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Link-Belt 210X4/210X4 LF Excavator SERVICE MANUAL WLSM2107-05LX – PDF DOWNLOAD
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Link-Belt 210X4/210X4 LF Excavator SERVICE MANUAL WLSM2107-05LX – PDF DOWNLOAD
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Description
Link-Belt 210X4/210X4 LF Excavator SERVICE MANUAL WLSM2107-05LX – PDF DOWNLOAD
FILE DETAILS:
Link-Belt 210X4/210X4 LF Excavator SERVICE MANUAL WLSM2107-05LX – PDF DOWNLOAD
Language : English
Pages :2063
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Link-Belt 210X4/210X4 LF Excavator SERVICE MANUAL WLSM2107-05LX – 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:
Link-Belt 210X4/210X4 LF Excavator SERVICE MANUAL WLSM2107-05LX – PDF DOWNLOAD
Excavator 1
SAFETY 9
Safety, general information and standard torque data 12
General Information 13
Safety 13
ROPS 15
ROPS Judgment 15
Standard Torque Data For Cap Screws And Nuts 19
Bolt and Nut Tightening 19
A LOWER 21
Main Equipment Table 25
Lower Component 25
Travel Unit 25
Take-up Roller 25
Upper Roller 25
Lower Roller 25
Recoil Spring 25
Shoe 25
Shoe (LF) 26
Center Joint 26
Main Equipment Structure and Operation Explanation 27
Travel Motor 27
Travel motor operation explanation 27
Explanation of Component Device Operation 27
Double Counter Balance Valve 27
Crossover Relief Valve 32
Automatic 2-speed Switchover Mechanism 33
Parking Brake Function 36
Piston Motor 37
Reduction Gear 38
Port Diagram 40
Travel Motor 40
Center Joint 40
Basic Functions 41
Travel Speed Selection 41
Travel Alarm 41
Removal and Installation of Track 43
Removal and Installation of Shoe Assembly 44
Removal of Shoe Assembly 44
Installation of Shoe Assembly 45
Removal and Installation of Shoe Plate 48
Removal of Shoe Plate 48
Installation of Shoe Plate 48
Removal and Installation of Roller 49
Removal and Installation of Upper Roller 50
Removal of Upper Roller 50
Installation of Upper Roller 51
Assembly and Disassembly of Upper Roller 52
Configuration Diagram 52
Dimension Diagram 53
Jig Dimension Diagram 53
Disassembly Procedures 54
Assembly Procedures 56
Removal and Installation of Lower Roller 59
Removal of Lower Roller 59
Installation of Lower Roller 60
Assembly and Disassembly of Lower Roller 62
Configuration Diagram 62
Dimension Diagram 63
Jig Dimension Diagram 63
Disassembly Procedures 63
Assembly Procedures 66
Removal and Installation of Drive Sprocket 68
Removal of Drive Sprocket 68
Installation of Drive Sprocket 70
Removal and Installation of Take-up Roller 71
Removal of Take-up Roller 71
Installation of Take-up Roller 72
Assembly and Disassembly of Take-up Roller 73
Configuration Diagram 73
Dimension Diagram 74
Jig Dimension Diagram 74
Disassembly Procedures 74
Assembly Procedures 77
Removal and Installation of Grease Cylinder 81
Removal of Grease Cylinder 81
Installation of grease cylinder 82
Assembly and Disassembly of Tension Shock Absorber 83
Configuration Diagram 83
Dimension diagram 83
Jig dimension diagram 84
Disassembly procedures 84
Assembly procedures 84
Removal and Installation of Center Joint 87
Removal of Center Joint 87
Installation of Center Joint 89
Assembly and Disassembly of Center Joint 91
Configuration Diagram 92
Dimension Diagram 93
Jig Dimension Diagram 94
Disassembly Procedures 94
Assembly Procedures 95
Removal and Installation of Travel Motor 98
Removal of Travel Motor 98
Installation of Travel Motor 100
Assembly and Disassembly of Travel Motor 103
Tools for Assembly and Disassembly 103
Standard Tool 103
Secondary Materials 104
Special Tool (jig) 105
Measurement Device 106
Motor Disassembly Procedures 106
Precautions before Motor Disassembly 106
Tightening Torque 107
Disassembly Procedure 108
Maintenance Standards 116
Motor Parts Maintenance Standards 116
Reduction Gear Parts Maintenance Standards 119
Motor Assembly Procedures 121
Precautions before Motor Assembly 121
Assembly Procedure 122
Motor Installation 135
Inspection 135
Hydraulic Oil and Gear Oil Filling 136
Initial Pre-conditioning Operation 137
Troubleshooting 138
Structural Diagram 146
Internal Structure Diagram 149
Component Table 151
Maintenance Standards 152
Drive Sprocket 152
Take-up Roller 153
Upper Roller 154
Lower Roller 155
Track Shoe (grouser shoe) 156
Inspection Gauge 158
For Drive Sprocket 158
For Take-up Roller 158
For Upper Roller 159
For Lower Roller 159
Pressure Measurement and Adjustment Procedures 160
Main Pressure Measurement 160
B Travel Pressure Measurement 160
Drain Volume Measurement Procedures 161
Preparations 161
Travel Motor Drain Volume Measurement 161
Air Bleed Procedure 163
Travel Motor 163
B C SWING UNIT, COUNTERWEIGHT 165
Main Equipment Table 168
Upper Component 168
Swing Unit 168
Swing Unit (LF) 168
Main Equipment Structure and Operation Explanation 169
Swing Motor 169
Swing Motor Operation Explanation 169
Hydraulic Motor Section 169
Valve Casing Section 169
Brake Section 170
Relief Valve Operation Explanation (relief valve model: KRD22EK10) 170
Swing Motor Internal Structure Diagram 174
Swing Unit (LF) 177
Internal Configuration Diagram of Swing Motor (LF) 177
Port Diagram 179
Swing Motor 179
Basic Functions 180
Swing Brake 180
Swing Lock 180
Swing Speed Limit 181
Swing Relief Cut 183
Removal and Installation of Swing Unit 185
Removal of Swing Unit 185
Installation of Swing Unit 187
Assembly and Disassembly of Swing Motor 188
Causes of Trouble and Solutions 188
Maintenance Standard Table 190
Required Tools 191
Jig 191
Disassembly 192
Assembly 198
Swing Motor Internal Structure Diagram 206
Assembly and Disassembly of Swing Motor (LF) 209
Causes of Failures, and Actions (LF) 209
Maintenance Standard Tables (LF) 211
Required Tools (LF) 213
Jig (LF) 214
Disassembly (LF) 214
Assembly (LF) 216
Internal Configuration Diagram of Swing Motor (LF) 221
Assembly and Disassembly of Swing Unit 223
Disassembly 223
Assembly 224
Swing Reduction Gear Breakdown Diagram 226
Swing Reduction Gear Structure Diagram 227
Removal and Installation of Counterweight 228
Removal of Counterweight 228
Installation of Counterweight 229
Pressure Measurement and Adjustment Procedures 231
Main Pressure Measurement 231
C Swing Pressure Measurement 231
Drain Volume Measurement Procedures 232
Preparations 232
Swing Motor Drain Volume Measurement 232
Air Bleed Procedure 233
Swing Motor 233
Check 233
H ENGINE 235
Main Equipment Table 243
Engine-related 243
Engine 243
Air Cleaner (double element) 243
Radiator 243
SCR 243
Basic Functions 244
Fuel Gauge 244
Coolant Temperature Gauge 245
SCR Gauge 247
Fuel Economy Gauge 250
Neutral Start 251
Power-cut Delay 252
Preheat 252
Throttle 253
Throttle Volume Position Detection 254
Idling Start 260
Auto Idle 260
One-touch Idle 261
Auto Warm-Up 262
Idle Shutdown 267
Idle Up 268
Work Mode Control 269
Engine Emergency Stop 270
SCR RE-GEN 270
Inducement 275
Feed Pump Automatic Stop 279
Coolant Level Decrease 281
Air Filter Clogging 282
Fuel Filter Clogging 283
Battery Charge Abnormality 284
Horsepower Reduction Control (in Uplands) 285
Horsepower Reduction Control (at Engine Failure) 285
Main Data 288
Function, Structure, Operation 290
Function, structure, operation (SCR) 346
SCR Control System Inspection 372
Operation Explanation of SCR 373
Diagnosis for Each Symptom 375
Intermittent conditions of urea selective catalytic reduction system 375
Urea fluid consumption too high 378
Ammonia smell noticeable 378
White crystalline powder visible 379
Diagnosis for Each Symptom 380
Engine Start Problem 380
Engine Stalling 382
Engine Hunting, Rough Idling 384
Excessive White Smoke in Exhaust Gas 386
Excessive Black Smoke in Exhaust Gas 386
Abnormal Noise 387
High Fuel Consumption 388
High Oil Consumption 389
Engine Output Deficiency 390
Functional Inspection 392
Engine Compression Pressure Inspection 392
Fuel System Inspection 393
Lubrication system check 393
Suction air system inspection 394
Exhaust system inspection 394
EGR Control System Inspection 394
Start System Inspection 395
Glow control system check 395
OBD system check 397
Inspection of the monitor warning light illumination circuit system 397
Inspection of the monitor warning light blinking circuit system 398
Inspection of the starter circuit system 398
Removal and Installation of Engine Assembly 400
Removal of Engine Assembly 400
Installation of Engine Assembly 404
Removal and Installation of Fuel Cooler, Engine Intercooler, Radiator, and Oil Cooler 405
Removal and Installation of Fuel Cooler 405
Removal of Fuel Cooler 405
Installation of Fuel Cooler 405
Removal and Installation of Engine Intercooler 405
Removal of Intercooler 406
Installation of Inter Cooler 406
Inspection of Intercooler 406
Removal and Installation of Radiator 407
Removal of Radiator 407
Installation of Radiator 411
Inspection of Radiator 411
Removal and Installation of Oil Cooler 412
Removal of Oil Cooler 412
Installation of Oil Cooler 415
Removal and Installation of Turbo Charger 416
Removal of Turbo Charger 416
Installation of Turbo Charger 418
Inspection of Turbo Charger 421
Removal and Installation of EGR Valve 423
Removal of EGR Valve 423
Installation of EGR Valve 425
Inspection of EGR Valve 429
Removal and Installation of Engine Hood 430
Removal of Engine Hood 430
Installation of Engine Hood 431
Removal and Installation of SCR 432
Removal of SCR 432
Installation of SCR 433
Removal and installation of Silicon Controlled Rectifier Catalyst 434
Removal of Silicon Controlled Rectifier Catalyst 434
Installation of Silicon Controlled Rectifier Catalyst 434
Disassembly of Silicon Controlled Rectifier Catalyst 434
Assembly of Silicon Controlled Rectifier Catalyst 434
Inspection of Silicon Controlled Rectifier Catalyst 435
Removal and Installation of Cylinder Head Cover 436
Cylinder head cover Removal 436
Installation of Cylinder Head Cover 436
Removal and Installation of Cylinder Head 437
Removal of Cylinder Head 437
Disassembly of Cylinder Head 445
Assembly of Cylinder Head 450
Installation of Cylinder Head 457
Inspection 474
Removal and Installation of Cylinder Block 480
Removal of Cylinder Block 480
Installation of Cylinder Block 496
Inspection 531
Lubrication System 533
Removal and Installation of Oil Pan 533
Removal of Oil Pan 533
Installation of Oil Pan 533
Removal and Installation of Oil Level Switch 533
Removal of Oil Level Switch 533
Installation of Oil Level Switch 534
Removal and Installation of Oil Pump Assembly 534
Removal of Oil Pump Assembly 534
Disassembly of Oil Pump Assembly 546
Assembly of Oil Pump Assembly 547
Installation of Oil Pump Assembly 547
Inspection 571
Engine oil Inspection 572
Removal and Installation of Oil Port Cover 573
Removal of Oil Port Cover 573
Installation of Oil Port Cover 573
Cooling System 575
Removal and Installation of Water Pump Assembly 575
Removal of Water Pump Assembly 575
Installation of Water Pump Assembly 576
Inspection 580
Removal and Installation of Thermostat 580
Removal of Thermostat 580
Installation of Thermostat 581
Inspection 583
Inspection of Coolant 583
Inspection of Cooling Fan Belt 588
Removal and Installation of Overheat Switch 589
Removal of Overheat Switch 589
Installation of Overheat Switch 589
Induction System 590
Inspection of Air Cleaner Element 590
Exhaust System 591
Removal and installation of Oxidation Catalyst Assembly 591
Removal of Oxidation Catalyst Assembly 591
Installation of Oxidation Catalyst Assembly 591
Aux Emission Control Devices System 594
Removal and installation of Dosing Module 594
Removal of Dosing Module 594
Disassembly of Dosing Module 594
Assembly of Dosing Module 595
Installation of Dosing Module 595
Removal and installation of DEF Supply Module 597
Removal of DEF supply module 597
Disassembly of DEF Supply Module 598
Assembly of DEF Supply Module 598
Installation of DEF Supply Module 599
Removal and installation of Coolant Control Valve 601
Removal of Coolant Control Valve 601
Installation of Coolant Control Valve 602
Removal and installation of DEF Supply Module Filter 603
Removal of DEF Supply Module Filter 603
Installation of DEF Supply Module Filter 604
Removal and Installation of Exhaust Manifold 605
Removal of Exhaust Manifold 605
Installation of Exhaust Manifold 608
Inspection 614
Removal and Installation of Fuel Tank 615
Removal of Fuel Tank 615
Installation of fuel tank 618
Removal and Installation of Urea Pump 619
Removal of Urea Pump 619
Installation of Urea Pump 619
Removal and Installation of Urea Solution Tank 621
Removal of Urea Solution Tank 621
Installation of Urea Solution Tank 621
Removal and Installation of Fuel Supply Pump 623
Removal of Fuel Supply Pump 623
Installation of Fuel Supply Pump 624
Removal and Installation of Common Rail Assembly 628
Removal of Common Rail Assembly 628
Installation of Common Rail Assembly 630
Removal and Installation of Injector 635
Removal of Injector 635
Installation of Injector 638
Removal and installation of Idle Gear 644
Removal of Idle Gear 644
Installation of Idle Gear 656
Inspection of Idle Gear 680
Removal and installation of Inlet Cover 682
Removal of Inlet Cover 682
Installation of Inlet Cover 686
Removal and installation of Crankshaft 696
Removal of Crankshaft 696
Installation of Crankshaft 711
Disassembly of Crankshaft 743
Assembly of Crankshaft 743
Inspection of Crankshaft 744
Removal and installation of Piston 749
Removal of Piston 749
Installation of Piston 759
Disassembly of Piston 779
Assembly of Piston 779
Inspection of Piston 780
Removal and installation of Camshaft 787
Removal of Camshaft 787
Installation of Camshaft 788
Disassembly of Camshaft 792
Assembly of Camshaft 793
Inspection of Camshaft 793
Removal and installation of Flywheel 795
Removal of Flywheel 795
Installation of Flywheel 796
Inspection of Flywheel 797
Removal and installation of Crankshaft Front Oil Seal 798
Removal of Crankshaft Front Oil Seal 798
Installation of Crankshaft Front Oil Seal 799
Removal and installation of Crankshaft Rear Oil Seal 802
Removal of Crankshaft Rear Oil Seal 802
Installation of Crankshaft Rear Oil Seal 803
Removal and installation of Rocker Arm Shaft 806
Removal of Rocker Arm Shaft 806
Installation of Rocker Arm Shaft 807
Disassembly of Rocker Arm Shaft 810
Assembly of Rocker Arm Shaft 810
Inspection of Rocker Arm Shaft 811
Removal and installation of Valve Spring 814
Removal of Valve Spring 814
Installation of Valve Spring 816
Inspection of Valve Spring 821
Removal and installation of Valve Stem Oil Seal 823
Removal of Valve Stem Oil Seal 823
Installation of Valve Stem Oil Seal 825
Removal and installation of Front Cover 832
Removal of Front Cover 832
Installation of Front Cover 834
Removal and installation of Intake Throttle Valve 840
Removal of Intake Throttle Valve 840
Installation of Intake Throttle Valve 840
Removal and Installation of Starter Motor 841
Removal of Starter Motor 841
Installation of Starter Motor 842
Disassembly of Starter Motor 842
Assembly of Starter Motor 843
Inspection of Starter Motor 845
Removal and Installation of Alternator 849
Removal of Alternator 849
Installation of Alternator 850
Disassembly of Alternator 851
Assembly of Alternator 851
Inspection of Alternator 853
Removal and Installation of Glow Plug 857
Removal of Glow Plug 857
Installation of Glow Plug 857
Glow plug Inspection 857
Removal and Installation of Suction Control Valve 858
Removal of Suction Control Valve 858
Installation of Suction Control Valve 858
Removal and installation of Fuel Filter 861
Removal of Fuel Filter 861
Installation of Fuel Filter 861
Removal and installation of Relief Valve 864
Removal of Relief Valve 864
Installation of Relief Valve 864
Removal and installation of Fuel Filter Element 867
Removal of Fuel Filter Element 867
Installation of Fuel Filter Element 868
Removal and Installation of Fuel filter pressure 871
Fuel filter pressure sensor Removal 871
Fuel filter pressure sensor Installation 871
Removal and Installation of Engine coolant temperature sensor 872
Engine coolant temperature sensor Removal 872
Engine coolant temperature sensor Installation 872
Engine coolant temperature sensor Inspection 872
Removal and Installation of CKP sensor 873
CKP sensor Removal 873
CKP sensor Installation 873
CKP sensor Inspection 873
Removal and Installation of CMP sensor 874
CMP sensor Removal 874
CMP sensor Installation 874
CMP sensor Inspection 874
Removal and Installation of Oil pressure sensor 875
Oil pressure sensor Removal 875
Oil pressure sensor Installation 875
Oil pressure sensor Inspection 875
Removal and installation of Pressure Sensor/Boost Temperature Sensor 876
Removal of Pressure Sensor/Boost Temperature Sensor 876
Installation of Pressure Sensor/Boost Temperature Sensor 876
Inspection of Pressure Sensor/Boost Temperature Sensor 876
Removal and Installation of IMT sensor 877
Removal of IMT sensor 877
Installation of IMT sensor 877
Removal and installation of Charge Air Cooler Temperature Sensor 1 878
Removal of Charge Air Cooler Temperature Sensor 1 878
Installation of Charge Air Cooler Temperature Sensor 1 878
Inspection of Charge Air Cooler Temperature Sensor 1 878
Sampling Procedure 879
Sampling of Engine Oil 879
Removal and Installation of Exhaust gas temperature sensor 880
Exhaust gas temperature sensor Removal 880
Exhaust gas temperature sensor Installation 880
Exhaust gas temperature sensor Inspection 880
Removal and installation of EGR Gas Temperature Sensor 1 882
Removal of EGR Gas Temperature Sensor 1 882
Installation of EGR Gas Temperature Sensor 1 882
Inspection of EGR Gas Temperature Sensor 1 882
Removal and installation of EGR Gas Temperature Sensor 2 883
Removal of EGR Gas Temperature Sensor 2 883
Installation of EGR Gas Temperature Sensor 2 883
Inspection of EGR Gas Temperature Sensor 2 883
Removal and installation of NOx Sensor 885
Removal of NOx Sensor 885
Installation of NOx Sensor 885
Removal and installation of EGR Gas Temperature Sensor 3 887
Removal of EGR Gas Temperature Sensor 3 887
Installation of EGR Gas Temperature Sensor 3 887
Removal and installation of DEF Sensor 888
Removal of DEF Sensor 888
Installation of DEF Sensor 888
Engine-related Diagnostic Trouble Code List 889
Engine-side Trouble 894
ECM Trouble 894
DTC U0001 CAN Bus Error (ISO-CAN) 894
DTC P0016 Crankshaft Position – Camshaft Position Correlation Error 895
DTC P0045 Turbocharger Boost Control VNT Error 895
DTC U0073 Control Module Communication Bus Off 897
DTC P0087 Fuel Rail/System Pressure – Too Low 898
DTC P0089 Fuel Pressure Regulator Performance 901
DTC P0091 Fuel Pressure Regulator Control Circuit Low 902
DTC P0092 Fuel Pressure Regulator Control Circuit High 903
DTC P0097 Intake Air Temperature (IAT) Sensor 2 Circuit Low Voltage 904
DTC P0098 Intake Air Temperature (IAT) Sensor 2 Circuit High Voltage 904
DTC U0101 Lost Communication With CAN 905
DTC P0102 Mass Air Flow Sensor Circuit Low Input 906
DTC P0103 Mass Air Flow Sensor Circuit High Input 907
DTC U010E Lost Communications With Dosing Control Module 907
DTC U0110 Lost Communication With VNT System 908
DTC P0112 Intake Air Temperature Sensor Circuit Low 908
DTC P0113 Intake Air Temperature Sensor Circuit High 909
DTC P0117 Engine Coolant Temperature Sensor Circuit Low 910
DTC P0118 Engine Coolant Temperature Sensor Circuit High 910
DTC P0122 Throttle Position Sensor Circuit Low 911
DTC P0123 Throttle Position Sensor Circuit High 912
DTC P0182 Fuel Temperature Sensor Circuit Low 913
DTC P0183 Fuel Temperature Sensor Circuit High 914
DTC P0192 Fuel Rail Pressure Sensor Circuit Low 915
DTC P0193 Fuel Rail Pressure Sensor Circuit High 915
DTC P0201 Injector Circuit Open – Cylinder 1 917
DTC P0202 Injector Circuit Open – Cylinder 2 917
DTC P0203 Injector Circuit Open – Cylinder 3 918
DTC P0204 Injector Circuit Open – Cylinder 4 919
DTC P0217 Engine Coolant Over Temperature Condition 920
DTC P0219 Engine Overspeed Condition 920
DTC P0234 Turbocharger Overboost Condition 921
DTC P0237 Turbo Charger Boost Sensor Circuit Low 922
DTC P0238 Turbo Charger Boost Sensor Circuit High 922
DTC P0335 Crankshaft Position Sensor Circuit 923
DTC P0336 Crankshaft Position Sensor Circuit Range/Performance 924
DTC P0340 Camshaft Position Sensor Circuit 925
DTC P0380 Glow Relay Circuit Error 926
DTC P0401 EGR Flow Insufficient Detected 927
DTC P0404 EGR Control Circuit Range/Performance 928
DTC P0409 EGR Sensor Circuit 928
DTC U0411 Lost CAN Communications With VNT Control Module 930
DTC P041C EGR Cooler Outlet 1 Temp Sensor Circuit Low 930
DTC P041D EGR Cooler Outlet 1 Temp Sensor Circuit High 931
DTC P0427 Catalyst Temperature Sensor Circuit Low Sensor 1 932
DTC P0428 Catalyst Temperature Sensor Circuit High Sensor 1 932
DTC P042C Catalyst Temperature Sensor Circuit Low Sensor 2 933
DTC P042D Catalyst Temperature Sensor Circuit High Sensor 2 934
DTC P0522 Engine Oil Pressure Sensor Circuit Low Input 935
DTC P0523 Engine Oil Pressure Sensor Circuit High Input 936
DTC P0545 EGR Cooler Inlet 1 Temp Sensor Circuit Low 937
DTC P0546 EGR Cooler Inlet 1Temp Sensor Circuit High 937
DTC P0560 12 Volt Circuit Error 938
DTC P0563 System Voltage High 938
DTC P0601 Internal Control Module Memory Check Sum Error 939
DTC P0602 Internal Control Module QR Code Error 939
DTC P0604 Internal Control Module RAM Error 940
DTC P0606 Internal Control Module CPU Error 940
DTC P060A Internal Control Module CPU IC Error 940
DTC P060C Internal Control Module A/D Processing Performance 940
DTC P0615 Starter Relay Circuit Error 941
DTC P0638 Throttle Actuator Control Range/Performance 941
DTC P0685 ECM Power Relay Control Circuit Open 942
DTC P0687 ECM Power Relay Control Circuit High 943
DTC P06A6 Sensor Reference Voltage 1 Circuit 943
DTC P06A7 Sensor Reference Voltage 2 Circuit 944
DTC P06A8 Sensor Reference Voltage 3 Circuit 945
DTC P06A9 Sensor Reference Voltage 4 Circuit 945
DTC P06AF Torque Management System – Forced Engine Shutdown 946
DTC P06D5 Sensor Reference Voltage 5 Circuit 947
DTC P1076 Charge Air Cooler (CAC) Temperature Sensor 1 Circuit Low Voltage 947
DTC P1077 Charge Air Cooler (CAC) Temperature Sensor 1 Circuit High Voltage 947
DTC P1093 Fuel Rail Pressure Too Low 948
DTC P1097 Compressor Outlet Temperature Sensor Circuit High 951
DTC P1098 Compressor Outlet Temperature Sensor Circuit High 952
DTC P1236 Charge Air Cooler Performance Failure 953
DTC P1261 Injector Positive Voltage Control Circuit Group 1 953
DTC P1262 Injector Positive Voltage Control Circuit Group 2 954
DTC P1404 EGR Position Fault 954
DTC P1606 SW-IC Internal failure 955
DTC P160B AD-IC Failure Error 955
DTC P160C AD-IC2 Failure Error 955
DTC P1621 Control Module Long Term Memory Performance 955
DTC P1669 DPD Lamp Control Circuit 956
DTC P2000 Monitoring the NOx Efficiency 957
DTC P204F SCR System Error (No Inducement) 958
DTC P207F Urea Fluid Concentration Too Low 958
DTC P20C9 SCR System Error 958
DTC U2106 Lost CAN Communications With Wheel Loader Transmission Control System 959
DTC P2122 Pedal Position Sensor 1 Circuit Low Input 959
DTC P2123 Pedal Position Sensor 1 Circuit High Input 960
DTC P2127 Pedal Position Sensor 2 Circuit Low Input 960
DTC P2128 Pedal Position Sensor 2 Circuit High Input 961
DTC P2138 Pedal Position Sensor 1 – 2 Voltage Correlation 962
DTC P2146 Fuel Injector Group 1 Supply Voltage Circuit 962
DTC P2149 Fuel Injector Group 2 Supply Voltage Circuit 964
DTC P2210 Reading the error(open) information detected by Rr NOx sensor 965
DTC P2211 Reading the error(short) information detected by Rr NOx sensor 965
DTC P2228 Barometric Pressure Sensor Circuit Low 965
DTC P2229 Barometric Pressure Sensor Circuit High 966
DTC P2457 Exhaust Gas Recirculation (EGR) Cooling System Performance 966
DTC P2458 Purge time Out Error 967
DTC P2BA7 Urea Fluid Quantity Too Low 967
DTC P2BAA SCR System Error (Inducement, No Purge) 967
DTC P3093 Fuel Rail Pressure Too Low 967
DCU Trouble 970
DTC U0002 CAN Bus Off 970
DTC U0100 Lost Communication With ECM 971
DTC U029D Lost Communication With NOx Sensor 1 972
DTC U029E CAN communication error between DCU and Rr NOx sensor 974
DTC P0607 Control Module Performance 975
DTC P060B Internal Control Module A/D Processing Performance 975
DTC P062F Control Module EEPROM Error 975
DTC P0641 Sensor Reference Voltage 1 Circuit 976
DTC P0658 Actuator Supply Voltage Circuit 977
DTC P0659 Actuator Supply Voltage Circuit 978
DTC P1462 Urea Fluid Quality Sensor Timeout Error 979
DTC P1464 Main Relay Performance 980
DTC P1468 DCU Overtemperature 981
DTC P1491 Urea Fluid Overpressure 981
DTC P1493 DCU Driver Overtemperature 982
DTC P149C Urea Fluid Pressure Reduction Malfunction 983
DTC P149D Urea Fluid Tank Overtemperature 984
DTC P203B Urea Fluid Tank Level Sensor Stuck 985
DTC P203C Urea Fluid Tank Level Sensor Low Voltage 986
DTC P203D Urea Fluid Tank Level Sensor High Voltage 986
DTC P2048 Urea Fluid Injector Circuit Low Voltage 987
DTC P2049 Urea Fluid Injector Circuit High Voltage 988
DTC P204B Urea Fluid Pressure Sensor Performance 989
DTC P204C Urea Fluid Pressure Sensor Circuit Low Voltage 990
DTC P204D Urea Fluid Pressure Sensor Circuit High Voltage 990
DTC P205B Urea Fluid Tank Temperature Sensor Performance 991
DTC P205C Urea Fluid Tank Temperature Sensor Low Voltage 992
DTC P205D Urea Fluid Tank Temperature Sensor High Voltage 993
DTC P206A Urea Fluid Quality Sensor Circuit 993
DTC P206B Urea Sensor Over Temperature Condition 994
DTC P206C Urea Fluid Quality Sensor Circuit Low Voltage 995
DTC P206D Urea Fluid Quality Sensor Circuit High Voltage 995
DTC P207F Urea Fluid Concentration Too Low 996
DTC P208A Urea Fluid Pump Control Circuit 996
DTC P208B Usea Fluid Pump Performance 997
DTC P208C Urea Fluid Pump Control Circuit Low Voltage 998
DTC P208D Urea Fluid Pump Control Circuit High Voltage 998
DTC P208E Urea Fluid Injector Stuck 999
DTC P20A0 Urea Fluid Reverting Valve Circuit Open1000
DTC P20A2 Urea Fluid Reverting Valve Circuit Low Voltage1001
DTC P20A3 Urea Fluid Reverting Valve Circuit High Voltage1002
DTC P20AC Urea Fluid Pump Temperature Sensor Performance1003
DTC P20AD Urea Fluid Pump Module Temperature Sensor Performance1004
DTC P20B1 Urea Fluid Tank Heater Coolant Control Valve Circuit Open1004
DTC P20B3 Urea Fluid Tank Heater Coolant Control Valve Circuit Low Voltage1005
DTC P20B4 Urea Fluid Tank Heater Coolant Control Valve Circuit High Voltage1006
DTC P20E8 Urea Fluid Pressure Underpressure1007
DTC P20E9 Urea Fluid Overpressure1008
DTC P20EA Urea Fluid Pressure Reduction Malfunction1009
DTC P20FE Urea Fluid Pressure Build-Up Error1010
DTC P2201 Upstream Nox Sensor Performance1011
DTC P2206 NOx Sensor Heater Control Circuit Low Voltage Sensor 11012
DTC P2207 NOx Sensor Heater Control Circuit High Voltage Sensor 11012
DTC P242B Exhaust Gas Temperature (EGT) Sensor 3 Performance1012
DTC P242C Exhaust Gas Temperature (EGT) Sensor 3 Circuit Low Voltage1013
DTC P242D Exhaust Gas Temperature (EGT) Sensor 3 Circuit High Voltage1014
Data Reference Values1016
Idle Speed1016
Two Pump Relief1017
J HYDRAULIC EQUIPMENT (PUMP, OPERATION SYSTEM VALVE)1019
Main Equipment Table1025
Hydraulic Device1025
Hydraulic Pump1025
Control-related1026
Control Valve1026
Control Valve (LF)1026
Solenoid Valve (5 Stack)1027
Remote Control Valve for Left/Right Operations1027
Remote Control Valve for Travel Operation1027
Remote Control Valve Characteristic Diagram1027
Operation Remote Control Valve Control Diagram1028
Travel Remote Control Valve Control Diagram1029
Cushion Valve (heat circuit, with shuttle valve)1029
Selector Valve1029
Basic Functions1030
Oil temperature gauge1030
Static Horsepower Control1031
Overload Warning (Function for Europe Only)1032
Pressure Boost Control1032
Stroke Control1034
Boom Down Energy Save1036
Pump Horsepower Boost Control1037
Arm 1 Semi-parallel Control1037
Arm 2 Semi-parallel Control1038
Hot Shutdown Warning1039
Gate Lock1040
Breaker Mode1041
Crusher Mode1041
Quick coupler1042
Hydraulic Filter Clogging1043
Solenoid Sticking Prevention1044
Port Diagram1045
Hydraulic Pump (Standard Model)1045
Control Valve1046
Relief Valve1046
5 Stack Solenoid Valve1049
2 Stack Solenoid Valve1051
Remote Control Valves (upper, travel)1051
Remote Control Valves (left-right)1051
Remote Control Valve (Travel)1052
Cushion Valve1053
2-way Selector Valve1054
Direction Valve1055
6 Stack Proportional Valve1056
Relief Valve (electromagnetic proportional)1058
Manifold Under Cab1059
Manifold (accumulator section)1060
Hydraulic Oil Tank1061
Hydraulic Pump1062
Structure and Operation Explanation1062
Hydraulic Pump Internal Structure Diagram1063
Overall View1063
Drive Shaft Front Side1064
Drive Shaft Rear Side1065
Development Diagram1066
Component Table1069
Regulator1070
Regulator Operation Explanation1070
Regulator Operation Explanation Diagram1073
Internal Configuration Diagram of Regulator1076
Development Diagram of Regulator1078
Component Table1079
Operation Outline of Electronically-Controlled Pump1081
Control Valve1084
Basic Configuration1084
Operation1084
Operation of Main Unit1084
Activation of Relief Valve1104
5 Stack Solenoid Valve Operation Explanation1109
External Shape Diagram and Components1109
operation explanation1109
Upper Pilot Valve (remote control valve)1110
Structure1110
Function1110
Operation1111
Structural Diagram1114
Travel Pilot Valve (remote control valve)1115
Operation1115
Pressure Reducing Valve Section1115
Damping Mechanism in Operation Section1116
Structural Diagram1119
Cushion Valve 1121
structure1121
operation explanation1121
Selector Valve (2-way)1126
Structure1126
Operation Explanation1127
Development Diagram1128
Direction Valve (3-direction) 1129
Structure1129
Operation Explanation1130
6 Stack Proportional Valve (Pilot)1132
structure1132
operation principle1133
Electromagnetic Relief Valve1134
Structure1134
Operation Explanation1135
Operation of Check Valve1135
Operation of Electromagnetic Relief Valve1136
Removal and Installation of Hydraulic Tank1138
Removal of Hydraulic Reservoir1138
Installation of Hydraulic Oil Tank1140
Removal and Installation of Hydraulic Pump1141
Removal of Hydraulic Pump1141
Installation of Hydraulic Pump1143
Removal and Installation of Control Valve1144
Removal of Control Valve1144
Installation of Control Valve1148
Removal and Installation of Travel Remote Control Valve1149
Removal of Travel Remote Control Valve1149
Installation of Travel Remote Control Valve1150
Removal and Installation of Operation Remote Control Valve1153
Removal of Operation Remote Control Valve (Left)1153
Installation of Operation Remote Control Valve (Left)1155
Removal of Operation Remote Control Valve (right side)1157
Installation of Operation Remote Control Valve (right side)1159
Removal and Installation of 5 Stack Solenoid1162
Removal of 5 Stack Solenoid Valve1162
Installation of 5 Stack Solenoid Valve1163
Removal and Installation of Cushion Valve1164
Removal of Cushion Valve1164
Installation of Cushion Valve1165
Procedures for Assembly and Disassembly of Hydraulic Pump Main Unit1166
Tools1166
Disassembly Procedure1166
Assembly Procedures1168
Development Diagram1172
Component Table1175
Pump Main Unit Maintenance Standards1176
Replacement Standard of Wear Component1176
Correction Standard of Cylinder, Valve Plate, and Sash Plate (Shoe Plate)1176
Tightening torque1177
Overall View1177
Drive Shaft Front Side1178
Drive Shaft Rear Side1179
Development Diagram1180
Component Table1183
Regulator Maintenance Standards1184
Regulator Adjustment1184
Appendix Table and Drawings1185
Regulator Assembly and Disassembly Procedures1189
Tools1189
Preparations for Disassembly1189
Disassembly Procedure1189
Assembly Procedures1191
Internal Configuration Diagram of Regulator1194
Development Diagram of Regulator1196
Component Table1197
Assembly and Disassembly of Control Valve1199
Disassembly1199
Caution for Disassembly1199
Disassembly Procedure1199
Removal of Long Cap and Pulling Out of Main Spool1199
Disassembly of Arm 1, 2 Parallel-Tandem Spool, Neutral Cut Spool, Arm Regeneration Release Spool Section1200
Disassembly of Load Check Valve Section1200
Disassembly of Antidrift Valve Section (Sub Component in Assembly is Expressed by (Min Number – Sub Number))1201
Disassembly of Relief Valve1201
Disassembly of Option Section1201
Disassembly of Add-On Section1201
Disassembly of Valve Housing Coalescence Bolt1202
Cleaning1202
Inspection1202
assembly1202
Caution for Assembly1202
Caution for Handling O-ring1202
Caution for Handling Spool1202
Method to Apply Adhesive Agent (Male and Female Thread Section of Components Requiring Bonding)1202
Assembly Procedure of Sub-Assembly1203
Assembly of Spool Assembly (Main Spool)1203
Assembly of Arm 1, 2 Parallel-Tandem Spool, Neutral Cut Spool, Arm Regeneration Release Spool Assembly1203
Assembly of Antidrift Valve Assembly1204
Assembly Procedure of Control Valve Main Unit1204
Assembly of Relief Valve1204
Assembly of Load Check Valve1204
Assembly of Antidrift Valve1205
Assembly of Option Section1205
Assembly of Arm 1 Parallel-Tandem Spool1205
Assembly of Arm 2 Parallel-Tandem Spool, Neutral Cut Spool, Arm Regeneration Release Spool1205
Assembly of Main Spool1205
Assembly of Add-On Section1206
Assembly of Other Plugs1206
Internal Structural Diagram1207
Part List1213
Relief Valve1214
Assembly and Disassembly Procedure of Main Relief Valve1214
Assembly and Disassembly Procedures of Overload Relief1215
Assembly and Disassembly Procedure of Low-Pressure Relief Valve1216
Assembly and Disassembly Procedure of Main Relief Valve for Add-On1216
Adjustment of Relief Valve1217
Installation1218
Operation1218
Malfunction and Countermeasure1218
Procedures for Assembly and Disassembly of Operation Remote Control Valve1220
Maintenance Procedures1220
Required Tools and Tightening Torque1220
Maintenance Standards1220
Disassembly Procedures1221
Assembly Procedures1224
Causes of Trouble and Countermeasures1227
Procedures for Assembly and Disassembly of Travel Remote Control Valve1231
Maintenance Procedures1231
Disassembly Procedures1232
Assembly Procedures1236
Causes of Trouble and Countermeasures and Cross-section Diagram1241
Assembly and Disassembly of Cushion Valve1244
Disassembly Procedures1244
Reverse Operation Spool Section1244
Check Plunger Section with Throttle1244
Shuttle Valve Section1244
Assembly Procedures1245
Reverse Operation Spool Section1245
Check Plunger Section with Throttle1245
Shuttle Valve Section1245
Written Materials1246
Procedures for Assembly and Disassembly of 6 Stack Proportional Valve (Pilot)1248
Development Diagram1248
Assembly and disassembly procedures1249
Precautions1249
Replacement of Proportional Solenoid1249
Disassembly1249
Assembly1249
Replacement of Sleeve and Spool1250
Disassembly1250
Assembly1251
Replacement of Poppet (Check Valve for Normally Open)1252
Disassembly1252
assembly1253
Maintenance Standards1253
Troubleshooting1253
Pressure Measurement and Adjustment Procedures1255
Procedures for Pressure Measurement from the Monitor Display1255
Monitor and Switch Panel1255
Pressure Measurement Method1255
Operating Method1255
PROCEDURES FOR MEASURING HYDRAULIC OIL TEMPERATURE FROM THE MONITOR DISPLAY1255
Hydraulic Oil Temperature Measurement Method1255
Operating Method1256
Procedures for Pressure Measurement by Installing Pressure Gauge1257
Preparations1257
Items to prepare1257
Pressure Measuring Ports1258
Control Valve1260
Location of Relief Valves1260
Pressure Measurement Preparations1261
Pressure Measurement1263
Main Pressure Measurement1263
A Attachment Pressure Measurement1263
Boom-down pressure measurement1265
D Option Line Pressure Measurement1265
Pilot Pressure Measurement1265
Pressure Gauge Installation1265
Negative Control Pressure Measurement1266
Pressure Gauge Installation1266
Pressure Adjustment1266
Main Pressure Adjustment1266
Preparation Work of Pressure Measurement Adjustment1266
Main Relief Pressure Adjustment1268
Overload Relief Pressure Adjustment1269
Adjustment of Swing Relief Pressure1270
Pilot Pressure Adjustment1271
Hydraulic Pump Flow Measurement Procedures1272
Preparations1272
Items to Prepare1272
Work Preparations1273
Flow Measurement1274
Air Bleed Procedure1276
Hydraulic Pump1276
Sampling Procedure1277
Sampling of Hydraulic Fluid1277
Hydraulic Equipment Layout1278
Overall View1279
Pump Chamber Hydraulic Equipment Layout1280
Swing Body Center Section Hydraulic Equipment Layout1281
Housing Left Side Hydraulic Equipment Layout1283
Layout of Hydraulic Equipment in Cab1284
N CAB1437
Removal and Installation of Operator’s Seat1440
Removal of Operator’s Seat1440
Installation of Operator’s Seat1440
Removal and Installation of Cab Assembly1441
Removal of Cab Assembly1441
Installation of Cab Assembly1445
Removal and Installation of Wiper1446
Removal of Wiper1446
Installation of wiper1446
Removal and Installation of Cab Front Glass1447
Removal of Cab Front Glass1447
Installation of Cab Front Glass1448
Window Lock Adjustment Procedures1449
Window Lock (front side)1449
Window Lock (rear side)1449
Removal and Installation of Housing Guardrail1451
Removal of Housing Guardrail1451
Installation of Housing Guardrail1451
Tightening torque1452
R ELECTRICAL PARTS1453
Basic Functions1457
Monitor Control1457
Monitor Display Dimming1457
Diagnostic Trouble Code Indicator1458
Clock1458
Basic Operation1459
Battery Save1459
Accessories1461
Working Light1461
LED Light1462
Room Lamp1462
Radio Mute1464
Wiper and Washer1465
Safety1467
Horn1467
Back/Side View Monitor1468
Precautions for Camera Installation1469
Maintenance1469
Anti-theft1469
Manual Lock1470
Service Support Screen Lock1470
Customer-specific System Information Screen Lock1470
Maintenance Information Screen Lock1471
Option Line Setting Screen Lock1471
Setting1471
Clock Adjustment1471
Screen Brightness Setting1472
Battery Disconnect Switch1473
Explanation of Controller1474
Service Support1476
Screen Operations1476
Screen Display List1476
Service Monitor Structure1477
CHECK Screen List1478
MACHINE STATUS1479
HYDRAULIC STATUS1485
ENGINE STATUS1492
FAULT HISTORY1496
WORK HISTORY1497
HYDRAULIC HISTORY1505
ENGINE HISTORY1518
DEVICE TEST1539
ECM/DCU Memory Clear1539
SCR RE-GEN1540
Urea Line Leak Test1541
CCV Operation Test1542
Dosing Test1543
Reverting Valve Operation Test1544
Common Rail Pressure Test1545
Idle Speed Test / Injector Test1546
EGR Valve Control Test1547
VG Turbo Control Test1548
Intake Throttle Control Test1549
CONTROL UNIT Screen List1551
MCM-MAIN1551
MCM-SUB1555
COMMU TERMINAL1556
SETUP Screen List1558
MACHINE SELECT1558
DIMENSIONS1563
PARAMETERS1566
ENGINE INFORMATION1570
ENGINE INFORMATION1571
Data Confirmation1571
Data Transfer (Copy)1571
QR (INJECTOR) CODE1572
Injector number1572
Screen Layout1573
Data Source Selection1573
Manual Input1573
CAMERA1575
PASSWORD1578
CALIBRATE Screen List1580
THROTTLE VOLUME1581
OPTLINE RELIEF1582
PUMP FLOW1584
RESET Screen List1586
Connection Connector Pin Layout1589
Main Controller1589
Monitor1590
Sequence Circuit Diagram1591
Code List1591
Overall1594
Block diagram1597
Main controller1597
DCU1598
ECM1599
Monitor1600
Air Conditioner1601
Gate Lock1602
Horn1602
Working Light1603
Option1604
Other1605
Electrical Symbol List1605
Electrical Equipment Layout Diagram1608
Main Unit Left-side Layout Diagram1609
Engine Section Layout Diagram1611
Main Unit Right Side Layout Diagram (pump chamber)1614
Main Unit Center Section Layout Diagram1615
Cab Layout Diagram 11616
Cab Layout Diagram 21618
Layout Around Operator Seat1621
Stand Alone Parts Diagram1622
Removal and Installation of Wiper Controller1641
Removal of Wiper Controller1641
Installation of wiper controller1641
Removal and Installation of Wiper Motor1642
Removal of Wiper Motor1642
Installation of wiper motor1643
Removal and Installation of ECM1644
Removal of ECM1644
Installation of ECM1644
Removal and Installation of Main Controller1645
Removal of Main Controller1645
Installation of Main Controller1645
Removal and Installation of DCU1646
Removal of DCU1646
Installation of DCU1646
Removal and Installation of Monitor1647
Removal of Monitor1647
Installation of Monitor1647
Removal and Installation of Rear View Camera 1648
Removal of Rear View Camera1648
Installation of Rear View Camera1648
Removal and Installation of Side Camera (right)1649
Removal of Side Camera (Right)1649
Installation of Side Camera (right)1649
Removal and Installation of Side Camera (Left)1650
Removal of Side Camera (Left)1650
Installation of Side Camera (Left)1650
Removal and Installation of FVM Controller1651
Removal of FVM Controller1651
Installation of FVM Controller1651
How to Set FVM1652
Air Conditioner Overall Diagram1656
Frame1656
Cab1658
Equipment Layout Diagram1661
Circuit Diagram1663
Air Conditioner Circuit Diagram1663
Explanation of Functions1665
Explanation of Control1665
Air Mix Motor Actuator Control1666
Blow Mode Motor Actuator Control1666
Refresh/Recirculate Switch Motor Actuator Control1667
Blower Amp Control1668
Compressor Clutch Control1670
COOLMAX Control and HOTMAX Control1671
Abnormality Detection and Control after Abnormality Detected1671
Monitor Mode1675
Door Switch Control1677
Actuator Inspection1678
Air Mix Motor Actuator Inspection1678
Refresh/Recirculate Switch Motor Actuator Inspection1679
Mode Motor Actuator Inspection1680
Self-diagnosis Function with Panel Display1681
Abnormality Display and Self-check Procedures1681
Abnormality Display Position1681
Explanation of Abnormality Display1681
Motor Actuator Abnormality1681
Sensor Abnormality1682
Explanation of Monitor Mode1682
Monitor Mode Display Position1683
Monitor Mode Display Operating Method1683
Display Contents in Monitor Mode1684
Part Function and Good/Poor Judgment1690
Control Panel1690
Blower Amp1690
Relay1691
Air Mix Actuator1692
Refresh/Recirculate Actuator1693
Blow Mode Actuator1693
Evaporator Sensor1694
Dual Pressure Switch1694
Solar Radiation Sensor1695
Inside Air Sensor1695
Assembly and Disassembly of Unit1697
Removal of Blower Unit1697
Replacement of Blower Motor1697
Replacement of Blower Amp1697
Removal of Heater Core1698
Removal of Heat Case Right/Left1698
Replacement of Evaporator and Expansion Valve1698
Installation of Evaporator Sensor1699
Replacement of Motor Actuator1699
Removal and Installation of Compressor1700
Removal of Compressor1700
Installation of Compressor1700
Removal and Installation of Condenser1701
Removal of Condenser1701
Installation of Condenser1702
Removal and Installation of Receiver Dryer1703
Removal of Receiver Dryer1703
Installation of Receiver Dryer1703
Work Precautions1705
Work Procedures1705
Air Conditioner Refrigerant Filling is Divided into the “Vacuum Operation” and “Gas Filling Operation”1705
Operation Chart1706
Tools1706
Filling Procedures1708
Charging Hose Connection Position1708
Connecting Gauge Manifold1708
Vacuuming1709
Gas Filling Operation, High-pressure Side1710
Gas Filling Work, Low Pressure Side1710
V ATTACHMENTS1763
Main Equipment Table1767
Backhoe Attachment1767
Cylinder1767
Cylinder (LF)1767
Maintenance Standards1769
Attachment (Backhoe)1769
1 Boom and Swing Frame Installation Section1769
2 Boom Cylinder and Swing Frame Installation Section1770
3 Boom and Boom Cylinder Installation Section1770
4 Boom and Arm Cylinder Installation Section1771
5 Boom and Arm Installation Section1771
6 Arm and Arm Cylinder Installation Section1772
7 Arm and Bucket Cylinder Installation Section1773
8 Arm and Arm Link Installation Section1773
9 Bucket and Bucket Link Installation Section1774
10 Bucket Link and Bucket Cylinder Installation Section1774
11 Bucket and Arm Installation Section1775
Attachment (Backhoe) (LF)1777
1 Boom and Swing Frame Installation Section1777
2 Boom Cylinder and Swing Frame Installation Section1778
3 Boom and Boom Cylinder Installation Section1778
4 Boom and Arm Cylinder Installation Section1779
5 Boom and Arm Installation Section1779
6 Arm and Arm Cylinder Installation Section1780
7 Arm and Bucket Cylinder Installation Section1781
8 Arm and Arm Link Installation Section1781
9 Bucket and Bucket Link Installation Section1782
10 Bucket Link and Bucket Cylinder Installation Section1782
11 Bucket and Arm Installation Section1783
Removal and Installation of Bucket Cylinder1784
Removal of Bucket Cylinder1784
Installation of Bucket Cylinder1786
Removal and Installation of Arm Cylinder1788
Removal of Arm Cylinder1788
Installation of Arm Cylinder1790
Removal and Installation of Arm Cylinder (LF)1793
Removal of Arm Cylinder1793
Installation of Arm Cylinder1795
Removal and Installation of Boom Cylinder1798
Removal of Boom Cylinder1798
Installation of Boom Cylinder1800
Removal and Installation of Boom Cylinder (LF)1802
Removal of Boom Cylinder1802
Installation of Boom Cylinder1804
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder1807
Specifications and Structure Diagram (including the assembly diagram and parts table)1807
Basic Functions1807
Function of Each Location1807
Cylinder Head Assembly (made by KYB)1807
Piston Assembly (made by KYB)1808
Pipe Assembly (made by KYB)1810
Handling Precautions1810
Precautions for Installing the Cylinder on the Machine Body1810
Usage Cautions1811
Maintenance and Inspection Cautions1811
Maintenance Inspection and Service1813
Trouble Diagnostics1814
Storage Standards1819
Storing Parts Individually (In principle, store indoors)1819
When Mounted on Vehicle Body1819
Recommended Anti-rust Oil1819
Assembly and Disassembly Procedures1820
Preparations ····· Prepare the Following before Starting Disassembly1820
General Work Precautions1820
Maintenance Standards1820
Inspection after Assembly1820
Required Tool1821
General Tool1821
Special Jig (made by KYB)1822
Special Jig Parts Number List (made by KYB)1822
Disassembly Procedures (made by KYB)1823
Assembly Procedures (made by KYB)1827
Test Operation1831
Usage Limits1832
Structural Diagram (made by KYB)1833
Boom Cylinder1833
Arm Cylinder1835
Arm Cylinder (LF)1837
Bucket Cylinder1839
Bucket Cylinder (LF)1841
HBCV1843
structure1843
Function1843
operation explanation1843
Port Diagram1858
HBCV1858
Air Bleed Procedure1859
HBCV1859
Boom Cylinder HBCV1859
Arm Cylinder HBCV1860
Removal and Installation of HBCV1861
Removal and Installation of Arm HBCV1862
Removal of Arm HBCV1862
Installation of arm HBCV1862
Removal and Installation of Boom HBCV1863
Removal of Boom HBCV1863
Installation of Boom HBCV1864
Removal and Installation of Bucket1865
Removal of Bucket1865
Installation of Bucket1865
Removal and Installation of Bucket Link1867
Removal of Bucket Link1867
Installation of Bucket Link1867
Removal and Installation of Bucket Link (LF)1869
Removal of Bucket Link1869
Installation of Bucket Link1869
Removal and Installation of Arm1871
Removal of Arm1871
Installation of Arm1872
Removal and Installation of Arm (LF)1873
Removal of Arm1873
Installation of Arm1874
Removal and Installation of Boom1875
Removal of Boom1875
Installation of Boom1877
Removal and Installation of Boom (LF)1881
Removal of Boom1881
Installation of Boom1883
Z OTHER1887
Changes from Model -61892
Overall Layout1892
Lower1892
Swing Unit1893
Engine1893
hydraulic-related1895
Hydraulic Control1896
Cab, Housing1897
Electrical Data1899
Electric Control1900
Attachments1900
Specifications1901
ENGINE1901
HYDRAULIC SYSTEM1901
HYDRAULIC CONTROLS1902
ELECTRICAL SYSTEM1902
OPERATOR ENVIRONMENT1903
UNDERCARRIAGE1903
MASS1904
DIGGING FORCE (with 09 m3 Sumitomo Bucket) (ISO 6015)1904
DIMENSIONS1904
WORKING RANGES1905
SYSTEM FLUID CAPACITIES AND SPECIFICATIONS1905
Specifications (LF)1906
ENGINE1906
HYDRAULIC SYSTEM1906
HYDRAULIC CONTROLS1907
ELECTRICAL SYSTEM1907
OPERATOR ENVIRONMENT1908
UNDERCARRIAGE1908
MASS1909
DIGGING FORCE (with 037 m3 Sumitomo Bucket) (ISO 6015)1909
DIMENSIONS1909
WORKING RANGES1910
SYSTEM FLUID CAPACITIES AND SPECIFICATIONS1910
Arm Dimensions1911
210X41911
210X4 LF1913
Main Unit Weight1916
Divided Weight (standard specifications)1916
Divided Weight (LF)1917
Stand Alone Part Weight (Standard Specifications)1917
Stand Alone Part Weight (LF)1918
Shoe Weight (per Side)1918
Shoe Weight (per Side) (LF)1918
Arm Weight1918
Arm Weight (LF)1919
Bucket weight1919
Bucket Weight (LF)1920
Bolt Size and Torque Table1921
Special Torque Setting1921
Overall View1925
210X41925
Standard Arm [294 m (965 ft)]1925
Short Arm [240 m (787 ft)]1926
210X4 LF1927
Ultra-Long Arm [640 m (2100 ft)]1927
WORK RANGE DIAGRAM1928
210X41928
Standard Arm [294 m (96457 ft)]1928
Short Arm [240 m (78740 ft)]1930
210X4 LF1932
Ultra-Long Arm [640 m (2100 ft)]1932
New Machine Performance Judgment Table1934
Table of Standards1934
Table of Standards (LF)1936
Measurement Method1939
Engine speed1939
Pressure at Each Part1939
Pump Command Displacement1940
Cylinder Down Amount1940
Attachment Speed1940
Swing Speed1941
Swing (180°) Brake Angle1942
Travel Speed1942
Off Travel Amount1942
Travel Sprocket Speed1943
Shoe Tension Amount1943
Swing Ball Race Bearing Movement Amount and Bucket Tip Movement Amount1944
FLUIDS AND LUBRICANTS1946
HYDRAULIC FLUID1946
Engine Oil1946
Fuel1946
Conditions applicable to diesel fuel1946
Recommended Conditions Applicable to Diesel Fuel1946
Main-unit-related Diagnostic Trouble Code List1947
Main Unit-side Trouble1950
Diagnostic Trouble Code: 7000 Pressure Sensor P1 Abnormality1950
Diagnostic Trouble Code: 7001 Pressure Sensor P2 Abnormality1951
Diagnostic Trouble Code: 7002 Pressure Sensor N1 Abnormality1953
Diagnostic Trouble Code: 7003 Pressure Sensor N2 Abnormality1954
Diagnostic Trouble Code: 7004 Pressure Sensor Boom Cylinder Bottom Abnormality1956
Diagnostic Trouble Code: 7007 Pressure Sensor Arm Cylinder Rod Abnormality1957
Diagnostic Trouble Code: 7021 Pressure Sensor Swing Pilot Abnormality1959
Diagnostic Trouble Code: 7023 Pressure Sensor Arm-In Pilot Abnormality1960
Diagnostic Trouble Code: 7040 Level Sensor Fuel Abnormality1962
Diagnostic Trouble Code: 7041 Temperature Sensor Hydraulic Fluid Abnormality1963
Diagnostic Trouble Code: 7065 Pressure Sensor Boom-Up Pilot Abnormality1964
Diagnostic Trouble Code: 7067 Pressure Sensor Bucket-Close Pilot Abnormality1966
Diagnostic Trouble Code: 7068 Pressure Sensor Boom-Down Pilot Abnormality1968
Diagnostic Trouble Code: 7069 Pressure Sensor Arm-Out Pilot Abnormality1969
Diagnostic Trouble Code: 7070 Pressure Sensor Bucket-Open Pilot Abnormality1971
Diagnostic Trouble Code: 7071 Pressure Sensor Travel Right Pilot Abnormality1972
Diagnostic Trouble Code: 7072 Pressure Sensor Travel Left Pilot Abnormality1974
Diagnostic Trouble Code: 7073 Pressure Sensor Travel 1 Pedal Abnormality1976
Diagnostic Trouble Code: 7074 Pressure Sensor 1st Option Pilot (Common/Front Pedal) Abnormality1978
Diagnostic Trouble Code: 7075 Pressure Sensor Arm Cylinder Bottom Abnormality1979
Diagnostic Trouble Code: 7078 Pressure Sensor 1st Option Pilot (Rear Pedal) Abnormality1981
Diagnostic Trouble Code: 7200 Swing Brake Solenoid Abnormality1983
Diagnostic Trouble Code: 7201 Travel 2nd-Speed Switchover Solenoid Abnormality1984
Diagnostic Trouble Code: 7202 Pressure Boost Solenoid Abnormality1985
Diagnostic Trouble Code: 7203 Travel Alarm Buzzer Abnormality1986
Diagnostic Trouble Code: 7206 Option Return Line Switchover Solenoid Abnormality1987
Diagnostic Trouble Code: 7207 Free Swing Solenoid Abnormality1988
Diagnostic Trouble Code: 7213 Quick Coupler Buzzer Abnormality1989
Diagnostic Trouble Code: 7214 Quick Coupler Solenoid Abnormality1991
Diagnostic Trouble Code: 7247 Boom 2-Down Pilot Proportional Valve Abnormality1992
Diagnostic Trouble Code: 7249 Bucket-Close Pilot Proportional Valve Abnormality1993
Diagnostic Trouble Code: 7250 Option Relief Pressure Proportional Valve Abnormality1995
Diagnostic Trouble Code: 7265 Arm 1 Semi-Parallel Proportional Valve Abnormality1996
Diagnostic Trouble Code: 7266 Arm 2 Semi-Parallel Proportional Valve Abnormality1997
Diagnostic Trouble Code: 7267 Arm 1 Regeneration Release Proportional Valve Abnormality1998
Diagnostic Trouble Code: 7270 Tilting 1 Proportional Valve Abnormality1999
Diagnostic Trouble Code: 7271 Tilting 2 Proportional Valve Abnormality2001
Diagnostic Trouble Code: 7273 Straight Travel Proportional Valve Abnormality2002
Diagnostic Trouble Code: 7400 Coolant Temperature Overheating 12003
Diagnostic Trouble Code: 7401 Coolant Temperature Overheating 22004
Diagnostic Trouble Code: 7404 Oil Temperature Overheating2005
Diagnostic Trouble Code: 7405 Boost Temperature Overheating 12006
Diagnostic Trouble Code: 7406 Boost Temperature Overheating 22007
Diagnostic Trouble Code: 7420 Alternator Power Generation Failure2008
Diagnostic Trouble Code: 7421 Coolant Level Decrease2009
Diagnostic Trouble Code: 7422 Engine Oil Pressure Decrease2010
Diagnostic Trouble Code: 7423 Air Cleaner Clogging2011
Diagnostic Trouble Code: 7424 Return Filter Clogging2012
Diagnostic Trouble Code: 7426 Fuel Filter Clogging 12013
Diagnostic Trouble Code: 7427 Fuel Filter Clogging 22014
Diagnostic Trouble Code: 7428 Inducement (Remaining Urea Level Low) – Warning2015
Diagnostic Trouble Code: 7429 Inducement (Remaining Urea Level Low) – Early2016
Diagnostic Trouble Code: 7430 Inducement (Remaining Urea Level Low) – Final2016
Diagnostic Trouble Code: 7602 ECM Communication Abnormality2017
Diagnostic Trouble Code: 7605 ECM Not-Matched2018
Diagnostic Trouble Code: 7606 EEPROM Abnormality2019
Diagnostic Trouble Code: 7608 Camera Abnormality2019
Diagnostic Trouble Code: 7612 Air Conditioner Communication Abnormality2021
Diagnostic Trouble Code: 7613 Monitor Communication (CAN) Abnormality2022
Diagnostic Trouble Code: 7615 Sub-Controller Communication Abnormality2023
Diagnostic Trouble Code: 7618 DCU Communication Abnormality2025
List of special tools2027
NUMERICAL VALUE CONVERSION TABLE2027
Unit conversion rate2027
Length2027
Area2029
Volume2030
Weight2032
Pressure2033
Torque2034
Temperature2035
A2038
Travel Motor Special Tool2038
210X4/250X42038
Take-up Roller Special Tool2041
210X4/250X42041
Upper Roller Special Tool2042
210X4/250X42042
Lower Roller Special Tool2043
210X4/250X42043
C2044
Swing Motor Special Tool2044
210X4/250X42044
H2047
Engine Oil Filter Special Tool2047
210X4／250X42047
Fuel Filter Special Tool2047
210X4／250X42047
Injector Special Tool2047
210X4／250X42047
Circuit Test Special Tool2048
210X4／250X42048
Valve Guide Special Tool2048
210X4／250X42048
Cylinder Head Special Tool2048
210X4／250X42048
Head Bolt Special Tool2051
210X4／250X42051
Crankshaft Special Tool2051
210X4／250X42051
Valve Spring Special Tool2053
210X4／250X42053
J2054
Remote Control Valve Special Tool2054
210X4/250X42054
R2056
Gas Filling Special Tool2056
210X4／250X42056
V2056
Attachment Special Tool (for Cylinder Assembly)2056
Special Jigs Part Number List2056
Paint Colors2058
Abbreviation2060
001_J_Explanation of Hydraulic Circuit and Operations (standard model)_210X4210X4LFpdf 0
J1285
Explanation of Hydraulic Circuit and Operations (standard model)1287
Travel Circuit1288
Travel Low-speed Circuit1288
Travel High-speed Circuit1290
Straight Travel Circuit (with HBCV)1292
Swing Circuit1294
Swing Speed Limit Control Circuit1294
Swing Relief Cut Control Circuit1296
Swing Brake Circuit1298
Swing Parking Circuit (lever in neutral)1300
Swing Parking Circuit (brake release)1302
Swing Parking Circuit (machine stop)1304
Boom Circuit1306
Boom-up Circuit (independent operation) (with HBCV)1306
Boom-up Spool Stroke Control Circuit (compound boom-up + arm-in) (with HBCV)1308
Boom-down Regenerative Circuit (with HBCV)1310
Boom-down Tilting Prevention Circuit (with HBCV)1312
Boom-down Load Holding Valve Circuit (with HBCV)1314
Arm Circuit1316
Arm-out Circuit (with HBCV)1316
Arm Semi-parallel 1 Circuit1318
Arm Semi-parallel 2 Circuit1320
Arm-in Regenerative Circuit (with HBCV)1322
Arm-in Load Holding Valve Circuit (with HBCV)1324
Bucket Circuit1326
Bucket-open Circuit1326
Bucket-close Regenerative Circuit1328
Bucket-close Spool Stroke Control Circuit1330
Negative Control Circuit1332
Negative Control Circuit1332
Other Circuits1334
Cushion Circuit (arm-out operation)1335
Cushion Circuit (when arm-out operation stopped)1338
Cushion Circuit (arm-out → arm-in operation)1340
Heat Circuit (lever in neutral)1342
Auto Pressure Boost Circuit (arm in)1344
002_J_Explanation of Hydraulic Circuit and Operations (standard model) (LF)_210X4210X4LFpdf 0
J1347
Explanation of Hydraulic Circuit and Operations (standard model) (LF)1349
Travel Circuit1350
Travel Low-speed Circuit1350
Travel High-speed Circuit1352
Straight Travel Circuit (with HBCV)1354
Swing Circuit1356
Swing Speed Limit Control Circuit1356
Swing Relief Cut Control Circuit1358
Swing Brake Circuit1360
Swing Parking Circuit (lever in neutral)1362
Swing Parking Circuit (brake release)1364
Swing Parking Circuit (machine stop)1366
Boom Circuit1368
Boom-up Circuit (independent operation) (with HBCV)1368
Boom-up Spool Stroke Control Circuit (compound boom-up + arm-in) (with HBCV)1370
Boom-down Regenerative Circuit (with HBCV)1372
Boom-down Tilting Prevention Circuit (with HBCV)1374
Boom-down Load Holding Valve Circuit (with HBCV)1376
Arm Circuit1378
Arm-out Circuit (with HBCV)1378
Arm Semi-parallel 1 Circuit1380
Arm Semi-parallel 2 Circuit1382
Arm-in Regenerative Circuit (with HBCV)1384
Arm-in Load Holding Valve Circuit (with HBCV)1386
Bucket Circuit1388
Bucket-open Circuit1388
Bucket-close Regenerative Circuit1390
Bucket-close Spool Stroke Control Circuit1392
Negative Control Circuit1394
Negative Control Circuit1394
Other Circuits1396
Cushion Circuit (arm-out operation)1397
Cushion Circuit (when arm-out operation stopped)1400
Cushion Circuit (arm-out → arm-in operation)1402
Heat Circuit (lever in neutral)1404
Auto Pressure Boost Circuit (arm in)1406
003_J_Explanation of Hydraulic Circuit and Operations (option)_210X4210X4LFpdf 0
J1409
Explanation of Hydraulic Circuit and Operations (option)1411
Option Circuits1412
Single Breaker Circuit (pedal type)1412
Single Breaker Circuit (switch type)1414
Single Breaker Circuit (proportional control type)1416
Single Double-acting Circuit (pedal type) (1 pump hydraulic fork)1418
Single Double-acting Circuit (switch type) (1 pump hydraulic fork)1420
Single Double-acting Circuit (proportional control type) (1 pump hydraulic fork)1422
Multi-purpose Circuit (proportional control type) (breaker)1424
Multi-purpose Circuit (proportional control type) (2 pumps flow crusher)1426
2nd Option Circuit (proportional control type) (hydraulic rotation fork)1428
004_J_Explanation of Hydraulic Circuit and Operations (option) (LF)_210X4210X4LFpdf 0
J1431
Explanation of Hydraulic Circuit and Operations (option) (LF)1433
Option Circuits1434
2nd Option Circuit (proportional control type) (hydraulic rotation fork)1434
006_R_Electrical Parts and Wiring Assembly Diagram_210X4210X4LFpdf 0
R1713
Electrical Parts and Wiring Assembly Diagram1715
Frame1716
Engine and Pump1718
Attachments1720
Battery1722
Cab1724
005_R_Electrical Connector Wiring Diagram_210X4210X4LFpdf 0
R1727
Electrical Connector Wiring Diagram1729
Main Frame1730
Control Valve Harness1732
SCR Harness1734
Light Harness (boom light)1736
Light Harness (cab light)1738
Light Harness (cab light) (with guard)1740
Travel Harness1742
Cab Main Harness1744
Indicator Jumper1746
Console Harness1748
GPS Computer Harness1750
GPS Computer Intermediate Harness1752
Feed Pump Harness1754
Camera Harness (FVM)1756
Camera Harness [500 mm (19685 in)]1758
Camera Harness [700 mm (27559 in)]1760
Camera Intermediate Harness [8000 mm (314961 in)]1762
S.M 3/1/25
