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Link Belt 245X4 Excavator Service Manual WLSM2457-02LX – PDF DOWNLOAD
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Link Belt 245X4 Excavator Service Manual WLSM2457-02LX – PDF DOWNLOAD
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Description
Link Belt 245X4 Excavator Service Manual WLSM2457-02LX – PDF DOWNLOAD
FILE DETAILS:
Link Belt 245X4 Excavator Service Manual WLSM2457-02LX – PDF DOWNLOAD
Language : English
Pages :2081
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Link Belt 245X4 Excavator Service Manual WLSM2457-02LX – 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 245X4 Excavator Service Manual WLSM2457-02LX – 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 20
Bolt and Nut Tightening 20
Removal of Under Cover 21
A LOWER 25
Main Equipment Table 29
Lower Component 29
Travel Unit 29
Take-up roller 29
Upper Roller 29
Lower Roller 29
Recoil Spring 29
Shoe 29
Shoe 30
Center Joint 30
Center Joint (Blade) 31
Main Equipment Structure and Operation Explanation 32
Travel Motor 32
Travel motor operation explanation 32
Explanation of Component Device Operation 32
Double Counter Balance Valve 32
Crossover Relief Valve 37
Automatic 2-speed Switchover Mechanism 38
Parking Brake Function 41
Piston Motor 42
Reduction Gear 43
Port Diagram 45
Travel Motor 45
Center Joint 45
Center Joint (Blade) 46
Basic Functions 47
Travel Speed Selection 47
Travel Alarm 47
Removal and Installation of Track 49
Removal and Installation of Shoe Assembly 50
Removal of Shoe Assembly 50
Installation of Shoe Assembly 51
Removal and Installation of Shoe Plate 54
Removal of Shoe Plate 54
Installation of Shoe Plate 54
Removal and Installation of Roller 55
Removal and Installation of Upper Roller 56
Removal of Upper Roller 56
Installation of Upper Roller 57
Assembly and Disassembly of Upper Roller 58
Configuration Diagram 58
Dimension Diagram 59
Jig Dimension Diagram 59
Disassembly Procedures 60
Assembly Procedures 62
Removal and Installation of Lower Roller 65
Removal of Lower Roller 65
Installation of Lower Roller 66
Assembly and Disassembly of Lower Roller 68
Configuration Diagram 68
Dimension Diagram 69
Jig Dimension Diagram 69
Disassembly Procedures 69
Assembly Procedures 72
Removal and Installation of Drive Sprocket 74
Removal of Drive Sprocket 74
Installation of Drive Sprocket 76
Removal and Installation of Take-up Roller 77
Removal of Take-up Roller 77
Installation of Take-up Roller 78
Assembly and Disassembly of Take-up Roller 79
Configuration Diagram 80
Dimension Diagram 80
Jig Dimension Diagram 81
Disassembly Procedures 81
Assembly Procedures 84
Removal and Installation of Grease Cylinder 87
Removal of Grease Cylinder 87
Installation of Grease Cylinder 88
Assembly and Disassembly of Tension Shock Absorber 89
Configuration Diagram 89
Dimension Diagram 89
Jig Dimension Diagram 90
Disassembly procedures 90
Assembly procedures 90
Removal and Installation of Center Joint 92
Removal of Center Joint 92
Installation of Center Joint 93
Assembly and Disassembly of Center Joint 94
Configuration Diagram 95
Dimension Diagram 96
Dimension Diagram (Blade) 97
Jig Dimension Diagram 98
Disassembly Procedures 98
Assembly Procedures 99
Removal and Installation of Travel Motor 102
Removal of Travel Motor 102
Installation of Travel Motor 104
Assembly and Disassembly of Travel Motor 107
Tools for Assembly and Disassembly 107
Standard Tools 107
Secondary Materials 108
Special Tool (jig) 109
Measurement Device 110
Motor Disassembly Procedures 110
Precautions before Motor Disassembly 110
Tightening Torque 111
Disassembly Procedure 112
Maintenance Standards 120
Motor Parts Maintenance Standards 120
Reduction Gear Parts Maintenance Standards 123
Motor Assembly Procedures 125
Precautions before Motor Assembly 125
Assembly Procedure 125
Motor Installation 139
Inspection 139
Hydraulic Oil and Gear Oil Filling 139
Initial Pre-conditioning Operation 140
Troubleshooting 142
Structural Diagram 150
Internal Structure Diagram 153
Part Table 155
Maintenance Standards 156
Drive sprocket 156
Take-up roller 157
Upper roller 158
Lower Roller 159
Track Shoe (Grouser Shoe) 160
Inspection Gauge 161
For Drive Sprocket 161
For Take-up Roller 161
For Upper Roller 162
For Lower Roller 162
Pressure Measurement and Adjustment Procedures 163
Main Pressure Measurement 163
B Travel Pressure Measurement 163
Drain Volume Measurement Procedures 164
Preparations 164
Travel Motor Drain Volume Measurement 164
Air Bleed Procedure 166
Travel Motor 166
B C SWING UNIT, COUNTERWEIGHT 167
Main Equipment Table 170
Upper Component 170
Swing Unit 170
Main Equipment Structure and Operation Explanation 171
Swing Motor 171
Swing Motor Operation Explanation 171
Hydraulic Motor Section 171
Valve Casing Section 171
Brake Section 172
Relief Valve Operation Explanation (relief valve model: KRD22EK10) 172
Swing Motor Internal Structure Diagram 175
Port Diagram 177
Swing Motor 177
Basic Functions 178
Swing brake 178
Swing Lock 178
Swing Speed Limit 179
Swing Relief Cut 181
Removal and Installation of Swing Unit 183
Removal of Swing Unit 183
Installation of Swing Unit 186
Assembly and Disassembly of Swing Motor 187
Troubleshooting 187
Maintenance Reference Table 189
Jig 190
Disassembling Instructions 192
Assembling Instructions 198
Swing Motor Internal Structure Diagram 207
Assembly and Disassembly of Swing Unit 209
Disassembly 209
Assembly 212
Jig 218
Swing Reduction Gear Internal Structure Diagram 219
Removal and Installation of Counterweight 220
Removal of Counterweight 220
Installation of Counterweight 223
Pressure Measurement and Adjustment Procedures 226
Main Pressure Measurement 226
C Swing Pressure Measurement 226
Drain Volume Measurement Procedures 227
Preparations 227
Swing Motor Drain Volume Measurement 227
Air Bleed Procedure 228
Swing motor 228
Check 228
H ENGINE 229
Main Equipment Table 237
Engine-related 237
Engine 237
Air Cleaner (double element) 237
Radiator 237
SCR 237
Basic Functions 238
Fuel Gauge 238
Coolant Temperature Gauge 239
SCR Gauge 241
Fuel Economy Gauge 244
Neutral start 245
Power-cut Delay 246
Preheat 247
Throttle 248
Throttle Volume Position Detection 249
Idle start 255
Auto Idle 256
One-touch Idle 256
Auto Warm-Up 257
Idle Shutdown 262
Idle up 263
Work Mode Control 263
Engine Emergency Stop 264
SCR RE-GEN 265
Inducement 270
Feed Pump Automatic Stop 274
Coolant Level Decrease 276
Air Filter Clogging 277
Fuel Filter Clogging 278
Battery Charge Abnormality 279
Horsepower Reduction Control (in Uplands) 280
Horsepower Reduction Control (at Engine Failure) 280
Main Data 283
Function, Structure, Operation 285
Function, structure, operation (SCR) 339
SCR Control System Inspection 366
Explanation of SCR Operation 367
Diagnosis for Each Symptom 369
Intermittent conditions of urea selective catalytic reduction system 369
Urea fluid consumption too high 372
Ammonia smell noticeable 372
White crystalline powder visible 373
Diagnosis for Each Symptom 374
Engine Start Problems 374
Engine Stalling 376
Engine Hunting, Rough Idling 378
Excess Amount of White Smoke in Exhaust Gas 379
Excess Amount of Black Smoke in Exhaust Gas 380
Abnormal Noise 380
High Fuel Consumption 381
High Oil Consumption 382
Engine Output Deficiency 383
Functional Inspection 386
Engine Compression Pressure Inspection 386
Fuel System Inspection 387
Lubrication system check 387
Air intake system inspection 388
Exhaust system inspection 388
Inspection of EGR Control System 388
Start System Inspection 389
Glow control system check 389
OBD system check 391
Inspection of the monitor warning light illumination circuit system 391
Inspection of the monitor warning light blinking circuit system 392
Inspection of the starter circuit system 393
Removal and Installation of Engine Assembly 394
Removal of Engine Assembly 394
Installation of Engine Assembly 399
Removal and Installation of Fuel Cooler, Engine Intercooler, Radiator, and Oil Cooler 400
Removal and Installation of Fuel Cooler 400
Removal of Fuel Cooler 400
Installation of Fuel Cooler 400
Removal and Installation of Engine Intercooler 400
Removal of Intercooler 401
Installation of Inter Cooler 402
Inspection of Intercooler 402
Removal and Installation of Radiator 402
Removal of Radiator 403
Installation of Radiator 406
Inspection of Radiator 406
Removal and Installation of Oil Cooler 407
Removal of Oil Cooler 407
Installation of Oil Cooler 408
Removal and Installation of Turbo Charger 409
Removal of Turbo Charger 409
Installation of Turbo Charger 411
Inspection of Turbo Charger 414
Removal and Installation of EGR Valve 416
Removal of EGR Valve 416
Installation of EGR Valve 418
Inspection of EGR Valve 422
Removal and Installation of Top Cover 423
Removal of Top Cover 423
Installation of Top Cover 424
Removal and Installation of SCR 425
Removal of SCR 425
Installation of SCR 426
Removal and installation of Silicon Controlled Rectifier Catalyst 427
Removal of Silicon Controlled Rectifier Catalyst 427
Installation of Silicon Controlled Rectifier Catalyst 428
Disassembly of Silicon Controlled Rectifier Catalyst 431
Assembly of Silicon Controlled Rectifier Catalyst 431
Inspection of Silicon Controlled Rectifier Catalyst 432
Removal and Installation of Cylinder Head Cover 433
Cylinder head cover Removal 433
Installation of Cylinder Head Cover 433
Removal and Installation of Cylinder Head 434
Removal of Cylinder Head 434
Disassembly of Cylinder Head 443
Assembly of Cylinder Head 447
Installation of Cylinder Head 454
Inspection 472
Removal and Installation of Cylinder Block 478
Removal of Cylinder Block 478
Installation of Cylinder Block 494
Inspection 529
Lubrication System 531
Removal and Installation of Oil Pan 531
Removal of Oil Pan 531
Installation of Oil Pan 531
Removal and Installation of Oil Level Switch 531
Removal of Oil Level Switch 531
Installation of Oil Level Switch 532
Removal and Installation of Oil Pump Assembly 532
Removal of Oil Pump Assembly 532
Disassembly of Oil Pump Assembly 545
Assembly of Oil Pump Assembly 545
Installation of Oil Pump Assembly 545
Inspection 569
Engine oil Inspection 570
Removal and Installation of Oil Port Cover 571
Removal of Oil Port Cover 571
Installation of Oil Port Cover 571
Cooling System 573
Removal and Installation of Water Pump Assembly 573
Removal of Water Pump Assembly 573
Installation of Water Pump Assembly 574
Inspection of Water Pump Assembly 578
Removal and Installation of Thermostat 578
Removal of Thermostat 578
Installation of Thermostat 579
Inspection 581
Inspection of Coolant 581
Inspection of Cooling Fan Belt 586
Removal and Installation of Overheat Switch 586
Removal of Overheat Switch 586
Installation of Overheat Switch 586
Induction System 588
Inspection of Air Cleaner Element 588
Exhaust System 589
Removal and installation of Oxidation Catalyst Assembly 589
Removal of Oxidation Catalyst Assembly 589
Installation of Oxidation Catalyst Assembly 590
Aux Emission Control Devices System 593
Removal and installation of Dosing Module 593
Removal of Dosing Module 593
Disassembly of Dosing Module 593
Assembly of Dosing Module 594
Installation of Dosing Module 594
Removal and installation of DEF Supply Module 596
Removal of DEF supply module 596
Disassembly of DEF Supply Module 597
Assembly of DEF Supply Module 597
Installation of DEF Supply Module 598
Removal and installation of Coolant Control Valve 600
Removal of Coolant Control Valve 600
Installation of Coolant Control Valve 601
Removal and installation of DEF Supply Module Filter 603
Removal of DEF Supply Module Filter 603
Installation of DEF Supply Module Filter 603
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 620
Removal and Installation of Urea Solution Tank 621
Removal of Urea Tank 621
Installation of Urea Solution Tank 622
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 744
Assembly of Crankshaft 744
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 781
Removal and installation of Camshaft 788
Removal of Camshaft 788
Installation of Camshaft 789
Disassembly of Camshaft 793
Assembly of Camshaft 794
Inspection of Camshaft 794
Removal and installation of Flywheel 796
Removal of Flywheel 796
Installation of Flywheel 797
Inspection of Flywheel 798
Removal and installation of Crankshaft Front Oil Seal 799
Removal of Crankshaft Front Oil Seal 799
Installation of Crankshaft Front Oil Seal 800
Removal and installation of Crankshaft Rear Oil Seal 803
Removal of Crankshaft Rear Oil Seal 803
Installation of Crankshaft Rear Oil Seal 804
Removal and installation of Rocker Arm Shaft 807
Removal of Rocker Arm Shaft 807
Installation of Rocker Arm Shaft 808
Disassembly of Rocker Arm Shaft 811
Assembly of Rocker Arm Shaft 811
Inspection of Rocker Arm Shaft 812
Removal and installation of Valve Spring 815
Removal of Valve Spring 815
Installation of Valve Spring 817
Inspection of Valve Spring 822
Removal and installation of Valve Stem Oil Seal 824
Removal of Valve Stem Oil Seal 824
Installation of Valve Stem Oil Seal 826
Removal and installation of Front Cover 833
Removal of Front Cover 833
Installation of Front Cover 835
Removal and installation of Intake Throttle Valve 841
Removal of Intake Throttle Valve 841
Installation of Intake Throttle Valve 841
Removal and Installation of Starter Motor 842
Removal of Starter Motor 842
Installation of Starter Motor 842
Disassembly of Starter Motor 843
Assembly of Starter Motor 844
Inspection of Starter Motor 845
Removal and Installation of Alternator 849
Removal of Alternator 849
Installation of Alternator 850
Disassembly of Alternator 850
Assembly of Alternator 851
Inspection of Alternator 852
Removal and Installation of Glow Plug 856
Removal of Glow Plug 856
Installation of Glow Plug 856
Glow plug Inspection 856
Removal and Installation of Suction Control Valve 857
Removal of Suction Control Valve 857
Installation of Suction Control Valve 857
Removal and installation of Fuel Filter 860
Removal of Fuel Filter 860
Installation of Fuel Filter 860
Removal and installation of Relief Valve 863
Removal of Relief Valve 863
Installation of Relief Valve 863
Removal and installation of Fuel Filter Element 866
Removal of Fuel Filter Element 866
Installation of Fuel Filter Element 867
Removal and Installation of Fuel filter pressure 870
Fuel filter pressure sensor Removal 870
Fuel filter pressure sensor Installation 870
Removal and Installation of Engine coolant temperature sensor 871
Engine coolant temperature sensor Removal 871
Engine coolant temperature sensor Installation 871
Engine coolant temperature sensor Inspection 871
Removal and Installation of CKP sensor 872
CKP sensor Removal 872
CKP sensor Installation 872
CKP sensor Inspection 872
Removal and Installation of CMP sensor 873
CMP sensor Removal 873
CMP sensor Installation 873
CMP sensor Inspection 873
Removal and Installation of Oil pressure sensor 874
Oil pressure sensor Removal 874
Oil pressure sensor Installation 874
Oil pressure sensor Inspection 874
Removal and installation of Pressure Sensor/Boost Temperature Sensor 875
Removal of Pressure Sensor/Boost Temperature Sensor 875
Installation of Pressure Sensor/Boost Temperature Sensor 875
Inspection of Pressure Sensor/Boost Temperature Sensor 875
Removal and Installation of IMT sensor 876
Removal of IMT sensor 876
Installation of IMT sensor 876
Removal and installation of Charge Air Cooler Temperature Sensor 1 877
Removal of Charge Air Cooler Temperature Sensor 1 877
Installation of Charge Air Cooler Temperature Sensor 1 877
Inspection of Charge Air Cooler Temperature Sensor 1 877
Sampling Procedure 878
Sampling of Engine Oil 878
Removal and Installation of Exhaust gas temperature sensor 879
Removal of Exhaust gas temperature sensor 879
Installation of Exhaust gas temperature sensor 879
Inspection of Exhaust gas temperature sensor 880
Removal and installation of EGR Gas Temperature Sensor 1 881
Removal of EGR Gas Temperature Sensor 1 881
Installation of EGR Gas Temperature Sensor 1 881
Inspection of EGR Gas Temperature Sensor 1 881
Removal and installation of EGR Gas Temperature Sensor 2 882
Removal of EGR Gas Temperature Sensor 2 882
Installation of EGR Gas Temperature Sensor 2 882
Inspection of EGR Gas Temperature Sensor 2 882
Removal and installation of NOx Sensor 884
Removal of NOx Sensor 884
Installation of NOx Sensor 884
Removal and Installation of Exhaust gas temperature sensor 3 887
Removal of Exhaust gas temperature sensor 3 887
Installation of Exhaust gas temperature sensor 3 887
Removal and installation of DEF Sensor 889
Removal of DEF Sensor 889
Installation of DEF Sensor 889
Engine-related Diagnostic Trouble Code List 890
Engine-side Trouble 899
ECM Trouble 899
DTC P0016 Crankshaft Position – Camshaft Position Correlation Error 899
DTC P0045 Turbocharger Boost Control VNT Error 900
DTC P0087 Fuel Rail/System Pressure – Too Low 902
DTC P0089 Fuel Pressure Regulator Performance 905
DTC P0091 Fuel Pressure Regulator Control Circuit Low 906
DTC P0092 Fuel Pressure Regulator Control Circuit High 907
DTC P0097 Intake Air Temperature (IAT) Sensor 2 Circuit Low Voltage 909
DTC P0098 Intake Air Temperature (IAT) Sensor 2 Circuit High Voltage 910
DTC P0102 Mass Air Flow Sensor Circuit Low Input 911
DTC P0103 Mass Air Flow Sensor Circuit High Input 912
DTC P0112 Intake Air Temperature Sensor Circuit Low 913
DTC P0113 Intake Air Temperature Sensor Circuit High 914
DTC P0117 Engine Coolant Temperature Sensor Circuit Low 916
DTC P0118 Engine Coolant Temperature Sensor Circuit High 917
DTC P0122 Throttle Position Sensor Circuit Low 918
DTC P0123 Throttle Position Sensor Circuit High 919
DTC P0182 Fuel Temperature Sensor Circuit Low 920
DTC P0183 Fuel Temperature Sensor Circuit High 921
DTC P0192 Fuel Rail Pressure Sensor Circuit Low 923
DTC P0193 Fuel Rail Pressure Sensor Circuit High 924
DTC P0201 Injector Circuit Open – Cylinder 1 925
DTC P0202 Injector Circuit Open – Cylinder 2 926
DTC P0203 Injector Circuit Open – Cylinder 3 927
DTC P0204 Injector Circuit Open – Cylinder 4 928
DTC P0217 Engine Coolant Over Temperature Condition 929
DTC P0219 Engine Overspeed Condition 930
DTC P0234 Turbocharger Overboost Condition 931
DTC P0237 Turbo Charger Boost Sensor Circuit Low 933
DTC P0238 Turbo Charger Boost Sensor Circuit High 934
DTC P0335 Crankshaft Position Sensor Circuit 935
DTC P0336 Crankshaft Position Sensor Circuit Range/Performance 936
DTC P0340 Camshaft Position Sensor Circuit 937
DTC P0380 Glow Relay Circuit Error 939
DTC P0401 EGR Flow Insufficient Detected 940
DTC P0404 EGR Control Circuit Range/Performance 941
DTC P0409 EGR Sensor Circuit 942
DTC P041C EGR Cooler Outlet 1 Temp Sensor Circuit Low 944
DTC P041D EGR Cooler Outlet 1 Temp Sensor Circuit High 945
DTC P0427 Catalyst Temperature Sensor Circuit Low Sensor 1 946
DTC P0428 Catalyst Temperature Sensor Circuit High Sensor 1 947
DTC P042C Catalyst Temperature Sensor Circuit Low Sensor 2 949
DTC P042D Catalyst Temperature Sensor Circuit High Sensor 2 950
DTC P0522 Engine Oil Pressure Sensor Circuit Low Input 951
DTC P0523 Engine Oil Pressure Sensor Circuit High Input 952
DTC P0545 EGR Cooler Inlet 1 Temp Sensor Circuit Low 953
DTC P0546 EGR Cooler Inlet 1Temp Sensor Circuit High 954
DTC P0560 12 Volt Circuit Error 956
DTC P0563 System Voltage High 957
DTC P0601 Internal Control Module Memory Check Sum Error 957
DTC P0602 Internal Control Module QR Code Error 958
DTC P0604 Internal Control Module RAM Error 959
DTC P0606 Internal Control Module CPU Error 959
DTC P060A Internal Control Module CPU IC Error 960
DTC P060C Internal Control Module A/D Processing Performance 960
DTC P0615 Starter Relay Circuit Error 961
DTC P0638 Throttle Actuator Control Range/Performance 962
DTC P0685 ECM Power Relay Control Circuit Open 963
DTC P0687 ECM Power Relay Control Circuit High 964
DTC P06A6 Sensor Reference Voltage 1 Circuit 965
DTC P06A7 Sensor Reference Voltage 2 Circuit 966
DTC P06A8 Sensor Reference Voltage 3 Circuit 967
DTC P06A9 Sensor Reference Voltage 4 Circuit 968
DTC P06AF Torque Management System – Forced Engine Shutdown 970
DTC P06D5 Sensor Reference Voltage 5 Circuit 970
DTC P1076 Charge Air Cooler (CAC) Temperature Sensor 1 Circuit Low Voltage 971
DTC P1077 Charge Air Cooler (CAC) Temperature Sensor 1 Circuit High Voltage 972
DTC P1093 Fuel Rail Pressure Too Low 973
DTC P1097 Compressor Outlet Temperature Sensor Circuit High 976
DTC P1098 Compressor Outlet Temperature Sensor Circuit High 977
DTC P1236 Charge Air Cooler Performance Failure 979
DTC P1261 Injector Positive Voltage Control Circuit Group 1 980
DTC P1262 Injector Positive Voltage Control Circuit Group 2 980
DTC P1404 EGR Position Fault 981
DTC P1606 SW-IC Internal failure 982
DTC P160B AD-IC Failure Error 982
DTC P160C AD-IC2 Failure Error 983
DTC P1621 Control Module Long Term Memory Performance 983
DTC P1622 Control Module Long Term Memory Hardware 984
DTC P1669 DPD Lamp Control Circuit 985
DTC P204F SCR System Error (No Inducement) 986
DTC P207F Urea Fluid Concentration Too Low 987
DTC P20C9 SCR System Error 987
DTC P2122 Pedal Position Sensor 1 Circuit Low Input 988
DTC P2123 Pedal Position Sensor 1 Circuit High Input 989
DTC P2127 Pedal Position Sensor 2 Circuit Low Input 990
DTC P2128 Pedal Position Sensor 2 Circuit High Input 991
DTC P2138 Pedal Position Sensor 1 – 2 Voltage Correlation 992
DTC P2146 Fuel Injector Group 1 Supply Voltage Circuit 993
DTC P2149 Fuel Injector Group 2 Supply Voltage Circuit 994
DTC P2228 Barometric Pressure Sensor Circuit Low 996
DTC P2229 Barometric Pressure Sensor Circuit High 996
DTC P2457 Exhaust Gas Recirculation (EGR) Cooling System Performance 997
DTC P2458 Purge time Out Error 998
DTC P2BA7 Urea Fluid Quantity Too Low 998
DTC P2BAA SCR System Error (Inducement, No Purge) 999
DTC P3093 Fuel Rail Pressure Too Low 999
DTC U0001 CAN Bus Error (ISO-CAN)1002
DTC U0073 Control Module Communication Bus Off1004
DTC U0101 Lost Communication With CAN1005
DTC U010E Lost Communications With Dosing Control Module1006
DTC U0110 Lost Communication With VNT System1007
DTC U2106 Lost CAN Communications With Wheel Loader Transmission Control System1008
DTC U0411 Lost CAN Communications With VNT Control Module1009
DCU Trouble1009
Diagnostic Trouble Code_P0607: Control Module Characteristic Abnormality 1009
Diagnostic trouble code_P060B: Control Module A/D Conversion Processing Device Abnormality1010
Diagnostic trouble code_P062F: Control Module EEPROM Abnormality1011
Diagnostic trouble code_P0641: Sensor Reference Voltage Abnormality1012
Diagnostic trouble code_P0658: Actuator Supply Power Feed System Abnormality1013
Diagnostic trouble code_P0659: Actuator Supply Power Feed System Abnormality1015
Diagnostic trouble code_P1462: Urea Solution Quality Sensor Time-Out Abnormality1016
Diagnostic trouble code_P1464: Main Relay Abnormality (Early OPEN Error/Sticking Error of Main Relay)1017
Diagnostic trouble code_P1468: Urea Solution Injection Control Module (DCM) High Temperature Abnormality1018
Diagnostic trouble code_P1491: Urea Solution High Pressure Abnormality1019
Diagnostic trouble code_P1493: Urea Solution Injection Control Module (DCM) Screwdriver High Temperature Abnormality1020
Diagnostic trouble code_P149C: Urea Solution Reducing Pressure Abnormality1021
DTC P149D Urea Fluid Tank Overtemperature1022
Diagnostic trouble code_P2000: Cleaning Ratio Abnormality1024
Diagnostic trouble code_P203B: Urea Solution Tank Level Sensor1025
Diagnostic trouble code_P203C: Urea Solution Tank Level Sensor Low Voltage Potential1027
Diagnostic trouble code_P203D: Urea Solution Tank Level Sensor High Voltage Potential1028
Diagnostic trouble code_P2048: Urea Solution Injector System Low Voltage Potential1029
Diagnostic trouble code_P2049: Urea Solution Injector System High Voltage Potential1030
Diagnostic trouble code_P204B: Urea Solution Pressure Sensor System Characteristic Abnormality1031
Diagnostic trouble code_P204C: Urea Solution Pressure Sensor System Low Voltage Potential1032
Diagnostic trouble code_P204D: Urea Solution Pressure Sensor System High Voltage Potential1033
Diagnostic trouble code_P205B: Urea Solution Tank Temperature Sensor Characteristic Abnormality1035
Diagnostic trouble code_P205C: Urea Solution Tank Temperature Sensor Low Voltage Potential1036
Diagnostic trouble code_P205D: Urea solution tank temperature sensor high voltage potential1037
DTC P206A Urea Fluid Quality Sensor Circuit1038
Diagnostic trouble code_P206B: Urea Sensor High Temperature Abnormality1039
DTC P206C Urea Fluid Quality Sensor Circuit Low Voltage1040
DTC P206D Urea Fluid Quality Sensor Circuit High Voltage1041
Diagnostic trouble code_P207F: Urea Solution Concentration Low1041
Diagnostic trouble code_P208A: Urea Solution Pump Control System1042
Diagnostic trouble code_P208B: Urea Solution Pump Characteristic Abnormality1043
Diagnostic trouble code_P208C: Urea Solution Pump Control System Low Voltage Potential1045
Diagnostic trouble code_P208D: Urea Solution Pump Control System High Voltage Potential1046
Diagnostic trouble code_P208E: Urea Solution Injector Attachment1047
Diagnostic trouble code_P20A0: Urea Solution Reverting Valve System Disconnection1048
Diagnostic trouble code_P20A2: Urea Solution Reverting Valve System Low Voltage Potential1049
Diagnostic trouble code_P20A3: Urea Solution Reverting Valve System High Voltage Potential1050
Diagnostic trouble code_P20AC: Urea Solution Pump Temperature Sensor Characteristic Abnormality1051
DTC P20AD Urea Fluid Pump Module Temperature Sensor Performance1053
DTC P20B1 Urea Fluid Tank Heater Coolant Control Valve Circuit Open1054
Diagnostic trouble code_P20B3: Urea Solution Tank Heater Coolant Control Valve System Low Voltage Potential1055
Diagnostic trouble code_P20B4: Urea solution tank heater coolant control valve system high voltage potential1056
Diagnostic trouble code_P20E8: Urea Solution Low Pressure Abnormality1057
Diagnostic trouble code_P20E9: Urea Solution High Pressure Abnormality1059
Diagnostic trouble code_P20EA: Urea Solution Reducing Pressure Abnormality1060
Diagnostic trouble code_P20FE: Urea Solution Build-Up Abnormality1061
Diagnostic trouble code_P2201: NOx Sensor Upstream Function1063
Diagnostic trouble code_P2206: Ft NOx Sensor Disconnection1064
Diagnostic trouble code_P2207: Ft NOx Sensor Short-Circuit1065
Diagnostic trouble code_P2210: Rr NOx Sensor Disconnection1065
Diagnostic trouble code_P2211: Rr NOx Sensor Short-Circuit1066
Diagnostic trouble code_P242B: Exhaust Gas Temperature (EGT) Sensor 3 System Function1066
Diagnostic trouble code_P242C: Exhaust Gas Temperature (EGT) Sensor 3 System Low Voltage Potential1067
Diagnostic trouble code_P242D: Exhaust Gas Temperature (EGT) Sensor 3 System High Voltage Potential1068
DTC U0002 CAN Bus Off1069
DTC U0100 Lost Communication With ECM1070
Diagnostic trouble code_U029D: CAN Communication Error Between DCU-Ft NOx Sensors1071
Diagnostic trouble code_U029E: CAN Communication Error Between DCU-Rr NOx Sensors1074
Data Reference Values1076
Idle Speed1076
Two Pump Relief1077
J HYDRAULIC EQUIPMENT (PUMP, OPERATION SYSTEM VALVE)1079
Main Equipment Table1085
Hydraulic Device1085
Hydraulic Pump1085
Hydraulic Pump1085
Control-related1086
Control valve1086
Control valve1086
Solenoid Valve (5 Stack)1087
Remote Control Valve for Left/Right Operations1087
Remote Control Valve for Travel Operation1087
Valve for Blade Operation1087
Remote Control Valve Characteristic Diagram1087
Operation Remote Control Valve Control Diagram1088
Travel Remote Control Valve Control Diagram1089
Blade Remote Control Valve Control Diagram1089
Reducing Valve (6 Stack Proportional Valve)1089
Cushion Valve (heat circuit, with shuttle valve)1090
Selector Valve1090
Basic Functions1091
Oil temperature gauge1091
Static Horsepower Control1092
Overload Warning (Function for Europe Only)1093
Pressure Boost Control1093
Stroke Control1095
Boom Down Energy Save1097
Pump Horsepower Boost Control1098
Arm 1 Semi-parallel Control1098
Arm 2 Semi-parallel Control1099
Hot Shutdown Warning1100
Gate Lock1101
Breaker Mode1102
Crusher Mode1102
Quick coupler1103
Hydraulic Fluid Filter Clogging1104
Solenoid Sticking Prevention1105
Port Diagram1106
Hydraulic Pump (Standard Model)1106
Hydraulic Pump (Blade)1107
Control Valve1108
Relief Valve1108
Relief Valve (Blade)1111
5 stack solenoid valve1114
2 stack solenoid valve1115
Remote Control Valves (upper, travel)1115
Remote Control Valves (left-right)1115
Remote control valve (travel)1116
Remote Control Valve (blade)1116
Cushion Valve1117
2-way Selector Valve1118
Direction Valve1119
6 Stack Proportional Valve1120
Relief Valve (electromagnetic proportional)1122
Manifold Under Cab1123
Manifold (accumulator section)1124
Hydraulic Tank1125
Hydraulic Pump1126
Structure and Operation Explanation1126
Hydraulic Pump Internal Structure Diagram1127
Overall View1127
Drive Shaft Front Side1128
Drive Shaft Rear Side1129
Development Diagram1130
Component Table1133
Regulator1134
Regulator Operation Explanation1134
Regulator Operation Explanation Diagram1137
Internal Configuration Diagram of Regulator1140
Development Diagram of Regulator1142
Component Table1143
Operation Outline of Electronically-Controlled Pump1145
Control Valve1148
Basic Configuration1148
Operation1148
Operation of Main Unit1148
Activation of Relief Valve1168
5 Stack Solenoid Valve Operation Explanation1173
External Shape Diagram and Components1173
operation explanation1173
Upper Pilot Valve (remote control valve)1174
Structure1174
Function1174
Operation1174
Structural Diagram1178
Travel Pilot Valve (remote control valve)1179
Operation1179
Pressure Reducing Valve Section1179
Damping Mechanism in Operation Section1180
Structural Diagram1183
Cushion Valve 1185
structure1185
operation explanation1185
Selector Valve (2-way)1190
Structure1190
Operation Explanation1191
Development Diagram1192
Direction Valve (3-direction) 1193
Structure1193
Operation Explanation1194
6 Stack Proportional Valve (Pilot)1196
structure1196
operation principle1197
Electromagnetic Relief Valve1198
Structure1198
Operation Explanation1199
Operation of Check Valve1199
Operation of Electromagnetic Relief Valve1200
Removal and Installation of Hydraulic Reservoir1202
Removal of Hydraulic Reservoir1202
Installation of Hydraulic Oil Tank1205
Removal and Installation of Hydraulic Pump1206
Removal of Hydraulic Pump1206
Installation of Hydraulic Pump1207
Removal and Installation of Control Valve1208
Removal of Control Valve1208
Installation of Control Valve1210
Removal and Installation of Travel Remote Control Valve1211
Removal of Travel Remote Control Valve1211
Installation of Travel Remote Control Valve1212
Removal and Installation of Operation Remote Control Valve1215
Removal of Operation Remote Control Valve (left side)1215
Installation of Operation Remote Control Valve (left side)1217
Removal of Operation Remote Control Valve (right side)1218
Installation of Operation Remote Control Valve (right side)1220
Removal and Installation of 5 Stack Solenoid1223
Removal of 5 Stack Solenoid1223
Installation of 5 Stack Solenoid Valve1224
Removal and Installation of Cushion Valve1225
Removal of Cushion Valve1225
Installation of Cushion Valve1226
Procedures for Assembly and Disassembly of Hydraulic Pump Main Unit1227
Tools1227
Disassembly Procedure1227
Assembly Procedures1229
Development Diagram1233
Component Table1236
Pump Main Unit Maintenance Standards1237
Replacement Standard of Wear Component1237
Correction Standard of Cylinder, Valve Plate, and Sash Plate (Shoe Plate)1237
Tightening torque1238
Overall View1238
Drive Shaft Front Side1239
Drive Shaft Rear Side1240
Development Diagram1241
Component Table1244
Regulator Maintenance Standards1245
Regulator Adjustment1245
Appendix Table and Drawings1246
Regulator Assembly and Disassembly Procedures1250
Tools1250
Preparations for Disassembly1250
Disassembly Procedure1250
Assembly Procedures1252
Internal Configuration Diagram of Regulator1255
Development Diagram of Regulator1257
Component Table1258
Assembly and Disassembly of Control Valve1260
Disassembly1260
Caution for Disassembly1260
Disassembly Procedure1260
Removal of Long Cap and Pulling Out of Main Spool1260
Disassembly of Arm 1, 2 Parallel-Tandem Spool, Neutral Cut Spool, Arm Regeneration Release Spool Section1261
Disassembly of Load Check Valve Section1261
Disassembly of Antidrift Valve Section (Sub Component in Assembly is Expressed by (Min Number – Sub Number))1262
Disassembly of Relief Valve1262
Disassembly of Option Section1262
Disassembly of Add-On Section1262
Disassembly of Valve Housing Coalescence Bolt1263
Cleaning1263
Inspection1263
assembly1263
Caution for Assembly1263
Caution for Handling O-ring1263
Caution for Handling Spool1263
Method to Apply Adhesive Agent (Male and Female Thread Section of Components Requiring Bonding)1263
Assembly Procedure of Sub-Assembly1264
Assembly of Spool Assembly (Main Spool)1264
Assembly of Arm 1, 2 Parallel-Tandem Spool, Neutral Cut Spool, Arm Regeneration Release Spool Assembly1264
Assembly of Antidrift Valve Assembly1265
Assembly Procedure of Control Valve Main Unit1265
Assembly of Relief Valve1265
Assembly of Load Check Valve1265
Assembly of Antidrift Valve1266
Assembly of Option Section1266
Assembly of Arm 1 Parallel-Tandem Spool1266
Assembly of Arm 2 Parallel-Tandem Spool, Neutral Cut Spool, Arm Regeneration Release Spool1266
Assembly of Main Spool1266
Assembly of Add-On Section1267
Assembly of Other Plugs1267
Internal Structural Diagram1268
Part List1274
Relief Valve1275
Assembly and Disassembly Procedure of Main Relief Valve1275
Assembly and Disassembly Procedures of Overload Relief1276
Assembly and Disassembly Procedure of Low-Pressure Relief Valve1277
Assembly and Disassembly Procedure of Main Relief Valve for Add-On1277
Adjustment of Relief Valve1278
Installation1279
Operation1279
Malfunction and Countermeasure1279
Procedures for Assembly and Disassembly of Operation Remote Control Valve1281
Maintenance Procedures1281
Required Tools and Tightening Torque1281
Maintenance Standards1281
Disassembly Procedures1282
Assembly Procedures1284
Causes of Trouble and Countermeasures1288
Procedures for Assembly and Disassembly of Travel Remote Control Valve1292
Maintenance Procedures1292
Disassembly Procedures1293
Assembly Procedures1297
Causes of Trouble and Countermeasures and Cross-section Diagram1302
Assembly and Disassembly of Cushion Valve1305
Disassembly Procedures1305
Reverse Operation Spool Section1305
Check Plunger Section with Throttle1305
Shuttle Valve Section1305
Assembly Procedures1305
Reverse Operation Spool Section1306
Check Plunger Section with Throttle1306
Shuttle Valve Section1306
Written Materials1307
Procedures for Assembly and Disassembly of 6 Stack Proportional Valve (Pilot)1309
Development Diagram1309
Assembly and disassembly procedures1310
Precautions1310
Replacement of Proportional Solenoid1310
Disassembly1310
Assembly1310
Replacement of Sleeve and Spool1311
Disassembly1311
Assembly1312
Replacement of Poppet (Check Valve for Normally Open)1313
Disassembly1313
assembly1313
Maintenance Standards1314
Troubleshooting1314
Pressure Measurement and Adjustment Procedures1315
Procedures for Pressure Measurement from the Monitor Display1315
Monitor and Switch Panel1315
Pressure Measurement Method1315
Operating Method1315
PROCEDURES FOR MEASURING HYDRAULIC OIL TEMPERATURE FROM THE MONITOR DISPLAY1315
Hydraulic Oil Temperature Measurement Method1315
Operating Method1316
Procedures for Pressure Measurement by Installing Pressure Gauge1317
Preparations1317
Items to prepare1317
Pressure Measurement Port1318
Control Valve1320
Location of Relief Valves1320
Pressure Measurement Preparations1321
Pressure Measurement1323
Main Pressure Measurement1323
A Attachment Pressure Measurement1323
Boom-down Pressure Measurement1325
D Option Line Pressure Measurement1325
Pilot Pressure Measurement1325
Pressure Gauge Installation1325
Negative Control Pressure Measurement1326
Pressure Gauge Installation1326
Pressure Adjustment1326
Main Pressure Adjustment1326
Pressure Measurement and Adjustment Preparations1326
Main Relief Pressure Adjustment1328
Overload Relief Pressure Adjustment1328
Adjustment of Swing Relief Pressure1330
Pilot Pressure Adjustment1331
Hydraulic Pump Flow Measurement Procedures1332
Preparations1332
Items to Prepare1332
Work Preparations1333
Flow Measurement1334
Air Bleed Procedure1336
Hydraulic Pump1336
Sampling Procedure1337
Sampling of Hydraulic Fluid1337
Hydraulic Equipment Layout1338
Overall View1339
Pump Chamber Hydraulic Equipment Layout1340
Swing Body Center Section Hydraulic Equipment Layout1341
Housing Left Side Hydraulic Equipment Layout1342
Layout of Hydraulic Equipment in Cab1343
J HYDRAULIC EQUIPMENT-OVERSIZED PAGESpdf1345
001_J_Explanation of Hydraulic Circuit and Operations (standard model)_245X41345
J1345
Explanation of Hydraulic Circuit and Operations (standard model)1348
Travel Circuit1349
Travel Low-speed Circuit1349
Travel High-speed Circuit1351
Straight Travel Circuit (with HBCV)1353
Swing Circuit1355
Swing Speed Limit Control Circuit1355
Swing Relief Cut Control Circuit1357
Swing Brake Circuit1359
Swing Parking Circuit (lever in neutral)1361
Swing Parking Circuit (brake release)1363
Swing Parking Circuit (machine stop)1365
Boom Circuit1367
Boom-up Circuit (for independent operation) (with HBCV)1367
Boom-up Spool Stroke Control Circuit (for compound operation) (boom-up + arm-in operations) (with HBCV)1369
Boom-down Regenerative Circuit (arm-out + boom-down operations) (with HBCV)1371
Boom-down Load Holding Valve Circuit (with HBCV)1373
Arm Circuit1375
Arm-out Circuit (with HBCV)1375
Arm Semi-parallel 1 Circuit (for independent operation) (with HBCV)1377
Arm Semi-parallel 1 Circuit (for compound operation) (ex: arm-out + right swing operations) (with HBCV)1379
Arm Semi-parallel 1 Circuit (for compound operation) (ex: arm-in + boom-up operations) (with HBCV)1381
Arm Semi-parallel 2 Circuit (for independent operation) (with HBCV)1383
Arm Semi-parallel 2 Circuit (for compound operation) (ex: arm-in + boom-up operations) (with HBCV)1385
Arm-in Regenerative Circuit (with HBCV)1387
Arm-in Load Holding Valve Circuit (with HBCV)1389
Bucket Circuit1391
Bucket-open Circuit1391
Bucket-close Regenerative Circuit1393
Bucket-close Spool Stroke Control Circuit1395
Negative Control Circuit1397
Negative Control Circuit1397
Other Circuits1399
Cushion Circuit (arm-out operation)1401
Cushion Circuit (when stopping arm-out operation)1403
Cushion Circuit (arm-out → arm-in operation)1405
Heat Circuit (lever in neutral)1407
Auto Pressure Boost Circuit (arm in)1409
002_J_Explanation of Hydraulic Circuit and Operations (option)_245X41412
J1412
Explanation of Hydraulic Circuit and Operations (option)1414
Option Circuits1415
Single Breaker Circuit (pedal type)1415
Single Double-acting Circuit (proportional control type) (1 pump hydraulic fork)1417
Multi-purpose Circuit (proportional control type) (breaker)1419
Multi-purpose Circuit (proportional control type) (2 pumps flow crusher)1421
Multi-purpose Circuit (proportional control type) (electromagnetic relief) (breaker)1423
Multi-purpose Circuit (proportional control type) (electromagnetic relief) (crusher)1425
2nd Option Circuit (proportional control type) (hydraulic rotation fork)1427
N CAB1430
Removal and Installation of Operator’s Seat1433
Removal of Operator’s Seat1433
Installation of Operator’s Seat1433
Removal and Installation of Cab Assembly1434
Removal of Cab Assembly1434
Installation of Cab Assembly1437
Removal and Installation of Wiper1438
Removal of Wiper1438
Installation of wiper1438
Removal and Installation of Cab Windshield1439
Removal of Cab Windshield1439
Installation of Cab Front Glass1439
Window Lock Adjustment Procedure1440
Window Lock (front side)1440
Window Lock (rear side)1440
Removal and Installation of Housing Guardrail1441
Removal of Housing Guardrail1441
Installation of Housing Guardrail1441
Tightening torque1442
R ELECTRICAL PARTS1444
Basic Functions1448
Monitor Control1448
Monitor Display Dimming1448
Diagnostic Trouble Code Indicator1449
Clock1449
Basic Operation1450
Battery save1450
Accessories1452
Working Light1452
LED Light1453
Room Lamp1453
Radio Mute1455
Wiper and Washer1456
Safety1458
Horn1458
Back/Side View Monitor1459
Precautions for Camera Installation1460
Maintenance1460
Anti-theft1460
Manual Lock1461
Service Support Screen Lock1461
Customer-specific System Information Screen Lock1461
Maintenance Information Screen Lock1462
Option Line Setting Screen Lock1462
Setting1462
Clock Adjustment1462
Screen Brightness Setting1463
Battery disconnect switch1464
Explanation of Controller1465
Service Support1468
Screen Operations1468
Screen Display List1468
Service Monitor Structure1469
CHECK Screen List1470
MACHINE STATUS1471
HYDRAULIC STATUS1478
ENGINE STATUS1485
FAULT HISTORY1490
WORK HISTORY1490
HYDRAULIC HISTORY1498
ENGINE HISTORY1511
DEVICE TEST1534
ECM/DCU Memory Clear1534
SCR RE-GEN1535
Urea Line Leak Test1536
CCV Operation Test1536
Dosing Test1537
Reverting Valve Operation Test1538
Common Rail Pressure Test1539
Idle Speed Test / Injector Test1540
EGR Valve Control Test1542
VG Turbo Control Test1543
Intake Throttle Control Test1544
CONTROL UNIT Screen List1545
MCM-MAIN1545
MCM-SUB1549
COMMU TERMINAL1550
SETUP Screen List1552
MACHINE SELECT1552
DIMENSIONS1557
PARAMETERS1560
ENGINE INFORMATION1564
ENGINE INFORMATION1565
Data Confirmation1565
Data Transfer (Copy)1565
QR (INJECTOR) CODE1566
Injector number1566
Screen Layout1567
Data Source Selection1567
Manual Input1567
CAMERA1569
PASSWORD1572
CALIBRATE Screen List1574
THROTTLE VOLUME1575
OPTLINE RELIEF1576
PUMP FLOW1578
RESET Screen List1580
Connection Connector Pin Layout1583
Main Controller1583
Monitor1584
Sequence Circuit Diagram1585
Code table1585
Overall1588
Block diagram1591
Main controller1591
DCU1592
ECM1593
Monitor1594
Air conditioner1594
Gate Lock1595
Option1595
Others1596
Electrical Symbol List1596
Electrical Equipment Layout Diagram1598
Main Unit Left-side Layout Diagram1599
Engine Section Layout Diagram1600
Main Unit Right Side Layout Diagram1602
Cab Layout Diagram 11604
Cab Layout Diagram 21605
Layout Around Operator Seat1608
Stand Alone Parts Diagram1609
Removal and Installation of Wiper Controller1628
Removal of Wiper Controller1628
Installation of wiper controller1628
Removal and Installation of Wiper Motor1629
Removal of Wiper Motor1629
Installation of wiper motor1630
Removal and Installation of ECM1631
Removal of ECM1631
Installation of ECM1631
Removal and Installation of Main Controller1632
Main controller Removal1632
Installation of Main Controller1632
Removal and Installation of DCU1633
Removal of DCU1633
Installation of DCU1633
Removal and Installation of Monitor1634
Removal of Monitor1634
Installation of Monitor1635
Removal and Installation of Rear View Camera 1636
Removal of Rear View Camera1636
Installation of Rear View Camera1636
Removal and Installation of Side Camera (right)1637
Removal of Side Camera (Right)1637
Installation of Side Camera (Right)1637
Removal and Installation of Side Camera (Left)1638
Removal of Side Camera (Left)1638
Installation of Side Camera (Left)1638
Removal and Installation of WAVES Controller1639
Removal of WAVES Controller1639
Installation of WAVES Controller1639
How to Set WAVES1640
Air Conditioner Overall Diagram1644
Frame1644
Cab1647
Equipment Layout Diagram1650
Circuit Diagram1652
Air Conditioner Circuit Diagram1652
Explanation of Functions1654
Explanation of Control1654
Air Mix Motor Actuator Control1655
Blow Mode Motor Actuator Control1655
Refresh/Recirculate Switch Motor Actuator Control1657
Blower Amp Control1657
Compressor Clutch Control1660
COOLMAX Control and HOTMAX Control1661
Abnormality Detection and Control after Abnormality Detected1661
Monitor Mode1664
Door Switch Control1666
Actuator Inspection1667
Air Mix Motor Actuator Inspection1667
Refresh/Recirculate Switch Motor Actuator Inspection1668
Mode Motor Actuator Inspection1669
Self-diagnosis Function with Panel Display1671
Abnormality Display and Self-check Procedures1671
Abnormality Display Position1671
Explanation of Abnormality Display1671
Motor Actuator Abnormality1671
Sensor Abnormality1672
Explanation of Monitor Mode1672
Monitor Mode Display Position1672
Monitor Mode Display Operating Method1673
Display Contents in Monitor Mode1674
Air Conditioner Troubleshooting1680
Part Function and Good/Poor Judgment1685
Control Panel1685
Blower Amp1685
Relay1686
Air Mix Actuator1687
Refresh/Recirculate Actuator1688
Mode switch actuator1688
Evaporator Sensor1689
Dual Pressure Switch1689
Solar Radiation Sensor1690
Inside Air Sensor1691
Assembly and Disassembly of Unit1692
Removal of Blower Unit1692
Replacement of Blower Motor1692
Replacement of Blower Amp1693
Removal of Heater Core1693
Removal of Switchover BOX1693
Replacement of Evaporator and Expansion Valve1694
Installation of Evaporator Sensor1695
Replacement of Motor Actuator1695
Removal and Installation of Compressor1697
Removal of Compressor1697
Installation of Compressor1697
Removal and Installation of Condenser1698
Removal of Condenser1698
Installation of Condenser1699
Removal and Installation of Receiver Dryer1700
Removal of Receiver Dryer1700
Installation of Receiver Dryer1700
Work Precautions1702
Work Procedures1702
Air Conditioner Refrigerant Filling is Divided into the “Vacuum Operation” and “Gas Filling Operation”1702
Operation Chart1703
Tools1703
Filling Procedures1705
Charging Hose Connection Position1705
Connecting Gauge Manifold1705
Vacuuming1706
Gas Filling Operation, High-pressure Side1707
Gas Filling Work, Low Pressure Side1707
R ELECTRICAL PARTS-OVERSIZED PAGESpdf1710
004_R_Electrical Parts and Wiring Assembly Diagram_245X41710
R1710
Electrical Parts and Wiring Assembly Diagram1712
Frame (main unit right side, main unit center section)1713
Frame (main unit left side)1715
Engine and Pump1717
Battery1719
Cab 11721
Cab 21723
003_R_Electrical Connector Wiring Diagram_245X41726
R1726
Electrical Connector Wiring Diagram1728
Frame Main Harness1729
Control Valve Harness1731
SCR Harness1733
Light Harness (boom light)1735
Light Harness (cab light)1737
Cab Light Harness (with guard)1739
1-pedal Travel Harness1741
Cab Main Harness1743
Indicator Jumper1745
Indicator Jumper1747
Jumper Harness1749
Console Harness1751
GPS Harness1753
GPS Harness1755
Computer S Harness1757
Feed Pump Harness1759
WAVES Harness1761
Camera Harness [700 mm (27559 in)]1763
Camera Harness [1200 mm (47244 in)]1765
Camera Intermediate Harness [6500 mm (255906 in)]1767
Camera Harness1769
Quick Coupler Harness1771
Option Harness (pedal)1773
Option Harness (proportional control)1775
2nd Option Harness (proportional control)1777
V ATTACHMENTS1780
Main Equipment Table1784
Backhoe Attachment1784
Cylinder1784
Maintenance Standards1785
Attachment (Backhoe)1785
1 Boom and Swing Frame Installation Section1785
2 Boom Cylinder and Swing Frame Installation Section1786
3 Boom and Boom Cylinder Installation Section1786
4 Boom and Arm Cylinder Installation Section1787
5 Boom and Arm Installation Section1787
6 Arm and Arm Cylinder Installation Section1788
7 Arm and Bucket Cylinder Installation Section1789
8 Arm and Arm Link Installation Section1789
9 Bucket and Bucket Link Installation Section1790
10 Bucket Link and Bucket Cylinder Installation Section1790
11 Bucket and Arm Installation Section1791
Dozer Blade1793
1 Blade Cylinder Installation Section1793
2 Lower Frame and Blade Cylinder Installation Section1794
3 Lower Frame and Blade Installation Section1794
Removal and Installation of Bucket Cylinder1795
Removal of Bucket Cylinder1795
Installation of Bucket Cylinder1797
Removal and Installation of Arm Cylinder1798
Removal of Arm Cylinder1798
Installation of Arm Cylinder1800
Removal and Installation of Boom Cylinder1802
Removal of Boom Cylinder1802
Installation of Boom Cylinder1804
Removal and Installation of Blade Cylinder1807
Removal of Blade Cylinder1807
Installation of Blade Cylinder1808
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder1810
Specifications and Structure Diagram (including the assembly diagram and parts table)1810
Basic Functions1810
Function of Each Location1810
Cylinder Head Assembly (made by KYB)1810
Piston Assembly (made by KYB)1811
Pipe Assembly (made by KYB)1813
Handling Precautions1813
Precautions for Installing the Cylinder on the Machine Body1813
Usage Cautions1814
Maintenance and Inspection Cautions1814
Maintenance Inspection and Service1816
Trouble Diagnostics1817
Storage Standards1822
Storing Parts Individually (In principle, store indoors)1822
When Mounted on Vehicle Body1822
Recommended Anti-rust Oil1822
Assembly and Disassembly Procedures1823
Preparations ····· Prepare the Following before Starting Disassembly1823
General Work Precautions1823
Maintenance Standards1823
Inspection after Assembly1823
Required Tool1824
General Tool1824
Special Jig (made by KYB)1825
Special Jig Parts Number List (made by KYB)1825
Disassembly Procedures (made by KYB)1826
Assembly Procedures (made by KYB)1829
Test Operation1834
Usage Limits1835
Structural Diagram (made by KYB)1836
Boom Cylinder1836
Arm Cylinder1838
Bucket Cylinder1840
Blade Cylinder1842
HBCV1844
structure1844
Function1844
operation explanation1844
Port Diagram1859
HBCV1859
Air Bleed Procedure1860
HBCV1860
Boom Cylinder HBCV1860
Arm Cylinder HBCV1861
Removal and Installation of HBCV1862
Removal and Installation of Arm HBCV1863
Removal of Arm HBCV1863
Installation of arm HBCV1863
Removal and Installation of Boom HBCV1864
Removal of Boom HBCV1864
Installation of Boom HBCV1865
Removal and Installation of Bucket1866
Removal of Bucket1866
Installation of Bucket1866
Removal and Installation of Bucket Link1868
Removal of Bucket Link1868
Installation of Bucket Link1868
Removal and Installation of Arm1870
Removal of Arm1870
Installation of Arm1871
Removal and Installation of Boom1872
Removal of Boom1872
Installation of Boom1874
Removal and Installation of Blade1878
Removal of Blade1878
Installation of Blade1879
Z OTHER1880
Change from Type 61885
Overall Layout1885
Lower1885
Engine1885
Hydraulic-related Data1888
Hydraulic Control1889
Cab, House1890
Electrical Data1890
Electric Control1891
Specifications1892
245X41893
ENGINE1893
HYDRAULIC SYSTEM1893
HYDRAULIC CONTROLS1894
ELECTRICAL SYSTEM1894
OPERATOR ENVIRONMENT1895
UNDERCARRIAGE1895
MASS1896
DIGGING FORCE (with 09 m3 Sumitomo Bucket) (ISO 6015)1896
DIMENSIONS1896
WORKING RANGES1897
SYSTEM FLUID CAPACITIES AND SPECIFICATIONS1897
245X4 (BB)1898
ENGINE1898
HYDRAULIC SYSTEM1898
HYDRAULIC CONTROLS1899
ELECTRICAL SYSTEM1899
OPERATOR ENVIRONMENT1900
UNDERCARRIAGE1901
DOZER BLADE1901
MASS1901
DIGGING FORCE (with 09 m3 Sumitomo Bucket) (ISO 6015)1901
DIMENSIONS1901
WORKING RANGES1902
SYSTEM FLUID CAPACITIES AND SPECIFICATIONS1902
Arm Dimension1903
Standard Arm [294 m (965 ft)]1903
Short Arm [240 m (787 ft)]1905
Main Unit Weight1907
Divided Weight (standard specifications)1907
Divided Weight (Blade Specifications)1908
Stand Alone Part Weight (standard specifications)1909
Stand Alone Part Weight (Blade Specifications)1909
Shoe Weight (per Side)1909
Shoe Weight (per Side) (Blade Specifications)1909
Arm Weight1910
Bolt Size and Torque Table1911
Special Torque Setting1911
Overall View1916
245X4 (Grouser Shoe)1916
Standard Arm [294 m (96457 ft)]1916
Short Arm [240 m (78740 ft)]1917
245X4 (Link Chain)1919
Standard Arm [294 m (96457 ft)]1919
Short Arm [240 m (78740 ft)]1921
245X4 (BB) (Grouser Shoe)1923
Standard Arm [294 m (96457 ft)]1923
Short Arm [240 m (78740 ft)]1924
245X4 (BB) (Link Chain)1925
Standard Arm [294 m (96457 ft)]1925
Short Arm [240 m (78740 ft)]1926
WORK RANGE DIAGRAM1927
245X41927
Standard Arm [294 m (96457 ft)]1927
Short Arm [240 m (78740 ft)]1929
245X4 (BB)1931
Standard Arm [294 m (96457 ft)]1931
Short Arm [240 m (78740 ft)]1933
New Machine Performance Judgment Table1935
Table of Standards1935
Measurement Method1938
Engine speed1938
Pressure at Each Part1938
Pump Command Displacement1938
Cylinder Down Amount1938
Attachment Speed1939
Swing Speed1939
Swing (180°) Brake Angle1939
Travel Speed1940
Off Travel Amount1940
Travel Sprocket Speed1940
Shoe Tension Amount1941
Swing Ball Race Bearing Movement Amount and Bucket Tip Movement Amount1941
FLUIDS AND LUBRICANTS1943
HYDRAULIC FLUID1943
Engine Oil1943
Fuel1943
Conditions applicable to diesel fuel1943
Recommended conditions applicable to diesel fuels1943
Main-Unit-related Diagnostic Trouble Code List1944
Main Unit-side Trouble1947
Diagnostic Trouble Code: 7000 Pressure Sensor P1 Abnormality1947
Diagnostic Trouble Code: 7001 Pressure Sensor P2 Abnormality1949
Diagnostic Trouble Code: 7002 Pressure Sensor N1 Abnormality1951
Diagnostic Trouble Code: 7003 Pressure Sensor N2 Abnormality1953
Diagnostic Trouble Code: 7004 Pressure sensor boom cylinder bottom abnormality1955
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 abnormality1961
Diagnostic Trouble Code: 7040 Level sensor fuel abnormality1963
Diagnostic Trouble Code: 7041 Temperature sensor hydraulic oil abnormality1965
Diagnostic Trouble Code: 7065 Pressure sensor boom-up pilot abnormality1967
Diagnostic Trouble Code: 7067 Pressure sensor bucket-close pilot abnormality1969
Diagnostic Trouble Code: 7068 Pressure sensor boom-down pilot abnormality1971
Diagnostic Trouble Code: 7069 Pressure sensor arm-out pilot abnormality1973
Diagnostic Trouble Code: 7070 Pressure sensor bucket-open pilot abnormality1975
Diagnostic Trouble Code: 7071 Pressure Sensor Travel Right Pilot Abnormality1977
Diagnostic Trouble Code: 7072 Pressure Sensor Travel Left Pilot Abnormality1979
Diagnostic Trouble Code: 7073 Pressure Sensor Travel 1 Pedal Abnormality1981
Diagnostic Trouble Code: 7074 Pressure Sensor 1st Option Pilot (Common/Front Press) Abnormality1983
Diagnostic Trouble Code: 7075 Pressure Sensor Arm Cylinder Bottom Abnormality1985
Diagnostic Trouble Code: 7078 Pressure Sensor 1st Option Pilot (Back Press) Abnormality1987
Diagnostic Trouble Code: 7200 Swing Brake Solenoid Abnormality1989
Diagnostic Trouble Code: 7201 Travel 2nd Speed Switchover Solenoid Abnormality1991
Diagnostic Trouble Code: 7202 Pressure Boost Solenoid Abnormality1992
Diagnostic Trouble Code: 7203 Travel Alarm Buzzer Abnormality1993
Diagnostic Trouble Code: 7206 Option Return Line Switchover Solenoid Abnormality1994
Diagnostic Trouble Code: 7207 Free Swing Solenoid Abnormality1996
Diagnostic Trouble Code: 7213 Quick Coupler Buzzer Abnormality1997
Diagnostic Trouble Code: 7214 Quick Coupler Solenoid Abnormality1999
Diagnostic Trouble Code: 7247 Boom 2-Down Pilot Proportional Valve Abnormality2001
Diagnostic Trouble Code: 7249 Bucket-Close Pilot Proportional Valve Abnormality2003
Diagnostic Trouble Code: 7250 Option Relief Pressure Proportional Valve Abnormality2005
Diagnostic Trouble Code: 7265 Arm 1 Semi-Parallel Proportional Valve Abnormality2007
Diagnostic Trouble Code: 7266 Arm 2 Semi-Parallel Proportional Valve Abnormality2009
Diagnostic Trouble Code: 7267 Arm 1 Regeneration Release Proportional Valve Abnormality2011
Diagnostic Trouble Code: 7270 Tilting 1 Proportional Valve Abnormality2013
Diagnostic Trouble Code: 7271 Tilting 2 Proportional Valve Abnormality2015
Diagnostic Trouble Code: 7273 Straight Travel Proportional Valve Abnormality2017
Diagnostic Trouble Code: 7400 Coolant Temperature Overheating 12019
Diagnostic Trouble Code: 7401 Coolant Temperature Overheating 22020
Diagnostic Trouble Code: 7404 Oil Temperature Overheating2021
Diagnostic Trouble Code: 7405 Boost Temperature Overheating 12022
Diagnostic Trouble Code: 7406 Boost Temperature Overheating 22023
Diagnostic Trouble Code: 7420 Alternator Power Generation Defect2024
Diagnostic Trouble Code: 7421 Decrease in Coolant Level2026
Diagnostic Trouble Code: 7422 Decrease in Engine Oil Pressure2027
Diagnostic Trouble Code: 7423 Air Cleaner Clogging2028
Diagnostic Trouble Code: 7424 Return Filter Clogging2029
Diagnostic Trouble Code: 7426 Fuel Filter Clogging 12030
Diagnostic Trouble Code: 7427 Fuel Filter Clogging 22032
Diagnostic Trouble Code: 7428 Inducement (Remaining Urea Level Low) – Warning2034
Diagnostic Trouble Code: 7429 Inducement (Remaining Urea Level Low) – Early2035
Diagnostic Trouble Code: 7430 Inducement (Remaining Urea Level Low) – Final2036
Diagnostic Trouble Code: 7602: ECM Communication Abnormality2037
Diagnostic Trouble Code: 7605 ECM Not Matched2039
Diagnostic Trouble Code: 7606 EEPROM Abnormality2040
Diagnostic Trouble Code: 7608 Camera Abnormality2041
Diagnostic Trouble Code: 7612 Air Conditioner Communication Abnormality2043
Diagnostic Trouble Code: 7613 Monitor communication (CAN) abnormality2045
Diagnostic Trouble Code: 7618 DCU Communication Abnormality2047
List of special tools2049
NUMERICAL VALUE CONVERSION TABLE2049
Unit conversion rate2049
Length2049
Area2051
Volume2052
Weight2054
Pressure2055
Torque2056
Temperature2057
A2059
Take-up Roller Special Tool2059
245X42059
Upper Roller Special Tool2060
210X4/245X4/250X42060
Lower Roller Special Tool2061
210X4/245X4/250X52061
C2062
Swing Motor Special Tool2062
210X4/245X4/250X62062
H2065
Engine Oil Filter Special Tool2065
210X4/245X4/250X72065
Fuel Filter Special Tool2065
210X4/245X4/250X82065
Injector Special Tool2065
210X4/245X4/250X92065
Circuit Test Special Tool2066
210X4/245X4/250X102066
Valve Guide Special Tool2066
210X4/245X4/250X112066
Cylinder Head Special Tool2066
210X4/245X4/250X122066
Head Bolt Special Tool2069
210X4/245X4/250X132069
Crankshaft Special Tool2069
210X4/245X4/250X142069
Valve Spring Special Tool2071
210X4/245X4/250X152071
J2072
Remote Control Valve Special Tool2072
210X4/245X4/250X162072
R2074
Gas Filling Special Tool2074
210X4/245X4/250X172074
V2074
Attachment Special Tool (for Cylinder Assembly)2074
Special Jigs Part Number List2074
Paint Colors2076
Abbreviation2078
S.M 31/12/24
