Linkbelt 145X3 Excavator SERVICE MANUAL WLSM1456-01LX – PDF DOWNLOAD

Description

Linkbelt 145X3 Excavator SERVICE MANUAL WLSM1456-01LX – PDF DOWNLOAD

FILE DETAILS:

Linkbelt 145X3 Excavator SERVICE MANUAL WLSM1456-01LX – PDF DOWNLOAD

Language : English
Pages :1297
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Linkbelt 145X3 Excavator SERVICE MANUAL WLSM1456-01LX – PDF DOWNLOAD

General Information

• Cleaning Clean the metal parts with cleaning solution that meets the standard and steam cleaning. (except for bearings) After cleaning, dry well, and inject oil in all parts. Also inject oil into the bearings after drying. Inspection When disassembling parts, check all the parts. If there are any worn or damaged parts, replace them. Inspect carefully to prevent initial breakdowns.
• Bearing Replace any loose bearings. Air dry bearings before installing them. Needle bearing When inserting needle bearings, be very careful not to damage them. Apply grease to the section where the needle bearing will be inserted. Gear Check that there is no wear and no damage. Oil seal, O-ring, gasket Always install new oil seals, O-rings, and gaskets. Apply grease to sections where oil seals and O-rings will be inserted. Shaft Check that there is no wear and no damage. Check the bearings and check for damaged oil seals on the shaft.
• Service parts Install LBX Link-Belt genuine service parts. When placing an order, check the parts catalog. It contains the LBX Link-Belt genuine part numbers. Any breakdowns arising from the installation of non-genuine parts are not covered by the warranty. Lubricants (fuel, hydraulic oil) Use the oil from the specified company or specified in the operator’s manual or service manual. Any breakdowns arising from any fuel or hydraulic oil other than those specified are not covered by the warranty.

TABLE OF CONTENTS:

Linkbelt 145X3 Excavator SERVICE MANUAL WLSM1456-01LX – PDF DOWNLOAD

Excavator 1
SAFETY 7
Safety, general information and standard torque data 10
General Information 11
Safety 11
ROPS 13
ROPS Judgment Method 13
Standard Torque Data For Cap Screws And Nuts 18
Bolt and Nut Tightening 18
Specifications And Special Torque Settings 19
A LOWER 21
Specifications 25
145X3 25
Travel Lower Body 25
145X3 (Blade) 25
Travel Lower Body 25
Main Equipment Table 26
145X3 26
Lower Component 26
Travel Unit 26
Take-up Roller 26
Upper Roller 26
Lower Roller 26
Recoil Spring 26
Shoe 26
Center Joint 27
145X3 (Blade) 27
Lower Component 27
Travel Unit 27
Take-up Roller 28
Upper Roller 28
Lower Roller 28
Recoil Spring 28
Shoe 28
Center Joint 28
Main Equipment Structure and Operation Explanation 30
Travel Motor 30
Travel motor operation explanation 30
Explanation of Component Device Operation 30
Hydraulic motor 30
Brake valve 30
Parking brake 33
Relief mechanism 34
High and Low Speed 2-stage Switchover Mechanism 38
Reduction Gear 42
Port Diagram 43
Travel Motor 43
Center Joint 43
Center Joint (Blade) 44
Basic Functions 45
Travel Speed Selection 45
Travel Alarm 45
Removal and Installation of Track 48
Removal and Installation of Shoe Assembly 49
Removal of Shoe Assembly 49
Installation of Shoe Assembly 51
Removal and Installation of Shoe Plate 53
Removal of Shoe Plate 53
Installation of Shoe Plate 53
Removal and Installation of Roller 54
Removal and Installation of Upper Roller 55
Removal of Upper Roller 55
Installation of Upper Roller 56
Assembly and Disassembly of Upper Roller 57
Configuration Diagram 57
Dimension Diagram 58
Jig Dimension Diagram 58
Disassembly Procedures 58
Assembly Procedures 60
Removal and Installation of Lower Roller 63
Removal of Lower Roller 63
Installation of Lower Roller 64
Assembly and Disassembly of Lower Roller 65
Configuration Diagram 65
Dimension Diagram 66
Jig Dimension Diagram 66
Disassembly Procedures 66
Assembly Procedures 69
Removal and Installation of the Sprocket 71
Removal of Drive Sprocket 71
Installation of Sprocket 72
Removal and Installation of Take-up Roller 73
Removal of Take-up Roller 73
Installation of Take-up Roller 74
Assembly and Disassembly of Take-up Roller 75
Configuration Diagram 75
Dimension Diagram 76
Jig Dimension Diagram 76
Disassembly Procedures 76
Assembly Procedures 79
Removal and Installation of Grease Cylinder 83
Removal of grease cylinder 83
Installation of grease cylinder 84
Assembly and Disassembly of Tension Shock Absorber 85
Configuration diagram 85
Dimension diagram 85
Jig dimension diagram 86
Disassembly procedures 86
Assembly procedures 86
Removal and Installation of Center Joint 88
Removal of Center Joint 88
Installation of Center Joint 90
Assembly and Disassembly of Center Joint 92
Configuration Diagram 93
Dimension Diagram 94
Jig Dimension Diagram 95
Disassembly Procedures 95
Assembly Procedures 96
Removal and Installation of Travel Motor 99
Removal of Travel Motor 99
Installation of Travel Motor 101
Assembly and Disassembly of Travel Motor 104
Tools for Assembly and Disassembly 104
Standard Tools 104
Secondary Materials 104
Special Tool (jig) 105
Motor Disassembly Procedures 108
Precautions before Motor Disassembly 108
Tightening Torque 109
Disassembly Procedure 110
Maintenance Standards 120
Motor Parts Maintenance Standards 120
Motor Assembly Procedures 121
Motor Assembly Procedures 122
Precautions before Motor Assembly 122
Assembly Procedure 122
Initial Pre-conditioning Operation 134
Structural Diagram 136
Internal Structure Diagram 139
Part Table 141
Maintenance Standards 142
Drive Sprocket 142
Take-up Roller 143
Upper Roller 144
Lower Roller 145
Track Shoe (grouser shoe) 146
Inspection Gauge 147
For Drive Sprocket 147
For Take-up Roller 147
For Upper Roller 148
For Lower Roller 148
Pressure Measurement and Adjustment Procedures 149
Main Pressure Measurement 149
Travel pressure measurement 149
Drain Volume Measurement Procedures 150
Preparations 150
Travel Motor Drain Volume Measurement 150
Air Bleed Procedure 152
Travel Motor 152
Check 152
B C SWING UNIT, COUNTERWEIGHT 153
Specifications 156
145X3 156
Upper Side Work System 156
Swing Units 156
145X3 (Blade) 156
Upper Side Work System 156
Swing Units 157
Main Equipment Table 158
145X3 158
Upper Component 158
Swing Unit 158
145X3 (Blade) 158
Upper Component 158
Swing Unit 158
Main Equipment Structure and Operation Explanation 160
Swing Motor 160
Swing Motor Operation Explanation 160
Hydraulic Motor Section 160
Valve Casing Section 161
Brake Section 162
Relief Valve Operation Explanation (relief valve model: KRD22EK10) 162
Hydraulic Motor Section 165
Valve Casing Section 166
Brake Section 167
Relief Valve Operation Explanation (relief valve model: KRD22EK10) 167
Swing Motor Internal Structure Diagram 170
Port Diagram 173
Swing Motor 173
Basic Functions 174
Swing Brake 174
Swing Lock 175
Swing Speed Limit 176
Free Swing (Optional) 176
Removal and Installation of Swing Unit 178
Removal of Swing Unit 178
Installation of Swing Unit 181
Assembly and Disassembly of Swing Motor 182
Causes of Trouble and Solutions 182
Jig 185
Disassembly 185
Assembly 188
Swing Motor Internal Structure Diagram 192
Assembly and Disassembly of Swing Unit 195
Disassembly 195
Assembly 196
Swing Reduction Gear Structure Diagram 197
Removal and Installation of Counterweight 199
Removal of Counterweight 199
Installation of Counterweight 201
Pressure Measurement and Adjustment Procedures 203
Main Pressure Measurement 203
Swing pressure measurement 203
Drain Volume Measurement Procedures 204
Preparations 204
Swing Motor Drain Volume Measurement 204
Air Bleed Procedure 205
Swing Motor 205
Check 205
H ENGINE 207
Specifications 212
145X3 212
Engine 212
Cooling System 212
Capacities, Filters 212
Coolant and Oil Capacities 212
Fuel Filter 212
145X3 (Blade) 212
Engine 212
Cooling System 213
Capacities, Filters 213
Coolant and Oil Capacities 213
Fuel Filter 213
Main Equipment Table 214
145X3 214
Engine-related 214
Engine 214
DPD 214
Air Cleaner (double element) 214
Radiator 214
145X3 (Blade) 215
Engine-related 215
Engine 215
DPD 215
Air Cleaner (double element) 215
Radiator 215
Basic Functions 216
Fuel Gauge 216
Coolant Temperature Gauge 217
DPD Gauge 218
Fuel Economy Gauge 219
Neutral Start 219
Engine Start/Stop Control 221
Preheating 222
Throttle 222
Idling Start 223
Auto Idle 224
One-touch Idle 225
Auto Warm Up 225
Quick Warm Up 226
Idling Stop 227
Idle up 228
Engine Emergency Stop 229
Coolant Level Reduction 229
Engine Air Filter Clog 230
Fuel Filter Clog 230
DPD Regeneration 231
Automatic Regeneration 233
Manual Regeneration 235
Optional Manual Regeneration 237
Hydraulic Assisting Load 239
Main Data 240
Function, Structure, Operation 242
Symptom 288
Frequent DPD regeneration by manual regeneration 288
Long DPD regeneration time 289
Engine start failure 290
Engine stalling 292
Engine hunting, rough idling 294
Excessive white smoke in the exhaust gas 295
Excessive black smoke in the exhaust gas 296
Abnormal noise 297
Large fuel consumption 297
Large oil consumption 299
Engine Output Deficiency 299
Functional Inspection 301
Inspection of the starter circuit system 301
Compression pressure inspection 301
Inspection of the starting system 302
Inspection of the fuel system 303
Inspection of the air intake system 304
Inspection of the exhaust system 304
Inspection of the EGR control system 304
Inspection of the glow control system 305
Functional inspection of the DPD 306
Inspection of the monitor warning light illumination circuit system 308
Maintenance precautions 309
Removal and Installation of Engine Assembly 312
Removal of Engine Assembly 312
Installation of Engine Assembly 316
Removal and installation of the fuel cooler engine inter-cooler radiator and oil cooler 317
Removal and Installation of Fuel Cooler 317
Removal of Fuel Cooler 317
Installation of Fuel Cooler 317
Removal and Installation of Engine Intercooler 317
Removal of Intercooler 318
Installation of Intercooler 320
Removal and Installation of Radiator 320
Removal of Radiator 320
Installation of Radiator 323
Removal and Installation of Oil Cooler 323
Removal of Oil Cooler 323
Installation of oil cooler 325
Removal and Installation of Turbo Charger 326
Turbocharger assembly Removal 326
Turbocharger assembly Installation 327
Removal and Installation of EGR Valve 329
Removal and Installation of EGR Cooler 329
EGR cooler Removal 329
EGR cooler Installation 330
Removal and Installation of EGR Valve 330
EGR valve Removal 330
EGR valve Installation 331
Removal and Installation of Top Cover 332
Removal of Top Cover 332
Installation of Top Cover 332
Removal and Installation of Muffler 333
Removal of Muffler 333
Installation of Muffler 333
Removal and Installation of Cylinder Head Cover 335
Cylinder head cover Removal 335
Installation of Cylinder Head Cover 336
Removal and Installation of Cylinder Head 337
Removal of Cylinder Head 337
Disassembly of Cylinder Head 346
Assembly of Cylinder Head 348
Installation of Cylinder Head 351
Inspection 368
Removal and Installation of Cylinder Block 374
Removal of Cylinder Block 374
Installation of Cylinder Block 390
Inspection 423
Lubrication System 425
Removal and Installation of Oil Pan and Crank Case 425
Removal of Oil Pan and Crank Case 425
Disassembly of Oil Pan and Crank Case 440
Assembly of Oil Pan and Crank Case 440
Installation of Oil Pan and Crank Case 440
Removal and Installation of Oil Pump Assembly 467
Removal of Oil Pump Assembly 467
Installation of Oil Pump Assembly 470
Inspection 473
Engine oil Inspection 474
Cooling System 476
Removal and Installation of Water Pump Assembly 476
Removal of Water Pump Assembly 476
Installation of Water Pump Assembly 477
Inspection 478
Removal and Installation of Thermostat 479
Removal of Thermostat 479
Installation of Thermostat 479
Inspection 479
InspectionInspection of Coolant 480
Inspection of Cooling Fan Belt 481
Removal and Installation of Exhaust Manifold 482
Removal of Exhaust Manifold 482
Installation of Exhaust Manifold 483
Inspection 486
Disassembly, Removal and Installation of DPD Assembly 487
Disassembly of DPD Assembly 487
Assembly of DPD Assembly 488
Inspection 491
Removal and Installation of Fuel Tank 492
Removal of Fuel Tank 492
Installation of fuel tank 494
Removal and Installation of Fuel Supply Pump 495
Removal of Fuel Supply Pump 495
Installation of Fuel Supply Pump 500
Removal and Installation of Common Rail Assembly 509
Removal of Common Rail Assembly 509
Installation of Common Rail Assembly 510
Removal and Installation of Injector 512
Removal of Injector 512
Installation of Injector 514
Removal and Installation of Starter Motor 517
Removal of Starter Motor 517
Installation of Starter Motor 517
Removal and Installation of Alternator 518
Removal of Alternator 518
Installation of Alternator 518
Preheating System 519
Removal and Installation of Glow Plug 519
Removal of Glow Plug 519
Installation of Glow Plug 519
Inspection 520
Introduction to the trouble diagnosis 521
Removal and Installation of Suction Control Valve 529
Removal of Suction Control Valve 529
Installation of Suction Control Valve 530
Removal and Installation of Fuel filter pressure 531
Fuel filter pressure sensor Removal 531
Fuel filter pressure sensor Installation 531
Removal and Installation of Engine coolant temperature sensor 531
Engine coolant temperature sensor Removal 531
Engine coolant temperature sensor Installation 532
Inspection 532
Removal and Installation of CKP sensor 532
CKP sensor Removal 532
CKP sensor Installation 533
Inspection 533
Removal and Installation of CMP sensor 533
CMP sensor Removal 533
CMP sensor Installation 533
Inspection 533
Removal and Installation of Oil pressure sensor 534
Oil pressure sensor Removal 534
Oil pressure sensor Installation 534
Inspection 534
Removal and Installation of Boost sensor 535
Boost sensor Removal 535
Boost sensor Installation 535
Inspection 535
Removal and Installation of IMT sensor 535
IMT sensor Removal 535
IMT sensor Installation 536
Removal and Installation of Exhaust differential pressure sensor 536
Exhaust differential pressure sensor Removal 536
Exhaust differential pressure sensor Installation 537
Inspection 538
Removal and Installation of Exhaust gas temperature sensor 538
DPD temperature sensor Removal 538
DPD temperature sensor Installation 538
Inspection 539
Engine-side DTC List 539
Troubleshooting – engine 542
Engine-side Trouble 542
Diagnostic Trouble Code U0001 CAN-Bus Malfunction 542
Diagnostic Trouble Code P0016 Crankshaft Position – Camshaft Position Correlation 542
Diagnostic Trouble Code P0045 Turbocharger Boost Control Solenoid Circuit 543
Diagnostic Trouble Code U0073 CAN-Bus Malfunction 544
Diagnostic Trouble Code P0087 Fuel Rail/System Pressure – Too Low 545
Diagnostic Trouble Code P0088 Fuel Rail/System Pressure – Too High 547
Diagnostic Trouble Code P0089 Fuel Pressure Regulator Performance 550
Diagnostic Trouble Code P0091 Fuel Pressure Regulator Control Circuit Low 551
Diagnostic Trouble Code P0092 Fuel Pressure Regulator Control Circuit High 552
Diagnostic Trouble Code P0093 Fuel System Leak Detected 553
Diagnostic Trouble Code U0101 Lost Communication with TCM 556
Diagnostic Trouble Code P0102 Mass Air Flow Circuit Low Input 557
Diagnostic Trouble Code P0103 Mass Air Flow Circuit High Input 557
Diagnostic Trouble Code P0112 Intake Air Temperature Sensor Circuit Low 558
Diagnostic Trouble Code P0113 Intake Air Temperature Sensor Circuit High 558
Diagnostic Trouble Code P0117 Engine Coolant Temperature Sensor Circuit Low 559
Diagnostic Trouble Code P0118 Engine Coolant Temperature Sensor Circuit High 560
Diagnostic Trouble Code P0122 Throttle Position Sensor Circuit Low 561
Diagnostic Trouble Code P0123 Throttle Position Sensor Circuit High 561
Diagnostic Trouble Code P0182 Fuel Temperature Sensor Circuit Low 562
Diagnostic Trouble Code P0183 Fuel Temperature Sensor Circuit High 563
Diagnostic Trouble Code P0192 Fuel Rail Pressure Sensor Circuit Low 564
Diagnostic Trouble Code P0193 Fuel Rail Pressure Sensor Circuit High 564
Diagnostic Trouble Code P0201 Injector Circuit – Cylinder 1 565
Diagnostic Trouble Code P0202 Injector Circuit – Cylinder 2 566
Diagnostic Trouble Code P0203 Injector Circuit – Cylinder 3 567
Diagnostic Trouble Code P0204 Injector Circuit – Cylinder 4 568
Diagnostic Trouble Code P0237 Turbo Charger Boost Sensor Circuit Low 569
Diagnostic Trouble Code P0238 Turbo Charger Boost Sensor Circuit High 570
Diagnostic Trouble Code P0335 Crankshaft Position Sensor Circuit 571
Diagnostic Trouble Code P0340 Camshaft Position Sensor Circuit 572
Diagnostic Trouble Code P0404 Exhaust Gas Recirculation 1 Control Circuit Range/Performance 573
Diagnostic Trouble Code P0409 Exhaust Gas Recirculation 1 Sensor Circuit 574
Diagnostic Trouble Code P0426 Exhaust Temperature Sensor Circuit Range/Performance Sensor 1 576
Diagnostic Trouble Code P0427 Exhaust Temperature Sensor Circuit Low Sensor 1 576
Diagnostic Trouble Code P0428 Exhaust Temperature Sensor Circuit High Sensor 1 576
Diagnostic Trouble Code P0522 Oil Pressure Sensor Circuit Low 577
Diagnostic Trouble Code P0523 Oil Pressure Sensor Circuit High 578
Diagnostic Trouble Code P0560 System Voltage 579
Diagnostic Trouble Code P0563 System Voltage High 580
Diagnostic Trouble Code P0601 Internal Control Module Memory Check Sum Error 580
Diagnostic Trouble Code P0602 Control Module Programming Error 580
Diagnostic Trouble Code P0604 Internal Control Module Random Access Memory (RAM) Error 581
Diagnostic Trouble Code P0606 ECM/PCM Processor 581
Diagnostic Trouble Code P0638 Throttle Actuator Control Range/Performance 581
Diagnostic Trouble Code P0641 Sensor Reference Voltage 1 Circuit 582
Diagnostic Trouble Code P0651 Sensor Reference Voltage 2 Circuit 583
Diagnostic Trouble Code P0685 ECM/PCM Power Relay Control Circuit/Open 584
Diagnostic Trouble Code P0687 ECM/PCM Power Relay Control Circuit High 585
Diagnostic Trouble Code P0697 Sensor Reference Voltage 3 Circuit 585
Diagnostic Trouble Code P1093 Fuel Rail Pressure (FRP) Too Low 586
Diagnostic Trouble Code P1112 Boost Temperature Sensor Circuit Low 589
Diagnostic Trouble Code P1113 Boost Temperature Sensor Circuit High 589
Diagnostic Trouble Code P1261 Injector Positive Voltage Control Circuit Group 1 590
Diagnostic Trouble Code P1262 Injector Positive Voltage Control Circuit Group 2 590
Diagnostic Trouble Code P1293 Fuel Filter Pressure Sensor Circuit Low 591
Diagnostic Trouble Code P1294 Fuel Filter Pressure Sensor Circuit High 591
Diagnostic Trouble Code P1404 Exhaust Gas Recirculation 1 Closed Position Performance 592
Diagnostic Trouble Code P1455 PM Over Accumulation 593
Diagnostic Trouble Code P1471 DPD Insufficient Regeneration 595
Diagnostic Trouble Code P1621 Control Module Long Term Memory Performance 596
Diagnostic Trouble Code P1655 Sensor Reference Voltage 4 Circuit 597
Diagnostic Trouble Code P1669 DPD Lamp Control Circuit 598
Diagnostic Trouble Code P2146 Fuel Injector Group 1 Supply Voltage Circuit 599
Diagnostic Trouble Code P2149 Fuel Injector Group 2 Supply Voltage Circuit 600
Diagnostic Trouble Code P2228 Barometric Pressure Circuit Low 601
Diagnostic Trouble Code P2229 Barometric Pressure Circuit High 601
Diagnostic Trouble Code P2452 DPD Differential Pressure Sensor Circuit 602
Diagnostic Trouble Code P2453 DPD Differential Pressure Sensor Circuit Range/Performance 603
Diagnostic Trouble Code P2454 DPD Differential Pressure Sensor Circuit Low 604
Diagnostic Trouble Code P2455 DPD Differential Pressure Sensor Circuit High 605
Diagnostic Trouble Code P2458 DPD Regeneration Duration 606
Diagnostic Trouble Code P042B Catalyst Temperature Sensor Circuit Range/Performance Sensor 2 608
Diagnostic Trouble Code P042C Catalyst Temperature Sensor Circuit Low Sensor 2 608
Diagnostic Trouble Code P042D Catalyst Temperature Sensor Circuit High Sensor 2 609
Diagnostic Trouble Code P060B Internal Control Module A/D Processing Performance 610
Diagnostic Trouble Code P242F DPD Restriction 610
Data Reference Values 612
Non-operational P rotation 612
Two pump relief 613
J HYDRAULIC EQUIPMENT (PUMP, OPERATION SYSTEM VALVE) 615
Specifications 620
145X3 620
Operating Device 620
Hydraulic Equipment 620
Hydraulic Device 620
Control Valve and Cylinder 621
Capacities, Filters 621
Hydraulic Oil Filters 621
145X3 (Blade) 621
Operating Device 621
Hydraulic Equipment 622
Hydraulic Device 622
Control Valve and Cylinder 622
Capacities, Filters 622
Hydraulic Oil Filters 622
Main Equipment Table 623
145X3 623
Hydraulic Device 623
Hydraulic Pump 623
Control-related 624
Control Valve 624
Solenoid Valve (4 stack) 624
Valve for Left/Right Operations 624
Valve for Travel Operation 624
Remote Control Valve Characteristic Diagram 624
Operation Remote Control Valve Control Diagram 625
Travel Remote Control Valve Control Diagram 626
Cushion Valve (heat circuit, with shuttle valve) 626
145X3 (Blade) 626
Hydraulic Device 626
Hydraulic Pump 626
Control-related 628
Control Valve 628
Solenoid Valve (4 stack) 628
Valve for Left/Right Operations 628
Valve for Travel Operation 628
Remote Control Valve Characteristic Diagram 628
Operation Remote Control Valve Control Diagram 629
Travel Remote Control Valve Control Diagram 630
Cushion Valve (heat circuit, with shuttle valve) 630
Basic Functions 631
Oil Temperature Gauge 631
Static Horsepower Control 632
Pressure Boost Control 632
Pump Standby Pressure Control 634
Swing Relief Cut 637
Boom Down Energy Save 638
Auto Energy Save 638
Overload Reduction Control 639
Overload Warning (Function for Europe only) 639
Stroke Control 640
Feed Pump Automatic Stop 642
Hydraulic Oil Filter Clog 643
Breaker Mode 645
Crusher Mode 646
Port Diagram 647
Hydraulic Pump (standard model) 647
Hydraulic Pump (blade) 648
Control Valve 649
Relief Valve 649
Relief Valve (blade) 652
4 Stack Solenoid Valve 656
2 Stack Solenoid Valve 658
Remote Control Valves (upper, travel) 658
Remote Control Valves (left-right) 658
Remote Control Valve (travel) 659
Cushion Valve 660
2-way Selector Valve 661
Direction Valve 662
Shut-off Valve 663
Manifold Under Cab 664
Manifold (accumulator section) 665
Manifold (hydraulic oil tank section) 666
Hydraulic Device 667
Pump P-Q Diagram 667
Main Equipment Structure and Operation Explanation 668
Hydraulic Pump 668
Structure and Operation Explanation 668
Hydraulic Pump Internal Structure Diagram 669
Overall View 669
Drive Shaft Front Side 670
Drive Shaft Rear Side 671
Part Table 672
Regulator 672
Regulator Operation Explanation 672
Regulator Operation Explanation Diagram 675
Front Side Regulator Internal Structure Diagrams 677
Rear Side Regulator Internal Structure Diagram 680
Gear Pump 683
Gear Pump Internal Structure Diagram 683
Structure and Operation Explanation 683
Control Valve 685
Basic configuration 685
Operation 698
4 Stack Solenoid Valve Operation Explanation 724
External Shape Diagram and Component Parts 724
Operation Explanation 725
Upper Pilot Valve (remote control valve) 726
Structure 726
Function 726
Operation 727
Structural Diagram 731
Travel Pilot Valve (remote control valve) 732
Operation 732
Pressure Reduction Valve Section 732
Operating Section Damping Mechanism Section 733
Structural Diagram 736
Cushion Valve 737
Structure 737
Operation Explanation 737
Removal and Installation of Hydraulic Oil Tank 742
Removal of Hydraulic Oil Tank 742
Installation of Hydraulic Oil Tank 745
Removal and Installation of Hydraulic Pump 746
Removal of Hydraulic Pump 746
Installation of hydraulic pump 749
Removal and Installation of Control Valve 750
Removal of Control Valve 750
Installation of Control Valve 753
Removal and Installation of Pilot Blocs 755
Removal and Installation of Travel Remote Control Valve 756
Removal of Travel Remote Control Valve 756
Installation of Travel Remote Control Valve 757
Removal and Installation of Operation Remote Control Valve 759
Removal of Operation Remote Control Valve (left side) 759
Installation of Operation Remote Control Valve (left side) 761
Removal of Operation Remote Control Valve (right side) 763
Installation of Operation Remote Control Valve (right side) 765
Removal and Installation of 4 Stack Solenoid 767
Removal of 4 Stack Solenoid Valve 767
Installation of 4 Stack Solenoid Valve 768
Removal and Installation of Cushion Valve 770
Removal of Cushion Valve 770
Installation of Cushion Valve 771
Procedures for Assembly and Disassembly of Hydraulic Pump Main Unit 774
Tools 774
Disassembly procedures 774
Assembly procedures 776
Pump Main Unit Maintenance Standards 780
Replacement standards for worn parts 780
Standards for repairing cylinders, valve plates, and swash plates (shoe plates) 780
Tightening torque 780
Overall View 781
Attached diagram 1 pump assembly cross-section diagram 781
Drive Shaft Front Side 782
Drive Shaft Rear Side 783
Part Table 784
Operation explanation 785
Regulator adjustment 788
Tables and diagrams 790
Procedures for Assembly and Disassembly of Regulator 794
Tools 794
Disassembly preparations 794
Disassembly procedures 794
Assembly procedures 796
Diagram 1 Front-side regulator assembly cross-section diagram 799
Diagram 2 Rear-side regulator assembly cross-section diagram 802
Procedures for Assembly and Disassembly of Control Valve 804
Disassembly 804
Cautions for disassembly 804
Disassembly procedure 804
Removal of long cap and pull out of main spool 804
Disassembly of arm 1 parallel-tandem spool, neutral cut spool section 805
Disassembly of arm regeneration release valve section 805
Disassembly of load check valve section 806
Disassembly of antidrift valve section 806
Disassembly of relief valve 807
Disassembly of option section 807
Disassembly of straight travel signal control valve 807
Disassembly of other plugs 807
Disassembly of add-on section 807
Disassembly of valve housing union bolt 808
Cleaning 808
Inspection 808
Cautions for assembly 808
Cautions for O-Ring handling 808
Cautions for spool handling 808
Adhesive application method (for male thread section and female thread section of parts requiring ad 808
Procedure for assembly of sub-assembly 809
Assembly of spool assembly (main spool) 809
Assembly of arm 1 parallel-tandem spool assembly 809
Assembly of neutral cut spool assembly 809
Assembly of antidrift valve assembly 810
Procedure for assembly of control valve main unit 810
Assembly of relief valve 810
Assembly of load check valve 810
Assembly of antidrift valve 811
Assembly of option section 811
Assembly of arm regeneration release valve 811
Assembly of arm 1 parallel-tandem spool 811
Assembly of neutral cut spool 811
Assembly of main spool 811
Assembly of straight travel signal control valve 812
Assembly of add-on section 812
Assembly of other plugs 812
Internal structure diagram 813
Part list 819
Main plunger section 820
Foot relief valve 823
Main relief valve 824
Disassembly 824
Assembly and pressure setting 825
Pressure setting 826
Overload relief valve 827
Center bypass valve 829
Arm regeneration check 830
Boom back pressure check 831
Load hold valve 832
Boom regeneration check 835
Check valve 836
Swing priority valve 838
Check valve (swing priority path) 841
Arm regeneration valve 843
Travel signal switchover spool 844
Procedures for Assembly and Disassembly of Operation Remote Control Valve 845
Maintenance Procedures 845
Required Tools and Tightening Torque 845
Maintenance Standards 845
Disassembly Procedures 846
Assembly Procedures 848
Causes of Trouble and Countermeasures 852
Procedures for Assembly and Disassembly of Travel Remote Control Valve 856
Maintenance Procedures 856
Disassembly Procedures 857
Assembly Procedures 861
Causes of Trouble and Countermeasures and Cross-section Diagram 866
Assembly and Disassembly of Cushion Valve 869
Disassembly Procedures 869
Reverse Operation Spool Section 869
Check Plunger Section with Throttle 869
Shuttle Valve Section 869
Assembly Procedures 869
Reverse Operation Spool Section 870
Check Plunger Section with Throttle 870
Shuttle Valve Section 870
Written Materials 871
Pressure Measurement and Adjustment Procedures 873
Procedures for Pressure Measurement from the Monitor Display 873
Monitor and switch panel 873
Pressure Measurement Method 873
Operating Method 873
PROCEDURES FOR MEASURING HYDRAULIC OIL TEMPERATURE FROM THE MONITOR DISPLAY 873
Hydraulic Oil Temperature Measurement Method 873
Operating Method 874
Procedures for Pressure Measurement by Installing Pressure Gauge 875
Preparations 875
Items to Prepare 875
Pressure Measuring Ports 875
Control Valve 877
Location of Relief Valves 877
Pressure Measurement Preparations 878
Pressure Measurement 880
Main Pressure Measurement 880
AAttachment pressure measurement 880
Boom-down pressure measurement 881
Option line pressure measurement 881
Pilot Pressure Measurement 881
Pressure gauge installation 881
Negative Control Pressure Measurement 882
Pressure gauge installation 882
Pressure Adjustment 882
Main Pressure Adjustment 882
Pressure measurement and adjustment preparation work 882
Main relief pressure adjustment 883
Overload relief pressure adjustment 884
Swing relief pressure adjustment 885
Pilot Pressure Adjustment 885
Hydraulic Pump Flow Measurement Procedures 887
Preparations 887
Items to Prepare 887
Work Preparations 888
Flow Measurement 889
Air Bleed Procedure 891
Hydraulic Pump 891
Check 891
Hydraulic Equipment Layout 892
Overall view 893
PUMP CHAMBER HYDRAULIC EQUIPMENT LAYOUT 894
SWING BODY CENTER SECTION HYDRAULIC EQUIPMENT 896
HOUSING LEFT SIDE HYDRAULIC EQUIPMENT LAYOUT 897
LAYOUT OF HYDRAULIC EQUIPMENT IN CAB 898
N CAB 899
Removal and Installation of Operator’s Seat 902
Removal of Operator’s Seat 902
Installation of Operator’s Seat 902
Removal and Installation of Cab Assembly 903
Removal of Cab Assembly 903
Installation of Cab Assembly 906
Removal and Installation of Wiper 907
Removal of Wiper 907
Installation of wiper 907
Removal and Installation of Cab Front Glass 908
Removal of Cab Front Glass 908
Installation of Cab Front Glass 909
Window Lock Adjustment Procedures 910
Window Lock (front side) 910
Window Lock (rear side) 910
Tightening torque 912
R ELECTRICAL PARTS 913
Electrical and Engine Functions and Service Support 917
Basic Functions 918
Monitor Display Dimming 918
Eco Gauge 918
Diagnostic Trouble Code Indicator 919
Clock 920
Accessories 921
Working Light 921
Radio Mute 921
Back/Side View Monitor 922
Anti-theft 922
Password 922
Milli-amp List 924
Service Support 926
Screen Operations 926
Screen Display List 926
CHECK Screen List 927
MACHINE STATUS 927
FAULT HISTORY 936
WORK HISTORY 936
ENGINE HISTORY 938
HYDRAULIC HISTORY 943
PART NUMBER 944
SETUP Screen List 945
MACHINE SELECT 945
PARAMETERS 950
Setting 952
Model Select 952
Throttle Volume Default Setting 955
Password Setting 956
Adjusting the Clock 956
Parameter Settings 956
Option Flow Pressure Setting 958
Screen Brightness Setting 961
Connection Connector Pin Layout 963
Computer A 963
Monitor 964
Sequence Circuit Diagram 965
Code table 965
Overall 968
Block diagram 970
Computer A 970
Computer B 971
ECM 972
Monitor 973
Air Conditioner 974
Lever Lock 975
Horn 975
Working lights 975
Option 976
Other 977
Electrical Symbol List 977
Electrical Equipment Layout Diagram 979
Main Unit Left Side Layout Diagram (radiator chamber) 979
Engine Section Layout Diagram 981
Main Unit Right Side Layout Diagram (pump chamber) 984
Main Unit Center Section Layout Diagram 985
Cab Layout Diagram 1 986
Cab Layout Diagram 2 988
Layout Around Operator Seat 990
Stand Alone Parts Diagram 991
Removal and Installation of Wiper Controller1009
Removal of Wiper Controller1009
Installation of wiper controller1009
Removal and Installation of Wiper Motor1010
Removal of Wiper Motor1010
Installation of wiper motor1011
Removal and Installation of Monitor1012
Removal of Monitor1012
Installation of Monitor1012
Air Conditioner Overall Diagram1013
Frame1013
Cab1015
Equipment Layout Diagram1018
Circuit Diagram1020
Air Conditioner Circuit Diagram1020
Explanation of Functions1022
Explanation of Control1022
Air Mix Motor Actuator Control1023
Blow Mode Motor Actuator Control1023
Refresh/Recirculate Switch Motor Actuator Control1024
Blower Amp Control1025
Compressor Clutch Control1027
COOLMAX Control and HOTMAX Control1028
Abnormality Detection and Control after Abnormality Detected1028
Monitor Mode1032
Door Switch Control1033
Actuator Inspection1034
Air Mix Motor Actuator Inspection1034
Refresh/Recirculate Switch Motor Actuator Inspection1035
Mode Motor Actuator Inspection1036
Self-diagnosis Function with Panel Display1038
Abnormality Display and Self-check Procedures1038
Abnormality Display Position1038
Explanation of Abnormality Display1038
Motor Actuator Abnormality1038
Sensor Abnormality1039
Explanation of Monitor Mode1039
Monitor Mode Display Position1040
Monitor Mode Display Operating Method1040
Display Contents in Monitor Mode1041
Part Function and Good/Poor Judgment1047
Control Panel1047
Blower Amp1047
Relay1048
Air Mix Actuator1049
Refresh/Recirculate Actuator1050
Mode switch actuator1050
Evaporator Sensor1051
Dual Pressure Switch1051
Solar Radiation Sensor1052
Inside Air Sensor1053
Assembly and Disassembly of Unit1054
Removal of inside air filter1054
Removal of Blower Unit1054
Replacement of Blower Motor1054
Replacement of Blower Amp1055
Removal of Heater Core1055
Removal of Switchover BOX1055
Replacement of Evaporator and Expansion Valve1056
Installation of Evaporator Sensor1057
Replacement of Motor Actuator1057
Removal and Installation of Compressor1059
Removal of Compressor1059
Installation of Compressor1059
Removal and Installation of Condenser1060
Removal of Condenser1060
Installation of Condenser1061
Removal and Installation of Receiver Dryer1062
Removal of Receiver Dryer1062
Installation of Receiver Dryer1062
Work Precautions1064
Work Procedures1064
Air Conditioner Refrigerant Filling is Divided into the “Vacuum Operation” and “Gas Filling Operation”1064
Operation Chart1065
Tools1065
Filling Procedures1067
Charging Hose Connection Positions1067
Gauge Manifold Connection1067
Vacuuming1068
Gas Filling Operation, High-pressure Side1069
Gas filling operation, low-pressure side1069
V ATTACHMENTS1073
Main Equipment Table1076
145X31076
Backhoe Attachment1076
Cylinder1076
145X3 (Blade)1076
Backhoe Attachment1076
Cylinder1076
Maintenance Standards1078
Attachment (backhoe)1078
1 Boom and Swing Frame Installation Section1078
2 Boom Cylinder and Swing Frame Installation Section1079
3 Boom and Boom Cylinder Installation Section1079
4 Boom and Arm Cylinder Installation Section1080
5 Boom and Arm Installation Section1081
6 Arm and Arm Cylinder Installation Section1081
7 Arm and Bucket Cylinder Installation Section1082
8 Arm and Arm Link Installation Section1083
9 Bucket and Bucket Link Installation Section1083
10 Bucket Link and Bucket Cylinder Installation Section1084
11 Bucket and Arm Installation Section1085
Removal and Installation of Bucket Cylinder1086
Removal of Bucket Cylinder1086
Installation of Bucket Cylinder1088
Removal and Installation of Arm Cylinder1089
Removal of Arm Cylinder1089
Installation of Arm Cylinder1091
Removal and Installation of Boom Cylinder1094
Removal of Boom Cylinder1094
Installation of Boom Cylinder1096
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder (made by KYB)1099
Specifications and Structure Diagram (including the assembly diagram and parts table)1099
Basic functions1099
Function of Each Location1099
Cylinder Head Assembly1099
Piston Assembly1100
Pipe Assembly1102
Handling Precautions1102
Precautions for Installing the Cylinder on the Machine Body1102
Usage Cautions1102
Maintenance and Inspection Cautions1103
Maintenance Inspection and Service1105
Trouble Diagnostics1106
Storage Standards1110
Storing Parts Individually (In principle, store indoors)1110
When Mounted on Vehicle Body1111
Recommended Anti-rust Oil1111
Assembly and Disassembly Procedures1111
Preparations ····· Prepare the Following before Starting Disassembly1111
General Work Precautions1111
Maintenance Standards1112
Inspection after Assembly1112
Required Tool1113
General Tool1113
Special Jig1114
Special Jigs Part Number List1114
Disassembly Procedures1115
Drain the Oil1115
Secure the Cylinder1115
Removal of Cylinder Head1116
Pull out the Piston Rod1116
Fasten the Piston Rod1117
Remove the Piston Nut1117
Removal of Piston etc1117
Disassembly of the Retraction Side Cushion Ring1118
Remove the Piston Seal1118
Disassembly of the Buffer Ring1118
Disassembly of U-ring and Wiper Ring1118
Removal of O-ring and Backup Ring1118
Disassembly of Bushing1118
Removal of Pin Bushing1119
Cleaning and Storage1119
Drain the Oil1119
Secure the Cylinder1119
Removal of Cylinder Head1119
Pull out the Piston Rod1119
Fasten the Piston Rod1120
Remove the Piston Nut1120
Removal of Piston etc1121
Disassembly of the Retraction Side Cushion Ring1121
Remove the Piston Seal1121
Disassembly of the Buffer Ring1122
Disassembly of U-ring and Wiper Ring1122
Removal of O-ring and Backup Ring1122
Disassembly of Bushing1122
Removal of Pin Bushing1122
Cleaning and Storage1122
Assembly Procedures1123
Installation of Pin Bushing1123
Replacement of Seals1123
Assembly of Cylinder Head Assembly1123
Assembly of Piston Assembly1124
Assembly of Piston Rod Assembly1124
Insertion of Piston Rod into the Tube1126
Cylinder Head Tightening1126
Installation of Line1126
Test Operation1127
Usage Limits1128
Structural Diagram1129
Boom Cylinder1129
Arm Cylinder1131
Bucket Cylinder1133
Blade Cylinder1135
Removal and Installation of Bucket1137
Removal of Bucket1137
Installation of Bucket1137
Removal and Installation of Bucket Link1139
Removal of Bucket Link1139
Installation of Bucket Link1139
Removal and Installation of Arm1141
Removal of Arm1141
Installation of Arm1142
Removal and Installation of Boom1143
Removal of Boom1143
Installation of Boom1145
Z OTHER1149
Specifications1153
145X31153
Main Data1153
Performance1153
Main Unit Dimensions1153
145X3 (Blade)1153
Main Data1153
Performance1154
Main Unit Dimensions1154
Main Unit Weight1155
145X31155
Divided Weight (backhoe specifications)1155
Stand Alone Part Weight1156
Shoe Weight (per side)1156
Arm Weight1156
145X3 (Blade)1157
Divided Weight (blade specifications)1157
Stand Alone Part Weight1158
Shoe Weight (per side)1158
Arm Weight1158
Bolt Size and Torque Table1159
Special Torque Settings1159
Overall View1164
145X31164
Standard Arm [250 m (82021 ft)]1164
Standard Arm [250 m (82021 ft)]1165
Long Arm [301 m (98753 ft)]1166
145X3 (Blade)1167
Standard Arm [250 m (82021 ft)]1167
Standard Arm [250 m (82021 ft)]1168
Long Arm [301 m (98753 ft)]1169
WORK RANGE DIAGRAM1170
145X31170
Standard Arm [250 m (82021 ft)]1170
Short Arm [211 m (69226 ft)]1172
Long Arm [301 m (98753 ft)]1174
145X3 (Blade)1176
Standard Arm [250 m (82021 ft)]1176
Short Arm [211 m (69226 ft)]1178
Long Arm [301 m (98753 ft)]1180
New Machine Performance Judgment Table1182
Standard Table1182
Measurement Method1183
Engine Speed1183
Pressure in Each Section1184
Cylinder Falling Amount1184
Attachment Speed1184
Swing Speed1185
Swing (180°) Brake Angle1185
Travel Speed1185
Off Travel Amount1186
Travel Sprocket Speed1186
Shoe Tension Amount1186
Swing Ball Race Bearing Movement Amount and Bucket Tip Movement Amount1187
FLUIDS AND LUBRICANTS1189
HYDRAULIC FLUID1189
ENGINE OIL1189
OIL RANGE1189
FUEL1189
Conditions applicable to diesel fuel1189
RECOMMENDED CONDITIONS THAT CAN BE APPLIED TO DIESEL FUEL1189
Main Unit-side Diagnostic Trouble Code List1191
Main Unit-side Trouble1193
Diagnostic Trouble Code: 7000 P1 Pressure Sensor Signal Abnormality1193
Diagnostic Trouble Code: 7001 P2 Pressure Sensor Signal Abnormality1194
Diagnostic Trouble Code: 7002 N1 Pressure Sensor Signal Abnormality 1196
Diagnostic Trouble Code: 7003 N2 Pressure Sensor Signal Abnormality1197
Diagnostic Trouble Code: 7020 Upper Pressure Sensor Signal Abnormality1199
Diagnostic Trouble Code: 7021 Swing Pressure Sensor Signal Abnormality1200
Diagnostic Trouble Code: 7022 Travel Pressure Sensor Signal Abnormality1202
Diagnostic Trouble Code: 7023 Arm-in Pressure Sensor Signal Abnormality1203
Diagnostic Trouble Code: 7040 Fuel Level Sensor Signal Abnormality1205
Diagnostic Trouble Code: 7041 Oil Temperature Sensor Signal Abnormality1206
故障コード： 7063 リターンフィルタ目詰まりスイッチ異常1207
(Breaker specifications)1207
(Other than breaker specifications)1208
Diagnostic Trouble Code: 7065 Boom-up Pilot Pressure Sensor Signal Abnormality1210
Diagnostic Trouble Code: 7067 Bucket-close Pilot Pressure Sensor Signal Abnormality1212
Diagnostic Trouble Code: 7200 Swing Brake Solenoid Signal Abnormality1214
Diagnostic Trouble Code: 7201 Travel High-speed Solenoid Signal Abnormality1216
Diagnostic Trouble Code: 7202 Pressure Boost Solenoid Signal Abnormality1218
Diagnostic Trouble Code: 7203 Travel Alarm Buzzer Signal Abnormality1221
Diagnostic Trouble Code: 7206 Option Line Switchover Solenoid Signal Abnormality1223
Diagnostic Trouble Code: 7207 Free Swing Solenoid Signal Abnormality1225
Diagnostic Trouble Code: 7212 Shut-off Solenoid Signal Abnormality1226
Diagnostic Trouble Code: 7240 Pump Horsepower Proportional Valve Signal Abnormality1228
Diagnostic Trouble Code: 7241 P1 Flow Control Proportional Valve Signal Abnormality1230
Diagnostic Trouble Code: 7246 2 Pumps Flow Solenoid Signal Abnormality1232
Diagnostic Trouble Code: 7247 Boom-down Proportional Valve Signal Abnormality1234
Diagnostic Trouble Code: 7253 DPD Regeneration Request Output Signal Abnormality1236
Diagnostic Trouble Code: 7254 Washer Output Abnormality1238
Diagnostic Trouble Code: 7400 Abnormally High Coolant Temperature [ 105 °C ( 2210 °F )or higher ]1240
Diagnostic Trouble Code: 7401 Abnormally High Coolant Temperature [ 110 °C ( 2300 °F )or higher ]1241
Diagnostic Trouble Code: 7404 Abnormally High Oil Temperature [ 95 °C ( 2030 °F )or higher ]1242
Diagnostic Trouble Code: 7405 Abnormally High Boost Temperature [ 80 °C ( 1760 °F )or higher ], 740 1243
Diagnostic Trouble Code: 7420 Abnormally Low Alternator Voltage1244
Diagnostic Trouble Code: 7421 Coolant Level Reduction1246
Diagnostic Trouble Code: 7422 Abnormally Low Engine Oil Pressure1247
Diagnostic Trouble Code: 7423 Air Cleaner Clogging1248
Diagnostic Trouble Code: 7424 Return Filter Clogging (breaker specifications)1249
Diagnostic Trouble Code: 7426 Fuel Filter Clogging 11250
Diagnostic Trouble Code: 7427 Fuel Filter Clogging 21252
Diagnostic Trouble Code: 7601 Monitor Communication Abnormality1254
Diagnostic Trouble Code: 7602 ECM Communication Abnormality1255
Diagnostic Trouble Code: 7603 Computer S Communication Abnormality1256
Diagnostic Trouble Code: 7605 ECM Mismatch1257
Diagnostic Trouble Code: 7606 EEPROM Data Abnormality1258
Diagnostic Trouble Code: 7607 Computer C Communication Abnormality1259
Diagnostic Trouble Code: 7608 Camera Abnormality1260
Diagnostic Trouble Code: 7609 EEPROM (B) Data Abnormality1262
Diagnostic Trouble Code: 7610 EEPROM (C) Data Abnormality1263
Diagnostic Trouble Code: 7611 Computer A Communication Abnormality1264
Diagnostic Trouble Code: 7612 Air Conditioner Communication Abnormality1265
Diagnostic Trouble Code: 7613 Monitor Communication CAN Abnormality1266
Diagnostic Trouble Code: 7614 Air Conditioner Panel Mismatch1267
List of special tools1268
NUMERICAL VALUE CONVERSION TABLE1268
Unit conversion rate1268
Length1268
Area1270
Volume1271
Weight1273
Pressure1274
Torque1275
Temperature1276
A1279
Travel Motor Special Tool1279
145X31279
Take-up Roller Special Tool1282
145X31282
Upper Roller Special Tool1283
145X31283
Lower Roller Special Tool1284
145X31284
Grease Cylinder Special Tool1285
145X31285
Center Joint Special Tool1285
145X31285
C1286
Swing Motor Special Tool1286
145X31286
H1289
Engine Oil Filter Special Tool1289
145X31289
Fuel Filter Special Tool1289
145X31289
Injector Special Tool1289
145X31289
Circuit Test Special Tool1290
145X31290
Valve Guide Special Tool1290
145X31290
Cylinder Head Special Tool1291
145X31291
Head Bolt Special Tool1292
145X31292
Crankshaft Special Tool1292
145X31292
Valve Spring Special Tool1294
145X31294
J1295
Remote Control Valve Special Tool1295
145X31295
R1297
Gas Filling Special Tool1297
145X31297

S.M 2/1/25