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Link-Belt 300X4 Excavator SERVICE MANUAL WLSM3007-01LX – PDF DOWNLOAD
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Description
Link-Belt 300X4 Excavator SERVICE MANUAL WLSM3007-01LX – PDF DOWNLOAD
FILE DETAILS:
Link-Belt 300X4 Excavator SERVICE MANUAL WLSM3007-01LX – PDF DOWNLOAD
Language : English
Pages :1892
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Link-Belt 300X4 Excavator SERVICE MANUAL WLSM3007-01LX – PDF DOWNLOAD
General Information
- Cleaning Clean the metal parts with cleaning solution that meets the standard and steam cleaning. (except for bearings) After cleaning, dry well, and inject oil in all parts. Also inject oil into the bearings after drying. Inspection When disassembling parts, check all the parts.
- If there are any worn or damaged parts, replace them. Inspect carefully to prevent initial breakdowns. Bearing Replace any loose bearings. Air dry bearings before installing them. Needle bearing When inserting needle bearings, be very careful not to damage them.
- Apply grease to the section where the needle bearing will be inserted. Gear Check that there is no wear and no damage. Oil seal, O-ring, gasket Always install new oil seals, O-rings, and gaskets. Apply grease to sections where oil seals and O-rings will be inserted.
- Shaft Check that there is no wear and no damage. Check the bearings and check for damaged oil seals on the shaft. Service parts Install LBX Link-Belt genuine service parts. When placing an order, check the parts catalog. It contains the LBX Link-Belt genuine part numbers.
- Any breakdowns arising from the installation of non-genuine parts are not covered by the warranty. Lubricants (fuel, hydraulic oil) Use the oil from the specified company or specified in the operator’s manual or service manual. Any breakdowns arising from any fuel or hydraulic oil other than those specified are not covered by the warranty.
TABLE OF CONTENTS:
Link-Belt 300X4 Excavator SERVICE MANUAL WLSM3007-01LX – PDF DOWNLOAD
Excavator 1
SAFETY 9
Safety, general information and standard torque data 12
General Information 13
Safety 13
ROPS 15
ROPS Judgment 15
Standard Torque Data For Cap Screws And Nuts 18
Bolt and Nut Tightening 18
A LOWER 19
Main Equipment Table 23
Lower Component 23
Travel Unit 23
Take-up Roller 23
Upper Roller 23
Lower Roller 23
Recoil Spring 23
Shoe 23
Center joint 24
Main Equipment Structure and Operation Explanation 25
Travel Motor 25
Safety Precautions 25
Data 25
Use of Product 25
Specifications 25
Type Indication 26
Outside Dimension Diagram and Hydraulic Circuit Diagram 27
Basic Structure and Drawing 30
Assembly Cross-Section Diagram 30
Part List 31
Operation Explanation 33
Reduction Gear 33
Hydraulic Motor Section 34
Usage Precautions 49
Installation Instructions 49
Line 50
Hydraulic Fluid 50
Maintenance and Inspection 51
Daily Inspection 51
Replacement of Hydraulic Fluid 51
Lubricant 51
Table of Seals 54
Failure and Necessary Action 55
Storage of Travel Motor 58
Port Diagram 59
Travel Motor 59
Center Joint 60
Basic Functions 61
Travel Speed Selection 61
Travel Alarm 62
Removal and Installation of Track 63
Removal and Installation of Shoe Assembly 64
Removal of Shoe Assembly 64
Installation of Shoe Assembly 65
Removal and Installation of Shoe Plate 67
Removal of Shoe Plate 67
Installation of Shoe Plate 67
Removal and Installation of Roller 68
Removal and Installation of Upper Roller 69
Removal of Upper Roller 69
Installation of Upper Roller 70
Assembly and Disassembly of Upper Roller 71
Configuration Diagram 71
Dimension Diagram 72
Jig Dimension Diagram 72
Disassembly Procedure 72
Assembly Procedures 74
Removal and Installation of Lower Roller 78
Removal of Lower Roller 78
Installation of Lower Roller 79
Assembly and Disassembly of Lower Roller 80
Configuration Diagram 80
Dimension Diagram 81
Jig Dimension Diagram 81
Disassembly Procedures 81
Assembly Procedures 84
Removal and Installation of Drive Sprocket 87
Removal of Drive Sprocket 87
Installation of Drive Sprocket 88
Removal and Installation of Take-up Roller 89
Removal of Take-up Roller 89
Installation of Take-up Roller 89
Assembly and Disassembly of Take-up Roller 91
Configuration Diagram 91
Dimension Diagram 92
Jig Dimension Diagram 92
Disassembly Procedures 92
Assembly Procedures 94
Removal and Installation of Grease Cylinder 97
Removal of Grease Cylinder 97
Installation of grease cylinder 98
Assembly and Disassembly of Grease Cylinder 99
Configuration Diagram 99
Dimension Diagram 99
Jig Dimension Diagram 100
Disassembly Procedures 100
Assembly Procedures 101
Removal and Installation of Center Joint 103
Removal of Center Joint 103
Installation of Center Joint 105
Assembly and Disassembly of Center Joint 107
Configuration Diagram 108
Dimension Diagram 109
Jig Dimension Diagram 110
Disassembly Procedures 110
Assembly Procedures 111
Removal and Installation of Travel Motor 115
Removal of Travel Motor 115
Installation of Travel Motor 117
Assembly and Disassembly of Travel Motor 120
Safety Precautions 120
Service Overview 120
Tools 120
Tightening Torque 125
Weight Table 126
Disassembly 126
Preparations 126
General Work Precautions 126
Disassembly Procedure 127
Maintenance Standards 138
Seals 138
Maintenance Standards for Worn Components 138
Assembly 140
Preparations 140
General Work Precautions 140
Assembly Procedure 140
Performance Check Test 155
Maintenance Standards 156
Drive Sprocket 156
Take-up Roller 157
Upper Roller 158
Lower Roller 159
Track Shoe (Grouser Shoe) 160
Inspection Gauge 161
For Drive Sprocket 161
For Take-up Roller 162
For Upper Roller 163
For Lower Roller 163
Pressure Measurement and Adjustment Procedures 165
Main Pressure Measurement 165
B Travel Pressure Measurement 165
Drain Volume Measurement Procedures 166
Preparations 166
Travel Motor Drain Volume Measurement 166
Air Bleed Procedure 168
Travel Motor 168
B C SWING UNIT, COUNTERWEIGHT 171
Main Equipment Table 174
Upper Component 174
Swing Unit 174
Main Equipment Structure and Operation Explanation 175
Swing Motor 175
Swing Motor Operation Explanation 175
Hydraulic Motor Section 175
Valve Casing Section 176
Brake Section 177
Relief Valve Operation Explanation (relief valve model: KRD22EK10) 177
Swing Motor Internal Structure Diagram 180
Port Diagram 183
Swing motor 183
Basic Functions 184
Swing Brake 184
Swing Lock 184
Swing Speed Limit 186
Swing Relief Cut 187
Removal and Installation of Swing Unit 189
Removal of Swing Unit 189
Installation of Swing Unit 191
Assembly and Disassembly of Swing Unit 192
Disassembly 192
Assembly 193
Assembly and Disassembly of Swing Motor 195
Causes of Trouble and Solutions 195
Maintenance Standard Table 197
Required Tools 199
Jig 200
Disassembly 200
Assembly 202
Swing Motor Internal Structural Diagram 207
Removal and Installation of Counterweight 210
Removal of Counterweight 210
Installation of Counterweight 211
Pressure Measurement and Adjustment Procedures 212
Main Pressure Measurement 212
C Swing Pressure Measurement 212
Drain Volume Measurement Procedures 213
Preparations 213
Swing Motor Drain Volume Measurement 213
Air Bleed Procedure 214
Swing Motor 214
Check 215
H ENGINE 217
Main Equipment Table 225
Engine-related 225
Engine 225
Air Cleaner (double element) 225
Radiator 225
SCR 226
Basic Functions 227
Fuel Gauge 227
Coolant Temperature Gauge 229
SCR Gauge 230
Fuel Economy Gauge 232
Neutral Start 232
Power-cut Delay 233
Preheat 234
Throttle 235
Throttle Volume Position Detection 235
Idling Start 241
Auto Idle 242
One-touch Idle 243
Auto Warm Up 243
Idle Shutdown 246
Idle Up 247
Work Mode Control 248
Engine Emergency Stop 249
SCR regeneration 249
Inducement 253
Feed Pump Automatic Stop 257
Coolant Level Decrease 259
Air Filter Clogging 260
Fuel Filter Clogging 261
Battery Charge Abnormality 262
Main Data 264
Function, Structure, Operation 267
Function, structure, operation (SCR) 320
SCR Control System Inspection 346
Operation Explanation of SCR 347
Diagnosis for Each Symptom 349
Intermittent conditions of urea selective catalytic reduction system 349
Urea fluid consumption too high 352
Ammonia smell noticeable 352
White crystalline powder visible 353
Symptom 354
Engine Start Problem 354
Engine Stalling 356
Engine Hunting, Rough Idling 358
Excessive White Smoke in Exhaust Gas 359
Excessive Black Smoke in Exhaust Gas 360
Abnormal Noise 360
High Fuel Consumption 361
High Oil Consumption 362
Engine Output Deficiency 363
Functional Inspection 365
Engine Compression Pressure Inspection 365
Fuel System Inspection 366
Lubrication System Inspection 366
Suction air system inspection 367
Exhaust System Inspection 367
EGR Control System Inspection 367
Start System Inspection 368
Glow Control System Inspection 368
OBD System Inspection 369
Monitor Warning Light Lighting Circuit System Inspection 370
Inspection of the monitor warning light blinking circuit system 371
Start Circuit System Inspection 371
Removal and Installation of Engine Assembly 373
Removal of Engine Assembly 373
Installation of Engine Assembly 375
Removal and Installation of Fuel Cooler, Engine Intercooler, Radiator, and Oil Cooler 376
Removal and Installation of Fuel Cooler 376
Removal of Fuel Cooler 376
Installation of Fuel Cooler 376
Removal and Installation of Engine Intercooler 376
Removal of Intercooler 376
Installation of Inter Cooler 377
Inspection of Intercooler 378
Removal and Installation of Radiator 378
Removal of Radiator 379
Installation of Radiator 381
Inspection of Radiator 382
Removal and Installation of Oil Cooler 382
Removal of Oil Cooler 383
Installation of Oil Cooler 385
Removal and Installation of Turbo Charger 386
Removal of Turbo Charger 386
Installation of Turbo Charger 387
Inspection of Turbo Charger 389
Removal and Installation of EGR Valve 391
Removal of EGR Valve 391
Installation of EGR Valve 392
Inspection of EGR Valve 396
Removal and Installation of Engine Hood 398
Removal of Engine Hood 398
Installation of Engine Hood 398
Removal and Installation of SCR 399
Removal of SCR 399
Installation of SCR 399
Removal and installation of Silicon Controlled Rectifier Catalyst 400
Removal of Silicon Controlled Rectifier Catalyst 400
Installation of Silicon Controlled Rectifier Catalyst 400
Disassembly of Silicon Controlled Rectifier Catalyst 400
Assembly of Silicon Controlled Rectifier Catalyst 400
Inspection of Silicon Controlled Rectifier Catalyst 401
Removal and Installation of Cylinder Head Cover 402
Cylinder head cover Removal 402
Cylinder head cover Installation 402
Removal and Installation of Cylinder Head 403
Removal of Cylinder head assembly 403
Cylinder head assembly Disassembly 412
Cylinder head assembly Reassembly 417
Installation of Cylinder head assembly 425
Cylinder head assembly Inspection 444
Removal and Installation of Cylinder Block 451
Removal of Cylinder block 451
Installation of Cylinder block 467
Cylinder block Inspection 505
Lubrication System 507
Removal and Installation of Oil Pan 507
Oil pan Removal 507
Oil pan Installation 507
Removal and Installation of Oil Level Switch 507
Oil level switch Removal 507
Oil level switch Installation 508
Removal and Installation of Oil Pump Assembly 508
Removal of Oil pump assembly 508
Disassembly of Oil Pump 521
Assembly of Oil Pump 522
Installation of Oil Pump 522
Inspection of Oil Pump 548
Inspection of Engine oil 549
Removal and Installation of Oil Port Cover 550
Removal of Oil port cover 550
Installation of Oil port cover 550
Cooling System 552
Removal and Installation of Water Pump Assembly 552
Removal of Water pump assembly 552
Installation of Water pump assembly 553
Inspection of Water pump assembly 557
Removal and Installation of Thermostat 557
Removal of Thermostat 557
Installation of Thermostat 558
Inspection of Thermostat 560
Coolant Inspection 561
Inspection of Cooling Fan Belt 562
Removal and Installation of Overheat Switch 563
Removal of Overheat switch 563
Installation of Overheat switch 563
Induction System 564
Inspection of Air cleaner element 564
Exhaust System 565
Removal and installation of Oxidation Catalyst Assembly 565
Removal of Oxidation Catalyst Assembly 565
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 571
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 576
Removal of DCU 576
Installation of DCU 577
Removal and installation of DEF Supply Module Filter 577
Removal of DEF Supply Module Filter 577
Installation of DEF Supply Module Filter 577
Removal and Installation of Exhaust Manifold 578
Removal of Exhaust manifold 578
Installation of Exhaust manifold 581
Exhaust manifold Inspection 587
Removal and Installation of Fuel Tank 589
Removal of Fuel Tank 589
Installation of fuel tank 592
Removal and Installation of Urea Pump 593
Removal of Urea Pump 593
Installation of Urea Pump 593
Removal and Installation of Urea Tank 595
Removal of Urea Reservoir 595
Installation of Urea Reservoir 595
Removal and Installation of Fuel Supply Pump 596
Removal of Fuel Supply Pump 596
Fuel supply pump Installation 596
Removal and Installation of Common Rail Assembly 600
Removal of Common rail assembly 600
Installation of Common rail assembly 603
Removal and Installation of Injector 613
Injector Removal 613
Injector Installation 615
Removal and installation of Idle Gear 619
Removal of Idle Gear 619
Installation of Idle Gear 631
Inspection of Idle Gear 657
Removal and installation of Inlet Cover 659
Removal of Inlet Cover 659
Installation of Inlet Cover 663
Removal and installation of Crankshaft 672
Removal of Crankshaft 672
Installation of Crankshaft 688
Disassembly of Crankshaft 723
Assembly of Crankshaft 723
Inspection of Crankshaft 724
Removal and installation of Piston 730
Removal of Piston 730
Installation of Piston 740
Disassembly of Piston 761
Assembly of Piston 762
Inspection of Piston 763
Removal and installation of Camshaft 771
Removal of Camshaft 771
Installation of Camshaft 773
Disassembly of Camshaft 778
Assembly of Camshaft 779
Inspection of Camshaft 780
Removal and installation of Flywheel 782
Removal of Flywheel 782
Installation of Flywheel 783
Inspection of Flywheel 784
Removal and installation of Crankshaft Front Oil Seal 785
Removal of Crankshaft Front Oil Seal 785
Installation of Crankshaft Front Oil Seal 786
Removal and installation of Crankshaft Rear Oil Seal 790
Removal of Crankshaft Rear Oil Seal 790
Installation of Crankshaft Rear Oil Seal 791
Removal and installation of Rocker Arm Shaft 794
Removal of Rocker Arm Shaft 794
Installation of Rocker Arm Shaft 795
Disassembly of Rocker Arm Shaft 799
Assembly of Rocker Arm Shaft 799
Inspection of Rocker Arm Shaft 801
Removal and installation of Valve Spring 803
Removal of Valve Spring 803
Installation of Valve Spring 805
Inspection of Valve Spring 811
Removal and installation of Valve Stem Oil Seal 813
Removal of Valve Stem Oil Seal 813
Installation of Valve Stem Oil Seal 815
Removal and installation of Front Cover 823
Removal of Front Cover 823
Installation of Front Cover 825
Removal and installation of Intake Throttle Valve 832
Removal of Intake Throttle Valve 832
Installation of Intake Throttle Valve 832
Removal and Installation of Starter Motor 833
Removal of Starter Motor 833
Installation of Starter Motor 834
Disassembly of Starter Motor 834
Assembly of Starter Motor 836
Inspection of Starter Motor 839
Removal and Installation of Alternator 842
Removal of Alternator 842
Installation of Alternator 842
Disassembly of Alternator 842
Assembly of Alternator 844
Inspection of Alternator 845
Removal and Installation of Glow Plug 849
Glow plug Removal 849
Glow plug Installation 849
Glow plug Inspection 850
Removal and Installation of Suction Control Valve 851
Suction control valve Removal 851
Suction control valve Installation 851
Removal and installation of Fuel Filter 854
Removal of Fuel Filter 854
Installation of Fuel Filter 854
Removal and installation of Relief Valve 857
Removal of Relief Valve 857
Installation of Relief Valve 857
Removal and installation of Fuel Filter Element 860
Removal of Fuel Filter Element 860
Installation of Fuel Filter Element 861
Removal and Installation of Fuel filter pressure 864
Fuel filter pressure sensor Removal 864
Fuel filter pressure sensor Installation 864
Removal and Installation of Engine coolant temperature sensor 865
Engine coolant temperature sensor Removal 865
Engine coolant temperature sensor Installation 865
Engine coolant temperature sensor Inspection 865
Removal and Installation of CKP sensor 866
Removal of CKP sensor 866
Installation of CKP sensor 866
CKP sensor Inspection 866
Removal and Installation of CMP sensor 867
CMP sensor Removal 867
CMP sensor Installation 867
CMP sensor Inspection 867
Removal and Installation of Oil pressure sensor 868
Removal of Oil pressure sensor 868
Installation of Oil pressure sensor 868
Inspection of Oil pressure sensor 868
Removal and installation of Pressure Sensor/Boost Temperature Sensor 869
Removal of Pressure sensor/boost temperature sensor 869
Installation of Pressure sensor/boost temperature sensor 869
Inspection of Pressure sensor/boost temperature sensor 869
Removal and Installation of IMT sensor 870
Removal of IMT sensor 870
Installation of IMT sensor 870
Removal and installation of Charge Air Cooler Temperature Sensor 1 871
Removal of Charge air cooler temperature sensor 1 871
Installation of Charge air cooler temperature sensor 1 871
Inspection of Charge air cooler temperature sensor 1 871
Sampling Procedure 872
Sampling of Engine Oil 872
Removal and Installation of Exhaust gas temperature sensor 873
Removal of Exhaust gas temperature sensor 873
Installation of Exhaust gas temperature sensor 873
Inspection of Exhaust gas temperature sensor 873
Removal and installation of EGR Gas Temperature Sensor 1 875
Removal of EGR Gas Temperature Sensor 1 875
Installation of EGR Gas Temperature Sensor 1 875
Inspection of EGR Gas Temperature Sensor 1 875
Removal and installation of EGR Gas Temperature Sensor 2 876
Removal of EGR Gas Temperature Sensor 2 876
Installation of EGR Gas Temperature Sensor 2 876
Inspection of EGR Gas Temperature Sensor 2 876
Removal and installation of NOx Sensor 878
Removal of NOx Sensor 878
Installation of NOx Sensor 878
Removal and Installation of Exhaust gas temperature sensor 3 879
Removal of Exhaust gas temperature sensor 3 879
Installation of Exhaust gas temperature sensor 3 879
Removal and installation of DEF Sensor 880
Removal of DEF Sensor 880
Installation of DEF Sensor 880
Engine-related Diagnostic Trouble Code List 881
Engine-side Trouble 886
ECM Trouble 886
DTC U0001 CAN Bus Error (ISO-CAN) 886
DTC P0016 Crankshaft Position – Camshaft Position Correlation Error 887
DTC P0045 Turbocharger Boost Control VNT Error 887
DTC U0073 Control Module Communication Bus Off 889
DTC P0087 Fuel Rail/System Pressure – Too Low 890
DTC P0089 Fuel Pressure Regulator Performance 893
DTC P0091 Fuel Pressure Regulator Control Circuit Low 894
DTC P0092 Fuel Pressure Regulator Control Circuit High 895
DTC P0097 Intake Air Temperature (IAT) Sensor 2 Circuit Low Voltage 896
DTC P0098 Intake Air Temperature (IAT) Sensor 2 Circuit High Voltage 896
DTC U0101 Lost Communication With CAN 897
DTC P0102 Mass Air Flow Sensor Circuit Low Input 898
DTC P0103 Mass Air Flow Sensor Circuit High Input 899
DTC U010E Lost Communications With Dosing Control Module 899
DTC U0110 Lost Communication With VNT System 900
DTC P0112 Intake Air Temperature Sensor Circuit Low 900
DTC P0113 Intake Air Temperature Sensor Circuit High 901
DTC P0117 Engine Coolant Temperature Sensor Circuit Low 902
DTC P0118 Engine Coolant Temperature Sensor Circuit High 902
DTC P0122 Throttle Position Sensor Circuit Low 903
DTC P0123 Throttle Position Sensor Circuit High 904
DTC P0182 Fuel Temperature Sensor Circuit Low 905
DTC P0183 Fuel Temperature Sensor Circuit High 906
DTC P0192 Fuel Rail Pressure Sensor Circuit Low 907
DTC P0193 Fuel Rail Pressure Sensor Circuit High 907
DTC P0201 Injector Circuit Open – Cylinder 1 909
DTC P0202 Injector Circuit Open – Cylinder 2 909
DTC P0203 Injector Circuit Open – Cylinder 3 910
DTC P0204 Injector Circuit Open – Cylinder 4 911
DTC P0217 Engine Coolant Over Temperature Condition 912
DTC P0219 Engine Overspeed Condition 912
DTC P0234 Turbocharger Overboost Condition 913
DTC P0237 Turbo Charger Boost Sensor Circuit Low 914
DTC P0238 Turbo Charger Boost Sensor Circuit High 914
DTC P0335 Crankshaft Position Sensor Circuit 915
DTC P0336 Crankshaft Position Sensor Circuit Range/Performance 916
DTC P0340 Camshaft Position Sensor Circuit 917
DTC P0380 Glow Relay Circuit Error 918
DTC P0401 EGR Flow Insufficient Detected 919
DTC P0404 EGR Control Circuit Range/Performance 920
DTC P0409 EGR Sensor Circuit 920
DTC U0411 Lost CAN Communications With VNT Control Module 922
DTC P041C EGR Cooler Outlet 1 Temp Sensor Circuit Low 922
DTC P041D EGR Cooler Outlet 1 Temp Sensor Circuit High 923
DTC P0427 Catalyst Temperature Sensor Circuit Low Sensor 1 924
DTC P0428 Catalyst Temperature Sensor Circuit High Sensor 1 924
DTC P042C Catalyst Temperature Sensor Circuit Low Sensor 2 925
DTC P042D Catalyst Temperature Sensor Circuit High Sensor 2 926
DTC P0522 Engine Oil Pressure Sensor Circuit Low Input 927
DTC P0523 Engine Oil Pressure Sensor Circuit High Input 928
DTC P0545 EGR Cooler Inlet 1 Temp Sensor Circuit Low 929
DTC P0546 EGR Cooler Inlet 1Temp Sensor Circuit High 929
DTC P0560 12 Volt Circuit Error 930
DTC P0563 System Voltage High 930
DTC P0601 Internal Control Module Memory Check Sum Error 931
DTC P0602 Internal Control Module QR Code Error 931
DTC P0604 Internal Control Module RAM Error 932
DTC P0606 Internal Control Module CPU Error 932
DTC P060A Internal Control Module CPU IC Error 932
DTC P060C Internal Control Module A/D Processing Performance 932
DTC P0615 Starter Relay Circuit Error 933
DTC P0638 Throttle Actuator Control Range/Performance 933
DTC P0685 ECM Power Relay Control Circuit Open 934
DTC P0687 ECM Power Relay Control Circuit High 935
DTC P06A6 Sensor Reference Voltage 1 Circuit 935
DTC P06A7 Sensor Reference Voltage 2 Circuit 936
DTC P06A8 Sensor Reference Voltage 3 Circuit 937
DTC P06A9 Sensor Reference Voltage 4 Circuit 937
DTC P06AF Torque Management System – Forced Engine Shutdown 938
DTC P06D5 Sensor Reference Voltage 5 Circuit 939
DTC P1076 Charge Air Cooler (CAC) Temperature Sensor 1 Circuit Low Voltage 939
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 943
DTC P1098 Compressor Outlet Temperature Sensor Circuit High 944
DTC P1236 Charge Air Cooler Performance Failure 945
DTC P1261 Injector Positive Voltage Control Circuit Group 1 945
DTC P1262 Injector Positive Voltage Control Circuit Group 2 946
DTC P1404 EGR Position Fault 946
DTC P1606 SW-IC Internal failure 947
DTC P160B AD-IC Failure Error 947
DTC P160C AD-IC2 Failure Error 947
DTC P1621 Control Module Long Term Memory Performance 947
DTC P1669 DPD Lamp Control Circuit 948
DTC P204F SCR System Error (No Inducement) 949
DTC P207F Urea Fluid Concentration Too Low 949
DTC P20C9 SCR System Error 949
DTC U2106 Lost CAN Communications With Wheel Loader Transmission Control System 949
DTC P2122 Pedal Position Sensor 1 Circuit Low Input 950
DTC P2123 Pedal Position Sensor 1 Circuit High Input 950
DTC P2127 Pedal Position Sensor 2 Circuit Low Input 951
DTC P2128 Pedal Position Sensor 2 Circuit High Input 952
DTC P2138 Pedal Position Sensor 1 – 2 Voltage Correlation 952
DTC P2146 Fuel Injector Group 1 Supply Voltage Circuit 953
DTC P2149 Fuel Injector Group 2 Supply Voltage Circuit 954
DTC P2228 Barometric Pressure Sensor Circuit Low 955
DTC P2229 Barometric Pressure Sensor Circuit High 956
DTC P2457 Exhaust Gas Recirculation (EGR) Cooling System Performance 956
DTC P2458 Purge time Out Error 957
DTC P2BA7 Urea Fluid Quantity Too Low 957
DTC P2BAA SCR System Error (Inducement, No Purge) 957
DTC P3093 Fuel Rail Pressure Too Low 957
DCU Trouble 960
DTC 0002 CAN Bus Off 960
DTC 0100 Lost Communication With ECM 961
DTC 029D Lost Communication With NOx Sensor 1 962
DTC 0607 Control Module Performance 964
DTC 060B Internal Control Module A/D Processing Performance 965
DTC 062F Control Module EEPROM Error 965
DTC 0641 Sensor Reference Voltage 1 Circuit 966
DTC 0658 Actuator Supply Voltage Circuit 967
DTC 0659 Actuator Supply Voltage Circuit 968
DTC 1462 Urea Fluid Quality Sensor Timeout Error 969
DTC 1464 Main Relay Performance 969
DTC 1468 DCU Overtemperature 970
DTC 1491 Urea Fluid Overpressure 970
DTC 1493 DCU Driver Overtemperature 972
DTC 149C Urea Fluid Pressure Reduction Malfunction 972
DTC 149D Urea Fluid Tank Overtemperature 973
DTC 203B Urea Fluid Tank Level Sensor Stuck 974
DTC 203C Urea Fluid Tank Level Sensor Low Voltage 975
DTC 203D Urea Fluid Tank Level Sensor High Voltage 976
DTC 2048 Urea Fluid Injector Circuit Low Voltage 977
DTC 2049 Urea Fluid Injector Circuit High Voltage 978
DTC 204B Urea Fluid Pressure Sensor Performance 978
DTC 204C Urea Fluid Pressure Sensor Circuit Low Voltage 979
DTC 204D Urea Fluid Pressure Sensor Circuit High Voltage 980
DTC 205B Urea Fluid Tank Temperature Sensor Performance 981
DTC 205C Urea Fluid Tank Temperature Sensor Low Voltage 982
DTC 205D Urea Fluid Tank Temperature Sensor High Voltage 982
DTC 206A Urea Fluid Quality Sensor Circuit 983
DTC 206B Urea Sensor Over Temperature Condition 983
DTC 206C Urea Fluid Quality Sensor Circuit Low Voltage 984
DTC 206D Urea Fluid Quality Sensor Circuit High Voltage 985
DTC 207F Urea Fluid Concentration Too Low 985
DTC 208A Urea Fluid Pump Control Circuit 986
DTC 208B Usea Fluid Pump Performance 986
DTC 208C Urea Fluid Pump Control Circuit Low Voltage 987
DTC 208D Urea Fluid Pump Control Circuit High Voltage 988
DTC 208E Urea Fluid Injector Stuck 989
DTC 20A0 Urea Fluid Reverting Valve Circuit Open 990
DTC 20A2 Urea Fluid Reverting Valve Circuit Low Voltage 990
DTC 20A3 Urea Fluid Reverting Valve Circuit High Voltage 991
DTC 20AC Urea Fluid Pump Temperature Sensor Performance 992
DTC 20AD Urea Fluid Pump Module Temperature Sensor Performance 993
DTC 20B1 Urea Fluid Tank Heater Coolant Control Valve Circuit Open 994
DTC 20B3 Urea Fluid Tank Heater Coolant Control Valve Circuit Low Voltage 995
DTC 20B4 Urea Fluid Tank Heater Coolant Control Valve Circuit High Voltage 995
DTC 20E8 Urea Fluid Pressure Underpressure 996
DTC 20E9 Urea Fluid Overpressure 997
DTC 20EA Urea Fluid Pressure Reduction Malfunction 999
DTC 20FE Urea Fluid Pressure Build-Up Error 999
DTC 2201 Upstream Nox Sensor Performance1001
DTC 2206 NOx Sensor Heater Control Circuit Low Voltage Sensor 11001
DTC 2207 NOx Sensor Heater Control Circuit High Voltage Sensor 11002
DTC 242B Exhaust Gas Temperature (EGT) Sensor 3 Performance1002
DTC 242C Exhaust Gas Temperature (EGT) Sensor 3 Circuit Low Voltage1002
DTC 242D Exhaust Gas Temperature (EGT) Sensor 3 Circuit High Voltage1003
Data Reference Values1005
Idle Speed1005
Two pump relief1006
J HYDRAULIC EQUIPMENT (PUMP, OPERATION SYSTEM VALVE)1007
Main Equipment Table1013
Hydraulic Device1013
Hydraulic Pump1013
PQ Diagram1013
Control-related1014
Control Valve1014
Solenoid Valve (5 Stack)1014
Remote Control Valve for Left/Right Operations1014
Remote Control Valve for Travel Operation1014
Remote Control Valve Characteristic Diagram1015
Operation Remote Control Valve Control Diagram1015
Travel Remote Control Valve Control Diagram1016
Cushion Valve (Heat Circuit, with Shuttle Valve)1016
Selector Valve (option)1016
Basic Functions1017
Oil Temperature Gauge1017
Static Horsepower Control1018
Overload Warning (Function for Europe Only)1019
Pressure Boost Control1020
Stroke Control1022
Boom Down Energy Save1023
Pump Horsepower Boost Control1024
Arm 1 Semi-parallel Control1024
Arm 2 Semi-parallel Control1025
Hot Shutdown Warning1026
Gate Lock1027
Breaker Mode1028
Crusher Mode1028
Quick coupler1029
Hydraulic Filter Clogging1030
Solenoid Sticking Prevention1031
Port Diagram1032
Hydraulic Pump (standard model)1032
Control Valve1034
Relief Valve1034
5 Stack Solenoid Valve1037
2 Stack Solenoid Valve1039
Remote Control Valves (upper, travel)1039
Remote Control Valves (left-right)1039
Remote Control Valve (Travel)1040
Cushion Valve1041
2-way Selector Valve1042
Direction Valve1043
6 Stack Proportional Valve1044
Relief Valve (electromagnetic proportional)1046
Manifold Under Cab1047
Manifold (accumulator section)1048
Hydraulic Oil Tank1049
Hydraulic Pump1050
Structure and Operation Explanation1050
Hydraulic Pump Internal Structure Diagram1051
Overall view1051
Drive Shaft Front Side1051
Drive Shaft on Rear Side1052
Parts Table1053
Regulator1054
Regulator Operation Explanation1054
Regulator Operation Explanation Diagram1056
Internal Configuration Diagram of Regulator1058
Development Diagram of Regulator1060
Component Table1061
Gear Pump1063
Gear Pump Internal Structure Diagram1063
Structure and Operation Explanation1064
Operation Outline of Electronically-Controlled Pump1065
Control Valve1068
Basic Configuration1068
Operation1068
Operation of Main Unit1068
Activation of Relief Valve1089
5 Stack Solenoid Valve Operation Explanation1094
External Shape Diagram and Components1094
operation explanation1094
Upper Pilot Valve (remote control valve)1095
Structure1095
Function1095
Operation1096
Structural Diagram1100
Travel Pilot Valve (remote control valve)1101
Operation1101
Pressure Reducing Valve Section1101
Damping Mechanism in Operation Section1102
Structural Diagram1105
Cushion Valve 1107
structure1107
operation explanation1107
Selector Valve (2-way)1112
structure1112
operation explanation1113
Development Diagram1114
Direction Valve (3-direction) 1115
Structure1115
Operation Explanation1116
6 Stack Proportional Valve (Pilot)1118
structure1118
operation principle1119
Electromagnetic Relief Valve1120
Structure1120
Operation Explanation1121
Operation of Check Valve1121
Operation of Electromagnetic Relief Valve1122
Removal and Installation of Hydraulic Tank1124
Removal of Hydraulic Reservoir1124
Installation of Hydraulic Oil Tank1126
Removal and Installation of Hydraulic Pump1127
Removal of Hydraulic Pump1127
Installation of Hydraulic Pump1129
Removal and Installation of Control Valve1130
Removal of Control Valve1130
Installation of Control Valve1134
Removal and Installation of Travel Remote Control Valve1135
Removal of Travel Remote Control Valve1135
Installation of Travel Remote Control Valve1136
Removal and Installation of Operation Remote Control Valve1139
Removal of Operation Remote Control Valve (Left)1139
Installation of Operation Remote Control Valve (Left)1141
Removal of Operation Remote Control Valve (right side)1143
Installation of Operation Remote Control Valve (right side)1145
Removal and Installation of 5 Stack Solenoid1147
Removal of 5 Stack Solenoid Valve1147
Installation of 5 Stack Solenoid Valve1148
Removal and Installation of Cushion Valve1149
Removal of Cushion Valve1149
Installation of Cushion Valve1150
Procedures for Assembly and Disassembly of Hydraulic Pump Main Unit1151
Tools1151
Disassembly Procedure1151
Assembly Procedure1153
Pump Main Unit Maintenance Standards1156
Worn Parts Replacement Standards1156
Standards for repairing cylinders, valve plates, and swash plates (shoe plates)1156
Tightening Torque1157
Overall View1157
Attached diagram 1 pump assembly cross-section diagram1157
Drive Shaft Front Side1158
Drive Shaft Rear Side1159
Part Table1160
Regulator Maintenance Standards1162
Regulator Adjustment1162
Appendix Table and Drawings1163
Regulator Assembly and Disassembly Procedures1167
Tools1167
Preparations for Disassembly1167
Disassembly Procedure1167
Assembly Procedure1169
Internal Configuration Diagram of Regulator1173
Development Diagram of Regulator1175
Component Table1176
Assembly and Disassembly of Control Valve1178
Disassembly1178
Caution for Disassembly1178
Disassembly Procedure1178
Removal of Long Cap and Pulling Out of Main Spool1178
Disassembly of Arm 1, 2 Parallel-Tandem Spool, Neutral Cut Spool, Arm Regeneration Release Spool Section1179
Disassembly of Load Check Valve Section1179
Disassembly of Antidrift Valve Section (Sub Component in Assembly is Expressed by (Min Number – Sub Number))1180
Disassembly of Relief Valve1180
Disassembly of Option Section1180
Disassembly of Add-On Section1180
Disassembly of Valve Housing Coalescence Bolt1181
Cleaning1181
Inspection1181
assembly1181
Caution for Assembly1181
Caution for Handling O-ring1181
Caution for Handling Spool1181
Method to Apply Adhesive Agent (Male and Female Thread Section of Components Requiring Bonding)1181
Assembly Procedure of Sub-Assembly1182
Assembly of Spool Assembly (Main Spool)1182
Assembly of Arm 1, 2 Parallel-Tandem Spool, Neutral Cut Spool, Arm Regeneration Release Spool Assembly1182
Assembly of Antidrift Valve Assembly1183
Assembly Procedure of Control Valve Main Unit1183
Assembly of Relief Valve1183
Assembly of Load Check Valve1183
Assembly of Antidrift Valve1184
Assembly of Option Section1184
Assembly of Arm 1 Parallel-Tandem Spool1184
Assembly of Arm 2 Parallel-Tandem Spool, Neutral Cut Spool, Arm Regeneration Release Spool1184
Assembly of Main Spool1184
Assembly of Add-On Section1185
Assembly of Other Plugs1185
Internal Structural Diagram1186
Part List1192
Relief Valve1193
Assembly and Disassembly Procedure of Main Relief Valve1193
Assembly and Disassembly Procedures of Overload Relief1194
Assembly and Disassembly Procedure of Low-Pressure Relief Valve1195
Assembly and Disassembly Procedure of Main Relief Valve for Add-On1195
Adjustment of Relief Valve1196
Installation1197
Operation1197
Malfunction and Countermeasure1197
Procedures for Assembly and Disassembly of Operation Remote Control Valve1199
Maintenance Procedures1199
Required Tools and Tightening Torque1199
Maintenance Standards1199
Disassembly Procedures1200
Assembly Procedures1202
Causes of Trouble and Countermeasures1206
Procedures for Assembly and Disassembly of Travel Remote Control Valve1210
Maintenance Procedures1210
Disassembly Procedures1211
Assembly Procedures1215
Causes of Trouble and Countermeasures1220
Assembly and Disassembly of Cushion Valve1223
Disassembly Procedures1223
Reverse Operation Spool Section1223
Check Plunger Section with Throttle1223
Shuttle Valve Section1223
Assembly Procedures1224
Reverse Operation Spool Section1224
Check Plunger Section with Throttle1224
Shuttle Valve Section1224
Written Materials1225
Procedures for Assembly and Disassembly of 6 Stack Proportional Valve (Pilot)1227
Development Diagram1227
Assembly and disassembly procedures1228
Precautions1228
Replacement of Proportional Solenoid1228
Disassembly1228
Assembly1228
Replacement of Sleeve and Spool1229
Disassembly1229
Assembly1230
Replacement of Poppet (Check Valve for Normally Open)1231
Disassembly1231
assembly1232
Maintenance Standards1232
Troubleshooting1232
Pressure Measurement and Adjustment Procedures1234
Procedures for Pressure Measurement from the Monitor Display1234
Monitor and Switch Panel1234
Pressure Measurement Method1234
Operating Method1234
PROCEDURES FOR MEASURING HYDRAULIC OIL TEMPERATURE FROM THE MONITOR DISPLAY1234
Hydraulic Oil Temperature Measurement Method1234
Operating Method1235
Procedures for Pressure Measurement by Installing Pressure Gauge1236
Preparations1236
Items to Prepare1236
Pressure Measuring Ports1237
Control Valve1239
Location of Relief Valves1239
Pressure Measurement Preparations1240
Pressure Measurement1242
Main Pressure Measurement1242
A Attachment Pressure Measurement1242
Boom-down Pressure Measurement1243
D Option Line Pressure Measurement1244
Pilot Pressure Measurement1244
Pressure Gauge Installation1244
Negative Control Pressure Measurement1245
Pressure Gauge Installation1245
Pressure Adjustment1245
Main Pressure Adjustment1245
Pressure Measurement and Adjustment Preparations1245
Main Relief Pressure Adjustment1247
Overload Relief Pressure Adjustment1248
Swing Relief Pressure Adjustment1249
Pilot Pressure Adjustment1250
Hydraulic Pump Flow Measurement Procedures1251
Preparations1251
Items to Prepare1251
Work Preparations1251
Flow Measurement1253
Air Bleed Procedure1255
Hydraulic Pump1255
Sampling Procedure1256
Sampling of Hydraulic Fluid1256
Hydraulic Equipment Layout1257
Overall View1258
Pump Chamber Hydraulic Equipment Layout1259
Swing Body Center Section Hydraulic Equipment Layout1261
Housing Left Side Hydraulic Equipment Layout1262
Layout of Hydraulic Equipment in Cab1263
N CAB1339
Removal and Installation of Operator’s Seat1342
Removal of Operator’s Seat1342
Installation of Operator’s Seat1342
Removal and Installation of Cab Assembly1343
Removal of Cab Assembly1343
Installation of Cab Assembly1347
Removal and Installation of Wiper1348
Removal of Wiper1348
Installation of wiper1348
Removal and Installation of Cab Front Glass1349
Removal of Cab Front Glass1349
Installation of Cab Front Glass1350
Window Lock Adjustment Procedures1351
Window Lock (front side)1351
Window Lock (rear side)1351
Removal and Installation of Housing Guardrail1353
Removal of Housing Guardrail1353
Installation of Housing Guardrail1354
Tightening Torque1355
R ELECTRICAL PARTS1357
Basic Functions1361
Monitor Control1361
Monitor Display Dimming1361
Diagnostic Trouble Code Indicator1362
Clock1362
Basic Operation1363
Battery Save1363
Accessories1365
Working Light1365
LED Light1366
Room Lamp1367
Radio Mute1368
Wiper and Washer1369
Safety1372
Horn1372
Back/Side View Monitor1373
Precautions for Camera Installation1373
Maintenance1374
Anti-theft1374
Manual Lock1374
Service Support Screen Lock1374
Customer-specific System Information Screen Lock1374
Maintenance Information Screen Lock1375
Option Line Setting Screen Lock1375
Setting1375
Clock Adjustment1375
Screen Brightness Setting1376
Battery Disconnect Switch1377
Explanation of Controller1378
Service Support1380
Screen Operations1380
Screen Display List1380
Service Monitor Structure1381
CHECK Screen List1382
MACHINE STATUS1382
HYDRAULIC STATUS1388
ENGINE STATUS1395
FAULT HISTORY1400
WORK HISTORY1400
HYDRAULIC HISTORY1409
ENGINE HISTORY1421
DEVICE TEST1442
ECM/DCU Memory Clear1442
Urea Line Leak Test1443
CCV Operation Test1444
Dosing Test1445
Reverting Valve Operation Test1446
Common Rail Pressure Test1447
Injector Balance Test1448
Injector Forced Drive Test1449
EGR Valve Control Test1450
VG Turbo Control Test1451
Intake Throttle Control Test1452
CONTROL UNIT Screen List1453
MCM-MAIN1453
MCM-SUB1457
COMMU TERMINAL1458
SETUP Screen List1460
MACHINE SELECT1461
DIMENSIONS1465
PARAMETERS1466
ENGINE INFORMATION1468
ENGINE INFORMATION1469
Data Confirmation1469
Data Transfer (Copy)1470
QR (INJECTOR) CODE1471
Injector number1471
Screen Layout1471
Data Source Selection1471
Manual Input1472
CAMERA1473
PASSWORD1476
CALIBRATE Screen List1479
Throttle Volume1479
OPTLINE RELIEF1480
PUMP FLOW1481
Connection Connector Pin Layout1484
Main Controller1484
Monitor1485
Sequence Circuit Diagram1486
Code List1486
Overall1492
Block diagram1495
Main Controller1495
DCU1496
ECM1497
Monitor1498
Air Conditioner1499
Lever Lock1500
Horn1500
Working Light1500
Option1501
Others1502
Electrical Symbol List1502
Electrical Equipment Layout Diagram1504
Main Unit Left Side Layout Diagram1505
Engine Section Layout Diagram1509
Main Unit Right Side Layout Diagram (Pump Chamber)1512
Main Unit Center Section Layout Diagram1513
Cab Layout Diagram 11514
Cab Layout Diagram 21516
Layout Around Operator Seat1519
Stand Alone Parts Diagram1520
Removal and Installation of Wiper Controller1542
Removal of Wiper Controller1542
Installation of wiper controller1542
Removal and Installation of Wiper Motor1543
Removal of Wiper Motor1543
Installation of wiper motor1544
Removal and Installation of ECM1545
Removal of ECM1545
Installation of ECM1545
Removal and Installation of Main Controller1546
Removal of Main Controller1546
Installation of Main Controller1546
Removal and Installation of DCU1547
Removal of DCU1547
Installation of DCU1547
Removal and Installation of Monitor1548
Removal of Monitor1548
Installation of Monitor1548
Air Conditioner Overall Diagram1549
Frame1549
Cab1552
Equipment Layout Diagram1555
Circuit Diagram1557
Air Conditioner Circuit Diagram1557
Explanation of Functions1559
Explanation of Control1559
Air Mix Motor Actuator Control1560
Blow Mode Motor Actuator Control1560
Refresh/Recirculate Switch Motor Actuator Control1561
Blower Amp Control1562
Compressor Clutch Control1564
COOLMAX Control and HOTMAX Control1565
Abnormality Detection and Control after Abnormality Detected1565
Monitor Mode1569
Door Switch Control1571
Actuator Inspection1572
Air Mix Motor Actuator Inspection1572
Refresh/Recirculate Switch Motor Actuator Inspection1573
Mode Motor Actuator Inspection1574
Self-diagnosis Function with Panel Display1575
Abnormality Display and Self-check Procedures1575
Abnormality Display Position1575
Explanation of Abnormality Display1575
Motor Actuator Abnormality1575
Sensor Abnormality1576
Explanation of Monitor Mode1576
Monitor Mode Display Position1577
Monitor Mode Display Operating Method1577
Display Contents in Monitor Mode1578
Part Function and Good/Poor Judgment1584
Control Panel1584
Blower Amp1584
Relay1585
Air Mix Actuator1586
Refresh/Recirculate Actuator1587
Blow Mode Actuator1587
Evaporator Sensor1588
Dual Pressure Switch1588
Solar Radiation Sensor1589
Inside Air Sensor1589
Assembly and Disassembly of Unit1591
Removal of Blower Unit1591
Replacement of Blower Motor1591
Replacement of Blower Amp1591
Removal of Heater Core1592
Removal of Heat Case Right/Left1592
Replacement of Evaporator and Expansion Valve1592
Installation of Evaporator Sensor1593
Replacement of Motor Actuator1593
Removal and Installation of Compressor1594
Removal of Compressor1594
Installation of Compressor1594
Removal and Installation of Condenser1595
Removal of Condenser1595
Installation of Condenser1596
Removal and Installation of Receiver Dryer1597
Removal of Receiver Dryer1597
Installation of Receiver Dryer1597
Work Precautions1599
Work Procedures1599
Air Conditioner Refrigerant Filling is Divided into the “Vacuum Operation” and “Gas Filling Operation”1599
Operation Chart1600
Tools1600
Filling Procedures1602
Charging Hose Connection Position1602
Connecting Gauge Manifold1602
Vacuuming1603
Gas Filling Operation, High-pressure Side1604
Gas Filling Work, Low Pressure Side1604
V ATTACHMENTS1635
Main Equipment Table1639
Backhoe Attachment1639
Cylinder1639
Maintenance Standards1640
Attachment (Backhoe)1640
1 Boom and Swing Frame Installation Section1640
2 Boom Cylinder and Swing Frame Installation Section1641
3 Boom and Boom Cylinder Installation Section1641
4 Boom and Arm Cylinder Installation Section1642
5 Boom and Arm Installation Section1642
6 Arm and Arm Cylinder Installation Section1643
7 Arm and Bucket Cylinder Installation Section1643
8 Arm and Arm Link Installation Section1644
9 Bucket and Bucket Link Installation Section1644
10 Bucket Link and Bucket Cylinder Installation Section1645
11 Bucket and Arm Installation Section1645
Removal and Installation of Bucket Cylinder1647
Removal of Bucket Cylinder1647
Installation of Bucket Cylinder1649
Removal and Installation of Arm Cylinder1650
Removal of Arm Cylinder1650
Installation of Arm Cylinder1652
Removal and Installation of Boom Cylinder1654
Removal of Boom Cylinder1654
Installation of Boom Cylinder1656
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder1659
Specifications and Structure Diagram (including the assembly diagram and parts table)1659
Basic Functions1659
Function of Each Location1659
Cylinder Head Assembly (made by KYB)1659
Piston Assembly (made by KYB)1660
Pipe Assembly (made by KYB)1662
Handling Precautions1662
Precautions for Installing the Cylinder on the Machine Body1662
Usage Cautions1663
Maintenance and Inspection Cautions1663
Maintenance Inspection and Service1665
Trouble Diagnostics1666
Storage Standards1671
Storing Parts Individually (In principle, store indoors)1671
When Mounted on Vehicle Body1671
Recommended Anti-rust Oil1671
Assembly and Disassembly Procedures1672
Preparations ····· Prepare the Following before Starting Disassembly1672
General Work Precautions1672
Maintenance Standards1672
Inspection after Assembly1672
Required Tool1673
General Tool1673
Special Jig (made by KYB)1674
Special Jig Parts Number List (made by KYB)1674
Disassembly Procedures (made by KYB)1675
Assembly Procedures (made by KYB)1678
Test Operation1683
Usage Limits1684
Structural Diagram (made by KYB)1685
Boom Cylinder1685
Arm Cylinder1687
Bucket Cylinder1689
HBCV1691
structure1691
Function1691
operation explanation1691
Port Diagram1706
HBCV1706
Air Bleed Procedure1707
HBCV1707
Boom Cylinder HBCV1707
Arm Cylinder HBCV1708
Removal and Installation of HBCV1709
Removal and Installation of Arm HBCV1710
Removal of Arm HBCV1710
Installation of Arm HBCV1710
Removal and Installation of Boom HBCV1712
Removal of Boom HBCV1712
Installation of Boom HBCV1713
Removal and Installation of Bucket1715
Removal of Bucket1715
Installation of Bucket1715
Removal and Installation of Bucket Link1717
Removal of Bucket Link1717
Installation of Bucket Link1717
Removal and Installation of Arm1719
Removal of Arm1719
Installation of Arm1720
Removal and Installation of Boom1721
Removal of Boom1721
Installation of Boom1723
Z OTHER1727
Changes from Model -61732
Overall Layout1732
Lower1732
Swing Unit1733
Engine1733
hydraulic-related1735
Hydraulic Control1736
Cab, Housing1737
Electrical Data1739
Electric Control1740
Attachments1740
Specifications1741
ENGINE1741
HYDRAULIC SYSTEM1741
HYDRAULIC CONTROLS1742
ELECTRICAL SYSTEM1742
OPERATOR ENVIRONMENT1743
UNDERCARRIAGE1743
Mass1744
Digging force (with 11 m3 Sumitomo Bucket) (ISO 6015)1744
DIMENSIONS1744
WORKING RANGES1745
SYSTEM FLUID CAPACITIES AND SPECIFICATIONS1745
Main Unit Weight1746
Divided Weight (Standard Specifications)1746
Stand Alone Part Weight1746
Shoe Weight (Per Side)1747
Arm Weight1747
Bucket Weight1747
Bolt Size and Torque Table1749
Special Torque Setting1749
Overall View1754
300X41754
Standard Arm (318 m (1043 ft))1754
Short Arm (265 m (869 ft))1755
Long Arm (366 m (1201 ft))1756
WORK RANGE DIAGRAM1757
300X41757
Standard Arm (318 m (1043 ft))1757
Short Arm (265 m (869 ft))1759
Long Arm (366 m (1201 ft))1761
New Machine Performance Judgment Table1763
Measurement Method1763
Engine speed1763
Pressure at Each Part1763
Cylinder Down Amount1764
Attachment Speed1764
Swing Speed1765
Swing (180°) Brake Angle1765
Travel Speed1765
Off Travel Amount1766
Travel Sprocket Speed1766
Shoe Tension Amount1766
Swing Ball Race Bearing Movement Amount and Bucket Tip Movement Amount1767
FLUIDS AND LUBRICANTS1769
HYDRAULIC FLUID1769
Engine Oil1769
Fuel1769
Conditions applicable to diesel fuel1769
Recommended Conditions Applicable to Diesel Fuel1769
Main-unit-related Diagnostic Trouble Code List1770
Main Unit-side Trouble1773
Diagnostic Trouble Code: 7000 Pressure Sensor P1 Abnormality1773
Diagnostic Trouble Code: 7001 Pressure Sensor P2 Abnormality1774
Diagnostic Trouble Code: 7002 Pressure Sensor N1 Abnormality1776
Diagnostic Trouble Code: 7003 Pressure Sensor N2 Abnormality1777
Diagnostic Trouble Code: 7004 Pressure Sensor Boom Cylinder Bottom Abnormality1779
Diagnostic Trouble Code: 7007 Pressure Sensor Arm Cylinder Rod Abnormality1780
Diagnostic Trouble Code: 7021 Pressure Sensor Swing Pilot Abnormality1782
Diagnostic Trouble Code: 7023 Pressure Sensor Arm-In Pilot Abnormality1783
Diagnostic Trouble Code: 7040 Level Sensor Fuel Abnormality1785
Diagnostic Trouble Code: 7041 Temperature Sensor Hydraulic Fluid Abnormality1786
Diagnostic Trouble Code: 7065 Pressure Sensor Boom-Up Pilot Abnormality1787
Diagnostic Trouble Code: 7067 Pressure Sensor Bucket-Close Pilot Abnormality1789
Diagnostic Trouble Code: 7068 Pressure Sensor Boom-Down Pilot Abnormality1790
Diagnostic Trouble Code: 7069 Pressure Sensor Arm-Out Pilot Abnormality1792
Diagnostic Trouble Code: 7070 Pressure Sensor Bucket-Open Pilot Abnormality1794
Diagnostic Trouble Code: 7071 Pressure Sensor Travel Right Pilot Abnormality1796
Diagnostic Trouble Code: 7072 Pressure Sensor Travel Left Pilot Abnormality1797
Diagnostic Trouble Code: 7073 Pressure Sensor Travel 1 Pedal Abnormality1799
Diagnostic Trouble Code: 7074 Pressure Sensor 1st Option Pilot (Common/Front Pedal) Abnormality1801
Diagnostic Trouble Code: 7075 Pressure Sensor Arm Cylinder Bottom Abnormality1803
Diagnostic Trouble Code: 7078 Pressure Sensor 1st Option Pilot (Rear Pedal) Abnormality1804
Diagnostic Trouble Code: 7200 Swing Brake Solenoid Abnormality1806
Diagnostic Trouble Code: 7201 Travel 2nd-Speed Switchover Solenoid Abnormality1807
Diagnostic Trouble Code: 7202 Pressure Boost Solenoid Abnormality1808
Diagnostic Trouble Code: 7203 Travel Alarm Buzzer Abnormality1809
Diagnostic Trouble Code: 7206 Option Return Line Switchover Solenoid Abnormality1810
Diagnostic Trouble Code: 7207 Free Swing Solenoid Abnormality1812
Diagnostic Trouble Code: 7213 Quick Coupler Buzzer Abnormality1813
Diagnostic Trouble Code: 7214 Quick Coupler Solenoid Abnormality1814
Diagnostic Trouble Code: 7247 Boom 2-Down Pilot Proportional Valve Abnormality1816
Diagnostic Trouble Code: 7249 Bucket-Close Pilot Proportional Valve Abnormality1817
Diagnostic Trouble Code: 7250 Option Relief Pressure Proportional Valve Abnormality1818
Diagnostic Trouble Code: 7265 Arm 1 Semi-Parallel Proportional Valve Abnormality1820
Diagnostic Trouble Code: 7266 Arm 2 Semi-Parallel Proportional Valve Abnormality1821
Diagnostic Trouble Code: 7267 Arm 1 Regeneration Release Proportional Valve Abnormality1822
Diagnostic Trouble Code: 7270 Tilting 1 Proportional Valve Abnormality1823
Diagnostic Trouble Code: 7271 Tilting 2 Proportional Valve Abnormality1825
Diagnostic Trouble Code: 7273 Straight Travel Proportional Valve Abnormality1826
Diagnostic Trouble Code: 7400 Coolant Temperature Overheating 11827
Diagnostic Trouble Code: 7401 Coolant Temperature Overheating 21828
Diagnostic Trouble Code: 7404 Oil Temperature Overheating1829
Diagnostic Trouble Code: 7405 Boost Temperature Overheating 11830
Diagnostic Trouble Code: 7406 Boost Temperature Overheating 21831
Diagnostic Trouble Code: 7420 Alternator Power Generation Failure1832
Diagnostic Trouble Code: 7421 Coolant Level Decrease1833
Diagnostic Trouble Code: 7422 Engine Oil Pressure Decrease1834
Diagnostic Trouble Code: 7423 Air Cleaner Clogging1835
Diagnostic Trouble Code: 7424 Return Filter Clogging1836
Diagnostic Trouble Code: 7426 Fuel Filter Clogging 11837
Diagnostic Trouble Code: 7427 Fuel Filter Clogging 21838
Diagnostic Trouble Code: 7428 Inducement (Remaining Urea Level Low) – Warning1839
Diagnostic Trouble Code: 7429 Inducement (Remaining Urea Level Low) – Early1840
Diagnostic Trouble Code: 7430 Inducement (Remaining Urea Level Low) – Final1840
Diagnostic Trouble Code: 7602 ECM Communication Abnormality1841
Diagnostic Trouble Code: 7605 ECM Not-Matched1842
Diagnostic Trouble Code: 7606 EEPROM Abnormality1843
Diagnostic Trouble Code: 7608 Camera Abnormality1843
Diagnostic Trouble Code: 7612 Air Conditioner Communication Abnormality1845
Diagnostic Trouble Code: 7613 Monitor Communication (CAN) Abnormality1846
Diagnostic Trouble Code: 7615 Sub-Controller Communication Abnormality1847
Diagnostic Trouble Code: 7618 DCU Communication Abnormality1849
List of special tools1851
NUMERICAL VALUE CONVERSION TABLE1851
Unit conversion rate1851
Length1851
Area1853
Volume1854
Weight1856
Pressure1857
Torque1858
Temperature1859
A1862
Travel Motor Special Tool1862
300X41862
Take-up Roller Special Tool1869
300X41869
Upper Roller Special Tool1870
300X41870
Lower Roller Special Tool1871
300X41871
Grease Cylinder Special Tool1871
300X41871
Center Joint Special Tool1872
300X41872
C1873
Swing Motor Special Tool1873
300X41873
H1875
Engine Oil Filter Special Tool1875
300X41875
Fuel Filter Special Tool1875
300X41875
Injector Special Tool1875
300X41875
Circuit Test Special Tool1876
300X41876
Valve Guide Special Tool1876
300X41876
Cylinder Head Special Tool1876
300X41876
Head Bolt Special Tool1879
300X41879
Crankshaft Special Tool1879
300X41879
Camshaft Special Tool1882
300X41882
Valve Spring Special Tool1882
300X41882
J1883
Remote Control Valve Special Tool1883
300X41883
R1884
Gas Filling Special Tool1884
300X41884
V1885
Attachment Special Tool (for Cylinder Assembly)1885
Special Jigs Part Number List1885
Attachment Special Tool (Other)1886
300X41886
Paint Colors1887
Abbreviation1889
WLSM3007-00LX-A3-Jpdf 0
A3 Assembly Diagrams 0
J1265
Explanation of Hydraulic Circuit and Operations (standard model)1267
Travel Circuit1268
Travel Low-speed Circuit1268
Travel High-speed Circuit1270
Straight Travel Circuit (with HBCV)1272
Swing Circuit1274
Swing Speed Limit Control Circuit1274
Swing Relief Cut Control Circuit1276
Swing Brake Circuit1278
Swing Parking Circuit (lever in neutral)1280
Swing Parking Circuit (brake release)1282
Swing Parking Circuit (machine stop)1284
Boom Circuit1286
Boom-up Circuit (independent operation) (with HBCV)1286
Boom-up Spool Stroke Control Circuit (compound boom-up + arm-in) (with HBCV)1288
Boom-down Regenerative Circuit (with HBCV)1290
Boom-down Tilting Prevention Circuit (with HBCV)1292
Boom-down Load Holding Valve Circuit (with HBCV)1294
Arm Circuit1296
Arm-out Circuit (with HBCV)1296
Arm Semi-Parallel 1 Circuit1298
Arm Semi-Parallel 2 Circuit1300
Arm-in Regenerative Circuit (with HBCV)1302
Arm-in Load Holding Valve Circuit (with HBCV)1304
Bucket Circuit1306
Bucket-open Circuit1306
Bucket-close Regenerative Circuit1308
Bucket-Close Spool Stroke Control Circuit1310
Negative Control Circuit1312
Negative Control Circuit1312
Other Circuits1314
Cushion Circuit (arm-out operation)1314
Cushion Circuit (when arm-out operation stopped)1316
Cushion Circuit (arm-out → arm-in operation)1318
Heat Circuit (lever in neutral)1320
Auto Pressure Boost Circuit (arm in)1322
J1325
Explanation of Hydraulic Circuit and Operations (option)1327
Option Circuits1328
Breaker Circuit (independent operation)1328
Double-acting Circuit (hydraulic fork)1330
Multi-purpose Circuit (breaker Q control)1332
Multi-purpose Circuit (2 pumps flow crusher)1334
2nd Option Circuit (hydraulic rotation fork)1336
R 0
Electrical Connector Wiring Diagram 0
Main Frame 0
Control Valve 0
SCR 0
Cab Main Harness 0
Console 0
Indicator Jumper 0
R 0
Electrical Parts and Wiring Assembly Diagram 0
Frame 0
Engine and Pump 0
Attachments 0
Battery 0
Cab 0
WLSM3007-00LX-A3-Rpdf 0
A3 Assembly Diagrams 0
J 0
Explanation of Hydraulic Circuit and Operations (standard model) 0
Travel Circuit 0
Travel Low-speed Circuit 0
Travel High-speed Circuit 0
Straight Travel Circuit (with HBCV) 0
Swing Circuit 0
Swing Speed Limit Control Circuit 0
Swing Relief Cut Control Circuit 0
Swing Brake Circuit 0
Swing Parking Circuit (lever in neutral) 0
Swing Parking Circuit (brake release) 0
Swing Parking Circuit (machine stop) 0
Boom Circuit 0
Boom-up Circuit (independent operation) (with HBCV) 0
Boom-up Spool Stroke Control Circuit (compound boom-up + arm-in) (with HBCV) 0
Boom-down Regenerative Circuit (with HBCV) 0
Boom-down Tilting Prevention Circuit (with HBCV) 0
Boom-down Load Holding Valve Circuit (with HBCV) 0
Arm Circuit 0
Arm-out Circuit (with HBCV) 0
Arm Semi-Parallel 1 Circuit 0
Arm Semi-Parallel 2 Circuit 0
Arm-in Regenerative Circuit (with HBCV) 0
Arm-in Load Holding Valve Circuit (with HBCV) 0
Bucket Circuit 0
Bucket-open Circuit 0
Bucket-close Regenerative Circuit 0
Bucket-Close Spool Stroke Control Circuit 0
Negative Control Circuit 0
Negative Control Circuit 0
Other Circuits 0
Cushion Circuit (arm-out operation) 0
Cushion Circuit (when arm-out operation stopped) 0
Cushion Circuit (arm-out → arm-in operation) 0
Heat Circuit (lever in neutral) 0
Auto Pressure Boost Circuit (arm in) 0
J 0
Explanation of Hydraulic Circuit and Operations (option) 0
Option Circuits 0
Breaker Circuit (independent operation) 0
Double-acting Circuit (hydraulic fork) 0
Multi-purpose Circuit (breaker Q control) 0
Multi-purpose Circuit (2 pumps flow crusher) 0
2nd Option Circuit (hydraulic rotation fork) 0
R1607
Electrical Connector Wiring Diagram1609
Main Frame1610
Control Valve1612
SCR1614
Cab Main Harness1616
Console1618
Indicator Jumper1620
R1621
Electrical Parts and Wiring Assembly Diagram1623
Frame1624
Engine and Pump1626
Attachments1628
Battery1630
Cab1632
S.M 3/1/25
