Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Link-Belt 490X4 Excavator SERVICE MANUAL WLSM4707-02LX – PDF DOWNLOAD
$34.95
Link-Belt 490X4 Excavator SERVICE MANUAL WLSM4707-02LX – PDF DOWNLOAD
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Link-Belt 490X4 Excavator SERVICE MANUAL WLSM4707-02LX – PDF DOWNLOAD
FILE DETAILS:
Link-Belt 490X4 Excavator SERVICE MANUAL WLSM4707-02LX – PDF DOWNLOAD
Language : English
Pages :1984
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Link-Belt 490X4 Excavator SERVICE MANUAL WLSM4707-02LX – PDF DOWNLOAD
General Information
Cleaning Clean the metal parts with cleaning solution that meets the standard and steam cleaning. (except for bearings) After cleaning, dry well, and inject oil in all parts. Also inject oil into the bearings after drying. Inspection When disassembling parts, check all the parts.
- If there are any worn or damaged parts, replace them. Inspect carefully to prevent initial breakdowns. Bearing Replace any loose bearings. Air dry bearings before installing them. Needle bearing When inserting needle bearings, be very careful not to damage them. Apply grease to the section where the needle bearing will be inserted. Gear Check that there is no wear and no damage.
- Oil seal, O-ring, gasket Always install new oil seals, O-rings, and gaskets. Apply grease to sections where oil seals and O-rings will be inserted. Shaft Check that there is no wear and no damage. Check the bearings and check for damaged oil seals on the shaft.
- Service parts Install LBX Link-Belt genuine service parts. When placing an order, check the parts catalog. It contains the LBX Link-Belt genuine part numbers.
- Any breakdowns arising from the installation of non-genuine parts are not covered by the warranty. Lubricants (fuel, hydraulic oil) Use the oil from the specified company or specified in the operator’s manual or service manual. Any breakdowns arising from any fuel or hydraulic oil other than those specified are not covered by the warranty.
TABLE OF CONTENTS:
Link-Belt 490X4 Excavator SERVICE MANUAL WLSM4707-02LX – 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 19
Bolt and Nut TighteningΒ 19
A LOWERΒ 21
Main Equipment TableΒ 25
Lower ComponentΒ 25
Travel UnitΒ 25
Take-up rollerΒ 25
Upper RollerΒ 25
Lower RollerΒ 25
Recoil springΒ 25
ShoeΒ 25
Center jointΒ 26
Main Equipment Structure and Operation ExplanationΒ 27
Travel MotorΒ 27
Travel motor operation explanationΒ 27
StructureΒ 27
Summary explanation of component partsΒ 28
Rotary groupΒ 28
Parking BrakeΒ 28
Variable Capacity Mechanism SectionΒ 28
Overload Relief ValveΒ 29
Brake Valve SectionΒ 29
FunctionΒ 30
Motor operationΒ 31
Parking Brake OperationΒ 32
Operation of Variable Capacity Mechanism SectionΒ 33
Overload Relief Valve OperationΒ 34
Brake Valve OperationΒ 35
Port DiagramΒ 40
Travel MotorΒ 40
Center JointΒ 41
Basic FunctionsΒ 42
Travel Speed SelectionΒ 42
Travel AlarmΒ 42
Removal and Installation of TrackΒ 44
Removal and Installation of Shoe AssemblyΒ 45
Removal of Shoe AssemblyΒ 45
Installation of Shoe AssemblyΒ 47
Removal and Installation of Shoe PlateΒ 49
Removal of Shoe PlateΒ 49
Installation of Shoe PlateΒ 49
Removal and Installation of RollerΒ 50
Removal and Installation of Upper RollerΒ 51
Removal of Upper RollerΒ 51
Installation of Upper RollerΒ 52
Assembly and Disassembly of Upper RollerΒ 53
Configuration DiagramΒ 53
Dimension DiagramΒ 54
Jig Dimension DiagramΒ 54
Disassembly ProcedureΒ 54
Assembly ProceduresΒ 56
Removal and Installation of Lower RollerΒ 60
Removal of Lower RollerΒ 60
Installation of Lower RollerΒ 61
Assembly and Disassembly of Lower RollerΒ 62
Configuration DiagramΒ 62
Dimension DiagramΒ 63
Jig Dimension DiagramΒ 63
Disassembly ProceduresΒ 63
Assembly ProceduresΒ 66
Removal and Installation of Retractable Lower FrameΒ 68
Removal of Retractable Lower FrameΒ 68
Installation of Retractable Lower FrameΒ 69
Removal and Installation of Drive SprocketΒ 70
Removal of Drive SprocketΒ 70
Installation of Drive SprocketΒ 71
Removal and Installation of Take-up RollerΒ 72
Removal of Take-up RollerΒ 72
Installation of Take-up RollerΒ 73
Assembly and Disassembly of Take-up RollerΒ 74
Configuration DiagramΒ 74
Dimension DiagramΒ 75
Jig Dimension DiagramΒ 75
Disassembly ProceduresΒ 75
Assembly ProceduresΒ 77
Removal and Installation of Grease CylinderΒ 80
Removal of Grease CylinderΒ 80
Installation of Grease CylinderΒ 81
Assembly and Disassembly of Grease CylinderΒ 82
Configuration DiagramΒ 82
Dimension DiagramΒ 82
Jig Dimension DiagramΒ 83
Disassembly ProceduresΒ 83
Assembly ProceduresΒ 84
Removal and Installation of Center JointΒ 86
Removal of Center JointΒ 86
Installation of Center JointΒ 88
Assembly and Disassembly of Center JointΒ 89
Configuration DiagramΒ 90
Dimension DiagramΒ 91
Jig Dimension DiagramΒ 92
Disassembly ProceduresΒ 92
Assembly ProceduresΒ 93
Removal and Installation of Travel MotorΒ 97
Removal of Travel MotorΒ 97
Installation of Travel MotorΒ 99
Assembly and Disassembly of Travel Motor 102
Tools for Assembly and Disassembly 102
Standard tools 102
Secondary Materials 102
Special Tool (jig) 103
Measurement Device 106
Motor Disassembly Procedures 106
Precautions before motor disassembly 106
Tightening Torque 107
Disassembly procedure 107
Removal of supplied valves 107
Disassembly of motor 108
Disassembly of overload relief valve 111
Reduction gear disassembly procedures 112
Disassembly preparations 112
Disassembly procedure 112
Installation to Receiving Platform Of Reduction Gear (unit) 112
Removal of Reduction Gear Cover 113
Removal of carrier 1 assembly 113
Removal of carrier 2 assembly 113
Removal of housing assembly 113
Disassembly of Housing Assembly 114
Removal of floating seal from motor 115
Disassembly of carrier 1 assembly 115
Disassembly of Carrier 2 Assembly 116
Maintenance standards 118
Motor Parts Maintenance Standards 118
Reduction gear parts maintenance standards 120
Inspection prior to reassembly 120
Thrust washer 120
Gears 121
Bearing 121
Floating seal 121
Parts Maintenance 122
Assembly of motor 123
Precautions before Motor Assembly 123
Assembly procedure 123
Motor Assembly Procedures 123
Motor assembly procedure 127
Assembly of the Carrier 2 Assembly 127
Assembly of the carrier 1 assembly 127
Installation of bearing and floating seal 128
Assembly of the housing assembly 128
Determining the thickness of the angular bearing shim 129
Installation of housing assembly 130
Installation of Carrier 2 Assembly 131
Installation of carrier 1 assembly 131
Cover Attachment 132
Gear Oil Filling 132
Initial pre-conditioning operation 133
Drain charge 133
Performing initial operation (pre-conditioning operation) 133
Troubleshooting 134
General cautions 134
Causes of troubles and countermeasures 134
Structural diagram 136
Maintenance Standards 137
Drive sprocket 137
Take-up roller 138
Upper Roller 139
Lower Roller 140
Track Shoe (Grouser Shoe) 141
Inspection Gauge 142
For Drive Sprocket 142
For Take-up Roller 142
For Upper Roller 143
For Lower Roller 143
Pressure Measurement and Adjustment Procedures 144
Main Pressure Measurement 144
B Travel Pressure Measurement 144
Drain Volume Measurement Procedures 145
Preparations 145
Travel Motor Drain Volume Measurement 145
Air Bleed Procedure 147
Travel Motor 147
B C SWING UNIT, COUNTERWEIGHT 149
Main Equipment Table 152
Upper Component 152
Swing Unit 152
Main Equipment Structure and Operation Explanation 153
Swing Motor 153
Swing Motor Operation Explanation 153
Hydraulic motor operation explanation 153
Mechanical brake operation explanation 153
Make-up valve operation explanation 153
Relief valve operation explanation (relief valve internal structure diagram) 154
Bypass valve operation explanation (bypass valve internal structure diagram) 156
Swing motor internal diagram 157
Port Diagram 159
Swing motor 159
Basic Functions 160
Swing Brake 160
Swing Lock 160
Swing Speed Limit 161
Swing Relief Cut 163
Removal and Installation of Swing Unit 165
Removal of Swing Unit 165
Installation of Swing Unit 167
Assembly and Disassembly of Swing Unit 168
Disassembly 168
Assembly 169
Assembly and Disassembly of Swing Motor 172
Causes of Trouble and Solutions 172
Maintenance Standard Table 174
Jig 176
Disassembly 176
Assembly 181
Swing Motor Internal Structural Diagram 188
Removal and Installation of Counterweight 190
Removal of Counterweight 190
Installation of Counterweight 191
Pressure Measurement and Adjustment Procedures 192
Main Pressure Measurement 192
C Swing Pressure Measurement 192
Drain Volume Measurement Procedures 193
Preparations 193
Swing Motor Drain Volume Measurement 193
Air Bleed Procedure 194
Swing motor 194
Check 195
H ENGINE 197
Main Equipment Table 205
Engine-related 205
Engine 205
Air Cleaner (double element) 205
Radiator 205
SCR 205
Basic Functions 207
Fuel Gauge 207
Coolant Temperature Gauge 208
SCR Gauge 210
Fuel Economy Gauge 213
Neutral Start 214
Power-cut Delay 215
Preheat 215
Throttle 216
Throttle Volume Position Detection 217
Idling Start 223
Auto Idle 223
One-touch Idle 224
Auto Warm-Up 225
Idle Shutdown 230
Idle Up 231
Work Mode Control 232
Engine Emergency Stop 233
SCR RE-GEN 233
Inducement 238
Feed Pump Automatic Stop 242
Coolant Level Decrease 244
Air Filter Clogging 245
Fuel Filter Clogging 246
Battery Charge Abnormality 247
Horsepower Reduction Control (in Uplands) 248
Horsepower Reduction Control (at Engine Failure) 248
Main Data 251
Function, Structure, Operation 254
Function, structure, operation (SCR) 305
SCR Control System Inspection 331
Operation Explanation of SCR 332
Diagnosis for Each Symptom 334
Intermittent conditions of urea selective catalytic reduction system 334
Urea fluid consumption too high 337
Ammonia smell noticeable 337
White crystalline powder visible 338
Symptom 339
Engine start failure 339
Engine stalling 340
Engine hunching, rough idling 342
Excessive white smoke in the exhaust gas 343
Excessive black smoke in the exhaust gas 343
Abnormal noise 344
Large fuel consumption 344
Large oil consumption 346
Insufficient engine output 347
Functional Inspection 349
Engine compression pressure inspection 349
Inspection of the fuel system 350
Lubrication System Inspection 350
Inspection of the air intake system 351
Inspection of the exhaust system 351
Inspection of the EGR control system 352
Inspection of the starting system 352
Inspection of the glow control system 353
OBD system check with EIDSS (Isuzu engine tool) 354
Inspection of the diagnostic light warning light illumination circuit system 355
Inspection of the monitor warning light blinking circuit system 355
Inspection of the starter circuit system 356
Removal and Installation of Engine Assembly 358
Removal of Engine Assembly 358
Installation of Engine Assembly 361
Removal and Installation of Fuel Cooler, Engine Intercooler, Radiator, and Oil Cooler 362
Removal and Installation of Fuel Cooler 362
Removal of Fuel Cooler 362
Installation of Fuel Cooler 362
Removal and Installation of Engine Intercooler 362
Removal of Intercooler 362
Installation of Inter Cooler 363
Inspection of Intercooler 363
Removal and Installation of Radiator 364
Removal of Radiator 364
Installation of Radiator 367
Inspection of Radiator 368
Removal and Installation of Oil Cooler 369
Removal of Oil Cooler 369
Installation of oil cooler 370
Removal and Installation of Hydraulic Drive Fan 370
Removal of Hydraulic Drive Fan 371
Installation of Hydraulic Drive Fan 371
Removal and Installation of Turbo Charger 372
Removal of Turbo Charger 372
Installation of Turbo Charger 373
Inspection of Turbo Charger 378
Removal and Installation of EGR Valve 379
Removal of EGR Valve 379
Installation of EGR Valve 381
Inspection of EGR Valve 386
Removal and Installation of Engine Hood 388
Removal of Engine Hood 388
Installation of Engine Hood 392
Removal and Installation of SCR 393
Removal of SCR 393
Installation of SCR 393
Removal and installation of Silicon Controlled Rectifier Catalyst 394
Removal of Silicon Controlled Rectifier Catalyst 394
Installation of Silicon Controlled Rectifier Catalyst 394
Disassembly ofγSilicon Controlled Rectifier Catalyst 395
Assembly of Silicon Controlled Rectifier Catalyst 395
Inspection of Silicon Controlled Rectifier Catalyst 396
Removal and Installation of Cylinder Head Cover 397
Removal of Cylinder head cover 397
Installation of Cylinder head cover 397
Removal and Installation of Cylinder Head 400
Removal of Cylinder head assembly 400
Disassembly of Cylinder head assembly 407
Assembly of Cylinder head assembly 410
Installation of Cylinder head assembly 416
Cylinder head assembly Inspection 434
Removal and Installation of Cylinder Block 441
Removal of Cylinder block 441
Cylinder liner removal 454
Cylinder liner installation 455
Installation of Cylinder block 457
Cylinder block Inspection 489
Lubrication System 491
Removal and Installation of Oil Pan 491
Oil pan Removal 491
Oil pan Installation 491
Removal and Installation of Oil Level Switch 491
Oil level switch Removal 491
Oil level switch Installation 492
Removal and Installation of Oil Pump Assembly 492
Oil pump assembly Removal 492
Oil pump assembly Disassembly 493
Oil pump assembly Reassembly 493
Oil pump assembly Installation 493
Oil pump assembly Inspection 494
Engine oil Inspection 495
Removal and installation of Piston oil jet 495
Removal of Piston oil jet 495
Installation of Piston oil jet 495
Removal and installation of Oil filter element 496
Removal of Oil filter element 496
Installation of Oil filter element 497
Cooling System 498
Removal and Installation of Water Pump Assembly 498
Removal of Water pump assembly 498
Installation of Water pump assembly 500
Disassembly of Water pump assembly 507
Assembly of Water pump assembly 508
Water pump assembly Inspection 510
Removal and Installation of Thermostat 510
Removal of Thermostat 510
Installation of Thermostat 513
Thermostat Inspection 519
Inspection of Coolant 520
Removal and installation of Generator drive belt 525
Removal of Generator drive belt 525
Inspection of Generator drive belt 525
Installation of Generator drive belt 526
Removal and Installation of Overheat Switch 526
Overheat switch Removal 526
Overheat switch Installation 526
Induction System 527
Inspection of Air cleaner element 527
Exhaust System 528
Removal and installation of Oxidation Catalyst Assembly 528
Removal of Oxidation Catalyst Assembly 528
Installation of Oxidation Catalyst Assembly 528
Aux Emission Control Devices System 530
Removal and installation of Dosing Module 530
Removal of Dosing Module 530
Disassembly of Dosing Module 530
Assembly of Dosing Module 531
Installation of Dosing Module 531
Removal and installation of DEF Supply Module 533
Removal of DEF supply module 533
Disassembly of DEF Supply Module 534
Assembly of DEF Supply Module 534
Installation of DEF Supply Module 535
Removal and installation of Coolant Control Valve 537
Removal of Coolant Control Valve 537
Installation of Coolant Control Valve 538
Removal and Installation of DCU 540
Removal of DCU 540
Installation of DCU 540
Removal and installation of DEF Supply Module Filter 540
Removal of DEF Supply Module Filter 540
Installation of DEF Supply Module Filter 541
Removal and Installation of Fuel Tank 542
Removal of Fuel Tank 542
Installation of Fuel Tank 545
Removal and Installation of Urea Pump 546
Removal of Urea Pump 546
Installation of Urea Pump 546
Removal and Installation of Urea Solution Tank 548
Removal of Urea Solution Tank 548
Installation of Urea Solution Tank 549
Removal and Installation of Fuel Supply Pump 550
Removal of Fuel Supply Pump 550
Installation of Fuel Supply Pump 553
Inspection ofγFuel Supply Pump 564
Removal and Installation of Common Rail Assembly 565
Removal of Common rail assembly 565
Installation of Common rail assembly 568
Removal and Installation of Injector 576
Removal of Injector 576
Installation of Injector 579
Removal and installation of Idle Gear 589
Removal of Idle Gear 589
Installation of Idle Gear 600
Inspection of Idle Gear 626
Removal and installation of Crankshaft 627
Removal of Crankshaft 627
Installation of Crankshaft 640
Disassembly of Crankshaft 673
Assembly of Crankshaft 673
Inspection of Crankshaft 674
Removal and installation of Piston 677
Removal of Piston 677
Installation of Piston 686
Disassembly of Piston 707
Assembly of Piston 707
Inspection of Piston 709
Removal and installation of Camshaft 714
Removal of Camshaft 714
Installation of Camshaft 715
Disassembly of Camshaft 720
Assembly of Camshaft 721
Inspection of Camshaft 721
Removal and installation of Flywheel 723
Removal of Flywheel 723
Installation of Flywheel 723
Disassembly of Flywheel 723
Assembly of Flywheel 724
Inspection of Flywheel 724
Removal and installation of Rocker Arm Shaft 725
Removal of Rocker Arm Shaft 725
Installation of Rocker Arm Shaft 726
Disassembly of Rocker Arm Shaft 729
Assembly of Rocker Arm Shaft 730
Inspection of Rocker Arm Shaft 730
Removal and installation of Front Cover 732
Removal of Front Cover 732
Installation of Front Cover 734
Removal and installation of Intake Throttle Valve 739
Removal of Intake Throttle Valve 739
Installation of Intake Throttle Valve 739
Removal and Installation of Starter Motor 741
Removal of Starter Motor 741
Installation of Starter Motor 741
Disassembly of Starter Motor 741
Assembly of Starter Motor 743
Inspection of Starter Motor 747
Removal and Installation of Alternator 751
Removal of Alternator 751
Installation of Alternator 751
Disassembly of Alternator 751
Assembly of Alternator 753
Inspection of Alternator 754
Removal and Installation of Glow Plug 758
Removal of Glow plug 758
Installation of Glow plug 760
Glow plug Inspection 765
Removal and installation of Fuel Filter 766
Removal of Fuel Filter 766
Installation of Fuel Filter 766
Removal and installation of Fuel Filter Element 768
Removal of Fuel Filter Element 768
Installation of Fuel Filter Element 768
Removal and installation of Fuel temperature sensor 770
Removal of Fuel temperature sensor 770
Installation of Fuel temperature sensor 770
Inspection of Fuel temperature sensor 771
Removal and installation of Pressure limiter 772
Removal of Pressure limiter 772
Installation of Pressure limiter 772
Removal and installation of Fuel pressure sensor 775
Removal of Fuel pressure sensor 775
Installation of Fuel pressure sensor 776
Inspection of Fuel pressure sensor 781
Removal and Installation of Fuel filter pressure 782
Removal of Fuel filter pressure sensor 782
Installation of Fuel filter pressure sensor 782
Removal and Installation of Engine coolant temperature sensor 783
Removal of Engine coolant temperature sensor 783
Installation of Engine coolant temperature sensor 783
Inspection of Engine coolant temperature sensor 786
Removal and Installation of CKP sensor 787
Removal of CKP sensor 787
CKP sensor Installation 787
CKP sensor Inspection 787
Removal and Installation of CMP sensor 788
Removal of CMP sensor 788
CMP sensor Installation 788
CMP sensor Inspection 788
Removal and Installation of Oil pressure sensor 789
Oil pressure sensor Removal 789
Oil pressure sensor Installation 789
Removal and installation of Pressure Sensor/Boost Temperature Sensor 790
Removal of Pressure sensor/boost temperature sensor 790
Installation of Pressure sensor/boost temperature sensor 790
Inspection of Pressure sensor/boost temperature sensor 790
Removal and Installation of IMT sensor 791
Removal of IMT sensor 791
Installation of IMT sensor 791
Removal and installation of MAF and IAT sensor 792
Removal of MAF and IAT sensor 792
Installation of MAF and IAT sensor 792
Inspection of MAF and IAT sensor 792
Removal and installation of Charge Air Cooler Temperature Sensor 1 794
Removal of Charge air cooler temperature sensor 1 794
Installation of Charge air cooler temperature sensor 1 794
Inspection of Charge air cooler temperature sensor 1 794
Sampling Procedure 795
Sampling of Engine Oil 795
Removal and Installation of Exhaust gas temperature sensor 796
Removal of Exhaust gas temperature sensor 796
Installation of Exhaust gas temperature sensor 796
Inspection of Exhaust gas temperature sensor 796
Removal and installation of EGR Gas Temperature Sensor 1 797
Removal of EGR Gas Temperature Sensor 1 797
Installation of EGR Gas Temperature Sensor 1 797
Inspection of EGR Gas Temperature Sensor 1 797
Removal and installation of EGR Gas Temperature Sensor 2 799
Removal of EGR Gas Temperature Sensor 2 799
Installation of EGR Gas Temperature Sensor 2 799
Inspection of EGR Gas Temperature Sensor 2 799
Removal and installation of EGR Gas Temperature Sensor 3 801
Removal of EGR Gas Temperature Sensor 3 801
Installation of EGR Gas Temperature Sensor 3 801
Inspection of EGR Gas Temperature Sensor 3 801
Removal and installation of EGR Gas Temperature Sensor 4 802
Removal of EGR Gas Temperature Sensor 4 802
Installation of EGR Gas Temperature Sensor 4 802
Inspection of EGR Gas Temperature Sensor 4 802
Removal and installation of NOx Sensor 804
Removal of NOx Sensor 804
Installation of NOx Sensor 804
Removal and Installation of Exhaust gas temperature sensor 3 806
Removal of Exhaust gas temperature sensor 3 806
Installation of Exhaust gas temperature sensor 3 806
Removal and installation of DEF Sensor 807
Removal of DEF Sensor 807
Installation of DEF Sensor 807
Engine-related Diagnostic Trouble Code List 808
Engine-side Trouble 813
ECM Trouble 813
DTC U0001 CAN Bus Error (ISO-CAN) 813
DTC P0016 Crankshaft Position – Camshaft Position Correlation Error 814
DTC P0045 Turbocharger Boost Control VNT Error 814
DTC U0073 Control Module Communication Bus Off 816
DTC P0087 Fuel Rail/System Pressure – Too Low 817
DTC P0089 Fuel Pressure Regulator Performance 820
DTC P0091 Fuel Pressure Regulator Control Circuit Low 821
DTC P0092 Fuel Pressure Regulator Control Circuit High 822
DTC P0097 Intake Air Temperature (IAT) Sensor 2 Circuit Low Voltage 823
DTC P0098 Intake Air Temperature (IAT) Sensor 2 Circuit High Voltage 823
DTC U0101 Lost Communication With CAN 824
DTC P0102 Mass Air Flow Sensor Circuit Low Input 825
DTC P0103 Mass Air Flow Sensor Circuit High Input 826
DTC U010E Lost Communications With Dosing Control Module 826
DTC U0110 Lost Communication With VNT System 827
DTC P0112 Intake Air Temperature Sensor Circuit Low 827
DTC P0113 Intake Air Temperature Sensor Circuit High 828
DTC P0117 Engine Coolant Temperature Sensor Circuit Low 829
DTC P0118 Engine Coolant Temperature Sensor Circuit High 829
DTC P0122 Throttle Position Sensor Circuit Low 830
DTC P0123 Throttle Position Sensor Circuit High 831
DTC P0182 Fuel Temperature Sensor Circuit Low 832
DTC P0183 Fuel Temperature Sensor Circuit High 833
DTC P0192 Fuel Rail Pressure Sensor Circuit Low 834
DTC P0193 Fuel Rail Pressure Sensor Circuit High 834
DTC P0201 Injector Circuit Open – Cylinder 1 836
DTC P0202 Injector Circuit Open – Cylinder 2 836
DTC P0203 Injector Circuit Open – Cylinder 3 837
DTC P0204 Injector Circuit Open – Cylinder 4 838
DTC P0217 Engine Coolant Over Temperature Condition 839
DTC P0219 Engine Overspeed Condition 839
DTC P0234 Turbocharger Overboost Condition 840
DTC P0237 Turbo Charger Boost Sensor Circuit Low 841
DTC P0238 Turbo Charger Boost Sensor Circuit High 841
DTC P0335 Crankshaft Position Sensor Circuit 842
DTC P0336 Crankshaft Position Sensor Circuit Range/Performance 843
DTC P0340 Camshaft Position Sensor Circuit 844
DTC P0380 Glow Relay Circuit Error 845
DTC P0401 EGR Flow Insufficient Detected 846
DTC P0404 EGR Control Circuit Range/Performance 847
DTC P0409 EGR Sensor Circuit 847
DTC U0411 Lost CAN Communications With VNT Control Module 849
DTC P041C EGR Cooler Outlet 1 Temp Sensor Circuit Low 849
DTC P041D EGR Cooler Outlet 1 Temp Sensor Circuit High 850
DTC P0427 Catalyst Temperature Sensor Circuit Low Sensor 1 851
DTC P0428 Catalyst Temperature Sensor Circuit High Sensor 1 851
DTC P042C Catalyst Temperature Sensor Circuit Low Sensor 2 852
DTC P042D Catalyst Temperature Sensor Circuit High Sensor 2 853
DTC P0522 Engine Oil Pressure Sensor Circuit Low Input 854
DTC P0523 Engine Oil Pressure Sensor Circuit High Input 855
DTC P0545 EGR Cooler Inlet 1 Temp Sensor Circuit Low 856
DTC P0546 EGR Cooler Inlet 1Temp Sensor Circuit High 856
DTC P0560 12 Volt Circuit Error 857
DTC P0563 System Voltage High 857
DTC P0601 Internal Control Module Memory Check Sum Error 858
DTC P0602 Internal Control Module QR Code Error 858
DTC P0604 Internal Control Module RAM Error 859
DTC P0606 Internal Control Module CPU Error 859
DTC P060A Internal Control Module CPU IC Error 859
DTC P060C Internal Control Module A/D Processing Performance 859
DTC P0615 Starter Relay Circuit Error 860
DTC P0638 Throttle Actuator Control Range/Performance 860
DTC P0685 ECM Power Relay Control Circuit Open 861
DTC P0687 ECM Power Relay Control Circuit High 862
DTC P06A6 Sensor Reference Voltage 1 Circuit 862
DTC P06A7 Sensor Reference Voltage 2 Circuit 863
DTC P06A8 Sensor Reference Voltage 3 Circuit 864
DTC P06A9 Sensor Reference Voltage 4 Circuit 864
DTC P06AF Torque Management System – Forced Engine Shutdown 865
DTC P06D5 Sensor Reference Voltage 5 Circuit 866
DTC P1076 Charge Air Cooler (CAC) Temperature Sensor 1 Circuit Low Voltage 866
DTC P1077 Charge Air Cooler (CAC) Temperature Sensor 1 Circuit High Voltage 866
DTC P1093 Fuel Rail Pressure Too Low 867
DTC P1097 Compressor Outlet Temperature Sensor Circuit High 870
DTC P1098 Compressor Outlet Temperature Sensor Circuit High 871
DTC P1236 Charge Air Cooler Performance Failure 872
DTC P1261 Injector Positive Voltage Control Circuit Group 1 872
DTC P1262 Injector Positive Voltage Control Circuit Group 2 873
DTC P1404 EGR Position Fault 873
DTC P1606 SW-IC Internal failure 874
DTC P160B AD-IC Failure Error 874
DTC P160C AD-IC2 Failure Error 874
DTC P1621 Control Module Long Term Memory Performance 874
DTC P1669 DPD Lamp Control Circuit 875
DTC P2000 Monitoring the NOx Efficiency 876
DTC P204F SCR System Error (No Inducement) 877
DTC P207F Urea Fluid Concentration Too Low 877
DTC P20C9 SCR System Error 877
DTC U2106 Lost CAN Communications With Wheel Loader Transmission Control System 878
DTC P2122 Pedal Position Sensor 1 Circuit Low Input 878
DTC P2123 Pedal Position Sensor 1 Circuit High Input 879
DTC P2127 Pedal Position Sensor 2 Circuit Low Input 879
DTC P2128 Pedal Position Sensor 2 Circuit High Input 880
DTC P2138 Pedal Position Sensor 1 – 2 Voltage Correlation 881
DTC P2146 Fuel Injector Group 1 Supply Voltage Circuit 881
DTC P2149 Fuel Injector Group 2 Supply Voltage Circuit 883
DTC P2210 Reading the error(open) information detected by Rr NOx sensor 884
DTC P2211 Reading the error(short) information detected by Rr NOx sensor 884
DTC P2228 Barometric Pressure Sensor Circuit Low 884
DTC P2229 Barometric Pressure Sensor Circuit High 885
DTC P2457 Exhaust Gas Recirculation (EGR) Cooling System Performance 885
DTC P2458 Purge time Out Error 886
DTC P2BA7 Urea Fluid Quantity Too Low 886
DTC P2BAA SCR System Error (Inducement, No Purge) 886
DTC P3093 Fuel Rail Pressure Too Low 886
DCU Trouble 889
DTC U0002 CAN Bus Off 889
DTC U0100 Lost Communication With ECM 890
DTC U029D Lost Communication With NOx Sensor 1 891
DTC U029E CAN communication error between DCU and Rr NOx sensor 893
DTC P0607 Control Module Performance 894
DTC P060B Internal Control Module A/D Processing Performance 894
DTC P062F Control Module EEPROM Error 894
DTC P0641 Sensor Reference Voltage 1 Circuit 895
DTC P0658 Actuator Supply Voltage Circuit 896
DTC P0659 Actuator Supply Voltage Circuit 897
DTC P1462 Urea Fluid Quality Sensor Timeout Error 898
DTC P1464 Main Relay Performance 899
DTC P1468 DCU Overtemperature 900
DTC P1491 Urea Fluid Overpressure 900
DTC P1493 DCU Driver Overtemperature 901
DTC P149C Urea Fluid Pressure Reduction Malfunction 902
DTC P149D Urea Fluid Tank Overtemperature 903
DTC P203B Urea Fluid Tank Level Sensor Stuck 904
DTC P203C Urea Fluid Tank Level Sensor Low Voltage 905
DTC P203D Urea Fluid Tank Level Sensor High Voltage 905
DTC P2048 Urea Fluid Injector Circuit Low Voltage 906
DTC P2049 Urea Fluid Injector Circuit High Voltage 907
DTC P204B Urea Fluid Pressure Sensor Performance 908
DTC P204C Urea Fluid Pressure Sensor Circuit Low Voltage 909
DTC P204D Urea Fluid Pressure Sensor Circuit High Voltage 909
DTC P205B Urea Fluid Tank Temperature Sensor Performance 910
DTC P205C Urea Fluid Tank Temperature Sensor Low Voltage 911
DTC P205D Urea Fluid Tank Temperature Sensor High Voltage 912
DTC P206A Urea Fluid Quality Sensor Circuit 912
DTC P206B Urea Sensor Over Temperature Condition 913
DTC P206C Urea Fluid Quality Sensor Circuit Low Voltage 914
DTC P206D Urea Fluid Quality Sensor Circuit High Voltage 914
DTC P207F Urea Fluid Concentration Too Low 915
DTC P208A Urea Fluid Pump Control Circuit 915
DTC P208B Usea Fluid Pump Performance 916
DTC P208C Urea Fluid Pump Control Circuit Low Voltage 917
DTC P208D Urea Fluid Pump Control Circuit High Voltage 917
DTC P208E Urea Fluid Injector Stuck 918
DTC P20A0 Urea Fluid Reverting Valve Circuit Open 919
DTC P20A2 Urea Fluid Reverting Valve Circuit Low Voltage 920
DTC P20A3 Urea Fluid Reverting Valve Circuit High Voltage 921
DTC P20AC Urea Fluid Pump Temperature Sensor Performance 922
DTC P20AD Urea Fluid Pump Module Temperature Sensor Performance 923
DTC P20B1 Urea Fluid Tank Heater Coolant Control Valve Circuit Open 923
DTC P20B3 Urea Fluid Tank Heater Coolant Control Valve Circuit Low Voltage 924
DTC P20B4 Urea Fluid Tank Heater Coolant Control Valve Circuit High Voltage 925
DTC P20E8 Urea Fluid Pressure Underpressure 926
DTC P20E9 Urea Fluid Overpressure 927
DTC P20EA Urea Fluid Pressure Reduction Malfunction 928
DTC P20FE Urea Fluid Pressure Build-Up Error 929
DTC P2201 Upstream Nox Sensor Performance 930
DTC P2206 NOx Sensor Heater Control Circuit Low Voltage Sensor 1 931
DTC P2207 NOx Sensor Heater Control Circuit High Voltage Sensor 1 931
DTC P242B Exhaust Gas Temperature (EGT) Sensor 3 Performance 931
DTC P242C Exhaust Gas Temperature (EGT) Sensor 3 Circuit Low Voltage 932
DTC P242D Exhaust Gas Temperature (EGT) Sensor 3 Circuit High Voltage 933
Data Reference Values 935
Non-operational P rotation 935
J HYDRAULIC EQUIPMENT (PUMP, OPERATION SYSTEM VALVE) 937
Main Equipment Table 943
Hydraulic Device 943
Hydraulic Pump 943
PQ Diagram 944
Hydraulically-operated fan pump 944
Hydraulically-operated fan motor 945
Control-related 946
Control valve 946
Solenoid Valve (5 Stack) 946
Remote Control Valve for Left/Right Operations 946
Remote Control Valve for Travel Operation 946
Remote Control Valve Characteristic Diagram 947
Operation Remote Control Valve Control Diagram 947
Travel Remote Control Valve Control Diagram 948
Cushion Valve (heat circuit, with shuttle valve) 948
Selector Valve (option) 948
Basic Functions 949
Oil temperature gauge 949
Static Horsepower Control 950
Overload Warning (Function for Europe Only) 951
Pressure Boost Control 951
Stroke Control 953
Boom Down Energy Save 955
Pump Horsepower Cut Control 956
Pump Horsepower Boost Control 958
Arm 1 Semi-parallel Control 958
Arm 2 Semi-parallel Control 959
Hot Shutdown Warning 960
Gate Lock 961
Breaker Mode 962
Crusher Mode 962
Quick coupler 963
Hydraulic Filter Clogging 964
Solenoid Sticking Prevention 965
Port Diagram 966
Hydraulic Pump (Standard Model) 966
Control Valve 968
Relief Valve 968
5 Stack Solenoid Valve 971
2 Stack Solenoid Valve 973
Remote Control Valves (upper, travel) 973
Remote Control Valves (left-right) 973
Remote Control Valve (Travel) 974
Cushion Valve 975
2-way Selector Valve 976
Direction Valve 977
Reducing valve (5-line) 978
Relief Valve (electromagnetic proportional) 980
Manifold Under Cab 981
Manifold (accumulator section) 982
Manifold (hydraulic oil tank section) 983
Hydraulic Pump 984
Type Indication 984
Specifications 984
Structure and Operation Explanation 984
Hydraulic Circuit Diagram 986
Hydraulic Pump Internal Structure Diagram 986
Overall View 986
Drive Shaft Front Side 990
Drive Shaft on Rear Side 991
Development Diagram 992
Parts Table 994
Regulator 994
Regulator Overview 994
Regulator Operation Explanation 995
Regulator Operation Explanation Diagram 998
Internal Configuration Diagram of Regulator1000
Development Diagram of Regulator1002
Component Table1003
Gear Pump1005
Gear Pump Internal Structure Diagram1005
Structure and Operation Explanation1006
Operation Outline of Electronically-Controlled Pump1007
Hydraulically-operated fan pump1010
Handling Procedures1010
How to Read Model Numbers1014
Performance1014
Structure1017
Causes of Trouble and Countermeasures1020
Hydraulically-operated fan motor1022
External shape diagram1022
Internal Structure Diagram1024
Operation Explanation1024
Control Valve1035
Basic Configuration1035
Operation1035
Operation of Main Unit1035
Activation of Relief Valve1051
5 Stack Solenoid Valve Operation Explanation1056
External Shape Diagram and Components1056
operation explanation1056
Upper Pilot Valve (remote control valve)1057
Structure1057
Function1057
Operation1058
Structural Diagram1061
Travel Pilot Valve (remote control valve)1062
Operation1062
Pressure Reducing Valve Section1062
Damping Mechanism in Operation Section1063
Structural Diagram1066
Cushion Valve 1068
structure1068
operation explanation1068
Selector Valve (2-way)1073
structure1073
operation explanation1074
Development Diagram1075
Direction Valve (3-direction) 1076
Structure1076
Operation Explanation1077
Electromagnetic Relief Valve1079
Structure1079
Operation Explanation1080
Operation of Check Valve1080
Operation of Electromagnetic Relief Valve1081
Removal and Installation of Hydraulic Reservoir1083
Removal of Hydraulic Reservoir1083
Installation of Hydraulic Oil Tank1086
Removal and Installation of Hydraulic Pump1087
Removal of Hydraulic Pump1087
Installation of Hydraulic Pump1089
Removal and Installation of Pump Coupling1090
Removal of Pump Coupling1090
Installation of Pump Coupling1090
Removal and Installation of Control Valve1091
Removal of Control Valve1091
Installation of Control Valve1095
Removal and Installation of Travel Remote Control Valve1096
Removal of Travel Remote Control Valve1096
Installation of Travel Remote Control Valve1097
Removal and Installation of Operation Remote Control Valve1100
Removal of Operation Remote Control Valve (left side)1100
Installation of Operation Remote Control Valve (left side)1102
Removal of Operation Remote Control Valve (right side)1104
Installation of Operation Remote Control Valve (right side)1106
Installation and Removal of 5 Stack Solenoid Valve1109
Removal of 5 Stack Solenoid Valve1109
Installation of 5 Stack Solenoid Valve1110
Removal and Installation of Cushion Valve1111
Removal of Cushion Valve1111
Installation of Cushion Valve1112
Removal and Installation of Hydraulically-Operated Fan Pump1114
Removal of Hydraulically-Operated Fan Pump1114
Installation of Hydraulically-Operated Fan Pump1114
Removal and Installation of Hydraulically-Operated Fan Motor1116
Removal of Hydraulically-Operated Fan Motor1116
Installation of Hydraulically-Operated Fan Motor1117
Procedures for Assembly and Disassembly of Hydraulic Pump Main Unit1118
Tools1118
Disassembly Procedure1118
Assembly Procedure1120
Pump Main Unit Maintenance Standards1124
Replacement Standard of Wear Component1124
Standards for repairing cylinders, valve plates, and swash plates (shoe plates)1124
Tightening torque1125
Overall View1125
Drive Shaft Front Side1129
Drive Shaft on Rear Side1130
Development Diagram1131
Parts Table1133
Causes of Failures, and Actions1134
Regulator Maintenance Standards1136
Regulator Adjustment1136
Appendix Table and Drawings1137
Regulator Assembly and Disassembly Procedures1141
Tools1141
Preparations for Disassembly1141
Disassembly Procedure1141
Assembly Procedure1143
Internal Configuration Diagram of Regulator1147
Development Diagram of Regulator1149
Component Table1150
Assembly and Disassembly of Control Valve1152
Disassembly1152
Caution for Disassembly1152
Disassembly Procedure1152
Disassembly of Main Spool Section1152
Disassembly of Sub Spool Section1153
Disassembly of Boom, Arm Antidrift Valve1154
Disassembly of Load Check Valve1154
Disassembly of Other Check Valves1154
Disassembly of Flange1155
Disassembly of Relief Valve1155
Disassembly of Other Plugs1155
Cleaning1155
Inspection1155
assembly1156
Caution for Assembly1156
Assembly of Subassembly1156
Assembly of Main Spool1156
Assembly of Sub Spool Section1156
Assembly of Boom, Antidrift Valve1157
Assembly of Control Valve1157
Assembly of Load Check Valve1157
Assembly of Other Check Valves1157
Assembly of Flange1157
Assembly of Boom, Arm Antidrift Valve1158
Assembly of Relief Valve1158
Assembly of Sub Spool1158
Assembly of Main Spool1158
Assembly of Other Plugs1159
Internal Structural Diagram1160
part list1170
Relief Valve1171
Assembly and Disassembly Procedure of Main Relief Valve1171
Assembly and Disassembly Procedures of Overload Relief1172
Assembly and Disassembly Procedure of Low-Pressure Relief Valve1173
Adjustment of Relief Valve1173
Installation1174
Operation1174
Malfunction and Countermeasure1175
Procedures for Assembly and Disassembly of Operation Remote Control Valve1177
Maintenance Procedures1177
Required Tools and Tightening Torque1177
Maintenance Standards1177
Disassembly Procedures1178
Assembly Procedures1181
Causes of Trouble and Countermeasures1184
Procedures for Assembly and Disassembly of Travel Remote Control Valve1188
Maintenance Procedures1188
Disassembly Procedures1189
Assembly Procedures1193
Causes of Trouble and Countermeasures1198
Assembly and Disassembly of Cushion Valve1201
Disassembly Procedures1201
Reverse Operation Spool Section1201
Check Plunger Section with Throttle1201
Shuttle Valve Section1201
Assembly Procedures1202
Reverse Operation Spool Section1202
Check Plunger Section with Throttle1202
Shuttle Valve Section1202
Written Materials1203
Pressure Measurement and Adjustment Procedures1206
Procedures for Pressure Measurement from the Monitor Display1206
Monitor and Switch Panel1206
Pressure Measurement Method1206
Operating Method1206
PROCEDURES FOR MEASURING HYDRAULIC OIL TEMPERATURE FROM THE MONITOR DISPLAY1206
Hydraulic Oil Temperature Measurement Method1206
Operating Method1207
Procedures for Pressure Measurement by Installing Pressure Gauge1208
Preparations1208
Items to Prepare1208
Pressure Measuring Ports1209
Control Valve1211
Location of Relief Valves1211
Pressure Measurement Preparations1212
Pressure Measurement1214
Main Pressure Measurement1214
A Attachment Pressure Measurement1214
Boom-down Pressure Measurement1215
D Option Line Pressure Measurement1216
Pilot Pressure Measurement1216
Pressure Gauge Installation1216
Negative Control Pressure Measurement1217
Pressure Gauge Installation1217
Pressure Adjustment1217
Main Pressure Adjustment1217
Pressure Measurement and Adjustment Preparations1217
Main Relief Pressure Adjustment1219
Overload Relief Pressure Adjustment1220
Adjustment of Swing Relief Pressure1221
Pilot Pressure Adjustment1222
Hydraulic Pump Flow Measurement Procedures1223
Preparations1223
Items to Prepare1223
Work Preparations1223
Flow Measurement1225
Air Bleed Procedure1227
Hydraulic Pump1227
Sampling Procedure1228
Sampling of Hydraulic Fluid1228
Hydraulic Equipment Layout1229
Overall View1230
Pump Chamber Hydraulic Equipment Layout1231
Swing Body Center Section Hydraulic Equipment Layout1232
Housing Left Side Hydraulic Equipment Layout1234
Layout of Hydraulic Equipment in Cab1235
N CAB1321
Removal and Installation of Operator’s Seat1324
Removal of Operator’s Seat1324
Installation of Operator’s Seat1324
Removal and Installation of Cab Assembly1325
Removal of Cab Assembly1325
Installation of Cab Assembly1329
Removal and Installation of Wiper1330
Removal of Wiper1330
Installation of wiper1330
Removal and Installation of Cab Front Glass1331
Removal of Cab Front Glass1331
Installation of Cab Front Glass1332
Window Lock Adjustment Procedures1333
Window Lock (front side)1333
Window Lock (rear side)1333
Removal and Installation of Housing Guardrail1335
Removal of Housing Guardrail1335
Installation of Housing Guardrail1336
Tightening Torque1337
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 Lamp1348
Radio Mute1350
Wiper and Washer1351
Safety1353
Horn1353
Back/Side View Monitor1354
Precautions for Camera Installation1355
Maintenance1355
Anti-theft1355
Manual Lock1356
Service Support Screen Lock1356
Customer-specific System Information Screen Lock1356
Maintenance Information Screen Lock1356
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 STATUS1365
HYDRAULIC STATUS1371
ENGINE STATUS1378
FAULT HISTORY1382
WORK HISTORY1383
HYDRAULIC HISTORY1391
ENGINE HISTORY1404
DEVICE TEST1425
ECM/DCU Memory Clear1425
SCR RE-GEN1426
Urea Line Leak Test1427
CCV Operation Test1428
Dosing Test1429
Reverting Valve Operation Test1430
Common Rail Pressure Test1431
Idle Speed Test / Injector Test1432
EGR Valve Control Test1433
VG Turbo Control Test1434
Intake Throttle Control Test1435
CONTROL UNIT Screen List1437
MCM-MAIN1437
MCM-SUB1441
COMMU TERMINAL1442
MONITOR1444
SETUP Screen List1445
MACHINE SELECT1445
DIMENSIONS1450
PARAMETERS1453
ENGINE INFORMATION1457
ENGINE INFORMATION1458
Data Confirmation1458
Data Transfer (Copy)1458
QR (INJECTOR) CODE1459
Injector number1459
Screen Layout1460
Data Source Selection1460
Manual Input1460
CAMERA1462
PASSWORD1465
CALIBRATE Screen List1467
THROTTLE VOLUME1468
OPTLINE RELIEF1469
PUMP FLOW1471
RESET Screen List1473
Connection Connector Pin Layout1476
Main Controller1476
Monitor1477
Sequence Circuit Diagram1478
Code List1478
Overall1481
Block diagram1486
Main controller1486
DCU1487
ECM1488
Monitor1490
Air conditioner1491
Gate Lock1492
Horn1493
Working Light1493
Option1494
Others1495
Electrical Symbol List1497
Electrical Equipment Layout Diagram1499
Main Unit Left-side Layout Diagram1500
Engine Section Layout Diagram1501
Main Unit Right Side Layout Diagram (pump chamber)1505
Main Unit Center Section Layout Diagram1506
Cab Layout Diagram 11508
Cab Layout Diagram 21510
Layout Around Operator Seat1513
Stand Alone Parts Diagram1514
Removal and Installation of Wiper Controller1540
Removal of Wiper Controller1540
Installation of wiper controller1540
Removal and Installation of Wiper Motor1541
Removal of Wiper Motor1541
Installation of wiper motor1542
Removal and Installation of ECM1543
Removal of ECM1543
Installation of ECM1543
Removal and Installation of Main Controller1544
Removal of Main Controller1544
Installation of Main Controller1544
Removal and Installation of DCU1545
Removal of DCU1545
Installation of DCU1545
Removal and Installation of Monitor1546
Removal of Monitor1546
Installation of Monitor1547
Removal and Installation of Rear View Camera1548
Removal of Rear View Camera1548
Installation of Rear View Camera1548
Removal and Installation of Side Camera (Right)1549
Removal of Side Camera (Right)1549
Installation of Side Camera (right)1549
Removal and Installation of Side Camera (Left)1550
Removal of Side Camera (Left)1550
Installation of Side Camera (Left)1550
Removal and Installation of FVM Controller1551
Removal of FVM Controller1551
Installation of FVM Controller1551
How to Set FVM1552
Air Conditioner Overall Diagram1556
Frame1556
Cab1559
Equipment Layout Diagram1562
Circuit Diagram1564
Air Conditioner Circuit Diagram1564
Explanation of Functions1566
Explanation of Control1566
Air Mix Motor Actuator Control1567
Blow Mode Motor Actuator Control1567
Refresh/Recirculate Switch Motor Actuator Control1568
Blower Amp Control1569
Compressor Clutch Control1571
COOLMAX Control and HOTMAX Control1572
Abnormality Detection and Control after Abnormality Detected1572
Monitor Mode1576
Door Switch Control1578
Actuator Inspection1579
Air Mix Motor Actuator Inspection1579
Refresh/Recirculate Switch Motor Actuator Inspection1580
Mode Motor Actuator Inspection1581
Self-diagnosis Function with Panel Display1582
Abnormality Display and Self-check Procedures1582
Abnormality Display Position1582
Explanation of Abnormality Display1582
Motor Actuator Abnormality1582
Sensor Abnormality1583
Explanation of Monitor Mode1583
Monitor Mode Display Position1584
Monitor Mode Display Operating Method1584
Display Contents in Monitor Mode1585
Part Function and Good/Poor Judgment1591
Control Panel1591
Blower Amp1591
Relay1592
Air Mix Actuator1593
Refresh/Recirculate Actuator1594
Blow Mode Actuator1594
Evaporator Sensor1595
Dual Pressure Switch1595
Solar Radiation Sensor1596
Inside Air Sensor1596
Assembly and Disassembly of Unit1598
Removal of Blower Unit1598
Replacement of Blower Motor1598
Replacement of Blower Amp1598
Removal of Heater Core1599
Removal of Heat Case Right/Left1599
Replacement of Evaporator and Expansion Valve1599
Installation of Evaporator Sensor1600
Replacement of Motor Actuator1600
Removal and Installation of Compressor1601
Removal of Compressor1601
Installation of Compressor1601
Removal and Installation of Condenser1603
Removal of Condenser1603
Installation of Condenser1603
Removal and Installation of Receiver Dryer1604
Removal of Receiver Dryer1604
Installation of Receiver Dryer1604
Work Precautions1605
Work Procedures1605
Air Conditioner Refrigerant Filling is Divided into the “Vacuum Operation” and “Gas Filling Operation”1605
Operation Chart1606
Tools1606
Filling Procedures1608
Charging Hose Connection Position1608
Connecting Gauge Manifold1608
Vacuuming1609
Gas Filling Operation, High-pressure Side1610
Gas Filling Work, Low Pressure Side1610
V ATTACHMENTS1685
Main Equipment Table1689
Backhoe Attachment1689
Cylinder1689
Maintenance Standards1690
Attachment (Backhoe)1690
1 Boom and Swing Frame Installation Section1690
2 Boom Cylinder and Swing Frame Installation Section1691
3 Boom and Boom Cylinder Installation Section1691
4 Boom and Arm Cylinder Installation Section1692
5 Boom and Arm Installation Section1692
6 Arm and Arm Cylinder Installation Section1693
7 Arm and Bucket Cylinder Installation Section1693
8 Arm and Arm Link Installation Section1694
9 Bucket and Bucket Link Installation Section1694
10 Bucket Link and Bucket Cylinder Installation Section1695
11 Bucket and Arm Installation Section1695
Removal and Installation of Bucket Cylinder1697
Removal of Bucket Cylinder1697
Installation of Bucket Cylinder1699
Removal and Installation of Arm Cylinder1701
Removal of Arm Cylinder1701
Installation of Arm Cylinder1703
Removal and Installation of Boom Cylinder1706
Removal of Boom Cylinder1706
Installation of Boom Cylinder1708
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder1711
Specifications and Structure Diagram (including the assembly diagram and parts table)1711
Basic Functions1711
Function of Each Location1711
Cylinder Head Assembly (made by KYB)1711
Piston Assembly (made by KYB)1712
Pipe Assembly (made by KYB)1714
Handling Precautions1714
Precautions for Installing the Cylinder on the Machine Body1714
Usage Cautions1715
Maintenance and Inspection Cautions1715
Maintenance Inspection and Service1717
Trouble Diagnostics1718
Storage Standards1723
Storing Parts Individually (In principle, store indoors)1723
When Mounted on Vehicle Body1723
Recommended Anti-rust Oil1723
Assembly and Disassembly Procedures1724
Preparations Β·Β·Β·Β·Β· Prepare the Following before Starting Disassembly1724
General Work Precautions1724
Maintenance Standards1724
Inspection after Assembly1724
Required Tool1725
General Tool1725
Special Jig (made by KYB)1726
Special Jig Parts Number List (made by KYB)1726
Disassembly Procedures (made by KYB)1727
Assembly Procedures (made by KYB)1731
Test Operation1735
Usage Limits1736
Structural Diagram (made by KYB)1737
Boom Cylinder1737
Arm Cylinder1739
Bucket Cylinder1741
HBCV1743
Structure1743
Port Diagram1750
HBCV1750
Air Bleed Procedure1752
HBCV1752
Boom Cylinder HBCV1752
Arm Cylinder HBCV1753
Removal and Installation of HBCV1754
Removal and Installation of Arm HBCV1755
Removal of Arm HBCV1755
Installation of Arm HBCV1755
Removal and Installation of Boom HBCV1757
Removal of Boom HBCV1757
Installation of Boom HBCV1758
Removal and Installation of Bucket1760
Removal of Bucket1760
Installation of Bucket1760
Removal and Installation of Bucket Link1762
Removal of Bucket Link1762
Installation of Bucket Link1762
Removal and Installation of Arm1764
Removal of Arm1764
Installation of Arm1765
Removal and Installation of Boom1766
Removal of Boom1766
Installation of Boom1768
Z OTHER1771
Changes from Model -61776
Overall Layout1776
Lower1777
Swing Unit1777
Engine1777
Hydraulic-related Data1779
Hydraulic Control1780
Cab, House1781
Electrical Data1782
Electric Control1783
Attachments1784
Specifications (Standard Lower Specifications)1785
ENGINE1785
HYDRAULIC SYSTEM1785
HYDRAULIC CONTROLS1786
ELECTRICAL SYSTEM1786
OPERATOR ENVIRONMENT1787
UNDERCARRIAGE1788
MASS1788
DIGGING FORCE (with 20 m3 Sumitomo Bucket) (ISO 6015)1788
DIMENSIONS1789
WORKING RANGES1789
SYSTEM FLUID CAPACITIES AND SPECIFICATIONS1790
Specifications (Retract Lower Specifications)1791
ENGINE1791
HYDRAULIC SYSTEM1791
HYDRAULIC CONTROLS1792
ELECTRICAL SYSTEM1792
OPERATOR ENVIRONMENT1793
UNDERCARRIAGE1794
MASS1794
DIGGING FORCE (with 20 m3 Sumitomo Bucket) (ISO 6015)1794
DIMENSIONS1795
WORKING RANGES1795
SYSTEM FLUID CAPACITIES AND SPECIFICATIONS1796
Specifications (High Soil Volume Specifications)1797
ENGINE1797
HYDRAULIC SYSTEM1797
HYDRAULIC CONTROLS1798
ELECTRICAL SYSTEM1798
OPERATOR ENVIRONMENT1799
UNDERCARRIAGE1800
MASS1800
DIGGING FORCE (with 30 m3 Bucket)1800
DIMENSIONS1801
WORKING RANGES1801
SYSTEM FLUID CAPACITIES AND SPECIFICATIONS1802
Arm Dimensions1803
Main Unit Weight1805
Divided Weight (standard specifications)1805
Divided Weight (Retract Specifications)1806
Stand Alone Part Weight1807
Shoe Weight (per Side)1807
Arm Weight1807
Bucket Weight1807
Bolt Size and Torque Table1809
Special Torque Setting1809
Overall View1814
490X4 Standard Lower Specifications1814
Standard Arm [338 m (1109 ft)]1814
Short Arm [253 m (830 ft)]1815
Long Arm [400 m (1312 ft)]1816
Ultra-Long Arm [485 m (1591 ft)]1817
490X4 Retract Lower Specifications1818
Standard Arm [338 m (1109 ft)]1818
Short Arm [253 m (830 ft)]1819
Long Arm [400 m (1312 ft)]1820
Ultra-Long Arm [485 m (1591 ft)]1821
490X4 High Soil Volume Specifications1822
Short Arm [253 m (830 ft)] Standard Lower Specifications1822
Short Arm [253 m (830 ft)] Retract Lower Specifications1823
WORK RANGE DIAGRAM1824
490X4 (Standard Lower Specifications)1824
Standard Arm [338 m (1109 ft)]1824
Short Arm [253 m (830 ft)]1826
Long Arm [400 m (1312 ft)]1828
Ultra-Long Arm [485 m (1591 ft)]1830
490X4 Retract Lower Specifications1832
Standard Arm [338 m (1109 ft)]1832
Short Arm [253 m (830 ft)]1834
Long Arm [400 m (1312 ft)]1836
Ultra-Long Arm [485 m (1591 ft)]1838
490X4 High Soil Volume Specifications1840
Short Arm [253 m (830 ft)] Standard Lower Specifications1840
Short Arm [253 m (830 ft)] Retract Lower Specifications1842
New Machine Performance Judgment Table1844
Table of Standards1844
Measurement Method1847
Engine speed1847
Pressure at Each Part1847
Pump Command Displacement1848
Cylinder Down Amount1848
Attachment Speed1848
Swing Speed1849
Swing (180Β°) Brake Angle1850
Travel Speed1850
Off Travel Amount1850
Travel Sprocket Speed1851
Shoe Tension Amount1851
Swing Ball Race Bearing Movement Amount and Bucket Tip Movement Amount1852
FLUIDS AND LUBRICANTS1854
HYDRAULIC FLUID1854
Engine Oil1854
Fuel1854
Conditions applicable to diesel fuel1854
Recommended Conditions Applicable to Diesel Fuel1854
Main-unit-related Diagnostic Trouble Code List1855
Main Unit-side Trouble1858
Diagnostic Trouble Code: 7000 Pressure Sensor P1 Abnormality1858
Diagnostic Trouble Code: 7001 Pressure Sensor P2 Abnormality1859
Diagnostic Trouble Code: 7002 Pressure Sensor N1 Abnormality1861
Diagnostic Trouble Code: 7003 Pressure Sensor N2 Abnormality1862
Diagnostic Trouble Code: 7004 Pressure Sensor Boom Cylinder Bottom Abnormality1864
Diagnostic Trouble Code: 7006 Rod Pressure Sensor Signal Abnormality1865
Diagnostic Trouble Code: 7007 Pressure Sensor Arm Cylinder Rod Abnormality1867
Diagnostic Trouble Code: 7021 Pressure Sensor Swing Pilot Abnormality1868
Diagnostic Trouble Code: 7023 Pressure Sensor Arm-In Pilot Abnormality1870
Diagnostic Trouble Code: 7040 Level Sensor Fuel Abnormality1871
Diagnostic Trouble Code: 7041 Temperature Sensor Hydraulic Fluid Abnormality1873
Diagnostic Trouble Code: 7065 Pressure Sensor Boom-Up Pilot Abnormality1874
Diagnostic Trouble Code: 7067 Pressure Sensor Bucket-Close Pilot Abnormality1875
Diagnostic Trouble Code: 7068 Pressure Sensor Boom-Down Pilot Abnormality1877
Diagnostic Trouble Code: 7069 Pressure Sensor Arm-Out Pilot Abnormality1879
Diagnostic Trouble Code: 7070 Pressure Sensor Bucket-Open Pilot Abnormality1880
Diagnostic Trouble Code: 7071 Pressure Sensor Travel Right Pilot Abnormality1882
Diagnostic Trouble Code: 7072 Pressure Sensor Travel Left Pilot Abnormality1884
Diagnostic Trouble Code: 7073 Pressure Sensor Travel 1 Pedal Abnormality1886
Diagnostic Trouble Code: 7074 Pressure Sensor 1st Option Pilot (Common/Front Pedal) Abnormality1887
Diagnostic Trouble Code: 7075 Pressure Sensor Arm Cylinder Bottom Abnormality1889
Diagnostic Trouble Code: 7078 Pressure Sensor 1st Option Pilot (Rear Pedal) Abnormality1891
Diagnostic Trouble Code: 7200 Swing Brake Solenoid Abnormality1893
Diagnostic Trouble Code: 7201 Travel 2nd-Speed Switchover Solenoid Abnormality1894
Diagnostic Trouble Code: 7202 Pressure Boost Solenoid Abnormality1895
Diagnostic Trouble Code: 7203 Travel Alarm Buzzer Abnormality1896
Diagnostic Trouble Code: 7206 Option Return Line Switchover Solenoid Abnormality1897
Diagnostic Trouble Code: 7207 Free Swing Solenoid Abnormality1898
Diagnostic Trouble Code: 7208 Fan Reverse Solenoid Signal Abnormality1899
Diagnostic Trouble Code: 7212 Shut-off Solenoid Signal Abnormality1900
Diagnostic Trouble Code: 7213 Quick Coupler Buzzer Abnormality1901
Diagnostic Trouble Code: 7214 Quick Coupler Solenoid Abnormality1903
Diagnostic Trouble Code: 7242 Fan Proportional Valve Signal Abnormality1905
Diagnostic Trouble Code: 7246 2 Pumps Flow Solenoid Signal Abnormality1906
Diagnostic Trouble Code: 7247 Boom 2-Down Pilot Proportional Valve Abnormality1908
Diagnostic Trouble Code: 7249 Bucket-Close Pilot Proportional Valve Abnormality1909
Diagnostic Trouble Code: 7250 Option Relief Pressure Proportional Valve Abnormality1910
Diagnostic Trouble Code: 7265 Arm 1 Semi-Parallel Proportional Valve Abnormality1911
Diagnostic Trouble Code: 7266 Arm 2 Semi-Parallel Proportional Valve Abnormality1912
Diagnostic Trouble Code: 7267 Arm 1 Regeneration Release Proportional Valve Abnormality1914
Diagnostic Trouble Code: 7270 Tilting 1 Proportional Valve Abnormality1915
Diagnostic Trouble Code: 7271 Tilting 2 Proportional Valve Abnormality1916
Diagnostic Trouble Code: 7273 Straight Travel Proportional Valve Abnormality1917
Diagnostic Trouble Code: 7400 Coolant Temperature Overheating 11918
Diagnostic Trouble Code: 7401 Coolant Temperature Overheating 21919
Diagnostic Trouble Code: 7404 Oil Temperature Overheating1920
Diagnostic Trouble Code: 7405 Boost Temperature Overheating 11921
Diagnostic Trouble Code: 7406 Boost Temperature Overheating 21922
Diagnostic Trouble Code: 7420 Alternator Power Generation Failure1923
Diagnostic Trouble Code: 7421 Coolant Level Decrease1924
Diagnostic Trouble Code: 7422 Engine Oil Pressure Decrease1925
Diagnostic Trouble Code: 7423 Air Cleaner Clogging1926
Diagnostic Trouble Code: 7424 Return Filter Clogging1927
Diagnostic Trouble Code: 7426 Fuel Filter Clogging 11928
Diagnostic Trouble Code: 7427 Fuel Filter Clogging 21929
Diagnostic Trouble Code: 7428 Inducement (Remaining Urea Level Low) – Warning1930
Diagnostic Trouble Code: 7429 Inducement (Remaining Urea Level Low) – Early1931
Diagnostic Trouble Code: 7430 Inducement (Remaining Urea Level Low) – Final1931
Diagnostic Trouble Code: 7602 ECM Communication Abnormality1932
Diagnostic Trouble Code: 7603 Computer S Communication Abnormality1933
Diagnostic Trouble Code: 7605 ECM Not-Matched1934
Diagnostic Trouble Code: 7606 EEPROM Abnormality1934
Diagnostic Trouble Code: 7608 Camera Abnormality1935
Diagnostic Trouble Code: 7612 Air Conditioner Communication Abnormality1936
Diagnostic Trouble Code: 7613 Monitor Communication (CAN) Abnormality1938
Diagnostic Trouble Code: 7615 Sub-Controller Communication Abnormality1939
Diagnostic Trouble Code: 7618 DCU Communication Abnormality1940
List of special tools1942
NUMERICAL VALUE CONVERSION TABLE1942
Unit conversion rate1942
Length1942
Area1944
Volume1945
Weight1947
Pressure1948
Torque1949
Temperature1950
A1953
Travel Motor Special Tool1953
490X41953
Take-up Roller Special Tool1961
490X41961
Upper Roller Special Tool1962
490X41962
Lower Roller Special Tool1963
490X41963
Grease Cylinder Special Tool1963
490X41963
Center Joint Special Tool1964
490X41964
C1965
Swing Motor Special Tool1965
490X41965
H1967
Engine Oil Filter Special Tool1967
490X41967
Fuel Filter Special Tool1967
490X41967
Injector Special Tool1967
490X41967
Circuit Test Special Tool1968
490X41968
Valve Guide Special Tool1968
490X41968
Cylinder Head Special Tool1968
490X41968
Head Bolt Special Tool1970
490X41970
Crankshaft Special Tool1971
490X41971
Valve Spring Special Tool1972
490X41972
Special Tools for Piston1972
490X41972
Special Tools for Engine Cooling System1973
490X41973
J1974
Remote Control Valve Special Tool1974
490X41974
R1976
Gas Filling Special Tool1976
490X41976
V1976
Attachment Special Tool (for Cylinder Assembly)1976
Special Jigs Part Number List1976
Attachment Special Tool (Other)1978
490X41978
Paint Colors1979
Abbreviation1981
J_Explanation of Hydraulic Circuit and Operations (standard model)_490X4pdfΒ Β 0
J1237
Explanation of Hydraulic Circuit and Operations (standard model)1239
Travel Circuit1240
Travel Low-speed Circuit1240
Travel High-speed Circuit1242
Straight Travel Circuit (with HBCV)1244
Swing Circuit1246
Swing Relief Cut Control Circuit1246
Swing Brake Circuit1248
Swing Parking Circuit (lever in neutral)1250
Swing Parking Circuit (brake release)1252
Swing Parking Circuit (machine stop)1254
Boom Circuit1256
Boom-up Circuit (independent operation) (with HBCV)1256
Boom-up Spool Stroke Control Circuit (compound boom-up + arm-in) (with HBCV)1258
Boom-down Regenerative Circuit (with HBCV)1260
Boom-down Tilting Prevention Circuit (with HBCV)1262
Boom-down Load Holding Valve Circuit (with HBCV)1264
Arm Circuit1266
Arm-out Circuit (with HBCV)1266
Arm Semi-parallel 1 Circuit (for independent operation) (with HBCV)1268
Arm Semi-parallel 1 Circuit (for compound operation) (ex arm-out + right swing operations) (with HBCV)1270
Arm Semi-parallel 1 Circuit (for compound operation) (ex arm-in + boom-up operations) (with HBCV)1272
Arm-in Regenerative Circuit (with HBCV)1274
Arm-in Load Holding Valve Circuit (with HBCV)1276
Arm-in Spool Stroke Control (with HBCV)1278
Bucket Circuit1280
Bucket-open Circuit1280
Bucket-close Circuit1282
Bucket-close Spool Stroke Control Circuit1284
Negative Control Circuit1286
Negative Control Circuit1286
Other Circuits1288
Cushion Circuit (arm-out operation)1289
Cushion Circuit (when arm-out operation stopped)1292
Cushion Circuit (arm-out β arm-in operation)1294
Heat Circuit (lever in neutral)1296
Auto Pressure Boost Circuit (arm in)1298
002_J_Explanation of Hydraulic Circuit and Operations (option)_490X4pdfΒ Β 0
J1301
Explanation of Hydraulic Circuit and Operations (option)1303
Option Circuits1304
Single Breaker Circuit (pedal type)1304
Single Breaker Circuit (switch type)1306
Single Breaker Circuit (proportional control type)1308
Multi-purpose Circuit (proportional control type) (breaker)1310
Multi-purpose Circuit (proportional control type) (2 pumps flow crusher)1312
Multi-purpose Circuit (proportional control type) (electromagnetic relief) (breaker)1314
Multi-purpose Circuit (proportional control type) (electromagnetic relief) (crusher)1316
2nd Option Circuit (proportional control type) (hydraulic rotation fork)1318
R_Electrical Connector Wiring Diagram_490X4pdfΒ Β 0
R1613
Electrical Connector Wiring Diagram1615
Frame Main Harness1616
Control Valve Harness1618
SCR Harness1620
ATT Harness1622
Travel Harness1624
Cab Main Harness1626
Indicator Harness1628
Indicator Jumper1630
Console Harness1632
GPS Computer Harness1634
GPS Computer Intermediate Harness1636
Fan Motor Harness1638
Free Swing Harness1640
Relief Valve Harness1642
Camera Harness [600 mm (23622 in)]1644
Camera Harness [1900 mm (74803 in)]1646
Camera Harness [2750 mm (108268 in)]1648
Camera Intermediate Harness [9400 mm (370079 in)]1650
Camera Intermediate Harness [9400 mm (370079 in)]1652
Camera Harness (WAVES)1654
Option Harness (pedal)1656
Option Harness (proportional control)1658
Option Harness (SV)1660
Option + 2nd Option Harness (SV)1662
2nd Option Harness (proportional control)1664
2nd Option Harness (SV)1666
004_R_Electrical Parts and Wiring Assembly Diagram_490X4pdfΒ Β 0
R1669
Electrical Parts and Wiring Assembly Diagram1671
Frame1672
Engine and Pump1676
Attachments1678
Battery1680
Cab1682
S.M 3/1/25
