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Link belt 250X4/250X4 LF Excavator SERVICE MANUAL WLSM2507-08LX – PDF DOWNLOAD
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Description
Link belt 250X4/250X4 LF Excavator SERVICE MANUAL WLSM2507-08LX – PDF DOWNLOAD
FILE DETAILS:
Link belt 250X4/250X4 LF Excavator SERVICE MANUAL WLSM2507-08LX – PDF DOWNLOAD
Language : English
Pages :1842
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Link belt 250X4/250X4 LF Excavator SERVICE MANUAL WLSM2507-08LX – 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 WLSM2507-08LX – PDF DOWNLOAD
Excavator 1
SAFETY 9
Safety, general information and standard torque data 12
General Information 13
Safety 13
ROPS 15
ROPS Judgment 15
Standard Torque Data For Cap Screws And Nuts 19
Bolt and Nut Tightening 19
A LOWER 21
Main Equipment Table 25
Lower Component 25
Travel Unit 25
Take-up Roller 25
Upper Roller 25
Lower Roller 25
Recoil Spring 25
Shoe 25
Shoes (LF) 26
Center Joint 26
Main Equipment Structure and Operation Explanation 27
Travel Motor 27
Travel motor operation explanation 27
Explanation of Component Device Operation 27
Double Counter Balance Valve 27
Crossover Relief Valve 32
Automatic 2-speed Switchover Mechanism 33
Parking Brake Function 36
Piston Motor 37
Reduction Gear 38
Port Diagram 40
Travel Motor 40
Center Joint 40
Basic Functions 41
Travel Speed Selection 41
Travel Alarm 41
Removal and Installation of Track 43
Removal and Installation of Shoe Assembly 44
Removal of Shoe Assembly 44
Installation of Shoe Assembly 45
Removal and Installation of Shoe Plate 48
Removal of Shoe Plate 48
Installation of Shoe Plate 48
Removal and Installation of Roller 49
Removal and Installation of Upper Roller 50
Removal of Upper Roller 50
Installation of Upper Roller 51
Assembly and Disassembly of Upper Roller 52
Configuration Diagram 52
Dimension Diagram 53
Jig Dimension Diagram 53
Disassembly Procedures 54
Assembly Procedures 56
Removal and Installation of Lower Roller 59
Removal of Lower Roller 59
Installation of Lower Roller 60
Assembly and Disassembly of Lower Roller 61
Configuration Diagram 61
Dimension Diagram 62
Jig Dimension Diagram 62
Disassembly Procedures 62
Assembly Procedures 65
Removal and Installation of Drive Sprocket 67
Removal of Drive Sprocket 67
Installation of Drive Sprocket 69
Removal and Installation of Take-up Roller 70
Removal of Take-up Roller 70
Installation of Take-up Roller 71
Assembly and Disassembly of Take-up Roller 72
Configuration Diagram 72
Dimension Diagram 73
Jig Dimension Diagram 73
Disassembly Procedures 73
Assembly Procedures 76
Removal and Installation of Grease Cylinder 80
Removal of grease cylinder 80
Installation of grease cylinder 81
Assembly and Disassembly of Tension Shock Absorber 82
Configuration Diagram 82
Dimension Diagram 82
Jig Dimension Diagram 83
Disassembly procedures 83
Assembly procedures 83
Removal and Installation of Center Joint 86
Removal of Center Joint 86
Installation of Center Joint 88
Assembly and Disassembly of Center Joint 90
Configuration Diagram 91
Dimension Diagram 92
Jig Dimension Diagram 93
Disassembly Procedures 93
Assembly Procedures 94
Removal and Installation of Travel Motor 97
Removal of Travel Motor 97
Installation of Travel Motor 99
Assembly and Disassembly of Travel Motor 102
Tools for Assembly and Disassembly 102
Standard Tool 102
Secondary Materials 103
Special Tool (jig) 104
Measurement Device 105
Motor Disassembly Procedures 105
Precautions before Motor Disassembly 105
Tightening torque 106
Disassembly Procedure 107
Maintenance Standards 115
Motor Parts Maintenance Standards 115
Reduction Gear Parts Maintenance Standards 118
Motor Assembly Procedures 120
Precautions before Motor Assembly 120
Assembly Procedure 121
Motor Installation 134
Inspection 134
Hydraulic Oil and Gear Oil Filling 135
Initial Pre-conditioning Operation 136
Troubleshooting 137
Structural Diagram 145
Internal Structure Diagram 148
Component Table 150
Maintenance Standards 151
Drive Sprocket 151
Take-up Roller 152
Upper Roller 153
Lower Roller 154
Track Shoe (grouser shoe) 155
Inspection Gauge 157
For Drive Sprocket 157
For Take-up Roller 157
For Upper Roller 158
For Lower Roller 158
Pressure Measurement and Adjustment Procedures 159
Main Pressure Measurement 159
Travel pressure measurement 159
Drain Volume Measurement Procedures 160
Preparations 160
Travel Motor Drain Volume Measurement 160
Air Bleed Procedure 162
Travel Motor 162
B C SWING UNIT, COUNTERWEIGHT 163
Main Equipment Table 166
Upper Component 166
Swing Unit 166
Swing Unit (LF) 166
Main Equipment Structure and Operation Explanation 167
Swing Motor 167
Swing Motor Operation Explanation 167
Hydraulic Motor Section 167
Valve Casing Section 167
Brake Section 168
Relief Valve Operation Explanation (relief valve model: KRD22EK10) 168
Swing Motor Internal Structure Diagram 172
Port Diagram 175
Swing motor 175
Basic Functions 176
Swing Brake 176
Swing Lock 176
Swing Speed Limit 177
Swing Relief Cut 179
Removal and Installation of Swing Unit 181
Removal of Swing Unit 181
Installation of Swing Unit 183
Assembly and Disassembly of Swing Motor 184
Causes of Trouble and Solutions 184
Maintenance Standard Table 186
Required Tools 188
Jig 189
Disassembly 189
Assembly 191
Swing Motor Internal Structural Diagram 196
Assembly and Disassembly of Swing Unit 198
Disassembly 198
Assembly 199
Swing Reduction Gear Breakdown Diagram 201
Swing Reduction Gear Structure Diagram 202
Removal and Installation of Counterweight 203
Removal of Counterweight 203
Installation of Counterweight 204
Pressure Measurement and Adjustment Procedures 206
Main Pressure Measurement 206
Swing pressure measurement 206
Drain Volume Measurement Procedures 207
Preparations 207
Swing Motor Drain Volume Measurement 207
Air Bleed Procedure 208
Swing Motor 208
Check 209
H ENGINE 211
Main Equipment Table 219
Engine-related 219
Engine 219
Air Cleaner (double element) 219
Radiator 219
SCR 219
Basic Functions 220
Fuel Gauge 220
Coolant Temperature Gauge 221
SCR Gauge 223
Fuel Economy Gauge 226
Neutral Start 227
Power-cut Delay 228
Preheat 228
Throttle 229
Throttle Volume Position Detection 230
Idling Start 236
Auto Idle 236
One-touch Idle 237
Auto Warm-Up 238
Idle Shutdown 243
Idle Up 244
Work Mode Control 245
Engine Emergency Stop 246
SCR RE-GEN 246
Inducement 251
Feed Pump Automatic Stop 255
Coolant Level Decrease 257
Air Filter Clogging 258
Fuel Filter Clogging 259
Battery Charge Abnormality 260
Horsepower Reduction Control (in Uplands) 261
Horsepower Reduction Control (at Engine Failure) 261
Main Data 264
Function, Structure, Operation 266
Function, structure, operation (SCR) 322
SCR Control System Inspection 348
Operation Explanation of SCR 349
Diagnosis for Each Symptom 351
Intermittent conditions of urea selective catalytic reduction system 351
Urea fluid consumption too high 354
Ammonia smell noticeable 354
White crystalline powder visible 355
Diagnosis for Each Symptom 356
Engine Start Problem 356
Engine Stalling 358
Engine Hunting, Rough Idling 360
Excessive White Smoke in Exhaust Gas 362
Excessive Black Smoke in Exhaust Gas 362
Abnormal Noise 363
High Fuel Consumption 364
High Oil Consumption 365
Engine Output Deficiency 366
Functional Inspection 368
Engine Compression Pressure Inspection 368
Fuel System Inspection 369
Lubrication system check 369
Suction air system inspection 370
Exhaust system inspection 370
EGR Control System Inspection 370
Start System Inspection 371
Glow control system check 371
OBD system check 373
Inspection of the monitor warning light illumination circuit system 373
Inspection of the monitor warning light blinking circuit system 374
Inspection of the starter circuit system 374
Removal and Installation of Engine Assembly 376
Removal of Engine Assembly 376
Installation of Engine Assembly 381
Removal and Installation of Fuel Cooler, Engine Intercooler, Radiator, and Oil Cooler 382
Removal and Installation of Fuel Cooler 382
Removal of Fuel Cooler 382
Installation of Fuel Cooler 382
Removal and Installation of Engine Intercooler 382
Removal of Intercooler 383
Installation of Inter Cooler 383
Inspection of Intercooler 383
Removal and Installation of Radiator 384
Removal of Radiator 384
Installation of Radiator 388
Inspection of Radiator 388
Removal and Installation of Oil Cooler 389
Removal of Oil Cooler 389
Installation of Oil Cooler 392
Removal and Installation of Turbo Charger 393
Removal of Turbo Charger 393
Installation of Turbo Charger 395
Inspection of Turbo Charger 398
Removal and Installation of EGR Valve 400
Removal of EGR Valve 400
Installation of EGR Valve 402
Inspection of EGR Valve 406
Removal and Installation of Engine Hood 407
Removal of Engine Hood 407
Installation of Engine Hood 408
Removal and Installation of SCR 409
Removal of SCR 409
Installation of SCR 410
Removal and installation of Silicon Controlled Rectifier Catalyst 411
Removal of Silicon Controlled Rectifier Catalyst 411
Installation of Silicon Controlled Rectifier Catalyst 411
Disassembly of Silicon Controlled Rectifier Catalyst 411
Assembly of Silicon Controlled Rectifier Catalyst 411
Inspection of Silicon Controlled Rectifier Catalyst 412
Removal and Installation of Cylinder Head Cover 413
Cylinder head cover Removal 413
Installation of Cylinder Head Cover 413
Removal and Installation of Cylinder Head 414
Removal of Cylinder Head 414
Disassembly of Cylinder Head 422
Assembly of Cylinder Head 427
Installation of Cylinder Head 434
Inspection 451
Removal and Installation of Cylinder Block 457
Removal of Cylinder Block 457
Installation of Cylinder Block 473
Inspection 508
Lubrication System 510
Removal and Installation of Oil Pan 510
Removal of Oil Pan 510
Installation of Oil Pan 510
Removal and Installation of Oil Level Switch 510
Removal of Oil Level Switch 510
Installation of Oil Level Switch 511
Removal and Installation of Oil Pump Assembly 511
Removal of Oil Pump Assembly 511
Disassembly of Oil Pump Assembly 523
Assembly of Oil Pump Assembly 524
Installation of Oil Pump Assembly 524
Inspection 548
Engine oil Inspection 549
Removal and Installation of Oil Port Cover 550
Removal of Oil Port Cover 550
Installation of Oil Port Cover 550
Cooling System 552
Removal and Installation of Water Pump Assembly 552
Removal of Water Pump Assembly 552
Installation of Water Pump Assembly 553
Inspection 557
Removal and Installation of Thermostat 557
Removal of Thermostat 557
Installation of Thermostat 558
Inspection 560
Inspection of Coolant 560
Inspection of Cooling Fan Belt 565
Removal and Installation of Overheat Switch 566
Removal of Overheat Switch 566
Installation of Overheat Switch 566
Induction System 567
Inspection of Air Cleaner Element 567
Exhaust System 568
Removal and installation of Oxidation Catalyst Assembly 568
Removal of Oxidation Catalyst Assembly 568
Installation of Oxidation Catalyst Assembly 568
Aux Emission Control Devices System 571
Removal and installation of Dosing Module 571
Removal of Dosing Module 571
Disassembly of Dosing Module 571
Assembly of Dosing Module 572
Installation of Dosing Module 572
Removal and installation of DEF Supply Module 574
Removal of DEF supply module 574
Disassembly of DEF Supply Module 575
Assembly of DEF Supply Module 575
Installation of DEF Supply Module 576
Removal and installation of Coolant Control Valve 578
Removal of Coolant Control Valve 578
Installation of Coolant Control Valve 579
Removal and installation of DEF Supply Module Filter 580
Removal of DEF Supply Module Filter 580
Installation of DEF Supply Module Filter 581
Removal and Installation of Exhaust Manifold 582
Removal of Exhaust Manifold 582
Installation of Exhaust Manifold 585
Inspection 591
Removal and Installation of Fuel Tank 592
Removal of Fuel Tank 592
Installation of fuel tank 595
Removal and Installation of Urea Pump 596
Removal of Urea Pump 596
Installation of Urea Pump 597
Removal and Installation of Urea Solution Tank 598
Removal of Urea Solution Tank 598
Installation of Urea Solution Tank 598
Removal and Installation of Fuel Supply Pump 600
Removal of Fuel Supply Pump 600
Installation of Fuel Supply Pump 601
Removal and Installation of Common Rail Assembly 605
Removal of Common Rail Assembly 605
Installation of Common Rail Assembly 607
Removal and Installation of Injector 612
Removal of Injector 612
Installation of Injector 615
Removal and installation of Idle Gear 621
Removal of Idle Gear 621
Installation of Idle Gear 633
Inspection of Idle Gear 657
Removal and installation of Inlet Cover 659
Removal of Inlet Cover 659
Installation of Inlet Cover 663
Removal and installation of Crankshaft 673
Removal of Crankshaft 673
Installation of Crankshaft 688
Disassembly of Crankshaft 720
Assembly of Crankshaft 720
Inspection of Crankshaft 721
Removal and installation of Piston 726
Removal of Piston 726
Installation of Piston 736
Disassembly of Piston 756
Assembly of Piston 756
Inspection of Piston 757
Removal and installation of Camshaft 764
Removal of Camshaft 764
Installation of Camshaft 765
Disassembly of Camshaft 769
Assembly of Camshaft 770
Inspection of Camshaft 770
Removal and installation of Flywheel 772
Removal of Flywheel 772
Installation of Flywheel 773
Inspection of Flywheel 774
Removal and installation of Crankshaft Front Oil Seal 775
Removal of Crankshaft Front Oil Seal 775
Installation of Crankshaft Front Oil Seal 776
Removal and installation of Crankshaft Rear Oil Seal 779
Removal of Crankshaft Rear Oil Seal 779
Installation of Crankshaft Rear Oil Seal 780
Removal and installation of Rocker Arm Shaft 783
Removal of Rocker Arm Shaft 783
Installation of Rocker Arm Shaft 784
Disassembly of Rocker Arm Shaft 787
Assembly of Rocker Arm Shaft 787
Inspection of Rocker Arm Shaft 788
Removal and installation of Valve Spring 791
Removal of Valve Spring 791
Installation of Valve Spring 793
Inspection of Valve Spring 798
Removal and installation of Valve Stem Oil Seal 800
Removal of Valve Stem Oil Seal 800
Installation of Valve Stem Oil Seal 802
Removal and installation of Front Cover 809
Removal of Front Cover 809
Installation of Front Cover 811
Removal and installation of Intake Throttle Valve 817
Removal of Intake Throttle Valve 817
Installation of Intake Throttle Valve 817
Removal and Installation of Starter Motor 818
Removal of Starter Motor 818
Installation of Starter Motor 819
Disassembly of Starter Motor 819
Assembly of Starter Motor 820
Inspection of Starter Motor 822
Removal and Installation of Alternator 826
Removal of Alternator 826
Installation of Alternator 827
Disassembly of Alternator 828
Assembly of Alternator 828
Inspection of Alternator 830
Removal and Installation of Glow Plug 834
Removal of Glow Plug 834
Installation of Glow Plug 834
Glow plug Inspection 834
Removal and Installation of Suction Control Valve 835
Removal of Suction Control Valve 835
Installation of Suction Control Valve 835
Removal and installation of Fuel Filter 838
Removal of Fuel Filter 838
Installation of Fuel Filter 838
Removal and installation of Relief Valve 841
Removal of Relief Valve 841
Installation of Relief Valve 841
Removal and installation of Fuel Filter Element 844
Removal of Fuel Filter Element 844
Installation of Fuel Filter Element 845
Removal and Installation of Fuel filter pressure 848
Fuel filter pressure sensor Removal 848
Fuel filter pressure sensor Installation 848
Removal and Installation of Engine coolant temperature sensor 849
Engine coolant temperature sensor Removal 849
Engine coolant temperature sensor Installation 849
Engine coolant temperature sensor Inspection 849
Removal and Installation of CKP sensor 850
CKP sensor Removal 850
CKP sensor Installation 850
CKP sensor Inspection 850
Removal and Installation of CMP sensor 851
CMP sensor Removal 851
CMP sensor Installation 851
CMP sensor Inspection 851
Removal and Installation of Oil pressure sensor 852
Oil pressure sensor Removal 852
Oil pressure sensor Installation 852
Oil pressure sensor Inspection 852
Removal and installation of Pressure Sensor/Boost Temperature Sensor 853
Removal of Pressure Sensor/Boost Temperature Sensor 853
Installation of Pressure Sensor/Boost Temperature Sensor 853
Inspection of Pressure Sensor/Boost Temperature Sensor 853
Removal and Installation of IMT sensor 854
Removal of IMT sensor 854
Installation of IMT sensor 854
Removal and installation of Charge Air Cooler Temperature Sensor 1 855
Removal of Charge Air Cooler Temperature Sensor 1 855
Installation of Charge Air Cooler Temperature Sensor 1 855
Inspection of Charge Air Cooler Temperature Sensor 1 855
Sampling Procedure 856
Sampling of Engine Oil 856
Removal and Installation of Exhaust gas temperature sensor 857
Exhaust gas temperature sensor Removal 857
Exhaust gas temperature sensor Installation 857
Exhaust gas temperature sensor Inspection 857
Removal and installation of EGR Gas Temperature Sensor 1 859
Removal of EGR Gas Temperature Sensor 1 859
Installation of EGR Gas Temperature Sensor 1 859
Inspection of EGR Gas Temperature Sensor 1 859
Removal and installation of EGR Gas Temperature Sensor 2 860
Removal of EGR Gas Temperature Sensor 2 860
Installation of EGR Gas Temperature Sensor 2 860
Inspection of EGR Gas Temperature Sensor 2 860
Removal and installation of NOx Sensor 862
Removal of NOx Sensor 862
Installation of NOx Sensor 862
Removal and installation of EGR Gas Temperature Sensor 3 864
Removal of EGR Gas Temperature Sensor 3 864
Installation of EGR Gas Temperature Sensor 3 864
Removal and installation of DEF Sensor 865
Removal of DEF Sensor 865
Installation of DEF Sensor 865
Engine-related Diagnostic Trouble Code List 866
Engine-side Trouble 871
ECM Trouble 871
DTC U0001 CAN Bus Error (ISO-CAN) 871
DTC P0016 Crankshaft Position – Camshaft Position Correlation Error 872
DTC P0045 Turbocharger Boost Control VNT Error 872
DTC U0073 Control Module Communication Bus Off 874
DTC P0087 Fuel Rail/System Pressure – Too Low 875
DTC P0089 Fuel Pressure Regulator Performance 878
DTC P0091 Fuel Pressure Regulator Control Circuit Low 879
DTC P0092 Fuel Pressure Regulator Control Circuit High 880
DTC P0097 Intake Air Temperature (IAT) Sensor 2 Circuit Low Voltage 881
DTC P0098 Intake Air Temperature (IAT) Sensor 2 Circuit High Voltage 881
DTC U0101 Lost Communication With CAN 882
DTC P0102 Mass Air Flow Sensor Circuit Low Input 883
DTC P0103 Mass Air Flow Sensor Circuit High Input 884
DTC U010E Lost Communications With Dosing Control Module 884
DTC U0110 Lost Communication With VNT System 885
DTC P0112 Intake Air Temperature Sensor Circuit Low 885
DTC P0113 Intake Air Temperature Sensor Circuit High 886
DTC P0117 Engine Coolant Temperature Sensor Circuit Low 887
DTC P0118 Engine Coolant Temperature Sensor Circuit High 887
DTC P0122 Throttle Position Sensor Circuit Low 888
DTC P0123 Throttle Position Sensor Circuit High 889
DTC P0182 Fuel Temperature Sensor Circuit Low 890
DTC P0183 Fuel Temperature Sensor Circuit High 891
DTC P0192 Fuel Rail Pressure Sensor Circuit Low 892
DTC P0193 Fuel Rail Pressure Sensor Circuit High 892
DTC P0201 Injector Circuit Open – Cylinder 1 894
DTC P0202 Injector Circuit Open – Cylinder 2 894
DTC P0203 Injector Circuit Open – Cylinder 3 895
DTC P0204 Injector Circuit Open – Cylinder 4 896
DTC P0217 Engine Coolant Over Temperature Condition 897
DTC P0219 Engine Overspeed Condition 897
DTC P0234 Turbocharger Overboost Condition 898
DTC P0237 Turbo Charger Boost Sensor Circuit Low 899
DTC P0238 Turbo Charger Boost Sensor Circuit High 899
DTC P0335 Crankshaft Position Sensor Circuit 900
DTC P0336 Crankshaft Position Sensor Circuit Range/Performance 901
DTC P0340 Camshaft Position Sensor Circuit 902
DTC P0380 Glow Relay Circuit Error 903
DTC P0401 EGR Flow Insufficient Detected 904
DTC P0404 EGR Control Circuit Range/Performance 905
DTC P0409 EGR Sensor Circuit 905
DTC U0411 Lost CAN Communications With VNT Control Module 907
DTC P041C EGR Cooler Outlet 1 Temp Sensor Circuit Low 907
DTC P041D EGR Cooler Outlet 1 Temp Sensor Circuit High 908
DTC P0427 Catalyst Temperature Sensor Circuit Low Sensor 1 909
DTC P0428 Catalyst Temperature Sensor Circuit High Sensor 1 909
DTC P042C Catalyst Temperature Sensor Circuit Low Sensor 2 910
DTC P042D Catalyst Temperature Sensor Circuit High Sensor 2 911
DTC P0522 Engine Oil Pressure Sensor Circuit Low Input 912
DTC P0523 Engine Oil Pressure Sensor Circuit High Input 913
DTC P0545 EGR Cooler Inlet 1 Temp Sensor Circuit Low 914
DTC P0546 EGR Cooler Inlet 1Temp Sensor Circuit High 914
DTC P0560 12 Volt Circuit Error 915
DTC P0563 System Voltage High 915
DTC P0601 Internal Control Module Memory Check Sum Error 916
DTC P0602 Internal Control Module QR Code Error 916
DTC P0604 Internal Control Module RAM Error 917
DTC P0606 Internal Control Module CPU Error 917
DTC P060A Internal Control Module CPU IC Error 917
DTC P060C Internal Control Module A/D Processing Performance 917
DTC P0615 Starter Relay Circuit Error 918
DTC P0638 Throttle Actuator Control Range/Performance 918
DTC P0685 ECM Power Relay Control Circuit Open 919
DTC P0687 ECM Power Relay Control Circuit High 920
DTC P06A6 Sensor Reference Voltage 1 Circuit 920
DTC P06A7 Sensor Reference Voltage 2 Circuit 921
DTC P06A8 Sensor Reference Voltage 3 Circuit 922
DTC P06A9 Sensor Reference Voltage 4 Circuit 922
DTC P06AF Torque Management System – Forced Engine Shutdown 923
DTC P06D5 Sensor Reference Voltage 5 Circuit 924
DTC P1076 Charge Air Cooler (CAC) Temperature Sensor 1 Circuit Low Voltage 924
DTC P1077 Charge Air Cooler (CAC) Temperature Sensor 1 Circuit High Voltage 924
DTC P1093 Fuel Rail Pressure Too Low 925
DTC P1097 Compressor Outlet Temperature Sensor Circuit High 928
DTC P1098 Compressor Outlet Temperature Sensor Circuit High 929
DTC P1236 Charge Air Cooler Performance Failure 930
DTC P1261 Injector Positive Voltage Control Circuit Group 1 930
DTC P1262 Injector Positive Voltage Control Circuit Group 2 931
DTC P1404 EGR Position Fault 931
DTC P1606 SW-IC Internal failure 932
DTC P160B AD-IC Failure Error 932
DTC P160C AD-IC2 Failure Error 932
DTC P1621 Control Module Long Term Memory Performance 932
DTC P1669 DPD Lamp Control Circuit 933
DTC P2000 Monitoring the NOx Efficiency 934
DTC P204F SCR System Error (No Inducement) 935
DTC P207F Urea Fluid Concentration Too Low 935
DTC P20C9 SCR System Error 935
DTC U2106 Lost CAN Communications With Wheel Loader Transmission Control System 936
DTC P2122 Pedal Position Sensor 1 Circuit Low Input 936
DTC P2123 Pedal Position Sensor 1 Circuit High Input 937
DTC P2127 Pedal Position Sensor 2 Circuit Low Input 937
DTC P2128 Pedal Position Sensor 2 Circuit High Input 938
DTC P2138 Pedal Position Sensor 1 – 2 Voltage Correlation 939
DTC P2146 Fuel Injector Group 1 Supply Voltage Circuit 939
DTC P2149 Fuel Injector Group 2 Supply Voltage Circuit 941
DTC P2210 Reading the error(open) information detected by Rr NOx sensor 942
DTC P2211 Reading the error(short) information detected by Rr NOx sensor 942
DTC P2228 Barometric Pressure Sensor Circuit Low 942
DTC P2229 Barometric Pressure Sensor Circuit High 943
DTC P2457 Exhaust Gas Recirculation (EGR) Cooling System Performance 943
DTC P2458 Purge time Out Error 944
DTC P2BA7 Urea Fluid Quantity Too Low 944
DTC P2BAA SCR System Error (Inducement, No Purge) 944
DTC P3093 Fuel Rail Pressure Too Low 944
DCU Trouble 947
DTC U0002 CAN Bus Off 947
DTC U0100 Lost Communication With ECM 948
DTC U029D Lost Communication With NOx Sensor 1 949
DTC U029E CAN communication error between DCU and Rr NOx sensor 951
DTC P0607 Control Module Performance 952
DTC P060B Internal Control Module A/D Processing Performance 952
DTC P062F Control Module EEPROM Error 952
DTC P0641 Sensor Reference Voltage 1 Circuit 953
DTC P0658 Actuator Supply Voltage Circuit 954
DTC P0659 Actuator Supply Voltage Circuit 955
DTC P1462 Urea Fluid Quality Sensor Timeout Error 956
DTC P1464 Main Relay Performance 957
DTC P1468 DCU Overtemperature 958
DTC P1491 Urea Fluid Overpressure 958
DTC P1493 DCU Driver Overtemperature 959
DTC P149C Urea Fluid Pressure Reduction Malfunction 960
DTC P149D Urea Fluid Tank Overtemperature 961
DTC P203B Urea Fluid Tank Level Sensor Stuck 962
DTC P203C Urea Fluid Tank Level Sensor Low Voltage 963
DTC P203D Urea Fluid Tank Level Sensor High Voltage 963
DTC P2048 Urea Fluid Injector Circuit Low Voltage 964
DTC P2049 Urea Fluid Injector Circuit High Voltage 965
DTC P204B Urea Fluid Pressure Sensor Performance 966
DTC P204C Urea Fluid Pressure Sensor Circuit Low Voltage 967
DTC P204D Urea Fluid Pressure Sensor Circuit High Voltage 967
DTC P205B Urea Fluid Tank Temperature Sensor Performance 968
DTC P205C Urea Fluid Tank Temperature Sensor Low Voltage 969
DTC P205D Urea Fluid Tank Temperature Sensor High Voltage 970
DTC P206A Urea Fluid Quality Sensor Circuit 970
DTC P206B Urea Sensor Over Temperature Condition 971
DTC P206C Urea Fluid Quality Sensor Circuit Low Voltage 972
DTC P206D Urea Fluid Quality Sensor Circuit High Voltage 972
DTC P207F Urea Fluid Concentration Too Low 973
DTC P208A Urea Fluid Pump Control Circuit 973
DTC P208B Usea Fluid Pump Performance 974
DTC P208C Urea Fluid Pump Control Circuit Low Voltage 975
DTC P208D Urea Fluid Pump Control Circuit High Voltage 975
DTC P208E Urea Fluid Injector Stuck 976
DTC P20A0 Urea Fluid Reverting Valve Circuit Open 977
DTC P20A2 Urea Fluid Reverting Valve Circuit Low Voltage 978
DTC P20A3 Urea Fluid Reverting Valve Circuit High Voltage 979
DTC P20AC Urea Fluid Pump Temperature Sensor Performance 980
DTC P20AD Urea Fluid Pump Module Temperature Sensor Performance 981
DTC P20B1 Urea Fluid Tank Heater Coolant Control Valve Circuit Open 981
DTC P20B3 Urea Fluid Tank Heater Coolant Control Valve Circuit Low Voltage 982
DTC P20B4 Urea Fluid Tank Heater Coolant Control Valve Circuit High Voltage 983
DTC P20E8 Urea Fluid Pressure Underpressure 984
DTC P20E9 Urea Fluid Overpressure 985
DTC P20EA Urea Fluid Pressure Reduction Malfunction 986
DTC P20FE Urea Fluid Pressure Build-Up Error 987
DTC P2201 Upstream Nox Sensor Performance 988
DTC P2206 NOx Sensor Heater Control Circuit Low Voltage Sensor 1 989
DTC P2207 NOx Sensor Heater Control Circuit High Voltage Sensor 1 989
DTC P242B Exhaust Gas Temperature (EGT) Sensor 3 Performance 989
DTC P242C Exhaust Gas Temperature (EGT) Sensor 3 Circuit Low Voltage 990
DTC P242D Exhaust Gas Temperature (EGT) Sensor 3 Circuit High Voltage 991
Data Reference Values 993
Idle Speed 993
Two Pump Relief 994
J HYDRAULIC EQUIPMENT (PUMP, OPERATION SYSTEM VALVE) 997
Main Equipment Table1003
Hydraulic Device1003
Hydraulic Pump1003
Control-related1004
Control valve1004
Control Valve (LF)1004
Solenoid Valve (5 Stack)1004
Remote Control Valve for Left/Right Operations1005
Remote Control Valve for Travel Operation1005
Remote Control Valve Characteristic Diagram1005
Operation Remote Control Valve Control Diagram1005
Travel Remote Control Valve Control Diagram1006
Cushion Valve (heat circuit, with shuttle valve)1007
Selector Valve1007
Basic Functions1008
Oil temperature gauge1008
Static Horsepower Control1009
Overload Warning (Function for Europe Only)1010
Pressure Boost Control1010
Stroke Control1012
Boom Down Energy Save1014
Pump Horsepower Boost Control1015
Arm 1 Semi-parallel Control1015
Arm 2 Semi-parallel Control1016
Hot Shutdown Warning1017
Gate Lock1018
Breaker Mode1019
Crusher Mode1019
Quick coupler1020
Hydraulic Filter Clogging1021
Solenoid Sticking Prevention1022
Port Diagram1023
Hydraulic Pump (Standard Model)1023
Control Valve1024
Relief Valve1024
5 Stack Solenoid Valve1027
2 Stack Solenoid Valve1029
Remote Control Valves (upper, travel)1029
Remote Control Valves (left-right)1029
Remote Control Valve (Travel)1030
Cushion Valve1031
2-way Selector Valve1032
Direction Valve1033
6 Stack Proportional Valve1034
Relief Valve (electromagnetic proportional)1036
Manifold Under Cab1037
Manifold (accumulator section)1038
Hydraulic Oil Tank1039
Hydraulic Pump1040
Structure and Operation Explanation1040
Hydraulic Pump Internal Structure Diagram1041
Overall View1041
Drive Shaft Front Side1042
Drive Shaft Rear Side1043
Development Diagram1044
Component Table1047
Regulator1048
Regulator Operation Explanation1048
Regulator Operation Explanation Diagram1051
Internal Configuration Diagram of Regulator1054
Development Diagram of Regulator1056
Component Table1057
Operation Outline of Electronically-Controlled Pump1059
Control Valve1062
Basic Configuration1062
Operation1062
Operation of Main Unit1062
Activation of Relief Valve1082
5 Stack Solenoid Valve Operation Explanation1087
External Shape Diagram and Components1087
operation explanation1087
Upper Pilot Valve (remote control valve)1088
Structure1088
Function1088
Operation1089
Structural Diagram1092
Travel Pilot Valve (remote control valve)1093
Operation1093
Pressure Reducing Valve Section1093
Damping Mechanism in Operation Section1094
Structural Diagram1097
Cushion Valve 1099
structure1099
operation explanation1099
Selector Valve (2-way)1104
structure1104
operation explanation1105
Development Diagram1106
Direction Valve (3-direction) 1107
Structure1107
Operation Explanation1108
6 Stack Proportional Valve (Pilot)1110
structure1110
operation principle1111
Electromagnetic Relief Valve1112
Structure1112
Operation Explanation1113
Operation of Check Valve1113
Operation of Electromagnetic Relief Valve1114
Removal and Installation of Hydraulic Tank1116
Removal of Hydraulic Reservoir1116
Installation of Hydraulic Oil Tank1118
Removal and Installation of Hydraulic Pump1119
Removal of Hydraulic Pump1119
Installation of Hydraulic Pump1121
Removal and Installation of Control Valve1122
Removal of Control Valve1122
Installation of Control Valve1126
Removal and Installation of Travel Remote Control Valve1127
Removal of Travel Remote Control Valve1127
Installation of Travel Remote Control Valve1128
Removal and Installation of Operation Remote Control Valve1131
Removal of Operation Remote Control Valve (Left)1131
Installation of Operation Remote Control Valve (Left)1133
Removal of Operation Remote Control Valve (right side)1135
Installation of Operation Remote Control Valve (right side)1137
Removal and Installation of 5 Stack Solenoid1140
Removal of 5 Stack Solenoid Valve1140
Installation of 5 Stack Solenoid Valve1141
Removal and Installation of Cushion Valve1142
Removal of Cushion Valve1142
Installation of Cushion Valve1143
Procedures for Assembly and Disassembly of Hydraulic Pump Main Unit1144
Tools1144
Disassembly Procedure1144
Assembly Procedures1146
Development Diagram1150
Component Table1153
Pump Main Unit Maintenance Standards1154
Replacement Standard of Wear Component1154
Correction Standard of Cylinder, Valve Plate, and Sash Plate (Shoe Plate)1154
Tightening torque1155
Overall View1155
Drive Shaft Front Side1156
Drive Shaft Rear Side1157
Development Diagram1158
Component Table1161
Regulator Maintenance Standards1162
Regulator Adjustment1162
Appendix Table and Drawings1163
Regulator Assembly and Disassembly Procedures1167
Tools1167
Preparations for Disassembly1167
Disassembly Procedure1167
Assembly Procedures1169
Internal Configuration Diagram of Regulator1172
Development Diagram of Regulator1174
Component Table1175
Assembly and Disassembly of Control Valve1177
Disassembly1177
Caution for Disassembly1177
Disassembly Procedure1177
Removal of Long Cap and Pulling Out of Main Spool1177
Disassembly of Arm 1, 2 Parallel-Tandem Spool, Neutral Cut Spool, Arm Regeneration Release Spool Section1178
Disassembly of Load Check Valve Section1178
Disassembly of Antidrift Valve Section (Sub Component in Assembly is Expressed by (Min Number – Sub Number))1179
Disassembly of Relief Valve1179
Disassembly of Option Section1179
Disassembly of Add-On Section1179
Disassembly of Valve Housing Coalescence Bolt1180
Cleaning1180
Inspection1180
assembly1180
Caution for Assembly1180
Caution for Handling O-ring1180
Caution for Handling Spool1180
Method to Apply Adhesive Agent (Male and Female Thread Section of Components Requiring Bonding)1180
Assembly Procedure of Sub-Assembly1181
Assembly of Spool Assembly (Main Spool)1181
Assembly of Arm 1, 2 Parallel-Tandem Spool, Neutral Cut Spool, Arm Regeneration Release Spool Assembly1181
Assembly of Antidrift Valve Assembly1182
Assembly Procedure of Control Valve Main Unit1182
Assembly of Relief Valve1182
Assembly of Load Check Valve1182
Assembly of Antidrift Valve1183
Assembly of Option Section1183
Assembly of Arm 1 Parallel-Tandem Spool1183
Assembly of Arm 2 Parallel-Tandem Spool, Neutral Cut Spool, Arm Regeneration Release Spool1183
Assembly of Main Spool1183
Assembly of Add-On Section1184
Assembly of Other Plugs1184
Internal Structural Diagram1185
Part List1191
Relief Valve1192
Assembly and Disassembly Procedure of Main Relief Valve1192
Assembly and Disassembly Procedures of Overload Relief1193
Assembly and Disassembly Procedure of Low-Pressure Relief Valve1194
Assembly and Disassembly Procedure of Main Relief Valve for Add-On1194
Adjustment of Relief Valve1195
Installation1196
Operation1196
Malfunction and Countermeasure1196
Procedures for Assembly and Disassembly of Operation Remote Control Valve1198
Maintenance Procedures1198
Required Tools and Tightening Torque1198
Maintenance Standards1198
Disassembly Procedures1199
Assembly Procedures1202
Causes of Trouble and Countermeasures1205
Procedures for Assembly and Disassembly of Travel Remote Control Valve1209
Maintenance Procedures1209
Disassembly Procedures1210
Assembly Procedures1214
Causes of Trouble and Countermeasures and Cross-section Diagram1219
Assembly and Disassembly of Cushion Valve1222
Disassembly Procedures1222
Reverse Operation Spool Section1222
Check Plunger Section with Throttle1222
Shuttle Valve Section1222
Assembly Procedures1223
Reverse Operation Spool Section1223
Check Plunger Section with Throttle1223
Shuttle Valve Section1223
Written Materials1224
Procedures for Assembly and Disassembly of 6 Stack Proportional Valve (Pilot)1226
Development Diagram1226
Assembly and disassembly procedures1227
Precautions1227
Replacement of Proportional Solenoid1227
Disassembly1227
Assembly1227
Replacement of Sleeve and Spool1228
Disassembly1228
Assembly1229
Replacement of Poppet (Check Valve for Normally Open)1230
Disassembly1230
assembly1231
Maintenance Standards1231
Troubleshooting1231
Pressure Measurement and Adjustment Procedures1233
Procedures for Pressure Measurement from the Monitor Display1233
Monitor and Switch Panel1233
Pressure Measurement Method1233
Operating Method1233
PROCEDURES FOR MEASURING HYDRAULIC OIL TEMPERATURE FROM THE MONITOR DISPLAY1233
Hydraulic Oil Temperature Measurement Method1233
Operating Method1234
Procedures for Pressure Measurement by Installing Pressure Gauge1235
Preparations1235
Items to prepare1235
Pressure Measuring Ports1236
Control Valve1238
Location of Relief Valves1238
Pressure Measurement Preparations1239
Pressure Measurement1241
Main Pressure Measurement1241
A Attachments Pressure Measurement1241
Boom-down pressure measurement1243
D Option Line Pressure Measurement1243
Pilot Pressure Measurement1243
Pressure Gauge Installation1243
Negative Control Pressure Measurement1244
Pressure Gauge Installation1244
Pressure Adjustment1244
Main Pressure Adjustment1244
Preparation Work of Pressure Measurement Adjustment1244
Main Relief Pressure Adjustment1246
Overload Relief Pressure Adjustment1247
Swing Relief Pressure Adjustment1248
Pilot Pressure Adjustment1249
Hydraulic Pump Flow Measurement Procedures1250
Preparations1250
Items to Prepare1250
Work Preparations1251
Flow Measurement1252
Air Bleed Procedure1254
Hydraulic Pump1254
Sampling Procedure1255
Sampling of Hydraulic Fluid1255
Hydraulic Equipment Layout1256
Overall View1257
Pump Chamber Hydraulic Equipment Layout1258
Swing Body Center Section Hydraulic Equipment Layout1259
Housing Left Side Hydraulic Equipment Layout1261
Layout of Hydraulic Equipment in Cab1262
N CAB1263
Removal and Installation of Operator’s Seat1266
Removal of Operator’s Seat1266
Installation of Operator’s Seat1266
Removal and Installation of Cab Assembly1267
Removal of Cab Assembly1267
Installation of Cab Assembly1271
Removal and Installation of Wiper1272
Removal of Wiper1272
Installation of wiper1272
Removal and Installation of Cab Front Glass1273
Removal of Cab Front Glass1273
Installation of Cab Front Glass1274
Window Lock Adjustment Procedures1275
Window Lock (front side)1275
Window Lock (rear side)1275
Removal and Installation of Housing Guardrail1277
Removal of Housing Guardrail1277
Installation of Housing Guardrail1277
Tightening torque1278
R ELECTRICAL PARTS1279
Basic Functions1283
Monitor Control1283
Monitor Display Dimming1283
Diagnostic Trouble Code Indicator1284
Clock1284
Basic Operation1285
Battery Save1285
Accessories1287
Working Light1287
LED Light1288
Room Lamp1288
Radio Mute1290
Wiper and Washer1291
Safety1293
Horn1293
Back/Side View Monitor1294
Precautions for Camera Installation1295
Maintenance1295
Anti-theft1295
Manual Lock1296
Service Support Screen Lock1296
Customer-specific System Information Screen Lock1296
Maintenance Information Screen Lock1297
Option Line Setting Screen Lock1297
Setting1297
Clock Adjustment1297
Screen Brightness Setting1298
Battery Disconnect Switch1299
Explanation of Controller1300
Service Support1302
Screen Operations1302
Screen Display List1302
Service Monitor Structure1303
CHECK Screen List1304
MACHINE STATUS1305
HYDRAULIC STATUS1311
ENGINE STATUS1318
FAULT HISTORY1322
WORK HISTORY1323
HYDRAULIC HISTORY1331
ENGINE HISTORY1344
DEVICE TEST1365
ECM/DCU Memory Clear1365
SCR RE-GEN1366
Urea Line Leak Test1367
CCV Operation Test1368
Dosing Test1369
Reverting Valve Operation Test1370
Common Rail Pressure Test1371
Idle Speed Test / Injector Test1372
EGR Valve Control Test1373
VG Turbo Control Test1374
Intake Throttle Control Test1375
CONTROL UNIT Screen List1377
MCM-MAIN1377
MCM-SUB1381
COMMU TERMINAL1382
SETUP Screen List1384
MACHINE SELECT1384
DIMENSIONS1389
PARAMETERS1392
ENGINE INFORMATION1396
ENGINE INFORMATION1397
Data Confirmation1397
Data Transfer (Copy)1397
QR (INJECTOR) CODE1398
Injector number1398
Screen Layout1399
Data Source Selection1399
Manual Input1399
CAMERA1401
PASSWORD1404
CALIBRATE Screen List1406
THROTTLE VOLUME1407
OPTLINE RELIEF1408
PUMP FLOW1410
RESET Screen List1412
Connection Connector Pin Layout1415
Main Controller1415
Monitor1416
Sequence Circuit Diagram1417
Code List1417
Overall1420
Block diagram1423
Main controller1423
DCU1424
ECM1425
Monitor1426
Air Conditioner1427
Gate Lock1428
Horn1428
Working Light1429
Option1430
Other1431
Electrical Symbol List1431
Electrical Equipment Layout Diagram1434
Main Unit Left-side Layout Diagram1435
Engine Section Layout Diagram1437
Main Unit Right Side Layout Diagram (pump chamber)1440
Main Unit Center Section Layout Diagram1441
Cab Layout Diagram 11442
Cab Layout Diagram 21444
Layout Around Operator Seat1447
Stand Alone Parts Diagram1448
Removal and Installation of Wiper Controller1467
Removal of Wiper Controller1467
Installation of wiper controller1467
Removal and Installation of Wiper Motor1468
Removal of Wiper Motor1468
Installation of wiper motor1469
Removal and Installation of ECM1470
Removal of ECM1470
Installation of ECM1470
Removal and Installation of Main Controller1471
Removal of Main Controller1471
Installation of Main Controller1471
Removal and Installation of DCU1472
Removal of DCU1472
Installation of DCU1472
Removal and Installation of Monitor1473
Removal of Monitor1473
Installation of Monitor1473
Removal and Installation of Rear View Camera 1474
Removal of Rear View Camera1474
Installation of Rear View Camera1474
Removal and Installation of Side Camera (right)1475
Removal of Side Camera (Right)1475
Installation of Side Camera (right)1475
Removal and Installation of Side Camera (Left)1476
Removal of Side Camera (Left)1476
Installation of Side Camera (Left)1476
Removal and Installation of FVM Controller1477
Removal of FVM Controller1477
Installation of FVM Controller1477
How to Set FVM1478
Air Conditioner Overall Diagram1482
Frame1482
Cab1484
Equipment Layout Diagram1487
Circuit Diagram1489
Air Conditioner Circuit Diagram1489
Explanation of Functions1491
Explanation of Control1491
Air Mix Motor Actuator Control1492
Blow Mode Motor Actuator Control1492
Refresh/Recirculate Switch Motor Actuator Control1493
Blower Amp Control1494
Compressor Clutch Control1496
COOLMAX Control and HOTMAX Control1497
Abnormality Detection and Control after Abnormality Detected1497
Monitor Mode1501
Door Switch Control1503
Actuator Inspection1504
Air Mix Motor Actuator Inspection1504
Refresh/Recirculate Switch Motor Actuator Inspection1505
Mode Motor Actuator Inspection1506
Self-diagnosis Function with Panel Display1507
Abnormality Display and Self-check Procedures1507
Abnormality Display Position1507
Explanation of Abnormality Display1507
Motor Actuator Abnormality1507
Sensor Abnormality1508
Explanation of Monitor Mode1508
Monitor Mode Display Position1509
Monitor Mode Display Operating Method1509
Display Contents in Monitor Mode1510
Part Function and Good/Poor Judgment1516
Control Panel1516
Blower Amp1516
Relay1517
Air Mix Actuator1518
Refresh/Recirculate Actuator1519
Blow Mode Actuator1519
Evaporator Sensor1520
Dual Pressure Switch1520
Solar Radiation Sensor1521
Inside Air Sensor1521
Assembly and Disassembly of Unit1523
Removal of Blower Unit1523
Replacement of Blower Motor1523
Replacement of Blower Amp1523
Removal of Heater Core1524
Removal of Heat Case Right/Left1524
Replacement of Evaporator and Expansion Valve1524
Installation of Evaporator Sensor1525
Replacement of Motor Actuator1525
Removal and Installation of Compressor1526
Removal of Compressor1526
Installation of Compressor1526
Removal and Installation of Condenser1527
Removal of Condenser1527
Installation of Condenser1528
Removal and Installation of Receiver Dryer1529
Removal of Receiver Dryer1529
Installation of Receiver Dryer1529
Work Precautions1531
Work Procedures1531
Air Conditioner Refrigerant Filling is Divided into the “Vacuum Operation” and “Gas Filling Operation”1531
Operation Chart1532
Tools1532
Filling Procedures1534
Charging Hose Connection Position1534
Connecting Gauge Manifold1534
Vacuuming1535
Gas Filling Operation, High-pressure Side1536
Gas Filling Work, Low Pressure Side1536
V ATTACHMENTS1539
Main Equipment Table1543
Backhoe Attachment1543
Cylinder1543
Cylinder (LF)1543
Maintenance Standards1545
Attachment (Backhoe)1545
1 Boom and Swing Frame Installation Section1545
2 Boom Cylinder and Swing Frame Installation Section1546
3 Boom and Boom Cylinder Installation Section1546
4 Boom and Arm Cylinder Installation Section1547
5 Boom and Arm Installation Section1548
6 Arm and Arm Cylinder Installation Section1548
7 Arm and Bucket Cylinder Installation Section1549
8 Arm and Arm Link Installation Section1550
9 Bucket and Bucket Link Installation Section1550
10 Bucket Link and Bucket Cylinder Installation Section1551
11 Bucket and Arm Installation Section1552
Attachment (Backhoe) (LF)1553
1 Boom and Swing Frame Installation Section1553
2 Boom Cylinder and Swing Frame Installation Section1554
3 Boom and Boom Cylinder Installation Section1554
4 Boom and Arm Cylinder Installation Section1555
5 Boom and Arm Installation Section1556
6 Arm and Arm Cylinder Installation Section1556
7 Arm and Bucket Cylinder Installation Section1557
8 Arm and Arm Link Installation Section1557
9 Bucket and Bucket Link Installation Section1558
10 Bucket Link and Bucket Cylinder Installation Section1558
11 Bucket and Arm Installation Section1559
Removal and Installation of Bucket Cylinder1560
Removal of Bucket Cylinder1560
Installation of Bucket Cylinder1562
Removal and Installation of Arm Cylinder1564
Removal of Arm Cylinder1564
Installation of Arm Cylinder1566
Removal and Installation of Arm Cylinder (LF)1569
Removal of Arm Cylinder1569
Installation of Arm Cylinder1571
Removal and Installation of Boom Cylinder1574
Removal of Boom Cylinder1574
Installation of Boom Cylinder1576
Removal and Installation of Boom Cylinder (LF)1578
Removal of Boom Cylinder1578
Installation of Boom Cylinder1580
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder1583
Specifications and Structure Diagram (including the assembly diagram and parts table)1583
Basic Functions1583
Function of Each Location1583
Cylinder Head Assembly (made by KYB)1583
Piston Assembly (made by KYB)1584
Pipe Assembly (made by KYB)1586
Handling Precautions1586
Precautions for Installing the Cylinder on the Machine Body1586
Usage Cautions1587
Maintenance and Inspection Cautions1587
Maintenance Inspection and Service1589
Trouble Diagnostics1590
Storage Standards1595
Storing Parts Individually (In principle, store indoors)1595
When Mounted on Vehicle Body1595
Recommended Anti-rust Oil1595
Assembly and Disassembly Procedures1596
Preparations ····· Prepare the Following before Starting Disassembly1596
General Work Precautions1596
Maintenance Standards1596
Inspection after Assembly1596
Required Tool1597
General Tool1597
Special Jig (made by KYB)1598
Special Jig Parts Number List (made by KYB)1598
Disassembly Procedures (made by KYB)1599
Assembly Procedures (made by KYB)1603
Test Operation1607
Usage Limits1608
Structural Diagram (made by KYB)1609
Boom Cylinder1609
Arm Cylinder1611
Arm Cylinder (LF)1613
Bucket Cylinder1615
Bucket Cylinder (LF)1617
HBCV1619
structure1619
Function1619
operation explanation1619
Port Diagram1634
HBCV1634
Air Bleed Procedure1635
HBCV1635
Boom Cylinder HBCV1635
Arm Cylinder HBCV1636
Removal and Installation of HBCV1637
Removal and Installation of Arm HBCV1638
Removal of Arm HBCV1638
Installation of arm HBCV1638
Removal and Installation of Boom HBCV1639
Removal of Boom HBCV1639
Installation of boom HBCV1640
Removal and Installation of Bucket1641
Removal of Bucket1641
Installation of Bucket1641
Removal and Installation of Bucket Link1643
Removal of Bucket Link1643
Installation of Bucket Link1643
Removal and Installation of Bucket Link (LF)1645
Removal of Bucket Link1645
Installation of Bucket Link1645
Removal and Installation of Arm1647
Removal of Arm1647
Installation of Arm1648
Removal and Installation of Arm (LF)1649
Removal of Arm1649
Installation of Arm1650
Removal and Installation of Boom1651
Removal of Boom1651
Installation of Boom1653
Removal and Installation of Boom (LF)1657
Removal of Boom1657
Installation of Boom1659
Z OTHER1663
Changes from Model -61668
Overall Layout1668
Lower1668
Swing Unit1669
Engine1669
hydraulic-related1671
Hydraulic Control1672
Cab, Housing1673
Electrical Data1675
Electric Control1676
Attachments1676
Specifications1677
ENGINE1677
HYDRAULIC SYSTEM1677
HYDRAULIC CONTROLS1678
ELECTRICAL SYSTEM1678
OPERATOR ENVIRONMENT1679
UNDERCARRIAGE1679
MASS1680
DIGGING FORCE (with 11 m3 Sumitomo Bucket) (ISO 6015)1680
DIMENSIONS1680
WORKING RANGES1681
SYSTEM FLUID CAPACITIES AND SPECIFICATIONS1681
Specifications (LF)1682
ENGINE1682
HYDRAULIC SYSTEM1682
HYDRAULIC CONTROLS1683
ELECTRICAL SYSTEM1683
OPERATOR ENVIRONMENT1684
UNDERCARRIAGE1685
MASS1685
DIGGING FORCE (with 037 m3 Sumitomo Bucket) (ISO 6015)1685
DIMENSIONS1685
WORKING RANGES1686
SYSTEM FLUID CAPACITIES AND SPECIFICATIONS1686
Arm Dimension1687
250X41687
250X4 LF1689
Main Unit Weight1692
Divided Weight (Standard Specifications)1692
Divided Weight (LF)1693
Stand Alone Part Weight1693
Stand Alone Part Weight (LF)1694
Shoe Weight (per side)1694
Shoe Weight (per Side) (LF)1694
Arm Weight1694
Arm Weight (LF)1695
Bucket weight1695
Bucket Weight (LF)1696
Bolt Size and Torque Table1697
Special Torque Setting1697
Overall View1701
250X41701
Standard Arm [300 m (98425 ft)]1701
Long Arm [352 m (115486 ft)]1702
Short Arm [250 m (82021 ft)]1703
250X4 LF1704
Ultra-long Arm [80 m (26247 ft)]1704
WORK RANGE DIAGRAM1705
250X41705
Standard Arm [300 m (98425 ft)]1705
Long Arm [352 m (115486 ft)]1707
Short Arm [250 m (82021 ft)]1709
250X4 LF1711
Ultra-long Arm [80 m (26247 ft)]1711
New Machine Performance Judgment Table1713
Table of Standards1713
Table of Standards (LF)1715
Measurement Method1718
Engine speed1718
Pressure at Each Part1718
Pump Command Displacement1719
Cylinder Down Amount1719
Attachment Speed1719
Swing Speed1720
Swing (180°) Brake Angle1721
Travel Speed1721
Off Travel Amount1721
Travel Sprocket Speed1722
Shoe Tension Amount1722
Swing Ball Race Bearing Movement Amount and Bucket Tip Movement Amount1723
FLUIDS AND LUBRICANTS1725
HYDRAULIC FLUID1725
Engine Oil1725
Fuel1725
Conditions applicable to diesel fuel1725
Recommended Conditions Applicable to Diesel Fuel1725
Main-unit-related Diagnostic Trouble Code List1726
Main Unit-side Trouble1729
Diagnostic Trouble Code: 7000 Pressure Sensor P1 Abnormality1729
Diagnostic Trouble Code: 7001 Pressure Sensor P2 Abnormality1730
Diagnostic Trouble Code: 7002 Pressure Sensor N1 Abnormality1732
Diagnostic Trouble Code: 7003 Pressure Sensor N2 Abnormality1733
Diagnostic Trouble Code: 7004 Pressure Sensor Boom Cylinder Bottom Abnormality1735
Diagnostic Trouble Code: 7007 Pressure Sensor Arm Cylinder Rod Abnormality1736
Diagnostic Trouble Code: 7021 Pressure Sensor Swing Pilot Abnormality1738
Diagnostic Trouble Code: 7023 Pressure Sensor Arm-In Pilot Abnormality1739
Diagnostic Trouble Code: 7040 Level Sensor Fuel Abnormality1741
Diagnostic Trouble Code: 7041 Temperature Sensor Hydraulic Fluid Abnormality1742
Diagnostic Trouble Code: 7065 Pressure Sensor Boom-Up Pilot Abnormality1743
Diagnostic Trouble Code: 7067 Pressure Sensor Bucket-Close Pilot Abnormality1745
Diagnostic Trouble Code: 7068 Pressure Sensor Boom-Down Pilot Abnormality1747
Diagnostic Trouble Code: 7069 Pressure Sensor Arm-Out Pilot Abnormality1748
Diagnostic Trouble Code: 7070 Pressure Sensor Bucket-Open Pilot Abnormality1750
Diagnostic Trouble Code: 7071 Pressure Sensor Travel Right Pilot Abnormality1751
Diagnostic Trouble Code: 7072 Pressure Sensor Travel Left Pilot Abnormality1753
Diagnostic Trouble Code: 7073 Pressure Sensor Travel 1 Pedal Abnormality1755
Diagnostic Trouble Code: 7074 Pressure Sensor 1st Option Pilot (Common/Front Pedal) Abnormality1757
Diagnostic Trouble Code: 7075 Pressure Sensor Arm Cylinder Bottom Abnormality1758
Diagnostic Trouble Code: 7078 Pressure Sensor 1st Option Pilot (Rear Pedal) Abnormality1760
Diagnostic Trouble Code: 7200 Swing Brake Solenoid Abnormality1762
Diagnostic Trouble Code: 7201 Travel 2nd-Speed Switchover Solenoid Abnormality1763
Diagnostic Trouble Code: 7202 Pressure Boost Solenoid Abnormality1764
Diagnostic Trouble Code: 7203 Travel Alarm Buzzer Abnormality1765
Diagnostic Trouble Code: 7206 Option Return Line Switchover Solenoid Abnormality1766
Diagnostic Trouble Code: 7207 Free Swing Solenoid Abnormality1767
Diagnostic Trouble Code: 7213 Quick Coupler Buzzer Abnormality1768
Diagnostic Trouble Code: 7214 Quick Coupler Solenoid Abnormality1770
Diagnostic Trouble Code: 7247 Boom 2-Down Pilot Proportional Valve Abnormality1771
Diagnostic Trouble Code: 7249 Bucket-Close Pilot Proportional Valve Abnormality1772
Diagnostic Trouble Code: 7250 Option Relief Pressure Proportional Valve Abnormality1774
Diagnostic Trouble Code: 7265 Arm 1 Semi-Parallel Proportional Valve Abnormality1775
Diagnostic Trouble Code: 7266 Arm 2 Semi-Parallel Proportional Valve Abnormality1776
Diagnostic Trouble Code: 7267 Arm 1 Regeneration Release Proportional Valve Abnormality1777
Diagnostic Trouble Code: 7270 Tilting 1 Proportional Valve Abnormality1778
Diagnostic Trouble Code: 7271 Tilting 2 Proportional Valve Abnormality1780
Diagnostic Trouble Code: 7273 Straight Travel Proportional Valve Abnormality1781
Diagnostic Trouble Code: 7400 Coolant Temperature Overheating 11782
Diagnostic Trouble Code: 7401 Coolant Temperature Overheating 21783
Diagnostic Trouble Code: 7404 Oil Temperature Overheating1784
Diagnostic Trouble Code: 7405 Boost Temperature Overheating 11785
Diagnostic Trouble Code: 7406 Boost Temperature Overheating 21786
Diagnostic Trouble Code: 7420 Alternator Power Generation Failure1787
Diagnostic Trouble Code: 7421 Coolant Level Decrease1788
Diagnostic Trouble Code: 7422 Engine Oil Pressure Decrease1789
Diagnostic Trouble Code: 7423 Air Cleaner Clogging1790
Diagnostic Trouble Code: 7424 Return Filter Clogging1791
Diagnostic Trouble Code: 7426 Fuel Filter Clogging 11792
Diagnostic Trouble Code: 7427 Fuel Filter Clogging 21793
Diagnostic Trouble Code: 7428 Inducement (Remaining Urea Level Low) – Warning1794
Diagnostic Trouble Code: 7429 Inducement (Remaining Urea Level Low) – Early1795
Diagnostic Trouble Code: 7430 Inducement (Remaining Urea Level Low) – Final1795
Diagnostic Trouble Code: 7602 ECM Communication Abnormality1796
Diagnostic Trouble Code: 7605 ECM Not-Matched1797
Diagnostic Trouble Code: 7606 EEPROM Abnormality1798
Diagnostic Trouble Code: 7608 Camera Abnormality1798
Diagnostic Trouble Code: 7612 Air Conditioner Communication Abnormality1800
Diagnostic Trouble Code: 7613 Monitor Communication (CAN) Abnormality1801
Diagnostic Trouble Code: 7615 Sub-Controller Communication Abnormality1802
Diagnostic Trouble Code: 7618 DCU Communication Abnormality1804
List of special tools1806
NUMERICAL VALUE CONVERSION TABLE1806
Unit conversion rate1806
Length1806
Area1808
Volume1809
Weight1811
Pressure1812
Torque1813
Temperature1814
A1817
Travel Motor Special Tool1817
250X41817
Take-up Roller Special Tool1820
250X41820
Upper Roller Special Tool1821
250X41821
Lower Roller Special Tool1822
250X41822
C1823
Swing Motor Special Tool1823
250X41823
H1826
Engine Oil Filter Special Tool1826
210X4／250X41826
Fuel Filter Special Tool1826
210X4／250X41826
Injector Special Tool1826
210X4／250X41826
Circuit Test Special Tool1827
210X4／250X41827
Valve Guide Special Tool1827
210X4／250X41827
Cylinder Head Special Tool1827
210X4／250X41827
Head Bolt Special Tool1830
210X4／250X41830
Crankshaft Special Tool1830
210X4／250X41830
Valve Spring Special Tool1832
210X4／250X41832
J1833
Remote Control Valve Special Tool1833
250X41833
R1835
Gas Filling Special Tool1835
210X4／250X41835
V1835
Attachment Special Tool (for Cylinder Assembly)1835
Special Jigs Part Number List1835
Paint Colors1837
Abbreviation1839
S.M 3/1/25
