Linkbelt 800 X2 Excavator Service Manual UST-00-00-014LX – PDF DOWNLOAD

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Linkbelt 800 X2 Excavator Service Manual UST-00-00-014LX – PDF DOWNLOAD

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Linkbelt 800 X2 Excavator Service Manual UST-00-00-014LX – PDF DOWNLOAD

Language : English
Pages : 1169
Downloadable : Yes
File Type : PDF
Size: 67.2 MB

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TABLE OF CONTENTS:’

Linkbelt 800 X2 Excavator Service Manual UST-00-00-014LX – PDF DOWNLOAD

Overall 1
1 Main Data 1
2 Performance 1
3 Main Unit Dimensions 1
4 Engine 2
5 Cooling System 2
6 Upper Side Work System 3
7 Operating Device 4
8 Swing Units 5
9 Travel Lower Body 5
Hydraulic Equipment 5
1 Hydraulic Device 5
2 Control Valve, Cylinder 6
Capacities, Filters 6
1 Coolant and Oil Capacities 6
2 Hydraulic Oil Filters 6
3 Fuel Filter 6
Lifting Capacity
Precautions for lifting loads with the hydraulic excavator 1
Lifting Capacities (800X2) 2
1 Standard Arm 12 01 ft (4 m), 750 Grouser Shoe 2
2 Long Arm 14 56 ft (4 m), 750 Grouser Shoe 3
3 Super Long Arm 18 45 ft (6 m), 750 Grouser Shoe 4
Lifting Capacities (800X2 Mass) 5
1 Short Arm 9 76 ft (3 m), 750 Grouser Shoe 5
Overall View
Overall View (Standard boom) 1
1 Standard Arm 3 9 yd (3 66 m) 1
2 Long Arm 4 9 yd (4 44 m) 1
3 Super Long Arm 6 1 yd (5 62 m) 2
Overall View (MASS Excavator) 3
1 Short Arm 3 3 yd (2 98 m) 3
Work Range Diagram
Work Range Diagram (Standard boom) 1
1 Standard Arm 4 yd (3 66 m) 1
2 Long Arm 4 9 yd (4 44 m) 2
1
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Contents
3 Super Long Arm 6 yd (5 62 m) 3
Work Range Diagram (MASS Excavator) 4
1 Short Arm 3 yd (2 98 m) 4
2
Contents
UST-00-00-014LX
Summary Section
Main Equipment Table
Lower Component 1
1 Travel Unit 1
2 Take-up Roller 1
3 Upper Roller 1
4 Lower Roller 1
5 Recoil Spring 2
6 Shoe 2
Upper Component 3
1 Swing Unit 3
Engine-related 4
1 Engine 4
2 Muffler 5
3 Air Cleaner (double element) 5
4 Radiator 5
Hydraulic Device 6
1 Hydraulic Pump 6
2 Pump P-Q Diagram 7
Control-related 8
1 Control Valve 8
2 Solenoid Valve (5 stack) 8
3 Remote Control Valve 9
4 Remote Control Valve Characteristic Diagram 10
5 Cushion Valve (heat circuit, with shuttle valve) 11
6 Selector Valve 11
7 Center Joint 11
Backhoe Attachment 12
1 Cylinder 12
2 Attachments 13
Equipment Layout Diagram
Main Equipment Layout 1
Consumable Part Layout 2
Standard Machine Option List
List of Optional Components 1
3
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Contents
Hydraulics Section
Hydraulic Equipment Layout
Overall View 1
Pump Chamber Hydraulic Equipment Layout 2
Swing Body Center Section Hydraulic Equipment Layout 3
Housing Left Side Hydraulic Equipment Layout 4
Layout of Hydraulic Equipment in Cab 5
Port Diagram
Pump 1
1 Hydraulic Pump (standard model) 1
Valves 2
1 Control Valve 2
2 5 Stack Solenoid Valve 4
3 2 Stack Solenoid Valve 5
4 Remote Control Valves (upper, travel) 6
5 Cushion Valve 7
6 HBCV (Option for Export, Europe) 8
Manifolds 9
1 Manifold Under Cab 9
2 Manifold (accumulator section) 9
3 Manifold 10
Motors 11
1 Swing Motor 11
2 Travel Motor 12
3 Center Joint 13
Pilot Hose Connection Diagram
Pilot P and T Lines 1
Pilot Control Line 3
Pilot Control Line (2-way selector valve) 5
Function List
Function Table 1
Explanation of New Functions 3
1 Swing Relief Cut-off Control 3
2 Option Line Flow Adjustment Control 5
4
Contents
UST-00-00-014LX
Explanation of Hydraulic Circuit and Operations (standard model)
Travel Circuit 1
Travel Low-speed Circuit 1
Travel High-speed Circuit 3
Straight Travel Circuit 5
Swing Circuit 7
Swing Relief Cut-off Control Circuit 7
Swing Priority Circuit 9
Swing Brake Circuit 11
Swing Parking Circuit (lever in neutral) 13
Swing Parking Circuit (brake release) 15
Swing Parking Circuit (machine stop) 17
Boom Circuit 19
Boom-up Circuit (single operation) (with / without HBCV) 19
Boom-up Circuit (compound boom-up + bucket) 22
Boom-up Circuit (compound boom-up + swing) 24
Boom-down Regenerative Circuit (with / without HBCV) 26
Boom-down Load Holding Valve Circuit 29
Arm Circuit 31
Arm-out Circuit (with / without HBCV) 31
Arm-in Forced Regenerative Circuit 34
Arm-in Load Holding Valve Circuit 36
Bucket Circuit 38
Bucket-open Circuit 38
Bucket Close 40
Negative Control Circuit 42
Negative Control Circuit 42
Horsepower Boost Circuits 44
High load Horsepower Boost Circuit 44
Other Circuits 46
Cushion Circuit (arm-out operation) 46
Cushion Circuit (arm-out operation stopped) 48
Cushion Circuit (arm-out → arm-in operation) 50
Heat Circuit (lever in neutral) 52
Auto Pressure Boost Circuit (bucket close) 54
Explanation of Hydraulic Circuit and Operations (option)
Option Circuits 1
Breaker circuit (independent operation) 1
Double-acting circuit (hydraulic fork) 3
Multi-purpose circuit (breaker circuits) 5
Multi-purpose circuit (2 pumps flow circuit) 7
5
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Contents
2nd option circuit (hydraulic rotation fork) 9
Main Equipment Structure and Operation Explanation
Pump 1
1 Hydraulic Pump 1
2 Regulator 4
3 Gear Pump 14
Motor 15
1 Travel Motor 15
2 Swing Motor 27
Valve 34
1 Control Valve 34
2 5 Stack Solenoid Valve Operation Explanation 50
3 Upper Pilot Valve (remote control valve) 52
4 Travel Pilot Valve (remote control valve) 56
5 Cushion Valve 60
Hydraulic Drive Fan Motor 65
1 External Shape Diagram 65
2 Internal Structure Diagram 66
3 Operation principles 67
6
Contents
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Electrics Section
Explanation of New Functions
Work Mode Select Switch 1
The Throttle Volume and Work Mode Select Switch are Linked!! 1
Computer Connection Method 4
Monitor Changes 5
Pilot Pressure Switch Changed to Pressure Sensor 7
Pump Electromagnetization Proportional Valve 9
1 Horsepower Control Proportional Valve 9
2 P1 Flow Control Proportional Valve 9
System Control for Energy Saving 10
1 Reduced Fuel Consumption Through Transient Load Reduction Control 10
2 Reduced Fuel Consumption Through Swing Relief Cut Control 12
Electrical Equipment Layout Diagram
Overall View 1
1 Main Unit Left Side Layout Diagram (radiator chamber) 2
2 Engine Section Layout Diagram 3
3 Main Unit Right Side Layout Diagram (pump chamber) 4
4 Main Unit Center Section Layout Diagram 5
5 Cab Layout Diagram 1 6
6 Layout Around Operator’s Seat 8
Stand Alone Parts Diagram 9
Main Equipment Structural Diagrams
Connection Connector Pin Layout 1
1 Computer A 1
2 Monitor 2
Electrical Circuit Diagram
Overall View 1
1 Sequence Circuit Diagram 1
Block Diagram 3
1 Computer A 3
2 ECM 4
3 Monitor Display 5
4 Air Conditioner 6
5 Lever Lock 7
6 Horn 7
7 Hydraulic motor fan 8
8 Mounting Counterweight 8
7
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Contents
9 Working Light 9
10 Option 9
11 Others 10
12 Electrical Symbol List 11
Electrical Connector Wiring Diagram
Wire Harness 1
1 Main Frame Harness 1
Cab 4
1 Cab Main Harness 4
2 Cab Sub Harness 7
3 In Cab 9
4 Engine Harness 11
Console 12
1 Console Right Harness 12
2 Console Left Harness 13
Electrical Parts and Wiring Assembly Diagram
Main Frame 1
Cab 5
Explanation of Functions and Operations
Explanation of Electrical Functions 1
Engine Speed Control 3
1 Throttle Control 3
2 Idling Control (auto / one-touch) 7
3 Idling Start 8
4 Auto warm up 9
Engine Start / Stop Control 11
1 Engine Start / Stop Judgment 11
2 Power-cut Delay 12
3 Engine Emergency Stop 13
4 Neutral Start 15
Pump Control 16
1 Work Mode Control 16
2 Pump Horsepower Boost Control 17
3 Pump Horsepower Cut Control 18
Swing 19
1 Swing Brake 19
2 Swing Free Swing 20
3 Swing Relief Cut 21
8
Contents
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Travel 23
1 Travel Speed Switchover 23
2 Travel Alarm 24
Valve Control 26
1 Lever Lock 26
2 Solenoid Sticking Prevention 27
3 Pressure Boost Control 28
Monitor Control 30
1 Bar Graph (coolant temperature gauge, oil temperature gauge,
fuel gauge) 30
Accessories 37
1 Horn 37
2 Working Light 38
3 Wiper and Washer 39
4 Room Lamp 41
5 Radio Mute 43
Others 44
1 Anti-theft 44
2 Battery Save Function 45
3 Alternator Power Generation Detection 46
4 Overload Alarm (Option for Europe) 47
5 Control of Hydraulic Driven Fan 49
Options 58
1 Option Line Control 58
2 Option Line Control 61
3 Feed Pump Automatic Stop 63
4 Return Filter Clogging Detected 66
5 Beacon 67
Service Support
Screen Operations 1
1 Screen Shift 1
Screen Display List 3
1 CHK (status display) Screen List 3
2 DIAG (trouble diagnosis) Screen 12
3 HR (usage log) Screen List 14
4 CFG (setting change) Screen 19
5 CAL (troubleshooting support) Screen 22
6 Check the Monitor Switch (self-diagnosis function) 25
7 Option Flow Setting 27
9
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Contents
8 Anti-theft Setting 29
9 Model Setting 31
10 Engine Information Screen 33
Screen Display Details 35
1 Message Display List 35
Abnormality Display 37
1 Diagnostic Trouble Code Display 37
2 Main Unit Diagnostic Trouble Code List 38
3 Diagnostic Trouble Code (monitor display) 41
4 Sensor Trouble Operation Table 48
5 EPF (Engine Protection Feature) 51
10
Contents
UST-00-00-014LX
Engine Section
Engine Summary
Main Data Table 1
Overall Appearance Diagram 2
Sensor and Auxiliary Equipment Layout (left) 4
Sensor and Auxiliary Equipment Layout (rear) 5
Engine System Diagram 5
Fuel System Diagram 6
Detailed Parts Diagrams 7
1 ECM (engine control module) 7
2 Supply Pump/PCV (pressure control valve) 8
3 Common Rail/Flow Damper 9
4 Common Rail Pressure Sensor/Pressure Limiter 10
5 Injector 10
6 Engine Coolant Temperature Sensor 11
7 Engine Oil Pressure Sensor 11
8 Cam Position Sensor (G sensor) 12
9 Crank Position Sensor (CKP sensor) 12
10 Atmospheric Pressure Sensor 13
11 Suction Air Temperature Sensor 13
12 Boost Pressure Sensor 14
13 Boost Temperature Sensor 14
14 EGR Cooler 15
15 Lead Valve (check valve) 15
16 EGR Valve 16
Engine Control Summary 17
Explanation of Engine Terms
Function Explanation Table 18
Explanation of Engine Structure
Technology for Exhaust Gases 20
1 Common Rail System 20
2 Multi-Stage Fuel Injection (multiple injection) 21
3 Inter Cooler 23
4 EGR (exhaust gas recirculation) 24
11
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Contents
Explanation of Engine Operation
Fuel Unit 26
1 Common Rail System Summary 26
2 Change Points for Injection Method (governor, common rail) 27
3 Explanation of Injector Operation 28
4 Explanation of Supply Pump Operation 31
5 Supply Pump Disassembly Diagram 32
6 Explanation of Flow Damper Operation 34
7 Pressure Limiter 35
8 Cautions for Maintenance 36
Explanation of Engine Control 39
1 Fuel Injection Quantity Correction 39
2 Starting Q Correction 39
3 Preheat Control (QOS quick on start) 39
4 Atmospheric Pressure Correction (high altitude correction) 39
5 Control for Overheating 40
6 Control for Boost Temperature Rise 41
7 Control for Engine Oil Pressure Drop 41
8 Start Control (coolant temperature monitoring) 41
9 Long Cranking Control 42
10 Starting Control for Reduced Number of Cylinders 42
11 Normal Stop (key switch OFF operation) 42
12 Engine Start / Stop Judgment 43
Engine Maintenance Standards
Engine Information Screen 44
1 Purpose 44
2 How to Go to This Screen 44
3 Engine Start Restriction 44
4 Screen 44
Monitor Operating Method 46
1 View Mode 46
2 Edit Mode 46
Engine Information (Q resistance, QR code, engine serial number)
Copying Method 47
Rewriting Injector QR Codes 48
When Replacing Computer A at the Same Time 50
Engine Information Acquisition Timing 50
Redoing Engine Information Acquisition 50
Abnormality Display 50
12
Contents
UST-00-00-014LX
Engine Equipment Table
Exhaust Gas 3rd Accessory Electrical Parts Compatibility (Isuzu part number) 51
Exhaust Gas Regulations
Features of Materials Subject to Exhaust Gas Regulation 52
Exhaust Gas Regulation Values 52
Cautions for Fuel Used
Engine Fuel and Maintenance of Fuel Filters 54
1 Fuel to be applied 54
2 Maintenance of fuel filters 56
13
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Contents
Air Conditioner Section
Layout Diagram
Air Conditioner Overall Diagram 1
1 Frame 1
2 Cab 3
Equipment Layout Diagram 5
Circuit Diagram
Air Conditioner Circuit Diagram 1
Air Conditioner Circuit Diagram 3
Explanation of Functions
Explanation of Control 1
1 Air Mix Motor Actuator Control 2
2 Blow Mode Motor Actuator Control 2
3 Refresh / Recirculate Switch Motor Actuator Control 3
4 Blower Amp Control 4
5 Compressor Clutch Control 7
6 COOLMAX Control and HOTMAX Control 8
7 Trouble Detection and Control after Trouble Detected 9
8 Monitor Mode 11
9 Door Switch Control 13
10 Inside Air Filter Clogging Detection Control 13
Actuator Inspection
Air Mix Motor Actuator Inspection 1
Refresh / Recirculate Motor Actuator Inspection 3
Mode Motor Actuator Inspection 5
Self-diagnosis Function with Panel Display
Abnormality Display and Self-check Procedures 1
1 Abnormality Display Position 1
2 Explanation of Abnormality Display 1
3 Explanation of Monitor Mode 3
Part Function and OK/NG Judgment
Control Panel and Control Unit 1
Blower Amp 1
Relay 2
Air Mix Actuator 2
Refresh / Recirculate Actuator 2
Blow Mode Actuator 3
Evaporator Sensor 3
Dual Pressure Switch 3
Solar Radiation Sensor 4
Maintenance Section
Pressure Measurement and Adjustment Procedures
Procedures for Pressure Measurement from the Monitor Display 1
1 Pressure Measurement Method 1
2 Operating Method 1
Procedures for Measuring Hydraulic Oil Temperature from the Monitor Display 2
1 Hydraulic Oil Temperature Measurement Method 2
2 Operating Method 2
Procedures for Pressure Measurement by Installing Pressure Gauge 3
1 Preparations 3
2 Items to prepare 3
Pressure Measuring Ports 4
Pressure Adjustment Location 5
1 Location of Relief Valves 5
Pressure Measurement Preparations 6
Pressure Measurement and Adjustment Procedures 9
1 Main Pressure Measurement 9
2 Pilot Pressure Measurement 13
3 Negative Control Pressure Measurement 14
Pressure Adjustment 15
1 Main Pressure Adjustment 15
2 Pilot Pressure Adjustment 18
Hydraulic Pump Flow Measurement Procedure
Preparations 19
1 Items to Prepare 19
Work Preparations 20
Flow Measurement 23
Drain Volume Measurement Procedure
Preparations 24
Travel Motor Drain Volume Measurement 24
Swing Motor Drain Volume Measurement 27
Air Bleed Procedure
Hydraulic Pump 1
Travel Motor 2
Swing Motor 3
HBCV 4
1 Boom Cylinder HBCV 4
2 Arm Cylinder HBCV 4
Procedures for Replacing Consumable Parts
Air Conditioner Belt and Fan Belt Replacement 1
1 Air Conditioner Belt Replacement 1
2 Fan Belt Replacement 3
Fuel Filter Replacement 4
1 Filter Replacement 4
2 Air Bleeding 7
Engine Oil Filter and Engine Oil Replacement 8
1 Engine Oil Replacement 8
2 Engine Oil Filter Replacement 9
Radiator Coolant Replacement 11
Air Cleaner Cleaning and Replacement 13
Hydraulic Oil Filter Replacement 15
1 Return Filter Replacement 15
2 Suction Filter Replacement 16
3 Air Breather Element Replacement 17
4 Pilot Oil Filter Replacement 18
5 Hydraulic Oil Replacement 18
Others 21
1 Coolant Filling 21
2 Washer Fluid Filling 21
Periodic Maintenance Procedures
Maintenance Every 250 Hours 1
1 Battery Inspection and Replacement 1
Maintenance after First 250 Hours for New Machine / Every 1000 Hours
from Then on 2
1 Swing Reduction Gear Oil Replacement 2
2 Gear Oil Filling 3
Replace the Flange Packing at the Bottom of the Fuel Tank 4
Bolt Size and Torque Table
Bolt and Nut Tightening 1
Bolt and nut retightening [after 1st 50 hours for new machine]
[every 250 hours] 1
Retightening Torque Table 2
Data Section
Main Unit Weight
Major Component Weight (standard specifications) 1
Individual Part Weight 2
Shoe Weight (one side) 2
Arm Weight 2
Bucket Weight 3
Interchangeability
Interchangeability 1
1 Main Part Interchangeability Table (Model 5) 1
Attachment Installation Methods
Attachment Dimensions 1
Paint Colors
Paint Colors 1
Unit Conversion Ratio
Unit Conversion Ratio 1
Assembly and Disassembly Section
Assembly
Overall Process 1
Major Machines • Tools • Equipment Table 2
Matters to be Attended 5
Prior Preparation 5
Ensuring assembly/disassembly work place 5
Major layout 6
Prior Preparation Procedure 7
Unloading Work 8
1 Unloading Work No 1 8
2 Unloading 1 Procedure 9
3 Unloading Work No 2 10
4 Procedure for Unloading Work No 2 11
5 Unloading Work No 3 12
6 Procedure for Unloading Work No 3 13
Connection of Lower Sideframes to Upper Swing Body 14
1 Assembling work No 1 (One side) 14
2 Procedure for Mounting No 1 15
3 Assembling work No 2 (Remaining one sideframe) 16
4 Procedure for Mounting No 2 18
Mounting Travel Motor Lines 19
1 Procedure for Mounting 20
Mounting Counterweight 21
Procedure for Mounting 22
Mounting Attachments 23
1 Mounting Boom Cylinders 23
2 Mounting Boom and Connecting Cylinder Hose 25
3 Mounting Boom Cylinder Top Pin 27
4 Mounting ARM 29
5 Connecting Bucket Cylinder Hose and Mounting Bucket 31
6 Mounting bucket 32
Checking Work 33
Confirmation of Movement after Assembling Work 34
1 Attended items when assembling work is done 34
2 Procedure for confirmation of movement and the items to be attended
after the assembling work is completed 34
Disassembly
1 Bucket removal 35
2 Arm removal 35
3 Boom cylinder removal 36
4 Boom removal 36
5 Counterweight removal 37
6 Removal of travel motor piping and their small accessories 37
7 Separation of upper body and lower, and loading 38
Attached data
Stool Assembly Drawing (BKWA4024-B01) 1
1 Stool (Upper) (BKWA4025-B01) 1
2 Stool (Under) (BKWA4026-B01) 1
Lower Frame Assembly Drawing 2
Piping Cover Assembly Drawing 3
Traction Motor Line Assembly Drawing 4
Counterweight Assembly Drawing 6
Catwalk Assembly Drawing 8
House Assembly Drawing 10
Attachment Assembly Drawing 12

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