Linkbelt 145X4 DZ 145X4 LC Excavator Service Manual WLSM1457-04LX – PDF DOWNLOAD

Description

Linkbelt 145X4 DZ 145X4 LC Excavator Service Manual WLSM1457-04LX – PDF DOWNLOAD

FILE DETAILS:

Linkbelt 145X4 DZ 145X4 LC Excavator Service Manual WLSM1457-04LX – PDF DOWNLOAD

Language : English
Pages : 2100
Downloadable : Yes
File Type : PDF
Size: 102 MB

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DESCRIPTION:

Linkbelt 145X4 DZ 145X4 LC Excavator Service Manual WLSM1457-04LX – PDF DOWNLOAD

General Information:
Cleaning:
Clean the metal parts with a cleaning fluid or steamer that meets standards. (except for the bearing) After cleaning the parts, let them dry well and inject oil into all parts. Inject oil into the bearing after letting it dry.
Inspection:
When disassembling parts, inspect all the parts. Replace any worn or damaged parts. Inspect them thoroughly to prevent early failures.
Bearing:
If the bearing is loose, replace it. Install the bearing after air drying it.
Needle bearing:

• When inserting the needle bearing, be careful not to scratch it.
• Inject grease into the location where the needle bearing is to be inserted.

Gear:
Check for any wear or damage.
Oil seals, O-rings, gaskets:

• Always install new oil seals, O-rings, and gaskets.
• Inject grease into the locations where oil seals and O-rings are to be inserted.

Shaft:

• Check for any wear or damage.
• Check the oil seal on the bearing and damaged shaft.

Service parts:
Install genuine LBX Link-Belt service parts. When ordering parts, see the parts catalog that has genuine LBX Link-Belt part numbers listed. Any failures caused by installing a nongenuine part are not covered by the warranty.
Lubrication (fuel, hydraulic oil):
Use oils from specified manufacturers or the ones specified in the operator’s manual or Service Manual. Any failures caused by using other fuel or hydraulic oil than specified are not covered by the warranty.

TABLE OF CONTENTS:

Linkbelt 145X4 DZ 145X4 LC Excavator Service Manual WLSM1457-04LX – PDF DOWNLOAD

Excavator 1
SAFETY 9
Safety, general information and standard torque data 12
General Information 13
Safety 13
ROPS 16
ROPS Judgment Method 16
Standard Torque Data For Cap Screws And Nuts 21
Bolt and Nut Tightening 21
Protection of Electric/Electronics System During Charging or Welding 22
A LOWER 23
Main Equipment Table 27
Lower Component 27
Travel Unit 27
Take-up Roller 27
Upper Roller 27
Lower Roller 27
Recoil Spring 27
Shoe (LC) 27
Shoe (Blade) 28
Center Joint (LC) 29
Center Joint (Blade) 29
Main Equipment Structure and Operation Explanation 30
Travel Motor 30
Safety Precautions 30
Data 31
Use of Product 31
Specifications 31
Type Indication 31
Outside Dimension Diagram and Hydraulic Circuit Diagram 32
Basic Structure and Drawing 35
Assembly Cross-Section Diagram 35
Part List 37
Exploded Views 39
Operation Explanation 42
Reduction Gear 42
Hydraulic Motor Section 43
Usage Precautions 59
Installation Instructions 59
Line 60
Hydraulic Fluid 61
Maintenance and Inspection 62
Daily Inspection 62
Replacement of Hydraulic Fluid 62
Lubricant 63
Table of Seals 65
Failure and Necessary Action 66
Storage of Travel Motor 68
Port Diagram 69
Travel Motor 69
Center Joint 70
Center Joint (Blade) 71
Basic Functions 72
Travel speed selection 72
Travel Alarm 74
Removal and Installation of Track 75
Removal and Installation of Shoe Assembly 75
Removal of Shoe Assembly 75
Installation of Shoe Assembly 76
Removal and Installation of Shoe Plate 78
Removal of Shoe Plate 78
Installation of Shoe Plate 78
Precautions for Shoe Bolt Installation 79
Removal and Installation of Roller 80
Removal and Installation of Upper Roller 80
Removal of Upper Roller 80
Installation of Upper Roller 81
Assembly and Disassembly of Upper Roller 82
Configuration Diagram 82
Dimension Diagram 83
Jig Dimension Diagram 83
Disassembly Procedures 84
Assembly Procedures 86
Removal and Installation of Lower Roller 88
Removal of Lower Roller 88
Installation of Lower Roller 89
Assembly and Disassembly of Lower Roller 90
Configuration Diagram 91
Dimension Diagram 91
Jig Dimension Diagram 92
Disassembly Procedures 92
Assembly Procedures 94
Removal and Installation of Drive Sprocket 97
Removal of Drive Sprocket 97
Installation of Drive Sprocket 99
Removal and Installation of Take-up Roller 100
Removal of Take-up Roller 100
Installation of Take-up Roller 101
Assembly and Disassembly of Take-up Roller 102
Configuration Diagram 103
Dimension Diagram 103
Jig Dimension Diagram 104
Disassembly Procedures 104
Assembly Procedures 107
Removal and Installation of Grease Cylinder 110
Removal of Grease Cylinder 110
Installation of grease cylinder 111
Assembly and Disassembly of Tension Shock Absorber 112
Configuration Diagram 112
Dimension Diagram 112
Jig dimension diagram 113
Disassembly procedures 113
Assembly procedures 113
Removal and Installation of Center Joint 115
Removal of Center Joint 115
Installation of Center Joint 116
Assembly and Disassembly of Center Joint 117
Configuration Diagram 118
Dimension Diagram 119
Dimension Diagram (Blade) 120
Jig Dimension Diagram 121
Disassembly Procedures 121
Assembly Procedures 122
Removal and Installation of Travel Motor 125
Removal of Travel Motor 125
Installation of Travel Motor 127
Assembly and Disassembly of Travel Motor (nabtesco) 130
Safety Precautions 130
Service Overview 131
Tools 131
Tightening Torque 137
Weight Table 137
Disassembly 138
Preparations 138
General Work Precautions 138
Disassembly Procedure 139
Maintenance Standards 152
Seals 152
Maintenance Standards for Worn Components 152
Assembly 154
Preparations 154
General Work Precautions 154
Assembly Procedure 155
Performance Check Test 172
Maintenance Standards 173
Drive Sprocket 173
Take-up Roller 174
Upper roller 175
Lower Roller 176
Track Shoe (Grouser Shoe) 177
Inspection Gauge 178
For Drive Sprocket 178
For Take-up Roller 178
For Upper Roller 179
For Lower Roller 179
Pressure Measurement and Adjustment Procedures 180
Main Pressure Measurement 180
B Travel Pressure Measurement 180
Drain Volume Measurement Procedures 181
Preparations 181
Travel Motor Drain Volume Measurement 181
Air Bleed Procedure 183
Travel Motor 183
B C SWING UNIT, COUNTERWEIGHT 185
Main Equipment Table 188
Upper Component 188
Swing Unit 188
Main Equipment Structure and Operation Explanation 189
Swing Unit 189
Explanation of Swing Reduction Gear 189
Swing Motor Operation Explanation 190
Hydraulic Motor 190
Mechanical Brake 191
Relief Valve 192
Make-up valve 194
Bypass Valve 195
Assembly cross-section diagram 196
Parts List 197
Disassembly and Assembly Diagram (Swing Motor) 198
Disassembly and Assembly Diagram (Reduction Gear) 199
Port Diagram 200
Swing motor 200
Basic Functions 201
Swing brake 201
Swing lock 202
Swing Speed Limit 204
Swing Relief Cut 206
Removal and Installation of Swing Unit 207
Removal of Swing Unit 207
Installation of Swing Unit 210
Assembly and Disassembly of Swing Motor and Swing Reduction Gear 211
Causes of Failures, and Actions 212
Maintenance Standards 214
Tools 215
Jig 217
Tightening torque 218
Weight Table 218
Disassembly 219
Disassembly of Swing Unit 219
Disassembly of Swing Motor 219
Disassembly of Swing Reduction Gear 223
Assembly 226
Assembly of Swing Reduction Gear 226
Assembly of Swing Motor 229
Assembly of Swing Unit 235
Assembly cross-section diagram 237
Parts List 238
Disassembly and Assembly Diagram (Swing Motor) 239
Disassembly and Assembly Diagram (Reduction Gear) 240
Removal and Installation of Counterweight 241
Removal of Counterweight 241
Installation of Counterweight 244
Pressure Measurement and Adjustment Procedures 245
Main Pressure Measurement 245
C Swing Pressure Measurement 245
Drain Volume Measurement Procedures 246
Preparations 246
Swing Motor Drain Volume Measurement 246
Air Bleed Procedure 247
Swing Motor 247
Check 247
H ENGINE 249
Main Equipment Table 258
Engine-related 258
Engine 258
Air Cleaner (double element) 258
Radiator 258
SCR 258
Basic Functions 259
Fuel Gauge 259
Coolant Temperature Gauge 261
SCR Gauge 263
Fuel economy gauge 268
Neutral start 269
Power-cut Delay 270
Preheat 271
Throttle 272
Throttle volume position detection 273
Idle start 278
Auto idle 280
One-touch idle 282
Auto Warm-up 283
Idle shut down 289
Idle up 291
Work mode control 292
Engine Emergency Stop 293
SCR RE-GEN 294
Inducement 300
Feed Pump Automatic Stop 305
Coolant Level Decrease 307
Air Filter Clogging 308
Fuel Filter Clogging 310
Battery Charge Abnormality 312
Horsepower Reduction Control (in Uplands) 314
Horsepower Reduction Control (at Engine Failure) 315
Primary specifications 317
Function, Structure, Operation 319
Function, structure, operation (SCR) 367
SCR Control System Inspection 397
Explanation of SCR Operation 398
Diagnosis for Each Symptom 400
Intermittent conditions of urea selective catalytic reduction system 400
Urea fluid consumption too high 402
Ammonia smell noticeable 403
White crystalline powder visible 403
Diagnosis for Each Symptom 405
Engine start failure 405
Engine stalling 406
Engine Hunting, Rough Idling 408
Excess Amount of White Smoke in Exhaust Gas 409
Excessive Black Smoke in Exhaust Gas 410
Abnormal Noise 410
High Fuel Consumption 411
High Oil Consumption 412
Insufficient engine output 413
Functional Inspection 415
Engine compression pressure inspection 415
Fuel System Inspection 416
Lubrication system check 416
Suction air system inspection 417
Exhaust system inspection 417
Inspection of EGR Control System 417
Starting system check 418
Glow control system check 419
OBD system check 420
Inspection of the monitor warning light illumination circuit system 421
Inspection of the monitor warning light blinking circuit system 421
Inspection of the starter circuit system 422
Removal and Installation of Engine Assembly 424
Removal of Engine Assembly 424
Installation of Engine Assembly 428
Removal and Installation of Fuel Cooler, Engine Intercooler, Radiator, and Oil Cooler 429
Removal and Installation of Fuel Cooler 429
Removal of Fuel Cooler 429
Installation of Fuel Cooler 429
Removal and Installation of Engine Intercooler 430
Removal of Intercooler 430
Installation of Inter Cooler 432
Inspection of Intercooler 432
Removal and Installation of Radiator 433
Removal of Radiator 433
Installation of Radiator 436
Inspection of Radiator 436
Removal and Installation of Oil Cooler 437
Removal of Oil Cooler 437
Installation of oil cooler 439
Removal and Installation of Turbo Charger 440
Turbocharger assembly Removal 440
Turbocharger assembly Installation 441
Inspection of Turbocharger assembly 443
Removal and Installation of EGR Valve (if equipped) 444
Removal of EGR Valve 444
Installation of EGR Valve 444
Inspection of EGR Valve 444
Removal and Installation of EGR Cooler 445
Removal of EGR Cooler 445
Installation of EGR Cooler 446
Inspection of EGR Cooler 448
Removal and Installation of Engine Hood 450
Removal of Top Cover 450
Installation of Engine Hood 450
Removal and Installation of SCR 451
Removal of SCR 451
Installation of SCR 452
Removal and Installation of SCR Catalyst 453
Removal of SCR Catalyst 453
Installation of SCR Catalyst 455
Disassembly of SCR Catalyst 459
Assembly of SCR Catalyst 459
Inspection of SCR Catalyst 459
Removal and Installation of Cylinder Head Cover 460
Cylinder head cover Removal 460
Installation of Cylinder Head Cover 461
Removal and Installation of Cylinder Head 462
Removal of Cylinder Head 462
Disassembly of Cylinder Head 471
Assembly of Cylinder Head 472
Installation of Cylinder Head 475
Inspection of Cylinder Head 493
Removal and Installation of Cylinder Block 499
Removal of Cylinder block 499
Installation of Cylinder block 514
Inspection of Cylinder Block 545
Lubrication System 547
Removal and Installation of Oil Pan and Crank Case 547
Removal of Oil pan and crank case 547
Installation of Oil pan and crank case 561
Disassembly of Crankcase 587
Assembly of Crankcase 587
Removal and Installation of Oil Level Switch 587
Removal of Oil Level Switch 587
Installation of Oil Level Switch 588
Removal and Installation of Oil Pump Assembly 588
Removal of Oil pump assembly 588
Installation of Oil pump assembly 591
Inspection of Oil Pump Assembly 594
Engine oil Inspection 595
Removal and Installation of Oil Port Cover 595
Removal of Oil Port Cover 595
Installation of Oil Port Cover 596
Cooling System 597
Removal and Installation of Water Pump Assembly 597
Removal of Water Pump Assembly 597
Installation of Water Pump Assembly 598
Inspection of Water Pump Assembly 599
Removal and Installation of Thermostat 600
Removal of Thermostat 600
Installation of Thermostat 600
Inspection of Thermostat 601
InspectionInspection of Coolant 601
Inspection of Cooling Fan Belt 602
Removal and Installation of Overheat Switch 603
Removal of Overheat switch 603
Installation of Overheat switch 603
Induction System 604
Inspection of Air Cleaner Element 604
Exhaust System 605
Removal and installation of Oxidation Catalyst Assembly 605
Removal of Oxidation Catalyst Assembly 605
Installation of Oxidation Catalyst Assembly 607
Aux Emission Control Devices System 610
Removal and installation of Dosing Module 610
Removal of Dosing Module 610
Disassembly of Dosing Module 610
Assembly of Dosing Module 611
Installation of Dosing Module 611
Removal and installation of DEF Supply Module 612
Removal of DEF Supply Module 612
Disassembly of DEF Supply Module 612
Assembly of DEF Supply Module 613
Installation of DEF Supply Module 613
Removal and installation of Coolant Control Valve 614
Removal of Coolant Control Valve 614
Installation of Coolant Control Valve 614
Removal and Installation of DCU 615
Removal of DCU 615
Installation of DCU 615
Removal and installation of DEF Supply Module Filter 615
Removal of DEF Supply Module Filter 615
Installation of DEF Supply Module Filter 616
Removal and Installation of Exhaust Manifold 617
Removal of Exhaust Manifold 617
Installation of Exhaust Manifold 619
Inspection of Exhaust Manifold 622
Removal and Installation of Fuel Tank 623
Removal of Fuel Tank 623
Installation of fuel tank 626
Removal and Installation of Urea Pump 627
Removal of Urea Pump 627
Installation of Urea Pump 628
Removal and Installation of Urea Solution Tank 629
Removal of Urea Tank 629
Installation of Urea Solution Tank 630
Removal and Installation of Fuel Supply Pump 631
Removal of Fuel Supply Pump 631
Installation of Fuel Supply Pump 636
Removal and Installation of Common Rail Assembly 644
Removal of Common Rail Assembly 644
Installation of Common Rail Assembly 645
Removal and Installation of Injector 647
Removal of Injector 647
Installation of Injector 649
Removal and Installation of Crankshaft 653
Removal of Crankshaft 653
Installation of Crankshaft 668
Disassembly of Crankshaft 698
Assembly of Crankshaft 698
Inspection of Crankshaft 698
Removal and Installation of Piston and Connecting Rod 703
Removal of Piston and connecting rod 703
Installation of Piston and connecting rod 717
Disassembly of Piston and Connecting Rod 744
Assembly of Piston and Connecting Rod 745
Inspection of Piston and Connecting Rod 745
Removal and Installation of Camshaft 750
Removal of Camshaft 750
Installation of Camshaft 752
Inspection of Camshaft 756
Removal and Installation of Flywheel 758
Removal of Flywheel 758
Installation of Flywheel 759
Inspection of Flywheel 760
Removal and Installation of Crankshaft front oil seal 761
Removal of Crankshaft front oil seal 761
Installation of Crankshaft front oil seal 763
Removal and Installation of Crankshaft rear oil seal 766
Removal of Crankshaft Rear Oil Seal 766
Installation of Crankshaft Rear Oil Seal 767
Removal and Installation of Timing Chain 771
Removal of Timing chain 771
Installation of Timing chain 774
Removal and Installation of Timing Gear Train 780
Removal of Timing gear train 780
Installation of Timing gear train 785
Inspection of Timing Gear Train 794
Removal and Installation of Timing Gear Case 796
Removal of Timing gear case 796
Installation of Timing gear case 807
Removal and Installation of Inlet Manifold 830
Removal of Inlet manifold 830
Installation of Inlet manifold 831
Removal and Installation of Rocker Arm Shaft 835
Removal of Rocker arm shaft assembly 835
Installation of Rocker arm shaft assembly 838
Removal and Inspection of Valve Stem Oil Seal and Valve Spring 848
Removal of Valve stem oil seal and valve spring 848
Installation of Valve stem oil seal and valve spring 851
Inspection of Valve Spring 857
Removal and installation of Intake Throttle Valve 859
Removal of Intake throttle valve 859
Installation of Intake throttle valve 859
Removal and Installation of Starter Motor 860
Removal of Starter Motor 860
Installation of Starter Motor 861
Inspection of Starter Motor 861
Removal and Installation of Alternator 863
Removal of Alternator 863
Installation of Alternator 863
Inspection of Alternator 864
Removal and Installation of Glow Plug 868
Removal of Glow Plug 868
Installation of Glow Plug 868
Inspection of Glow Plug 869
Removal and Installation of Suction Control Valve 870
Removal of Suction Control Valve 870
Installation of Suction Control Valve 871
Removal and installation of Fuel Filter 872
Removal of Fuel Filter 872
Installation of Fuel Filter 872
Removal and installation of Relief Valve 875
Removal of Relief valve 875
Installation of Relief valve 875
Removal and installation of Fuel Filter Element 876
Removal of Fuel filter element 876
Installation of Fuel Filter Element 876
Removal and installation of Fuel temperature sensor 880
Removal of Fuel temperature sensor 880
Installation of Fuel temperature sensor 885
Inspection of Fuel temperature sensor 892
Removal and installation of Pressure limiter 893
Removal of Pressure limiter 893
Installation of Pressure limiter 893
Removal and installation of Fuel pressure sensor 894
Removal of Fuel pressure sensor 894
Installation of Fuel pressure sensor 894
Removal and Installation of Fuel filter pressure 895
Fuel filter pressure sensor Removal 895
Fuel filter pressure sensor Installation 895
Removal and Installation of Engine coolant temperature sensor 896
Engine coolant temperature sensor Removal 896
Engine coolant temperature sensor Installation 896
Inspection of Engine coolant temperature sensor 896
Removal and Installation of CKP sensor 898
CKP sensor Removal 898
CKP sensor Installation 898
Inspection of CKP sensor 898
Removal and Installation of CMP sensor 899
CMP sensor Removal 899
CMP sensor Installation 899
Inspection of CMP sensor 899
Removal and Installation of Oil pressure sensor 900
Oil pressure sensor Removal 900
Oil pressure sensor Installation 900
Inspection of Oil pressure sensor 900
Removal and installation of Boost Sensor 902
Removal of Boost sensor 902
Installation of Boost sensor 902
Inspection of Boost sensor 902
Removal and installation of Boost Temperature Sensor 903
Removal of Boost temperature sensor 903
Installation of Boost temperature sensor 903
Removal and installation of Turbocharger control solenoid 904
Removal of Turbocharger control solenoid 904
Installation of Turbocharger control solenoid 904
Inspection of Turbocharger control solenoid 905
Removal and Installation of IMT sensor 906
IMT sensor Removal 906
IMT sensor Installation 906
Removal and installation of MAF and IAT sensor 907
Removal of MAF and IAT sensor 907
Installation of MAF and IAT sensor 907
Inspection of MAF and IAT sensor 907
Removal and installation of Charge Air Cooler Temperature Sensor 1 908
Removal of Charge Air Cooler Temperature Sensor 1 908
Installation of Charge Air Cooler Temperature Sensor 1 908
Inspection of Charge Air Cooler Temperature Sensor 1 908
Sampling Procedure 909
Sampling of Engine Oil 909
Removal and Installation of Exhaust gas temperature sensor 910
Removal of Exhaust gas temperature sensor 910
Installation of Exhaust gas temperature sensor 910
Inspection of Exhaust gas temperature sensor 911
Removal and installation of EGR Gas Temperature Sensor 1 912
Removal of EGR Gas Temperature Sensor 1 912
Installation of EGR Gas Temperature Sensor 1 912
Inspection of EGR Gas Temperature Sensor 1 912
Removal and installation of EGR Gas Temperature Sensor 2 913
Removal of EGR Gas Temperature Sensor 2 913
Installation of EGR Gas Temperature Sensor 2 913
Inspection of EGR Gas Temperature Sensor 2 913
Removal and installation of NOx Sensor 915
Removal of NOx Sensor 915
Installation of NOx Sensor 915
Removal and installation of EGR Gas Temperature Sensor 3 918
Removal of EGR Gas Temperature Sensor 3 918
Installation of EGR Gas Temperature Sensor 3 918
Removal and Installation of Urea sensor 920
Removal of Urea Sensor 920
Installation of Urea Sensor 922
Engine-related Diagnostic Trouble Code List 925
Engine-side Trouble 934
ECM Trouble 934
DTC P0016 Crankshaft Position – Camshaft Position Correlation Error 934
DTC P0045 Turbocharger Boost Control VNT Error 935
DTC P0047 Turbocharger EVRV Control Circuit High 937
DTC P0087 Fuel Rail/System Pressure – Too Low 938
DTC P0089 Fuel Pressure Regulator Performance 941
DTC P0091 Fuel Pressure Regulator Control Circuit Low 942
DTC P0092 Fuel Pressure Regulator Control Circuit High 943
DTC P0097 Intake Air Temperature (IAT) Sensor 2 Circuit Low Voltage 945
DTC P0098 Intake Air Temperature (IAT) Sensor 2 Circuit High Voltage 946
DTC P0102 Mass Air Flow Sensor Circuit Low Input 947
DTC P0103 Mass Air Flow Sensor Circuit High Input 948
DTC P0112 Intake Air Temperature Sensor Circuit Low 949
DTC P0113 Intake Air Temperature Sensor Circuit High 950
DTC P0117 Engine Coolant Temperature Sensor Circuit Low 952
DTC P0118 Engine Coolant Temperature Sensor Circuit High 953
DTC P0122 Throttle Position Sensor Circuit Low 954
DTC P0123 Throttle Position Sensor Circuit High 955
DTC P0182 Fuel Temperature Sensor Circuit Low 956
DTC P0183 Fuel Temperature Sensor Circuit High 957
DTC P0192 Fuel Rail Pressure Sensor Circuit Low 959
DTC P0193 Fuel Rail Pressure Sensor Circuit High 960
DTC P0201 Injector Circuit Open – Cylinder 1 961
DTC P0202 Injector Circuit Open – Cylinder 2 963
DTC P0203 Injector Circuit Open – Cylinder 3 964
DTC P0204 Injector Circuit Open – Cylinder 4 966
DTC P0217 Engine Coolant Over Temperature Condition 967
DTC P0219 Engine Overspeed Condition 968
DTC P0234 Turbocharger Overboost Condition 969
DTC P0237 Turbo Charger Boost Sensor Circuit Low 971
DTC P0238 Turbo Charger Boost Sensor Circuit High 972
DTC P0299 Turbocharger Underboost 973
DTC P0335 Crankshaft Position Sensor Circuit 975
DTC P0336 Crankshaft Position Sensor Circuit Range/Performance 976
DTC P0340 Camshaft Position Sensor Circuit 977
DTC P0380 Glow Relay Circuit Error 979
DTC P0401 EGR Flow Insufficient Detected 980
DTC P0404 EGR Control Circuit Range/Performance 981
DTC P0409 EGR Sensor Circuit 982
DTC P041C EGR Cooler Outlet 1 Temp Sensor Circuit Low 984
DTC P041D EGR Cooler Outlet 1 Temp Sensor Circuit High 985
DTC P0427 Catalyst Temperature Sensor Circuit Low Sensor 1 986
DTC P0428 Catalyst Temperature Sensor Circuit High Sensor 1 987
DTC P042C Catalyst Temperature Sensor Circuit Low Sensor 2 989
DTC P042D Catalyst Temperature Sensor Circuit High Sensor 2 990
DTC P0522 Engine Oil Pressure Sensor Circuit Low Input 991
DTC P0523 Engine Oil Pressure Sensor Circuit High Input 992
DTC P0545 EGR Cooler Inlet 1 Temp Sensor Circuit Low 993
DTC P0546 EGR Cooler Inlet 1Temp Sensor Circuit High 994
DTC P0560 12 Volt Circuit Error 996
DTC P0563 System Voltage High 997
DTC P0601 Internal Control Module Memory Check Sum Error 997
DTC P0602 Internal Control Module QR Code Error 998
DTC P0604 Internal Control Module RAM Error 999
DTC P0606 Internal Control Module CPU Error 999
DTC P060A Internal Control Module CPU IC Error 1000
DTC P060C Internal Control Module A/D Processing Performance 1000
DTC P0615 Starter Relay Circuit Error 1001
DTC P0638 Throttle Actuator Control Range/Performance 1002
DTC P0685 ECM Power Relay Control Circuit Open 1003
DTC P0687 ECM Power Relay Control Circuit High 1004
DTC P06A6 Sensor Reference Voltage 1 Circuit 1005
DTC P06A7 Sensor Reference Voltage 2 Circuit 1006
DTC P06A8 Sensor Reference Voltage 3 Circuit 1007
DTC P06A9 Sensor Reference Voltage 4 Circuit 1008
DTC P06AF Torque Management System – Forced Engine Shutdown 1010
DTC P06D5 Sensor Reference Voltage 5 Circuit 1010
DTC P1076 Charge Air Cooler (CAC) Temperature Sensor 1 Circuit Low Voltage 1011
DTC P1077 Charge Air Cooler (CAC) Temperature Sensor 1 Circuit High Voltage 1012
DTC P1093 Fuel Rail Pressure Too Low 1013
DTC P1097 Compressor Outlet Temperature Sensor Circuit High 1016
DTC P1098 Compressor Outlet Temperature Sensor Circuit High 1017
DTC P1236 Charge Air Cooler Performance Failure 1019
DTC P1261 Injector Positive Voltage Control Circuit Group 1 1020
DTC P1262 Injector Positive Voltage Control Circuit Group 2 1020
DTC P1404 EGR Position Fault 1021
DTC P1606 SW-IC Internal failure 1022
DTC P160B AD-IC Failure Error 1022
DTC P160C AD-IC2 Failure Error 1023
DTC P1621 Control Module Long Term Memory Performance 1023
DTC P1622 Control Module Long Term Memory Hardware 1024
DTC P1669 DPD Lamp Control Circuit 1025
DTC P204F SCR System Error (No Inducement) 1026
DTC P207F Urea Fluid Concentration Too Low 1027
DTC P20C9 SCR System Error 1027
DTC P2122 Pedal Position Sensor 1 Circuit Low Input 1028
DTC P2123 Pedal Position Sensor 1 Circuit High Input 1029
DTC P2127 Pedal Position Sensor 2 Circuit Low Input 1030
DTC P2128 Pedal Position Sensor 2 Circuit High Input 1031
DTC P2138 Pedal Position Sensor 1 – 2 Voltage Correlation 1032
DTC P2146 Fuel Injector Group 1 Supply Voltage Circuit 1033
DTC P2149 Fuel Injector Group 2 Supply Voltage Circuit 1034
DTC P2228 Barometric Pressure Sensor Circuit Low 1035
DTC P2229 Barometric Pressure Sensor Circuit High 1035
DTC P2457 Exhaust Gas Recirculation (EGR) Cooling System Performance 1036
DTC P2458 Purge time Out Error 1037
DTC P2BA7 Urea Fluid Quantity Too Low 1037
DTC P2BAA SCR System Error (Inducement, No Purge) 1038
DTC P3093 Fuel Rail Pressure Too Low 1038
DTC U0001 CAN Bus Error (ISO-CAN) 1041
DTC U0073 Control Module Communication Bus Off 1043
DTC U0101 Lost Communication With CAN 1044
DTC U010E Lost Communications With Dosing Control Module 1045
DTC U0110 Lost Communication With VNT System 1046
DTC U2106 Lost CAN Communications With Wheel Loader Transmission Control System 1047
DTC U0411 Lost CAN Communications With VNT Control Module 1048
DCU Trouble 1048
Diagnostic Trouble Code_P0607: Control Module Characteristic Abnormality　 1048
Diagnostic trouble code_P060B: Control Module A/D Conversion Processing Device Abnormality 1049
Diagnostic trouble code_P062F: Control Module EEPROM Abnormality 1050
Diagnostic trouble code_P0641: Sensor Reference Voltage Abnormality 1051
Diagnostic trouble code_P0658: Actuator Supply Power Feed System Abnormality 1052
Diagnostic trouble code_P0659: Actuator Supply Power Feed System Abnormality 1054
Diagnostic trouble code_P1462: Urea Solution Quality Sensor Time-Out Abnormality 1055
Diagnostic trouble code_P1464: Main Relay Abnormality (Early OPEN Error/Sticking Error of Main Relay) 1056
Diagnostic trouble code_P1468: Urea Solution Injection Control Module (DCM) High Temperature Abnormality 1057
Diagnostic trouble code_P1491: Urea Solution High Pressure Abnormality 1058
Diagnostic trouble code_P1493: Urea Solution Injection Control Module (DCM) Screwdriver High Temperature Abnormality 1059
Diagnostic trouble code_P149C: Urea Solution Reducing Pressure Abnormality 1060
DTC P149D Urea Fluid Tank Overtemperature 1061
Diagnostic trouble code_P2000: Cleaning Ratio Abnormality 1063
Diagnostic trouble code_P203B: Urea Solution Tank Level Sensor 1064
Diagnostic trouble code_P203C: Urea Solution Tank Level Sensor Low Voltage Potential 1066
Diagnostic trouble code_P203D: Urea Solution Tank Level Sensor High Voltage Potential 1067
Diagnostic trouble code_P2048: Urea Solution Injector System Low Voltage Potential 1068
Diagnostic trouble code_P2049: Urea Solution Injector System High Voltage Potential 1069
Diagnostic trouble code_P204B: Urea Solution Pressure Sensor System Characteristic Abnormality 1070
Diagnostic trouble code_P204C: Urea Solution Pressure Sensor System Low Voltage Potential 1071
Diagnostic trouble code_P204D: Urea Solution Pressure Sensor System High Voltage Potential 1072
Diagnostic trouble code_P205B: Urea Solution Tank Temperature Sensor Characteristic Abnormality 1074
Diagnostic trouble code_P205C: Urea Solution Tank Temperature Sensor Low Voltage Potential 1075
Diagnostic trouble code_P205D: Urea solution tank temperature sensor high voltage potential 1076
DTC P206A Urea Fluid Quality Sensor Circuit 1077
Diagnostic trouble code_P206B: Urea Sensor High Temperature Abnormality 1078
DTC P206C Urea Fluid Quality Sensor Circuit Low Voltage 1079
DTC P206D Urea Fluid Quality Sensor Circuit High Voltage 1080
Diagnostic trouble code_P207F: Urea Solution Concentration Low 1080
Diagnostic trouble code_P208A: Urea Solution Pump Control System 1081
Diagnostic trouble code_P208B: Urea Solution Pump Characteristic Abnormality 1082
Diagnostic trouble code_P208C: Urea Solution Pump Control System Low Voltage Potential 1084
Diagnostic trouble code_P208D: Urea Solution Pump Control System High Voltage Potential 1085
Diagnostic trouble code_P208E: Urea Solution Injector Attachment 1086
Diagnostic trouble code_P20A0: Urea Solution Reverting Valve System Disconnection 1087
Diagnostic trouble code_P20A2: Urea Solution Reverting Valve System Low Voltage Potential 1088
Diagnostic trouble code_P20A3: Urea Solution Reverting Valve System High Voltage Potential 1089
Diagnostic trouble code_P20AC: Urea Solution Pump Temperature Sensor Characteristic Abnormality 1090
Diagnostic trouble code_P20AD: Urea Solution Pump Module Temperature Sensor Function 1092
Diagnostic trouble code_P20B1: Urea Solution Tank Heater Coolant Control Valve System Disconnection 1093
Diagnostic trouble code_P20B3: Urea Solution Tank Heater Coolant Control Valve System Low Voltage Potential 1094
Diagnostic trouble code_P20B4: Urea solution tank heater coolant control valve system high voltage potential 1095
Diagnostic trouble code_P20E8: Urea Solution Low Pressure Abnormality 1096
Diagnostic trouble code_P20E9: Urea Solution High Pressure Abnormality 1098
Diagnostic trouble code_P20EA: Urea Solution Reducing Pressure Abnormality 1099
Diagnostic trouble code_P20FE: Urea Solution Build-Up Abnormality 1100
Diagnostic trouble code_P2201: NOx Sensor Upstream Function 1102
Diagnostic trouble code_P2206: Ft NOx Sensor Disconnection 1103
Diagnostic trouble code_P2207: Ft NOx Sensor Short-Circuit 1104
Diagnostic trouble code_P2210: Rr NOx Sensor Disconnection 1104
Diagnostic trouble code_P2211: Rr NOx Sensor Short-Circuit 1105
Diagnostic trouble code_P242B: Exhaust Gas Temperature (EGT) Sensor 3 System Function 1105
Diagnostic trouble code_P242C: Exhaust Gas Temperature (EGT) Sensor 3 System Low Voltage Potential 1106
Diagnostic trouble code_P242D: Exhaust Gas Temperature (EGT) Sensor 3 System High Voltage Potential 1107
DTC U0002 CAN Bus Off 1108
DTC U0100 Lost Communication With ECM 1109
Diagnostic trouble code_U029D: CAN Communication Error Between DCU-Ft NOx Sensors 1110
Diagnostic trouble code_U029E: CAN Communication Error Between DCU-Rr NOx Sensors 1113
J HYDRAULIC EQUIPMENT (PUMP, OPERATION SYSTEM VALVE) 1115
Main Equipment Table 1121
Hydraulic Device 1121
Hydraulic Pump (LC) 1121
Hydraulic Pump (Blade) 1121
Control-related 1122
Control Valve (LC) 1122
Control valve (Blade) 1122
Solenoid Valve (4 stack) 1123
Remote Control Valve for Left/Right Operations 1123
Remote Control Valve for Travel Operation 1123
Valve for Blade Operation 1123
Remote Control Valve Characteristic Diagram 1124
Operation Remote Control Valve Control Diagram 1124
Travel Remote Control Valve Control Diagram 1125
Blade Remote Control Valve Control Diagram 1125
Cushion Valve (with Heat Circuit, Shuttle Valve) 1126
Selector Valve 1126
Relief Valve (Electromagnetic Proportional) 1126
Basic Functions 1127
Oil temperature gauge 1127
Static Horsepower Control 1129
Overload Warning (Function for Europe Only) 1131
Pressure Boost Control 1132
Stroke Control 1135
Boom Down Energy Save 1137
Pump Horsepower Boost Control 1138
Arm 1 Semi-parallel Control 1139
Arm 2 Semi-parallel Control 1140
Hot Shutdown Warning 1141
Gate Lock 1143
Breaker Mode 1145
Crusher Mode 1147
Quick coupler 1148
Hydraulic Oil Filter Clog 1149
Solenoid Sticking Prevention 1150
Port Diagram 1151
Hydraulic Pump (standard model) 1151
Hydraulic Pump (Blade) 1153
Control valve 1155
4 Stack Solenoid Valve 1158
2 Stack Solenoid Valve 1159
Remote Control Valves (upper, travel) 1160
Remote Control Valves (left and right) 1160
Remote control valve (travel) 1160
Remote Control Valve (blade) 1161
Cushion valve 1161
2-way Selector Valve 1162
Direction Valve 1162
Reducing valve (4-line) 1163
Relief Valve (electromagnetic proportional) 1164
Manifold Under Cab 1164
Manifold (accumulator section) 1165
Hydraulic tank 1166
Hydraulic Pump 1167
Type Indication 1167
Specifications 1167
Structure and Operation Explanation 1168
Hydraulic Circuit Diagram 1169
Hydraulic Pump Internal Structure Diagram 1170
Overall View 1170
Drive Shaft Front Side 1174
Drive Shaft Rear Side 1175
Development Diagram 1176
Part Table 1178
Regulator 1179
Regulator Operation Explanation 1179
Regulator Operation Explanation Diagram 1182
Internal Configuration Diagram of Regulator 1185
Development Diagram of Regulator 1187
Component Table 1189
Operation Outline of Electronically-Controlled Pump 1190
Control Valve 1193
Basic Configuration 1193
Operation 1193
Operation of Main Unit 1193
Activation of Relief Valve 1209
4 Stack Solenoid Valve Operation Explanation 1214
External Shape Diagram and Component Parts 1214
Operation Explanation 1215
Upper Pilot Valve (remote control valve) 1216
Structure 1216
Function 1216
Operation 1217
Structural Diagram 1221
Travel Pilot Valve (remote control valve) 1222
Operation 1222
Pressure Reducing Valve Section 1223
Damping Mechanism in Operation Section 1223
Structural Diagram 1226
Cushion Valve 1228
Structure 1228
Operation Explanation 1229
Selector Valve (2-way) 1232
Structure 1232
Operation Explanation 1233
Development Diagram 1234
Direction Valve (3-direction) 1235
Structure 1235
Operation Explanation 1236
Electromagnetic Relief Valve 1238
Structure 1238
Operation Explanation 1239
Operation of Check Valve 1239
Operation of Electromagnetic Relief Valve 1240
Removal and Installation of Hydraulic Reservoir 1242
Removal of Hydraulic Reservoir 1242
Installation of Hydraulic Tank 1245
Removal and Installation of Hydraulic Pump 1246
Removal of Hydraulic Pump 1246
Installation of Hydraulic Pump 1247
Removal and Installation of Pump coupling 1249
Removal of Pump Coupling 1249
Installation of Pump Coupling 1249
Removal and Installation of Control Valve 1251
Removal of Control Valve 1251
Installation of Control Valve 1256
Removal and Installation of Travel Remote Control Valve 1257
Removal of Travel Remote Control Valve 1257
Installation of Travel Remote Control Valve 1258
Removal and Installation of Operation Remote Control Valve 1261
Removal of Operation Remote Control Valve (left side) 1261
Installation of Operation Remote Control Valve (left side) 1263
Removal of Operation Remote Control Valve (right side) 1264
Installation of Operation Remote Control Valve (right side) 1266
Removal and Installation of 4 Stack Solenoid 1269
Removal of 4 Stack Solenoid Valve 1269
Installation of 4 Stack Solenoid Valve 1270
Removal and Installation of Cushion Valve 1271
Removal of Cushion Valve 1271
Installation of Cushion Valve 1272
Removal and Installation of 4 Stack Reducing Valve 1273
Removal of 4 Stack Reducing Valve 1273
Installation of 4 Stack Reducing Valve 1274
Procedures for Assembly and Disassembly of Hydraulic Pump Main Unit 1275
Tools 1275
Disassembly Procedure 1276
Assembly Procedure 1278
Pump Main Unit Maintenance Standards 1282
Replacement standards for worn parts 1282
Standards for repairing cylinders, valve plates, and swash plates (shoe plates) 1282
Tightening torque 1283
Overall View 1283
Drive Shaft Front Side 1287
Drive Shaft Rear Side 1288
Development Diagram 1289
Part Table 1291
Causes of Failures, and Actions 1292
Regulator Adjustment 1293
Appendix Table and Drawings 1295
Regulator Assembly and Disassembly Procedures 1298
Tools 1298
Preparations for Disassembly 1298
Disassembly Procedure 1298
Assembly Procedures 1300
Internal Configuration Diagram of Regulator 1303
Development Diagram of Regulator 1305
Component Table 1307
Procedures for Assembly and Disassembly of Control Valve 1308
Disassembly 1308
Caution for Disassembly 1308
Disassembly Procedure 1308
Cleaning 1311
Inspection 1311
Assembly 1311
Internal Structural Diagram 1316
part list 1322
Relief Valve 1324
Assembly and Disassembly Procedure of Main Relief Valve 1324
Assembly and Disassembly Procedures of Overload Relief 1325
Assembly and Disassembly Procedure of Main Relief Valve for Add-On 1326
Assembly and Disassembly Procedure of Negative Control Relief Valve 1327
Adjustment of Relief Valve 1327
Installation 1328
Operation 1328
Malfunction and Countermeasure 1328
Procedures for Assembly and Disassembly of Operation Remote Control Valve 1330
Maintenance Procedures 1330
Required Tools and Tightening Torque 1330
Maintenance Standards 1331
Disassembly Procedures 1332
Assembly Procedures 1334
Causes of Trouble and Countermeasures 1337
Procedures for Assembly and Disassembly of Travel Remote Control Valve 1341
Maintenance Procedures 1342
Disassembly Procedures 1342
Assembly Procedures 1346
Causes of Trouble and Countermeasures and Cross-section Diagram 1351
Assembly and Disassembly of Cushion Valve 1354
Disassembly Procedures 1354
Reverse Operation Spool 1354
Check Plunger With Orifice 1354
Shuttle valve 1354
Assembly Procedures 1355
Reverse Operation Spool 1355
Check Plunger with Orifice 1355
Shuttle Valve 1356
Document 1357
Pressure Measurement and Adjustment Procedures 1360
Procedures for Pressure Measurement from the Monitor Display 1360
Monitor and Switch Panel 1360
Pressure Measurement Method 1360
Operating Method 1360
PROCEDURES FOR MEASURING HYDRAULIC OIL TEMPERATURE FROM THE MONITOR DISPLAY 1362
Hydraulic Oil Temperature Measurement Method 1362
Operating Method 1362
Procedures for Pressure Measurement by Installing Pressure Gauge 1363
Preparations 1363
Items to Prepare 1363
Pressure Measuring Port 1364
Control Valve 1366
Location of Relief Valves 1366
Pressure Measurement Preparations 1368
Pressure Measurement 1370
Main Pressure Measurement 1370
A Attachment Pressure Measurement 1371
Boom-down Pressure Measurement 1372
D Option Line Pressure Measurement 1372
Pilot Pressure Measurement 1372
Pressure Gauge Installation 1372
Negative Control Pressure Measurement 1373
Pressure Gauge Installation 1373
Pressure Adjustment 1373
Main Pressure Adjustment 1373
Pressure Measurement and Adjustment Preparations 1373
Main Relief Pressure Adjustment 1374
Overload Relief Pressure Adjustment 1375
Adjustment of Swing Relief Pressure 1376
Pilot Pressure Adjustment 1376
Hydraulic Pump Flow Measurement Procedures 1377
Preparations 1377
Items to Prepare 1377
Work Preparations 1378
Flow Measurement 1379
Air Bleed Procedure 1381
Hydraulic Pump 1381
Sampling Procedure 1382
Sampling of Hydraulic Fluid 1382
Hydraulic Equipment Layout 1383
Overall View 1384
Pump Chamber Hydraulic Equipment Layout 1385
Swing Body Center Section Hydraulic Equipment Layout 1386
Housing Left Side Hydraulic Equipment Layout 1387
Layout of Hydraulic Equipment in Cab 1388
N CAB 1389
Removal and Installation of Operator’s Seat 1392
Removal of Operator’s Seat 1392
Installation of Operator’s Seat 1392
Removal and Installation of Cab Assembly 1393
Removal of Cab Assembly 1393
Installation of Cab Assembly 1396
Removal and Installation of Wiper 1397
Removal of Wiper 1397
Installation of wiper 1397
Removal and Installation of Cab Windshield 1398
Removal of Cab Windshield 1398
Installation of Cab Front Glass 1398
Window Lock Adjustment Procedure 1399
Window Lock (front side) 1399
Window Lock (rear side) 1399
Removal and Installation of Housing Guardrail 1400
Removal of Housing Guardrail 1400
Installation of Housing Guardrail 1400
Tightening torque 1401
R ELECTRICAL PARTS 1403
Basic Functions 1407
Monitor Control 1407
Monitor Display Dimming 1407
Diagnostic trouble code indicator 1408
Clock 1409
Basic Operation 1410
Battery save 1410
Accessories 1411
Working Light 1411
LED Light 1413
Room Lamp 1414
Radio mute 1416
Wiper and Washer 1418
Safety 1422
Horn 1422
Back/Side View Monitor 1423
Precautions for Camera Installation 1425
Switching of Camera Input 1425
Maintenance 1429
Anti-theft 1429
Manual Lock 1429
Service Support Screen Lock 1430
Customer-specific System Information Screen Lock 1430
Maintenance Information Screen Lock 1431
Option Line Setting Screen Lock 1431
Setting 1432
Clock Adjustment 1432
Screen Brightness Setting 1432
Battery disconnect switch 1434
Explanation of Controller 1435
Service Support 1438
Screen Operations 1438
Screen Display List 1438
Service Monitor Structure 1440
CHECK Screen List 1442
MACHINE STATUS 1443
HYDRAULIC STATUS 1456
ENGINE STATUS 1472
FAULT HISTORY 1479
WORK HISTORY 1480
HYDRAULIC HISTORY 1494
ENGINE HISTORY 1516
DEVICE TEST 1548
ECM/DCU Memory Clear 1548
SCR Regeneration 1550
Urea line leak test 1552
CCV Operation Test 1553
Dosing test 1554
Reverting valve test 1555
Common rail pressure test 1556
Idle speed test/injector test 1557
EGR valve control test 1559
VG turbo control test 1560
Intake throttle control test 1561
Turbo Boost Pressure Test 1562
CONTROL UNIT Screen List 1563
MCM-MAIN 1564
MCM-SUB1 1573
COMMU TERMINAL 1577
MONITOR 1580
SETUP Screen List 1581
MACHINE SELECT 1582
DIMENSIONS 1587
PARAMETERS 1591
ENGINE INFORMATION 1604
ENGINE INFORMATION 1605
Data check 1605
Data transfer (copy) 1605
QR (INJECTOR) CODE 1606
Injector number 1606
Screen Layout 1607
Data Source Selection 1607
Manual Input 1607
Message Area 1608
CAMERA 1609
PASSWORD 1615
CALIBRATE Screen List 1619
THROTTLE VOLUME 1619
OPT LINE RELIEF 1621
PUMP FLOW 1623
RESET Screen List 1625
Connection Connector Pin Layout 1628
Main Controller 1628
Monitor 1629
Sequence Circuit Diagram 1630
Code List 1630
Overall 1633
Block diagram 1636
Main controller 1636
DCU 1637
ECM 1638
Monitor 1639
Air conditioner 1639
Gate Lock 1640
Option 1640
Others 1641
Electrical Symbol List 1642
Electrical Equipment Layout Diagram 1643
Main Unit Left-side Layout Diagram 1644
Engine Section Layout Diagram 1646
Main Unit Right Rear Section Layout Diagram 1649
Main Unit Right Front Section Layout Diagram 1650
Cab Layout Diagram 1 1652
Cab Layout Diagram 2 1654
Layout Around Operator Seat 1658
Stand Alone Parts Diagram 1660
Removal and Installation of Wiper Controller 1682
Removal of Wiper Controller 1682
Installation of wiper controller 1682
Removal and Installation of Wiper Motor 1683
Removal of Wiper Motor 1683
Installation of wiper motor 1684
Removal and Installation of ECM 1685
Removal of ECM 1685
Installation of ECM 1685
Removal and Installation of Main Controller 1686
Main controller Removal 1686
Installation of Main Controller 1686
Removal and Installation of DCU 1687
Removal of DCU 1687
Installation of DCU 1687
Removal and Installation of Monitor 1688
Removal of Monitor 1688
Installation of Monitor 1689
Removal and Installation of Rear View Camera 1690
Removal of Rear View Camera 1690
Installation of Rear View Camera 1690
Removal and Installation of Side Camera (Right) 1691
Removal of Side Camera (Right) 1691
Installation of Side Camera (Right) 1691
Removal and Installation of Side Camera (Left) 1692
Removal of Side Camera (Left) 1692
Installation of Side Camera (Left) 1693
Removal and Installation of Ambient light 1694
Removal of Ambient Light 1694
Installation of Ambient Light 1695
Removal and Installation of WAVES Controller 1696
Removal of WAVES Controller 1696
Installation of WAVES Controller 1696
How to Set WAVES 1697
Air Conditioner Overall Diagram 1701
Frame 1701
Cab 1704
Equipment Layout Diagram 1707
Circuit Diagram 1709
Air Conditioner Circuit Diagram 1709
Explanation of Functions 1712
Explanation of Control 1712
Air Mix Motor Actuator Control 1713
Blow Mode Motor Actuator Control 1714
Refresh/Recirculate Switch Motor Actuator Control 1715
Blower Amp Control 1716
Compressor Clutch Control 1719
COOLMAX Control and HOTMAX Control 1720
Abnormality Detection and Control after Abnormality Detected 1720
Monitor Mode 1724
Door Switch Control 1726
Actuator Inspection 1727
Air Mix Motor Actuator Inspection 1727
Refresh/Recirculate Switch Motor Actuator Inspection 1728
Mode Motor Actuator Inspection 1729
Self-diagnosis Function with Panel Display 1730
Abnormality Display and Self-check Procedures 1730
Abnormality Display Position 1730
Explanation of Abnormality Display 1730
Motor Actuator Abnormality 1730
Sensor Abnormality 1731
Explanation of Monitor Mode 1731
Monitor Mode Display Position 1731
Monitor Mode Display Operating Method 1732
Display Contents in Monitor Mode 1734
Air Conditioner Troubleshooting 1735
Part Function and Good/Poor Judgment 1740
Control Panel 1740
Blower Amp 1741
Relay 1742
Air Mix Actuator 1743
Refresh/Recirculate Actuator 1744
Mode switch actuator 1744
Evaporator Sensor 1745
Dual Pressure Switch 1746
Solar Radiation Sensor 1747
Inside Air Sensor 1747
Assembly and Disassembly of Unit 1748
Removal of Blower Unit 1748
Replacement of Blower Motor 1748
Replacement of Blower Amp 1749
Removal of Heater Core 1749
Removal of Switchover BOX 1750
Replacement of Evaporator and Expansion Valve 1750
Installation of Evaporator Sensor 1751
Replacement of Motor Actuator 1751
Removal and Installation of Compressor 1753
Removal of Compressor 1753
Installation of Compressor 1753
Removal and Installation of Condenser 1754
Removal of Condenser 1754
Installation of Condenser 1755
Removal and Installation of Receiver Dryer 1756
Removal of Receiver Dryer 1756
Installation of Receiver Dryer 1757
Work Precautions 1758
Work Procedures 1759
Air Conditioner Refrigerant Filling is Divided into the “Vacuum Operation” and “Gas Filling Operation” 1759
Operation Chart 1759
Tools 1760
Filling Procedures 1761
Charging Hose Connection Position 1761
Connecting Gauge Manifold 1762
Vacuuming 1763
Gas Filling Operation, High-pressure Side 1764
Gas Filling Work, Low Pressure Side 1765
V ATTACHMENTS 1767
Main Equipment Table 1771
Backhoe Attachment 1771
Cylinder 1771
Cylinder (Blade) 1771
Maintenance Standards 1772
Attachment (Backhoe) 1772
1 Boom and Swing Frame Installation Section 1773
2 Boom Cylinder and Swing Frame Installation Section 1774
3 Boom and Boom Cylinder Installation Section 1775
4 Boom and Arm Cylinder Installation Section 1776
5 Boom and Arm Installation Section 1777
6 Arm and Arm Cylinder Installation Section 1778
7 Arm and Bucket Cylinder Installation Section 1779
8 Arm and Arm Link Installation Section 1780
9 Bucket and Bucket Link Installation Section 1781
10 Bucket Link and Bucket Cylinder Installation Section 1782
11 Bucket and Arm Installation Section 1783
Dozer Blade 1784
1 Blade Cylinder Installation Section 1784
2 Lower Frame and Blade Cylinder Installation Section 1785
3 Lower Frame and Blade Installation Section 1785
Removal and Installation of Bucket Cylinder 1786
Removal of Bucket Cylinder 1786
Installation of Bucket Cylinder 1788
Removal and Installation of Arm Cylinder 1789
Removal of Arm Cylinder 1789
Installation of Arm Cylinder 1791
Removal and Installation of Boom Cylinder 1794
Removal of Boom Cylinder 1794
Installation of Boom Cylinder 1796
Removal and Installation of Blade Cylinder 1798
Removal of Blade Cylinder 1798
Installation of Blade Cylinder 1800
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder 1802
Specifications and Structure Diagram (including the assembly diagram and parts table) 1802
Basic Functions 1802
Function of Each Location 1802
Cylinder Head Assembly (made by KYB) 1803
Piston Assembly (made by KYB) 1804
Pipe Assembly (made by KYB) 1806
Handling Precautions 1807
Precautions for Installing the Cylinder on the Machine Body 1807
Usage Cautions 1807
Maintenance and Inspection Cautions 1808
Maintenance Inspection and Service 1809
Trouble Diagnostics 1810
Storage Standards 1815
Storing Parts Individually (In principle, store indoors ) 1815
When Mounted on Vehicle Body 1815
Recommended Anti-rust Oil 1816
Assembly and Disassembly Procedures 1816
Preparations ····· Prepare the Following before Starting Disassembly 1816
General Work Precautions 1816
Maintenance Standards 1817
Inspection after Assembly 1817
Required Tool 1818
General Tool 1818
Special Jig (made by KYB) 1819
Special Jig Parts Number List (made by KYB) 1820
Disassembly Procedures (made by KYB) 1821
Assembly Procedures (made by KYB) 1824
Test Operation 1828
Usage Limits 1829
Structural Diagram (made by KYB) 1831
Boom Cylinder 1831
Arm Cylinder 1833
Bucket Cylinder 1835
Blade Cylinder 1837
HBCV 1839
structure 1839
Function 1839
operation explanation 1840
Port Diagram 1855
HBCV 1855
Air Bleed Procedure 1856
HBCV 1856
Boom Cylinder HBCV 1856
Arm Cylinder HBCV 1857
Removal and Installation of HBCV 1858
Removal and Installation of Arm HBCV 1859
Removal of arm HBCV 1859
Installation of Arm HBCV 1859
Removal and Installation of Boom HBCV 1860
Removal of Boom HBCV 1860
Installation of boom HBCV 1861
Removal and Installation of Bucket 1862
Removal of Bucket 1862
Installation of Bucket 1862
Removal and Installation of Bucket Link 1864
Removal of Bucket Link 1864
Installation of Bucket Link 1864
Removal and Installation of Arm 1866
Removal of Arm 1866
Installation of Arm 1867
Removal and Installation of Boom 1868
Removal of Boom 1868
Installation of Boom 1870
Removal and Installation of Blade 1873
Removal of Blade 1873
Blade Installation 1874
Z OTHER 1875
Change from Type 6 1880
Overall Layout 1880
Engine 1880
Hydraulic-related Data 1882
Oil Pressure Control 1883
Cab, House 1884
Electrical Data 1884
Electric Control 1885
Specifications (145X4) (LC Specifications) 1886
ENGINE 1886
HYDRAULIC SYSTEM 1886
HYDRAULIC CONTROLS 1887
ELECTRICAL SYSTEM 1887
OPERATOR ENVIRONMENT 1888
UNDERCARRIAGE 1889
MASS 1889
DIGGING FORCE (with 0 5 m3 Sumitomo Bucket) (ISO 6015) 1890
DIMENSIONS 1890
WORKING RANGES 1890
SYSTEM FLUID CAPACITIES AND SPECIFICATIONS 1891
Specifications (145X4) (Blade Specifications) 1892
ENGINE 1892
HYDRAULIC SYSTEM 1892
HYDRAULIC CONTROLS 1893
ELECTRICAL SYSTEM 1894
OPERATOR ENVIRONMENT 1894
UNDERCARRIAGE 1895
DOZER BLADE 1895
MASS 1895
DIGGING FORCE (with 0 5 m3 Sumitomo Bucket) (ISO 6015) 1896
DIMENSIONS 1896
WORKING RANGES 1896
SYSTEM FLUID CAPACITIES AND SPECIFICATIONS 1897
Arm Dimensions 1898
Standard Arm [2 50 m (8 2021 ft )] 1898
Short Arm [2 11 m (6 9226 ft )] 1900
Long Arm [3 01 m (9 8753 ft )] 1902
Main Unit Weight 1904
Divided Weight (LC Specifications) 1904
Divided Weight (Blade Specifications) 1905
Stand Alone Part Weight 1906
Stand Alone Part Weight 1906
Shoe Weight (per Side) (LC Specifications) 1906
Shoe Weight (per Side) (Blade Specifications) 1907
Arm Weight 1907
Bolt Size and Torque Table 1908
Special Torque Setting 1908
Overall View 1913
145X4 (LC Specifications) (Grouser Shoe) 1913
Standard Arm [2 50 m (8 2021 ft )] 1914
Long Arm [3 01 m (9 8753 ft )] 1915
Short Arm [2 11 m (6 9226 ft )] 1916
145X4 (LC Specifications) (Link Chain) 1917
Standard Arm [2 50 m (8 2021 ft )] 1917
Long Arm [3 01 m (9 8753 ft )] 1918
Short Arm [2 11 m (6 9226 ft )] 1919
145X4 (Blade Specifications) (Grouser Shoe) 1920
Standard Arm [2 50 m (8 2021 ft )] 1920
Long Arm [3 01 m (9 8753 ft )] 1921
Short Arm [2 11 m (6 9226 ft )] 1922
145X4 (Blade Specifications) (Link Chain) 1923
Standard Arm [2 50 m (8 2021 ft )] 1923
Short Arm [2 11 m (6 9226 ft )] 1924
Long Arm [3 01 m (9 8753 ft )] 1925
WORK RANGE DIAGRAM 1926
145X4 (LC Specifications) 1926
Standard Arm [2 50 m (8 2021 ft )] 1926
Long Arm [3 01 m (9 8753 ft )] 1928
Short Arm [2 11 m (6 9226 ft )] 1930
145X4 (Blade Specifications) 1932
Standard Arm [2 50 m (8 2021 ft )] 1932
Long Arm [3 01 m (9 8753 ft )] 1934
Short Arm [2 11 m (6 9226 ft )] 1936
New Machine Performance Judgment Table 1938
Table of Standards 1938
Measurement Method 1941
Engine Speed 1941
Pressure in Each Section 1941
Pump command displacement 1941
Cylinder Falling Amount 1942
Attachment Speed 1942
Swing Speed 1943
Swing (180°) Brake Angle 1943
Travel Speed 1943
Travel Deviation 1944
Travel Sprocket Speed 1945
Shoe Tension Amount 1945
Swing Ball Race Bearing Movement Amount and Bucket Tip Movement Amount 1946
FLUIDS AND LUBRICANTS 1948
HYDRAULIC FLUID 1948
Engine Oil 1948
Fuel 1948
Conditions applicable to diesel fuel 1948
Recommended conditions applicable to diesel fuels 1948
Main-Unit-related Diagnostic Trouble Code List 1949
Main Unit-side Trouble 1952
Diagnostic Trouble Code: 7000 Pressure Sensor P1 Abnormality 1952
Diagnostic Trouble Code: 7001 Pressure Sensor P2 Abnormality 1954
Diagnostic Trouble Code: 7002 Pressure Sensor N1 Abnormality 1956
Diagnostic Trouble Code: 7003 Pressure Sensor N2 Abnormality 1958
Diagnostic Trouble Code: 7004 Pressure sensor Boom Cylinder Bottom Abnormality 1960
Diagnostic Trouble Code: 7007 Pressure Sensor Arm Cylinder Rod Abnormality 1962
Diagnostic Trouble Code: 7021 Pressure sensor swing pilot abnormality 1964
Diagnostic Trouble Code: 7023 Pressure sensor arm-in pilot abnormality 1966
Diagnostic Trouble Code: 7040 Level Sensor Fuel Abnormality 1968
Diagnostic Trouble Code: 7041 Temperature sensor hydraulic oil abnormality 1970
Diagnostic Trouble Code: 7065 Pressure sensor boom-up pilot abnormality 1972
Diagnostic Trouble Code: 7067 Pressure sensor bucket-close pilot abnormality 1974
Diagnostic Trouble Code: 7068 Pressure sensor boom-down pilot abnormality 1976
Diagnostic Trouble Code: 7069 Pressure sensor arm-out pilot abnormality 1978
Diagnostic Trouble Code: 7070 Pressure sensor bucket-open pilot abnormality 1980
Diagnostic Trouble Code: 7071 Pressure Sensor Travel Right Pilot Abnormality 1982
Diagnostic Trouble Code: 7072 Pressure Sensor Travel Left Pilot Abnormality 1984
Diagnostic Trouble Code: 7074 Pressure Sensor 1st Option Pilot (Common/Front Press) Abnormality 1986
Diagnostic Trouble Code: 7075 Pressure Sensor Arm Cylinder Bottom Abnormality 1988
Diagnostic Trouble Code: 7078 Pressure Sensor 1st Option Pilot (Back Press) Abnormality 1990
Diagnostic Trouble Code: 7200 Swing Brake Solenoid Abnormality 1992
Diagnostic Trouble Code: 7201 Travel 2nd Speed Switchover Solenoid Abnormality 1994
Diagnostic Trouble Code: 7202 Pressure Boost Solenoid Abnormality 1995
Diagnostic Trouble Code: 7203 Travel Alarm Buzzer Abnormality 1996
Diagnostic Trouble Code: 7206 Option Return Line Switchover Solenoid Abnormality 1998
Diagnostic Trouble Code: 7207 Free Swing Solenoid Abnormality 2000
Diagnostic Trouble Code: 7213 Quick Coupler Buzzer Abnormality 2002
Diagnostic Trouble Code: 7214 Quick Coupler Solenoid Abnormality 2004
Diagnostic Trouble Code: 7247 Boom-2 Down Pilot Proportional Valve Abnormality 2006
Diagnostic Trouble Code: 7249 Bucket-close Pilot Proportional Valve Abnormality 2008
Diagnostic Trouble Code: 7250 Option Relief Pressure Proportional Valve Abnormality 2010
Diagnostic Trouble Code: 7265 Arm 1 Semi-Parallel Proportional Valve Abnormality 2012
Diagnostic Trouble Code: 7270 Tilting 1 Proportional Valve Abnormality 2014
Diagnostic Trouble Code: 7271 Tilting 2 Proportional Valve Abnormality 2016
Diagnostic Trouble Code: 7273 Straight Travel Proportional Valve Abnormality 2018
Diagnostic Trouble Code: 7400 Coolant Temperature Overheating 1 2020
Diagnostic Trouble Code: 7401 Coolant Temperature Overheating 2 2021
Diagnostic Trouble Code: 7404 Oil Temperature Overheating 2022
Diagnostic Trouble Code: 7405 Boost Temperature Overheating 1 2023
Diagnostic Trouble Code: 7406 Boost Temperature Overheating 2 2024
Diagnostic Trouble Code: 7420 Alternator Power Generation Defect 2026
Diagnostic Trouble Code: 7421 Decrease in Coolant Level 2028
Diagnostic Trouble Code: 7422 Decrease in Engine Oil Pressure 2029
Diagnostic Trouble Code: 7423 Air Cleaner Clogging 2030
Diagnostic Trouble Code: 7424 Return Filter Clogging 2031
Diagnostic Trouble Code: 7426 Fuel Filter Clogging 1 2032
Diagnostic Trouble Code: 7427 Fuel Filter Clogging 2 2034
Diagnostic Trouble Code: 7428 Inducement (Remaining Urea Level Low) – Warning 2036
Diagnostic Trouble Code: 7429 Inducement (Remaining Urea Level Low) – Early 2037
Diagnostic Trouble Code: 7430 Inducement (Remaining Urea Level Low) – Final 2038
Diagnostic Trouble Code: 7602: ECM Communication Abnormality 2039
Diagnostic Trouble Code: 7605 ECM Not Matched 2041
Diagnostic Trouble Code: 7606 EEPROM Abnormality 2042
Diagnostic Trouble Code: 7608 Camera Abnormality 2043
Diagnostic Trouble Code: 7612 Air Conditioner Communication Abnormality 2054
Diagnostic Trouble Code: 7613 Monitor communication (CAN) abnormality 2056
Diagnostic Trouble Code: 7618 DCU Communication Abnormality 2058
List of special tools 2060
NUMERICAL VALUE CONVERSION TABLE 2060
Unit Conversion Ratio 2060
Length 2061
Area 2064
Volume 2065
Weight 2067
Pressure 2069
Torque 2071
Temperature 2073
A 2075
Travel Motor Special Tool 2075
145X4 2075
Take-up Roller Special Tool 2080
145X4 2080
Upper Roller Special Tool 2081
130X4/145X4 2081
Lower Roller Special Tool 2082
130X4/145X4 2082
C 2083
Swing Motor Special Tool 2083
145X4 2083
H 2084
Engine Oil Filter Special Tool 2084
130X4/145X4/160X4 2084
Fuel Filter Special Tool 2084
130X4/145X4/160X4 2084
Injector Special Tool 2085
130X4/145X4/160X4 2085
Circuit Test Special Tool 2085
130X4/145X4/160X4 2085
Valve Guide Special Tool 2085
130X4/145X4/160X4 2085
Cylinder Head Special Tool 2086
130X4/145X4/160X4 2086
Head Bolt Special Tool 2087
130X4/145X4/160X4 2087
Crankshaft Special Tool 2088
130X4/145X4/160X4 2088
Valve Spring Special Tool 2089
130X4/145X4/160X4 2089
J 2090
Remote Control Valve Special Tool 2090
130X4/145X4 2090
R 2092
Gas Filling Special Tool 2092
130X4/145X4 2092
V 2093
Attachment Special Tool (for Cylinder Assembly) 2093
Special Jigs Part Number List 2093
Paint Colors 2095
Abbreviation 2097

PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

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