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Link belt 250X4 250X4 LF Excavator SERVICE MANUAL WLSM2507-05LX PDF
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Description
Link belt 250X4 250X4 LF Excavator SERVICE MANUAL WLSM2507-05LX – PDF DOWNLOAD
FILE DETAILS:
Link belt 250X4 250X4 LF Excavator SERVICE MANUAL WLSM2507-05LX – PDF DOWNLOAD
Language : English
Pages :1906
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Link belt 250X4 250X4 LF Excavator SERVICE MANUAL WLSM2507-05LX – 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 250X4 250X4 LF Excavator SERVICE MANUAL WLSM2507-05LX – 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 18
Bolt and Nut Tightening 18
A LOWER 19
Main Equipment Table 23
Lower Component 23
Travel Unit 23
Take-up Roller 23
Upper Roller 23
Lower Roller 23
Recoil Spring 23
Shoe 23
Shoes (LF) 24
Center Joint 24
Main Equipment Structure and Operation Explanation 25
Travel Motor 25
Travel motor operation explanation 25
Explanation of Component Device Operation 25
Double Counter Balance Valve 25
Crossover Relief Valve 30
Automatic 2-speed Switchover Mechanism 32
Parking Brake Function 35
Piston Motor 36
Reduction Gear 37
Port Diagram 39
Travel Motor 39
Center Joint 39
Basic Functions 40
Travel Speed Selection 40
Travel Alarm 41
Removal and Installation of Track 42
Removal and Installation of Shoe Assembly 43
Removal of Shoe Assembly 43
Installation of Shoe Assembly 44
Removal and Installation of Shoe Plate 46
Removal of Shoe Plate 46
Installation of Shoe Plate 46
Removal and Installation of Roller 47
Removal and Installation of Upper Roller 48
Removal of Upper Roller 48
Installation of Upper Roller 49
Assembly and Disassembly of Upper Roller 50
Configuration Diagram 50
Dimension Diagram 51
Jig Dimension Diagram 51
Disassembly Procedures 52
Assembly Procedures 54
Removal and Installation of Lower Roller 57
Removal of Lower Roller 57
Installation of Lower Roller 58
Assembly and Disassembly of Lower Roller 59
Configuration Diagram 59
Dimension Diagram 60
Jig Dimension Diagram 60
Disassembly Procedures 60
Assembly Procedures 63
Removal and Installation of Drive Sprocket 65
Removal of Drive Sprocket 65
Installation of Drive Sprocket 66
Removal and Installation of Take-up Roller 67
Removal of Take-up Roller 67
Installation of Take-up Roller 67
Assembly and Disassembly of Take-up Roller 69
Configuration Diagram 69
Dimension Diagram 70
Jig Dimension Diagram 70
Disassembly Procedures 70
Assembly Procedures 73
Removal and Installation of Grease Cylinder 77
Removal of grease cylinder 77
Installation of grease cylinder 78
Assembly and Disassembly of Tension Shock Absorber 79
Configuration Diagram 79
Dimension Diagram 79
Jig Dimension Diagram 80
Disassembly procedures 80
Assembly procedures 80
Removal and Installation of Center Joint 82
Removal of Center Joint 82
Installation of Center Joint 84
Assembly and Disassembly of Center Joint 86
Configuration Diagram 87
Dimension Diagram 88
Jig Dimension Diagram 89
Disassembly Procedures 89
Assembly Procedures 90
Removal and Installation of Travel Motor 93
Removal of Travel Motor 93
Installation of Travel Motor 95
Assembly and Disassembly of Travel Motor 98
Tools for Assembly and Disassembly 98
Standard Tool 98
Secondary Materials 99
Special Tool (jig) 100
Measurement Device 101
Motor Disassembly Procedures 101
Precautions before Motor Disassembly 101
Tightening torque 102
Disassembly Procedure 103
Maintenance Standards 112
Motor Parts Maintenance Standards 112
Reduction Gear Parts Maintenance Standards 115
Motor Assembly Procedures 117
Precautions before Motor Assembly 117
Assembly Procedure 118
Motor Installation 131
Inspection 131
Hydraulic Oil and Gear Oil Filling 132
Initial Pre-conditioning Operation 133
Troubleshooting 134
Structural Diagram 142
Internal Structure Diagram 145
Component Table 147
Maintenance Standards 148
Drive Sprocket 148
Take-up Roller 149
Upper Roller 150
Lower Roller 151
Track Shoe (grouser shoe) 152
Inspection Gauge 154
For Drive Sprocket 154
For Take-up Roller 154
For Upper Roller 155
For Lower Roller 155
Pressure Measurement and Adjustment Procedures 156
Main Pressure Measurement 156
Travel pressure measurement 156
Drain Volume Measurement Procedures 157
Preparations 157
Travel Motor Drain Volume Measurement 157
Air Bleed Procedure 159
Travel Motor 159
B C SWING UNIT, COUNTERWEIGHT 161
Main Equipment Table 164
Upper Component 164
Swing Unit 164
Swing Unit (LF) 164
Main Equipment Structure and Operation Explanation 165
Swing Motor 165
Swing Motor Operation Explanation 165
Hydraulic Motor Section 165
Valve Casing Section 166
Brake Section 167
Relief Valve Operation Explanation (relief valve model: KRD22EK10) 167
Swing Motor Internal Structure Diagram 170
Port Diagram 173
Swing motor 173
Basic Functions 174
Swing Brake 174
Swing Lock 174
Swing Speed Limit 176
Swing Relief Cut 177
Removal and Installation of Swing Unit 179
Removal of Swing Unit 179
Installation of Swing Unit 181
Assembly and Disassembly of Swing Motor 182
Causes of Trouble and Solutions 182
Maintenance Standard Table 184
Required Tools 186
Jig 187
Disassembly 187
Assembly 189
Swing Motor Internal Structural Diagram 193
Assembly and Disassembly of Swing Unit 195
Disassembly 195
Assembly 196
Swing Reduction Gear Breakdown Diagram 198
Swing Reduction Gear Structure Diagram 199
Removal and Installation of Counterweight 200
Removal of Counterweight 200
Installation of Counterweight 201
Pressure Measurement and Adjustment Procedures 203
Main Pressure Measurement 203
Swing pressure measurement 203
Drain Volume Measurement Procedures 204
Preparations 204
Swing Motor Drain Volume Measurement 204
Air Bleed Procedure 205
Swing Motor 205
Check 206
H ENGINE 207
Main Equipment Table 215
Engine-related 215
Engine 215
Air Cleaner (double element) 215
Radiator 215
SCR 215
Basic Functions 216
Fuel Gauge 216
Coolant Temperature Gauge 218
SCR Gauge 219
Fuel Economy Gauge 223
Neutral Start 223
Power-cut Delay 224
Preheat 225
Throttle 226
Throttle Volume Position Detection 226
Idling Start 232
Auto Idle 233
One-touch Idle 234
Auto Warm-Up 234
Idle Shutdown 239
Idle Up 240
Work Mode Control 241
Engine Emergency Stop 242
SCR RE-GEN 242
Inducement 247
Feed Pump Automatic Stop 251
Coolant Level Decrease 253
Air Filter Clogging 254
Fuel Filter Clogging 255
Battery Charge Abnormality 256
Horsepower Reduction Control (in Uplands) 257
Horsepower Reduction Control (at Engine Failure) 257
Main Data 260
Function, Structure, Operation 262
Function, structure, operation (SCR) 317
SCR Control System Inspection 343
Operation Explanation of SCR 344
Diagnosis for Each Symptom 346
Intermittent conditions of urea selective catalytic reduction system 346
Urea fluid consumption too high 349
Ammonia smell noticeable 349
White crystalline powder visible 350
Diagnosis for Each Symptom 351
Engine Start Problem 351
Engine Stalling 353
Engine Hunting, Rough Idling 355
Excessive White Smoke in Exhaust Gas 357
Excessive Black Smoke in Exhaust Gas 357
Abnormal Noise 358
High Fuel Consumption 359
High Oil Consumption 360
Engine Output Deficiency 361
Functional Inspection 363
Engine Compression Pressure Inspection 363
Fuel System Inspection 364
Lubrication system check 364
Suction air system inspection 365
Exhaust system inspection 365
EGR Control System Inspection 365
Start System Inspection 366
Glow control system check 366
OBD system check 368
Inspection of the monitor warning light illumination circuit system 368
Inspection of the monitor warning light blinking circuit system 369
Inspection of the starter circuit system 369
Removal and Installation of Engine Assembly 371
Removal of Engine Assembly 371
Installation of Engine Assembly 375
Removal and Installation of Fuel Cooler, Engine Intercooler, Radiator, and Oil Cooler 376
Removal and Installation of Fuel Cooler 376
Removal of Fuel Cooler 376
Installation of Fuel Cooler 376
Removal and Installation of Engine Intercooler 376
Removal of Intercooler 377
Installation of Inter Cooler 377
Inspection of Intercooler 377
Removal and Installation of Radiator 378
Removal of Radiator 378
Installation of Radiator 381
Inspection of Radiator 382
Removal and Installation of Oil Cooler 382
Removal of Oil Cooler 383
Installation of Oil Cooler 385
Removal and Installation of Turbo Charger 386
Removal of Turbo Charger 386
Installation of Turbo Charger 388
Inspection of Turbo Charger 391
Removal and Installation of EGR Valve 393
Removal of EGR Valve 393
Installation of EGR Valve 395
Inspection of EGR Valve 398
Removal and Installation of Engine Hood 400
Removal of Engine Hood 400
Installation of Engine Hood 401
Removal and Installation of SCR 402
Removal of SCR 402
Installation of SCR 403
Removal and installation of Silicon Controlled Rectifier Catalyst 404
Removal of Silicon Controlled Rectifier Catalyst 404
Installation of Silicon Controlled Rectifier Catalyst 404
Disassembly of Silicon Controlled Rectifier Catalyst 404
Assembly of Silicon Controlled Rectifier Catalyst 404
Inspection of Silicon Controlled Rectifier Catalyst 405
Removal and Installation of Cylinder Head Cover 406
Cylinder head cover Removal 406
Installation of Cylinder Head Cover 406
Removal and Installation of Cylinder Head 407
Removal of Cylinder Head 407
Disassembly of Cylinder Head 415
Assembly of Cylinder Head 420
Installation of Cylinder Head 427
Inspection 444
Removal and Installation of Cylinder Block 451
Removal of Cylinder Block 451
Installation of Cylinder Block 467
Inspection 502
Lubrication System 504
Removal and Installation of Oil Pan 504
Removal of Oil Pan 504
Installation of Oil Pan 504
Removal and Installation of Oil Level Switch 504
Removal of Oil Level Switch 504
Installation of Oil Level Switch 505
Removal and Installation of Oil Pump Assembly 505
Removal of Oil Pump Assembly 505
Disassembly of Oil Pump Assembly 517
Assembly of Oil Pump Assembly 518
Installation of Oil Pump Assembly 518
Inspection 542
Engine oil Inspection 543
Removal and Installation of Oil Port Cover 544
Removal of Oil Port Cover 544
Installation of Oil Port Cover 544
Cooling System 546
Removal and Installation of Water Pump Assembly 546
Removal of Water Pump Assembly 546
Installation of Water Pump Assembly 547
Inspection 551
Removal and Installation of Thermostat 551
Removal of Thermostat 551
Installation of Thermostat 552
Inspection 554
Inspection of Coolant 554
Inspection of Cooling Fan Belt 559
Removal and Installation of Overheat Switch 559
Removal of Overheat Switch 559
Installation of Overheat Switch 560
Induction System 561
Inspection of Air Cleaner Element 561
Exhaust System 562
Removal and installation of Oxidation Catalyst Assembly 562
Removal of Oxidation Catalyst Assembly 562
Installation of Oxidation Catalyst Assembly 563
Aux Emission Control Devices System 565
Removal and installation of Dosing Module 565
Removal of Dosing Module 565
Disassembly of Dosing Module 565
Assembly of Dosing Module 566
Installation of Dosing Module 566
Removal and installation of DEF Supply Module 568
Removal of DEF supply module 568
Disassembly of DEF Supply Module 569
Assembly of DEF Supply Module 569
Installation of DEF Supply Module 570
Removal and installation of Coolant Control Valve 572
Removal of Coolant Control Valve 572
Installation of Coolant Control Valve 573
Removal and installation of DEF Supply Module Filter 574
Removal of DEF Supply Module Filter 574
Installation of DEF Supply Module Filter 575
Removal and Installation of Exhaust Manifold 576
Removal of Exhaust Manifold 576
Installation of Exhaust Manifold 579
Inspection 585
Removal and Installation of Fuel Tank 586
Removal of Fuel Tank 586
Installation of fuel tank 589
Removal and Installation of Urea Pump 590
Removal of Urea Pump 590
Installation of Urea Pump 591
Removal and Installation of Urea Solution Tank 592
Removal of Urea Solution Tank 592
Installation of Urea Solution Tank 592
Removal and Installation of Fuel Supply Pump 594
Removal of Fuel Supply Pump 594
Installation of Fuel Supply Pump 595
Removal and Installation of Common Rail Assembly 599
Removal of Common Rail Assembly 599
Installation of Common Rail Assembly 601
Removal and Installation of Injector 606
Removal of Injector 606
Installation of Injector 609
Removal and installation of Idle Gear 614
Removal of Idle Gear 614
Installation of Idle Gear 626
Inspection of Idle Gear 650
Removal and installation of Inlet Cover 652
Removal of Inlet Cover 652
Installation of Inlet Cover 656
Removal and installation of Crankshaft 666
Removal of Crankshaft 666
Installation of Crankshaft 681
Disassembly of Crankshaft 713
Assembly of Crankshaft 713
Inspection of Crankshaft 714
Removal and installation of Piston 719
Removal of Piston 719
Installation of Piston 729
Disassembly of Piston 748
Assembly of Piston 749
Inspection of Piston 750
Removal and installation of Camshaft 758
Removal of Camshaft 758
Installation of Camshaft 759
Disassembly of Camshaft 763
Assembly of Camshaft 764
Inspection of Camshaft 764
Removal and installation of Flywheel 766
Removal of Flywheel 766
Installation of Flywheel 767
Inspection of Flywheel 768
Removal and installation of Crankshaft Front Oil Seal 769
Removal of Crankshaft Front Oil Seal 769
Installation of Crankshaft Front Oil Seal 770
Removal and installation of Crankshaft Rear Oil Seal 773
Removal of Crankshaft Rear Oil Seal 773
Installation of Crankshaft Rear Oil Seal 774
Removal and installation of Rocker Arm Shaft 777
Removal of Rocker Arm Shaft 777
Installation of Rocker Arm Shaft 778
Disassembly of Rocker Arm Shaft 781
Assembly of Rocker Arm Shaft 782
Inspection of Rocker Arm Shaft 783
Removal and installation of Valve Spring 785
Removal of Valve Spring 785
Installation of Valve Spring 787
Inspection of Valve Spring 792
Removal and installation of Valve Stem Oil Seal 794
Removal of Valve Stem Oil Seal 794
Installation of Valve Stem Oil Seal 796
Removal and installation of Front Cover 803
Removal of Front Cover 803
Installation of Front Cover 805
Removal and installation of Intake Throttle Valve 811
Removal of Intake Throttle Valve 811
Installation of Intake Throttle Valve 811
Removal and Installation of Starter Motor 812
Removal of Starter Motor 812
Installation of Starter Motor 813
Disassembly of Starter Motor 813
Assembly of Starter Motor 814
Inspection of Starter Motor 816
Removal and Installation of Alternator 820
Removal of Alternator 820
Installation of Alternator 820
Disassembly of Alternator 821
Assembly of Alternator 822
Inspection of Alternator 823
Removal and Installation of Glow Plug 827
Removal of Glow Plug 827
Installation of Glow Plug 827
Glow plug Inspection 827
Removal and Installation of Suction Control Valve 828
Removal of Suction Control Valve 828
Installation of Suction Control Valve 828
Removal and installation of Fuel Filter 831
Removal of Fuel Filter 831
Installation of Fuel Filter 831
Removal and installation of Relief Valve 834
Removal of Relief Valve 834
Installation of Relief Valve 834
Removal and installation of Fuel Filter Element 837
Removal of Fuel Filter Element 837
Installation of Fuel Filter Element 838
Removal and Installation of Fuel filter pressure 841
Fuel filter pressure sensor Removal 841
Fuel filter pressure sensor Installation 841
Removal and Installation of Engine coolant temperature sensor 842
Engine coolant temperature sensor Removal 842
Engine coolant temperature sensor Installation 842
Engine coolant temperature sensor Inspection 842
Removal and Installation of CKP sensor 843
CKP sensor Removal 843
CKP sensor Installation 843
CKP sensor Inspection 843
Removal and Installation of CMP sensor 844
CMP sensor Removal 844
CMP sensor Installation 844
CMP sensor Inspection 844
Removal and Installation of Oil pressure sensor 845
Oil pressure sensor Removal 845
Oil pressure sensor Installation 845
Oil pressure sensor Inspection 845
Removal and installation of Pressure Sensor/Boost Temperature Sensor 846
Removal of Pressure Sensor/Boost Temperature Sensor 846
Installation of Pressure Sensor/Boost Temperature Sensor 846
Inspection of Pressure Sensor/Boost Temperature Sensor 846
Removal and Installation of IMT sensor 847
Removal of IMT sensor 847
Installation of IMT sensor 847
Removal and installation of Charge Air Cooler Temperature Sensor 1 848
Removal of Charge Air Cooler Temperature Sensor 1 848
Installation of Charge Air Cooler Temperature Sensor 1 848
Inspection of Charge Air Cooler Temperature Sensor 1 848
Sampling Procedure 849
Sampling of Engine Oil 849
Removal and Installation of Exhaust gas temperature sensor 850
Exhaust gas temperature sensor Removal 850
Exhaust gas temperature sensor Installation 850
Exhaust gas temperature sensor Inspection 850
Removal and installation of EGR Gas Temperature Sensor 1 852
Removal of EGR Gas Temperature Sensor 1 852
Installation of EGR Gas Temperature Sensor 1 852
Inspection of EGR Gas Temperature Sensor 1 852
Removal and installation of EGR Gas Temperature Sensor 2 853
Removal of EGR Gas Temperature Sensor 2 853
Installation of EGR Gas Temperature Sensor 2 853
Inspection of EGR Gas Temperature Sensor 2 853
Removal and installation of NOx Sensor 855
Removal of NOx Sensor 855
Installation of NOx Sensor 855
Removal and installation of EGR Gas Temperature Sensor 3 856
Removal of EGR Gas Temperature Sensor 3 856
Installation of EGR Gas Temperature Sensor 3 856
Removal and installation of DEF Sensor 857
Removal of DEF Sensor 857
Installation of DEF Sensor 857
Engine-related Diagnostic Trouble Code List 858
Engine-side Trouble 863
ECM Trouble 863
DTC U0001 CAN Bus Error (ISO-CAN) 863
DTC P0016 Crankshaft Position – Camshaft Position Correlation Error 864
DTC P0045 Turbocharger Boost Control VNT Error 864
DTC U0073 Control Module Communication Bus Off 866
DTC P0087 Fuel Rail/System Pressure – Too Low 867
DTC P0089 Fuel Pressure Regulator Performance 870
DTC P0091 Fuel Pressure Regulator Control Circuit Low 871
DTC P0092 Fuel Pressure Regulator Control Circuit High 872
DTC P0097 Intake Air Temperature (IAT) Sensor 2 Circuit Low Voltage 873
DTC P0098 Intake Air Temperature (IAT) Sensor 2 Circuit High Voltage 873
DTC U0101 Lost Communication With CAN 874
DTC P0102 Mass Air Flow Sensor Circuit Low Input 875
DTC P0103 Mass Air Flow Sensor Circuit High Input 876
DTC U010E Lost Communications With Dosing Control Module 876
DTC U0110 Lost Communication With VNT System 877
DTC P0112 Intake Air Temperature Sensor Circuit Low 877
DTC P0113 Intake Air Temperature Sensor Circuit High 878
DTC P0117 Engine Coolant Temperature Sensor Circuit Low 879
DTC P0118 Engine Coolant Temperature Sensor Circuit High 879
DTC P0122 Throttle Position Sensor Circuit Low 880
DTC P0123 Throttle Position Sensor Circuit High 881
DTC P0182 Fuel Temperature Sensor Circuit Low 882
DTC P0183 Fuel Temperature Sensor Circuit High 883
DTC P0192 Fuel Rail Pressure Sensor Circuit Low 884
DTC P0193 Fuel Rail Pressure Sensor Circuit High 884
DTC P0201 Injector Circuit Open – Cylinder 1 886
DTC P0202 Injector Circuit Open – Cylinder 2 886
DTC P0203 Injector Circuit Open – Cylinder 3 887
DTC P0204 Injector Circuit Open – Cylinder 4 888
DTC P0217 Engine Coolant Over Temperature Condition 889
DTC P0219 Engine Overspeed Condition 889
DTC P0234 Turbocharger Overboost Condition 890
DTC P0237 Turbo Charger Boost Sensor Circuit Low 891
DTC P0238 Turbo Charger Boost Sensor Circuit High 891
DTC P0335 Crankshaft Position Sensor Circuit 892
DTC P0336 Crankshaft Position Sensor Circuit Range/Performance 893
DTC P0340 Camshaft Position Sensor Circuit 894
DTC P0380 Glow Relay Circuit Error 895
DTC P0401 EGR Flow Insufficient Detected 896
DTC P0404 EGR Control Circuit Range/Performance 897
DTC P0409 EGR Sensor Circuit 897
DTC U0411 Lost CAN Communications With VNT Control Module 899
DTC P041C EGR Cooler Outlet 1 Temp Sensor Circuit Low 899
DTC P041D EGR Cooler Outlet 1 Temp Sensor Circuit High 900
DTC P0427 Catalyst Temperature Sensor Circuit Low Sensor 1 901
DTC P0428 Catalyst Temperature Sensor Circuit High Sensor 1 901
DTC P042C Catalyst Temperature Sensor Circuit Low Sensor 2 902
DTC P042D Catalyst Temperature Sensor Circuit High Sensor 2 903
DTC P0522 Engine Oil Pressure Sensor Circuit Low Input 904
DTC P0523 Engine Oil Pressure Sensor Circuit High Input 905
DTC P0545 EGR Cooler Inlet 1 Temp Sensor Circuit Low 906
DTC P0546 EGR Cooler Inlet 1Temp Sensor Circuit High 906
DTC P0560 12 Volt Circuit Error 907
DTC P0563 System Voltage High 907
DTC P0601 Internal Control Module Memory Check Sum Error 908
DTC P0602 Internal Control Module QR Code Error 908
DTC P0604 Internal Control Module RAM Error 909
DTC P0606 Internal Control Module CPU Error 909
DTC P060A Internal Control Module CPU IC Error 909
DTC P060C Internal Control Module A/D Processing Performance 909
DTC P0615 Starter Relay Circuit Error 910
DTC P0638 Throttle Actuator Control Range/Performance 910
DTC P0685 ECM Power Relay Control Circuit Open 911
DTC P0687 ECM Power Relay Control Circuit High 912
DTC P06A6 Sensor Reference Voltage 1 Circuit 912
DTC P06A7 Sensor Reference Voltage 2 Circuit 913
DTC P06A8 Sensor Reference Voltage 3 Circuit 914
DTC P06A9 Sensor Reference Voltage 4 Circuit 914
DTC P06AF Torque Management System – Forced Engine Shutdown 915
DTC P06D5 Sensor Reference Voltage 5 Circuit 916
DTC P1076 Charge Air Cooler (CAC) Temperature Sensor 1 Circuit Low Voltage 916
DTC P1077 Charge Air Cooler (CAC) Temperature Sensor 1 Circuit High Voltage 916
DTC P1093 Fuel Rail Pressure Too Low 917
DTC P1097 Compressor Outlet Temperature Sensor Circuit High 920
DTC P1098 Compressor Outlet Temperature Sensor Circuit High 921
DTC P1236 Charge Air Cooler Performance Failure 922
DTC P1261 Injector Positive Voltage Control Circuit Group 1 922
DTC P1262 Injector Positive Voltage Control Circuit Group 2 923
DTC P1404 EGR Position Fault 923
DTC P1606 SW-IC Internal failure 924
DTC P160B AD-IC Failure Error 924
DTC P160C AD-IC2 Failure Error 924
DTC P1621 Control Module Long Term Memory Performance 924
DTC P1669 DPD Lamp Control Circuit 925
DTC P204F SCR System Error (No Inducement) 926
DTC P207F Urea Fluid Concentration Too Low 926
DTC P20C9 SCR System Error 926
DTC U2106 Lost CAN Communications With Wheel Loader Transmission Control System 926
DTC P2122 Pedal Position Sensor 1 Circuit Low Input 927
DTC P2123 Pedal Position Sensor 1 Circuit High Input 927
DTC P2127 Pedal Position Sensor 2 Circuit Low Input 928
DTC P2128 Pedal Position Sensor 2 Circuit High Input 929
DTC P2138 Pedal Position Sensor 1 – 2 Voltage Correlation 929
DTC P2146 Fuel Injector Group 1 Supply Voltage Circuit 930
DTC P2149 Fuel Injector Group 2 Supply Voltage Circuit 931
DTC P2228 Barometric Pressure Sensor Circuit Low 932
DTC P2229 Barometric Pressure Sensor Circuit High 933
DTC P2457 Exhaust Gas Recirculation (EGR) Cooling System Performance 933
DTC P2458 Purge time Out Error 934
DTC P2BA7 Urea Fluid Quantity Too Low 934
DTC P2BAA SCR System Error (Inducement, No Purge) 934
DTC P3093 Fuel Rail Pressure Too Low 934
DCU Trouble 937
DTC 0002 CAN Bus Off 937
DTC 0100 Lost Communication With ECM 938
DTC 029D Lost Communication With NOx Sensor 1 939
DTC 0607 Control Module Performance 941
DTC 060B Internal Control Module A/D Processing Performance 942
DTC 062F Control Module EEPROM Error 942
DTC 0641 Sensor Reference Voltage 1 Circuit 943
DTC 0658 Actuator Supply Voltage Circuit 944
DTC 0659 Actuator Supply Voltage Circuit 945
DTC 1462 Urea Fluid Quality Sensor Timeout Error 946
DTC 1464 Main Relay Performance 946
DTC 1468 DCU Overtemperature 947
DTC 1491 Urea Fluid Overpressure 947
DTC 1493 DCU Driver Overtemperature 949
DTC 149C Urea Fluid Pressure Reduction Malfunction 949
DTC 149D Urea Fluid Tank Overtemperature 950
DTC 203B Urea Fluid Tank Level Sensor Stuck 951
DTC 203C Urea Fluid Tank Level Sensor Low Voltage 952
DTC 203D Urea Fluid Tank Level Sensor High Voltage 953
DTC 2048 Urea Fluid Injector Circuit Low Voltage 954
DTC 2049 Urea Fluid Injector Circuit High Voltage 955
DTC 204B Urea Fluid Pressure Sensor Performance 955
DTC 204C Urea Fluid Pressure Sensor Circuit Low Voltage 956
DTC 204D Urea Fluid Pressure Sensor Circuit High Voltage 957
DTC 205B Urea Fluid Tank Temperature Sensor Performance 958
DTC 205C Urea Fluid Tank Temperature Sensor Low Voltage 959
DTC 205D Urea Fluid Tank Temperature Sensor High Voltage 959
DTC 206A Urea Fluid Quality Sensor Circuit 960
DTC 206B Urea Sensor Over Temperature Condition 960
DTC 206C Urea Fluid Quality Sensor Circuit Low Voltage 961
DTC 206D Urea Fluid Quality Sensor Circuit High Voltage 962
DTC 207F Urea Fluid Concentration Too Low 962
DTC 208A Urea Fluid Pump Control Circuit 963
DTC 208B Usea Fluid Pump Performance 963
DTC 208C Urea Fluid Pump Control Circuit Low Voltage 964
DTC 208D Urea Fluid Pump Control Circuit High Voltage 965
DTC 208E Urea Fluid Injector Stuck 966
DTC 20A0 Urea Fluid Reverting Valve Circuit Open 967
DTC 20A2 Urea Fluid Reverting Valve Circuit Low Voltage 967
DTC 20A3 Urea Fluid Reverting Valve Circuit High Voltage 968
DTC 20AC Urea Fluid Pump Temperature Sensor Performance 969
DTC 20AD Urea Fluid Pump Module Temperature Sensor Performance 970
DTC 20B1 Urea Fluid Tank Heater Coolant Control Valve Circuit Open 971
DTC 20B3 Urea Fluid Tank Heater Coolant Control Valve Circuit Low Voltage 972
DTC 20B4 Urea Fluid Tank Heater Coolant Control Valve Circuit High Voltage 972
DTC 20E8 Urea Fluid Pressure Underpressure 973
DTC 20E9 Urea Fluid Overpressure 974
DTC 20EA Urea Fluid Pressure Reduction Malfunction 976
DTC 20FE Urea Fluid Pressure Build-Up Error 976
DTC 2201 Upstream Nox Sensor Performance 978
DTC 2206 NOx Sensor Heater Control Circuit Low Voltage Sensor 1 978
DTC 2207 NOx Sensor Heater Control Circuit High Voltage Sensor 1 979
DTC 242B Exhaust Gas Temperature (EGT) Sensor 3 Performance 979
DTC 242C Exhaust Gas Temperature (EGT) Sensor 3 Circuit Low Voltage 979
DTC 242D Exhaust Gas Temperature (EGT) Sensor 3 Circuit High Voltage 980
Data Reference Values 982
Idle Speed 982
Two Pump Relief 983
J HYDRAULIC EQUIPMENT (PUMP, OPERATION SYSTEM VALVE) 985
Main Equipment Table 991
Hydraulic Device 991
Hydraulic Pump 991
Control-related 992
Control valve 992
Control Valve (LF) 992
Solenoid Valve (5 Stack) 992
Remote Control Valve for Left/Right Operations 993
Remote Control Valve for Travel Operation 993
Remote Control Valve Characteristic Diagram 993
Operation Remote Control Valve Control Diagram 993
Travel Remote Control Valve Control Diagram 994
Cushion Valve (heat circuit, with shuttle valve) 994
Selector Valve 995
Basic Functions 996
Oil Temperature Gauge 996
Static Horsepower Control 997
Overload Warning (Function for Europe Only) 998
Pressure Boost Control 999
Stroke Control1001
Boom Down Energy Save1002
Pump Horsepower Boost Control1003
Arm 1 Semi-parallel Control1003
Arm 2 Semi-parallel Control1004
Hot Shutdown Warning1005
Gate Lock1006
Breaker Mode1007
Crusher Mode1007
Quick coupler1008
Hydraulic Filter Clogging1009
Solenoid Sticking Prevention1010
Port Diagram1011
Hydraulic Pump (Standard Model)1011
Control Valve1012
Relief Valve1012
5 Stack Solenoid Valve1015
2 Stack Solenoid Valve1017
Remote Control Valves (upper, travel)1017
Remote Control Valves (left-right)1017
Remote Control Valve (Travel)1018
Cushion Valve1019
2-way Selector Valve1020
Direction Valve1021
6 Stack Proportional Valve1022
Relief Valve (electromagnetic proportional)1024
Manifold Under Cab1025
Manifold (accumulator section)1026
Hydraulic Oil Tank1027
Hydraulic Pump1028
Structure and Operation Explanation1028
Hydraulic Pump Internal Structure Diagram1029
Overall View1029
Drive Shaft Front Side1030
Drive Shaft Rear Side1031
Development Diagram1032
Component Table1035
Regulator1036
Regulator Operation Explanation1036
Regulator Operation Explanation Diagram1039
Internal Configuration Diagram of Regulator1042
Development Diagram of Regulator1044
Component Table1045
Operation Outline of Electronically-Controlled Pump1047
Control Valve1050
Basic Configuration1050
Operation1050
Operation of Main Unit1050
Activation of Relief Valve1071
5 Stack Solenoid Valve Operation Explanation1076
External Shape Diagram and Components1076
operation explanation1076
Upper Pilot Valve (remote control valve)1077
Structure1077
Function1077
Operation1078
Structural Diagram1082
Travel Pilot Valve (remote control valve)1083
Operation1083
Pressure Reducing Valve Section1083
Damping Mechanism in Operation Section1084
Structural Diagram1087
Cushion Valve 1089
structure1089
operation explanation1089
Selector Valve (2-way)1094
structure1094
operation explanation1095
Development Diagram1096
Direction Valve (3-direction) 1097
Structure1097
Operation Explanation1098
6 Stack Proportional Valve (Pilot)1100
structure1100
operation principle1101
Electromagnetic Relief Valve1102
Structure1102
Operation Explanation1103
Operation of Check Valve1103
Operation of Electromagnetic Relief Valve1104
Removal and Installation of Hydraulic Tank1106
Removal of Hydraulic Reservoir1106
Installation of Hydraulic Oil Tank1108
Removal and Installation of Hydraulic Pump1109
Removal of Hydraulic Pump1109
Installation of Hydraulic Pump1111
Removal and Installation of Control Valve1112
Removal of Control Valve1112
Installation of Control Valve1116
Removal and Installation of Travel Remote Control Valve1117
Removal of Travel Remote Control Valve1117
Installation of Travel Remote Control Valve1118
Removal and Installation of Operation Remote Control Valve1121
Removal of Operation Remote Control Valve (Left)1121
Installation of Operation Remote Control Valve (Left)1123
Removal of Operation Remote Control Valve (right side)1125
Installation of Operation Remote Control Valve (right side)1127
Removal and Installation of 5 Stack Solenoid1129
Removal of 5 Stack Solenoid Valve1129
Installation of 5 Stack Solenoid Valve1130
Removal and Installation of Cushion Valve1131
Removal of Cushion Valve1131
Installation of Cushion Valve1132
Procedures for Assembly and Disassembly of Hydraulic Pump Main Unit1133
Tools1133
Disassembly Procedure1133
Assembly Procedures1135
Development Diagram1139
Component Table1142
Pump Main Unit Maintenance Standards1143
Replacement Standard of Wear Component1143
Correction Standard of Cylinder, Valve Plate, and Sash Plate (Shoe Plate)1143
Tightening torque1144
Overall View1144
Drive Shaft Front Side1145
Drive Shaft Rear Side1146
Development Diagram1147
Component Table1150
Regulator Maintenance Standards1151
Regulator Adjustment1151
Appendix Table and Drawings1152
Regulator Assembly and Disassembly Procedures1156
Tools1156
Preparations for Disassembly1156
Disassembly Procedure1156
Assembly Procedures1158
Internal Configuration Diagram of Regulator1161
Development Diagram of Regulator1163
Component Table1164
Assembly and Disassembly of Control Valve1166
Disassembly1166
Caution for Disassembly1166
Disassembly Procedure1166
Removal of Long Cap and Pulling Out of Main Spool1166
Disassembly of Arm 1, 2 Parallel-Tandem Spool, Neutral Cut Spool, Arm Regeneration Release Spool Section1167
Disassembly of Load Check Valve Section1167
Disassembly of Antidrift Valve Section (Sub Component in Assembly is Expressed by (Min Number – Sub Number))1168
Disassembly of Relief Valve1168
Disassembly of Option Section1168
Disassembly of Add-On Section1168
Disassembly of Valve Housing Coalescence Bolt1169
Cleaning1169
Inspection1169
assembly1169
Caution for Assembly1169
Caution for Handling O-ring1169
Caution for Handling Spool1169
Method to Apply Adhesive Agent (Male and Female Thread Section of Components Requiring Bonding)1169
Assembly Procedure of Sub-Assembly1170
Assembly of Spool Assembly (Main Spool)1170
Assembly of Arm 1, 2 Parallel-Tandem Spool, Neutral Cut Spool, Arm Regeneration Release Spool Assembly1170
Assembly of Antidrift Valve Assembly1171
Assembly Procedure of Control Valve Main Unit1171
Assembly of Relief Valve1171
Assembly of Load Check Valve1171
Assembly of Antidrift Valve1172
Assembly of Option Section1172
Assembly of Arm 1 Parallel-Tandem Spool1172
Assembly of Arm 2 Parallel-Tandem Spool, Neutral Cut Spool, Arm Regeneration Release Spool1172
Assembly of Main Spool1172
Assembly of Add-On Section1173
Assembly of Other Plugs1173
Internal Structural Diagram1174
Part List1180
Relief Valve1181
Assembly and Disassembly Procedure of Main Relief Valve1181
Assembly and Disassembly Procedures of Overload Relief1182
Assembly and Disassembly Procedure of Low-Pressure Relief Valve1183
Assembly and Disassembly Procedure of Main Relief Valve for Add-On1183
Adjustment of Relief Valve1184
Installation1185
Operation1185
Malfunction and Countermeasure1185
Procedures for Assembly and Disassembly of Operation Remote Control Valve1187
Maintenance Procedures1187
Required Tools and Tightening Torque1187
Maintenance Standards1187
Disassembly Procedures1188
Assembly Procedures1190
Causes of Trouble and Countermeasures1194
Procedures for Assembly and Disassembly of Travel Remote Control Valve1198
Maintenance Procedures1198
Disassembly Procedures1199
Assembly Procedures1203
Causes of Trouble and Countermeasures and Cross-section Diagram1208
Assembly and Disassembly of Cushion Valve1211
Disassembly Procedures1211
Reverse Operation Spool Section1211
Check Plunger Section with Throttle1211
Shuttle Valve Section1211
Assembly Procedures1211
Reverse Operation Spool Section1212
Check Plunger Section with Throttle1212
Shuttle Valve Section1212
Written Materials1213
Procedures for Assembly and Disassembly of 6 Stack Proportional Valve (Pilot)1215
Development Diagram1215
Assembly and disassembly procedures1216
Precautions1216
Replacement of Proportional Solenoid1216
Disassembly1216
Assembly1216
Replacement of Sleeve and Spool1217
Disassembly1217
Assembly1218
Replacement of Poppet (Check Valve for Normally Open)1219
Disassembly1219
assembly1220
Maintenance Standards1220
Troubleshooting1220
Pressure Measurement and Adjustment Procedures1222
Procedures for Pressure Measurement from the Monitor Display1222
Monitor and Switch Panel1222
Pressure Measurement Method1222
Operating Method1222
PROCEDURES FOR MEASURING HYDRAULIC OIL TEMPERATURE FROM THE MONITOR DISPLAY1222
Hydraulic Oil Temperature Measurement Method1222
Operating Method1223
Procedures for Pressure Measurement by Installing Pressure Gauge1224
Preparations1224
Items to prepare1224
Pressure Measuring Ports1225
Control Valve1227
Location of Relief Valves1227
Pressure Measurement Preparations1228
Pressure Measurement1230
Main Pressure Measurement1230
A Attachments Pressure Measurement1230
Boom-down pressure measurement1232
D Option Line Pressure Measurement1232
Pilot Pressure Measurement1232
Pressure Gauge Installation1232
Negative Control Pressure Measurement1233
Pressure Gauge Installation1233
Pressure Adjustment1233
Main Pressure Adjustment1233
Preparation Work of Pressure Measurement Adjustment1233
Main Relief Pressure Adjustment1235
Overload Relief Pressure Adjustment1236
Swing Relief Pressure Adjustment1237
Pilot Pressure Adjustment1238
Hydraulic Pump Flow Measurement Procedures1239
Preparations1239
Items to Prepare1239
Work Preparations1240
Flow Measurement1241
Air Bleed Procedure1243
Hydraulic Pump1243
Sampling Procedure1244
Sampling of Hydraulic Fluid1244
Hydraulic Equipment Layout1245
Overall View1246
Pump Chamber Hydraulic Equipment Layout1247
Swing Body Center Section Hydraulic Equipment Layout1248
Housing Left Side Hydraulic Equipment Layout1250
Layout of Hydraulic Equipment in Cab1251
N CAB1327
Removal and Installation of Operator’s Seat1330
Removal of Operator’s Seat1330
Installation of Operator’s Seat1330
Removal and Installation of Cab Assembly1331
Removal of Cab Assembly1331
Installation of Cab Assembly1335
Removal and Installation of Wiper1336
Removal of Wiper1336
Installation of wiper1336
Removal and Installation of Cab Front Glass1337
Removal of Cab Front Glass1337
Installation of Cab Front Glass1338
Window Lock Adjustment Procedures1339
Window Lock (front side)1339
Window Lock (rear side)1339
Removal and Installation of Housing Guardrail1341
Removal of Housing Guardrail1341
Installation of Housing Guardrail1341
Tightening torque1342
R ELECTRICAL PARTS1343
Basic Functions1347
Monitor Control1347
Monitor Display Dimming1347
Diagnostic Trouble Code Indicator1348
Clock1348
Basic Operation1349
Battery Save1349
Accessories1351
Working Light1351
LED Light1352
Room Lamp1353
Radio Mute1354
Wiper and Washer1355
Safety1358
Horn1358
Back/Side View Monitor1359
Precautions for Camera Installation1359
Maintenance1360
Anti-theft1360
Manual Lock1360
Service Support Screen Lock1360
Customer-specific System Information Screen Lock1360
Maintenance Information Screen Lock1361
Option Line Setting Screen Lock1361
Setting1361
Clock Adjustment1361
Screen Brightness Setting1362
Battery Disconnect Switch1363
Explanation of Controller1364
Service Support1366
Screen Operations1366
Screen Display List1366
Service Monitor Structure1367
CHECK Screen List1368
MACHINE STATUS1368
HYDRAULIC STATUS1374
ENGINE STATUS1381
FAULT HISTORY1386
WORK HISTORY1386
HYDRAULIC HISTORY1395
ENGINE HISTORY1407
DEVICE TEST1428
ECM/DCU Memory Clear1428
SCR RE-GEN1429
Urea Line Leak Test1430
CCV Operation Test1431
Dosing Test1432
Reverting Valve Operation Test1433
Common Rail Pressure Test1434
Idle Speed Test / Injector Test1435
EGR Valve Control Test1436
VG Turbo Control Test1437
Intake Throttle Control Test1438
CONTROL UNIT Screen List1440
MCM-MAIN1440
MCM-SUB1444
COMMU TERMINAL1445
SETUP Screen List1447
MACHINE SELECT1448
DIMENSIONS1452
PARAMETERS1453
ENGINE INFORMATION1455
ENGINE INFORMATION1456
Data Confirmation1456
Data Transfer (Copy)1457
QR (INJECTOR) CODE1458
Injector number1458
Screen Layout1458
Data Source Selection1458
Manual Input1459
CAMERA1460
PASSWORD1463
CALIBRATE Screen List1465
THROTTLE VOLUME1466
OPTLINE RELIEF1467
PUMP FLOW1469
Connection Connector Pin Layout1472
Main Controller1472
Monitor1473
Sequence Circuit Diagram1474
Code List1474
Overall1477
Block diagram1480
Main controller1480
DCU1481
ECM1482
Monitor1483
Air Conditioner1484
Gate Lock1485
Horn1485
Working Light1486
Option1487
Other1488
Electrical Symbol List1488
Electrical Equipment Layout Diagram1490
Main Unit Left-side Layout Diagram1491
Engine Section Layout Diagram1493
Main Unit Right Side Layout Diagram (pump chamber)1496
Main Unit Center Section Layout Diagram1498
Cab Layout Diagram 11500
Cab Layout Diagram 21502
Layout Around Operator Seat1505
Stand Alone Parts Diagram1506
Removal and Installation of Wiper Controller1525
Removal of Wiper Controller1525
Installation of wiper controller1525
Removal and Installation of Wiper Motor1526
Removal of Wiper Motor1526
Installation of wiper motor1527
Removal and Installation of ECM1528
Removal of ECM1528
Installation of ECM1528
Removal and Installation of Main Controller1529
Removal of Main Controller1529
Installation of Main Controller1529
Removal and Installation of DCU1530
Removal of DCU1530
Installation of DCU1530
Removal and Installation of Monitor1531
Removal of Monitor1531
Installation of Monitor1531
How to Set FVM1532
Air Conditioner Overall Diagram1536
Frame1536
Cab1538
Equipment Layout Diagram1541
Circuit Diagram1543
Air Conditioner Circuit Diagram1543
Explanation of Functions1545
Explanation of Control1545
Air Mix Motor Actuator Control1546
Blow Mode Motor Actuator Control1546
Refresh/Recirculate Switch Motor Actuator Control1547
Blower Amp Control1548
Compressor Clutch Control1550
COOLMAX Control and HOTMAX Control1551
Abnormality Detection and Control after Abnormality Detected1551
Monitor Mode1555
Door Switch Control1557
Actuator Inspection1558
Air Mix Motor Actuator Inspection1558
Refresh/Recirculate Switch Motor Actuator Inspection1559
Mode Motor Actuator Inspection1560
Self-diagnosis Function with Panel Display1561
Abnormality Display and Self-check Procedures1561
Abnormality Display Position1561
Explanation of Abnormality Display1561
Motor Actuator Abnormality1561
Sensor Abnormality1562
Explanation of Monitor Mode1562
Monitor Mode Display Position1563
Monitor Mode Display Operating Method1563
Display Contents in Monitor Mode1564
Part Function and Good/Poor Judgment1570
Control Panel1570
Blower Amp1570
Relay1571
Air Mix Actuator1572
Refresh/Recirculate Actuator1573
Blow Mode Actuator1573
Evaporator Sensor1574
Dual Pressure Switch1574
Solar Radiation Sensor1575
Inside Air Sensor1575
Assembly and Disassembly of Unit1577
Removal of Blower Unit1577
Replacement of Blower Motor1577
Replacement of Blower Amp1577
Removal of Heater Core1578
Removal of Heat Case Right/Left1578
Replacement of Evaporator and Expansion Valve1578
Installation of Evaporator Sensor1579
Replacement of Motor Actuator1579
Removal and Installation of Compressor1580
Removal of Compressor1580
Installation of Compressor1580
Removal and Installation of Condenser1581
Removal of Condenser1581
Installation of Condenser1582
Removal and Installation of Receiver Dryer1583
Removal of Receiver Dryer1583
Installation of Receiver Dryer1583
Work Precautions1585
Work Procedures1585
Air Conditioner Refrigerant Filling is Divided into the “Vacuum Operation” and “Gas Filling Operation”1585
Operation Chart1586
Tools1586
Filling Procedures1588
Charging Hose Connection Position1588
Connecting Gauge Manifold1588
Vacuuming1589
Gas Filling Operation, High-pressure Side1590
Gas Filling Work, Low Pressure Side1590
V ATTACHMENTS1623
Main Equipment Table1627
Backhoe Attachment1627
Cylinder1627
Cylinder (LF)1627
Maintenance Standards1629
Attachment (Backhoe)1629
1 Boom and Swing Frame Installation Section1629
2 Boom Cylinder and Swing Frame Installation Section1630
3 Boom and Boom Cylinder Installation Section1630
4 Boom and Arm Cylinder Installation Section1631
5 Boom and Arm Installation Section1632
6 Arm and Arm Cylinder Installation Section1632
7 Arm and Bucket Cylinder Installation Section1633
8 Arm and Arm Link Installation Section1634
9 Bucket and Bucket Link Installation Section1634
10 Bucket Link and Bucket Cylinder Installation Section1635
11 Bucket and Arm Installation Section1636
Attachment (Backhoe) (LF)1637
1 Boom and Swing Frame Installation Section1637
2 Boom Cylinder and Swing Frame Installation Section1638
3 Boom and Boom Cylinder Installation Section1638
4 Boom and Arm Cylinder Installation Section1639
5 Boom and Arm Installation Section1640
6 Arm and Arm Cylinder Installation Section1640
7 Arm and Bucket Cylinder Installation Section1641
8 Arm and Arm Link Installation Section1641
9 Bucket and Bucket Link Installation Section1642
10 Bucket Link and Bucket Cylinder Installation Section1642
11 Bucket and Arm Installation Section1643
Removal and Installation of Bucket Cylinder1644
Removal of Bucket Cylinder1644
Installation of Bucket Cylinder1646
Removal and Installation of Arm Cylinder1647
Removal of Arm Cylinder1647
Installation of Arm Cylinder1649
Removal and Installation of Boom Cylinder1651
Removal of Boom Cylinder1651
Installation of Boom Cylinder1653
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder1656
Specifications and Structure Diagram (including the assembly diagram and parts table)1656
Basic Functions1656
Function of Each Location1656
Cylinder Head Assembly (made by KYB)1656
Piston Assembly (made by KYB)1657
Pipe Assembly (made by KYB)1659
Handling Precautions1659
Precautions for Installing the Cylinder on the Machine Body1659
Usage Cautions1660
Maintenance and Inspection Cautions1660
Maintenance Inspection and Service1662
Trouble Diagnostics1663
Storage Standards1668
Storing Parts Individually (In principle, store indoors)1668
When Mounted on Vehicle Body1668
Recommended Anti-rust Oil1668
Assembly and Disassembly Procedures1669
Preparations ····· Prepare the Following before Starting Disassembly1669
General Work Precautions1669
Maintenance Standards1669
Inspection after Assembly1669
Required Tool1670
General Tool1670
Special Jig (made by KYB)1671
Special Jig Parts Number List (made by KYB)1671
Disassembly Procedures (made by KYB)1672
Assembly Procedures (made by KYB)1675
Test Operation1680
Usage Limits1681
Structural Diagram (made by KYB)1682
Boom Cylinder1682
Arm Cylinder1684
Arm Cylinder (LF)1686
Bucket Cylinder1688
Bucket Cylinder (LF)1690
HBCV1692
structure1692
Function1692
operation explanation1692
Port Diagram1707
HBCV1707
Air Bleed Procedure1708
HBCV1708
Boom Cylinder HBCV1708
Arm Cylinder HBCV1709
Removal and Installation of HBCV1710
Removal and Installation of Arm HBCV1711
Removal of Arm HBCV1711
Installation of arm HBCV1711
Removal and Installation of Boom HBCV1712
Removal of Boom HBCV1712
Installation of boom HBCV1713
Removal and Installation of Bucket1714
Removal of Bucket1714
Installation of Bucket1714
Removal and Installation of Bucket Link1716
Removal of Bucket Link1716
Installation of Bucket Link1716
Removal and Installation of Arm1718
Removal of Arm1718
Installation of Arm1719
Removal and Installation of Boom1720
Removal of Boom1720
Installation of Boom1722
Z OTHER1727
Changes from Model -61732
Overall Layout1732
Lower1732
Swing Unit1733
Engine1733
hydraulic-related1735
Hydraulic Control1736
Cab, Housing1737
Electrical Data1739
Electric Control1740
Attachments1740
Specifications1741
ENGINE1741
HYDRAULIC SYSTEM1741
HYDRAULIC CONTROLS1742
ELECTRICAL SYSTEM1742
OPERATOR ENVIRONMENT1743
UNDERCARRIAGE1743
MASS1744
DIGGING FORCE (with 11 m3 Sumitomo Bucket) (ISO 6015)1744
DIMENSIONS1744
WORKING RANGES1745
SYSTEM FLUID CAPACITIES AND SPECIFICATIONS1745
Specifications (LF)1746
ENGINE1746
HYDRAULIC SYSTEM1746
HYDRAULIC CONTROLS1747
ELECTRICAL SYSTEM1747
OPERATOR ENVIRONMENT1748
UNDERCARRIAGE1749
MASS1749
DIGGING FORCE (with 037 m3 Sumitomo Bucket) (ISO 6015)1749
DIMENSIONS1749
WORKING RANGES1750
SYSTEM FLUID CAPACITIES AND SPECIFICATIONS1750
Arm Dimension1751
250X41751
250X4 LF1753
Main Unit Weight1756
Divided Weight (Standard Specifications)1756
Divided Weight (LF)1757
Stand Alone Part Weight1757
Stand Alone Part Weight (LF)1758
Shoe Weight (per side)1758
Shoe Weight (per Side) (LF)1758
Arm Weight1758
Arm Weight (LF)1759
Bucket weight1759
Bolt Size and Torque Table1761
Special Torque Setting1761
Overall View1765
250X41765
Standard Arm [300 m (98425 ft)]1765
Short Arm [250 m (82021 ft)]1766
Long Arm [352 m (115486 ft)]1767
250X4 LF1768
Ultra-long Arm [80 m (26247 ft)]1768
WORK RANGE DIAGRAM1769
250X41769
Standard Arm [300 m (98425 ft)]1769
Short Arm [250 m (82021 ft)]1771
Long Arm [352 m (115486 ft)]1773
250X4 LF1775
Ultra-long Arm [80 m (26247 ft)]1775
New Machine Performance Judgment Table1777
Table of Standards1777
Table of Standards (LF)1779
Measurement Method1782
Engine speed1782
Pressure at Each Part1782
Pump Command Displacement1783
Cylinder Down Amount1783
Attachment Speed1783
Swing Speed1784
Swing (180°) Brake Angle1785
Travel Speed1785
Off Travel Amount1785
Travel Sprocket Speed1786
Shoe Tension Amount1786
Swing Ball Race Bearing Movement Amount and Bucket Tip Movement Amount1787
FLUIDS AND LUBRICANTS1789
HYDRAULIC FLUID1789
Engine Oil1789
Fuel1789
Conditions applicable to diesel fuel1789
Recommended Conditions Applicable to Diesel Fuel1789
Main-unit-related Diagnostic Trouble Code List1790
Main Unit-side Trouble1793
Diagnostic Trouble Code: 7000 Pressure Sensor P1 Abnormality1793
Diagnostic Trouble Code: 7001 Pressure Sensor P2 Abnormality1794
Diagnostic Trouble Code: 7002 Pressure Sensor N1 Abnormality1796
Diagnostic Trouble Code: 7003 Pressure Sensor N2 Abnormality1797
Diagnostic Trouble Code: 7004 Pressure Sensor Boom Cylinder Bottom Abnormality1799
Diagnostic Trouble Code: 7007 Pressure Sensor Arm Cylinder Rod Abnormality1800
Diagnostic Trouble Code: 7021 Pressure Sensor Swing Pilot Abnormality1802
Diagnostic Trouble Code: 7023 Pressure Sensor Arm-In Pilot Abnormality1803
Diagnostic Trouble Code: 7040 Level Sensor Fuel Abnormality1805
Diagnostic Trouble Code: 7041 Temperature Sensor Hydraulic Fluid Abnormality1806
Diagnostic Trouble Code: 7065 Pressure Sensor Boom-Up Pilot Abnormality1807
Diagnostic Trouble Code: 7067 Pressure Sensor Bucket-Close Pilot Abnormality1809
Diagnostic Trouble Code: 7068 Pressure Sensor Boom-Down Pilot Abnormality1811
Diagnostic Trouble Code: 7069 Pressure Sensor Arm-Out Pilot Abnormality1812
Diagnostic Trouble Code: 7070 Pressure Sensor Bucket-Open Pilot Abnormality1814
Diagnostic Trouble Code: 7071 Pressure Sensor Travel Right Pilot Abnormality1815
Diagnostic Trouble Code: 7072 Pressure Sensor Travel Left Pilot Abnormality1817
Diagnostic Trouble Code: 7073 Pressure Sensor Travel 1 Pedal Abnormality1819
Diagnostic Trouble Code: 7074 Pressure Sensor 1st Option Pilot (Common/Front Pedal) Abnormality1821
Diagnostic Trouble Code: 7075 Pressure Sensor Arm Cylinder Bottom Abnormality1822
Diagnostic Trouble Code: 7078 Pressure Sensor 1st Option Pilot (Rear Pedal) Abnormality1824
Diagnostic Trouble Code: 7200 Swing Brake Solenoid Abnormality1826
Diagnostic Trouble Code: 7201 Travel 2nd-Speed Switchover Solenoid Abnormality1827
Diagnostic Trouble Code: 7202 Pressure Boost Solenoid Abnormality1828
Diagnostic Trouble Code: 7203 Travel Alarm Buzzer Abnormality1829
Diagnostic Trouble Code: 7206 Option Return Line Switchover Solenoid Abnormality1830
Diagnostic Trouble Code: 7207 Free Swing Solenoid Abnormality1831
Diagnostic Trouble Code: 7213 Quick Coupler Buzzer Abnormality1832
Diagnostic Trouble Code: 7214 Quick Coupler Solenoid Abnormality1834
Diagnostic Trouble Code: 7247 Boom 2-Down Pilot Proportional Valve Abnormality1835
Diagnostic Trouble Code: 7249 Bucket-Close Pilot Proportional Valve Abnormality1836
Diagnostic Trouble Code: 7250 Option Relief Pressure Proportional Valve Abnormality1838
Diagnostic Trouble Code: 7265 Arm 1 Semi-Parallel Proportional Valve Abnormality1839
Diagnostic Trouble Code: 7266 Arm 2 Semi-Parallel Proportional Valve Abnormality1840
Diagnostic Trouble Code: 7267 Arm 1 Regeneration Release Proportional Valve Abnormality1841
Diagnostic Trouble Code: 7270 Tilting 1 Proportional Valve Abnormality1842
Diagnostic Trouble Code: 7271 Tilting 2 Proportional Valve Abnormality1844
Diagnostic Trouble Code: 7273 Straight Travel Proportional Valve Abnormality1845
Diagnostic Trouble Code: 7400 Coolant Temperature Overheating 11846
Diagnostic Trouble Code: 7401 Coolant Temperature Overheating 21847
Diagnostic Trouble Code: 7404 Oil Temperature Overheating1848
Diagnostic Trouble Code: 7405 Boost Temperature Overheating 11849
Diagnostic Trouble Code: 7406 Boost Temperature Overheating 21850
Diagnostic Trouble Code: 7420 Alternator Power Generation Failure1851
Diagnostic Trouble Code: 7421 Coolant Level Decrease1852
Diagnostic Trouble Code: 7422 Engine Oil Pressure Decrease1853
Diagnostic Trouble Code: 7423 Air Cleaner Clogging1854
Diagnostic Trouble Code: 7424 Return Filter Clogging1855
Diagnostic Trouble Code: 7426 Fuel Filter Clogging 11856
Diagnostic Trouble Code: 7427 Fuel Filter Clogging 21857
Diagnostic Trouble Code: 7428 Inducement (Remaining Urea Level Low) – Warning1858
Diagnostic Trouble Code: 7429 Inducement (Remaining Urea Level Low) – Early1859
Diagnostic Trouble Code: 7430 Inducement (Remaining Urea Level Low) – Final1859
Diagnostic Trouble Code: 7602 ECM Communication Abnormality1860
Diagnostic Trouble Code: 7605 ECM Not-Matched1861
Diagnostic Trouble Code: 7606 EEPROM Abnormality1862
Diagnostic Trouble Code: 7608 Camera Abnormality1862
Diagnostic Trouble Code: 7612 Air Conditioner Communication Abnormality1864
Diagnostic Trouble Code: 7613 Monitor Communication (CAN) Abnormality1865
Diagnostic Trouble Code: 7615 Sub-Controller Communication Abnormality1866
Diagnostic Trouble Code: 7618 DCU Communication Abnormality1868
List of special tools1870
NUMERICAL VALUE CONVERSION TABLE1870
Unit conversion rate1870
Length1870
Area1872
Volume1873
Weight1875
Pressure1876
Torque1877
Temperature1878
A1881
Travel Motor Special Tool1881
250X41881
Take-up Roller Special Tool1884
250X41884
Upper Roller Special Tool1885
250X41885
Lower Roller Special Tool1886
250X41886
C1887
Swing Motor Special Tool1887
250X41887
H1890
Engine Oil Filter Special Tool1890
210X4／250X41890
Fuel Filter Special Tool1890
210X4／250X41890
Injector Special Tool1890
210X4／250X41890
Circuit Test Special Tool1891
210X4／250X41891
Valve Guide Special Tool1891
210X4／250X41891
Cylinder Head Special Tool1891
210X4／250X41891
Head Bolt Special Tool1894
210X4／250X41894
Crankshaft Special Tool1894
210X4／250X41894
Valve Spring Special Tool1896
210X4／250X41896
J1897
Remote Control Valve Special Tool1897
250X41897
R1899
Gas Filling Special Tool1899
210X4／250X41899
V1899
Attachment Special Tool (for Cylinder Assembly)1899
Special Jigs Part Number List1899
Paint Colors1901
Abbreviation1903
WLSM2507-00LX-A3-Jpdf 0
A3 Assembly Diagrams 0
J1253
Explanation of Hydraulic Circuit and Operations (standard model)1255
Travel Circuit1256
Travel Low-speed Circuit1256
Travel High-speed Circuit1258
Straight Travel Circuit (with HBCV)1260
Swing Circuit1262
Swing Speed Limit Control Circuit1262
Swing Relief Cut Control Circuit1264
Swing Brake Circuit1266
Swing Parking Circuit (lever in neutral)1268
Swing Parking Circuit (brake release)1270
Swing Parking Circuit (machine stop)1272
Boom Circuit1274
Boom-up Circuit (independent operation) (with HBCV)1274
Boom-up Spool Stroke Control Circuit (compound boom-up + arm-in) (with HBCV)1276
Boom-down Regenerative Circuit (with HBCV)1278
Boom-down Tilting Prevention Circuit (with HBCV)1280
Boom-down Load Holding Valve Circuit (with HBCV)1282
Arm Circuit1284
Arm-out Circuit (with HBCV)1284
Arm Semi-Parallel 1 Circuit1286
Arm Semi-Parallel 2 Circuit1288
Arm-in Regenerative Circuit (with HBCV)1290
Arm-in Load Holding Valve Circuit (with HBCV)1292
Bucket Circuit1294
Bucket-open Circuit1294
Bucket-close Regenerative Circuit1296
Bucket-Close Spool Stroke Control Circuit1298
Negative Control Circuit1300
Negative Control Circuit1300
Other Circuits1302
Cushion Circuit (arm-out operation)1302
Cushion Circuit (when arm-out operation stopped)1304
Cushion Circuit (arm-out → arm-in operation)1306
Heat Circuit (lever in neutral)1308
Auto Pressure Boost Circuit (arm in)1310
J1313
Explanation of Hydraulic Circuit and Operations (option)1315
Option Circuits1316
Breaker Circuit (independent operation)1316
Double-acting Circuit (hydraulic fork)1318
Multi-purpose Circuit (breaker Q control)1320
Multi-purpose Circuit (2 pumps flow crusher)1322
2nd Option Circuit (hydraulic rotation fork)1324
R 0
Electrical Connector Wiring Diagram 0
Main Frame 0
Control Valve 0
SCR 0
Cab Main Harness 0
Console 0
EST-A 0
Indicator Jumper 0
R 0
Electrical Parts and Wiring Assembly Diagram 0
Frame 0
Engine and Pump 0
Attachments 0
Battery 0
Cab 0
WLSM2507-00LX-A3-Rpdf 0
A3 Assembly Diagrams 0
J 0
Explanation of Hydraulic Circuit and Operations (standard model) 0
Travel Circuit 0
Travel Low-speed Circuit 0
Travel High-speed Circuit 0
Straight Travel Circuit (with HBCV) 0
Swing Circuit 0
Swing Speed Limit Control Circuit 0
Swing Relief Cut Control Circuit 0
Swing Brake Circuit 0
Swing Parking Circuit (lever in neutral) 0
Swing Parking Circuit (brake release) 0
Swing Parking Circuit (machine stop) 0
Boom Circuit 0
Boom-up Circuit (independent operation) (with HBCV) 0
Boom-up Spool Stroke Control Circuit (compound boom-up + arm-in) (with HBCV) 0
Boom-down Regenerative Circuit (with HBCV) 0
Boom-down Tilting Prevention Circuit (with HBCV) 0
Boom-down Load Holding Valve Circuit (with HBCV) 0
Arm Circuit 0
Arm-out Circuit (with HBCV) 0
Arm Semi-Parallel 1 Circuit 0
Arm Semi-Parallel 2 Circuit 0
Arm-in Regenerative Circuit (with HBCV) 0
Arm-in Load Holding Valve Circuit (with HBCV) 0
Bucket Circuit 0
Bucket-open Circuit 0
Bucket-close Regenerative Circuit 0
Bucket-Close Spool Stroke Control Circuit 0
Negative Control Circuit 0
Negative Control Circuit 0
Other Circuits 0
Cushion Circuit (arm-out operation) 0
Cushion Circuit (when arm-out operation stopped) 0
Cushion Circuit (arm-out → arm-in operation) 0
Heat Circuit (lever in neutral) 0
Auto Pressure Boost Circuit (arm in) 0
J 0
Explanation of Hydraulic Circuit and Operations (option) 0
Option Circuits 0
Breaker Circuit (independent operation) 0
Double-acting Circuit (hydraulic fork) 0
Multi-purpose Circuit (breaker Q control) 0
Multi-purpose Circuit (2 pumps flow crusher) 0
2nd Option Circuit (hydraulic rotation fork) 0
R1593
Electrical Connector Wiring Diagram1595
Main Frame1596
Control Valve1598
SCR1600
Cab Main Harness1602
Console1604
EST-A1606
Indicator Jumper1608
R1609
Electrical Parts and Wiring Assembly Diagram1611
Frame1612
Engine and Pump1614
Attachments1616
Battery1618
Cab1620
S.M 3/1/25
