SENSOR)
0.85 YG 506
1.25 GR 312
680
681
1.25 GR 313
9
10
22
32
27
20
11
TACHO SENSOR (GND)
RPM SENSOR (SIG)
NV VB
RPM SENSOR (GND)
PULL DOWN (RED 4)
HEAT RELAY
TACHO SENSOR (SIG)
28
4
1
30
17
5
15
29
OR 506
Y 486
O 487
W 497
0.85 YL 465
0.85 LG 507
0.85 BP 494
1.25 B 730
PS (GE) PWR VB
CN A1
45
43
53
38
56
48
44
35
39
51
33
52
36
34
54
42
55
1.25 RG 950
SIG GND (RED 4)
PWM SOLL (RED 4)
VBB (RED 4)
PWM SOLL (RED 4)
0.85 WY 472
0.85 WL482
0.85 WG 473
57
VBB (RED 4)
SHLD (RED 4)
5V (RED 4)
GND (RED 4)
5V (RED 4)
GND (RED 4)
GND (MV)
37
41
40
47
50
49
15
46
1.25 B 731
BL 782
1.25 LG 952
1.25 BrB 951
1.25 GrB 953
0.85 BW 492
0.85 GR 954
0.85 BG 955
P 580
PG 581
YL 488
BY 498
V 1ST (RED 4)
CAN-L
Q ADJUST RES.
Q ADJUST RES.
CAN GND
CAN-H
CN 7
78
79
84
88
67
59
57
85
63
69
65
72
77
76
71
64
83
GrR 504
MAP SELECT-3
TW SENSOR (SIG)
CAN USE SW.
0.85 BrY 575
BW 505
BrR 501
86
70
BW 509
75
58
68
81
START SWITCH
ACCEL VOLUME (5V)
ACCEL VOLUME (SIG)
ACCEL VOLUME (SIG)
MAP SELECT-1
ACCEL VOLUME (GND)
MAP SELECT-0
KEY SWITCH
KEY SWITCH
ENGINE STOP SIG IN
LIMP HOME SW.
ANTI-REVERSE SW.
MEMORY CLEAR 82
61
60
62
74
73
65
80
LgR 503
LgR 502
0.85 L 481
0.85 L 480
0.85 PL 484
0.85 BL 490
BY 500
0.85 LY 470
MAP SELECT-2
CN 8
97
98
99
102
104
103
101
100
89
91
90
93
96
95
92
94
GND
GND
ENGINE STOP MOTOR
VG 576
TECH 2 (RXD)
MAIN POWER (VB)
CHECKER SELECT
MAIN POWER (VB)
TECH 2 (TXD) P 588
1.25 GR 310
0.85 GR 311
0.85 BG 631
1.25 BG 630
1.25 BG 600
CN A0 CN A1 CN 7 CN 8
12 13 14
123
15 16 17 19
25 26 27
18
67
32
458
21
9
22
10
23
11
20 24
28 29 30 31
68 69 70 71 72 73 75
80 81 82
74
88
76 77 78 79
58 59 60 61 62 63 64 65 66 67
83 84 85 86 87
41 42 43 44 45 46 48
51 52 53 54
47 49 50
33 34 35 36 37 38 39 40
55 56 57
94 95 96 97 98 99
101 102 104
100
89 90 91 92 93
103
BY 500
0.85 PL 484
BW 505
BP 509
23
63
57
1. COMPUTER
2. MONITOR DISPLAY ASSEMBLY
2A. SWITCH PANEL
2A1. TRAVEL MODE SWITCH
2A2. WORK MODE SWITCH
2A3. AUTO MODE SWITCH
2A4. CUSHION CONTROL SWITCH
2A5. FREE SWING SWITCH
2B. SWITCH PANEL
2B1. BUZZER STOP SWITCH
2B2. SWING LOCK SWITCH
2B3. ENGINE STOP SWITCH
2B4. WORKING LIGHT SWITCH
2B5. WIPER SWITCH
2B6. WASHER SWITCH
2C. MONITOR DISPLAY
2D. HOUR METER
2E. ALARM
3. CIGARETTE LIGHTER
4. DC-DC (24V-12V) CONVERTER
5. RADIO
6. OPT. LINE SW (OPT. 2 SPEED)
7. BREAKER / CRUSHER SWITCH
8. TRAVEL ALARM CANCELATION SWITCH
9. LEVER LOCK SWITCH
10. THROTTLE VOLUME
11. KEY SWITCH
12. HORN SWITCH
13. DBL-ACTING S/V (L)
14. ONE TOUCH IDLE
15. DBL-ACTING S/V (R)
16. INNER TEMPERATURE SENSOR
16A. EVA SENSOR
16B. BLOWER AMPLIFIER
16C. BLOWER MOTOR
16D. BLOWER OFF RELAY
16E. ACTUATOR MOTOR (AIR-MIX)
16F. ACTUATOR MOTOR (MODE)
16G. ACTUATOR MODE (AIR-CHANGE)
17. AIR CONDITIONER / HEATER CONTROL UNIT
19. AIR CONDITIONER / HEATER CONTROL PANEL
21. SUNLIGHT SENSOR
22A. RELAY-ENGINE STOP
22B. RELAY-GLOW PLUG
22C. RELAY-HORN
22D. RELAY-WORKING LIGHT
23. ENGINE CONTROLLER (ECU)
24A. 20A FUSIBLE LINK
24B. 65A FUSIBLE LINK
24C. 20A FUSIBLE LINK
24D. 20A FUSIBLE LINK
25. BATTERY RELAY
26. BATTERY
27. BATTERY
28A. VALVE (SECOND OPTION (R))
28B. VALVE (SECOND OPTION (L))
28C. SOLENOID VALVE (OPTION 2 SPEED)
29. WASHER MOTOR
30. SIX SOLENOID VALVE BANK
30A. FUNCTION SHUT DOWN SOLENOID (BLUE BAND)
30B. SWING BRAKE RELEASE SOLENOID (PINK BAND)
30C. HIGH SPEED TRAVEL SOLENOID (RED BAND)
30D. POWER-UP SOLENOID (YELLOW BAND)
30E. CUSHION CONTROL SOLENOID (LIGHT GREEN BAND)
30F. SWING SHUT-OFF SOLENOID (GREEN BAND)
31. ENGINE
31A. ALTERNATOR
31B. STARTER MOTOR
31C. GLOW PLUGS
31D. ENGINE OIL PRESSURE SWITCH
31E. WATER TEMPERATURE SENSOR
31F. FUEL TEMPERATURE SENSOR
31G. Q ADJUST RESISTOR
31H. BACKUP RPM SENSOR
31J. ELECTRONIC GOVERNOR
32. ENGINE EMERGENCY STOP MOTOR
33. TRAVEL ALARM
34. HORN
35. WORKING LIGHT (HOUSE)
36. WORKING LIGHT (BOOM)
37. HYDRAULIC PUMP PROPORTIONAL SOLENOID
38. FREE SWING SOLENOID VALVE
39. SWING PILOT PRESSURE SWITCH
40. UPPER PILOT PRESSURE SWITCH (YELLOW BAND)
41. TRAVEL PILOT PRESSURE SWITCH
42. BINARY SWITCH
43. A/C COMPRESSOR MAGNETIC SWITCH
44. HYDRAULIC OIL TEMPERATURE SENSOR
45. FUEL SENSOR
46A. PRESSURE SENSOR (P1)
46B. PRESSURE SENSOR (P2) (YELLOW BAND)
47. PRESSURE SENSOR (NEGATIVE CONTROL)
48. LOW COOLANT RESERVE TANK LIMIT SWITCH
49. WIPER MOTOR
50. FRONT WINDOW LIMIT SWITCH
51. DOOR LIMIT SWITCH
52. CAB LIGHT
53. ANTENNA
54. ENGINE TEST POINT CONNECTOR
55. CONTROLLER TEST POINT CONNECTOR
56. WIPER CONTROLER
57. OPTIONAL POWER
58. TO FUEL FEED PUMP
59. BREAKER / CRUSHER PILOT PRESSURE SWITCH
60. BREAKER PILOT PRESSURE SWITCH
61. 2ND OPTION LINE PILOT PRESSURE SWITCH
62. BLADE PILOT PRESSURE (130 LX ONLY)
63. FUSE BOX
F1. FUSE 20A; ENGINE CONTROLLER
F2. FUSE 20A; COMPUTER CONTROL
F3. FUSE 20A; COMPUTER POWER
F4. FUSE 10A; FUNCTION CANCELLATTION LEVER SWITCH
F5. FUSE 15A; LUBRICATOR (NOT USED)
F6. FUSE 10A; NOT USED
F7. FUSE 10A; NOT USED
F8. FUSE 15A; ENGINE STOP MOTOR
F9. FUSE 30A; ENGINE PRE HEAT
F10. FUSE 10A; OPTION LINE
F11. FUSE 10A; BACK-UP
F12. FUSE 10A; KEY SWITCH
F13. FUSE 20A; HEATER / AIR CONDITIONER
F14. FUSE 5A; AIR CONDITIONER COMPRESSOR
F15. FUSE 15A; WORKING LIGHT
F16. FUSE 15A; WORKING LIGHT (NOT USED)
F17. FUSE 10A; DC-DC (24V-12V) CONVERTER
F18. FUSE 15A; WIPER AND WASHER
F19. FUSE 10A; HORN
F20. FUSE 15A; CIGARETTE LIGHTER
ITEM DESCRIPTION
BLANK
1
P
Dr
5
P1
P2
39 4
RED
Pm2
Pm1 Ps
T2
Pi
9
Pb5
L1
K1
15
14.5 psi
41
B
B
A
MU
42.08 psi
RIGHT
LEFT
T2 T1 P1
3
41
C
GA GB
43
T
14
23
JI
D1
D1
*
56
55
A
PT
ø 2.5
13
ø 1.2
18
16
10 μ
14.9 psi
150 MESH
27
10 μ 31μ
4.35 psi 0.58 psi
T
D1
D2
26
T
9
Pa8
58
S3
58
S1
RIGHT
RAISE
LEFT
P4
A3
B3
Pbu
A5
Pc1
IN
OUT
Pb5'
B5
REVERSE
FORWARD
Pa1
Pb1
ON
Pb5
Pa5'
Pa5
Pc3'
Pc3
Pb4
Pb4'
Pb3
Pa3
A2
B2
Pb2
Pa2
A1
B1
3
Pi
42
D
42
A
48
B2 48
B1
ø 2.5
ø 2.5
19 17 20 21
3
T1
T1
D3
9
A2
42
9
B2
22
A
D
T
B
C
A
C
B
10
T
3
T2
9
Pa9
A
B
T
P
C
E
D
44
41 *
*
*
*
*
43
10μ
T 15
A
35
T
P
31
24
LOWER RAISE OPEN CLOSE
BOOM BUCKET
35
T
P
31
4
IN OUT LEFT RIGHT
ARM SWING
2
RAISE
LOWER
P4
P3 P2 P1
P5
T3 T2 T1
T4 T5
33
G
H
E
F
T
B
A
46
46
46 46
24
ON 290 psi
25 OFF 217 psi ON 174 psi
OFF 130 psi
P1 PT PP PA
1T2
P
PT
A
45
47
49
48 A1 S1 A2
B1 S2 B2
IN
OUT
ON 72.5 psi
OFF 43.5 psi
D
C
R
S
ON
HAMMER
9
Pb2
9
Pa2
ON 72.5 psi
OFF 43.5 psi
46
36
OPTIONAL
*
*
*
*
*
3S
S1
2S 1S
S2 S3
34
12
9
P2 P3 PH
32
REVERSE FORWARD FORWARD REVERSE
1243
P
TRAVEL (LEFT)
T
Pi1
M
9
Pb1
9
Pa6
9
Pa1
9
Pb6
31
ISUZU
6BG1T
103 Kw
at 1950 rpm
TRAVEL (RIGHT)
46
52
54
A
A
ISUZU
6BG1T
121.4 Kw
at 2150 rpm
240 LX
210 LX
58
S4 S3 S1 S2
A4 B2 A3 A1 B1 A2
P
1T
REAR FRONT
57
46
210 LX - 240 LX EXCAVATOR
HYDRAULIC SCHEMATIC
Number 7-28521
LEGEND
P1 PUMP
P2 PUMP
PILOT SYSTEM PUMP
RETURN TO RESERVOIR
LEAK-OFF RETURN
PILOT SYSTEM CIRCUIT
STRIP COLOUR INDICATION
ON SOLENOID VALVE WIRE
COMPONENT BOUNDARY
HOSE
PIPING CONNECTION
PIPING CROSS-OVER
COMPONENT ITEM NO.
COMPONENT NUMBER
CONNECTION ITEM NO.
OPTION ITEM NO.
41
9
al1
*
Pi2
A2
a2
(FRONT) (REAR)
A3
Dr B1 B3
A1 Psv a4
a1
a3
50 51
H
DESCRIPTION PRESSURE SETTING
210 LX 240 LX
A MAIN RELIEF (STANDARD)
MAIN RELIEF (BOOST)
B BOOM RAISE PORT RELIEF
B1/B2 RELIEF ON BOOM HBCV
C BOOM LOWER PORT RELIEF
D ARM OUT PORT RELIEF
D1 RELIEF ON ARM HBCV
E ARM IN PORT RELIEF
F BUCKET OPEN PORT RELIEF
G BUCKET CLOSE PORT RELIEF
H PILOT PRESSURE RELIEF
I SWING RIGHT PORT RELIEF
J SWING LEFT PORT RELIEF
K TRAVEL REVERSE PORT RELIEF (1 RH - 2 LH)
L TRAVEL FORWARD PORT RELIEF (1 RH - 2 LH)
M NEGATIVE CONTROL RELIEF PRESSURE
28 ACCUMULATOR PRECHARGE
4980 psi
5412 psi
5688 psi
5688 psi
5688 psi
5688 psi
5688 psi
5688 psi
5688 psi
5688 psi
568 psi
4048 psi
4048 psi
5076 psi
5076 psi
375 psi
212 psi
4980 psi
5412 psi
5688 psi
5688 psi
5688 psi
5688 psi
5688 psi
5688 psi
5688 psi
5688 psi
568 psi
4206 psi
4206 psi
5076 psi
5076 psi
375 psi
212 psi
ITEM
16. SUMP TANK BREATHER
17. HYDRAULIC SUMP TANK
18. FILTER
19. SUCTION SCREEN
20. RETURN FILTER BY PASS VALVE
21. RETURN FILTER
22. SHUT-OFF VALVE (OPTIONAL)
23. NEPHRON FILTER
24. UPPER PRESSURE SWITCH (SWING ATTACHMENT OPTION)
25. TRAVEL PRESSURE SWITCH
26. 6 STACK SOLENOID VALVE
27. RETURN MANIFOLD
28. ACCUMULATOR
29. PILOT SYSTEM MANIFOLD
30. PILOT FILTER
31. MAIN HYDRAULIC PUMP
32. TRAVEL CONTROL PEDAL
33. PILOT SYSTEM AND RETURN MANIFOLD
34. SWING PRESSURE SWITCH
35. JOYSTICK CONTROL
36. BOOM & ARM CUSHION ATTACHMENT
37. NEGATIVE CONTROL RELIEF
38. BOOM HOLDING VALVE
39. TRAVEL MOTOR BRAKE
40. PRESSURE SWITCH (FOR HBCV)
41. SAFETY VALVE RETURN MANIFOLD (OPTIONAL)
42. 3-WAY SELECTOR (OPTIONAL)
43. RETURN FILTER (OPTIONAL)
44. MULTI-PURPOSE 3 WAY VALVE
45. AUXILIARY HYDRAULICS CONTROL PEDAL (OPTIONAL)
46. INLINE FILTER
47. AUXILIARY HYDRAULICS PRESSURE SWITCH (OPTIONAL)
48. T-SHUTTLE
49. AUXILIARY HYDRAULICS SOLENOID VALVE
50. P1 PUMP PRESSURE TRANSDUCER
51. P2 PUMP PRESSURE TRANSDUCER
52. P1 PUMP NEGATIVE CONTROL PRESSURE TRANSDUCER
54. CONTROL SHUTTLE BALL (OPTIONAL)
55. FREE SWING FUNCTION ORIFICE
56. FREE SWING SOLENOID VALVE
57. STRAIGHT LINE TRAVEL PEDAL (240 LX ONLY)
58. SINGLE PEDAL TRAVEL SHUTTLE BLOCK
ITEM DESCRIPTION
1. SWING MOTOR
2. ROTATING JOINT
3. ARM HOSE BURST CHECK VALVE
4. TRAVAL MOTOR
5. ARM CYLINDER
6. BUCKET CYLINDER
7. RIGHT BOOM CYLINDER
8. LEFT BOOM CYLINDER
9. MAIN CONTROL VALVE
10. BOOM HOSE BURST CHECK VALVE
11. ARM HOLDING VALVE
12. SWING SHUTTLE BLOCK
13. NON-RETURN CHECK VALVE
14. OIL-COOLER BY-PASS
15. OIL-COOLER
10μ
LIGHT
GREEN
POWER UP
BLUE
FUNCTION SHUT DOWN/
LIVE DEAD CONTROL
YELLOW
CUSHION
CONTROL
PINK
SWING
BRAKE
GREEN
SWING
SHUT OFF
RED
HIGH SPEED TRAVEL
C2
P
BT
P3
P2
P
C4
P0
29 30
26 28
P1
14.5 psi
212 psi
27
D1
S4 2.9 psi
58
S2
58
C5
C1
C3
Pa9
Pc2
Pb8
Pb8'
Pa8'
Pa8
Pb7
Pa7
Pb6
Pa6
BOOM (1)
TRAVEL (LH)
38
OUT
CLOSE
OPEN
REVERSE
FORWARD
BUCKET
A8
B8
A7
B7
A6
B6
Pb4'
9
44
D
Pi
10
BC
RAISE
LOWER
ARM (1)
SWING
BOOM (2)
HAMMER (H)
TRAVEL (RH)
ED
F
G
2
C
A
EF
B
D
RH REVERSE
RH FORWARD
LH REVERSE
LH FORWARD
Pb9
MM
IN
Ps1 Dr T2 T1 Ps2
11
405 psi 405 psi
ARM (2)
ø3
T3 T5 T4
37 37
P2
P1
4 39
RE
D
Pm1
T1
10
Pi
P2 P3
P1 T T P1
41
A
9
Pb8
40
A2 A1
B
54
A
49
L2
*
*
*
K2
210 LX - 240 LX
EXCAVATOR
HYDRAULIC / ELECTRIC
SCHEMATIC
69
26 28 29
31
15
4
33
36
16 17 19 20 21
23
1
32
35
7
8
5
6
30
Ps Pm2 8 7
P3 P2
Pi
10 *
B2 B1
BLANK

Model Mejor Maq PDF

Încărcat de

Informații document

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Model Mejor Maq PDF

Încărcat de

Drepturi de autor:

Formate disponibile

MODEL ________________

Printed in U.S.A. Link-Belt Cre 7-28151LX November 2001

3. Boom cylinder head/Boom

6. Arm cylinder head/Arm

Control pattern modification

Removing the regulator

Regulator assembly instructions

210 LX - 240 LX EXCAVATOR

S-ar putea să vă placă și