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Link-Belt 250X4/250X4 LF Excavator SERVICE MANUAL WLSM2507-LX_T – PDF DOWNLOAD
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Link-Belt 250X4/250X4 LF Excavator SERVICE MANUAL WLSM2507-LX_T – PDF DOWNLOAD
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Description
Link-Belt 250X4/250X4 LF Excavator SERVICE MANUAL WLSM2507-LX_T – PDF DOWNLOAD
FILE DETAILS:
Link-Belt 250X4/250X4 LF Excavator SERVICE MANUAL WLSM2507-LX_T – PDF DOWNLOAD
Language : English
Pages :1881
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Link-Belt 250X4/250X4 LF Excavator SERVICE MANUAL WLSM2507-LX_T – 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-LX_T – PDF DOWNLOAD
ExcavatorΒ Β 1
SAFETYΒ Β 9
Safety, general information and standard torque dataΒ 12
General InformationΒ 13
SafetyΒ 13
ROPSΒ 15
ROPS JudgmentΒ 15
Standard Torque Data For Cap Screws And NutsΒ 18
Bolt and Nut TighteningΒ 18
A LOWERΒ 19
Main Equipment TableΒ 23
Lower ComponentΒ 23
Travel UnitΒ 23
Take-up RollerΒ 23
Upper RollerΒ 23
Lower RollerΒ 23
Recoil SpringΒ 23
ShoeΒ 23
Shoes (LF)Β 24
Center JointΒ 24
Main Equipment Structure and Operation ExplanationΒ 25
Travel MotorΒ 25
Travel motor operation explanationΒ 25
Explanation of Component Device OperationΒ 25
Double Counter Balance ValveΒ 25
Crossover Relief ValveΒ 30
Automatic 2-speed Switchover MechanismΒ 32
Parking Brake FunctionΒ 35
Piston MotorΒ 36
Reduction GearΒ 37
Port DiagramΒ 39
Travel MotorΒ 39
Center JointΒ 39
Basic FunctionsΒ 40
Travel Speed SelectionΒ 40
Travel AlarmΒ 41
Removal and Installation of TrackΒ 42
Removal and Installation of Shoe AssemblyΒ 43
Removal of Shoe AssemblyΒ 43
Installation of Shoe AssemblyΒ 44
Removal and Installation of Shoe PlateΒ 46
Removal of Shoe PlateΒ 46
Installation of Shoe PlateΒ 46
Removal and Installation of RollerΒ 47
Removal and Installation of Upper RollerΒ 48
Removal of Upper RollerΒ 48
Installation of Upper RollerΒ 49
Assembly and Disassembly of Upper RollerΒ 50
Configuration DiagramΒ 50
Dimension DiagramΒ 51
Jig Dimension DiagramΒ 51
Disassembly ProceduresΒ 52
Assembly ProceduresΒ 54
Removal and Installation of Lower RollerΒ 57
Removal of Lower RollerΒ 57
Installation of Lower RollerΒ 58
Assembly and Disassembly of Lower RollerΒ 59
Configuration DiagramΒ 59
Dimension DiagramΒ 60
Jig Dimension DiagramΒ 60
Disassembly ProceduresΒ 60
Assembly ProceduresΒ 63
Removal and Installation of Drive SprocketΒ 65
Removal of Drive SprocketΒ 65
Installation of Drive SprocketΒ 66
Removal and Installation of Take-up RollerΒ 67
Removal of Take-up RollerΒ 67
Installation of Take-up RollerΒ 67
Assembly and Disassembly of Take-up RollerΒ 69
Configuration DiagramΒ 69
Dimension DiagramΒ 70
Jig Dimension DiagramΒ 70
Disassembly ProceduresΒ 70
Assembly ProceduresΒ 73
Removal and Installation of Grease CylinderΒ 77
Removal of grease cylinderΒ 77
Installation of grease cylinderΒ 78
Assembly and Disassembly of Tension Shock AbsorberΒ 79
Configuration DiagramΒ 79
Dimension DiagramΒ 79
Jig Dimension DiagramΒ 80
Disassembly proceduresΒ 80
Assembly proceduresΒ 80
Removal and Installation of Center JointΒ 82
Removal of Center JointΒ 82
Installation of Center JointΒ 84
Assembly and Disassembly of Center JointΒ 86
Configuration DiagramΒ 87
Dimension DiagramΒ 88
Jig Dimension DiagramΒ 89
Disassembly ProceduresΒ 89
Assembly ProceduresΒ 90
Removal and Installation of Travel MotorΒ 93
Removal of Travel MotorΒ 93
Installation of Travel MotorΒ 95
Assembly and Disassembly of Travel MotorΒ 98
Tools for Assembly and DisassemblyΒ 98
Standard ToolΒ 98
Secondary MaterialsΒ 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
Main Data 258
Function, Structure, Operation 260
Function, structure, operation (SCR) 315
SCR Control System Inspection 341
Operation Explanation of SCR 342
Diagnosis for Each Symptom 344
Intermittent conditions of urea selective catalytic reduction system 344
Urea fluid consumption too high 347
Ammonia smell noticeable 347
White crystalline powder visible 348
Diagnosis for Each Symptom 349
Engine Start Problem 349
Engine Stalling 351
Engine Hunting, Rough Idling 353
Excessive White Smoke in Exhaust Gas 355
Excessive Black Smoke in Exhaust Gas 355
Abnormal Noise 356
High Fuel Consumption 357
High Oil Consumption 358
Engine Output Deficiency 359
Functional Inspection 361
Engine Compression Pressure Inspection 361
Fuel System Inspection 362
Lubrication system check 362
Suction air system inspection 363
Exhaust system inspection 363
EGR Control System Inspection 363
Start System Inspection 364
Glow control system check 364
OBD system check 366
Inspection of the monitor warning light illumination circuit system 366
Inspection of the monitor warning light blinking circuit system 367
Inspection of the starter circuit system 367
Removal and Installation of Engine Assembly 369
Removal of Engine Assembly 369
Installation of Engine Assembly 373
Removal and Installation of Fuel Cooler, Engine Intercooler, Radiator, and Oil Cooler 374
Removal and Installation of Fuel Cooler 374
Removal of Fuel Cooler 374
Installation of Fuel Cooler 374
Removal and Installation of Engine Intercooler 374
Removal of Intercooler 375
Installation of Inter Cooler 375
Inspection of Intercooler 375
Removal and Installation of Radiator 376
Removal of Radiator 376
Installation of Radiator 379
Inspection of Radiator 380
Removal and Installation of Oil Cooler 380
Removal of Oil Cooler 381
Installation of Oil Cooler 383
Removal and Installation of Turbo Charger 384
Removal of Turbo Charger 384
Installation of Turbo Charger 386
Inspection of Turbo Charger 389
Removal and Installation of EGR Valve 391
Removal of EGR Valve 391
Installation of EGR Valve 393
Inspection of EGR Valve 396
Removal and Installation of Engine Hood 398
Removal of Engine Hood 398
Installation of Engine Hood 399
Removal and Installation of SCR 400
Removal of SCR 400
Installation of SCR 401
Removal and installation of Silicon Controlled Rectifier Catalyst 402
Removal of Silicon Controlled Rectifier Catalyst 402
Installation of Silicon Controlled Rectifier Catalyst 402
Disassembly of Silicon Controlled Rectifier Catalyst 402
Assembly of Silicon Controlled Rectifier Catalyst 402
Inspection of Silicon Controlled Rectifier Catalyst 403
Removal and Installation of Cylinder Head Cover 404
Cylinder head cover Removal 404
Installation of Cylinder Head Cover 404
Removal and Installation of Cylinder Head 405
Removal of Cylinder Head 405
Disassembly of Cylinder Head 413
Assembly of Cylinder Head 418
Installation of Cylinder HeadΒ 425
Inspection 442
Removal and Installation of Cylinder Block 449
Removal of Cylinder Block 449
Installation of Cylinder Block 465
Inspection 500
Lubrication System 502
Removal and Installation of Oil Pan 502
Removal of Oil Pan 502
Installation of Oil Pan 502
Removal and Installation of Oil Level Switch 502
Removal of Oil Level Switch 502
Installation of Oil Level Switch 503
Removal and Installation of Oil Pump Assembly 503
Removal of Oil Pump Assembly 503
Disassembly of Oil Pump Assembly 515
Assembly of Oil Pump Assembly 516
Installation of Oil Pump Assembly 516
Inspection 540
Engine oil Inspection 541
Removal and Installation of Oil Port Cover 542
Removal of Oil Port Cover 542
Installation of Oil Port Cover 542
Cooling System 544
Removal and Installation of Water Pump Assembly 544
Removal of Water Pump Assembly 544
Installation of Water Pump Assembly 545
Inspection 549
Removal and Installation of Thermostat 549
Removal of Thermostat 549
Installation of Thermostat 550
Inspection 552
Inspection of Coolant 552
Inspection of Cooling Fan Belt 557
Removal and Installation of Overheat Switch 557
Removal of Overheat Switch 557
Installation of Overheat Switch 557
Induction System 559
Inspection of Air Cleaner Element 559
Exhaust System 560
Removal and installation of Oxidation Catalyst Assembly 560
Removal of Oxidation Catalyst Assembly 560
Installation of Oxidation Catalyst Assembly 561
Aux Emission Control Devices System 563
Removal and installation of Dosing Module 563
Removal of Dosing Module 563
Disassembly of Dosing Module 563
Assembly of Dosing Module 564
Installation of Dosing Module 564
Removal and installation of DEF Supply Module 566
Removal of DEF supply module 566
Disassembly of DEF Supply Module 567
Assembly of DEF Supply Module 567
Installation of DEF Supply Module 568
Removal and installation of Coolant Control Valve 570
Removal of Coolant Control Valve 570
Installation of Coolant Control Valve 570
Removal and installation of DEF Supply Module Filter 572
Removal of DEF Supply Module Filter 572
Installation of DEF Supply Module Filter 573
Removal and Installation of Exhaust Manifold 574
Removal of Exhaust Manifold 574
Installation of Exhaust Manifold 577
Inspection 583
Removal and Installation of Fuel Tank 584
Removal of Fuel Tank 584
Installation of fuel tank 587
Removal and Installation of Urea Pump 588
Removal of Urea Pump 588
Installation of Urea Pump 589
Removal and Installation of Urea Solution Tank 590
Removal of Urea Solution Tank 590
Installation of Urea Solution Tank 590
Removal and Installation of Fuel Supply Pump 592
Removal of Fuel Supply Pump 592
Installation of Fuel Supply Pump 593
Removal and Installation of Common Rail Assembly 597
Removal of Common Rail Assembly 597
Installation of Common Rail Assembly 599
Removal and Installation of Injector 604
Removal of Injector 604
Installation of Injector 607
Removal and installation of Idle Gear 612
Removal of Idle Gear 612
Installation of Idle Gear 624
Inspection of Idle Gear 648
Removal and installation of Inlet Cover 650
Removal of Inlet Cover 650
Installation of Inlet Cover 654
Removal and installation of Crankshaft 664
Removal of Crankshaft 664
Installation of Crankshaft 679
Disassembly of Crankshaft 711
Assembly of Crankshaft 711
Inspection of Crankshaft 712
Removal and installation of Piston 717
Removal of Piston 717
Installation of Piston 727
Disassembly of Piston 746
Assembly of Piston 747
Inspection of Piston 748
Removal and installation of Camshaft 756
Removal of Camshaft 756
Installation of Camshaft 757
Disassembly of Camshaft 761
Assembly of Camshaft 762
Inspection of Camshaft 762
Removal and installation of Flywheel 764
Removal of Flywheel 764
Installation of Flywheel 765
Inspection of Flywheel 766
Removal and installation of Crankshaft Front Oil Seal 767
Removal of Crankshaft Front Oil Seal 767
Installation of Crankshaft Front Oil Seal 768
Removal and installation of Crankshaft Rear Oil Seal 771
Removal of Crankshaft Rear Oil Seal 771
Installation of Crankshaft Rear Oil Seal 772
Removal and installation of Rocker Arm Shaft 775
Removal of Rocker Arm Shaft 775
Installation of Rocker Arm Shaft 776
Disassembly of Rocker Arm Shaft 779
Assembly of Rocker Arm Shaft 780
Inspection of Rocker Arm Shaft 781
Removal and installation of Valve Spring 783
Removal of Valve Spring 783
Installation of Valve Spring 785
Inspection of Valve Spring 790
Removal and installation of Valve Stem Oil Seal 792
Removal of Valve Stem Oil Seal 792
Installation of Valve Stem Oil Seal 794
Removal and installation of Front Cover 801
Removal of Front Cover 801
Installation of Front Cover 803
Removal and installation of Intake Throttle Valve 809
Removal of Intake Throttle Valve 809
Installation of Intake Throttle Valve 809
Removal and Installation of Starter Motor 810
Removal of Starter Motor 810
Installation of Starter Motor 811
Disassembly of Starter Motor 811
Assembly of Starter Motor 812
Inspection of Starter Motor 814
Removal and Installation of Alternator 818
Removal of Alternator 818
Installation of Alternator 818
Disassembly of Alternator 819
Assembly of Alternator 820
Inspection of Alternator 821
Removal and Installation of Glow Plug 825
Removal of Glow Plug 825
Installation of Glow Plug 825
Glow plug Inspection 825
Removal and Installation of Suction Control Valve 826
Removal of Suction Control Valve 826
Installation of Suction Control Valve 826
Removal and installation of Fuel Filter 829
Removal of Fuel Filter 829
Installation of Fuel Filter 829
Removal and installation of Relief Valve 832
Removal of Relief Valve 832
Installation of Relief Valve 832
Removal and installation of Fuel Filter Element 835
Removal of Fuel Filter Element 835
Installation of Fuel Filter Element 836
Removal and Installation of Fuel filter pressure 839
Fuel filter pressure sensor Removal 839
Fuel filter pressure sensor Installation 839
Removal and Installation of Engine coolant temperature sensor 840
Engine coolant temperature sensor Removal 840
Engine coolant temperature sensor Installation 840
Engine coolant temperature sensor Inspection 840
Removal and Installation of CKP sensor 841
CKP sensor Removal 841
CKP sensor Installation 841
CKP sensor Inspection 841
Removal and Installation of CMP sensor 842
CMP sensor Removal 842
CMP sensor Installation 842
CMP sensor Inspection 842
Removal and Installation of Oil pressure sensor 843
Oil pressure sensor Removal 843
Oil pressure sensor Installation 843
Oil pressure sensor Inspection 843
Removal and installation of Pressure Sensor/Boost Temperature Sensor 844
Removal of Pressure Sensor/Boost Temperature Sensor 844
Installation of Pressure Sensor/Boost Temperature Sensor 844
Inspection of Pressure Sensor/Boost Temperature Sensor 844
Removal and Installation of IMT sensor 845
Removal of IMT sensor 845
Installation of IMT sensor 845
Removal and installation of Charge Air Cooler Temperature Sensor 1 846
Removal of Charge Air Cooler Temperature Sensor 1 846
Installation of Charge Air Cooler Temperature Sensor 1 846
Inspection of Charge Air Cooler Temperature Sensor 1 846
Sampling Procedure 847
Sampling of Engine Oil 847
Removal and Installation of Exhaust gas temperature sensor 848
Exhaust gas temperature sensor Removal 848
Exhaust gas temperature sensor Installation 848
Exhaust gas temperature sensor Inspection 848
Removal and installation of EGR Gas Temperature Sensor 1 850
Removal of EGR Gas Temperature Sensor 1 850
Installation of EGR Gas Temperature Sensor 1 850
Inspection of EGR Gas Temperature Sensor 1 850
Removal and installation of EGR Gas Temperature Sensor 2 851
Removal of EGR Gas Temperature Sensor 2 851
Installation of EGR Gas Temperature Sensor 2 851
Inspection of EGR Gas Temperature Sensor 2 851
Removal and installation of NOx Sensor 853
Removal of NOx Sensor 853
Installation of NOx Sensor 853
Removal and installation of EGR Gas Temperature Sensor 3 854
Removal of EGR Gas Temperature Sensor 3 854
Installation of EGR Gas Temperature Sensor 3 854
Removal and installation of DEF Sensor 855
Removal of DEF Sensor 855
Installation of DEF Sensor 855
Engine-related Diagnostic Trouble Code List 856
Engine-side Trouble 861
ECM Trouble 861
DTC U0001 CAN Bus Error (ISO-CAN) 861
DTC P0016 Crankshaft Position – Camshaft Position Correlation Error 862
DTC P0045 Turbocharger Boost Control VNT Error 862
DTC U0073 Control Module Communication Bus Off 864
DTC P0087 Fuel Rail/System Pressure – Too Low 865
DTC P0089 Fuel Pressure Regulator Performance 868
DTC P0091 Fuel Pressure Regulator Control Circuit Low 869
DTC P0092 Fuel Pressure Regulator Control Circuit High 870
DTC P0097 Intake Air Temperature (IAT) Sensor 2 Circuit Low Voltage 871
DTC P0098 Intake Air Temperature (IAT) Sensor 2 Circuit High Voltage 871
DTC U0101 Lost Communication With CAN 872
DTC P0102 Mass Air Flow Sensor Circuit Low Input 873
DTC P0103 Mass Air Flow Sensor Circuit High Input 874
DTC U010E Lost Communications With Dosing Control Module 874
DTC U0110 Lost Communication With VNT System 875
DTC P0112 Intake Air Temperature Sensor Circuit Low 875
DTC P0113 Intake Air Temperature Sensor Circuit High 876
DTC P0117 Engine Coolant Temperature Sensor Circuit Low 877
DTC P0118 Engine Coolant Temperature Sensor Circuit High 877
DTC P0122 Throttle Position Sensor Circuit Low 878
DTC P0123 Throttle Position Sensor Circuit High 879
DTC P0182 Fuel Temperature Sensor Circuit Low 880
DTC P0183 Fuel Temperature Sensor Circuit High 881
DTC P0192 Fuel Rail Pressure Sensor Circuit Low 882
DTC P0193 Fuel Rail Pressure Sensor Circuit High 882
DTC P0201 Injector Circuit Open – Cylinder 1 884
DTC P0202 Injector Circuit Open – Cylinder 2 884
DTC P0203 Injector Circuit Open – Cylinder 3 885
DTC P0204 Injector Circuit Open – Cylinder 4 886
DTC P0217 Engine Coolant Over Temperature Condition 887
DTC P0219 Engine Overspeed Condition 887
DTC P0234 Turbocharger Overboost Condition 888
DTC P0237 Turbo Charger Boost Sensor Circuit Low 889
DTC P0238 Turbo Charger Boost Sensor Circuit High 889
DTC P0335 Crankshaft Position Sensor Circuit 890
DTC P0336 Crankshaft Position Sensor Circuit Range/Performance 891
DTC P0340 Camshaft Position Sensor Circuit 892
DTC P0380 Glow Relay Circuit Error 893
DTC P0401 EGR Flow Insufficient Detected 894
DTC P0404 EGR Control Circuit Range/Performance 895
DTC P0409 EGR Sensor Circuit 895
DTC U0411 Lost CAN Communications With VNT Control Module 897
DTC P041C EGR Cooler Outlet 1 Temp Sensor Circuit Low 897
DTC P041D EGR Cooler Outlet 1 Temp Sensor Circuit High 898
DTC P0427 Catalyst Temperature Sensor Circuit Low Sensor 1 899
DTC P0428 Catalyst Temperature Sensor Circuit High Sensor 1 899
DTC P042C Catalyst Temperature Sensor Circuit Low Sensor 2 900
DTC P042D Catalyst Temperature Sensor Circuit High Sensor 2 901
DTC P0522 Engine Oil Pressure Sensor Circuit Low Input 902
DTC P0523 Engine Oil Pressure Sensor Circuit High Input 903
DTC P0545 EGR Cooler Inlet 1 Temp Sensor Circuit Low 904
DTC P0546 EGR Cooler Inlet 1Temp Sensor Circuit High 904
DTC P0560 12 Volt Circuit Error 905
DTC P0563 System Voltage High 905
DTC P0601 Internal Control Module Memory Check Sum Error 906
DTC P0602 Internal Control Module QR Code Error 906
DTC P0604 Internal Control Module RAM Error 907
DTC P0606 Internal Control Module CPU Error 907
DTC P060A Internal Control Module CPU IC Error 907
DTC P060C Internal Control Module A/D Processing Performance 907
DTC P0615 Starter Relay Circuit Error 908
DTC P0638 Throttle Actuator Control Range/Performance 908
DTC P0685 ECM Power Relay Control Circuit Open 909
DTC P0687 ECM Power Relay Control Circuit High 910
DTC P06A6 Sensor Reference Voltage 1 Circuit 910
DTC P06A7 Sensor Reference Voltage 2 Circuit 911
DTC P06A8 Sensor Reference Voltage 3 Circuit 912
DTC P06A9 Sensor Reference Voltage 4 Circuit 912
DTC P06AF Torque Management System – Forced Engine Shutdown 913
DTC P06D5 Sensor Reference Voltage 5 Circuit 914
DTC P1076 Charge Air Cooler (CAC) Temperature Sensor 1 Circuit Low Voltage 914
DTC P1077 Charge Air Cooler (CAC) Temperature Sensor 1 Circuit High Voltage 914
DTC P1093 Fuel Rail Pressure Too Low 915
DTC P1097 Compressor Outlet Temperature Sensor Circuit High 918
DTC P1098 Compressor Outlet Temperature Sensor Circuit High 919
DTC P1236 Charge Air Cooler Performance Failure 920
DTC P1261 Injector Positive Voltage Control Circuit Group 1 920
DTC P1262 Injector Positive Voltage Control Circuit Group 2 921
DTC P1404 EGR Position Fault 921
DTC P1606 SW-IC Internal failure 922
DTC P160B AD-IC Failure Error 922
DTC P160C AD-IC2 Failure Error 922
DTC P1621 Control Module Long Term Memory Performance 922
DTC P1669 DPD Lamp Control Circuit 923
DTC P204F SCR System Error (No Inducement) 924
DTC P207F Urea Fluid Concentration Too Low 924
DTC P20C9 SCR System Error 924
DTC U2106 Lost CAN Communications With Wheel Loader Transmission Control System 924
DTC P2122 Pedal Position Sensor 1 Circuit Low Input 925
DTC P2123 Pedal Position Sensor 1 Circuit High Input 925
DTC P2127 Pedal Position Sensor 2 Circuit Low Input 926
DTC P2128 Pedal Position Sensor 2 Circuit High Input 927
DTC P2138 Pedal Position Sensor 1 – 2 Voltage Correlation 927
DTC P2146 Fuel Injector Group 1 Supply Voltage Circuit 928
DTC P2149 Fuel Injector Group 2 Supply Voltage Circuit 929
DTC P2228 Barometric Pressure Sensor Circuit Low 930
DTC P2229 Barometric Pressure Sensor Circuit High 931
DTC P2457 Exhaust Gas Recirculation (EGR) Cooling System Performance 931
DTC P2458 Purge time Out Error 932
DTC P2BA7 Urea Fluid Quantity Too Low 932
DTC P2BAA SCR System Error (Inducement, No Purge) 932
DTC P3093 Fuel Rail Pressure Too Low 932
DCU Trouble 935
DTC 0002 CAN Bus Off 935
DTC 0100 Lost Communication With ECM 936
DTC 029D Lost Communication With NOx Sensor 1 937
DTC 0607 Control Module Performance 939
DTC 060B Internal Control Module A/D Processing Performance 940
DTC 062F Control Module EEPROM Error 940
DTC 0641 Sensor Reference Voltage 1 Circuit 941
DTC 0658 Actuator Supply Voltage Circuit 942
DTC 0659 Actuator Supply Voltage Circuit 943
DTC 1462 Urea Fluid Quality Sensor Timeout Error 944
DTC 1464 Main Relay Performance 944
DTC 1468 DCU Overtemperature 945
DTC 1491 Urea Fluid Overpressure 945
DTC 1493 DCU Driver Overtemperature 947
DTC 149C Urea Fluid Pressure Reduction Malfunction 947
DTC 149D Urea Fluid Tank Overtemperature 948
DTC 203B Urea Fluid Tank Level Sensor Stuck 949
DTC 203C Urea Fluid Tank Level Sensor Low Voltage 950
DTC 203D Urea Fluid Tank Level Sensor High Voltage 951
DTC 2048 Urea Fluid Injector Circuit Low Voltage 952
DTC 2049 Urea Fluid Injector Circuit High Voltage 953
DTC 204B Urea Fluid Pressure Sensor Performance 953
DTC 204C Urea Fluid Pressure Sensor Circuit Low Voltage 954
DTC 204D Urea Fluid Pressure Sensor Circuit High Voltage 955
DTC 205B Urea Fluid Tank Temperature Sensor Performance 956
DTC 205C Urea Fluid Tank Temperature Sensor Low Voltage 957
DTC 205D Urea Fluid Tank Temperature Sensor High Voltage 957
DTC 206A Urea Fluid Quality Sensor Circuit 958
DTC 206B Urea Sensor Over Temperature Condition 958
DTC 206C Urea Fluid Quality Sensor Circuit Low Voltage 959
DTC 206D Urea Fluid Quality Sensor Circuit High Voltage 960
DTC 207F Urea Fluid Concentration Too Low 960
DTC 208A Urea Fluid Pump Control Circuit 961
DTC 208B Usea Fluid Pump Performance 961
DTC 208C Urea Fluid Pump Control Circuit Low Voltage 962
DTC 208D Urea Fluid Pump Control Circuit High Voltage 963
DTC 208E Urea Fluid Injector Stuck 964
DTC 20A0 Urea Fluid Reverting Valve Circuit Open 965
DTC 20A2 Urea Fluid Reverting Valve Circuit Low Voltage 965
DTC 20A3 Urea Fluid Reverting Valve Circuit High Voltage 966
DTC 20AC Urea Fluid Pump Temperature Sensor Performance 967
DTC 20AD Urea Fluid Pump Module Temperature Sensor Performance 968
DTC 20B1 Urea Fluid Tank Heater Coolant Control Valve Circuit Open 969
DTC 20B3 Urea Fluid Tank Heater Coolant Control Valve Circuit Low Voltage 970
DTC 20B4 Urea Fluid Tank Heater Coolant Control Valve Circuit High Voltage 970
DTC 20E8 Urea Fluid Pressure Underpressure 971
DTC 20E9 Urea Fluid Overpressure 972
DTC 20EA Urea Fluid Pressure Reduction Malfunction 974
DTC 20FE Urea Fluid Pressure Build-Up Error 974
DTC 2201 Upstream Nox Sensor Performance 976
DTC 2206 NOx Sensor Heater Control Circuit Low Voltage Sensor 1 976
DTC 2207 NOx Sensor Heater Control Circuit High Voltage Sensor 1 977
DTC 242B Exhaust Gas Temperature (EGT) Sensor 3 Performance 977
DTC 242C Exhaust Gas Temperature (EGT) Sensor 3 Circuit Low Voltage 977
DTC 242D Exhaust Gas Temperature (EGT) Sensor 3 Circuit High Voltage 978
Data Reference Values 980
J HYDRAULIC EQUIPMENT (PUMP, OPERATION SYSTEM VALVE) 981
Main Equipment Table 987
Hydraulic Device 987
Hydraulic Pump 987
Control-related 988
Control valve 988
Control Valve (LF) 988
Solenoid Valve (5 Stack) 988
Remote Control Valve for Left/Right Operations 989
Remote Control Valve for Travel Operation 989
Remote Control Valve Characteristic Diagram 989
Operation Remote Control Valve Control Diagram 989
Travel Remote Control Valve Control Diagram 990
Cushion Valve (heat circuit, with shuttle valve) 990
Selector Valve 991
Basic Functions 992
Oil Temperature Gauge 992
Static Horsepower Control 993
Overload Warning (Function for Europe Only) 994
Pressure Boost Control 995
Stroke Control 997
Boom Down Energy Save 998
Pump Horsepower Boost Control 999
Arm 1 Semi-parallel Control 999
Arm 2 Semi-parallel Control1000
Hot Shutdown Warning1001
Gate Lock1002
Breaker Mode1003
Crusher Mode1003
Quick coupler1004
Hydraulic Filter Clogging1005
Solenoid Sticking Prevention1006
Port Diagram1007
Hydraulic Pump (Standard Model)1007
Control Valve1008
Relief Valve1008
5 Stack Solenoid Valve1011
2 Stack Solenoid Valve1013
Remote Control Valves (upper, travel)1013
Remote Control Valves (left-right)1013
Remote Control Valve (Travel)1014
Cushion Valve1015
2-way Selector Valve1016
Direction Valve1017
6 Stack Proportional Valve1018
Relief Valve (electromagnetic proportional)1020
Manifold Under Cab1021
Manifold (accumulator section)1022
Hydraulic Oil Tank1023
Hydraulic Pump1024
Structure and Operation Explanation1024
Hydraulic Pump Internal Structure Diagram1025
Overall View1025
Drive Shaft Front Side1026
Drive Shaft Rear Side1027
Development Diagram1028
Component Table1031
Regulator1032
Regulator Operation Explanation1032
Regulator Operation Explanation Diagram1035
Internal Configuration Diagram of Regulator1038
Development Diagram of Regulator1040
Component Table1041
Operation Outline of Electronically-Controlled Pump1043
Control Valve1046
Basic Configuration1046
Operation1046
Operation of Main Unit1046
Activation of Relief Valve1067
5 Stack Solenoid Valve Operation Explanation1072
External Shape Diagram and Components1072
operation explanation1072
Upper Pilot Valve (remote control valve)1073
Structure1073
Function1073
Operation1074
Structural Diagram1078
Travel Pilot Valve (remote control valve)1079
Operation1079
Pressure Reducing Valve Section1079
Damping Mechanism in Operation Section1080
Structural Diagram1083
Cushion Valve 1085
structure1085
operation explanation1085
Selector Valve (2-way)1090
structure1090
operation explanation1091
Development Diagram1092
Direction Valve (3-direction) 1093
Structure1093
Operation Explanation1094
6 Stack Proportional Valve (Pilot)1096
structure1096
operation principle1097
Electromagnetic Relief Valve1098
Structure1098
Operation Explanation1099
Operation of Check Valve1099
Operation of Electromagnetic Relief Valve1100
Removal and Installation of Hydraulic Tank1102
Removal of Hydraulic Reservoir1102
Installation of Hydraulic Oil Tank1104
Removal and Installation of Hydraulic Pump1105
Removal of Hydraulic Pump1105
Installation of Hydraulic Pump1107
Removal and Installation of Control Valve1108
Removal of Control Valve1108
Installation of Control Valve1112
Removal and Installation of Travel Remote Control Valve1113
Removal of Travel Remote Control Valve1113
Installation of Travel Remote Control Valve1114
Removal and Installation of Operation Remote Control Valve1117
Removal of Operation Remote Control Valve (Left)1117
Installation of Operation Remote Control Valve (Left)1119
Removal of Operation Remote Control Valve (right side)1121
Installation of Operation Remote Control Valve (right side)1123
Removal and Installation of 5 Stack Solenoid1125
Removal of 5 Stack Solenoid Valve1125
Installation of 5 Stack Solenoid Valve1126
Removal and Installation of Cushion Valve1127
Removal of Cushion Valve1127
Installation of Cushion Valve1128
Procedures for Assembly and Disassembly of Hydraulic Pump Main Unit1129
Tools1129
Disassembly Procedure1129
Assembly Procedures1131
Development Diagram1135
Component Table1138
Pump Main Unit Maintenance Standards1139
Replacement Standard of Wear Component1139
Correction Standard of Cylinder, Valve Plate, and Sash Plate (Shoe Plate)1139
Tightening torque1140
Overall View1140
Drive Shaft Front Side1141
Drive Shaft Rear Side1142
Development Diagram1143
Component Table1146
Regulator Maintenance Standards1147
Regulator Adjustment1147
Appendix Table and Drawings1148
Regulator Assembly and Disassembly Procedures1152
Tools1152
Preparations for Disassembly1152
Disassembly Procedure1152
Assembly Procedures1154
Internal Configuration Diagram of Regulator1157
Development Diagram of Regulator1159
Component Table1160
Assembly and Disassembly of Control Valve1162
Disassembly1162
Caution for Disassembly1162
Disassembly Procedure1162
Removal of Long Cap and Pulling Out of Main Spool1162
Disassembly of Arm 1, 2 Parallel-Tandem Spool, Neutral Cut Spool, Arm Regeneration Release Spool Section1163
Disassembly of Load Check Valve Section1163
Disassembly of Antidrift Valve Section (Sub Component in Assembly is Expressed by (Min Number – Sub Number))1164
Disassembly of Relief Valve1164
Disassembly of Option Section1164
Disassembly of Add-On Section1164
Disassembly of Valve Housing Coalescence Bolt1165
Cleaning1165
Inspection1165
assembly1165
Caution for Assembly1165
Caution for Handling O-ring1165
Caution for Handling Spool1165
Method to Apply Adhesive Agent (Male and Female Thread Section of Components Requiring Bonding)1165
Assembly Procedure of Sub-Assembly1166
Assembly of Spool Assembly (Main Spool)1166
Assembly of Arm 1, 2 Parallel-Tandem Spool, Neutral Cut Spool, Arm Regeneration Release Spool Assembly1166
Assembly of Antidrift Valve Assembly1167
Assembly Procedure of Control Valve Main Unit1167
Assembly of Relief Valve1167
Assembly of Load Check Valve1167
Assembly of Antidrift Valve1168
Assembly of Option Section1168
Assembly of Arm 1 Parallel-Tandem Spool1168
Assembly of Arm 2 Parallel-Tandem Spool, Neutral Cut Spool, Arm Regeneration Release Spool1168
Assembly of Main Spool1168
Assembly of Add-On Section1169
Assembly of Other Plugs1169
Internal Structural Diagram1170
Part List1176
Relief Valve1177
Assembly and Disassembly Procedure of Main Relief Valve1177
Assembly and Disassembly Procedures of Overload Relief1178
Assembly and Disassembly Procedure of Low-Pressure Relief Valve1179
Assembly and Disassembly Procedure of Main Relief Valve for Add-On1179
Adjustment of Relief Valve1180
Installation1181
Operation1181
Malfunction and Countermeasure1181
Procedures for Assembly and Disassembly of Operation Remote Control Valve1183
Maintenance Procedures1183
Required Tools and Tightening Torque1183
Maintenance Standards1183
Disassembly Procedures1184
Assembly Procedures1186
Causes of Trouble and Countermeasures1190
Procedures for Assembly and Disassembly of Travel Remote Control Valve1194
Maintenance Procedures1194
Disassembly Procedures1195
Assembly Procedures1199
Causes of Trouble and Countermeasures and Cross-section Diagram1204
Assembly and Disassembly of Cushion Valve1207
Disassembly Procedures1207
Reverse Operation Spool Section1207
Check Plunger Section with Throttle1207
Shuttle Valve Section1207
Assembly Procedures1207
Reverse Operation Spool Section1208
Check Plunger Section with Throttle1208
Shuttle Valve Section1208
Written Materials1209
Procedures for Assembly and Disassembly of 6 Stack Proportional Valve (Pilot)1211
Development Diagram1211
Assembly and disassemblyΒ procedures1212
Precautions1212
Replacement of Proportional Solenoid1212
Disassembly1212
Assembly1212
Replacement of Sleeve and Spool1213
Disassembly1213
Assembly1214
Replacement of Poppet (Check Valve for Normally Open)1215
Disassembly1215
assembly1216
Maintenance Standards1216
Troubleshooting1216
Pressure Measurement and Adjustment Procedures1218
Procedures for Pressure Measurement from the Monitor Display1218
Monitor and Switch Panel1218
Pressure Measurement Method1218
Operating Method1218
PROCEDURES FOR MEASURING HYDRAULIC OIL TEMPERATURE FROM THE MONITOR DISPLAY1218
Hydraulic Oil Temperature Measurement Method1218
Operating Method1219
Procedures for Pressure Measurement by Installing Pressure Gauge1220
Preparations1220
Items to prepare1220
Pressure Measuring Ports1221
Control Valve1223
Location of Relief Valves1223
Pressure Measurement Preparations1224
Pressure Measurement1226
Main Pressure Measurement1226
A Attachments Pressure Measurement1226
Boom-down pressure measurement1228
D Option Line Pressure Measurement1228
Pilot Pressure Measurement1228
Pressure Gauge Installation1228
Negative Control Pressure Measurement1229
Pressure Gauge Installation1229
Pressure Adjustment1229
Main Pressure Adjustment1229
Preparation Work of Pressure Measurement Adjustment1229
Main Relief Pressure Adjustment1231
Overload Relief Pressure Adjustment1232
Swing Relief Pressure Adjustment1233
Pilot Pressure Adjustment1234
Hydraulic Pump Flow Measurement Procedures1235
Preparations1235
Items to Prepare1235
Work Preparations1236
Flow Measurement1237
Air Bleed Procedure1239
Hydraulic Pump1239
Sampling Procedure1240
Sampling of Hydraulic Fluid1240
Hydraulic Equipment Layout1241
Overall View1242
Pump Chamber Hydraulic Equipment Layout1243
Swing Body Center Section Hydraulic Equipment Layout1244
Housing Left Side Hydraulic Equipment Layout1246
Layout of Hydraulic Equipment in Cab1247
N CAB1323
Removal and Installation of Operator’s Seat1326
Removal of Operator’s Seat1326
Installation of Operator’s Seat1326
Removal and Installation of Cab Assembly1327
Removal of Cab Assembly1327
Installation of Cab Assembly1331
Removal and Installation of Wiper1332
Removal of Wiper1332
Installation of wiper1332
Removal and Installation of Cab Front Glass1333
Removal of Cab Front Glass1333
Installation of Cab Front Glass1334
Window Lock Adjustment Procedures1335
Window Lock (front side)1335
Window Lock (rear side)1335
Removal and Installation of Housing Guardrail1337
Removal of Housing Guardrail1337
Installation of Housing Guardrail1337
Tightening torque1338
R ELECTRICAL PARTS1339
Basic Functions1343
Monitor Control1343
Monitor Display Dimming1343
Diagnostic Trouble Code Indicator1344
Clock1344
Basic Operation1345
Battery Save1345
Accessories1347
Working Light1347
LED Light1348
Room Lamp1349
Radio Mute1350
Wiper and Washer1351
Safety1354
Horn1354
Back/Side View Monitor1355
Precautions for Camera Installation1355
Maintenance1356
Anti-theft1356
Manual Lock1356
Service Support Screen Lock1356
Customer-specific System Information Screen Lock1356
Maintenance Information Screen Lock1357
Option Line Setting Screen Lock1357
Setting1357
Clock Adjustment1357
Screen Brightness Setting1358
Battery Disconnect Switch1359
Explanation of Controller1360
Service Support1362
Screen Operations1362
Screen Display List1362
Service Monitor Structure1363
CHECK Screen List1364
MACHINE STATUS1364
HYDRAULIC STATUS1370
ENGINE STATUS1377
FAULT HISTORY1382
WORK HISTORY1382
HYDRAULIC HISTORY1391
ENGINE HISTORY1403
DEVICE TEST1424
ECM/DCU Memory Clear1424
SCR RE-GEN1425
Urea Line Leak Test1426
CCV Operation Test1427
Dosing Test1428
Reverting Valve Operation Test1429
Common Rail Pressure Test1430
Idle Speed Test / Injector Test1431
EGR Valve Control Test1432
VG Turbo Control Test1433
Intake Throttle Control Test1434
CONTROL UNIT Screen List1436
MCM-MAIN1436
MCM-SUB1440
COMMU TERMINAL1441
SETUP Screen List1443
MACHINE SELECT1444
DIMENSIONS1448
PARAMETERS1449
ENGINE INFORMATION1451
ENGINE INFORMATION1452
Data Confirmation1452
Data Transfer (Copy)1453
QR (INJECTOR) CODE1454
Injector number1454
Screen Layout1454
Data Source Selection1454
Manual Input1455
CAMERA1456
PASSWORD1459
CALIBRATE Screen List1462
Throttle Volume1462
OPTLINE RELIEF1463
PUMP FLOW1464
Connection Connector Pin Layout1467
Main Controller1467
Monitor1468
Sequence Circuit Diagram1469
Code List1469
Overall1472
Block diagram1475
Main controller1475
DCU1476
ECM1477
Monitor1478
Air Conditioner1479
Gate Lock1480
Horn1480
Working Light1481
Option1482
Other1483
Electrical Symbol List1483
Electrical Equipment Layout Diagram1485
Main Unit Left-side Layout Diagram1486
Engine Section Layout Diagram1488
Main Unit Right Side Layout Diagram (pump chamber)1491
Main Unit Center Section Layout Diagram1493
Cab Layout Diagram 11495
Cab Layout Diagram 21497
Layout Around Operator Seat1500
Stand Alone Parts Diagram1501
Removal and Installation of Wiper Controller1520
Removal of Wiper Controller1520
Installation of wiper controller1520
Removal and Installation of Wiper Motor1521
Removal of Wiper Motor1521
Installation of wiper motor1522
Removal and Installation of ECM1523
Removal of ECM1523
Installation of ECM1523
Removal and Installation of Main Controller1524
Removal of Main Controller1524
Installation of Main Controller1524
Removal and Installation of DCU1525
Removal of DCU1525
Installation of DCU1525
Removal and Installation of Monitor1526
Removal of Monitor1526
Installation of Monitor1526
Air Conditioner Overall Diagram1527
Frame1527
Cab1529
Equipment Layout Diagram1532
Circuit Diagram1534
Air Conditioner Circuit Diagram1534
Explanation of Functions1536
Explanation of Control1536
Air Mix Motor Actuator Control1537
Blow Mode Motor Actuator Control1537
Refresh/Recirculate Switch Motor Actuator Control1538
Blower Amp Control1539
Compressor Clutch Control1541
COOLMAX Control and HOTMAX Control1542
Abnormality Detection and Control after Abnormality Detected1542
Monitor Mode1546
Door Switch Control1548
Actuator Inspection1549
Air Mix Motor Actuator Inspection1549
Refresh/Recirculate Switch Motor Actuator Inspection1550
Mode Motor Actuator Inspection1551
Self-diagnosis Function with Panel Display1552
Abnormality Display and Self-check Procedures1552
Abnormality Display Position1552
Explanation of Abnormality Display1552
Motor Actuator Abnormality1552
Sensor Abnormality1553
Explanation of Monitor Mode1553
Monitor Mode Display Position1554
Monitor Mode Display Operating Method1554
Display Contents in Monitor Mode1555
Part Function and Good/Poor Judgment1561
Control Panel1561
Blower Amp1561
Relay1562
Air Mix Actuator1563
Refresh/Recirculate Actuator1564
Blow Mode Actuator1564
Evaporator Sensor1565
Dual Pressure Switch1565
Solar Radiation Sensor1566
Inside Air Sensor1566
Assembly and Disassembly of Unit1568
Removal of Blower Unit1568
Replacement of Blower Motor1568
Replacement of Blower Amp1568
Removal of Heater Core1569
Removal of Heat Case Right/Left1569
Replacement of Evaporator and Expansion Valve1569
Installation of Evaporator Sensor1570
Replacement of Motor Actuator1570
Removal and Installation of Compressor1571
Removal of Compressor1571
Installation of Compressor1571
Removal and Installation of Condenser1572
Removal of Condenser1572
Installation of Condenser1573
Removal and Installation of Receiver Dryer1574
Removal of Receiver Dryer1574
Installation of Receiver Dryer1574
Work Precautions1576
Work Procedures1576
Air Conditioner Refrigerant Filling is Divided into the “Vacuum Operation” and “Gas Filling Operation”1576
Operation Chart1577
Tools1577
Filling Procedures1579
Charging Hose Connection Position1579
Connecting Gauge Manifold1579
Vacuuming1580
Gas Filling Operation, High-pressure Side1581
Gas Filling Work, Low Pressure Side1581
V ATTACHMENTS1615
Main Equipment Table1619
Backhoe Attachment1619
Cylinder1619
Cylinder (LF)1619
Maintenance Standards1621
Attachment (Backhoe)1621
1 Boom and Swing Frame Installation Section1621
2 Boom Cylinder and Swing Frame Installation Section1622
3 Boom and Boom Cylinder Installation Section1622
4 Boom and Arm Cylinder Installation Section1623
5 Boom and Arm Installation Section1624
6 Arm and Arm Cylinder Installation Section1624
7 Arm and Bucket Cylinder Installation Section1625
8 Arm and Arm Link Installation Section1626
9 Bucket and Bucket Link Installation Section1626
10 Bucket Link and Bucket Cylinder Installation Section1627
11 Bucket and Arm Installation Section1628
Attachment (Backhoe) (LF)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 Section1633
9 Bucket and Bucket Link Installation Section1634
10 Bucket Link and Bucket Cylinder Installation Section1634
11 Bucket and Arm Installation Section1635
Removal and Installation of Bucket Cylinder1636
Removal of Bucket Cylinder1636
Installation of Bucket Cylinder1638
Removal and Installation of Arm Cylinder1639
Removal of Arm Cylinder1639
Installation of Arm Cylinder1641
Removal and Installation of Boom Cylinder1643
Removal of Boom Cylinder1643
Installation of Boom Cylinder1645
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder1648
Specifications and Structure Diagram (including the assembly diagram and parts table)1648
Basic Functions1648
Function of Each Location1648
Cylinder Head Assembly (made by KYB)1648
Piston Assembly (made by KYB)1649
Pipe Assembly (made by KYB)1651
Handling Precautions1651
Precautions for Installing the Cylinder on the Machine Body1651
Usage Cautions1652
Maintenance and Inspection Cautions1652
Maintenance Inspection and Service1654
Trouble Diagnostics1655
Storage Standards1660
Storing Parts Individually (In principle, store indoors)1660
When Mounted on Vehicle Body1660
Recommended Anti-rust Oil1660
Assembly and Disassembly Procedures1661
Preparations Β·Β·Β·Β·Β· Prepare the Following before Starting Disassembly1661
General Work Precautions1661
Maintenance Standards1661
Inspection after Assembly1661
Required Tool1662
General Tool1662
Special Jig (made by KYB)1663
Special Jig Parts Number List (made by KYB)1663
Disassembly Procedures (made by KYB)1664
Assembly Procedures (made by KYB)1667
Test Operation1672
Usage Limits1673
Structural Diagram (made by KYB)1674
Boom Cylinder1674
Arm Cylinder1676
Arm Cylinder (LF)1678
Bucket Cylinder1680
Bucket Cylinder (LF)1682
HBCV1684
structure1684
Function1684
operation explanation1684
Port Diagram1699
HBCV1699
Air Bleed Procedure1700
HBCV1700
Boom Cylinder HBCV1700
Arm Cylinder HBCV1701
Removal and Installation of HBCV1702
Removal and Installation of Arm HBCV1703
Removal of Arm HBCV1703
Installation of arm HBCV1703
Removal and Installation of Boom HBCV1704
Removal of Boom HBCV1704
Installation of boom HBCV1705
Removal and Installation of Bucket1706
Removal of Bucket1706
Installation of Bucket1706
Removal and Installation of Bucket Link1708
Removal of Bucket Link1708
Installation of Bucket Link1708
Removal and Installation of Arm1710
Removal of Arm1710
Installation of Arm1711
Removal and Installation of Boom1712
Removal of Boom1712
Installation of Boom1714
Z OTHER1719
Changes from Model -61724
Overall Layout1724
Lower1724
Swing Unit1725
Engine1725
hydraulic-related1727
Hydraulic Control1728
Cab, Housing1729
Electrical Data1731
Electric Control1732
Attachments1732
Specifications1733
ENGINE1733
HYDRAULIC SYSTEM1733
HYDRAULIC CONTROLS1734
ELECTRICAL SYSTEM1734
OPERATOR ENVIRONMENT1735
UNDERCARRIAGE1735
MASS1736
DIGGING FORCE (with 11 m3 Sumitomo Bucket) (ISO 6015)1736
DIMENSIONS1736
WORKING RANGES1737
SYSTEM FLUID CAPACITIES AND SPECIFICATIONS1737
Specifications (LF)1738
ENGINE1738
HYDRAULIC SYSTEM1738
HYDRAULIC CONTROLS1739
ELECTRICAL SYSTEM1739
OPERATOR ENVIRONMENT1740
UNDERCARRIAGE1741
MASS1741
DIGGING FORCE (with 037 m3 Sumitomo Bucket) (ISO 6015)1741
DIMENSIONS1741
WORKING RANGES1742
SYSTEM FLUID CAPACITIES AND SPECIFICATIONS1742
Main Unit Weight1743
Divided Weight (Standard Specifications)1743
Divided Weight (LF)1744
Stand Alone Part Weight1744
Stand Alone Part Weight (LF)1745
Shoe Weight (per side)1745
Shoe Weight (per Side) (LF)1745
Arm Weight1745
Arm Weight (LF)1746
Bucket weight1746
Bolt Size and Torque Table1748
Special Torque Setting1748
Overall View1752
250X41752
Standard Arm [300 m (98425 ft)]1752
Short Arm [250 m (82021 ft)]1753
Long Arm [352 m (115486 ft)]1754
250X4 LF1755
Ultra-long Arm [80 m (26247 ft)]1755
WORK RANGE DIAGRAM1756
250X41756
Standard Arm [300 m (98425 ft)]1756
Short Arm [250 m (82021 ft)]1758
Long Arm [352 m (115486 ft)]1760
250X4 LF1762
Ultra-long Arm [80 m (26247 ft)]1762
FLUIDS AND LUBRICANTS1764
HYDRAULIC FLUID1764
Engine Oil1764
Fuel1764
Conditions applicable to diesel fuel1764
Recommended Conditions Applicable to Diesel Fuel1764
Main-unit-related Diagnostic Trouble Code List1765
Main Unit-side Trouble1768
Diagnostic Trouble Code: 7000 Pressure Sensor P1 Abnormality1768
Diagnostic Trouble Code: 7001 Pressure Sensor P2 Abnormality1769
Diagnostic Trouble Code: 7002 Pressure Sensor N1 Abnormality1771
Diagnostic Trouble Code: 7003 Pressure Sensor N2 Abnormality1772
Diagnostic Trouble Code: 7004 Pressure Sensor Boom Cylinder Bottom Abnormality1774
Diagnostic Trouble Code: 7007 Pressure Sensor Arm Cylinder Rod Abnormality1775
Diagnostic Trouble Code: 7021 Pressure Sensor Swing Pilot Abnormality1777
Diagnostic Trouble Code: 7023 Pressure Sensor Arm-In Pilot Abnormality1778
Diagnostic Trouble Code: 7040 Level Sensor Fuel Abnormality1780
Diagnostic Trouble Code: 7041 Temperature Sensor Hydraulic Fluid Abnormality1781
Diagnostic Trouble Code: 7065 Pressure Sensor Boom-Up Pilot Abnormality1782
Diagnostic Trouble Code: 7067 Pressure Sensor Bucket-Close Pilot Abnormality1784
Diagnostic Trouble Code: 7068 Pressure Sensor Boom-Down Pilot Abnormality1786
Diagnostic Trouble Code: 7069 Pressure Sensor Arm-Out Pilot Abnormality1787
Diagnostic Trouble Code: 7070 Pressure Sensor Bucket-Open Pilot Abnormality1789
Diagnostic Trouble Code: 7071 Pressure Sensor Travel Right Pilot Abnormality1790
Diagnostic Trouble Code: 7072 Pressure Sensor Travel Left Pilot Abnormality1792
Diagnostic Trouble Code: 7073 Pressure Sensor Travel 1 Pedal Abnormality1794
Diagnostic Trouble Code: 7074 Pressure Sensor 1st Option Pilot (Common/Front Pedal) Abnormality1796
Diagnostic Trouble Code: 7075 Pressure Sensor Arm Cylinder Bottom Abnormality1797
Diagnostic Trouble Code: 7078 Pressure Sensor 1st Option Pilot (Rear Pedal) Abnormality1799
Diagnostic Trouble Code: 7200 Swing Brake Solenoid Abnormality1801
Diagnostic Trouble Code: 7201 Travel 2nd-Speed Switchover Solenoid Abnormality1802
Diagnostic Trouble Code: 7202 Pressure Boost Solenoid Abnormality1803
Diagnostic Trouble Code: 7203 Travel Alarm Buzzer Abnormality1804
Diagnostic Trouble Code: 7206 Option Return Line Switchover Solenoid Abnormality1805
Diagnostic Trouble Code: 7207 Free Swing Solenoid Abnormality1806
Diagnostic Trouble Code: 7213 Quick Coupler Buzzer Abnormality1807
Diagnostic Trouble Code: 7214 Quick Coupler Solenoid Abnormality1809
Diagnostic Trouble Code: 7247 Boom 2-Down Pilot Proportional Valve Abnormality1810
Diagnostic Trouble Code: 7249 Bucket-Close Pilot Proportional Valve Abnormality1811
Diagnostic Trouble Code: 7250 Option Relief Pressure Proportional Valve Abnormality1813
Diagnostic Trouble Code: 7265 Arm 1 Semi-Parallel Proportional Valve Abnormality1814
Diagnostic Trouble Code: 7266 Arm 2 Semi-Parallel Proportional Valve Abnormality1815
Diagnostic Trouble Code: 7267 Arm 1 Regeneration Release Proportional Valve Abnormality1816
Diagnostic Trouble Code: 7270 Tilting 1 Proportional Valve Abnormality1817
Diagnostic Trouble Code: 7271 Tilting 2 Proportional Valve Abnormality1819
Diagnostic Trouble Code: 7273 Straight Travel Proportional Valve Abnormality1820
Diagnostic Trouble Code: 7400 Coolant Temperature Overheating 11821
Diagnostic Trouble Code: 7401 Coolant Temperature Overheating 21822
Diagnostic Trouble Code: 7404 Oil Temperature Overheating1823
Diagnostic Trouble Code: 7405 Boost Temperature Overheating 11824
Diagnostic Trouble Code: 7406 Boost Temperature Overheating 21825
Diagnostic Trouble Code: 7420 Alternator Power Generation Failure1826
Diagnostic Trouble Code: 7421 Coolant Level Decrease1827
Diagnostic Trouble Code: 7422 Engine Oil Pressure Decrease1828
Diagnostic Trouble Code: 7423 Air Cleaner Clogging1829
Diagnostic Trouble Code: 7424 Return Filter Clogging1830
Diagnostic Trouble Code: 7426 Fuel Filter Clogging 11831
Diagnostic Trouble Code: 7427 Fuel Filter Clogging 21832
Diagnostic Trouble Code: 7428 Inducement (Remaining Urea Level Low) – Warning1833
Diagnostic Trouble Code: 7429 Inducement (Remaining Urea Level Low) – Early1834
Diagnostic Trouble Code: 7430 Inducement (Remaining Urea Level Low) – Final1834
Diagnostic Trouble Code: 7602 ECM Communication Abnormality1835
Diagnostic Trouble Code: 7605 ECM Not-Matched1836
Diagnostic Trouble Code: 7606 EEPROM Abnormality1837
Diagnostic Trouble Code: 7608 Camera Abnormality1837
Diagnostic Trouble Code: 7612 Air Conditioner Communication Abnormality1839
Diagnostic Trouble Code: 7613 Monitor Communication (CAN) Abnormality1840
Diagnostic Trouble Code: 7615 Sub-Controller Communication Abnormality1841
Diagnostic Trouble Code: 7618 DCU Communication Abnormality1843
List of special tools1845
NUMERICAL VALUE CONVERSION TABLE1845
Unit conversion rate1845
Length1845
Area1847
Volume1848
Weight1850
Pressure1851
Torque1852
Temperature1853
A1856
Travel Motor Special Tool1856
250X41856
Take-up Roller Special Tool1859
250X41859
Upper Roller Special Tool1860
250X41860
Lower Roller Special Tool1861
250X41861
C1862
Swing Motor Special Tool1862
250X41862
H1865
Engine Oil Filter Special Tool1865
210X4οΌ250X41865
Fuel Filter Special Tool1865
210X4οΌ250X41865
Injector Special Tool1865
210X4οΌ250X41865
Circuit Test Special Tool1866
210X4οΌ250X41866
Valve Guide Special Tool1866
210X4οΌ250X41866
Cylinder Head Special Tool1866
210X4οΌ250X41866
Head Bolt Special Tool1869
210X4οΌ250X41869
Crankshaft Special Tool1869
210X4οΌ250X41869
Valve Spring Special Tool1871
210X4οΌ250X41871
J1872
Remote Control Valve Special Tool1872
250X41872
R1874
Gas Filling Special Tool1874
210X4οΌ250X41874
V1874
Attachment Special Tool (for Cylinder Assembly)1874
Special Jigs Part Number List1874
Paint Colors1876
Abbreviation1878
WLSM2507-00LX-A3-JpdfΒ Β 0
A3 Assembly DiagramsΒ Β 0
J1249
Explanation of Hydraulic Circuit and Operations (standard model)1251
Travel Circuit1252
Travel Low-speed Circuit1252
Travel High-speed Circuit1254
Straight Travel Circuit (with HBCV)1256
Swing Circuit1258
Swing Speed Limit Control Circuit1258
Swing Relief Cut Control Circuit1260
Swing Brake Circuit1262
Swing Parking Circuit (lever in neutral)1264
Swing Parking Circuit (brake release)1266
Swing Parking Circuit (machine stop)1268
Boom Circuit1270
Boom-up Circuit (independent operation) (with HBCV)1270
Boom-up Spool Stroke Control Circuit (compound boom-up + arm-in) (with HBCV)1272
Boom-down Regenerative Circuit (with HBCV)1274
Boom-down Tilting Prevention Circuit (with HBCV)1276
Boom-down Load Holding Valve Circuit (with HBCV)1278
Arm Circuit1280
Arm-out Circuit (with HBCV)1280
Arm Semi-Parallel 1 Circuit1282
Arm Semi-Parallel 2 Circuit1284
Arm-in Regenerative Circuit (with HBCV)1286
Arm-in Load Holding Valve Circuit (with HBCV)1288
Bucket Circuit1290
Bucket-open Circuit1290
Bucket-close Regenerative Circuit1292
Bucket-Close Spool Stroke Control Circuit1294
Negative Control Circuit1296
Negative Control Circuit1296
Other Circuits1298
Cushion Circuit (arm-out operation)1298
Cushion Circuit (when arm-out operation stopped)1300
Cushion Circuit (arm-out β arm-in operation)1302
Heat Circuit (lever in neutral)1304
Auto Pressure Boost Circuit (arm in)1306
J1309
Explanation of Hydraulic Circuit and Operations (option)1311
Option Circuits1312
Breaker Circuit (independent operation)1312
Double-acting Circuit (hydraulic fork)1314
Multi-purpose Circuit (breaker Q control)1316
Multi-purpose Circuit (2 pumps flow crusher)1318
2nd Option Circuit (hydraulic rotation fork)1320
RΒ Β 0
Electrical Connector Wiring DiagramΒ Β 0
Main FrameΒ Β 0
Control ValveΒ Β 0
SCRΒ Β 0
Cab Main HarnessΒ Β 0
ConsoleΒ Β 0
EST-AΒ Β 0
Indicator JumperΒ Β 0
RΒ Β 0
Electrical Parts and Wiring Assembly DiagramΒ Β 0
FrameΒ Β 0
Engine and PumpΒ Β 0
AttachmentsΒ Β 0
BatteryΒ Β 0
CabΒ Β 0
WLSM2507-00LX-A3-RpdfΒ Β 0
A3 Assembly DiagramsΒ Β 0
JΒ Β 0
Explanation of Hydraulic Circuit and Operations (standard model)Β Β 0
Travel CircuitΒ Β 0
Travel Low-speed CircuitΒ Β 0
Travel High-speed CircuitΒ Β 0
Straight Travel Circuit (with HBCV)Β Β 0
Swing CircuitΒ Β 0
Swing Speed Limit Control CircuitΒ Β 0
Swing Relief Cut Control CircuitΒ Β 0
Swing Brake CircuitΒ Β 0
Swing Parking Circuit (lever in neutral)Β Β 0
Swing Parking Circuit (brake release)Β Β 0
Swing Parking Circuit (machine stop)Β Β 0
Boom CircuitΒ Β 0
Boom-up Circuit (independent operation) (with HBCV)Β Β 0
Boom-up Spool Stroke Control Circuit (compound boom-up + arm-in) (with HBCV)Β Β 0
Boom-down Regenerative Circuit (with HBCV)Β Β 0
Boom-down Tilting Prevention Circuit (with HBCV)Β Β 0
Boom-down Load Holding Valve Circuit (with HBCV)Β Β 0
Arm CircuitΒ Β 0
Arm-out Circuit (with HBCV)Β Β 0
Arm Semi-Parallel 1 CircuitΒ Β 0
Arm Semi-Parallel 2 CircuitΒ Β 0
Arm-in Regenerative Circuit (with HBCV)Β Β 0
Arm-in Load Holding Valve Circuit (with HBCV)Β Β 0
Bucket CircuitΒ Β 0
Bucket-open CircuitΒ Β 0
Bucket-close Regenerative CircuitΒ Β 0
Bucket-Close Spool Stroke Control CircuitΒ Β 0
Negative Control CircuitΒ Β 0
Negative Control CircuitΒ Β 0
Other CircuitsΒ Β 0
Cushion Circuit (arm-out operation)Β Β 0
Cushion Circuit (when arm-out operation stopped)Β Β 0
Cushion Circuit (arm-out β arm-in operation)Β Β 0
Heat Circuit (lever in neutral)Β Β 0
Auto Pressure Boost Circuit (arm in)Β Β 0
JΒ Β 0
Explanation of Hydraulic Circuit and Operations (option)Β Β 0
Option CircuitsΒ Β 0
Breaker Circuit (independent operation)Β Β 0
Double-acting Circuit (hydraulic fork)Β Β 0
Multi-purpose Circuit (breaker Q control)Β Β 0
Multi-purpose Circuit (2 pumps flow crusher)Β Β 0
2nd Option Circuit (hydraulic rotation fork)Β Β 0
R1585
Electrical Connector Wiring Diagram1587
Main Frame1588
Control Valve1590
SCR1592
Cab Main Harness1594
Console1596
EST-A1598
Indicator Jumper1600
R1601
Electrical Parts and Wiring Assembly Diagram1603
Frame1604
Engine and Pump1606
Attachments1608
Battery1610
Cab1612
S.M 3/1/25
