Linkbelt 600X4 MH Material Handler Service Manual WLSM6007MH-01LX – PDF DOWNLOAD

Description

Linkbelt 600X4 MH Material Handler Service Manual WLSM6007MH-01LX – PDF DOWNLOAD

FILE DETAILS:

Linkbelt 600X4 MH Material Handler Service Manual WLSM6007MH-01LX – PDF DOWNLOAD

Language : English
Pages : 1952
Downloadable : Yes
File Type : PDF
Size: 90.9 MB

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Linkbelt 600X4 MH Material Handler Service Manual WLSM6007MH-01LX – 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 600X4 MH Material Handler Service Manual WLSM6007MH-01LX – PDF DOWNLOAD

MATERIAL HANDLER 1
SAFETY 9
Safety, general information and standard torque data 12
General Information 13
Safety 13
ROPS 15
Non-ROPS Application 15
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 26
Center joint 26
Main Equipment Structure and Operation Explanation 27
Travel Motor 27
Travel motor operation explanation 27
Structure 27
Summary explanation of component parts 28
Rotary group 28
Parking Brake 28
Variable Capacity Mechanism Section 28
Overload Relief Valve 29
Brake Valve Section 30
Function 31
Motor operation 32
Parking Brake Operation 33
Operation of Variable Capacity Mechanism Section 34
Overload Relief Valve Operation 36
Brake Valve Operation 37
Port Diagram 43
Travel Motor 43
Center Joint 44
Basic Functions 45
Travel Speed Selection 45
Travel Alarm 46
Removal and Installation of Track 47
Removal and Installation of Shoe Assembly 47
Removal of Shoe Assembly 47
Installation of Shoe Assembly 49
Removal and Installation of Shoe Plate 50
Removal of Shoe Plate 50
Installation of Shoe Plate 50
Precautions for Shoe Bolt Installation 51
Removal and Installation of Roller 52
Removal and Installation of Upper Roller 52
Removal of Upper Roller 52
Installation of Upper Roller 53
Assembly and Disassembly of Upper Roller 54
Configuration Diagram 55
Dimension Diagram 55
Jig Dimension Diagram 56
Disassembly Procedure 56
Assembly Procedures 58
Removal and Installation of Lower Roller 60
Removal of Lower Roller 61
Installation of Lower Roller 61
Assembly and Disassembly of Lower Roller 62
Configuration Diagram 63
Dimension Diagram 63
Jig Dimension Diagram 64
Disassembly Procedures 64
Assembly Procedures 66
Removal and Installation of Retractable Lower Frame 69
Removal of Retractable Lower Frame 69
Installation of Retractable Lower Frame 70
Removal and Installation of Drive Sprocket 71
Removal of Drive Sprocket 71
Installation of Drive Sprocket 72
Removal and Installation of Take-up Roller 73
Removal of Take-up Roller 73
Installation of Take-up Roller 74
Assembly and Disassembly of Take-up Roller 75
Configuration Diagram 75
Dimension Diagram 76
Jig Dimension Diagram 76
Disassembly Procedures 76
Assembly Procedures 78
Removal and Installation of Grease Cylinder 81
Removal of Grease Cylinder 81
Installation of Grease Cylinder 82
Assembly and Disassembly of Grease Cylinder 83
Configuration Diagram 83
Dimension Diagram 83
Jig Dimension Diagram 84
Disassembly Procedures 84
Assembly Procedures 84
Removal and Installation of Center Joint 86
Removal of Center Joint 86
Installation of Center Joint 88
Assembly and Disassembly of Center Joint 89
Configuration Diagram 90
Dimension Diagram 91
Jig Dimension Diagram 92
Disassembly Procedures 92
Assembly Procedures 93
Removal and Installation of Travel Motor 97
Removal of Travel Motor 97
Installation of Travel Motor 99
Assembly and Disassembly of Travel Motor 102
Tools for Assembly and Disassembly 102
Standard tools 102
Secondary Materials 102
Special Tool (jig) 104
Measurement Device 106
Motor Disassembly Procedures 107
Precautions before motor disassembly 107
Tightening Torque 107
Disassembly procedure 108
Removal of supplied valves 108
Disassembly of motor 108
Disassembly of overload relief valve 112
Reduction gear disassembly procedures 112
Disassembly preparations 112
Disassembly procedure 113
Installation to Receiving Platform Of Reduction Gear (unit) 113
Removal of Reduction Gear Cover 113
Removal of carrier 1 assembly 113
Removal of carrier 2 assembly 114
Removal of housing assembly 114
Disassembly of Housing Assembly 115
Removal of floating seal from motor 116
Disassembly of carrier 1 assembly 116
Disassembly of Carrier 2 Assembly 117
Maintenance standards 118
Motor Parts Maintenance Standards 118
Reduction gear parts maintenance standards 120
Inspection prior to reassembly 120
Thrust washer 120
Gears 121
Bearing 121
Floating seal 121
Parts Maintenance 121
Assembly of motor 122
Precautions before Motor Assembly 122
Assembly procedure 122
Motor Assembly Procedures 122
Motor assembly procedure 126
Assembly of the Carrier 2 Assembly 126
Assembly of the carrier 1 assembly 127
Installation of bearing and floating seal 127
Assembly of the housing assembly 127
Determining the thickness of the angular bearing shim 128
Installation of housing assembly 129
Installation of Carrier 2 Assembly 130
Installation of carrier 1 assembly 130
Cover Attachment 131
Gear Oil Filling 131
Initial pre-conditioning operation 132
Drain charge 132
Performing initial operation (pre-conditioning operation) 132
Troubleshooting 133
General cautions 133
Causes of troubles and countermeasures 133
Maintenance Standards 136
Drive sprocket 136
Take-up roller 137
Upper Roller 138
Lower Roller 139
Track Shoe (Grouser Shoe) 140
Inspection Gauge 141
For Drive Sprocket 141
For Take-up Roller 141
For Upper Roller 142
For Lower Roller 142
Pressure Measurement and Adjustment Procedures 143
Main Pressure Measurement 143
B Travel Pressure Measurement 143
Drain Volume Measurement Procedures 144
Preparations 144
Travel Motor Drain Volume Measurement 144
Air Bleed Procedure 146
Travel Motor 146
B C SWING UNIT, COUNTERWEIGHT 149
Main Equipment Table 152
Upper Component 152
Swing unit 152
Main Equipment Structure and Operation Explanation 153
Swing Motor 153
Swing Motor Operation Explanation 153
Hydraulic motor operation explanation 153
Mechanical brake operation explanation 153
Make-up valve operation explanation 154
Relief valve operation explanation (relief valve internal structure diagram) 155
Bypass valve operation explanation (bypass valve internal structure diagram) 156
Swing motor internal diagram 157
Port Diagram 159
Swing motor 159
Basic Functions 160
Swing brake 160
Swing Lock 161
Swing Speed Limit 162
Swing Relief Cut 164
Free Swing (Option) 165
Removal and Installation of Swing Unit 166
Removal of Swing Unit 166
Installation of Swing Unit 168
Assembly and Disassembly of Swing Unit 169
Disassembly 169
Assembly 170
Assembly and Disassembly of Swing Motor 172
Causes of Trouble and Solutions 173
Maintenance Standard Table 175
Jig 176
Disassembly 176
Assembly 181
Swing Motor Internal Structural Diagram 189
Removal and Installation of Counterweight 190
Removal of Counterweight 190
Installation of Counterweight 191
Removal and Installation of Elevator Cylinder 193
Removal of Elevator Cylinder 193
Installation of Elevator Cylinder 197
Elevator Cylinder 202
Pressure Measurement and Adjustment Procedures 204
Main Pressure Measurement 204
C Swing Pressure Measurement 204
Drain Volume Measurement Procedures 205
Preparations 205
Swing Motor Drain Volume Measurement 205
Air Bleed Procedure 206
Swing motor 206
Check 207
H ENGINE 209
Main Equipment Table 217
Engine-related 217
Engine 217
Air Cleaner (double element) 217
Radiator 217
SCR 218
Basic Functions 219
Fuel Gauge 219
Coolant Temperature Gauge 221
SCR Gauge 223
Fuel Economy Gauge 228
Neutral start 229
Power-cut Delay 230
Preheat 231
Throttle 232
Throttle Volume Position Detection 233
Idle start 238
Auto Idle 239
One-touch Idle 240
Auto Warm-Up 241
Idle Shutdown 246
Idle up 247
Work Mode Control 248
Engine Emergency Stop 249
SCR RE-GEN 250
Inducement 256
Feed Pump Automatic Stop 261
Coolant Level Decrease 263
Air Filter Clogging 264
Fuel Filter Clogging 265
Battery Charge Abnormality 267
Horsepower Reduction Control (in Uplands) 268
Horsepower Reduction Control (at Engine Failure) 269
Main Data 271
Function, Structure, Operation 274
Function, structure, operation (SCR) 332
SCR Control System Inspection 362
Explanation of SCR Operation 363
Diagnosis for Each Symptom 365
Intermittent conditions of urea selective catalytic reduction system 365
Urea fluid consumption too high 367
Ammonia smell noticeable 368
White crystalline powder visible 368
Symptom 370
Engine start failure 370
Engine stalling 371
Engine hunching, rough idling 373
Excess Amount of White Smoke in Exhaust Gas 374
Excess Amount of Black Smoke in Exhaust Gas 374
Abnormal Noise 375
Large fuel consumption 375
Large oil consumption 377
Insufficient engine output 378
Functional Inspection 380
Engine compression pressure inspection 380
Inspection of the fuel system 381
Lubrication System Inspection 381
Inspection of the air intake system 382
Inspection of the exhaust system 382
Inspection of EGR Control System 383
Inspection of the starting system 383
Inspection of the glow control system 384
OBD System Check 385
Inspection of the diagnostic light warning light illumination circuit system 386
Inspection of the monitor warning light blinking circuit system 386
Inspection of the starter circuit system 387
Removal and Installation of Engine Assembly 389
Removal of Engine Assembly 389
Installation of Engine Assembly 392
Removal and Installation of Fuel Cooler, Engine Intercooler, Radiator, and Oil Cooler 393
Removal and Installation of Fuel Cooler 393
Removal of Fuel Cooler 393
Installation of Fuel Cooler 393
Removal and Installation of Engine Intercooler 393
Removal of Intercooler 393
Installation of Inter Cooler 394
Inspection of Intercooler 394
Removal and Installation of Radiator 395
Removal of Radiator 395
Installation of Radiator 398
Inspection of Radiator 399
Removal and Installation of Oil Cooler 400
Removal of Oil Cooler 400
Installation of oil cooler 401
Removal and Installation of Hydraulic Drive Fan 401
Removal of Hydraulic Drive Fan 402
Installation of Hydraulic Drive Fan 402
Removal and Installation of Turbo Charger 403
Removal of Turbo Charger 403
Installation of Turbo Charger 404
Inspection of Turbo Charger 408
Removal and Installation of EGR Valve (if equipped) 410
Removal of EGR Valve 410
Installation of EGR Valve 412
Inspection of EGR Valve 417
Removal and Installation of Engine Hood 419
Removal of Engine Hood 419
Installation of Engine Hood 423
Removal and Installation of SCR 424
Removal of SCR 424
Installation of SCR 424
Removal and installation of Silicon Controlled Rectifier Catalyst 425
Removal of Silicon Controlled Rectifier Catalyst 425
Installation of Silicon Controlled Rectifier Catalyst 427
Disassembly of　Silicon Controlled Rectifier Catalyst 429
Assembly of Silicon Controlled Rectifier Catalyst 430
Inspection of Silicon Controlled Rectifier Catalyst 430
Removal and Installation of Cylinder Head Cover 431
Removal of Cylinder head cover 431
Installation of Cylinder head cover 431
Removal and Installation of Cylinder Head 434
Removal of Cylinder head assembly 434
Disassembly of Cylinder head assembly 442
Assembly of Cylinder head assembly 445
Installation of Cylinder head assembly 450
Cylinder head assembly Inspection 469
Removal and Installation of Cylinder Block 476
Removal of Cylinder block 476
Cylinder liner removal 489
Cylinder liner installation 490
Installation of Cylinder block 492
Cylinder block Inspection 525
Lubrication System 527
Removal and Installation of Oil Pan 527
Oil pan Removal 527
Oil pan Installation 527
Removal and Installation of Oil Level Switch 527
Oil level switch Removal 527
Oil level switch Installation 528
Removal and Installation of Oil Pump Assembly 528
Oil pump assembly Removal 528
Oil pump assembly Disassembly 529
Oil pump assembly Reassembly 529
Oil pump assembly Installation 529
Oil pump assembly Inspection 530
Engine oil Inspection 531
Removal and installation of Piston oil jet 531
Removal of Piston oil jet 531
Installation of Piston oil jet 532
Removal and installation of Oil filter element 533
Removal of Oil filter element 533
Installation of Oil filter element 533
Cooling System 534
Removal and Installation of Water Pump Assembly 534
Removal of Water pump assembly 534
Installation of Water pump assembly 536
Disassembly of Water pump assembly 543
Assembly of Water pump assembly 544
Water pump assembly Inspection 546
Removal and Installation of Thermostat 546
Removal of Thermostat 546
Installation of Thermostat 549
Thermostat Inspection 555
Inspection of Coolant 556
Removal and installation of Generator drive belt 561
Removal of Generator drive belt 561
Installation of Generator drive belt 561
Inspection of Generator drive belt 561
Removal and Installation of Overheat Switch 562
Overheat switch Removal 562
Overheat switch Installation 562
Induction System 563
Inspection of Air cleaner element 563
Exhaust System 564
Removal and installation of Oxidation Catalyst Assembly 564
Removal of Oxidation Catalyst Assembly 564
Installation of Oxidation Catalyst Assembly 565
Aux Emission Control Devices System 567
Removal and installation of Dosing Module 567
Removal of Dosing Module 567
Disassembly of Dosing Module 567
Assembly of Dosing Module 568
Installation of Dosing Module 568
Removal and installation of DEF Supply Module 570
Removal of DEF supply module 570
Disassembly of DEF Supply Module 571
Assembly of DEF Supply Module 572
Installation of DEF Supply Module 572
Removal and installation of Coolant Control Valve 574
Removal of Coolant Control Valve 574
Installation of Coolant Control Valve 575
Removal and Installation of DCU 577
Removal of DCU 577
Installation of DCU 577
Removal and installation of DEF Supply Module Filter 578
Removal of DEF Supply Module Filter 578
Installation of DEF Supply Module Filter 578
Removal and Installation of Fuel Tank 579
Removal of Fuel Tank 579
Installation of Fuel Tank 582
Removal and Installation of Urea Solution Pump 583
Removal of Urea Solution Pump 583
Installation of Urea Pump 584
Removal and Installation of Urea Solution Tank 585
Removal of DEF Tank 585
Installation of Urea Solution Tank 586
Removal and Installation of Fuel Supply Pump 587
Removal of Fuel Supply Pump 587
Installation of Fuel Supply Pump 590
Inspection of　Fuel Supply Pump 600
Removal and Installation of Common Rail Assembly 602
Removal of Common rail assembly 602
Installation of Common rail assembly 604
Removal and Installation of Injector 613
Removal of Injector 613
Installation of Injector 616
Removal and installation of Idle Gear 626
Removal of Idle Gear 626
Installation of Idle Gear 637
Inspection of Idle Gear 664
Removal and installation of Crankshaft 666
Removal of Crankshaft 666
Installation of Crankshaft 679
Disassembly of Crankshaft 713
Assembly of Crankshaft 713
Inspection of Crankshaft 714
Removal and installation of Piston 717
Removal of Piston 717
Installation of Piston 726
Disassembly of Piston 748
Assembly of Piston 748
Inspection of Piston 750
Removal and installation of Camshaft 755
Removal of Camshaft 755
Installation of Camshaft 756
Disassembly of Camshaft 761
Assembly of Camshaft 762
Inspection of Camshaft 762
Removal and installation of Flywheel 764
Removal of Flywheel 764
Installation of Flywheel 764
Disassembly of Flywheel 764
Assembly of Flywheel 765
Inspection of Flywheel 765
Removal and installation of Rocker Arm Shaft 766
Removal of Rocker Arm Shaft 766
Installation of Rocker Arm Shaft 767
Disassembly of Rocker Arm Shaft 771
Assembly of Rocker Arm Shaft 771
Inspection of Rocker Arm Shaft 772
Removal and installation of Front Cover 774
Removal of Front Cover 774
Installation of Front Cover 775
Removal and installation of Intake Throttle Valve 781
Removal of Intake Throttle Valve 781
Installation of Intake Throttle Valve 781
Removal and Installation of Starter Motor 782
Removal of Starter Motor 782
Installation of Starter Motor 782
Disassembly of Starter Motor 782
Assembly of Starter Motor 784
Inspection of Starter Motor 788
Removal and Installation of Alternator 792
Removal of Alternator 792
Installation of Alternator 792
Disassembly of Alternator 792
Assembly of Alternator 794
Inspection of Alternator 795
Removal and Installation of Glow Plug 799
Removal of Glow plug 799
Installation of Glow plug 801
Glow plug Inspection 806
Removal and installation of Fuel Filter 807
Removal of Fuel Filter 807
Installation of Fuel Filter 807
Removal and installation of Fuel Filter Element 809
Removal of Fuel Filter Element 809
Installation of Fuel Filter Element 809
Removal and installation of Fuel temperature sensor 811
Removal of Fuel temperature sensor 811
Installation of Fuel temperature sensor 811
Inspection of Fuel temperature sensor 812
Removal and installation of Pressure limiter 813
Removal of Pressure limiter 813
Installation of Pressure limiter 813
Removal and installation of Fuel pressure sensor 816
Removal of Fuel pressure sensor 816
Installation of Fuel pressure sensor 817
Inspection of Fuel pressure sensor 822
Removal and Installation of Fuel filter pressure 823
Removal of Fuel filter pressure sensor 823
Installation of Fuel filter pressure sensor 823
Removal and Installation of Engine coolant temperature sensor 824
Removal of Engine coolant temperature sensor 824
Installation of Engine coolant temperature sensor 824
Engine coolant temperature sensor Inspection 827
Removal and Installation of CKP sensor 828
Removal of CKP sensor 828
CKP sensor Installation 828
CKP sensor Inspection 828
Removal and Installation of CMP sensor 829
Removal of CMP sensor 829
CMP sensor Installation 829
CMP sensor Inspection 829
Removal and Installation of Oil pressure sensor 830
Oil pressure sensor Removal 830
Oil pressure sensor Installation 830
Removal and installation of Pressure Sensor/Boost Temperature Sensor 831
Removal of Pressure sensor/boost temperature sensor 831
Installation of Pressure sensor/boost temperature sensor 831
Inspection of Pressure sensor/boost temperature sensor 831
Removal and Installation of IMT sensor 832
Removal of IMT sensor 832
Installation of IMT sensor 832
Removal and installation of MAF and IAT sensor 833
Removal of MAF and IAT sensor 833
Installation of MAF and IAT sensor 833
Inspection of MAF and IAT sensor 834
Removal and installation of Charge Air Cooler Temperature Sensor 1 835
Removal of Charge air cooler temperature sensor 1 835
Installation of Charge air cooler temperature sensor 1 835
Inspection of Charge air cooler temperature sensor 1 835
Sampling Procedure 836
Sampling of Engine Oil 836
Removal and Installation of Exhaust gas temperature sensor 837
Removal of Exhaust gas temperature sensor 837
Installation of Exhaust gas temperature sensor 837
Inspection of Exhaust gas temperature sensor 838
Removal and installation of EGR Gas Temperature Sensor 1 839
Removal of EGR Gas Temperature Sensor 1 839
Installation of EGR Gas Temperature Sensor 1 839
Inspection of EGR Gas Temperature Sensor 1 840
Removal and installation of EGR Gas Temperature Sensor 2 841
Removal of EGR Gas Temperature Sensor 2 841
Installation of EGR Gas Temperature Sensor 2 841
Inspection of EGR Gas Temperature Sensor 2 842
Removal and installation of EGR Gas Temperature Sensor 3 843
Removal of EGR Gas Temperature Sensor 3 843
Installation of EGR Gas Temperature Sensor 3 843
Inspection of EGR Gas Temperature Sensor 3 843
Removal and installation of EGR Gas Temperature Sensor 4 844
Removal of EGR Gas Temperature Sensor 4 844
Installation of EGR Gas Temperature Sensor 4 844
Inspection of EGR Gas Temperature Sensor 4 845
Removal and installation of NOx Sensor 846
Removal of NOx Sensor 846
Installation of NOx Sensor 846
Removal and Installation of Exhaust gas temperature sensor 3 849
Removal of Exhaust gas temperature sensor 3 849
Installation of Exhaust gas temperature sensor 3 849
Removal and installation of DEF Sensor 851
Removal of DEF Sensor 851
Installation of DEF Sensor 851
Engine-related Diagnostic Trouble Code List 852
Engine-side Trouble 861
ECM Trouble 861
DTC P0016 Crankshaft Position – Camshaft Position Correlation Error 861
DTC P0045 Turbocharger Boost Control VNT Error 862
DTC P0087 Fuel Rail/System Pressure – Too Low 864
DTC P0089 Fuel Pressure Regulator Performance 866
DTC P0091 Fuel Pressure Regulator Control Circuit Low 868
DTC P0092 Fuel Pressure Regulator Control Circuit High 869
DTC P0097 Intake Air Temperature (IAT) Sensor 2 Circuit Low Voltage 870
DTC P0098 Intake Air Temperature (IAT) Sensor 2 Circuit High Voltage 871
DTC P0102 Mass Air Flow Sensor Circuit Low Input 872
DTC P0103 Mass Air Flow Sensor Circuit High Input 873
DTC P0112 Intake Air Temperature Sensor Circuit Low 874
DTC P0113 Intake Air Temperature Sensor Circuit High 875
DTC P0117 Engine Coolant Temperature Sensor Circuit Low 876
DTC P0118 Engine Coolant Temperature Sensor Circuit High 877
DTC P0122 Throttle Position Sensor Circuit Low 879
DTC P0123 Throttle Position Sensor Circuit High 880
DTC P0182 Fuel Temperature Sensor Circuit Low 881
DTC P0183 Fuel Temperature Sensor Circuit High 882
DTC P0192 Fuel Rail Pressure Sensor Circuit Low 883
DTC P0193 Fuel Rail Pressure Sensor Circuit High 884
DTC P0201 Injector Circuit Open – Cylinder 1 886
DTC P0202 Injector Circuit Open – Cylinder 2 887
DTC P0203 Injector Circuit Open – Cylinder 3 888
DTC P0204 Injector Circuit Open – Cylinder 4 889
DTC P0205 Injector Circuit Open – Cylinder 5 890
DTC P0206 Injector Circuit Open – Cylinder 6 891
DTC P0217 Engine Coolant Over Temperature Condition 892
DTC P0219 Engine Overspeed Condition 893
DTC P0234 Turbocharger Overboost Condition 894
DTC P0237 Turbo Charger Boost Sensor Circuit Low 895
DTC P0238 Turbo Charger Boost Sensor Circuit High 896
DTC P0335 Crankshaft Position Sensor Circuit 897
DTC P0336 Crankshaft Position Sensor Circuit Range/Performance 899
DTC P0340 Camshaft Position Sensor Circuit 900
DTC P0380 Glow Relay Circuit Error 901
DTC P0401 EGR Flow Insufficient Detected 902
DTC P0404 EEGR Control Circuit Range/Performance 903
DTC P0409 EGR Sensor Circuit 904
DTC P040C EGR Cooler Outlet 2 Temp Sensor Circuit Low 906
DTC P040D EGR Cooler Outlet 2 Temp Sensor Circuit High 907
DTC P041C EGR Cooler Outlet 1 Temp Sensor Circuit Low 908
DTC P041D EGR Cooler Outlet 1 Temp Sensor Circuit High 909
DTC P0427 Catalyst Temperature Sensor Circuit Low Sensor 1 910
DTC P0428 Catalyst Temperature Sensor Circuit High Sensor 1 911
DTC P042C Catalyst Temperature Sensor Circuit Low Sensor 2 913
DTC P042D Catalyst Temperature Sensor Circuit High Sensor 2 914
DTC P045B EGR 2　Control Circuit Range/Performance 915
DTC P0522 Engine Oil Pressure Sensor Circuit Low Input 916
DTC P0523 Engine Oil Pressure Sensor Circuit High Input 917
DTC P0545 EGR Cooler Inlet 1 Temp Sensor Circuit Low 918
DTC P0546 EGR Cooler Inlet 1Temp Sensor Circuit High 919
DTC P0548 EGR Cooler Inlet 2 Temp Sensor Circuit Low 920
DTC P0549 EGR Cooler Inlet 2Temp Sensor Circuit High 921
DTC P0560 12 Volt Circuit Error 922
DTC P0563 System Voltage High 923
DTC P0601 Internal Control Module Memory Check Sum Error 923
DTC P0602 Internal Control Module QR Code Error 924
DTC P0604 Internal Control Module RAM Error 925
DTC P0606 Internal Control Module CPU Error 925
DTC P060A Internal Control Module CPU IC Error 926
DTC P060C Internal Control Module A/D Processing Performance 926
DTC P0615 Starter Relay Circuit Error 927
DTC P0638 Throttle Actuator Control Range/Performance 928
DTC P0685 ECM Power Relay Control Circuit Open 929
DTC P0687 ECM Power Relay Control Circuit High 930
DTC P06A6 Sensor Reference Voltage 1 Circuit 931
DTC P06A7 Sensor Reference Voltage 2 Circuit 932
DTC P06A8 Sensor Reference Voltage 3 Circuit 933
DTC P06A9 Sensor Reference Voltage 4 Circuit 934
DTC P06AF Torque Management System – Forced Engine Shutdown 935
DTC P06D5 Sensor Reference Voltage 5 Circuit 935
DTC P1062 Fuel Pressure Regulator 1 Solenoid Control Circuit 937
DTC P1063 Fuel Pressure Regulator 2 Solenoid Control Circuit 937
DTC P1076 Charge Air Cooler (CAC) Temperature Sensor 1 Circuit Low Voltage 938
DTC P1077 Charge Air Cooler (CAC) Temperature Sensor 1 Circuit High Voltage 939
DTC P1093 Fuel Rail Pressure Too Low 940
DTC P1097 Compressor Outlet Temperature Sensor Circuit High 942
DTC P1098 Compressor Outlet Temperature Sensor Circuit High 943
DTC P1236 Charge Air Cooler Performance Failure 944
DTC P1261 Injector Positive Voltage Control Circuit Group 1 945
DTC P1262 Injector Positive Voltage Control Circuit Group 2 945
DTC P1404 EGR Position Fault 946
DTC P140B EGR 2 Position Sensor Performance 947
DTC P140C EGR 2 Closed Position Performance 948
DTC P1606 SW-IC Internal failure 949
DTC P160B AD-IC Failure Error 950
DTC P160C AD-IC2 Failure Error 950
DTC P1621 EEPROM abnormality 951
DTC P1622 Control Module EEPROM Hardware Error 952
DTC P1669 DPD Lamp Control Circuit 953
DTC P204F SCR System Error (No Inducement) 954
DTC P207F Urea Fluid Concentration Too Low 954
DTC P20C9 SCR System Error 955
DTC P20DF Exhaust After-treatment Fuel Pressure Sensor Circuit Low 955
DTC P20E0 Exhaust After-treatment Fuel Pressure Sensor Circuit High 956
DTC P2146 Fuel Injector Group 1 Supply Voltage Circuit 957
DTC P2149 Fuel Injector Group 2 Supply Voltage Circuit 959
DTC P2228 Barometric Pressure Sensor Circuit Low 960
DTC P2229 Barometric Pressure Sensor Circuit High 961
DTC P2295 Fuel Pressure Regulator 2 Control Circuit Low 961
DTC P2296 Fuel Pressure Regulator 2 Control Circuit High 962
DTC P2457 Exhaust Gas Recirculation (EGR) Cooling System Performance 963
DTC P2458 Purge time Out Error 965
DTC P2BA7 Urea Fluid Quantity Too Low 965
DTC P2BAA SCR System Error (Inducement, No Purge) 966
DTC P3093 Fuel Rail Pressure Too Low 966
DTC U0001 CAN Bus Error (ISO-CAN) 968
DTC U0073 Control Module Communication Bus Off 969
DTC U0101 Lost Communication With CAN 971
DTC U010E Lost Communications With Dosing Control Module 972
DTC U0110 Lost Communication With VNT System 973
DTC U2106 Lost CAN Communications With Wheel Loader Transmission Control System 974
DTC U0411 Lost CAN Communications With VNT Control Module 974
DCU Trouble 975
Diagnostic Trouble Code_P0607: Control Module Characteristic Abnormality　 975
Diagnostic trouble code_P060B: Control Module A/D Conversion Processing Device Abnormality 976
Diagnostic trouble code_P062F: Control Module EEPROM Abnormality 976
Diagnostic trouble code_P0641: Sensor Reference Voltage Abnormality 977
Diagnostic trouble code_P0658: Actuator Supply Power Feed System Abnormality 979
Diagnostic trouble code_P0659: Actuator Supply Power Feed System Abnormality 980
Diagnostic trouble code_P1462: Urea Solution Quality Sensor Time-Out Abnormality 982
Diagnostic trouble code_P1464: Main Relay Abnormality (Early OPEN Error/Sticking Error of Main Relay) 983
Diagnostic trouble code_P1468: Urea Solution Injection Control Module (DCM) High Temperature Abnormality 984
Diagnostic trouble code_P1491: Urea Solution High Pressure Abnormality 984
Diagnostic trouble code_P1493: Urea Solution Injection Control Module (DCM) Screwdriver High Temperature Abnormality 986
Diagnostic trouble code_P149C: Urea Solution Reducing Pressure Abnormality 986
DTC P149D Urea Fluid Tank Overtemperature 988
Diagnostic trouble code_P2000: Cleaning Ratio Abnormality 989
Diagnostic trouble code_P203B: Urea Solution Tank Level Sensor 991
Diagnostic trouble code_P203C: Urea Solution Tank Level Sensor Low Voltage Potential 992
Diagnostic trouble code_P203D: Urea Solution Tank Level Sensor High Voltage Potential 993
Diagnostic trouble code_P2048: Urea Solution Injector System Low Voltage Potential 994
Diagnostic trouble code_P2049: Urea Solution Injector System High Voltage Potential 996
Diagnostic trouble code_P204B: Urea Solution Pressure Sensor System Characteristic Abnormality 997
Diagnostic trouble code_P204C: Urea Solution Pressure Sensor System Low Voltage Potential 998
Diagnostic trouble code_P204D: Urea Solution Pressure Sensor System High Voltage Potential 999
Diagnostic trouble code_P205B: Urea Solution Tank Temperature Sensor Characteristic Abnormality 1000
Diagnostic trouble code_P205C: Urea Solution Tank Temperature Sensor Low Voltage Potential 1001
Diagnostic trouble code_P205D: Urea solution tank temperature sensor high voltage potential 1002
DTC P206A Urea Fluid Quality Sensor Circuit 1003
Diagnostic trouble code_P206B: Urea Sensor High Temperature Abnormality 1004
DTC P206C Urea Fluid Quality Sensor Circuit Low Voltage 1005
DTC P206D Urea Fluid Quality Sensor Circuit High Voltage 1006
Diagnostic trouble code_P207F: Urea Solution Concentration Low 1007
Diagnostic trouble code_P208A: Urea Solution Pump Control System 1008
Diagnostic trouble code_P208B: Urea Solution Pump Characteristic Abnormality 1009
Diagnostic trouble code_P208C: Urea Solution Pump Control System Low Voltage Potential 1010
Diagnostic trouble code_P208D: Urea Solution Pump Control System High Voltage Potential 1011
Diagnostic trouble code_P208E: Urea Solution Injector Attachment 1012
Diagnostic trouble code_P20A0: Urea Solution Reverting Valve System Disconnection 1014
Diagnostic trouble code_P20A2: Urea Solution Reverting Valve System Low Voltage Potential 1015
Diagnostic trouble code_P20A3: Urea Solution Reverting Valve System High Voltage Potential 1016
Diagnostic trouble code_P20AC: Urea Solution Pump Temperature Sensor Characteristic Abnormality 1017
Diagnostic trouble code_P20AD: Urea Solution Pump Module Temperature Sensor Function 1018
Diagnostic trouble code_P20B1: Urea Solution Tank Heater Coolant Control Valve System Disconnection 1019
Diagnostic trouble code_P20B3: Urea Solution Tank Heater Coolant Control Valve System Low Voltage Potential 1020
Diagnostic trouble code_P20B4: Urea solution tank heater coolant control valve system high voltage potential 1021
Diagnostic trouble code_P20E8: Urea Solution Low Pressure Abnormality 1022
Diagnostic trouble code_P20E9: Urea Solution High Pressure Abnormality 1024
Diagnostic trouble code_P20EA: Urea Solution Reducing Pressure Abnormality 1026
Diagnostic trouble code_P20FE: Urea Solution Build-Up Abnormality 1027
Diagnostic trouble code_P2201: NOx Sensor Upstream Function 1029
Diagnostic trouble code_P2206: Ft NOx Sensor Disconnection 1030
Diagnostic trouble code_P2207: Ft NOx Sensor Short-Circuit 1030
Diagnostic trouble code_P2210: Rr NOx Sensor Disconnection 1031
Diagnostic trouble code_P2211: Rr NOx Sensor Short-Circuit 1031
Diagnostic trouble code_P242B: Exhaust Gas Temperature (EGT) Sensor 3 System Function 1032
Diagnostic trouble code_P242C: Exhaust Gas Temperature (EGT) Sensor 3 System Low Voltage Potential 1033
Diagnostic trouble code_P242D: Exhaust Gas Temperature (EGT) Sensor 3 System High Voltage Potential 1034
DTC U0002 CAN Bus Off 1035
DTC U0100 Lost Communication With ECM 1036
Diagnostic trouble code_U029D: CAN Communication Error Between DCU-Ft NOx Sensors 1037
Diagnostic trouble code_U029E: CAN Communication Error Between DCU-Rr NOx Sensors 1040
Data Reference Values 1041
Non-operational P rotation 1042
J HYDRAULIC EQUIPMENT (PUMP, OPERATION SYSTEM VALVE) 1043
Main Equipment Table 1049
Hydraulic Device 1049
Hydraulic Pump 1049
PQ Diagram 1050
Hydraulically-operated fan pump 1050
Hydraulic Drive Fan Motor 1051
Control-related 1052
Control valve 1052
Solenoid Valve (5 Stack) 1052
Solenoid Valve (2 stack) for EV Control 1052
Solenoid Valve (Single) for Free Swing 1053
Remote Control Valve for Left/Right Operations 1053
Remote Control Valve for Travel Operation 1053
Remote Control Valve for Option Operation 1053
Remote Control Valve Characteristic Diagram 1054
Operation Remote Control Valve Control Diagram 1054
Travel Remote Control Valve Control Diagram 1055
1-pedal Travel Remote Control Valve Control Diagram 1055
Reducing Valve (5 Stack Proportional Valve) 1056
Cushion Valve (with Heat Circuit, Shuttle Valve) 1056
Basic Functions 1057
Oil temperature gauge 1057
Static Horsepower Control 1059
Overload Warning (Function for Europe Only) 1061
Pressure Boost Control 1062
Stroke Control 1064
Boom Down Energy Save 1066
Pump Horsepower Cut Control 1067
Pump Horsepower Boost Control 1070
Arm 1 Semi-parallel Control 1071
Arm 2 Semi-parallel Control 1072
Hot Shutdown Warning 1073
Gate Lock 1074
Breaker Mode 1075
Crusher Mode 1076
Quick coupler 1077
Hydraulic Fluid Filter Clogging 1078
Solenoid Sticking Prevention 1079
Port Diagram 1080
Hydraulic Pump (Standard Model) 1080
Control Valve 1082
Relief Valve 1082
Relief Valve (Elevator 2nd Option Specifications) 1085
5 stack solenoid valve 1086
2 Stack Solenoid Valve (Elevator Control, 2nd Option) 1087
Solenoid Valve (for Generator) 1088
Solenoid Valve (for Free Swing) 1089
Remote Control Valves (upper, travel) 1089
Remote Control Valves (left-right) 1089
Remote control valve (travel) 1090
Remote Control Valve (Option and 2nd Option) 1091
Cushion valve 1092
Reducing valve (5-line) 1093
Relief Valve (electromagnetic proportional) 1094
Manifold Under Cab 1094
Manifold (accumulator section) 1095
Manifold (hydraulic oil tank section) 1096
Hydraulic Pump 1097
Type Indication 1097
Specifications 1097
Structure and Operation Explanation 1098
Hydraulic Circuit Diagram 1099
Hydraulic Pump Internal Structure Diagram 1099
Overall View 1099
Drive Shaft Front Side 1103
Drive Shaft on Rear Side 1104
Development Diagram 1105
Parts Table 1107
Regulator 1108
Regulator Overview 1108
Regulator Operation Explanation 1109
Regulator Operation Explanation Diagram 1112
Internal Configuration Diagram of Regulator 1113
Development Diagram of Regulator 1115
Component Table 1117
Gear Pump 1118
Gear Pump Internal Structure Diagram 1118
Structure and Operation Explanation 1119
Operation Outline of Electronically-Controlled Pump 1120
Hydraulically-operated fan pump 1123
Handling Procedures 1123
How to Read Model Numbers 1128
Performance 1129
Structure 1131
Causes of Trouble and Countermeasures 1134
Hydraulically-operated fan motor 1136
External shape diagram 1136
Internal Structure Diagram 1138
Operation Explanation 1139
Control Valve 1150
Basic Configuration 1150
Operation 1150
Operation of Main Unit 1150
Activation of Relief Valve 1168
5 Stack Solenoid Valve Operation Explanation 1172
External Shape Diagram and Components 1172
operation explanation 1172
2 Stack Solenoid Valve 1173
Structure 1173
Upper Pilot Valve (remote control valve) 1174
Structure 1174
Function 1174
Operation 1175
Structural Diagram 1178
Travel Pilot Valve (remote control valve) 1179
Operation 1179
Pressure Reducing Valve Section 1180
Damping Mechanism in Operation Section 1180
Structural Diagram 1183
1-pedal Travel Pilot Valve (remote control valve) 1185
Operation 1185
Structural Diagram 1187
Cushion Valve 1188
Structure 1188
operation explanation 1189
Electromagnetic Relief Valve 1193
Structure 1193
Operation Explanation 1194
Operation of Check Valve 1194
Operation of Electromagnetic Relief Valve 1195
Removal and Installation of Hydraulic Reservoir 1197
Removal of Hydraulic Reservoir 1197
Installation of Hydraulic Oil Tank 1200
Removal and Installation of Hydraulic Pump 1201
Removal of Hydraulic Pump 1201
Installation of Hydraulic Pump 1204
Removal and Installation of Pump coupling 1205
Removal of Pump Coupling 1205
Installation of Pump Coupling 1205
Removal and Installation of Control Valve 1207
Removal of Control Valve 1207
Installation of Control Valve 1212
Removal and Installation of Travel Remote Control Valve 1213
Removal of Travel Remote Control Valve 1213
Installation of Travel Remote Control Valve 1214
Removal and Installation of Operation Remote Control Valve 1217
Removal of Operation Remote Control Valve (left side) 1217
Installation of Operation Remote Control Valve (left side) 1219
Removal of Operation Remote Control Valve (right side) 1221
Installation of Operation Remote Control Valve (right side) 1223
Removal and Installation of Option Remote Control Valve 1225
Removal of Option Remote Control Valve 1225
Installation of Option Remote Control Valve 1226
Installation and Removal of 5 Stack Solenoid Valve 1228
Removal of 5 Stack Solenoid Valve 1228
Installation of 5 Stack Solenoid Valve 1229
Removal and Installation of Cushion Valve 1230
Removal of Cushion Valve 1230
Installation of Cushion Valve 1231
Removal and Installation of Hydraulically-Operated Fan Pump 1233
Removal of Hydraulically-Operated Fan Pump 1233
Installation of Hydraulically-Operated Fan Pump 1234
Removal and Installation of Hydraulically-Operated Fan Motor 1235
Removal of Hydraulically-Operated Fan Motor 1235
Installation of Hydraulically-Operated Fan Motor 1236
Procedures for Assembly and Disassembly of Hydraulic Pump Main Unit 1237
Tools 1237
Disassembly Procedure 1237
Assembly Procedure 1239
Pump Main Unit Maintenance Standards 1243
Replacement Standard of Wear Component 1243
Standards for repairing cylinders, valve plates, and swash plates (shoe plates) 1243
Tightening torque 1244
Overall View 1244
Drive Shaft Front Side 1248
Drive Shaft on Rear Side 1249
Development Diagram 1250
Parts Table 1252
Causes of Failures, and Actions 1253
Regulator Maintenance Standards 1255
Regulator Adjustment 1255
Appendix Table and Drawings 1257
Regulator Assembly and Disassembly Procedures 1260
Tools 1260
Preparations for Disassembly 1260
Disassembly Procedure 1260
Assembly Procedure 1262
Internal Configuration Diagram of Regulator 1266
Development Diagram of Regulator 1268
Component Table 1270
Assembly and Disassembly of Control Valve 1271
Disassembly 1271
Caution for Disassembly 1271
Disassembly Procedure 1271
Disassembly of Main Spool Section 1271
Disassembly of Sub Spool Section 1272
Disassembly of Boom, Arm Antidrift Valve 1273
Disassembly of Load Check Valve 1273
Disassembly of Other Check Valves 1273
Disassembly of Flange 1274
Disassembly of Relief Valve 1274
Disassembly of Other Plugs 1274
Cleaning 1274
Inspection 1274
assembly 1275
Caution for Assembly 1275
Assembly of Subassembly 1275
Assembly of Main Spool 1275
Assembly of Sub Spool Section 1275
Assembly of Boom, Antidrift Valve 1276
Assembly of Control Valve 1276
Assembly of Load Check Valve 1276
Assembly of Other Check Valves 1276
Assembly of Flange 1276
Assembly of Boom, Arm Antidrift Valve 1277
Assembly of Relief Valve 1277
Assembly of Sub Spool 1277
Assembly of Main Spool 1277
Assembly of Other Plugs 1278
Internal Structural Diagram 1279
part list 1289
Relief Valve 1290
Assembly and Disassembly Procedure of Main Relief Valve 1290
Assembly and Disassembly Procedures of Overload Relief 1291
Assembly and Disassembly Procedure of Low-Pressure Relief Valve 1292
Adjustment of Relief Valve 1292
Installation 1293
Operation 1293
Malfunction and Countermeasure 1294
Procedures for Assembly and Disassembly of Operation Remote Control Valve 1296
Maintenance Procedures 1296
Required Tools and Tightening Torque 1296
Maintenance Standards 1297
Disassembly Procedures 1298
Assembly Procedures 1300
Causes of Trouble and Countermeasures 1303
Procedures for Assembly and Disassembly of Travel Remote Control Valve 1307
Maintenance Procedures 1308
Disassembly Procedures 1308
Assembly Procedures 1312
Causes of Trouble and Countermeasures 1317
Assembly and Disassembly of Cushion Valve 1320
Disassembly Procedures 1320
Reverse Operation Spool Section 1320
Check Plunger Section with Throttle 1320
Shuttle Valve Section 1320
Assembly Procedures 1321
Reverse Operation Spool Section 1321
Check Plunger Section with Throttle 1321
Shuttle Valve Section 1321
Document 1322
Pressure Measurement and Adjustment Procedures 1324
Procedures for Pressure Measurement from the Monitor Display 1324
Monitor and Switch Panel 1324
Pressure Measurement Method 1325
Operating Method 1325
PROCEDURES FOR MEASURING HYDRAULIC OIL TEMPERATURE FROM THE MONITOR DISPLAY 1326
Hydraulic Oil Temperature Measurement Method 1326
Operating Method 1326
Procedures for Pressure Measurement by Installing Pressure Gauge 1327
Preparations 1327
Items to Prepare 1327
Pressure Measuring Ports 1328
Control Valve 1330
Location of Relief Valves 1330
Pressure Measurement Preparations 1332
Pressure Measurement 1333
Main Pressure Measurement 1333
A Attachment Pressure Measurement 1335
Boom-down Pressure Measurement 1336
Pilot Pressure Measurement 1336
Pressure Gauge Installation 1336
Negative Control Pressure Measurement 1336
Pressure Gauge Installation 1336
Pressure Adjustment 1337
Main Pressure Adjustment 1337
Pressure Measurement and Adjustment Preparations 1337
Main Relief Pressure Adjustment 1339
Overload Relief Pressure Adjustment 1339
Adjustment of Swing Relief Pressure 1341
Pilot Pressure Adjustment 1342
Elevator Circuit Pressure Adjustment 1343
Preparations 1343
Pressure Adjustment of Elevator Ascent Circuit 1343
Pressure Adjustment of Elevator Descent Circuit 1343
Hydraulic Pump Flow Measurement Procedures 1344
Preparations 1344
Items to Prepare 1344
Work Preparations 1345
Flow Measurement 1347
Air Bleed Procedure 1348
Hydraulic Pump 1348
Sampling Procedure 1349
Sampling of Hydraulic Fluid 1349
Hydraulic Equipment Layout 1350
Overall View 1351
Pump Chamber Hydraulic Equipment Layout 1352
Swing Body Center Section Hydraulic Equipment Layout 1353
Housing Left Side Hydraulic Equipment Layout 1355
Hydraulic Equipment Layout of Elevator Section 1356
Hydraulic Equipment Layout of Generator-related Section 1357
Layout of Hydraulic Equipment in Cab 1358
001_J_Explanation of Hydraulic Circuit and Operations (standard model) 1361
J 1361
Explanation of Hydraulic Circuit and Operations (standard model) 1362
Travel Circuit 1363
Travel Low-Speed Circuit 1363
Travel High-Speed Circuit 1365
Swing Circuit 1367
Swing Relief Cut Control Circuit 1367
Swing Brake Circuit 1369
Swing Parking Circuit (Operation Lever in Neutral) 1371
Swing Parking Circuit (Brake Release) 1373
Swing Parking Circuit (Machine Stop) 1375
Negative Control Circuit 1377
Negative Control Circuit 1377
Other Circuits 1379
Heat Circuit (When Operation Lever in Neutral) 1381
Elevator Cab Ascent Circuit 1383
LM Circuit 1385
N CAB 1388
Removal and Installation of Operator’s Seat 1391
Removal of Operator’s Seat 1391
Installation of Operator’s Seat 1391
Removal and Installation of Cab Assembly 1392
Removal of Cab Assembly 1392
Installation of Cab Assembly 1396
Removal and Installation of Wiper 1397
Removal of Wiper 1397
Installation of wiper 1397
Removal and Installation of Cab Front Glass 1398
Removal of Cab Front Glass 1398
Installation of Cab Front Glass 1399
Removal and Installation of Right-side Window Glass 1400
Removal of Right-side Window Glass 1401
Installation of Right-side Window Glass 1402
Removal and Installation of Door (Upper) Sash Glass 1405
Removal of Door (Upper) Sash Glass 1406
Installation of Door (Upper) Sash Glass 1407
Window Lock Adjustment Procedures 1410
Window Lock (front side) 1410
Window Lock (rear side) 1410
Removal and Installation of Hand Rail 1412
Removal of Hand Rail 1412
Installation of Hand Rail 1413
Tightening Torque 1414
R ELECTRICAL PARTS 1416
Basic Functions 1420
Monitor Control 1420
Monitor Display Dimming 1420
Diagnostic Trouble Code Indicator 1421
Clock 1422
Basic Operation 1423
Battery save 1423
Accessories 1424
Working Light 1424
LED Light 1426
Room Lamp 1427
Radio Mute 1429
Wiper and Washer 1430
Safety 1433
Horn 1433
Back/Side View Monitor 1434
Precautions for Camera Installation 1434
Maintenance 1435
Anti-theft 1435
Manual Lock 1435
Service Support Screen Lock 1435
Customer-specific System Information Screen Lock 1435
Maintenance Information Screen Lock 1436
Option Line Setting Screen Lock 1436
Setting 1437
Clock Adjustment 1437
Screen Brightness Setting 1438
Battery disconnect switch 1439
Explanation of Controller 1440
Service Support 1443
Screen Operations 1443
Screen Display List 1443
Service Monitor Structure 1444
CHECK Screen List 1445
MACHINE STATUS 1446
HYDRAULIC STATUS 1453
ENGINE STATUS 1461
FAULT HISTORY 1466
WORK HISTORY 1466
HYDRAULIC HISTORY 1475
ENGINE HISTORY 1489
DEVICE TEST 1511
ECM/DCU Memory Clear 1511
SCR RE-GEN 1512
Urea line leak test 1513
CCV operation test 1514
Dosing test 1515
Reverting valve test 1516
Common rail pressure test 1517
Idle speed test/injector test 1518
EGR valve control test 1520
VG turbo control test 1521
Intake throttle control test 1522
CONTROL UNIT Screen List 1523
MCM-MAIN 1523
MCM-SUB 1528
COMMU TERMINAL 1529
MONITOR 1532
SETUP Screen List 1533
MACHINE SELECT 1533
DIMENSIONS 1538
PARAMETERS 1540
ENGINE INFORMATION 1545
ENGINE INFORMATION 1546
Data check 1546
Data transfer (copy) 1547
QR (INJECTOR) CODE 1548
Injector number 1548
Screen Layout 1548
Data Source Selection 1548
Manual Input 1549
CAMERA 1550
PASSWORD 1552
CALIBRATE Screen List 1555
THROTTLE VOLUME 1555
PUMP FLOW 1556
RESET Screen List 1559
Connection Connector Pin Layout 1562
Main controller 1562
Monitor 1564
Sequence Circuit Diagram 1565
Code List 1565
Overall 1568
Block diagram 1576
Main controller 1576
DCU 1578
ECM 1579
Monitor 1580
Air conditioner 1581
Gate Lock 1582
Horn 1582
Working Light 1583
Option 1584
Others 1585
Electrical Symbol List 1586
Electrical Equipment Layout Diagram 1587
Main Unit Left-side Layout Diagram 1588
Engine Section Layout Diagram 1589
Main Unit Right Side Layout Diagram (pump chamber) 1593
Main Unit Center Section Layout Diagram 1594
Cab Layout Diagram 1 1596
Cab Layout Diagram 2 1598
Layout Around Operator Seat 1601
Stand Alone Parts Diagram 1602
Removal and Installation of Wiper Controller 1627
Removal of Wiper Controller 1627
Installation of wiper controller 1627
Removal and Installation of Wiper Motor 1628
Removal of Wiper Motor 1628
Installation of wiper motor 1629
Removal and Installation of ECM 1630
Removal of ECM 1630
Installation of ECM 1630
Removal and Installation of Main Controller 1631
Removal of Main Controller 1631
Installation of Main Controller 1631
Removal and Installation of DCU 1632
Removal of DCU 1632
Installation of DCU 1632
Removal and Installation of Monitor 1633
Removal of Monitor 1633
Installation of Monitor 1634
Removal and Installation of Rear View Camera 1635
Removal of Rear View Camera 1635
Installation of Rear View Camera 1635
Removal and Installation of Side Camera (Right) 1636
Removal of Side Camera (Right) 1636
Installation of Side Camera (right) 1636
Removal and Installation of Side Camera (Left) 1637
Removal of Side Camera (Left) 1637
Installation of Side Camera (left) 1637
Connecting Gauge Manifold 1638
Removal of Under View Camera (Option) 1639
Installation of Under View Camera (Option) 1639
Removal and Installation of FVM Controller 1640
Removal of FVM Controller 1640
Installation of FVM Computer 1640
How to Set FVM 1641
Air Conditioner Overall Diagram 1646
Frame 1646
Cab 1649
Equipment Layout Diagram 1652
Circuit Diagram 1654
Air Conditioner Circuit Diagram 1654
Explanation of Functions 1656
Explanation of Control 1656
Air Mix Motor Actuator Control 1656
Blow Mode Motor Actuator Control 1657
Refresh/Recirculate Switch Motor Actuator Control 1658
Blower Amp Control 1658
Compressor Clutch Control 1661
COOLMAX Control and HOTMAX Control 1662
Abnormality Detection and Control after Abnormality Detected 1662
Monitor Mode 1666
Door Switch Control 1668
Actuator Inspection 1669
Air Mix Motor Actuator Inspection 1669
Refresh/Recirculate Switch Motor Actuator Inspection 1670
Mode Motor Actuator Inspection 1671
Self-diagnosis Function with Panel Display 1672
Abnormality Display and Self-check Procedures 1672
Abnormality Display Position 1672
Explanation of Abnormality Display 1672
Motor Actuator Abnormality 1672
Sensor Abnormality 1673
Explanation of Monitor Mode 1673
Monitor Mode Display Position 1673
Monitor Mode Display Operating Method 1674
Display Contents in Monitor Mode 1676
Part Function and Good/Poor Judgment 1677
Control Panel 1677
Blower Amp 1678
Relay 1678
Air Mix Actuator 1679
Refresh/Recirculate Actuator 1680
Blow Mode Actuator 1680
Evaporator Sensor 1681
Dual Pressure Switch 1681
Solar Radiation Sensor 1682
Inside Air Sensor 1683
Assembly and Disassembly of Unit 1684
Removal of Blower Unit 1684
Replacement of Blower Motor 1684
Replacement of Blower Amp 1684
Removal of Heater Core 1685
Removal of Heat Case Right/Left 1685
Replacement of Evaporator and Expansion Valve 1685
Installation of Evaporator Sensor 1686
Replacement of Motor Actuator 1686
Removal and Installation of Compressor 1687
Removal of Compressor 1687
Installation of Compressor 1687
Removal and Installation of Condenser 1689
Removal of Condenser 1689
Installation of Condenser 1689
Removal and Installation of Receiver Dryer 1690
Removal of Receiver Dryer 1690
Installation of Receiver Dryer 1690
Work Precautions 1691
Work Procedures 1692
Air Conditioner Refrigerant Filling is Divided into the “Vacuum Operation” and “Gas Filling Operation” 1692
Operation Chart 1692
Tools 1693
Filling Procedures 1694
Charging Hose Connection Position 1694
Connecting Gauge Manifold 1694
Vacuuming 1695
Gas Filling Operation, High-pressure Side 1696
Gas Filling Work, Low Pressure Side 1696
R_ELECTRICAL PARTS_OVERSIZE PAGES pdf 1700
003_R_Electrical Parts and Wiring Assembly Diagram_600X4MH 1700
R 1700
Electrical Parts and Wiring Assembly Diagram 1702
Frame (main unit right side, main unit center section) 1703
Frame (main unit left side) 1705
Engine and Pump 1707
Battery 1709
Cab 1711
002_R_Electrical Connector Wiring Diagram_600X4MH 1714
R 1714
Electrical Connector Wiring Diagram 1716
Frame main harness 1717
Control Valve Harness 1719
SCR Harness 1721
Light Harness (cab light) 1723
Cab Light Harness (with guard) 1725
Light Harness (Cab Rear Light) (LED) 1727
ATT harness 1729
Right harness 1731
Light Harness 1733
Light Harness 1735
1-pedal Travel Harness 1737
Cab main harness 1739
Indicator Jumper 1741
Console harness 1743
GPS Computer Harness 1745
GPS Computer Intermediate Harness 1747
Fan Motor Harness 1749
Free Swing Harness 1751
Camera Harness [600 mm (23 622 in )] 1753
Camera Harness [1000 mm (39 370 in )] 1755
Camera Harness [1900 mm (74 803 in )] 1757
Camera Harness [2200 mm (86 614 in )] 1759
Camera Harness [2750 mm (108 268 in )] 1761
Camera Harness [3150 mm (124 016 in )] 1763
Camera Harness [4000 mm (157 480 in )] 1765
Camera Intermediate Harness [9400 mm (370 079 in )] 1767
Camera Middle Harness [9400 mm (370 079 in )] 1769
Camera Harness (WAVES) 1771
US Control Panel Harness 1773
Panel Board Select Harness 1775
2nd Option Harness (proportional control) 1777
Z OTHER 1780
Specifications 1784
ENGINE 1784
HYDRAULIC SYSTEM 1784
HYDRAULIC CONTROLS 1785
ELECTRICAL SYSTEM 1786
OPERATOR ENVIRONMENT 1786
UNDERCARRIAGE 1787
MASS 1787
DIMENSIONS 1788
SYSTEM FLUID CAPACITIES AND SPECIFICATIONS 1788
Main Unit Weight 1789
Divided Weight 1789
Stand Alone Part Weight 1790
Shoe Weight (per Side) 1790
Bolt Size and Torque Table 1791
Special Torque Setting 1791
Overall View 1796
600X4-MH 1796
Only Main Unit (Without Attachment) 1796
New Machine Performance Judgment Table 1797
Table of Standards 1797
Measurement Method 1800
Engine speed 1800
Pressure at Each Part 1800
Pump Command Displacement 1800
Cylinder Down Amount 1801
Attachment Speed 1801
Swing Speed 1802
Swing (180°) Brake Angle 1802
Travel Speed 1802
Off Travel Amount 1802
Travel Sprocket Speed 1803
Shoe Tension Amount 1803
Swing Ball Race Bearing Movement Amount 1803
FLUIDS AND LUBRICANTS 1805
HYDRAULIC FLUID 1805
Engine Oil 1805
Fuel 1805
Conditions applicable to diesel fuel 1805
Recommended conditions applicable to diesel fuels 1805
Main-Unit-related Diagnostic Trouble Code List 1806
Main Unit-side Trouble 1809
Diagnostic Trouble Code: 7000 Pressure Sensor P1 Abnormality 1809
Diagnostic Trouble Code: 7001 Pressure Sensor P2 Abnormality 1811
Diagnostic Trouble Code: 7002 Pressure Sensor N1 Abnormality 1813
Diagnostic Trouble Code: 7003 Pressure Sensor N2 Abnormality 1815
Diagnostic Trouble Code: 7007 Pressure sensor arm cylinder rod abnormality 1817
Diagnostic Trouble Code: 7021 Pressure Sensor Swing Pilot Abnormality 1819
Diagnostic Trouble Code: 7023 Pressure Sensor Arm-In Pilot Abnormality 1821
Diagnostic Trouble Code: 7040 Level sensor fuel abnormality 1823
Diagnostic Trouble Code: 7041 Temperature Sensor Hydraulic Fluid Abnormality 1825
Diagnostic Trouble Code: 7065 Pressure Sensor Boom-Up Pilot Abnormality 1827
Diagnostic Trouble Code: 7067 Pressure Sensor Bucket-Close Pilot Abnormality 1829
Diagnostic Trouble Code: 7068 Pressure Sensor Boom-Down Pilot Abnormality 1831
Diagnostic Trouble Code: 7069 Pressure Sensor Arm-Out Pilot Abnormality 1833
Diagnostic Trouble Code: 7070 Pressure Sensor Bucket-Open Pilot Abnormality 1835
Diagnostic Trouble Code: 7071 Pressure Sensor Travel Right Pilot Abnormality 1837
Diagnostic Trouble Code: 7072 Pressure Sensor Travel Left Pilot Abnormality 1839
Diagnostic Trouble Code: 7073 Pressure Sensor Travel 1 Pedal Abnormality 1841
Diagnostic Trouble Code: 7075 Pressure Sensor Arm Cylinder Bottom Abnormality 1843
Diagnostic Trouble Code: 7200 Swing Brake Solenoid Abnormality 1845
Diagnostic Trouble Code: 7201 Travel 2nd-Speed Switchover Solenoid Abnormality 1847
Diagnostic Trouble Code: 7202 Pressure Boost Solenoid Abnormality 1848
Diagnostic Trouble Code: 7203 Travel Alarm Buzzer Abnormality 1849
Diagnostic Trouble Code: 7207 Free Swing Solenoid Abnormality 1850
Diagnostic Trouble Code: 7208 Fan Reverse Solenoid Signal Abnormality 1851
Diagnostic Trouble Code: 7212 Gate Lock Solenoid Abnormality 1852
Diagnostic Trouble Code: 7242 Fan Proportional Valve Signal Abnormality 1854
Diagnostic Trouble Code: 7247 Boom-2 Down Pilot Proportional Valve Abnormality 1856
Diagnostic Trouble Code: 7249 Bucket-close Pilot Proportional Valve Abnormality 1858
Diagnostic Trouble Code: 7265 Arm 1 Semi-Parallel Proportional Valve Abnormality 1860
Diagnostic Trouble Code: 7266 Arm 2 Semi-Parallel Proportional Valve Abnormality 1862
Diagnostic Trouble Code: 7270 Tilting 1 Proportional Valve Abnormality 1864
Diagnostic Trouble Code: 7271 Tilting 2 Proportional Valve Abnormality 1866
Diagnostic Trouble Code: 7273 Straight Travel Proportional Valve Abnormality 1868
Diagnostic Trouble Code: 7274 Lift Cut Relay Abnormality 1870
Diagnostic Trouble Code: 7400 Coolant Temperature Overheating 1 1871
Diagnostic Trouble Code: 7401 Coolant Temperature Overheating 2 1872
Diagnostic Trouble Code: 7404 Oil Temperature Overheating 1873
Diagnostic Trouble Code: 7405 Boost Temperature Overheating 1 1874
Diagnostic Trouble Code: 7406 Boost Temperature Overheating 2 1875
Diagnostic Trouble Code: 7420 Alternator Power Generation Failure 1876
Diagnostic Trouble Code: 7421 Coolant Level Decrease 1878
Diagnostic Trouble Code: 7422 Decrease in Engine Oil Pressure 1879
Diagnostic Trouble Code: 7423 Air Cleaner Clogging 1880
Diagnostic Trouble Code: 7426 Fuel Filter Clogging 1 1881
Diagnostic Trouble Code: 7427 Fuel Filter Clogging 2 1883
Diagnostic Trouble Code: 7428 Inducement (Remaining Urea Level Low) – Warning 1885
Diagnostic Trouble Code: 7429 Inducement (Remaining Urea Level Low) – Early 1886
Diagnostic Trouble Code: 7430 Inducement (Remaining Urea Level Low) – Final 1887
Diagnostic Trouble Code: 7602 ECM Communication Abnormality 1888
Diagnostic Trouble Code: 7603 Computer S Communication Abnormality 1890
Diagnostic Trouble Code: 7605 ECM Not-Matched 1891
Diagnostic Trouble Code: 7606 EEPROM Abnormality 1892
Diagnostic Trouble Code: 7608 Camera Abnormality 1893
Diagnostic Trouble Code: 7612 Air Conditioner Communication Abnormality 1902
Diagnostic Trouble Code: 7613 Monitor Communication (CAN) Abnormality 1904
Diagnostic Trouble Code: 7618 DCU Communication Abnormality 1906
List of special tools 1908
NUMERICAL VALUE CONVERSION TABLE 1908
Unit Conversion Ratio 1908
Length 1909
Area 1912
Volume 1913
Weight 1915
Pressure 1917
Torque 1919
Temperature 1921
A 1923
Travel Motor Special Tool 1923
490X4/600X4 MH 1923
Take-up Roller Special Tool 1931
490X4/600X4 MH 1931
Upper Roller Special Tool 1932
490X4/600X4 MH 1932
Lower Roller Special Tool 1933
490X4/600X4 MH 1933
Grease Cylinder Special Tool 1933
490X4/600X4 MH 1933
Center Joint Special Tool 1934
490X4/600X4 MH 1934
C 1935
Swing Motor Special Tool 1935
490X4/600X4 MH 1935
H 1937
Engine Oil Filter Special Tool 1937
490X4/600X4 MH 1937
Fuel Filter Special Tool 1937
490X4/600X4 MH 1937
Injector Special Tool 1937
490X4/600X4 MH 1937
Circuit Test Special Tool 1938
490X4/600X4 MH 1938
Valve Guide Special Tool 1938
490X4/600X4 MH 1938
Cylinder Head Special Tool 1938
490X4/600X4 MH 1938
Head Bolt Special Tool 1940
490X4/600X4 MH 1940
Crankshaft Special Tool 1941
490X4/600X4 MH 1941
Valve Spring Special Tool 1942
490X4/600X4 MH 1942
Special Tools for Piston 1942
490X4/600X4 MH 1942
Special Tools for Engine Cooling System 1943
490X4/600X4 MH 1943
J 1945
Remote Control Valve Special Tool 1945
490X4/600X4 MH 1945
R 1946
Gas Filling Special Tool 1946
490X4/600X4 MH 1946
Paint Colors 1947
Abbreviation 1949

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