Linkbelt 3740 DL 3740 HP 3740 RB 3740 TL Excavator Service Manual WLSM2507TL-03LX – PDF DOWNLOAD

Description

Linkbelt 3740 DL 3740 HP 3740 RB 3740 TL Excavator Service Manual WLSM2507TL-03LX – PDF DOWNLOAD

FILE DETAILS:

Linkbelt 3740 DL 3740 HP 3740 RB 3740 TL Excavator Service Manual WLSM2507TL-03LX – PDF DOWNLOAD

Language : English
Pages : 2036
Downloadable : Yes
File Type : PDF
Size: 109 MB

IMAGES PREVIEW OF THE MANUAL:

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DESCRIPTION:

Linkbelt 3740 DL 3740 HP 3740 RB 3740 TL Excavator Service Manual WLSM2507TL-03LX – 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.

TABLE OF CONTENTS:

Linkbelt 3740 DL 3740 HP 3740 RB 3740 TL Excavator Service Manual WLSM2507TL-03LX – PDF DOWNLOAD

Excavator 1
SAFETY 9
Safety, general information and standard torque data 12
General Information 13
Safety 13
Standard Torque Data For Cap Screws And Nuts 16
Bolt and Nut Tightening 16
Removal of Under Cover 17
Protection of Electric/Electronics System During Charging or Welding 20
A LOWER 21
Main Equipment Table 25
Lower Component 25
Travel Unit 25
Take-up Roller 25
Upper Roller 25
Lower Roller 25
Recoil spring 25
Shoe 25
Center Joint 26
Main Equipment Structure and Operation Explanation 27
Travel Motor 27
Travel motor operation explanation 27
Motor Component Devices and Basic Functions 27
Component Device Functions 27
Component Device Configurations 27
Explanation of Component Device Operation 29
Internal Structure Diagram 46
Port Diagram 51
Travel Motor 51
Center Joint 51
Basic Functions 52
Travel Speed Selection 52
Travel Alarm 53
Removal and Installation of Track 54
Removal and Installation of Shoe Assembly 54
Removal of Shoe Assembly 54
Installation of Shoe Assembly 55
Removal and Installation of Shoe Plate 57
Removal of Shoe Plate 57
Installation of Shoe Plate 57
Precautions for Shoe Bolt Installation 58
Removal and Installation of Step 59
Removal of Step 59
Installation of Step 59
Removal and Installation of Paddle 60
Removal of Paddle 60
Installation of Paddle 60
Removal and Installation of Roller 61
Removal and Installation of Upper Roller 61
Removal of Upper Roller 61
Installation of Upper Roller 62
Assembly and Disassembly of Upper Roller 63
Configuration Diagram 63
Dimension Diagram 64
Jig Dimension Diagram 64
Disassembly Procedures 65
Assembly Procedures 67
Removal and Installation of Lower Roller 70
Removal of Lower Roller 70
Installation of Lower Roller 71
Assembly and Disassembly of Lower Roller 72
Configuration Diagram 73
Dimension Diagram 73
Jig Dimension Diagram 74
Disassembly Procedures 74
Assembly Procedures 76
Removal and Installation of Drive Sprocket 80
Removal of Drive Sprocket 80
Installation of Drive Sprocket 81
Removal and Installation of Take-up Roller 82
Removal of Take-up Roller 82
Installation of Take-up Roller 83
Assembly and Disassembly of Take-up Roller 84
Configuration Diagram 84
Dimension Diagram 85
Jig Dimension Diagram 85
Disassembly Procedures 86
Assembly Procedures 87
Removal and Installation of Grease Cylinder 90
Removal of Grease Cylinder 90
Installation of Grease Cylinder 91
Assembly and Disassembly of Grease Cylinder 92
Configuration Diagram 92
Dimension Diagram 92
Jig Dimension Diagram 93
Disassembly Procedures 93
Assembly Procedures 94
Removal and Installation of Center Joint 96
Removal of Center Joint 96
Installation of Center Joint 98
Assembly and Disassembly of Center Joint 100
Configuration Diagram 101
Dimension Diagram 102
Jig Dimension Diagram 103
Disassembly Procedures 103
Assembly Procedures 104
Removal and Installation of Travel Motor 107
Removal of Travel Motor 107
Installation of Travel Motor 109
Assembly and Disassembly of Travel Motor 112
Tools for Assembly and Disassembly 112
Standard Tools 112
Secondary Materials 113
Special Tool 114
Measurement Device 122
Disassembly of Motor 123
Maintenance Standards 136
Assembly of Motor 142
Angled Breakdown Diagram 159
Internal Structure Diagram 163
Part Table 166
Maintenance Standards 168
Drive sprocket 168
Take-up Roller 169
Upper roller 170
Lower Roller 171
Track Shoe (Grouser Shoe) 172
Inspection Gauge 173
For Drive Sprocket 173
For Take-up Roller 173
For Upper Roller 174
For Lower Roller 174
Pressure Measurement and Adjustment Procedures 175
Main Pressure Measurement 175
B Travel Pressure Measurement 175
Drain Volume Measurement Procedures 176
Preparations 176
Travel Motor Drain Volume Measurement 176
Air Bleed Procedure 178
Travel Motor 178
B C SWING UNIT, COUNTERWEIGHT 179
Main Equipment Table 182
Upper Component 182
Swing Unit 182
Main Equipment Structure and Operation Explanation 183
Swing Motor 183
Swing Motor Operation Explanation 183
Hydraulic Motor Section 183
Valve Casing Section 184
Brake Section 184
Relief Valve Operation Explanation (relief valve model: KRD22EK10) 186
Swing Motor Internal Structure Diagram 188
Port Diagram 191
Swing motor 191
Basic Functions 192
Swing brake 192
Swing Lock 193
Swing Relief Cut 194
Removal and Installation of Swing Unit 195
Removal of Swing Unit 195
Installation of Swing Unit 197
Assembly and Disassembly of Swing Unit 198
Disassembly 198
Assembly 199
Assembly and Disassembly of Swing Motor 201
Causes of Trouble and Solutions 202
Maintenance Standard Table 204
Required Tools 206
Jig 207
Disassembly 207
Assembly 210
Swing Motor Internal Structural Diagram 214
Removal and Installation of Counterweight 217
Removal of Counterweight 217
Installation of Counterweight 218
Pressure Measurement and Adjustment Procedures 220
Main Pressure Measurement 220
C Swing Pressure Measurement 220
Drain Volume Measurement Procedures 221
Preparations 221
Swing Motor Drain Volume Measurement 221
Air Bleed Procedure 222
Swing Motor 222
Check 223
H ENGINE 225
Main Equipment Table 233
Engine-related 233
Engine 233
Air Cleaner (double element) 233
Radiator 233
SCR 233
Basic Functions 234
Fuel Gauge 234
Coolant Temperature Gauge 236
SCR Gauge 238
Fuel Economy Gauge 242
Neutral start 243
Power-cut Delay 244
Preheat 245
Throttle 246
Throttle Volume Position Detection 247
Idle start 253
Auto Idle 254
One-touch Idle 255
Auto Warm-Up 256
Idle Shutdown 261
Idle up 262
Work Mode Control 263
Engine Emergency Stop 264
SCR RE-GEN 265
Inducement 271
Feed Pump Automatic Stop 276
Coolant Level Decrease 278
Air Filter Clogging 279
Fuel Filter Clogging 280
Battery Charge Abnormality 282
Reversible Fan 283
Fuel cut solenoid valve 284
Horsepower Reduction Control (in Uplands) 285
Horsepower Reduction Control (at Engine Failure) 286
Main Data 288
Function, Structure, Operation 290
Function, structure, operation (SCR) 344
SCR Control System Inspection 371
Explanation of SCR Operation 372
Diagnosis for Each Symptom 374
Intermittent conditions of urea selective catalytic reduction system 374
Urea fluid consumption too high 377
Ammonia smell noticeable 377
White crystalline powder visible 378
Diagnosis for Each Symptom 379
Engine Start Problems 379
Engine Stalling 381
Engine Hunting, Rough Idling 383
Excess Amount of White Smoke in Exhaust Gas 384
Excess Amount of Black Smoke in Exhaust Gas 385
Abnormal Noise 385
High Fuel Consumption 386
High Oil Consumption 388
Engine Output Deficiency 388
Functional Inspection 391
Engine Compression Pressure Inspection 391
Fuel System Inspection 392
Lubrication system check 392
Air intake system inspection 393
Exhaust system inspection 393
Inspection of EGR Control System 393
Start System Inspection 394
Glow control system check 394
OBD system check 396
Inspection of the monitor warning light illumination circuit system 396
Inspection of the monitor warning light blinking circuit system 397
Inspection of the starter circuit system 398
Removal and Installation of Engine Assembly 399
Removal of Engine Assembly 399
Installation of Engine Assembly 404
Removal and Installation of Fuel Cooler, Engine Intercooler, Radiator, and Oil Cooler 405
Removal and Installation of Fuel Cooler 405
Removal of Fuel Cooler 405
Installation of Fuel Cooler 405
Removal and Installation of Engine Intercooler 405
Removal of Intercooler 406
Installation of Inter Cooler 406
Inspection of Intercooler 406
Removal and Installation of Radiator 407
Removal of Radiator 407
Installation of Radiator 410
Inspection of Radiator 411
Removal and Installation of Oil Cooler 411
Removal of Oil Cooler 412
Installation of Oil Cooler 414
Removal and Installation of Turbo Charger 415
Removal of Turbo Charger 415
Installation of Turbo Charger 417
Inspection of Turbo Charger 420
Removal and Installation of EGR Valve (if equipped) 422
Removal of EGR Valve 422
Installation of EGR Valve 424
Inspection of EGR Valve 428
Removal and Installation of Engine Hood 429
Removal of Engine Hood 429
Installation of Engine Hood 429
Removal and Installation of SCR 430
Removal of SCR 430
Installation of SCR 431
Removal and installation of Silicon Controlled Rectifier Catalyst 432
Removal of Silicon Controlled Rectifier Catalyst 432
Installation of Silicon Controlled Rectifier Catalyst 433
Disassembly of Silicon Controlled Rectifier Catalyst 436
Assembly of Silicon Controlled Rectifier Catalyst 436
Inspection of Silicon Controlled Rectifier Catalyst 437
Removal and Installation of Cylinder Head Cover 438
Cylinder head cover Removal 438
Installation of Cylinder Head Cover 438
Removal and Installation of Cylinder Head 439
Removal of Cylinder Head 439
Disassembly of Cylinder Head 448
Assembly of Cylinder Head 452
Installation of Cylinder Head 459
Inspection 477
Removal and Installation of Cylinder Block 483
Removal of Cylinder Block 483
Installation of Cylinder Block 499
Inspection 534
Lubrication System 536
Removal and Installation of Oil Pan 536
Removal of Oil Pan 536
Installation of Oil Pan 536
Removal and Installation of Oil Level Switch 536
Removal of Oil Level Switch 536
Installation of Oil Level Switch 537
Removal and Installation of Oil Pump Assembly 537
Removal of Oil Pump Assembly 537
Disassembly of Oil Pump Assembly 550
Assembly of Oil Pump Assembly 550
Installation of Oil Pump Assembly 551
Inspection 575
Engine oil Inspection 576
Removal and Installation of Oil Port Cover 577
Removal of Oil Port Cover 577
Installation of Oil Port Cover 577
Cooling System 579
Removal and Installation of Water Pump Assembly 579
Removal of Water Pump Assembly 579
Installation of Water Pump Assembly 580
Inspection of Water Pump Assembly 584
Removal and Installation of Thermostat 584
Removal of Thermostat 584
Installation of Thermostat 585
Inspection 587
Inspection of Coolant 587
Inspection of Cooling Fan Belt 592
Removal and Installation of Overheat Switch 592
Removal of Overheat Switch 592
Installation of Overheat Switch 592
Induction System 594
Inspection of Air Cleaner Element 594
Exhaust System 595
Removal and installation of Oxidation Catalyst Assembly 595
Removal of Oxidation Catalyst Assembly 595
Installation of Oxidation Catalyst Assembly 596
Aux Emission Control Devices System 599
Removal and installation of Dosing Module 599
Removal of Dosing Module 599
Disassembly of Dosing Module 599
Assembly of Dosing Module 600
Installation of Dosing Module 600
Removal and installation of DEF Supply Module 602
Removal of DEF supply module 602
Disassembly of DEF Supply Module 603
Assembly of DEF Supply Module 603
Installation of DEF Supply Module 604
Removal and installation of Coolant Control Valve 606
Removal of Coolant Control Valve 606
Installation of Coolant Control Valve 607
Removal and Installation of DCU 609
Removal of DCU 609
Installation of DCU 609
Removal and installation of DEF Supply Module Filter 609
Removal of DEF Supply Module Filter 609
Installation of DEF Supply Module Filter 610
Removal and Installation of Exhaust Manifold 611
Removal of Exhaust Manifold 611
Installation of Exhaust Manifold 614
Inspection 620
Removal and Installation of Fuel Tank 621
Removal of Fuel Tank 621
Installation of fuel tank 622
Removal and Installation of Urea Pump 623
Removal of Urea Pump 623
Installation of Urea Pump 624
Removal and Installation of Urea Solution Tank 625
Removal of Urea Solution Tank 625
Installation of Urea Solution Tank 626
Removal and Installation of Fuel Supply Pump 627
Removal of Fuel Supply Pump 627
Installation of Fuel Supply Pump 628
Removal and Installation of Common Rail Assembly 632
Removal of Common Rail Assembly 632
Installation of Common Rail Assembly 634
Removal and Installation of Injector 639
Removal of Injector 639
Installation of Injector 642
Removal and installation of Idle Gear 648
Removal of Idle Gear 648
Installation of Idle Gear 660
Inspection of Idle Gear 684
Removal and installation of Inlet Cover 686
Removal of Inlet Cover 686
Installation of Inlet Cover 690
Removal and installation of Crankshaft 700
Removal of Crankshaft 700
Installation of Crankshaft 715
Disassembly of Crankshaft 748
Assembly of Crankshaft 748
Inspection of Crankshaft 748
Removal and installation of Piston 753
Removal of Piston 753
Installation of Piston 763
Disassembly of Piston 783
Assembly of Piston 783
Inspection of Piston 785
Removal and installation of Camshaft 792
Removal of Camshaft 792
Installation of Camshaft 793
Disassembly of Camshaft 797
Assembly of Camshaft 798
Inspection of Camshaft 798
Removal and installation of Flywheel 800
Removal of Flywheel 800
Installation of Flywheel 801
Inspection of Flywheel 802
Removal and installation of Crankshaft Front Oil Seal 803
Removal of Crankshaft Front Oil Seal 803
Installation of Crankshaft Front Oil Seal 804
Removal and installation of Crankshaft Rear Oil Seal 807
Removal of Crankshaft Rear Oil Seal 807
Installation of Crankshaft Rear Oil Seal 808
Removal and installation of Rocker Arm Shaft 811
Removal of Rocker Arm Shaft 811
Installation of Rocker Arm Shaft 812
Disassembly of Rocker Arm Shaft 815
Assembly of Rocker Arm Shaft 815
Inspection of Rocker Arm Shaft 817
Removal and installation of Valve Spring 819
Removal of Valve Spring 819
Installation of Valve Spring 821
Inspection of Valve Spring 826
Removal and installation of Valve Stem Oil Seal 828
Removal of Valve Stem Oil Seal 828
Installation of Valve Stem Oil Seal 830
Removal and installation of Front Cover 837
Removal of Front Cover 837
Installation of Front Cover 839
Removal and installation of Intake Throttle Valve 845
Removal of Intake Throttle Valve 845
Installation of Intake Throttle Valve 845
Removal and Installation of Starter Motor 846
Removal of Starter Motor 846
Installation of Starter Motor 847
Disassembly of Starter Motor 847
Assembly of Starter Motor 848
Inspection of Starter Motor 850
Removal and Installation of Alternator 854
Removal of Alternator 854
Installation of Alternator 855
Disassembly of Alternator 856
Assembly of Alternator 856
Inspection of Alternator 858
Removal and Installation of Glow Plug 862
Removal of Glow Plug 862
Installation of Glow Plug 862
Glow plug Inspection 862
Removal and Installation of Suction Control Valve 863
Removal of Suction Control Valve 863
Installation of Suction Control Valve 863
Removal and installation of Fuel Filter 866
Removal of Fuel Filter 866
Installation of Fuel Filter 866
Removal and installation of Relief Valve 869
Removal of Relief Valve 869
Installation of Relief Valve 869
Removal and installation of Fuel Filter Element 872
Removal of Fuel Filter Element 872
Installation of Fuel Filter Element 873
Removal and Installation of Fuel filter pressure 876
Fuel filter pressure sensor Removal 876
Fuel filter pressure sensor Installation 876
Removal and Installation of Engine coolant temperature sensor 877
Engine coolant temperature sensor Removal 877
Engine coolant temperature sensor Installation 877
Engine coolant temperature sensor Inspection 877
Removal and Installation of CKP sensor 878
CKP sensor Removal 878
CKP sensor Installation 878
CKP sensor Inspection 878
Removal and Installation of CMP sensor 879
CMP sensor Removal 879
CMP sensor Installation 879
CMP sensor Inspection 879
Removal and Installation of Oil pressure sensor 880
Oil pressure sensor Removal 880
Oil pressure sensor Installation 880
Oil pressure sensor Inspection 880
Removal and installation of Pressure Sensor/Boost Temperature Sensor 881
Removal of Pressure Sensor/Boost Temperature Sensor 881
Installation of Pressure Sensor/Boost Temperature Sensor 881
Inspection of Pressure Sensor/Boost Temperature Sensor 881
Removal and Installation of IMT sensor 882
Removal of IMT sensor 882
Installation of IMT sensor 882
Removal and installation of Charge Air Cooler Temperature Sensor 1 883
Removal of Charge Air Cooler Temperature Sensor 1 883
Installation of Charge Air Cooler Temperature Sensor 1 883
Inspection of Charge Air Cooler Temperature Sensor 1 883
Sampling Procedure 884
Sampling of Engine Oil 884
Removal and Installation of Exhaust gas temperature sensor 885
Removal of Exhaust gas temperature sensor 885
Installation of Exhaust gas temperature sensor 885
Inspection of Exhaust gas temperature sensor 886
Removal and installation of EGR Gas Temperature Sensor 1 887
Removal of EGR Gas Temperature Sensor 1 887
Installation of EGR Gas Temperature Sensor 1 887
Inspection of EGR Gas Temperature Sensor 1 887
Removal and installation of EGR Gas Temperature Sensor 2 888
Removal of EGR Gas Temperature Sensor 2 888
Installation of EGR Gas Temperature Sensor 2 888
Inspection of EGR Gas Temperature Sensor 2 889
Removal and installation of NOx Sensor 890
Removal of NOx Sensor 890
Installation of NOx Sensor 890
Removal and Installation of Exhaust gas temperature sensor 3 893
Removal of Exhaust gas temperature sensor 3 893
Installation of Exhaust gas temperature sensor 3 893
Removal and installation of DEF Sensor 895
Removal of DEF Sensor 895
Installation of DEF Sensor 895
Engine-related Diagnostic Trouble Code List 896
Engine-side Trouble 905
ECM Trouble 905
DTC P0016 Crankshaft Position – Camshaft Position Correlation Error 905
DTC P0045 Turbocharger Boost Control VNT Error 906
DTC P0087 Fuel Rail/System Pressure – Too Low 908
DTC P0089 Fuel Pressure Regulator Performance 911
DTC P0091 Fuel Pressure Regulator Control Circuit Low 912
DTC P0092 Fuel Pressure Regulator Control Circuit High 913
DTC P0097 Intake Air Temperature (IAT) Sensor 2 Circuit Low Voltage 915
DTC P0098 Intake Air Temperature (IAT) Sensor 2 Circuit High Voltage 916
DTC P0102 Mass Air Flow Sensor Circuit Low Input 917
DTC P0103 Mass Air Flow Sensor Circuit High Input 918
DTC P0112 Intake Air Temperature Sensor Circuit Low 919
DTC P0113 Intake Air Temperature Sensor Circuit High 920
DTC P0117 Engine Coolant Temperature Sensor Circuit Low 922
DTC P0118 Engine Coolant Temperature Sensor Circuit High 923
DTC P0122 Throttle Position Sensor Circuit Low 924
DTC P0123 Throttle Position Sensor Circuit High 925
DTC P0182 Fuel Temperature Sensor Circuit Low 926
DTC P0183 Fuel Temperature Sensor Circuit High 927
DTC P0192 Fuel Rail Pressure Sensor Circuit Low 929
DTC P0193 Fuel Rail Pressure Sensor Circuit High 930
DTC P0201 Injector Circuit Open – Cylinder 1 931
DTC P0202 Injector Circuit Open – Cylinder 2 932
DTC P0203 Injector Circuit Open – Cylinder 3 933
DTC P0204 Injector Circuit Open – Cylinder 4 934
DTC P0217 Engine Coolant Over Temperature Condition 935
DTC P0219 Engine Overspeed Condition 936
DTC P0234 Turbocharger Overboost Condition 937
DTC P0237 Turbo Charger Boost Sensor Circuit Low 939
DTC P0238 Turbo Charger Boost Sensor Circuit High 940
DTC P0335 Crankshaft Position Sensor Circuit 941
DTC P0336 Crankshaft Position Sensor Circuit Range/Performance 942
DTC P0340 Camshaft Position Sensor Circuit 943
DTC P0380 Glow Relay Circuit Error 945
DTC P0401 EGR Flow Insufficient Detected 946
DTC P0404 EGR Control Circuit Range/Performance 947
DTC P0409 EGR Sensor Circuit 948
DTC P041C EGR Cooler Outlet 1 Temp Sensor Circuit Low 950
DTC P041D EGR Cooler Outlet 1 Temp Sensor Circuit High 951
DTC P0427 Catalyst Temperature Sensor Circuit Low Sensor 1 952
DTC P0428 Catalyst Temperature Sensor Circuit High Sensor 1 953
DTC P042C Catalyst Temperature Sensor Circuit Low Sensor 2 955
DTC P042D Catalyst Temperature Sensor Circuit High Sensor 2 956
DTC P0522 Engine Oil Pressure Sensor Circuit Low Input 957
DTC P0523 Engine Oil Pressure Sensor Circuit High Input 958
DTC P0545 EGR Cooler Inlet 1 Temp Sensor Circuit Low 959
DTC P0546 EGR Cooler Inlet 1Temp Sensor Circuit High 960
DTC P0560 12 Volt Circuit Error 962
DTC P0563 System Voltage High 963
DTC P0601 Internal Control Module Memory Check Sum Error 963
DTC P0602 Internal Control Module QR Code Error 964
DTC P0604 Internal Control Module RAM Error 965
DTC P0606 Internal Control Module CPU Error 965
DTC P060A Internal Control Module CPU IC Error 966
DTC P060C Internal Control Module A/D Processing Performance 966
DTC P0615 Starter Relay Circuit Error 967
DTC P0638 Throttle Actuator Control Range/Performance 968
DTC P0685 ECM Power Relay Control Circuit Open 969
DTC P0687 ECM Power Relay Control Circuit High 970
DTC P06A6 Sensor Reference Voltage 1 Circuit 971
DTC P06A7 Sensor Reference Voltage 2 Circuit 972
DTC P06A8 Sensor Reference Voltage 3 Circuit 973
DTC P06A9 Sensor Reference Voltage 4 Circuit 974
DTC P06AF Torque Management System – Forced Engine Shutdown 976
DTC P06D5 Sensor Reference Voltage 5 Circuit 976
DTC P1076 Charge Air Cooler (CAC) Temperature Sensor 1 Circuit Low Voltage 977
DTC P1077 Charge Air Cooler (CAC) Temperature Sensor 1 Circuit High Voltage 978
DTC P1093 Fuel Rail Pressure Too Low 979
DTC P1097 Compressor Outlet Temperature Sensor Circuit High 982
DTC P1098 Compressor Outlet Temperature Sensor Circuit High 983
DTC P1236 Charge Air Cooler Performance Failure 985
DTC P1261 Injector Positive Voltage Control Circuit Group 1 986
DTC P1262 Injector Positive Voltage Control Circuit Group 2 986
DTC P1404 EGR Position Fault 987
DTC P1606 SW-IC Internal failure 988
DTC P160B AD-IC Failure Error 988
DTC P160C AD-IC2 Failure Error 989
DTC P1621 Control Module Long Term Memory Performance 989
DTC P1622 Control Module Long Term Memory Hardware 990
DTC P1669 DPD Lamp Control Circuit 991
DTC P204F SCR System Error (No Inducement) 992
DTC P207F Urea Fluid Concentration Too Low 993
DTC P20C9 SCR System Error 993
DTC P2122 Pedal Position Sensor 1 Circuit Low Input 994
DTC P2123 Pedal Position Sensor 1 Circuit High Input 995
DTC P2127 Pedal Position Sensor 2 Circuit Low Input 996
DTC P2128 Pedal Position Sensor 2 Circuit High Input 997
DTC P2138 Pedal Position Sensor 1 – 2 Voltage Correlation 998
DTC P2146 Fuel Injector Group 1 Supply Voltage Circuit 999
DTC P2149 Fuel Injector Group 2 Supply Voltage Circuit 1000
DTC P2228 Barometric Pressure Sensor Circuit Low 1002
DTC P2229 Barometric Pressure Sensor Circuit High 1002
DTC P2457 Exhaust Gas Recirculation (EGR) Cooling System Performance 1003
DTC P2458 Purge time Out Error 1004
DTC P2BA7 Urea Fluid Quantity Too Low 1004
DTC P2BAA SCR System Error (Inducement, No Purge) 1005
DTC P3093 Fuel Rail Pressure Too Low 1005
DTC U0001 CAN Bus Error (ISO-CAN) 1008
DTC U0073 Control Module Communication Bus Off 1010
DTC U0101 Lost Communication With CAN 1011
DTC U010E Lost Communications With Dosing Control Module 1012
DTC U0110 Lost Communication With VNT System 1013
DTC U2106 Lost CAN Communications With Wheel Loader Transmission Control System 1014
DTC U0411 Lost CAN Communications With VNT Control Module 1015
DCU Trouble 1015
Diagnostic Trouble Code_P0607: Control Module Characteristic Abnormality　 1015
Diagnostic trouble code_P060B: Control Module A/D Conversion Processing Device Abnormality 1016
Diagnostic trouble code_P062F: Control Module EEPROM Abnormality 1017
Diagnostic trouble code_P0641: Sensor Reference Voltage Abnormality 1018
Diagnostic trouble code_P0658: Actuator Supply Power Feed System Abnormality 1019
Diagnostic trouble code_P0659: Actuator Supply Power Feed System Abnormality 1021
Diagnostic trouble code_P1462: Urea Solution Quality Sensor Time-Out Abnormality 1022
Diagnostic trouble code_P1464: Main Relay Abnormality (Early OPEN Error/Sticking Error of Main Relay) 1023
Diagnostic trouble code_P1468: Urea Solution Injection Control Module (DCM) High Temperature Abnormality 1024
Diagnostic trouble code_P1491: Urea Solution High Pressure Abnormality 1025
Diagnostic trouble code_P1493: Urea Solution Injection Control Module (DCM) Screwdriver High Temperature Abnormality 1026
Diagnostic trouble code_P149C: Urea Solution Reducing Pressure Abnormality 1027
DTC P149D Urea Fluid Tank Overtemperature 1028
Diagnostic trouble code_P2000: Cleaning Ratio Abnormality 1030
Diagnostic trouble code_P203B: Urea Solution Tank Level Sensor 1031
Diagnostic trouble code_P203C: Urea Solution Tank Level Sensor Low Voltage Potential 1033
Diagnostic trouble code_P203D: Urea Solution Tank Level Sensor High Voltage Potential 1034
Diagnostic trouble code_P2048: Urea Solution Injector System Low Voltage Potential 1035
Diagnostic trouble code_P2049: Urea Solution Injector System High Voltage Potential 1036
Diagnostic trouble code_P204B: Urea Solution Pressure Sensor System Characteristic Abnormality 1037
Diagnostic trouble code_P204C: Urea Solution Pressure Sensor System Low Voltage Potential 1038
Diagnostic trouble code_P204D: Urea Solution Pressure Sensor System High Voltage Potential 1039
Diagnostic trouble code_P205B: Urea Solution Tank Temperature Sensor Characteristic Abnormality 1041
Diagnostic trouble code_P205C: Urea Solution Tank Temperature Sensor Low Voltage Potential 1042
Diagnostic trouble code_P205D: Urea solution tank temperature sensor high voltage potential 1043
DTC P206A Urea Fluid Quality Sensor Circuit 1044
Diagnostic trouble code_P206B: Urea Sensor High Temperature Abnormality 1045
DTC P206C Urea Fluid Quality Sensor Circuit Low Voltage 1046
DTC P206D Urea Fluid Quality Sensor Circuit High Voltage 1047
Diagnostic trouble code_P207F: Urea Solution Concentration Low 1047
Diagnostic trouble code_P208A: Urea Solution Pump Control System 1048
Diagnostic trouble code_P208B: Urea Solution Pump Characteristic Abnormality 1049
Diagnostic trouble code_P208C: Urea Solution Pump Control System Low Voltage Potential 1051
Diagnostic trouble code_P208D: Urea Solution Pump Control System High Voltage Potential 1052
Diagnostic trouble code_P208E: Urea Solution Injector Attachment 1053
Diagnostic trouble code_P20A0: Urea Solution Reverting Valve System Disconnection 1054
Diagnostic trouble code_P20A2: Urea Solution Reverting Valve System Low Voltage Potential 1055
Diagnostic trouble code_P20A3: Urea Solution Reverting Valve System High Voltage Potential 1056
Diagnostic trouble code_P20AC: Urea Solution Pump Temperature Sensor Characteristic Abnormality 1057
Diagnostic trouble code_P20AD: Urea Solution Pump Module Temperature Sensor Function 1059
Diagnostic trouble code_P20B1: Urea Solution Tank Heater Coolant Control Valve System Disconnection 1060
Diagnostic trouble code_P20B3: Urea Solution Tank Heater Coolant Control Valve System Low Voltage Potential 1061
Diagnostic trouble code_P20B4: Urea solution tank heater coolant control valve system high voltage potential 1062
Diagnostic trouble code_P20E8: Urea Solution Low Pressure Abnormality 1063
Diagnostic trouble code_P20E9: Urea Solution High Pressure Abnormality 1065
Diagnostic trouble code_P20EA: Urea Solution Reducing Pressure Abnormality 1066
Diagnostic trouble code_P20FE: Urea Solution Build-Up Abnormality 1067
Diagnostic trouble code_P2201: NOx Sensor Upstream Function 1069
Diagnostic trouble code_P2206: Ft NOx Sensor Disconnection 1070
Diagnostic trouble code_P2207: Ft NOx Sensor Short-Circuit 1071
Diagnostic trouble code_P2210: Rr NOx Sensor Disconnection 1071
Diagnostic trouble code_P2211: Rr NOx Sensor Short-Circuit 1072
Diagnostic trouble code_P242B: Exhaust Gas Temperature (EGT) Sensor 3 System Function 1072
Diagnostic trouble code_P242C: Exhaust Gas Temperature (EGT) Sensor 3 System Low Voltage Potential 1073
Diagnostic trouble code_P242D: Exhaust Gas Temperature (EGT) Sensor 3 System High Voltage Potential 1074
DTC U0002 CAN Bus Off 1075
DTC U0100 Lost Communication With ECM 1076
Diagnostic trouble code_U029D: CAN Communication Error Between DCU-Ft NOx Sensors 1077
Diagnostic trouble code_U029E: CAN Communication Error Between DCU-Rr NOx Sensors 1080
Data Reference Values 1082
Idle Speed 1082
Two Pump Relief 1083
J HYDRAULIC EQUIPMENT (PUMP, OPERATION SYSTEM VALVE) 1085
Main Equipment Table 1091
Hydraulic Device 1091
Hydraulic Pump 1091
PQ Diagram 1092
Control-related 1093
Control valve 1093
Solenoid Valve (5 Stack) 1093
Remote Control Valve for Left/Right Operations 1093
Remote Control Valve for Travel Operation 1094
Remote Control Valve Characteristic Diagram 1094
Operation Remote Control Valve Control Diagram 1094
Travel Remote Control Valve Control Diagram 1095
Cushion Valve (Heat Circuit, with Shuttle Valve) 1095
Basic Functions 1096
Oil temperature gauge 1096
Static Horsepower Control 1098
Overload Warning (Function for Europe Only) 1100
Pressure Boost Control 1101
Stroke Control 1103
Boom Down Energy Save 1104
Pump Horsepower Boost Control 1104
Arm 1 Semi-parallel Control 1105
Arm 2 Semi-parallel Control 1106
Hot Shutdown Warning 1107
Gate Lock 1108
Breaker Mode 1109
Crusher Mode 1110
Quick coupler 1111
Hydraulic Fluid Filter Clogging 1112
Solenoid Sticking Prevention 1113
Port Diagram 1114
Hydraulic Pump (Standard Model) 1114
Control Valve 1115
Relief Valve 1115
5 stack solenoid valve 1118
2 Stack Solenoid Valve 1119
Remote Control Valves (upper, travel) 1119
Remote Control Valves (left-right) 1119
Remote control valve (travel) 1120
Cushion Valve 1121
6 Stack Proportional Valve 1122
Relief Valve (electromagnetic proportional) 1123
Manifold Under Cab 1124
Manifold (accumulator section) 1124
Hydraulic Tank 1125
Hydraulic Pump 1126
Structure and Operation Explanation 1126
Hydraulic Pump Internal Structure Diagram 1127
Overall View 1127
Drive Shaft Front Side 1128
Drive Shaft Rear Side 1129
Development Diagram 1130
Component Table 1133
Regulator 1134
Regulator Operation Explanation 1134
Regulator Operation Explanation Diagram 1137
Internal Configuration Diagram of Regulator 1140
Development Diagram of Regulator 1142
Component Table 1144
Gear Pump 1145
Gear Pump Internal Structure Diagram 1145
Structure and Operation Explanation 1146
Operation Outline of Electronically-Controlled Pump 1147
Control Valve 1150
Basic Configuration 1150
Operation 1150
Operation of Main Unit 1150
Activation of Relief Valve 1170
5 Stack Solenoid Valve Operation Explanation 1176
External Shape Diagram and Components 1176
operation explanation 1176
Upper Pilot Valve (remote control valve) 1177
Structure 1177
Function 1177
Operation 1178
Structural Diagram 1182
Travel Pilot Valve (remote control valve) 1183
Operation 1183
Pressure Reducing Valve Section 1184
Damping Mechanism in Operation Section 1184
Structural Diagram 1187
Cushion Valve 1189
structure 1189
operation explanation 1190
6 Stack Proportional Valve (Pilot) 1194
structure 1194
operation principle 1195
Electromagnetic Relief Valve 1196
Structure 1196
Operation Explanation 1197
Operation of Check Valve 1197
Operation of Electromagnetic Relief Valve 1198
Removal and Installation of Hydraulic Reservoir 1200
Removal of Hydraulic Reservoir 1200
Installation of Hydraulic Oil Tank 1202
Removal and Installation of Hydraulic Pump 1203
Removal of Hydraulic Pump 1203
Installation of Hydraulic Pump 1205
Removal and Installation of Pump coupling 1207
Removal of Pump Coupling 1207
Installation of Pump Coupling 1207
Removal and Installation of Control Valve 1209
Removal of Control Valve 1209
Installation of Control Valve 1215
Removal and Installation of Travel Remote Control Valve 1216
Removal of Travel Remote Control Valve 1216
Installation of Travel Remote Control Valve 1217
Removal and Installation of Operation Remote Control Valve 1219
Removal of Operation Remote Control Valve (Left) 1219
Installation of Operation Remote Control Valve (Left) 1221
Removal of Operation Remote Control Valve (Right) 1223
Installation of Operation Remote Control Valve (Right) 1225
Removal and Installation of 5 Stack Solenoid 1227
Removal of 5 Stack Solenoid Valve 1227
Installation of 5 Stack Solenoid Valve 1228
Removal and Installation of Cushion Valve 1229
Removal of Cushion Valve 1229
Installation of Cushion Valve 1230
Procedures for Assembly and Disassembly of Hydraulic Pump Main Unit 1231
Tools 1231
Disassembly Procedure 1231
Assembly Procedures 1233
Development Diagram 1237
Component Table 1240
Pump Main Unit Maintenance Standards 1241
Replacement Standard of Wear Component 1241
Correction Standard of Cylinder, Valve Plate, and Sash Plate (Shoe Plate) 1241
Tightening torque 1242
Overall View 1242
Drive Shaft Front Side 1243
Drive Shaft Rear Side 1244
Development Diagram 1245
Component Table 1248
Regulator Maintenance Standards 1249
Regulator Adjustment 1249
Appendix Table and Drawings 1251
Regulator Assembly and Disassembly Procedures 1254
Tools 1254
Preparations for Disassembly 1254
Disassembly Procedure 1254
Assembly Procedures 1256
Internal Configuration Diagram of Regulator 1259
Development Diagram of Regulator 1261
Component Table 1263
Assembly and Disassembly of Control Valve 1264
Disassembly 1264
Caution for Disassembly 1264
Disassembly Procedure 1264
Removal of Long Cap and Pulling Out of Main Spool 1264
Disassembly of Arm 1, 2 Parallel-Tandem Spool, Neutral Cut Spool, Arm Regeneration Release Spool Section 1265
Disassembly of Load Check Valve Section 1265
Disassembly of Antidrift Valve Section (Sub Component in Assembly is Expressed by (Min Number – Sub Number) ) 1266
Disassembly of Relief Valve 1266
Disassembly of Option Section 1266
Disassembly of Add-On Section 1266
Disassembly of Valve Housing Coalescence Bolt 1267
Cleaning 1267
Inspection 1267
assembly 1267
Caution for Assembly 1267
Caution for Handling O-ring 1267
Caution for Handling Spool 1267
Method to Apply Adhesive Agent (Male and Female Thread Section of Components Requiring Bonding) 1267
Assembly Procedure of Sub-Assembly 1268
Assembly of Spool Assembly (Main Spool) 1268
Assembly of Arm 1, 2 Parallel-Tandem Spool, Neutral Cut Spool, Arm Regeneration Release Spool Assembly 1268
Assembly of Antidrift Valve Assembly 1269
Assembly Procedure of Control Valve Main Unit 1269
Assembly of Relief Valve 1269
Assembly of Load Check Valve 1269
Assembly of Antidrift Valve 1270
Assembly of Option Section 1270
Assembly of Arm 1 Parallel-Tandem Spool 1270
Assembly of Arm 2 Parallel-Tandem Spool, Neutral Cut Spool, Arm Regeneration Release Spool 1270
Assembly of Main Spool 1270
Assembly of Add-On Section 1271
Assembly of Other Plugs 1271
Internal Structural Diagram 1272
Part List 1278
Relief Valve 1279
Assembly and Disassembly Procedure of Main Relief Valve 1279
Assembly and Disassembly Procedures of Overload Relief 1280
Assembly and Disassembly Procedure of Low-Pressure Relief Valve 1281
Assembly and Disassembly Procedure of Main Relief Valve for Add-On 1281
Adjustment of Relief Valve 1282
Installation 1283
Operation 1283
Malfunction and Countermeasure 1283
Procedures for Assembly and Disassembly of Operation Remote Control Valve 1285
Maintenance Procedures 1285
Required Tools and Tightening Torque 1285
Maintenance Standards 1286
Disassembly Procedures 1287
Assembly Procedures 1289
Causes of Trouble and Countermeasures 1292
Procedures for Assembly and Disassembly of Travel Remote Control Valve 1296
Maintenance Procedures 1297
Disassembly Procedures 1297
Assembly Procedures 1301
Causes of Trouble and Countermeasures 1306
Assembly and Disassembly of Cushion Valve 1309
Disassembly Procedures 1309
Reverse Operation Spool Section 1309
Check Plunger Section with Throttle 1309
Shuttle Valve Section 1309
Assembly Procedures 1310
Reverse Operation Spool Section 1310
Check Plunger Section with Throttle 1310
Shuttle Valve Section 1310
Written Materials 1311
Procedures for Assembly and Disassembly of 6 Stack Proportional Valve (Pilot) 1313
Development Diagram 1313
Assembly and disassembly procedures 1314
Precautions 1314
Replacement of Proportional Solenoid 1314
Disassembly 1314
Assembly 1314
Replacement of Sleeve and Spool 1315
Disassembly 1315
Assembly 1316
Replacement of Poppet (Check Valve for Normally Open) 1317
Disassembly 1317
assembly 1317
Maintenance Standards 1318
Troubleshooting 1318
Pressure Measurement and Adjustment Procedures 1319
Procedures for Pressure Measurement from the Monitor Display 1319
Monitor and Switch Panel 1319
Pressure Measurement Method 1319
Operating Method 1319
PROCEDURES FOR MEASURING HYDRAULIC OIL TEMPERATURE FROM THE MONITOR DISPLAY 1321
Hydraulic Oil Temperature Measurement Method 1321
Operating Method 1321
Procedures for Pressure Measurement by Installing Pressure Gauge 1322
Preparations 1322
Items to prepare 1322
Pressure Measuring Ports 1323
Control Valve 1325
Location of Relief Valves 1325
Pressure Measurement Preparations 1327
Pressure Measurement 1328
Main Pressure Measurement 1328
A Attachment Pressure Measurement 1329
Boom-down Pressure Measurement 1330
Pilot Pressure Measurement 1330
Pressure Gauge Installation 1330
Negative Control Pressure Measurement 1330
Pressure Gauge Installation 1330
Pressure Adjustment 1331
Main Pressure Adjustment 1331
Pressure Measurement and Adjustment Preparations 1331
Main Relief Pressure Adjustment 1333
Overload Relief Pressure Adjustment 1333
Adjustment of Swing Relief Pressure 1335
Pilot Pressure Adjustment 1336
Hydraulic Pump Flow Measurement Procedures 1337
Preparations 1337
Items to Prepare 1337
Work Preparations 1338
Flow Measurement 1339
Air Bleed Procedure 1341
Hydraulic Pump 1341
Sampling Procedure 1342
Sampling of Hydraulic Fluid 1342
Hydraulic Equipment Layout 1343
Overall View 1344
Pump Chamber Hydraulic Equipment Layout 1345
Swing Body Center Section Hydraulic Equipment Layout 1347
Housing Left Side Hydraulic Equipment Layout 1348
Layout of Hydraulic Equipment in Cab 1349
J EXPLANATION OF HYDRAULIC CIRCUIT AND OPERATIONS (STANDARD) 1351
J EXLANATION OF HYDRAULIC CIRCUIT AND OEPRATIONS (OPTION) 1415
N CAB 1423
Removal and Installation of Operator’s Seat 1426
Removal of Operator’s Seat 1426
Installation of Operator’s Seat 1426
Removal and Installation of Cab Assembly 1427
Removal of Cab Assembly 1427
Installation of Cab Assembly 1431
Removal and Installation of Wiper 1432
Removal of Wiper 1432
Installation of wiper 1432
Removal and Installation of Cab Front Glass 1433
Removal of Cab Front Glass 1433
Installation of Cab Front Glass 1434
Window Lock Adjustment Procedures 1435
Window Lock (front side) 1435
Window Lock (rear side) 1435
Removal and Installation of Housing Guardrail 1437
Removal of Housing Guardrail 1437
Installation of Housing Guardrail 1438
Removal and Installation of Front Guard 1439
Removal of Front Guard 1439
Installation of Front Guard 1440
Door Latch Adjustment Procedure 1441
Tightening Torque 1442
R ELECTRICAL PARTS 1443
Basic Functions 1447
Monitor Control 1447
Monitor Display Dimming 1447
Diagnostic Trouble Code Indicator 1448
Clock 1449
Basic Operation 1450
Battery save 1450
Accessories 1451
Working Light 1451
LED Light 1453
Room Lamp 1454
Radio Mute 1456
Wiper and Washer 1457
Safety 1460
Horn 1460
Back View Monitor 1460
Precautions for Camera Installation 1461
Maintenance 1462
Anti-theft 1462
Manual Lock 1462
Service Support Screen Lock 1462
Customer-specific System Information Screen Lock 1462
Maintenance Information Screen Lock 1463
Option Line Setting Screen Lock 1463
Setting 1464
Clock Adjustment 1464
Screen Brightness Setting 1464
Battery disconnect switch 1466
Explanation of Controller 1467
Service Support 1469
Screen Operations 1469
Screen Display List 1469
Service Monitor Structure 1470
CHECK Screen List 1471
MACHINE STATUS 1472
HYDRAULIC STATUS 1479
ENGINE STATUS 1486
FAULT HISTORY 1491
WORK HISTORY 1491
HYDRAULIC HISTORY 1500
ENGINE HISTORY 1513
DEVICE TEST 1535
ECM/DCU Memory Clear 1535
SCR RE-GEN 1536
Urea Line Leak Test 1537
CCV Operation Test 1538
Dosing Test 1539
Reverting Valve Operation Test 1540
Common Rail Pressure Test 1541
Idle Speed Test / Injector Test 1542
Injector Forced Drive Test 1544
EGR Valve Control Test 1545
VG Turbo Control Test 1546
Intake Throttle Control Test 1547
CONTROL UNIT Screen List 1548
MCM-MAIN 1548
MCM-SUB 1552
COMMU TERMINAL 1553
SETUP Screen List 1556
MACHINE SELECT 1556
DIMENSIONS 1561
PARAMETERS 1563
ENGINE INFORMATION 1568
ENGINE INFORMATION 1569
Data Confirmation 1569
Data Transfer (Copy) 1569
QR (INJECTOR) CODE 1570
Injector number 1570
Screen Layout 1570
Data Source Selection 1571
Manual Input 1571
CAMERA 1572
PASSWORD 1574
CALIBRATE Screen List 1577
THROTTLE VOLUME 1577
OPT LINE RELIEF 1578
PUMP FLOW 1580
RESET Screen List 1583
Connection Connector Pin Layout 1586
Main controller 1586
Monitor 1588
Sequence Circuit Diagram 1589
Code List 1589
Overall 1592
Block diagram 1595
Main controller 1595
DCU 1596
ECM 1597
Monitor 1598
Air conditioner 1599
Gate Lock 1600
Horn 1600
Working Light 1601
Option 1602
Others 1603
Electrical Symbol List 1604
Electrical Equipment Layout Diagram 1605
Main Unit Left-side Layout Diagram 1606
Engine Section Layout Diagram 1608
Main Unit Right Side Layout Diagram (pump chamber) 1611
Main Unit Center Section Layout Diagram 1612
Cab Layout Diagram 1 1614
Cab Layout Diagram 2 1616
Layout Around Operator Seat 1619
Stand Alone Parts Diagram 1620
Removal and Installation of Wiper Controller 1640
Removal of Wiper Controller 1640
Installation of wiper controller 1640
Removal and Installation of Wiper Motor 1641
Removal of Wiper Motor 1641
Installation of wiper motor 1642
Removal and Installation of ECM 1643
Removal of ECM 1643
Installation of ECM 1643
Removal and Installation of Main Controller 1644
Removal of Main Controller 1644
Installation of Main Controller 1644
Removal and Installation of DCU 1645
Removal of DCU 1645
Installation of DCU 1645
Removal and Installation of Monitor 1646
Removal of Monitor 1646
Installation of Monitor 1646
Removal and Installation of Rear View Camera 1647
Removal of Rear View Camera 1647
Installation of Rear View Camera 1647
Air Conditioner Overall Diagram 1649
Frame 1649
Cab 1651
Equipment Layout Diagram 1654
Circuit Diagram 1656
Air Conditioner Circuit Diagram 1656
Explanation of Functions 1658
Explanation of Control 1658
Air Mix Motor Actuator Control 1659
Blow Mode Motor Actuator Control 1659
Refresh/Recirculate Switch Motor Actuator Control 1660
Blower Amp Control 1661
Compressor Clutch Control 1663
COOLMAX Control and HOTMAX Control 1664
Abnormality Detection and Control after Abnormality Detected 1664
Monitor Mode 1668
Door Switch Control 1670
Actuator Inspection 1671
Air Mix Motor Actuator Inspection 1671
Refresh/Recirculate Switch Motor Actuator Inspection 1672
Mode Motor Actuator Inspection 1673
Self-diagnosis Function with Panel Display 1674
Abnormality Display and Self-check Procedures 1674
Abnormality Display Position 1674
Explanation of Abnormality Display 1674
Motor Actuator Abnormality 1674
Sensor Abnormality 1675
Explanation of Monitor Mode 1675
Monitor Mode Display Position 1675
Monitor Mode Display Operating Method 1676
Display Contents in Monitor Mode 1677
Part Function and Good/Poor Judgment 1679
Control Panel 1679
Blower Amp 1680
Relay 1681
Air Mix Actuator 1682
Refresh/Recirculate Actuator 1683
Blow Mode Actuator 1683
Evaporator Sensor 1684
Dual Pressure Switch 1684
Solar Radiation Sensor 1685
Inside Air Sensor 1685
Assembly and Disassembly of Unit 1687
Removal of Blower Unit 1687
Replacement of Blower Motor 1687
Replacement of Blower Amp 1687
Removal of Heater Core 1688
Removal of Heat Case Right/Left 1688
Replacement of Evaporator and Expansion Valve 1688
Installation of Evaporator Sensor 1689
Replacement of Motor Actuator 1689
Removal and Installation of Compressor 1690
Removal of Compressor 1690
Installation of Compressor 1690
Removal and Installation of Condenser 1691
Removal of Condenser 1691
Installation of Condenser 1692
Removal and Installation of Receiver Dryer 1693
Removal of Receiver Dryer 1693
Installation of Receiver Dryer 1694
Work Precautions 1695
Work Procedures 1696
Air Conditioner Refrigerant Filling is Divided into the “Vacuum Operation” and “Gas Filling Operation” 1696
Operation Chart 1696
Tools 1697
Filling Procedures 1698
Charging Hose Connection Position 1698
Connecting Gauge Manifold 1698
Vacuuming 1700
Gas Filling Operation, High-pressure Side 1701
Gas Filling Work, Low Pressure Side 1702
R ELECTRICAL CONNECTOR WIRING DIAGRAM 1705
R 1705
Electrical Connector Wiring Diagram 1707
Frame Main Harness 1708
Control Valve Harness 1710
SCR Harness 1712
Light Harness FR RH 1714
Travel Harness 1716
Option Solenoid 1718
Cab Main Harness 1720
Console Harness SIDE ENTRY 1722
GPS Computer Intermediate Harness 1724
Cab Harness 1726
Camera Harness [2050 mm (80 709 in )] 1728
R ELECTRICAL PARTS AND WIRING ASSEMBLY DIAGRAM 1731
V ATTACHMENTS 1745
Main Equipment Table 1748
Backhoe Attachment 1748
Cylinder 1748
Maintenance Standards 1749
Attachment (Backhoe) 1749
1 Boom and Swing Frame Installation Section 1749
2 Boom Cylinder and Swing Frame Installation Section 1750
3 Boom and Boom Cylinder Installation Section 1750
4 Boom and Arm Cylinder Installation Section 1751
5 Boom and Arm Installation Section 1751
6 Arm and Arm Cylinder Installation Section 1752
7 Arm and Heel Cylinder Installation Section 1752
8 Heel and Heel Cylinder Installation Section 1753
9 Heel and Arm Installation Section 1753
Removal and Installation of Heel Cylinder 1754
Removal of Heel Cylinder 1754
Installation of Heel Cylinder 1756
Removal and Installation of Arm Cylinder 1758
Removal of Arm Cylinder 1758
Installation of Arm Cylinder 1760
Removal and Installation of Boom Cylinder 1763
Removal of Boom Cylinder 1763
Installation of Boom Cylinder 1765
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder 1768
Specifications and Structure Diagram (including the assembly diagram and parts table) 1768
Basic Functions 1768
Function of Each Location 1768
Cylinder Head Assembly (made by KYB) 1769
Piston Assembly (made by KYB) 1770
Pipe Assembly (made by KYB) 1772
Handling Precautions 1773
Precautions for Installing the Cylinder on the Machine Body 1773
Usage Cautions 1773
Maintenance and Inspection Cautions 1774
Maintenance Inspection and Service 1775
Trouble Diagnostics 1776
Storage Standards 1781
Storing Parts Individually (In principle, store indoors ) 1781
When Mounted on Vehicle Body 1781
Recommended Anti-rust Oil 1782
Assembly and Disassembly Procedures 1782
Preparations ····· Prepare the Following before Starting Disassembly 1782
General Work Precautions 1782
Maintenance Standards 1783
Inspection after Assembly 1783
Required Tool 1784
General Tool 1784
Special Jig (made by KYB) 1785
Special Jig Parts Number List (made by KYB) 1786
Disassembly Procedures (made by KYB) 1787
Assembly Procedures (made by KYB) 1790
Test Operation 1794
Usage Limits 1795
Structural Diagram (made by KYB) 1796
Boom Cylinder 1796
Arm Cylinder 1798
Heel Cylinder 1800
Removal and Installation of Heel 1802
Removal of Heel 1802
Installation of Heel 1803
Removal and Installation of Arm 1805
Removal of Arm 1805
Installation of Arm 1806
Removal and Installation of Boom 1808
Removal of Boom 1808
Installation of Boom 1810
Z OTHER 1813
Changes Compared with Standard Model 1818
Overall Layout 1818
Lower 1819
Swing Unit 1819
Engine 1820
Hydraulic-related Data 1821
Oil Pressure Control 1821
Cab, Housing 1821
Electrical Data 1823
Attachment 1823
Specifications 1824
ENGINE 1824
HYDRAULIC SYSTEM 1824
HYDRAULIC CONTROLS 1825
ELECTRICAL SYSTEM 1826
OPERATOR ENVIRONMENT 1826
UNDERCARRIAGE 1827
Mass 1827
DIMENSIONS 1827
WORKING RANGES 1828
SYSTEM FLUID CAPACITIES AND SPECIFICATIONS 1828
Arm Dimension 1829
Standard Arm [3 81 m (12 50 ft )] 1829
Main Unit Weight 1831
Divided Weight (standard specifications) 1831
Stand Alone Part Weight 1832
Shoe Weight (per Side) 1832
Arm Weight 1832
Heel Weight 1832
Bolt Size and Torque Table 1833
Special Torque Setting 1833
Overall View 1838
250X4-TL 1838
NARROW LOWER 1838
WIDE LOWER 1839
WORK RANGE DIAGRAM 1840
250X4-TL 1840
NARROW LOWER 1840
WIDE LOWER 1842
New Machine Performance Judgment Table 1844
Table of Standards 1844
Measurement Method 1847
Engine speed 1847
Pressure at Each Part 1847
Pump Command Displacement 1847
Cylinder Down Amount 1848
Attachment Speed 1848
Swing speed 1849
Swing (180°) Brake Angle 1849
Travel speed 1849
Off Travel Amount 1849
Travel Sprocket Speed 1850
Shoe Tension Amount 1850
Swing Ball Race Bearing Movement Amount and Heel Movement Amount 1851
FLUIDS AND LUBRICANTS 1853
HYDRAULIC FLUID 1853
Engine Oil 1853
Fuel 1853
Conditions applicable to diesel fuel 1853
Recommended conditions applicable to diesel fuels 1853
Main-Unit-related Diagnostic Trouble Code List 1854
Main Unit-side Trouble 1857
Diagnostic Trouble Code: 7000 Pressure Sensor P1 Abnormality 1857
Diagnostic Trouble Code: 7001 Pressure Sensor P2 Abnormality 1859
Diagnostic Trouble Code: 7002 Pressure Sensor N1 Abnormality 1861
Diagnostic Trouble Code: 7003 Pressure Sensor N2 Abnormality 1863
Diagnostic Trouble Code: 7007 Pressure Sensor Arm Cylinder Rod Abnormality 1865
Diagnostic Trouble Code: 7021 Pressure sensor Swing Pilot Abnormality 1867
Diagnostic Trouble Code: 7023 Pressure Sensor Arm-in Pilot Abnormality 1869
Diagnostic Trouble Code: 7040 Level Sensor; Fuel Abnormality 1871
Diagnostic Trouble Code: 7041 Temperature Sensor Hydraulic Fluid Abnormality 1873
Diagnostic Trouble Code: 7065 Pressure Sensor Boom-up Pilot Abnormality 1875
Diagnostic Trouble Code: 7067 Pressure Sensor Bucket-close Pilot abnormality 1877
Diagnostic Trouble Code: 7068 Pressure Sensor Boom-down Pilot Abnormality 1879
Diagnostic Trouble Code: 7069 Pressure Sensor Arm-out Pilot Abnormality 1881
Diagnostic Trouble Code: 7070 Pressure Sensor Bucket-open Pilot Abnormality 1883
Diagnostic Trouble Code: 7071 Pressure Sensor Travel Right Pilot Abnormality 1885
Diagnostic Trouble Code: 7072 Pressure Sensor Travel Left Pilot Abnormality 1887
Diagnostic Trouble Code: 7073 Pressure Sensor Travel 1 Pedal Abnormality 1889
Diagnostic Trouble Code: 7075 Pressure Sensor Arm Cylinder Bottom Abnormality 1891
Diagnostic Trouble Code: 7200 Swing Brake Solenoid Abnormality 1893
Diagnostic Trouble Code: 7201 Travel 2nd Speed Switchover Solenoid Abnormality 1895
Diagnostic Trouble Code: 7202 Pressure Boost Solenoid Abnormality 1896
Diagnostic Trouble Code: 7203 Travel Alarm Buzzer Abnormality 1897
Diagnostic Trouble Code: 7207 Free Swing Solenoid Abnormality 1898
Diagnostic Trouble Code: 7208 Fan reverse solenoid abnormality 1899
Diagnostic Trouble Code: 7213 Quick Coupler Buzzer Abnormality 1900
Diagnostic Trouble Code: 7214 Quick Coupler Solenoid Abnormality 1902
Diagnostic Trouble Code: 7247 Boom 2-Down Pilot Proportional Valve Abnormality 1904
Diagnostic Trouble Code: 7249 Bucket-Close Pilot Proportional Valve Abnormality 1906
Diagnostic Trouble Code: 7265 Arm 1 Semi-Parallel Proportional Valve Abnormality 1908
Diagnostic Trouble Code: 7266 Arm 2 Semi-Parallel Proportional Valve Abnormality 1910
Diagnostic Trouble Code: 7267 Arm 1 Regeneration Release Proportional Valve Abnormality 1912
Diagnostic Trouble Code: 7270 Tilting 1 Proportional Valve Abnormality 1914
Diagnostic Trouble Code: 7271 Tilting 2 Proportional Valve Abnormality 1916
Diagnostic Trouble Code: 7273 Straight Travel Proportional Valve Abnormality 1918
Diagnostic Trouble Code: 7400 Coolant Temperature Overheating 1 1920
Diagnostic Trouble Code: 7401 Coolant Temperature Overheating 2 1921
Diagnostic Trouble Code: 7404 Oil Temperature Overheating 1922
Diagnostic Trouble Code: 7405 Boost Temperature Overheating 1 1923
Diagnostic Trouble Code: 7406 Boost Temperature Overheating 2 1924
Diagnostic Trouble Code: 7420 Alternator Power Generation Defect 1925
Diagnostic Trouble Code: 7421 Decrease in Coolant Level 1927
Diagnostic Trouble Code: 7422 Decrease in Engine Oil Pressure 1928
Diagnostic Trouble Code: 7423 Air Cleaner Clogging 1929
Diagnostic Trouble Code: 7424 Return Filter Clogging 1930
Diagnostic Trouble Code: 7426 Fuel Filter Clogging 1 1931
Diagnostic Trouble Code: 7427 Fuel Filter Clogging 2 1933
Diagnostic Trouble Code: 7428 Inducement (Remaining Urea Level Low) – Warning 1935
Diagnostic Trouble Code: 7429 Inducement (Remaining Urea Level Low) – Early 1936
Diagnostic Trouble Code: 7430 Inducement (Remaining Urea Level Low) – Final 1937
Diagnostic Trouble Code: 7602: ECM Communication Abnormality 1938
Diagnostic Trouble Code: 7605 ECM not-matched 1940
Diagnostic Trouble Code: 7606 EEPROM Abnormality 1941
Diagnostic Trouble Code: 7608 Camera Abnormality 1942
Diagnostic Trouble Code: 7612 Air Conditioner Communication Abnormality 1944
Diagnostic Trouble Code: 7613 Monitor Communication (CAN) Abnormality 1946
Diagnostic Trouble Code: 7615 Sub-Controller Communication Abnormality 1947
Diagnostic Trouble Code: 7618 DCU Communication Abnormality 1949
List of special tools 1951
NUMERICAL VALUE CONVERSION TABLE 1951
Unit conversion rate 1951
Length 1952
Area 1955
Volume 1956
Weight 1958
Pressure 1960
Torque 1962
Temperature 1964
A 1966
Travel Motor Special Tool 1966
250X4-TL 1966
Take-up Roller Special Tool 1974
250X4-TL / 210X4-TL 1974
Upper Roller Special Tool 1975
250X4-TL / 210X4-TL 1975
Lower Roller Special Tool 1976
250X4-TL / 210X4-TL 1976
Grease Cylinder Special Tool 1976
250X4-TL / 210X4-TL 1976
Center Joint Special Tool 1977
250X4-TL / 210X4-TL 1977
C 1978
Swing Motor Special Tool 1978
250X4-TL / 210X4-TL 1978
H 1980
Engine Oil Filter Special Tool 1980
250X4 / 210X4 / 250X4-TL / 210X4-TL 1980
Fuel Filter Special Tool 1980
250X4 / 210X4 / 250X4-TL / 210X4-TL 1980
Injector Special Tool 1981
250X4 / 210X4 / 250X4-TL / 210X4-TL 1981
Circuit Test Special Tool 1981
250X4 / 210X4 / 250X4-TL / 210X4-TL 1981
Valve Guide Special Tool 1981
250X4 / 210X4 / 250X4-TL / 210X4-TL 1981
Cylinder Head Special Tool 1982
250X4 / 210X4 / 250X4-TL / 210X4-TL 1982
Head Bolt Special Tool 1984
250X4 / 210X4 / 250X4-TL / 210X4-TL 1984
Crankshaft Special Tool 1985
250X4 / 210X4 / 250X4-TL / 210X4-TL 1985
Valve Spring Special Tool 1986
250X4 / 210X4 / 250X4-TL / 210X4-TL 1986
J 1987
Remote Control Valve Special Tool 1987
250X4-TL / 210X4-TL 1987
R 1989
Gas Filling Special Tool 1989
250X4 / 210X4 / 250X4-TL / 210X4-TL 1989
V 1990
Attachment Special Tool (for Cylinder Assembly) 1990
Special Jigs Part Number List 1990
Attachment Special Tool (Other) 1992
250X4-TL / 210X4-TL 1992
Paint Colors 1993
Abbreviation 1995
Disassembly/Assembly/Transport Procedures 1999
Assembly Procedure 1999
Overall Processes 1999
Main Machine, Tool, and Item Tables 2000
Precautions 2001
Preliminary Preparation 2001
Securing the Work Area 2001
Main Layout 2002
Preliminary Preparation Procedure 2002
Unloading 2003
1 Unloading 1 2003
2 Procedure for Unloading 1 2004
3 Unloading 2 2005
4 Procedure for Unloading 2 2005
installation procedures 2006
Installation of Counterweight 2006
1 Installation Procedure 2008
Installation of Attachments 2011
1 Installation of Attachments (Arm + Heel Cylinder + Heel) 2013
2 Connection of Heel Cylinder and End Attachment Hoses 2015
Inspection 2017
Operation Check after Assembly 2018
1 Precautions during Assembly 2018
2 Procedures and Precautions for Operation Check after Assembly 2018
Disassembly Procedure 2019
1 Removal of Attachments (Arm + Heel Cylinder + Heel) 2019
2 Removal of Counterweight 2022
Attached Documents of Assembly and Disassembly 2024
Counterweight Assembly Diagram 2024
Attachment Assembly Diagram 2028

PLEASE NOTE:

• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
• You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
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