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Link Belt Excavator 245X4 Service Manual WLSM2457-00LX – PDF DOWNLOAD
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Link Belt Excavator 245X4 Service Manual WLSM2457-00LX – PDF DOWNLOAD
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Description
Link Belt Excavator 245X4 Service Manual WLSM2457-00LX – PDF DOWNLOAD
FILE DETAILS:
Link Belt Excavator 245X4 Service Manual WLSM2457-00LX – PDF DOWNLOAD
Language : English
Pages :1849
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Link Belt Excavator 245X4 Service Manual WLSM2457-00LX – 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 Excavator 245X4 Service Manual WLSM2457-00LX – PDF DOWNLOAD
Excavator 1
SAFETY 9
Safety, general information and standard torque data 12
General Information 13
Safety 13
ROPS 15
ROPS Judgment 15
Standard Torque Data For Cap Screws And Nuts 20
Bolt and Nut Tightening 20
Removal of Under Cover 21
A LOWER 25
Main Equipment Table 29
Lower Component 29
Travel Unit 29
Take-up roller 29
Upper Roller 29
Lower Roller 29
Recoil Spring 29
Shoe 29
Shoe 30
Center Joint 30
Center Joint (Blade) 31
Main Equipment Structure and Operation Explanation 32
Travel Motor 32
Travel motor operation explanation 32
Explanation of Component Device Operation 32
Double Counter Balance Valve 32
Crossover Relief Valve 37
Automatic 2-speed Switchover Mechanism 38
Parking Brake Function 41
Piston Motor 42
Reduction Gear 43
Port Diagram 45
Travel Motor 45
Center Joint 45
Center Joint (Blade) 46
Basic Functions 47
Travel Speed Selection 47
Travel Alarm 47
Removal and Installation of Track 49
Removal and Installation of Shoe Assembly 50
Removal of Shoe Assembly 50
Installation of Shoe Assembly 51
Removal and Installation of Shoe Plate 54
Removal of Shoe Plate 54
Installation of Shoe Plate 54
Removal and Installation of Roller 55
Removal and Installation of Upper Roller 56
Removal of Upper Roller 56
Installation of Upper Roller 57
Assembly and Disassembly of Upper Roller 58
Configuration Diagram 58
Dimension Diagram 59
Jig Dimension Diagram 59
Disassembly Procedures 60
Assembly Procedures 62
Removal and Installation of Lower Roller 65
Removal of Lower Roller 65
Installation of Lower Roller 66
Assembly and Disassembly of Lower Roller 68
Configuration Diagram 68
Dimension Diagram 69
Jig Dimension Diagram 69
Disassembly Procedures 69
Assembly Procedures 72
Removal and Installation of Drive Sprocket 74
Removal of Drive Sprocket 74
Installation of Drive Sprocket 76
Removal and Installation of Take-up Roller 77
Removal of Take-up Roller 77
Installation of Take-up Roller 78
Assembly and Disassembly of Take-up Roller 79
Configuration Diagram 79
Dimension Diagram 80
Jig Dimension Diagram 80
Disassembly Procedures 80
Assembly Procedures 83
Removal and Installation of Grease Cylinder 87
Removal of Grease Cylinder 87
Installation of Grease Cylinder 88
Assembly and Disassembly of Tension Shock Absorber 89
Configuration Diagram 89
Dimension Diagram 89
Jig Dimension Diagram 90
Disassembly procedures 90
Assembly procedures 90
Removal and Installation of Center Joint 92
Removal of Center Joint 92
Installation of Center Joint 93
Assembly and Disassembly of Center Joint 94
Configuration Diagram 95
Dimension Diagram 96
Dimension Diagram (Blade) 97
Jig Dimension Diagram 98
Disassembly Procedures 98
Assembly Procedures 99
Removal and Installation of Travel Motor 102
Removal of Travel Motor 102
Installation of Travel Motor 104
Assembly and Disassembly of Travel Motor 107
Tools for Assembly and Disassembly 107
Standard Tools 107
Secondary Materials 108
Special Tool (jig) 109
Measurement Device 110
Motor Disassembly Procedures 110
Precautions before Motor Disassembly 110
Tightening Torque 111
Disassembly Procedure 112
Maintenance Standards 120
Motor Parts Maintenance Standards 120
Reduction Gear Parts Maintenance Standards 123
Motor Assembly Procedures 125
Precautions before Motor Assembly 125
Assembly Procedure 125
Motor Installation 139
Inspection 139
Hydraulic Oil and Gear Oil Filling 139
Initial Pre-conditioning Operation 140
Troubleshooting 142
Structural Diagram 150
Internal Structure Diagram 153
Part Table 155
Maintenance Standards 156
Drive sprocket 156
Take-up roller 157
Upper roller 158
Lower Roller 159
Track Shoe (Grouser Shoe) 160
Inspection Gauge 161
For Drive Sprocket 161
For Take-up Roller 161
For Upper Roller 162
For Lower Roller 162
Pressure Measurement and Adjustment Procedures 163
Main Pressure Measurement 163
B Travel Pressure Measurement 163
Drain Volume Measurement Procedures 164
Preparations 164
Travel Motor Drain Volume Measurement 164
Air Bleed Procedure 166
Travel Motor 166
B C SWING UNIT, COUNTERWEIGHT 167
Main Equipment Table 170
Upper Component 170
Swing Unit 170
Main Equipment Structure and Operation Explanation 171
Swing Motor 171
Swing Motor Operation Explanation 171
Hydraulic Motor Section 171
Valve Casing Section 171
Brake Section 172
Relief Valve Operation Explanation (relief valve model: KRD22EK10) 172
Swing Motor Internal Structure Diagram 175
Port Diagram 177
Swing Motor 177
Basic Functions 178
Swing Brake 178
Swing Lock 178
Swing Speed Limit 179
Swing Relief Cut 181
Removal and Installation of Swing Unit 183
Removal of Swing Unit 183
Installation of Swing Unit 186
Assembly and Disassembly of Swing Motor 187
Troubleshooting 187
Maintenance Reference Table 189
Jig 190
Disassembling Instructions 192
Assembling Instructions 198
Swing Motor Internal Structure Diagram 207
Assembly and Disassembly of Swing Unit 209
Disassembly 209
Assembly 212
Jig 218
Swing Reduction Gear Internal Structure Diagram 219
Removal and Installation of Counterweight 220
Removal of Counterweight 220
Installation of Counterweight 223
Pressure Measurement and Adjustment Procedures 226
Main Pressure Measurement 226
C Swing Pressure Measurement 226
Drain Volume Measurement Procedures 227
Preparations 227
Swing Motor Drain Volume Measurement 227
Air Bleed Procedure 228
Swing motor 228
Check 228
H ENGINE 229
Main Equipment Table 237
Engine-related 237
Engine 237
Air Cleaner (double element) 237
Radiator 237
SCR 237
Basic Functions 238
Fuel Gauge 238
Coolant Temperature Gauge 239
SCR Gauge 241
Fuel Economy Gauge 244
Neutral start 245
Power-cut Delay 246
Preheat 247
Throttle 248
Throttle Volume Position Detection 249
Idle start 255
Auto Idle 256
One-touch Idle 256
Auto Warm-Up 257
Idle Shutdown 262
Idle Up 263
Work Mode Control 264
Engine Emergency Stop 265
SCR RE-GEN 265
Inducement 270
Feed Pump Automatic Stop 274
Coolant Level Decrease 276
Air Filter Clogging 277
Fuel Filter Clogging 278
Battery Charge Abnormality 279
Horsepower Reduction Control (in Uplands) 280
Horsepower Reduction Control (at Engine Failure) 280
Main Data 283
Function, Structure, Operation 285
Function, structure, operation (SCR) 339
SCR Control System Inspection 366
Operation Explanation of SCR 367
Diagnosis for Each Symptom 369
Intermittent conditions of urea selective catalytic reduction system 369
Urea fluid consumption too high 372
Ammonia smell noticeable 372
White crystalline powder visible 373
Diagnosis for Each Symptom 374
Engine Start Problems 374
Engine Stalling 376
Engine Hunting, Rough Idling 378
Excess Amount of White Smoke in Exhaust Gas 379
Excess Amount of Black Smoke in Exhaust Gas 380
Abnormal Noise 380
High Fuel Consumption 381
High Oil Consumption 382
Engine Output Deficiency 383
Functional Inspection 386
Engine Compression Pressure Inspection 386
Fuel System Inspection 387
Lubrication system check 387
Air intake system inspection 388
Exhaust system inspection 388
Inspection of EGR Control System 388
Start System Inspection 389
Glow control system check 389
OBD system check 391
Inspection of the monitor warning light illumination circuit system 391
Inspection of the monitor warning light blinking circuit system 392
Inspection of the starter circuit system 393
Removal and Installation of Engine Assembly 394
Removal of Engine Assembly 394
Installation of Engine Assembly 399
Removal and Installation of Fuel Cooler, Engine Intercooler, Radiator, and Oil Cooler 400
Removal and Installation of Fuel Cooler 400
Removal of Fuel Cooler 400
Installation of Fuel Cooler 400
Removal and Installation of Engine Intercooler 400
Removal of Intercooler 401
Installation of Inter Cooler 402
Inspection of Intercooler 402
Removal and Installation of Radiator 402
Removal of Radiator 403
Installation of Radiator 406
Inspection of Radiator 406
Removal and Installation of Oil Cooler 407
Removal of Oil Cooler 407
Installation of Oil Cooler 408
Removal and Installation of Turbo Charger 409
Removal of Turbo Charger 409
Installation of Turbo Charger 411
Inspection of Turbo Charger 414
Removal and Installation of EGR Valve 416
Removal of EGR Valve 416
Installation of EGR Valve 418
Inspection of EGR Valve 422
Removal and Installation of Top Cover 423
Removal of Top Cover 423
Installation of Top Cover 424
Removal and Installation of SCR 425
Removal of SCR 425
Installation of SCR 426
Removal and installation of Silicon Controlled Rectifier Catalyst 427
Removal of Silicon Controlled Rectifier Catalyst 427
Installation of Silicon Controlled Rectifier Catalyst 428
Disassembly of Silicon Controlled Rectifier Catalyst 431
Assembly of Silicon Controlled Rectifier Catalyst 431
Inspection of Silicon Controlled Rectifier Catalyst 432
Removal and Installation of Cylinder Head Cover 433
Cylinder head cover Removal 433
Installation of Cylinder Head Cover 433
Removal and Installation of Cylinder Head 434
Removal of Cylinder Head 434
Disassembly of Cylinder Head 443
Assembly of Cylinder Head 447
Installation of Cylinder Head 454
Inspection 472
Removal and Installation of Cylinder Block 478
Removal of Cylinder Block 478
Installation of Cylinder Block 494
Inspection 529
Lubrication System 531
Removal and Installation of Oil Pan 531
Removal of Oil Pan 531
Installation of Oil Pan 531
Removal and Installation of Oil Level Switch 531
Removal of Oil Level Switch 531
Installation of Oil Level Switch 532
Removal and Installation of Oil Pump Assembly 532
Removal of Oil Pump Assembly 532
Disassembly of Oil Pump Assembly 545
Assembly of Oil Pump Assembly 545
Installation of Oil Pump Assembly 545
Inspection 569
Engine oil Inspection 570
Removal and Installation of Oil Port Cover 571
Removal of Oil Port Cover 571
Installation of Oil Port Cover 571
Cooling System 573
Removal and Installation of Water Pump Assembly 573
Removal of Water Pump Assembly 573
Installation of Water Pump Assembly 574
Inspection of Water Pump Assembly 578
Removal and Installation of Thermostat 578
Removal of Thermostat 578
Installation of Thermostat 579
Inspection 581
Inspection of Coolant 581
Inspection of Cooling Fan Belt 586
Removal and Installation of Overheat Switch 586
Removal of Overheat Switch 586
Installation of Overheat Switch 586
Induction System 588
Inspection of Air Cleaner Element 588
Exhaust System 589
Removal and installation of Oxidation Catalyst Assembly 589
Removal of Oxidation Catalyst Assembly 589
Installation of Oxidation Catalyst Assembly 590
Aux Emission Control Devices System 593
Removal and installation of Dosing Module 593
Removal of Dosing Module 593
Disassembly of Dosing Module 593
Assembly of Dosing Module 594
Installation of Dosing Module 594
Removal and installation of DEF Supply Module 596
Removal of DEF supply module 596
Disassembly of DEF Supply Module 597
Assembly of DEF Supply Module 597
Installation of DEF Supply Module 598
Removal and installation of Coolant Control Valve 600
Removal of Coolant Control Valve 600
Installation of Coolant Control Valve 601
Removal and installation of DEF Supply Module Filter 603
Removal of DEF Supply Module Filter 603
Installation of DEF Supply Module Filter 603
Removal and Installation of Exhaust Manifold 605
Removal of Exhaust Manifold 605
Installation of Exhaust Manifold 608
Inspection 614
Removal and Installation of Fuel Tank 615
Removal of Fuel Tank 615
Installation of fuel tank 618
Removal and Installation of Urea Pump 619
Removal of Urea Pump 619
Installation of Urea Pump 620
Removal and Installation of Urea Solution Tank 621
Removal of Urea Tank 621
Installation of Urea Solution Tank 622
Removal and Installation of Fuel Supply Pump 623
Removal of Fuel Supply Pump 623
Installation of Fuel Supply Pump 624
Removal and Installation of Common Rail Assembly 628
Removal of Common Rail Assembly 628
Installation of Common Rail Assembly 630
Removal and Installation of Injector 635
Removal of Injector 635
Installation of Injector 638
Removal and installation of Idle Gear 644
Removal of Idle Gear 644
Installation of Idle Gear 656
Inspection of Idle Gear 680
Removal and installation of Inlet Cover 682
Removal of Inlet Cover 682
Installation of Inlet Cover 686
Removal and installation of Crankshaft 696
Removal of Crankshaft 696
Installation of Crankshaft 711
Disassembly of Crankshaft 744
Assembly of Crankshaft 744
Inspection of Crankshaft 744
Removal and installation of Piston 749
Removal of Piston 749
Installation of Piston 759
Disassembly of Piston 779
Assembly of Piston 779
Inspection of Piston 781
Removal and installation of Camshaft 788
Removal of Camshaft 788
Installation of Camshaft 789
Disassembly of Camshaft 793
Assembly of Camshaft 794
Inspection of Camshaft 794
Removal and installation of Flywheel 796
Removal of Flywheel 796
Installation of Flywheel 797
Inspection of Flywheel 798
Removal and installation of Crankshaft Front Oil Seal 799
Removal of Crankshaft Front Oil Seal 799
Installation of Crankshaft Front Oil Seal 800
Removal and installation of Crankshaft Rear Oil Seal 803
Removal of Crankshaft Rear Oil Seal 803
Installation of Crankshaft Rear Oil Seal 804
Removal and installation of Rocker Arm Shaft 807
Removal of Rocker Arm Shaft 807
Installation of Rocker Arm Shaft 808
Disassembly of Rocker Arm Shaft 811
Assembly of Rocker Arm Shaft 811
Inspection of Rocker Arm Shaft 812
Removal and installation of Valve Spring 815
Removal of Valve Spring 815
Installation of Valve Spring 817
Inspection of Valve Spring 822
Removal and installation of Valve Stem Oil Seal 824
Removal of Valve Stem Oil Seal 824
Installation of Valve Stem Oil Seal 826
Removal and installation of Front Cover 833
Removal of Front Cover 833
Installation of Front Cover 835
Removal and installation of Intake Throttle Valve 841
Removal of Intake Throttle Valve 841
Installation of Intake Throttle Valve 841
Removal and Installation of Starter Motor 842
Removal of Starter Motor 842
Installation of Starter Motor 842
Disassembly of Starter Motor 843
Assembly of Starter Motor 844
Inspection of Starter Motor 845
Removal and Installation of Alternator 849
Removal of Alternator 849
Installation of Alternator 850
Disassembly of Alternator 850
Assembly of Alternator 851
Inspection of Alternator 852
Removal and Installation of Glow Plug 856
Removal of Glow Plug 856
Installation of Glow Plug 856
Glow plug Inspection 856
Removal and Installation of Suction Control Valve 857
Removal of Suction Control Valve 857
Installation of Suction Control Valve 857
Removal and installation of Fuel Filter 860
Removal of Fuel Filter 860
Installation of Fuel Filter 860
Removal and installation of Relief Valve 863
Removal of Relief Valve 863
Installation of Relief Valve 863
Removal and installation of Fuel Filter Element 866
Removal of Fuel Filter Element 866
Installation of Fuel Filter Element 867
Removal and Installation of Fuel filter pressure 870
Fuel filter pressure sensor Removal 870
Fuel filter pressure sensor Installation 870
Removal and Installation of Engine coolant temperature sensor 871
Engine coolant temperature sensor Removal 871
Engine coolant temperature sensor Installation 871
Engine coolant temperature sensor Inspection 871
Removal and Installation of CKP sensor 872
CKP sensor Removal 872
CKP sensor Installation 872
CKP sensor Inspection 872
Removal and Installation of CMP sensor 873
CMP sensor Removal 873
CMP sensor Installation 873
CMP sensor Inspection 873
Removal and Installation of Oil pressure sensor 874
Oil pressure sensor Removal 874
Oil pressure sensor Installation 874
Oil pressure sensor Inspection 874
Removal and installation of Pressure Sensor/Boost Temperature Sensor 875
Removal of Pressure Sensor/Boost Temperature Sensor 875
Installation of Pressure Sensor/Boost Temperature Sensor 875
Inspection of Pressure Sensor/Boost Temperature Sensor 875
Removal and Installation of IMT sensor 876
Removal of IMT sensor 876
Installation of IMT sensor 876
Removal and installation of Charge Air Cooler Temperature Sensor 1 877
Removal of Charge Air Cooler Temperature Sensor 1 877
Installation of Charge Air Cooler Temperature Sensor 1 877
Inspection of Charge Air Cooler Temperature Sensor 1 877
Sampling Procedure 878
Sampling of Engine Oil 878
Removal and Installation of Exhaust gas temperature sensor 879
Removal of Exhaust gas temperature sensor 879
Installation of Exhaust gas temperature sensor 879
Inspection of Exhaust gas temperature sensor 880
Removal and installation of EGR Gas Temperature Sensor 1 881
Removal of EGR Gas Temperature Sensor 1 881
Installation of EGR Gas Temperature Sensor 1 881
Inspection of EGR Gas Temperature Sensor 1 881
Removal and installation of EGR Gas Temperature Sensor 2 882
Removal of EGR Gas Temperature Sensor 2 882
Installation of EGR Gas Temperature Sensor 2 882
Inspection of EGR Gas Temperature Sensor 2 882
Removal and installation of NOx Sensor 884
Removal of NOx Sensor 884
Installation of NOx Sensor 884
Removal and Installation of Exhaust gas temperature sensor 3 887
Removal of Exhaust gas temperature sensor 3 887
Installation of Exhaust gas temperature sensor 3 887
Removal and installation of DEF Sensor 889
Removal of DEF Sensor 889
Installation of DEF Sensor 889
Engine-related Diagnostic Trouble Code List 890
Engine-side Trouble 899
ECM Trouble 899
DTC P0016 Crankshaft Position – Camshaft Position Correlation Error 899
DTC P0045 Turbocharger Boost Control VNT Error 899
DTC P0087 Fuel Rail/System Pressure – Too Low 901
DTC P0089 Fuel Pressure Regulator Performance 904
DTC P0091 Fuel Pressure Regulator Control Circuit Low 905
DTC P0092 Fuel Pressure Regulator Control Circuit High 906
DTC P0097 Intake Air Temperature (IAT) Sensor 2 Circuit Low Voltage 907
DTC P0098 Intake Air Temperature (IAT) Sensor 2 Circuit High Voltage 908
DTC P0102 Mass Air Flow Sensor Circuit Low Input 909
DTC P0103 Mass Air Flow Sensor Circuit High Input 910
DTC P0112 Intake Air Temperature Sensor Circuit Low 910
DTC P0113 Intake Air Temperature Sensor Circuit High 911
DTC P0117 Engine Coolant Temperature Sensor Circuit Low 912
DTC P0118 Engine Coolant Temperature Sensor Circuit High 912
DTC P0122 Throttle Position Sensor Circuit Low 914
DTC P0123 Throttle Position Sensor Circuit High 914
DTC P0182 Fuel Temperature Sensor Circuit Low 915
DTC P0183 Fuel Temperature Sensor Circuit High 916
DTC P0192 Fuel Rail Pressure Sensor Circuit Low 917
DTC P0193 Fuel Rail Pressure Sensor Circuit High 918
DTC P0201 Injector Circuit Open – Cylinder 1 919
DTC P0202 Injector Circuit Open – Cylinder 2 920
DTC P0203 Injector Circuit Open – Cylinder 3 921
DTC P0204 Injector Circuit Open – Cylinder 4 922
DTC P0217 Engine Coolant Over Temperature Condition 923
DTC P0219 Engine Overspeed Condition 923
DTC P0234 Turbocharger Overboost Condition 924
DTC P0237 Turbo Charger Boost Sensor Circuit Low 925
DTC P0238 Turbo Charger Boost Sensor Circuit High 926
DTC P0335 Crankshaft Position Sensor Circuit 927
DTC P0336 Crankshaft Position Sensor Circuit Range/Performance 928
DTC P0340 Camshaft Position Sensor Circuit 929
DTC P0380 Glow Relay Circuit Error 930
DTC P0401 EGR Flow Insufficient Detected 931
DTC P0404 EGR Control Circuit Range/Performance 932
DTC P0409 EGR Sensor Circuit 933
DTC P041C EGR Cooler Outlet 1 Temp Sensor Circuit Low 934
DTC P041D EGR Cooler Outlet 1 Temp Sensor Circuit High 935
DTC P0427 Catalyst Temperature Sensor Circuit Low Sensor 1 936
DTC P0428 Catalyst Temperature Sensor Circuit High Sensor 1 936
DTC P042C Catalyst Temperature Sensor Circuit Low Sensor 2 938
DTC P042D Catalyst Temperature Sensor Circuit High Sensor 2 938
DTC P0522 Engine Oil Pressure Sensor Circuit Low Input 939
DTC P0523 Engine Oil Pressure Sensor Circuit High Input 940
DTC P0545 EGR Cooler Inlet 1 Temp Sensor Circuit Low 941
DTC P0546 EGR Cooler Inlet 1Temp Sensor Circuit High 942
DTC P0560 12 Volt Circuit Error 943
DTC P0563 System Voltage High 943
DTC P0601 Internal Control Module Memory Check Sum Error 944
DTC P0602 Internal Control Module QR Code Error 944
DTC P0604 Internal Control Module RAM Error 945
DTC P0606 Internal Control Module CPU Error 945
DTC P060A Internal Control Module CPU IC Error 945
DTC P060C Internal Control Module A/D Processing Performance 946
DTC P0615 Starter Relay Circuit Error 946
DTC P0638 Throttle Actuator Control Range/Performance 947
DTC P0685 ECM Power Relay Control Circuit Open 948
DTC P0687 ECM Power Relay Control Circuit High 949
DTC P06A6 Sensor Reference Voltage 1 Circuit 949
DTC P06A7 Sensor Reference Voltage 2 Circuit 950
DTC P06A8 Sensor Reference Voltage 3 Circuit 951
DTC P06A9 Sensor Reference Voltage 4 Circuit 952
DTC P06AF Torque Management System – Forced Engine Shutdown 953
DTC P06D5 Sensor Reference Voltage 5 Circuit 953
DTC P1076 Charge Air Cooler (CAC) Temperature Sensor 1 Circuit Low Voltage 953
DTC P1077 Charge Air Cooler (CAC) Temperature Sensor 1 Circuit High Voltage 954
DTC P1093 Fuel Rail Pressure Too Low 955
DTC P1097 Compressor Outlet Temperature Sensor Circuit High 958
DTC P1098 Compressor Outlet Temperature Sensor Circuit High 958
DTC P1236 Charge Air Cooler Performance Failure 960
DTC P1261 Injector Positive Voltage Control Circuit Group 1 960
DTC P1262 Injector Positive Voltage Control Circuit Group 2 961
DTC P1404 EGR Position Fault 961
DTC P1606 SW-IC Internal failure 962
DTC P160B AD-IC Failure Error 962
DTC P160C AD-IC2 Failure Error 963
DTC P1621 Control Module Long Term Memory Performance 963
DTC P1622 Control Module Long Term Memory Hardware 964
DTC P1669 DPD Lamp Control Circuit 965
DTC P204F SCR System Error (No Inducement) 966
DTC P207F Urea Fluid Concentration Too Low 966
DTC P20C9 SCR System Error 966
DTC P2122 Pedal Position Sensor 1 Circuit Low Input 967
DTC P2123 Pedal Position Sensor 1 Circuit High Input 967
DTC P2127 Pedal Position Sensor 2 Circuit Low Input 968
DTC P2128 Pedal Position Sensor 2 Circuit High Input 969
DTC P2138 Pedal Position Sensor 1 – 2 Voltage Correlation 970
DTC P2146 Fuel Injector Group 1 Supply Voltage Circuit 971
DTC P2149 Fuel Injector Group 2 Supply Voltage Circuit 972
DTC P2228 Barometric Pressure Sensor Circuit Low 973
DTC P2229 Barometric Pressure Sensor Circuit High 973
DTC P2457 Exhaust Gas Recirculation (EGR) Cooling System Performance 974
DTC P2458 Purge time Out Error 974
DTC P2BA7 Urea Fluid Quantity Too Low 975
DTC P2BAA SCR System Error (Inducement, No Purge) 975
DTC P3093 Fuel Rail Pressure Too Low 975
DTC U0001 CAN Bus Error (ISO-CAN) 978
DTC U0073 Control Module Communication Bus Off 980
DTC U0101 Lost Communication With CAN 981
DTC U010E Lost Communications With Dosing Control Module 982
DTC U0110 Lost Communication With VNT System 983
DTC U2106 Lost CAN Communications With Wheel Loader Transmission Control System 983
DTC U0411 Lost CAN Communications With VNT Control Module 984
DCU Trouble 984
DTC P0607 Control Module Performance 984
DTC P060B Internal Control Module A/D Processing Performance 985
DTC P062F Control Module EEPROM Error 985
DTC P0641 Sensor Reference Voltage 1 Circuit 986
DTC P0658 Actuator Supply Voltage Circuit 987
DTC P0659 Actuator Supply Voltage Circuit 988
DTC P1462 Urea Fluid Quality Sensor Timeout Error 990
DTC P1464 Main Relay Performance 991
DTC P1468 DCU Overtemperature 991
DTC P1491 Urea Fluid Overpressure 992
DTC P1493 DCU Driver Overtemperature 993
DTC P149C Urea Fluid Pressure Reduction Malfunction 994
DTC P149D Urea Fluid Tank Overtemperature 995
DTC P2000 Monitoring the NOx Efficiency 996
DTC P203B Urea Fluid Tank Level Sensor Stuck 998
DTC P203C Urea Fluid Tank Level Sensor Low Voltage 999
DTC P203D Urea Fluid Tank Level Sensor High Voltage1000
DTC P2048 Urea Fluid Injector Circuit Low Voltage1001
DTC P2049 Urea Fluid Injector Circuit High Voltage1002
DTC P204B Urea Fluid Pressure Sensor Performance1002
DTC P204C Urea Fluid Pressure Sensor Circuit Low Voltage1003
DTC P204D Urea Fluid Pressure Sensor Circuit High Voltage1004
DTC P205B Urea Fluid Tank Temperature Sensor Performance1005
DTC P205C Urea Fluid Tank Temperature Sensor Low Voltage1006
DTC P205D Urea Fluid Tank Temperature Sensor High Voltage1007
DTC P206A Urea Fluid Quality Sensor Circuit1007
DTC P206B Urea Sensor Over Temperature Condition1008
DTC P206C Urea Fluid Quality Sensor Circuit Low Voltage1009
DTC P206D Urea Fluid Quality Sensor Circuit High Voltage1010
DTC P207F Urea Fluid Concentration Too Low1010
DTC P208A Urea Fluid Pump Control Circuit1010
DTC P208B Usea Fluid Pump Performance1011
DTC P208C Urea Fluid Pump Control Circuit Low Voltage1012
DTC P208D Urea Fluid Pump Control Circuit High Voltage1013
DTC P208E Urea Fluid Injector Stuck1014
DTC P20A0 Urea Fluid Reverting Valve Circuit Open1015
DTC P20A2 Urea Fluid Reverting Valve Circuit Low Voltage1016
DTC P20A3 Urea Fluid Reverting Valve Circuit High Voltage1017
DTC P20AC Urea Fluid Pump Temperature Sensor Performance1018
DTC P20AD Urea Fluid Pump Module Temperature Sensor Performance1019
DTC P20B1 Urea Fluid Tank Heater Coolant Control Valve Circuit Open1020
DTC P20B3 Urea Fluid Tank Heater Coolant Control Valve Circuit Low Voltage1020
DTC P20B4 Urea Fluid Tank Heater Coolant Control Valve Circuit High Voltage1021
DTC P20E8 Urea Fluid Pressure Underpressure1022
DTC P20E9 Urea Fluid Overpressure1024
DTC P20EA Urea Fluid Pressure Reduction Malfunction1025
DTC P20FE Urea Fluid Pressure Build-Up Error1026
DTC P2201 Upstream Nox Sensor Performance1027
DTC P2206 Reading the error(open) information detected by Ft NOx sensor1028
DTC P2207 Reading the error(short) information detected by Ft NOx sensor1028
DTC P2210 Reading the error(open) information detected by Rr NOx sensor1029
DTC P2211 Reading the error(short) information detected by Rr NOx sensor1029
DTC P242B Exhaust Gas Temperature (EGT) Sensor 3 Performance1029
DTC P242C Exhaust Gas Temperature (EGT) Sensor 3 Circuit Low Voltage1030
DTC P242D Exhaust Gas Temperature (EGT) Sensor 3 Circuit High Voltage1031
DTC U0002 CAN Bus Off1032
DTC U0100 Lost Communication With ECM1033
DTC U029D CAN communication error between DCU and Ft NOx sensor1034
DTC U029E CAN communication error between DCU and Rr NOx sensor1036
Data Reference Values1038
Idle Speed1038
Two Pump Relief1039
J HYDRAULIC EQUIPMENT (PUMP, OPERATION SYSTEM VALVE)1041
Main Equipment Table1047
Hydraulic Device1047
Hydraulic Pump1047
Hydraulic Pump1047
Control-related1048
Control valve1048
Control valve1048
Solenoid Valve (5 Stack)1049
Remote Control Valve for Left/Right Operations1049
Remote Control Valve for Travel Operation1049
Valve for Blade Operation1049
Remote Control Valve Characteristic Diagram1049
Operation Remote Control Valve Control Diagram1050
Travel Remote Control Valve Control Diagram1051
Blade Remote Control Valve Control Diagram1051
Reducing Valve (6 Stack Proportional Valve)1051
Cushion Valve (heat circuit, with shuttle valve)1052
Selector Valve1052
Basic Functions1053
Oil temperature gauge1053
Static Horsepower Control1054
Overload Warning (Function for Europe Only)1055
Pressure Boost Control1055
Stroke Control1057
Boom Down Energy Save1059
Pump Horsepower Boost Control1060
Arm 1 Semi-parallel Control1060
Arm 2 Semi-parallel Control1061
Hot Shutdown Warning1062
Gate Lock1063
Breaker Mode1064
Crusher Mode1064
Quick coupler1065
Hydraulic Fluid Filter Clogging1066
Solenoid Sticking Prevention1067
Port Diagram1068
Hydraulic Pump (Standard Model)1068
Hydraulic Pump (Blade)1069
Control Valve1070
Relief Valve1070
Relief Valve (Blade)1073
5 stack solenoid valve1076
2 stack solenoid valve1077
Remote Control Valves (upper, travel)1077
Remote Control Valves (left-right)1077
Remote control valve (travel)1078
Remote Control Valve (blade)1078
Cushion Valve1079
2-way Selector Valve1080
Direction Valve1081
6 Stack Proportional Valve1082
Relief Valve (electromagnetic proportional)1084
Manifold Under Cab1085
Manifold (accumulator section)1086
Hydraulic Tank1087
Hydraulic Pump1088
Structure and Operation Explanation1088
Hydraulic Pump Internal Structure Diagram1089
Overall View1089
Drive Shaft Front Side1090
Drive Shaft Rear Side1091
Development Diagram1092
Component Table1095
Regulator1096
Regulator Operation Explanation1096
Regulator Operation Explanation Diagram1099
Internal Configuration Diagram of Regulator1102
Development Diagram of Regulator1104
Component Table1105
Operation Outline of Electronically-Controlled Pump1107
Control Valve1110
Basic Configuration1110
Operation1110
Operation of Main Unit1110
Activation of Relief Valve1130
5 Stack Solenoid Valve Operation Explanation1135
External Shape Diagram and Components1135
operation explanation1135
Upper Pilot Valve (remote control valve)1136
Structure1136
Function1136
Operation1136
Structural Diagram1140
Travel Pilot Valve (remote control valve)1141
Operation1141
Pressure Reducing Valve Section1141
Damping Mechanism in Operation Section1142
Structural Diagram1145
Cushion Valve 1147
structure1147
operation explanation1147
Selector Valve (2-way)1152
Structure1152
Operation Explanation1153
Development Diagram1154
Direction Valve (3-direction) 1155
Structure1155
Operation Explanation1156
6 Stack Proportional Valve (Pilot)1158
structure1158
operation principle1159
Electromagnetic Relief Valve1160
Structure1160
Operation Explanation1161
Operation of Check Valve1161
Operation of Electromagnetic Relief Valve1162
Removal and Installation of Hydraulic Reservoir1164
Removal of Hydraulic Reservoir1164
Installation of Hydraulic Oil Tank1167
Removal and Installation of Hydraulic Pump1168
Removal of Hydraulic Pump1168
Installation of Hydraulic Pump1169
Removal and Installation of Control Valve1170
Removal of Control Valve1170
Installation of Control Valve1172
Removal and Installation of Travel Remote Control Valve1173
Removal of Travel Remote Control Valve1173
Installation of Travel Remote Control Valve1174
Removal and Installation of Operation Remote Control Valve1177
Removal of Operation Remote Control Valve (left side)1177
Installation of Operation Remote Control Valve (left side)1179
Removal of Operation Remote Control Valve (right side)1180
Installation of Operation Remote Control Valve (right side)1182
Removal and Installation of 5 Stack Solenoid1185
Removal of 5 Stack Solenoid1185
Installation of 5 Stack Solenoid Valve1186
Removal and Installation of Cushion Valve1187
Removal of Cushion Valve1187
Installation of Cushion Valve1188
Procedures for Assembly and Disassembly of Hydraulic Pump Main Unit1189
Tools1189
Disassembly Procedure1189
Assembly Procedures1191
Development Diagram1195
Component Table1198
Pump Main Unit Maintenance Standards1199
Replacement Standard of Wear Component1199
Correction Standard of Cylinder, Valve Plate, and Sash Plate (Shoe Plate)1199
Tightening torque1200
Overall View1200
Drive Shaft Front Side1201
Drive Shaft Rear Side1202
Development Diagram1203
Component Table1206
Regulator Maintenance Standards1207
Regulator Adjustment1207
Appendix Table and Drawings1208
Regulator Assembly and Disassembly Procedures1212
Tools1212
Preparations for Disassembly1212
Disassembly Procedure1212
Assembly Procedures1214
Internal Configuration Diagram of Regulator1217
Development Diagram of Regulator1219
Component Table1220
Assembly and Disassembly of Control Valve1222
Disassembly1222
Caution for Disassembly1222
Disassembly Procedure1222
Removal of Long Cap and Pulling Out of Main Spool1222
Disassembly of Arm 1, 2 Parallel-Tandem Spool, Neutral Cut Spool, Arm Regeneration Release Spool Section1223
Disassembly of Load Check Valve Section1223
Disassembly of Antidrift Valve Section (Sub Component in Assembly is Expressed by (Min Number – Sub Number))1224
Disassembly of Relief Valve1224
Disassembly of Option Section1224
Disassembly of Add-On Section1224
Disassembly of Valve Housing Coalescence Bolt1225
Cleaning1225
Inspection1225
assembly1225
Caution for Assembly1225
Caution for Handling O-ring1225
Caution for Handling Spool1225
Method to Apply Adhesive Agent (Male and Female Thread Section of Components Requiring Bonding)1225
Assembly Procedure of Sub-Assembly1226
Assembly of Spool Assembly (Main Spool)1226
Assembly of Arm 1, 2 Parallel-Tandem Spool, Neutral Cut Spool, Arm Regeneration Release Spool Assembly1226
Assembly of Antidrift Valve Assembly1227
Assembly Procedure of Control Valve Main Unit1227
Assembly of Relief Valve1227
Assembly of Load Check Valve1227
Assembly of Antidrift Valve1228
Assembly of Option Section1228
Assembly of Arm 1 Parallel-Tandem Spool1228
Assembly of Arm 2 Parallel-Tandem Spool, Neutral Cut Spool, Arm Regeneration Release Spool1228
Assembly of Main Spool1228
Assembly of Add-On Section1229
Assembly of Other Plugs1229
Internal Structural Diagram1230
Part List1236
Relief Valve1237
Assembly and Disassembly Procedure of Main Relief Valve1237
Assembly and Disassembly Procedures of Overload Relief1238
Assembly and Disassembly Procedure of Low-Pressure Relief Valve1239
Assembly and Disassembly Procedure of Main Relief Valve for Add-On1239
Adjustment of Relief Valve1240
Installation1241
Operation1241
Malfunction and Countermeasure1241
Procedures for Assembly and Disassembly of Operation Remote Control Valve1243
Maintenance Procedures1243
Required Tools and Tightening Torque1243
Maintenance Standards1243
Disassembly Procedures1244
Assembly Procedures1246
Causes of Trouble and Countermeasures1250
Procedures for Assembly and Disassembly of Travel Remote Control Valve1254
Maintenance Procedures1254
Disassembly Procedures1255
Assembly Procedures1259
Causes of Trouble and Countermeasures and Cross-section Diagram1264
Assembly and Disassembly of Cushion Valve1267
Disassembly Procedures1267
Reverse Operation Spool Section1267
Check Plunger Section with Throttle1267
Shuttle Valve Section1267
Assembly Procedures1267
Reverse Operation Spool Section1268
Check Plunger Section with Throttle1268
Shuttle Valve Section1268
Written Materials1269
Procedures for Assembly and Disassembly of 6 Stack Proportional Valve (Pilot)1271
Development Diagram1271
Assembly and disassembly procedures1272
Precautions1272
Replacement of Proportional Solenoid1272
Disassembly1272
Assembly1272
Replacement of Sleeve and Spool1273
Disassembly1273
Assembly1274
Replacement of Poppet (Check Valve for Normally Open)1275
Disassembly1275
assembly1275
Maintenance Standards1276
Troubleshooting1276
Pressure Measurement and Adjustment Procedures1277
Procedures for Pressure Measurement from the Monitor Display1277
Monitor and Switch Panel1277
Pressure Measurement Method1277
Operating Method1277
PROCEDURES FOR MEASURING HYDRAULIC OIL TEMPERATURE FROM THE MONITOR DISPLAY1277
Hydraulic Oil Temperature Measurement Method1277
Operating Method1278
Procedures for Pressure Measurement by Installing Pressure Gauge1279
Preparations1279
Items to prepare1279
Pressure Measurement Port1280
Control Valve1282
Location of Relief Valves1282
Pressure Measurement Preparations1283
Pressure Measurement1285
Main Pressure Measurement1285
A Attachment Pressure Measurement1285
Boom-down Pressure Measurement1287
D Option Line Pressure Measurement1287
Pilot Pressure Measurement1287
Pressure Gauge Installation1287
Negative Control Pressure Measurement1288
Pressure Gauge Installation1288
Pressure Adjustment1288
Main Pressure Adjustment1288
Pressure Measurement and Adjustment Preparations1288
Main Relief Pressure Adjustment1290
Overload Relief Pressure Adjustment1290
Adjustment of Swing Relief Pressure1292
Pilot Pressure Adjustment1293
Hydraulic Pump Flow Measurement Procedures1294
Preparations1294
Items to Prepare1294
Work Preparations1295
Flow Measurement1296
Air Bleed Procedure1298
Hydraulic Pump1298
Sampling Procedure1299
Sampling of Hydraulic Fluid1299
Hydraulic Equipment Layout1300
Overall View1301
Pump Chamber Hydraulic Equipment Layout1302
Swing Body Center Section Hydraulic Equipment Layout1303
Housing Left Side Hydraulic Equipment Layout1304
Layout of Hydraulic Equipment in Cab1305
N CAB1307
Removal and Installation of Operator’s Seat1310
Removal of Operator’s Seat1310
Installation of Operator’s Seat1310
Removal and Installation of Cab Assembly1311
Removal of Cab Assembly1311
Installation of Cab Assembly1314
Removal and Installation of Wiper1315
Removal of Wiper1315
Installation of wiper1315
Removal and Installation of Cab Windshield1316
Removal of Cab Windshield1316
Installation of Cab Front Glass1316
Window Lock Adjustment Procedure1317
Window Lock (front side)1317
Window Lock (rear side)1317
Removal and Installation of Housing Guardrail1318
Removal of Housing Guardrail1318
Installation of Housing Guardrail1318
Tightening torque1319
R ELECTRICAL PARTS1321
Basic Functions1325
Monitor Control1325
Monitor Display Dimming1325
Diagnostic Trouble Code Indicator1326
Clock1326
Basic Operation1327
Battery save1327
Accessories1329
Working Light1329
LED Light1330
Room Lamp1330
Radio Mute1332
Wiper and Washer1333
Safety1335
Horn1335
Back/Side View Monitor1336
Precautions for Camera Installation1337
Maintenance1337
Anti-theft1337
Manual Lock1338
Service Support Screen Lock1338
Customer-specific System Information Screen Lock1338
Maintenance Information Screen Lock1339
Option Line Setting Screen Lock1339
Setting1339
Clock Adjustment1339
Screen Brightness Setting1340
Battery disconnect switch1341
Explanation of Controller1342
Service Support1345
Screen Operations1345
Screen Display List1345
Service Monitor Structure1346
CHECK Screen List1347
MACHINE STATUS1348
HYDRAULIC STATUS1355
ENGINE STATUS1362
FAULT HISTORY1367
WORK HISTORY1367
HYDRAULIC HISTORY1375
ENGINE HISTORY1388
DEVICE TEST1411
ECM/DCU Memory Clear1411
SCR RE-GEN1412
Urea Line Leak Test1413
CCV Operation Test1413
Dosing Test1414
Reverting Valve Operation Test1415
Common Rail Pressure Test1416
Idle Speed Test / Injector Test1417
EGR Valve Control Test1419
VG Turbo Control Test1420
Intake Throttle Control Test1421
CONTROL UNIT Screen List1422
MCM-MAIN1422
MCM-SUB1426
COMMU TERMINAL1427
SETUP Screen List1429
MACHINE SELECT1429
DIMENSIONS1434
PARAMETERS1437
ENGINE INFORMATION1441
ENGINE INFORMATION1442
Data Confirmation1442
Data Transfer (Copy)1442
QR (INJECTOR) CODE1443
Injector number1443
Screen Layout1444
Data Source Selection1444
Manual Input1444
CAMERA1446
PASSWORD1449
CALIBRATE Screen List1451
THROTTLE VOLUME1452
OPTLINE RELIEF1453
PUMP FLOW1455
RESET Screen List1457
Connection Connector Pin Layout1460
Main Controller1460
Monitor1461
Sequence Circuit Diagram1462
Code table1462
Overall1465
Block diagram1468
Main controller1468
DCU1469
ECM1470
Monitor1471
Air conditioner1471
Gate Lock1472
Option1472
Others1473
Electrical Symbol List1473
Electrical Equipment Layout Diagram1475
Main Unit Left-side Layout Diagram1476
Engine Section Layout Diagram1477
Main Unit Right Side Layout Diagram1479
Cab Layout Diagram 11481
Cab Layout Diagram 21482
Layout Around Operator Seat1485
Stand Alone Parts Diagram1486
Removal and Installation of Wiper Controller1505
Removal of Wiper Controller1505
Installation of wiper controller1505
Removal and Installation of Wiper Motor1506
Removal of Wiper Motor1506
Installation of wiper motor1507
Removal and Installation of ECM1508
Removal of ECM1508
Installation of ECM1508
Removal and Installation of Main Controller1509
Main controller Removal1509
Installation of Main Controller1509
Removal and Installation of DCU1510
Removal of DCU1510
Installation of DCU1510
Removal and Installation of Monitor1511
Removal of Monitor1511
Installation of Monitor1512
Removal and Installation of Rear View Camera 1513
Removal of Rear View Camera1513
Installation of Rear View Camera1513
Removal and Installation of Side Camera (right)1514
Removal of Side Camera (Right)1514
Installation of Side Camera (Right)1514
Removal and Installation of Side Camera (Left)1515
Removal of Side Camera (Left)1515
Installation of Side Camera (Left)1515
Removal and Installation of WAVES Controller1516
Removal of WAVES Controller1516
Installation of WAVES Controller1516
How to Set WAVES1517
Air Conditioner Overall Diagram1521
Frame1521
Cab1524
Equipment Layout Diagram1527
Circuit Diagram1529
Air Conditioner Circuit Diagram1529
Explanation of Functions1531
Explanation of Control1531
Air Mix Motor Actuator Control1532
Blow Mode Motor Actuator Control1532
Refresh/Recirculate Switch Motor Actuator Control1534
Blower Amp Control1534
Compressor Clutch Control1537
COOLMAX Control and HOTMAX Control1538
Abnormality Detection and Control after Abnormality Detected1538
Monitor Mode1541
Door Switch Control1543
Actuator Inspection1544
Air Mix Motor Actuator Inspection1544
Refresh/Recirculate Switch Motor Actuator Inspection1545
Mode Motor Actuator Inspection1546
Self-diagnosis Function with Panel Display1548
Abnormality Display and Self-check Procedures1548
Abnormality Display Position1548
Explanation of Abnormality Display1548
Motor Actuator Abnormality1548
Sensor Abnormality1549
Explanation of Monitor Mode1549
Monitor Mode Display Position1549
Monitor Mode Display Operating Method1550
Display Contents in Monitor Mode1551
Air Conditioner Troubleshooting1557
Part Function and Good/Poor Judgment1562
Control Panel1562
Blower Amp1562
Relay1563
Air Mix Actuator1564
Refresh/Recirculate Actuator1565
Mode switch actuator1565
Evaporator Sensor1566
Dual Pressure Switch1566
Solar Radiation Sensor1567
Inside Air Sensor1568
Assembly and Disassembly of Unit1569
Removal of Blower Unit1569
Replacement of Blower Motor1569
Replacement of Blower Amp1570
Removal of Heater Core1570
Removal of Switchover BOX1570
Replacement of Evaporator and Expansion Valve1571
Installation of Evaporator Sensor1572
Replacement of Motor Actuator1572
Removal and Installation of Compressor1574
Removal of Compressor1574
Installation of Compressor1574
Removal and Installation of Condenser1575
Removal of Condenser1575
Installation of Condenser1576
Removal and Installation of Receiver Dryer1577
Removal of Receiver Dryer1577
Installation of Receiver Dryer1577
Work Precautions1579
Work Procedures1579
Air Conditioner Refrigerant Filling is Divided into the “Vacuum Operation” and “Gas Filling Operation”1579
Operation Chart1580
Tools1580
Filling Procedures1582
Charging Hose Connection Position1582
Connecting Gauge Manifold1582
Vacuuming1583
Gas Filling Operation, High-pressure Side1584
Gas Filling Work, Low Pressure Side1584
V ATTACHMENTS1587
Main Equipment Table1591
Backhoe Attachment1591
Cylinder1591
Maintenance Standards1592
Attachment (Backhoe)1592
1 Boom and Swing Frame Installation Section1592
2 Boom Cylinder and Swing Frame Installation Section1593
3 Boom and Boom Cylinder Installation Section1593
4 Boom and Arm Cylinder Installation Section1594
5 Boom and Arm Installation Section1594
6 Arm and Arm Cylinder Installation Section1595
7 Arm and Bucket Cylinder Installation Section1596
8 Arm and Arm Link Installation Section1596
9 Bucket and Bucket Link Installation Section1597
10 Bucket Link and Bucket Cylinder Installation Section1597
11 Bucket and Arm Installation Section1598
Dozer Blade1600
1 Blade Cylinder Installation Section1600
2 Lower Frame and Blade Cylinder Installation Section1601
3 Lower Frame and Blade Installation Section1601
Removal and Installation of Bucket Cylinder1602
Removal of Bucket Cylinder1602
Installation of Bucket Cylinder1604
Removal and Installation of Arm Cylinder1605
Removal of Arm Cylinder1605
Installation of Arm Cylinder1607
Removal and Installation of Boom Cylinder1609
Removal of Boom Cylinder1609
Installation of Boom Cylinder1611
Removal and Installation of Blade Cylinder1614
Removal of Blade Cylinder1614
Installation of Blade Cylinder1615
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder1617
Specifications and Structure Diagram (including the assembly diagram and parts table)1617
Basic Functions1617
Function of Each Location1617
Cylinder Head Assembly (made by KYB)1617
Piston Assembly (made by KYB)1618
Pipe Assembly (made by KYB)1620
Handling Precautions1620
Precautions for Installing the Cylinder on the Machine Body1620
Usage Cautions1621
Maintenance and Inspection Cautions1621
Maintenance Inspection and Service1623
Trouble Diagnostics1624
Storage Standards1629
Storing Parts Individually (In principle, store indoors)1629
When Mounted on Vehicle Body1629
Recommended Anti-rust Oil1629
Assembly and Disassembly Procedures1630
Preparations ····· Prepare the Following before Starting Disassembly1630
General Work Precautions1630
Maintenance Standards1630
Inspection after Assembly1630
Required Tool1631
General Tool1631
Special Jig (made by KYB)1632
Special Jig Parts Number List (made by KYB)1632
Disassembly Procedures (made by KYB)1633
Assembly Procedures (made by KYB)1636
Test Operation1641
Usage Limits1642
Structural Diagram (made by KYB)1643
Boom Cylinder1643
Arm Cylinder1645
Bucket Cylinder1647
Blade Cylinder1649
HBCV1651
structure1651
Function1651
operation explanation1651
Port Diagram1666
HBCV1666
Air Bleed Procedure1667
HBCV1667
Boom Cylinder HBCV1667
Arm Cylinder HBCV1668
Removal and Installation of HBCV1669
Removal and Installation of Arm HBCV1670
Removal of Arm HBCV1670
Installation of arm HBCV1670
Removal and Installation of Boom HBCV1671
Removal of Boom HBCV1671
Installation of Boom HBCV1672
Removal and Installation of Bucket1673
Removal of Bucket1673
Installation of Bucket1673
Removal and Installation of Bucket Link1675
Removal of Bucket Link1675
Installation of Bucket Link1675
Removal and Installation of Arm1677
Removal of Arm1677
Installation of Arm1678
Removal and Installation of Boom1679
Removal of Boom1679
Installation of Boom1681
Removal and Installation of Blade1685
Removal of Blade1685
Installation of Blade1686
Z OTHER1687
Change from Type 61692
Overall Layout1692
Lower1692
Engine1692
Hydraulic-related Data1695
Hydraulic Control1695
Cab, House1696
Electrical Data1697
Electric Control1698
Specifications1699
245X41700
ENGINE1700
HYDRAULIC SYSTEM1700
HYDRAULIC CONTROLS1701
ELECTRICAL SYSTEM1701
OPERATOR ENVIRONMENT1702
UNDERCARRIAGE1702
MASS1703
DIGGING FORCE (with 09 m3 Sumitomo Bucket) (ISO 6015)1703
DIMENSIONS1703
WORKING RANGES1704
SYSTEM FLUID CAPACITIES AND SPECIFICATIONS1704
245X4 (BB)1705
ENGINE1705
HYDRAULIC SYSTEM1705
HYDRAULIC CONTROLS1706
ELECTRICAL SYSTEM1706
OPERATOR ENVIRONMENT1707
UNDERCARRIAGE1708
DOZER BLADE1708
MASS1708
DIGGING FORCE (with 09 m3 Sumitomo Bucket) (ISO 6015)1708
DIMENSIONS1708
WORKING RANGES1709
SYSTEM FLUID CAPACITIES AND SPECIFICATIONS1709
Main Unit Weight1710
Divided Weight (standard specifications)1710
Divided Weight (Blade Specifications)1711
Stand Alone Part Weight (standard specifications)1712
Stand Alone Part Weight (Blade Specifications)1712
Shoe Weight (per Side)1712
Shoe Weight (per Side) (Blade Specifications)1712
Arm Weight1713
Bolt Size and Torque Table1714
Special Torque Setting1714
Overall View1719
245X4 (Grouser Shoe)1719
Standard Arm [294 m (96457 ft)]1719
Short Arm [240 m (78740 ft)]1720
245X4 (Link Chain)1721
Standard Arm [294 m (96457 ft)]1721
Short Arm [240 m (78740 ft)]1723
245X4 (BB) (Grouser Shoe)1725
Standard Arm [294 m (96457 ft)]1725
Short Arm [240 m (78740 ft)]1725
245X4 (BB) (Link Chain)1727
Standard Arm [294 m (96457 ft)]1727
Short Arm [240 m (78740 ft)]1728
WORK RANGE DIAGRAM1729
245X41729
Standard Arm [294 m (96457 ft)]1729
Short Arm [240 m (78740 ft)]1731
245X4 (BB)1732
Standard Arm [294 m (96457 ft)]1732
Short Arm [240 m (78740 ft)]1734
New Machine Performance Judgment Table1736
FLUIDS AND LUBRICANTS1737
HYDRAULIC FLUID1737
Engine Oil1737
Fuel1737
Conditions applicable to diesel fuel1737
Recommended conditions applicable to diesel fuels1737
Main-Unit-related Diagnostic Trouble Code List1738
Main Unit-side Trouble1741
Diagnostic Trouble Code: 7000 Pressure Sensor P1 Abnormality1741
Diagnostic Trouble Code: 7001 Pressure Sensor P2 Abnormality1742
Diagnostic Trouble Code: 7002 Pressure Sensor N1 Abnormality1744
Diagnostic Trouble Code: 7003 Pressure Sensor N2 Abnormality1745
Diagnostic Trouble Code: 7004 Pressure sensor boom cylinder bottom abnormality1747
Diagnostic Trouble Code: 7007 Pressure sensor arm cylinder rod abnormality1748
Diagnostic Trouble Code: 7021 Pressure sensor swing pilot abnormality1750
Diagnostic Trouble Code: 7023 Pressure sensor arm-in pilot abnormality1751
Diagnostic Trouble Code: 7040 Level sensor fuel abnormality1753
Diagnostic Trouble Code: 7041 Temperature sensor hydraulic oil abnormality1754
Diagnostic Trouble Code: 7065 Pressure sensor boom-up pilot abnormality1756
Diagnostic Trouble Code: 7067 Pressure sensor bucket-close pilot abnormality1757
Diagnostic Trouble Code: 7068 Pressure sensor boom-down pilot abnormality1759
Diagnostic Trouble Code: 7069 Pressure sensor arm-out pilot abnormality1760
Diagnostic Trouble Code: 7070 Pressure sensor bucket-open pilot abnormality1762
Diagnostic Trouble Code: 7071 Pressure Sensor Travel Right Pilot Abnormality1764
Diagnostic Trouble Code: 7072 Pressure Sensor Travel Left Pilot Abnormality1765
Diagnostic Trouble Code: 7073 Pressure Sensor Travel 1 Pedal Abnormality1767
Diagnostic Trouble Code: 7074 Pressure Sensor 1st Option Pilot (Common/Front Press) Abnormality1769
Diagnostic Trouble Code: 7075 Pressure Sensor Arm Cylinder Bottom Abnormality1770
Diagnostic Trouble Code: 7078 Pressure Sensor 1st Option Pilot (Back Press) Abnormality1772
Diagnostic Trouble Code: 7200 Swing Brake Solenoid Abnormality1774
Diagnostic Trouble Code: 7201 Travel 2nd Speed Switchover Solenoid Abnormality1775
Diagnostic Trouble Code: 7202 Pressure Boost Solenoid Abnormality1776
Diagnostic Trouble Code: 7203 Travel Alarm Buzzer Abnormality1777
Diagnostic Trouble Code: 7206 Option Return Line Switchover Solenoid Abnormality1778
Diagnostic Trouble Code: 7207 Free Swing Solenoid Abnormality1779
Diagnostic Trouble Code: 7213 Quick Coupler Buzzer Abnormality1780
Diagnostic Trouble Code: 7214 Quick Coupler Solenoid Abnormality1782
Diagnostic Trouble Code: 7247 Boom 2-Down Pilot Proportional Valve Abnormality1784
Diagnostic Trouble Code: 7249 Bucket-Close Pilot Proportional Valve Abnormality1785
Diagnostic Trouble Code: 7250 Option Relief Pressure Proportional Valve Abnormality1786
Diagnostic Trouble Code: 7265 Arm 1 Semi-Parallel Proportional Valve Abnormality1788
Diagnostic Trouble Code: 7266 Arm 2 Semi-Parallel Proportional Valve Abnormality1789
Diagnostic Trouble Code: 7267 Arm 1 Regeneration Release Proportional Valve Abnormality1790
Diagnostic Trouble Code: 7270 Tilting 1 Proportional Valve Abnormality1791
Diagnostic Trouble Code: 7271 Tilting 2 Proportional Valve Abnormality1793
Diagnostic Trouble Code: 7273 Straight Travel Proportional Valve Abnormality1794
Diagnostic Trouble Code: 7400 Coolant Temperature Overheating 11795
Diagnostic Trouble Code: 7401 Coolant Temperature Overheating 21796
Diagnostic Trouble Code: 7404 Oil Temperature Overheating1797
Diagnostic Trouble Code: 7405 Boost Temperature Overheating 11798
Diagnostic Trouble Code: 7406 Boost Temperature Overheating 21799
Diagnostic Trouble Code: 7420 Alternator Power Generation Defect1800
Diagnostic Trouble Code: 7421 Decrease in Coolant Level1801
Diagnostic Trouble Code: 7422 Decrease in Engine Oil Pressure1802
Diagnostic Trouble Code: 7423 Air Cleaner Clogging1803
Diagnostic Trouble Code: 7424 Return Filter Clogging1804
Diagnostic Trouble Code: 7426 Fuel Filter Clogging 11805
Diagnostic Trouble Code: 7427 Fuel Filter Clogging 21806
Diagnostic Trouble Code: 7428 Inducement (Remaining Urea Level Low) – Warning1807
Diagnostic Trouble Code: 7429 Inducement (Remaining Urea Level Low) – Early1808
Diagnostic Trouble Code: 7430 Inducement (Remaining Urea Level Low) – Final1808
Diagnostic Trouble Code: 7602: ECM Communication Abnormality1809
Diagnostic Trouble Code: 7605 ECM Not Matched1810
Diagnostic Trouble Code: 7606 EEPROM Abnormality1811
Diagnostic Trouble Code: 7608 Camera Abnormality1811
Diagnostic Trouble Code: 7612 Air Conditioner Communication Abnormality1813
Diagnostic Trouble Code: 7613 Monitor communication (CAN) abnormality1814
Diagnostic Trouble Code: 7618 DCU Communication Abnormality1815
List of special tools1817
NUMERICAL VALUE CONVERSION TABLE1817
Unit conversion rate1817
Length1817
Area1819
Volume1820
Weight1822
Pressure1823
Torque1824
Temperature1825
A1827
Take-up Roller Special Tool1827
245X41827
Upper Roller Special Tool1828
210X4/245X4/250X41828
Lower Roller Special Tool1829
210X4/245X4/250X51829
C1830
Swing Motor Special Tool1830
210X4/245X4/250X61830
H1833
Engine Oil Filter Special Tool1833
210X4/245X4/250X71833
Fuel Filter Special Tool1833
210X4/245X4/250X81833
Injector Special Tool1833
210X4/245X4/250X91833
Circuit Test Special Tool1834
210X4/245X4/250X101834
Valve Guide Special Tool1834
210X4/245X4/250X111834
Cylinder Head Special Tool1834
210X4/245X4/250X121834
Head Bolt Special Tool1837
210X4/245X4/250X131837
Crankshaft Special Tool1837
210X4/245X4/250X141837
Valve Spring Special Tool1839
210X4/245X4/250X151839
J1840
Remote Control Valve Special Tool1840
210X4/245X4/250X161840
R1842
Gas Filling Special Tool1842
210X4/245X4/250X171842
V1842
Attachment Special Tool (for Cylinder Assembly)1842
Special Jigs Part Number List1842
Paint Colors1844
Abbreviation1846
S.M 31/12/24
