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Link-Belt 350X4 Excavator SERVICE MANUAL WLSM3507-05LX – PDF DOWNLOAD
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Link-Belt 350X4 Excavator SERVICE MANUAL WLSM3507-05LX – PDF DOWNLOAD
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Description
Link-Belt 350X4 Excavator SERVICE MANUAL WLSM3507-05LX – PDF DOWNLOAD
FILE DETAILS:
Link-Belt 350X4 Excavator SERVICE MANUAL WLSM3507-05LX – PDF DOWNLOAD
Language : English
Pages :1900
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Link-Belt 350X4 Excavator SERVICE MANUAL WLSM3507-05LX – 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:
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
Shoes 23
Center joint 24
Main Equipment Structure and Operation Explanation 25
Travel Motor 25
Travel motor operation explanation 25
Structure 25
Summary explanation of component parts 26
Rotary group 26
Parking Brake 26
Variable Capacity Mechanism Section 26
Overload Relief Valve 27
Brake Valve Section 27
Function 28
Motor operation 29
Parking Brake Operation 30
Operation of Variable Capacity Mechanism Section 31
Overload Relief Valve Operation 32
Brake Valve Operation 33
Port Diagram 37
Travel Motor 37
Center Joint 38
Basic Functions 39
Travel Speed Selection 39
Travel Alarm 40
Removal and Installation of Track 41
Removal and Installation of Shoe Assembly 42
Removal of Shoe Assembly 42
Installation of Shoe Assembly 44
Removal and Installation of Shoe Plate 46
Removal of Shoe Plate 46
Installation of Shoe Plate 46
Removal and Installation of Roller 47
Removal and Installation of Upper Roller 48
Removal of Upper Roller 48
Installation of Upper Roller 48
Assembly and Disassembly of Upper Roller 50
Configuration Diagram 50
Dimension Diagram 51
Jig Dimension Diagram 51
Disassembly Procedure 51
Assembly Procedures 53
Removal and Installation of Lower Roller 57
Removal of Lower Roller 57
Installation of Lower Roller 58
Assembly and Disassembly of Lower Roller 59
Configuration Diagram 59
Dimension Diagram 60
Jig Dimension Diagram 60
Disassembly Procedures 60
Assembly Procedures 63
Removal and Installation of Sprocket 65
Removal of Drive Sprocket 65
Installation of Drive Sprocket 66
Removal and Installation of Take-up Roller 67
Removal of Take-up Roller 67
Installation of Take-up Roller 67
Assembly and Disassembly of Take-up Roller 69
Configuration Diagram 69
Dimension Diagram 70
Jig Dimension Diagram 70
Disassembly Procedures 70
Assembly Procedures 72
Removal and Installation of Grease Cylinder 75
Removal of Grease Cylinder 75
Installation of Grease Cylinder 76
Assembly and Disassembly of Grease Cylinder 77
Configuration Diagram 77
Dimension Diagram 77
Jig Dimension Diagram 78
Disassembly Procedures 78
Assembly Procedures 79
Removal and Installation of Center Joint 81
Removal of Center Joint 81
Installation of Center Joint 83
Assembly and Disassembly of Center Joint 84
Configuration Diagram 85
Dimension Diagram 86
Jig Dimension Diagram 87
Disassembly Procedures 87
Assembly Procedures 88
Removal and Installation of Travel Motor 92
Removal of Travel Motor 92
Installation of Travel Motor 94
Assembly and Disassembly of Travel Motor 97
Tools for Assembly and Disassembly 97
Standard tools 97
Secondary Materials 97
Special Tool (jig) 98
Measurement Device 101
Motor Disassembly Procedures 101
Precautions before Motor Disassembly 101
Tightening Torque 102
Disassembly Procedure 102
Removal of Supplied Valves 102
Disassembly of Motor 103
Disassembly of Overload Relief Valve 106
Reduction Gear Disassembly Procedures 106
Preparation before Disassembly 106
Disassembly Procedure 106
Installation to Receiving Platform of Reduction Gear (unit) 107
Removal of Reduction Gear Cover 107
Removal of Carrier 1 Assembly 107
Removal of Carrier 2 Assembly 108
Removal of Housing Assembly 108
Disassembly of Housing Assembly 109
Removal of Floating Seal on Motor 110
Disassembly of Carrier 1 Assembly 110
Disassembly of Carrier 2 Assembly 111
Maintenance standards 112
Motor Parts Maintenance Standards 112
Reduction gear parts maintenance standards 114
Inspection before Assembly 114
Thrust Washer 114
Gears 114
Bearing 114
Floating Seal 114
Parts Maintenance 115
Motor Assembly Procedures 116
Precautions before Motor Assembly 116
Assembly Procedure 116
Motor Assembly Procedures 116
Reduction Gear Assembly Procedure 120
Assembly of Carrier 2 Assembly 120
Assembly of Carrier 1 Assembly 120
Installation of Bearing and Floating Seal 121
Assembly of Housing Assembly 121
Determining Thickness of Angular Bearing Shim 122
Installation of Housing Assembly 123
Installation of Carrier 2 Assembly 123
Installation of Carrier 1 Assembly 124
Cover Attachment 125
Gear Oil Filling 125
Initial pre-conditioning operation 125
Drain charge 125
Performing initial operation (pre-conditioning operation) 125
Troubleshooting 126
General cautions 127
Causes of troubles and countermeasures 128
Structural Diagram 130
Internal Structure Diagram 133
Part Table 135
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 142
For Upper Roller 142
For Lower Roller 143
Pressure Measurement and Adjustment Procedures 144
Main Pressure Measurement 144
B Travel Pressure Measurement 144
Drain Volume Measurement Procedures 145
Preparations 145
Travel Motor Drain Volume Measurement 145
Air Bleed Procedure 147
Travel Motor 147
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 Section 153
Valve Casing Section 154
Brake Section 155
Relief Valve Operation Explanation (relief valve model: KRD22EK10) 155
Swing Motor Internal Structure Diagram 158
Port Diagram 161
Swing Motor 161
Basic Functions 162
Swing Brake 162
Swing Lock 162
Swing Speed Limit 164
Swing Relief Cut 165
Removal and Installation of Swing Unit 167
Removal of Swing Unit 167
Installation of Swing Unit 169
Assembly and Disassembly of Swing Unit 170
Disassembly 170
Assembly 171
Assembly and Disassembly of Swing Motor 173
Causes of Trouble and Solutions 173
Maintenance Standard Table 175
Jig 177
Disassembly 177
Assembly 179
Swing Motor Internal Structural Diagram 184
Removal and Installation of Counterweight 187
Removal of Counterweight 187
Installation of Counterweight 188
Pressure Measurement and Adjustment Procedures 189
Main Pressure Measurement 189
C Swing Pressure Measurement 189
Drain Volume Measurement Procedures 190
Preparations 190
Swing Motor Drain Volume Measurement 190
Air Bleed Procedure 191
Swing Motor 191
Check 192
H ENGINE 193
Main Equipment Table 201
Engine-related 201
Engine 201
Air Cleaner (double element) 201
Radiator 201
SCR 202
Basic Functions 203
Fuel Gauge 203
Coolant Temperature Gauge 205
SCR Gauge 206
Fuel Economy Gauge 210
Neutral Start 210
Power-cut Delay 211
Preheat 212
Throttle 213
Throttle Volume Position Detection 213
Idling Start 219
Auto Idle 220
One-touch Idle 221
Auto Warm-Up 221
Idle Shutdown 226
Idle Up 227
Work Mode Control 228
Engine Emergency Stop 229
SCR RE-GEN 229
Inducement 234
Feed Pump Automatic Stop 238
Coolant Level Decrease 240
Air Filter Clogging 241
Fuel Filter Clogging 242
Battery Charge Abnormality 243
Horsepower Reduction Control (in Uplands) 244
Horsepower Reduction Control (at Engine Failure) 244
Main Data 247
Function, Structure, Operation 250
Function, structure, operation (SCR) 303
SCR Control System Inspection 329
Operation Explanation of SCR 330
Diagnosis for Each Symptom 332
Intermittent conditions of urea selective catalytic reduction system 332
Urea fluid consumption too high 335
Ammonia smell noticeable 335
White crystalline powder visible 336
Symptom 337
Engine Start Problem 337
Engine Stalling 339
Engine Hunting, Rough Idling 341
Excessive White Smoke in Exhaust Gas 342
Excessive Black Smoke in Exhaust Gas 343
Abnormal Noise 343
High Fuel Consumption 344
High Oil Consumption 345
Engine Output Deficiency 346
Functional Inspection 348
Engine Compression Pressure Inspection 348
Fuel System Inspection 349
Lubrication System Inspection 349
Suction air system inspection 350
Exhaust System Inspection 350
EGR Control System Inspection 350
Start System Inspection 351
Glow Control System Inspection 351
OBD System Inspection 352
Monitor Warning Light Lighting Circuit System Inspection 353
Inspection of the monitor warning light blinking circuit system 354
Start Circuit System Inspection 354
Removal and Installation of Engine Assembly 356
Removal of Engine Assembly 356
Installation of Engine Assembly 358
Removal and Installation of Fuel Cooler, Engine Intercooler, Radiator, and Oil Cooler 359
Removal and Installation of Fuel Cooler 359
Removal of Fuel Cooler 359
Installation of Fuel Cooler 359
Removal and Installation of Engine Intercooler 359
Removal of Intercooler 360
Installation of Inter Cooler 360
Inspection of Intercooler 360
Removal and Installation of Radiator 361
Removal of Radiator 361
Installation of Radiator 364
Inspection of Radiator 364
Removal and Installation of Oil Cooler 365
Removal of Oil Cooler 365
Installation of oil cooler 367
Removal and Installation of Turbo Charger 368
Removal of Turbo Charger 368
Installation of Turbo Charger 369
Inspection of Turbo Charger 371
Removal and Installation of EGR Valve 373
Removal of EGR Valve 373
Installation of EGR Valve 374
Inspection of EGR Valve 378
Removal and Installation of Engine Hood 380
Removal of Engine Hood 380
Installation of Engine Hood 380
Removal and Installation of SCR 381
Removal of SCR 381
Installation of SCR 381
Removal and installation of Silicon Controlled Rectifier Catalyst 382
Removal of Silicon Controlled Rectifier Catalyst 382
Installation of Silicon Controlled Rectifier Catalyst 382
Disassembly of Silicon Controlled Rectifier Catalyst 382
Assembly of Silicon Controlled Rectifier Catalyst 382
Inspection of Silicon Controlled Rectifier Catalyst 383
Removal and Installation of Cylinder Head Cover 384
Cylinder head cover Removal 384
Cylinder head cover Installation 384
Removal and Installation of Cylinder Head 385
Removal of Cylinder head assembly 385
Cylinder head assembly Disassembly 394
Cylinder head assembly Reassembly 399
Installation of Cylinder head assembly 407
Cylinder head assembly Inspection 426
Removal and Installation of Cylinder Block 433
Removal of Cylinder block 433
Installation of Cylinder block 449
Cylinder block Inspection 487
Lubrication System 489
Removal and Installation of Oil Pan 489
Oil pan Removal 489
Oil pan Installation 489
Removal and Installation of Oil Level Switch 489
Oil level switch Removal 489
Oil level switch Installation 490
Removal and Installation of Oil Pump Assembly 490
Removal of Oil pump assembly 490
Disassembly of Oil Pump 503
Assembly of Oil Pump 504
Installation of Oil Pump 504
Inspection of Oil Pump 530
Inspection of Engine oil 531
Removal and Installation of Oil Port Cover 532
Removal of Oil port cover 532
Installation of Oil port cover 532
Cooling System 534
Removal and Installation of Water Pump Assembly 534
Removal of Water pump assembly 534
Installation of Water pump assembly 535
Inspection of Water pump assembly 539
Removal and Installation of Thermostat 539
Removal of Thermostat 539
Installation of Thermostat 540
Inspection of Thermostat 542
Inspection of Coolant 543
Inspection of Cooling Fan Belt 548
Removal and Installation of Overheat Switch 548
Removal of Overheat switch 548
Installation of Overheat switch 549
Induction System 550
Inspection of Air cleaner element 550
Exhaust System 551
Removal and installation of Oxidation Catalyst Assembly 551
Removal of Oxidation Catalyst Assembly 551
Installation of Oxidation Catalyst Assembly 551
Aux Emission Control Devices System 553
Removal and installation of Dosing Module 553
Removal of Dosing Module 553
Disassembly of Dosing Module 553
Assembly of Dosing Module 554
Installation of Dosing Module 554
Removal and installation of DEF Supply Module 556
Removal of DEF supply module 556
Disassembly of DEF Supply Module 557
Assembly of DEF Supply Module 557
Installation of DEF Supply Module 558
Removal and installation of Coolant Control Valve 561
Removal of Coolant Control Valve 561
Installation of Coolant Control Valve 561
Removal and Installation of DCU 563
Removal of DCU 563
Installation of DCU 563
Removal and installation of DEF Supply Module Filter 563
Removal of DEF Supply Module Filter 563
Installation of DEF Supply Module Filter 564
Removal and Installation of Exhaust Manifold 565
Removal of Exhaust manifold 565
Installation of Exhaust manifold 568
Exhaust manifold Inspection 574
Removal and Installation of Fuel Tank 576
Removal of Fuel Tank 576
Installation of fuel tank 579
Removal and Installation of Urea Pump 580
Removal of Urea Pump 580
Installation of Urea Pump 580
Removal and Installation of Urea Solution Tank 581
Removal of Urea Solution Tank 581
Installation of Urea Solution Tank 582
Removal and Installation of Fuel Supply Pump 583
Removal of Fuel Supply Pump 583
Fuel supply pump Installation 583
Removal and Installation of Common Rail Assembly 587
Removal of Common rail assembly 587
Installation of Common rail assembly 590
Removal and Installation of Injector 600
Injector Removal 600
Injector Installation 602
Removal and installation of Idle Gear 606
Removal of Idle Gear 606
Installation of Idle Gear 618
Inspection of Idle Gear 644
Removal and installation of Inlet Cover 646
Removal of Inlet Cover 646
Installation of Inlet Cover 650
Removal and installation of Crankshaft 659
Removal of Crankshaft 659
Installation of Crankshaft 675
Disassembly of Crankshaft 710
Assembly of Crankshaft 710
Inspection of Crankshaft 711
Removal and installation of Piston 717
Removal of Piston 717
Installation of Piston 727
Disassembly of Piston 748
Assembly of Piston 749
Inspection of Piston 750
Removal and installation of Camshaft 758
Removal of Camshaft 758
Disassembly of Camshaft 759
Installation of Camshaft 760
Assembly of Camshaft 765
Inspection of Camshaft 766
Removal and installation of Flywheel 768
Removal of Flywheel 768
Installation of Flywheel 769
Inspection of Flywheel 770
Removal and installation of Crankshaft Front Oil Seal 771
Removal of Crankshaft Front Oil Seal 771
Installation of Crankshaft Front Oil Seal 772
Removal and installation of Crankshaft Rear Oil Seal 776
Removal of Crankshaft Rear Oil Seal 776
Installation of Crankshaft Rear Oil Seal 777
Removal and installation of Rocker Arm Shaft 780
Removal of Rocker Arm Shaft 780
Installation of Rocker Arm Shaft 781
Disassembly of Rocker Arm Shaft 785
Assembly of Rocker Arm Shaft 785
Inspection of Rocker Arm Shaft 787
Removal and installation of Valve Spring 789
Removal of Valve Spring 789
Installation of Valve Spring 791
Inspection of Valve Spring 797
Removal and installation of Valve Stem Oil Seal 799
Removal of Valve Stem Oil Seal 799
Installation of Valve Stem Oil Seal 801
Removal and installation of Front Cover 809
Removal of Front Cover 809
Installation of Front Cover 811
Removal and installation of Intake Throttle Valve 818
Removal of Intake Throttle Valve 818
Installation of Intake Throttle Valve 818
Removal and Installation of Starter Motor 819
Removal of Starter Motor 819
Installation of Starter Motor 819
Disassembly of Starter Motor 820
Assembly of Starter Motor 821
Inspection of Starter Motor 825
Removal and Installation of Alternator 828
Removal of Alternator 828
Installation of Alternator 828
Disassembly of Alternator 828
Assembly of Alternator 830
Inspection of Alternator 831
Removal and Installation of Glow Plug 835
Removal of Glow Plug 835
Installation of Glow Plug 835
Glow Plug Inspection 836
Removal and Installation of Suction Control Valve 837
Suction control valve Removal 837
Suction control valve Installation 837
Removal and installation of Fuel Filter 840
Removal of Fuel Filter 840
Installation of Fuel Filter 840
Removal and installation of Relief Valve 843
Removal of Relief Valve 843
Installation of Relief Valve 843
Removal and installation of Fuel Filter Element 846
Removal of Fuel Filter Element 846
Installation of Fuel Filter Element 847
Removal and Installation of Fuel filter pressure 850
Suction control valve Removal 850
Suction control valve Installation 850
Removal and Installation of Engine coolant temperature sensor 853
Suction control valve Installation 853
Suction control valve Removal 854
Suction control valve Installation 855
Removal and Installation of CKP sensor 857
Removal of CKP sensor 857
Installation of CKP sensor 857
CKP sensor Inspection 857
Removal and Installation of CMP sensor 858
CMP sensor Removal 858
CMP sensor Installation 858
CMP sensor Inspection 858
Removal and Installation of Oil pressure sensor 859
Removal of Oil pressure sensor 859
Installation of Oil pressure sensor 859
Inspection of Oil pressure sensor 859
Removal and Installation of Boost sensor 860
Removal of Boost Sensor 860
Installation of Boost Sensor 860
Inspection of Boost Sensor 860
Removal and Installation of Boost temperature sensor 861
Removal of Boost Temperature Sensor 861
Installation of Boost Temperature Sensor 861
Removal and installation of Pressure Sensor/Boost Temperature Sensor 862
Removal of Pressure sensor/boost temperature sensor 862
Installation of Pressure sensor/boost temperature sensor 862
Inspection of Pressure sensor/boost temperature sensor 862
Removal and Installation of IMT sensor 863
Removal of IMT sensor 863
Installation of IMT sensor 863
Removal and installation of Charge Air Cooler Temperature Sensor 1 864
Removal of Charge air cooler temperature sensor 1 864
Installation of Charge air cooler temperature sensor 1 864
Inspection of Charge air cooler temperature sensor 1 864
Sampling Procedure 865
Sampling of Engine Oil 865
Removal and Installation of Exhaust gas temperature sensor 866
Removal of Exhaust gas temperature sensor 866
Installation of Exhaust gas temperature sensor 866
Inspection of Exhaust gas temperature sensor 866
Removal and installation of EGR Gas Temperature Sensor 1 868
Removal of EGR Gas Temperature Sensor 1 868
Installation of EGR Gas Temperature Sensor 1 868
Inspection of EGR Gas Temperature Sensor 1 868
Removal and installation of EGR Gas Temperature Sensor 2 869
Removal of EGR Gas Temperature Sensor 2 869
Installation of EGR Gas Temperature Sensor 2 869
Inspection of EGR Gas Temperature Sensor 2 869
Removal and installation of NOx Sensor 871
Removal of NOx Sensor 871
Installation of NOx Sensor 871
Removal and Installation of Exhaust gas temperature sensor 3 872
Removal of Exhaust gas temperature sensor 3 872
Installation of Exhaust gas temperature sensor 3 872
Removal and installation of DEF Sensor 873
Removal of DEF Sensor 873
Installation of DEF Sensor 873
Engine-related Diagnostic Trouble Code List 874
Engine-side Trouble 879
ECM Trouble 879
DTC U0001 CAN Bus Error (ISO-CAN) 879
DTC P0016 Crankshaft Position – Camshaft Position Correlation Error 880
DTC P0045 Turbocharger Boost Control VNT Error 880
DTC U0073 Control Module Communication Bus Off 882
DTC P0087 Fuel Rail/System Pressure – Too Low 883
DTC P0089 Fuel Pressure Regulator Performance 886
DTC P0091 Fuel Pressure Regulator Control Circuit Low 887
DTC P0092 Fuel Pressure Regulator Control Circuit High 888
DTC P0097 Intake Air Temperature (IAT) Sensor 2 Circuit Low Voltage 889
DTC P0098 Intake Air Temperature (IAT) Sensor 2 Circuit High Voltage 889
DTC U0101 Lost Communication With CAN 890
DTC P0102 Mass Air Flow Sensor Circuit Low Input 891
DTC P0103 Mass Air Flow Sensor Circuit High Input 892
DTC U010E Lost Communications With Dosing Control Module 892
DTC U0110 Lost Communication With VNT System 893
DTC P0112 Intake Air Temperature Sensor Circuit Low 893
DTC P0113 Intake Air Temperature Sensor Circuit High 894
DTC P0117 Engine Coolant Temperature Sensor Circuit Low 895
DTC P0118 Engine Coolant Temperature Sensor Circuit High 895
DTC P0122 Throttle Position Sensor Circuit Low 896
DTC P0123 Throttle Position Sensor Circuit High 897
DTC P0182 Fuel Temperature Sensor Circuit Low 898
DTC P0183 Fuel Temperature Sensor Circuit High 899
DTC P0192 Fuel Rail Pressure Sensor Circuit Low 900
DTC P0193 Fuel Rail Pressure Sensor Circuit High 900
DTC P0201 Injector Circuit Open – Cylinder 1 902
DTC P0202 Injector Circuit Open – Cylinder 2 902
DTC P0203 Injector Circuit Open – Cylinder 3 903
DTC P0204 Injector Circuit Open – Cylinder 4 904
DTC P0217 Engine Coolant Over Temperature Condition 905
DTC P0219 Engine Overspeed Condition 905
DTC P0234 Turbocharger Overboost Condition 906
DTC P0237 Turbo Charger Boost Sensor Circuit Low 907
DTC P0238 Turbo Charger Boost Sensor Circuit High 907
DTC P0335 Crankshaft Position Sensor Circuit 908
DTC P0336 Crankshaft Position Sensor Circuit Range/Performance 909
DTC P0340 Camshaft Position Sensor Circuit 910
DTC P0380 Glow Relay Circuit Error 911
DTC P0401 EGR Flow Insufficient Detected 912
DTC P0404 EGR Control Circuit Range/Performance 913
DTC P0409 EGR Sensor Circuit 913
DTC U0411 Lost CAN Communications With VNT Control Module 915
DTC P041C EGR Cooler Outlet 1 Temp Sensor Circuit Low 915
DTC P041D EGR Cooler Outlet 1 Temp Sensor Circuit High 916
DTC P0427 Catalyst Temperature Sensor Circuit Low Sensor 1 917
DTC P0428 Catalyst Temperature Sensor Circuit High Sensor 1 917
DTC P042C Catalyst Temperature Sensor Circuit Low Sensor 2 918
DTC P042D Catalyst Temperature Sensor Circuit High Sensor 2 919
DTC P0522 Engine Oil Pressure Sensor Circuit Low Input 920
DTC P0523 Engine Oil Pressure Sensor Circuit High Input 921
DTC P0545 EGR Cooler Inlet 1 Temp Sensor Circuit Low 922
DTC P0546 EGR Cooler Inlet 1Temp Sensor Circuit High 922
DTC P0560 12 Volt Circuit Error 923
DTC P0563 System Voltage High 923
DTC P0601 Internal Control Module Memory Check Sum Error 924
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 925
DTC P060C Internal Control Module A/D Processing Performance 925
DTC P0615 Starter Relay Circuit Error 926
DTC P0638 Throttle Actuator Control Range/Performance 926
DTC P0685 ECM Power Relay Control Circuit Open 927
DTC P0687 ECM Power Relay Control Circuit High 928
DTC P06A6 Sensor Reference Voltage 1 Circuit 928
DTC P06A7 Sensor Reference Voltage 2 Circuit 929
DTC P06A8 Sensor Reference Voltage 3 Circuit 930
DTC P06A9 Sensor Reference Voltage 4 Circuit 930
DTC P06AF Torque Management System – Forced Engine Shutdown 931
DTC P06D5 Sensor Reference Voltage 5 Circuit 932
DTC P1076 Charge Air Cooler (CAC) Temperature Sensor 1 Circuit Low Voltage 932
DTC P1077 Charge Air Cooler (CAC) Temperature Sensor 1 Circuit High Voltage 932
DTC P1093 Fuel Rail Pressure Too Low 933
DTC P1097 Compressor Outlet Temperature Sensor Circuit High 936
DTC P1098 Compressor Outlet Temperature Sensor Circuit High 937
DTC P1236 Charge Air Cooler Performance Failure 938
DTC P1261 Injector Positive Voltage Control Circuit Group 1 938
DTC P1262 Injector Positive Voltage Control Circuit Group 2 939
DTC P1404 EGR Position Fault 939
DTC P1606 SW-IC Internal failure 940
DTC P160B AD-IC Failure Error 940
DTC P160C AD-IC2 Failure Error 940
DTC P1621 Control Module Long Term Memory Performance 940
DTC P1669 DPD Lamp Control Circuit 941
DTC P204F SCR System Error (No Inducement) 942
DTC P207F Urea Fluid Concentration Too Low 942
DTC P20C9 SCR System Error 942
DTC U2106 Lost CAN Communications With Wheel Loader Transmission Control System 942
DTC P2122 Pedal Position Sensor 1 Circuit Low Input 943
DTC P2123 Pedal Position Sensor 1 Circuit High Input 943
DTC P2127 Pedal Position Sensor 2 Circuit Low Input 944
DTC P2128 Pedal Position Sensor 2 Circuit High Input 945
DTC P2138 Pedal Position Sensor 1 – 2 Voltage Correlation 945
DTC P2146 Fuel Injector Group 1 Supply Voltage Circuit 946
DTC P2149 Fuel Injector Group 2 Supply Voltage Circuit 947
DTC P2228 Barometric Pressure Sensor Circuit Low 948
DTC P2229 Barometric Pressure Sensor Circuit High 949
DTC P2457 Exhaust Gas Recirculation (EGR) Cooling System Performance 949
DTC P2458 Purge time Out Error 950
DTC P2BA7 Urea Fluid Quantity Too Low 950
DTC P2BAA SCR System Error (Inducement, No Purge) 950
DTC P3093 Fuel Rail Pressure Too Low 950
DCU Trouble 953
DTC 0002 CAN Bus Off 953
DTC 0100 Lost Communication With ECM 954
DTC 029D Lost Communication With NOx Sensor 1 955
DTC 0607 Control Module Performance 957
DTC 060B Internal Control Module A/D Processing Performance 958
DTC 062F Control Module EEPROM Error 958
DTC 0641 Sensor Reference Voltage 1 Circuit 959
DTC 0658 Actuator Supply Voltage Circuit 960
DTC 0659 Actuator Supply Voltage Circuit 961
DTC 1462 Urea Fluid Quality Sensor Timeout Error 962
DTC 1464 Main Relay Performance 962
DTC 1468 DCU Overtemperature 963
DTC 1491 Urea Fluid Overpressure 963
DTC 1493 DCU Driver Overtemperature 965
DTC 149C Urea Fluid Pressure Reduction Malfunction 965
DTC 149D Urea Fluid Tank Overtemperature 966
DTC 203B Urea Fluid Tank Level Sensor Stuck 967
DTC 203C Urea Fluid Tank Level Sensor Low Voltage 968
DTC 203D Urea Fluid Tank Level Sensor High Voltage 969
DTC 2048 Urea Fluid Injector Circuit Low Voltage 970
DTC 2049 Urea Fluid Injector Circuit High Voltage 971
DTC 204B Urea Fluid Pressure Sensor Performance 971
DTC 204C Urea Fluid Pressure Sensor Circuit Low Voltage 972
DTC 204D Urea Fluid Pressure Sensor Circuit High Voltage 973
DTC 205B Urea Fluid Tank Temperature Sensor Performance 974
DTC 205C Urea Fluid Tank Temperature Sensor Low Voltage 975
DTC 205D Urea Fluid Tank Temperature Sensor High Voltage 975
DTC 206A Urea Fluid Quality Sensor Circuit 976
DTC 206B Urea Sensor Over Temperature Condition 976
DTC 206C Urea Fluid Quality Sensor Circuit Low Voltage 977
DTC 206D Urea Fluid Quality Sensor Circuit High Voltage 978
DTC 207F Urea Fluid Concentration Too Low 978
DTC 208A Urea Fluid Pump Control Circuit 979
DTC 208B Usea Fluid Pump Performance 979
DTC 208C Urea Fluid Pump Control Circuit Low Voltage 980
DTC 208D Urea Fluid Pump Control Circuit High Voltage 981
DTC 208E Urea Fluid Injector Stuck 982
DTC 20A0 Urea Fluid Reverting Valve Circuit Open 983
DTC 20A2 Urea Fluid Reverting Valve Circuit Low Voltage 983
DTC 20A3 Urea Fluid Reverting Valve Circuit High Voltage 984
DTC 20AC Urea Fluid Pump Temperature Sensor Performance 985
DTC 20AD Urea Fluid Pump Module Temperature Sensor Performance 986
DTC 20B1 Urea Fluid Tank Heater Coolant Control Valve Circuit Open 987
DTC 20B3 Urea Fluid Tank Heater Coolant Control Valve Circuit Low Voltage 988
DTC 20B4 Urea Fluid Tank Heater Coolant Control Valve Circuit High Voltage 988
DTC 20E8 Urea Fluid Pressure Underpressure 989
DTC 20E9 Urea Fluid Overpressure 990
DTC 20EA Urea Fluid Pressure Reduction Malfunction 992
DTC 20FE Urea Fluid Pressure Build-Up Error 992
DTC 2201 Upstream Nox Sensor Performance 994
DTC 2206 NOx Sensor Heater Control Circuit Low Voltage Sensor 1 994
DTC 2207 NOx Sensor Heater Control Circuit High Voltage Sensor 1 995
DTC 242B Exhaust Gas Temperature (EGT) Sensor 3 Performance 995
DTC 242C Exhaust Gas Temperature (EGT) Sensor 3 Circuit Low Voltage 995
DTC 242D Exhaust Gas Temperature (EGT) Sensor 3 Circuit High Voltage 996
Data Reference Values 998
Idle Speed 998
Two Pump Relief 999
J HYDRAULIC EQUIPMENT (PUMP, OPERATION SYSTEM VALVE)1001
Main Equipment Table1007
Hydraulic Device1007
Hydraulic Pump1007
PQ Diagram1007
Control-related1008
Control valve1008
Solenoid Valve (5 Stack)1008
Remote Control Valve for Left/Right Operations1008
Remote Control Valve for Travel Operation1008
Remote Control Valve Characteristic Diagram1009
Operation Remote Control Valve Control Diagram1009
Travel Remote Control Valve Control Diagram1010
Cushion Valve (heat circuit, with shuttle valve)1010
Selector Valve (option)1011
Basic Functions1012
Oil Temperature Gauge1012
Static Horsepower Control1013
Overload Warning (Function for Europe Only)1014
Pressure Boost Control1015
Stroke Control1017
Boom Down Energy Save1018
Pump Horsepower Cut Control1019
Pump Horsepower Boost Control1021
Arm 1 Semi-parallel Control1022
Arm 2 Semi-parallel Control1023
Hot Shutdown Warning1024
Gate Lock1025
Breaker Mode1026
Crusher Mode1026
Quick coupler1027
Hydraulic Filter Clogging1028
Solenoid Sticking Prevention1029
Port Diagram1030
Hydraulic Pump (standard model)1030
Control Valve1032
Relief Valve1032
5 Stack Solenoid Valve1035
2 Stack Solenoid Valve1037
Remote Control Valves (upper, travel)1037
Remote Control Valves (left-right)1037
Remote Control Valve (Travel)1038
Cushion Valve1039
2-way Selector Valve1040
Direction Valve1041
6 Stack Proportional Valve1042
Relief Valve (electromagnetic proportional)1044
Manifold Under Cab1045
Manifold (accumulator section)1046
Manifold (hydraulic oil tank section)1047
Hydraulic Pump1048
Structure and Operation Explanation1048
Hydraulic Pump Internal Structure Diagram1049
Overall view1049
Drive Shaft Front Side1049
Drive Shaft on Rear Side1050
Parts Table1051
Regulator1052
Regulator Operation Explanation1052
Regulator Operation Explanation Diagram1054
Internal Configuration Diagram of Regulator1056
Development Diagram of Regulator1058
Component Table1059
Gear Pump1061
Gear Pump Internal Structure Diagram1061
Structure and Operation Explanation1062
Operation Outline of Electronically-Controlled Pump1063
Control Valve1066
Basic Configuration1066
Operation1066
Operation of Main Unit1066
Activation of Relief Valve1087
5 Stack Solenoid Valve Operation Explanation1092
External Shape Diagram and Components1092
operation explanation1092
Upper Pilot Valve (remote control valve)1093
Structure1093
Function1093
Operation1094
Structural Diagram1098
Travel Pilot Valve (remote control valve)1099
Operation1099
Pressure Reducing Valve Section1099
Damping Mechanism in Operation Section1100
Structural Diagram1103
Cushion Valve 1105
structure1105
operation explanation1105
Selector Valve (2-way)1110
structure1110
operation explanation1111
Development Diagram1112
Direction Valve (3-direction) 1113
Structure1113
Operation Explanation1114
6 Stack Proportional Valve (Pilot)1116
structure1116
operation principle1117
Electromagnetic Relief Valve1118
Structure1118
Operation Explanation1119
Operation of Check Valve1119
Operation of Electromagnetic Relief Valve1120
Removal and Installation of Hydraulic Reservoir1122
Removal of Hydraulic Reservoir1122
Installation of Hydraulic Oil Tank1125
Removal and Installation of Hydraulic Pump1126
Removal of Hydraulic Pump1126
Installation of Hydraulic Pump1129
Removal and Installation of Control Valve1130
Removal of Control Valve1130
Installation of Control Valve1135
Removal and Installation of Travel Remote Control Valve1136
Removal of Travel Remote Control Valve1136
Installation of Travel Remote Control Valve1137
Removal and Installation of Operation Remote Control Valve1140
Removal of Operation Remote Control Valve (left side)1140
Installation of Operation Remote Control Valve (left side)1142
Removal of Operation Remote Control Valve (right side)1144
Installation of Operation Remote Control Valve (right side)1146
Installation and Removal of 5 Stack Solenoid Valve1148
Removal of 5 Stack Solenoid Valve1148
Installation of 5 Stack Solenoid Valve1149
Removal and Installation of Cushion Valve1150
Removal of Cushion Valve1150
Installation of Cushion Valve1151
Procedures for Assembly and Disassembly of Hydraulic Pump Main Unit1153
Tools1153
Disassembly Procedure1153
Assembly Procedure1155
Regulator Maintenance Standards1158
Regulator Adjustment1158
Appendix Table and Drawings1159
Regulator Assembly and Disassembly Procedures1163
Tools1163
Preparations for Disassembly1163
Disassembly Procedure1163
Assembly Procedure1165
Internal Configuration Diagram of Regulator1169
Development Diagram of Regulator1171
Component Table1172
Assembly and Disassembly of Control Valve1174
Disassembly1174
Caution for Disassembly1174
Disassembly Procedure1174
Removal of Long Cap and Pulling Out of Main Spool1174
Disassembly of Arm 1, 2 Parallel-Tandem Spool, Neutral Cut Spool, Arm Regeneration Release Spool Section1175
Disassembly of Load Check Valve Section1175
Disassembly of Antidrift Valve Section (Sub Component in Assembly is Expressed by (Min Number – Sub Number))1176
Disassembly of Relief Valve1176
Disassembly of Option Section1176
Disassembly of Add-On Section1176
Disassembly of Valve Housing Coalescence Bolt1177
Cleaning1177
Inspection1177
assembly1177
Caution for Assembly1177
Caution for Handling O-ring1177
Caution for Handling Spool1177
Method to Apply Adhesive Agent (Male and Female Thread Section of Components Requiring Bonding)1177
Assembly Procedure of Sub-Assembly1178
Assembly of Spool Assembly (Main Spool)1178
Assembly of Arm 1, 2 Parallel-Tandem Spool, Neutral Cut Spool, Arm Regeneration Release Spool Assembly1178
Assembly of Antidrift Valve Assembly1179
Assembly Procedure of Control Valve Main Unit1179
Assembly of Relief Valve1179
Assembly of Load Check Valve1179
Assembly of Antidrift Valve1180
Assembly of Option Section1180
Assembly of Arm 1 Parallel-Tandem Spool1180
Assembly of Arm 2 Parallel-Tandem Spool, Neutral Cut Spool, Arm Regeneration Release Spool1180
Assembly of Main Spool1180
Assembly of Add-On Section1181
Assembly of Other Plugs1181
Internal Structural Diagram1182
Part List1188
Relief Valve1189
Assembly and Disassembly Procedure of Main Relief Valve1189
Assembly and Disassembly Procedures of Overload Relief1190
Assembly and Disassembly Procedure of Low-Pressure Relief Valve1191
Assembly and Disassembly Procedure of Main Relief Valve for Add-On1191
Adjustment of Relief Valve1192
Installation1193
Operation1193
Malfunction and Countermeasure1193
Procedures for Assembly and Disassembly of Operation Remote Control Valve1195
Maintenance Procedures1195
Required Tools and Tightening Torque1195
Maintenance Standards1195
Disassembly Procedures1196
Assembly Procedures1198
Causes of Trouble and Countermeasures1202
Procedures for Assembly and Disassembly of Travel Remote Control Valve1206
Maintenance Procedures1206
Disassembly Procedures1207
Assembly Procedures1211
Causes of Trouble and Countermeasures1216
Assembly and Disassembly of Cushion Valve1219
Disassembly Procedures1219
Reverse Operation Spool Section1219
Check Plunger Section with Throttle1219
Shuttle Valve Section1219
Assembly Procedures1220
Reverse Operation Spool Section1220
Check Plunger Section with Throttle1220
Shuttle Valve Section1220
Written Materials1221
Procedures for Assembly and Disassembly of 6 Stack Proportional Valve (Pilot)1223
Development Diagram1223
Assembly and disassembly procedures1224
Precautions1224
Replacement of Proportional Solenoid1224
Disassembly1224
Assembly1224
Replacement of Sleeve and Spool1225
Disassembly1225
Assembly1226
Replacement of Poppet (Check Valve for Normally Open)1227
Disassembly1227
assembly1228
Maintenance Standards1228
Troubleshooting1228
Pressure Measurement and Adjustment Procedures1230
Procedures for Pressure Measurement from the Monitor Display1230
Monitor and Switch Panel1230
Pressure Measurement Method1230
Operating Method1230
PROCEDURES FOR MEASURING HYDRAULIC OIL TEMPERATURE FROM THE MONITOR DISPLAY1230
Hydraulic Oil Temperature Measurement Method1230
Operating Method1231
Procedures for Pressure Measurement by Installing Pressure Gauge1232
Preparations1232
Items to Prepare1232
Pressure Measuring Ports1233
Control Valve1235
Location of Relief Valves1235
Pressure Measurement Preparations1236
Pressure Measurement1238
Main Pressure Measurement1238
A Attachment Pressure Measurement1238
Boom-down Pressure Measurement1239
D Option Line Pressure Measurement1240
Pilot Pressure Measurement1240
Pressure Gauge Installation1240
Negative Control Pressure Measurement1241
Pressure Gauge Installation1241
Pressure Adjustment1241
Main Pressure Adjustment1241
Pressure Measurement and Adjustment Preparations1241
Main Relief Pressure Adjustment1243
Overload Relief Pressure Adjustment1244
Swing Relief Pressure Adjustment1245
Pilot Pressure Adjustment1246
Hydraulic Pump Flow Measurement Procedures1247
Preparations1247
Items to Prepare1247
Work Preparations1247
Flow Measurement1249
Air Bleed Procedure1251
Hydraulic Pump1251
Sampling Procedure1252
Sampling of Hydraulic Fluid1252
Hydraulic Equipment Layout1253
Overall View1254
Pump Chamber Hydraulic Equipment Layout1255
Swing Body Center Section Hydraulic Equipment Layout1257
Housing Left Side Hydraulic Equipment Layout1259
Layout of Hydraulic Equipment in Cab1260
N CAB1335
Removal and Installation of Operator’s Seat1338
Removal of Operator’s Seat1338
Installation of Operator’s Seat1338
Removal and Installation of Cab Assembly1339
Removal of Cab Assembly1339
Installation of Cab Assembly1343
Removal and Installation of Wiper1344
Removal of Wiper1344
Installation of wiper1344
Removal and Installation of Cab Front Glass1345
Removal of Cab Front Glass1345
Installation of Cab Front Glass1346
Window Lock Adjustment Procedures1347
Window Lock (front side)1347
Window Lock (rear side)1347
Removal and Installation of Housing Guardrail1349
Removal of Housing Guardrail1349
Installation of Housing Guardrail1350
Tightening Torque1351
R ELECTRICAL PARTS1353
Basic Functions1357
Monitor Control1357
Monitor Display Dimming1357
Diagnostic Trouble Code Indicator1358
Clock1358
Basic Operation1359
Battery Save1359
Accessories1361
Working Light1361
LED Light1362
Room Lamp1363
Radio Mute1364
Wiper and Washer1365
Safety1368
Horn1368
Back/Side View Monitor1369
Precautions for Camera Installation1369
Maintenance1370
Anti-theft1370
Manual Lock1370
Service Support Screen Lock1370
Customer-specific System Information Screen Lock1370
Maintenance Information Screen Lock1371
Option Line Setting Screen Lock1371
Setting1371
Clock Adjustment1371
Screen Brightness Setting1372
Battery Disconnect Switch1373
Explanation of Controller1374
Service Support1376
Screen Operations1376
Screen Display List1376
Service Monitor Structure1377
CHECK Screen List1378
MACHINE STATUS1378
HYDRAULIC STATUS1384
ENGINE STATUS1391
FAULT HISTORY1396
WORK HISTORY1396
HYDRAULIC HISTORY1405
ENGINE HISTORY1417
DEVICE TEST1438
ECM/DCU Memory Clear1438
SCR RE-GEN1439
Urea Line Leak Test1440
CCV Operation Test1441
Dosing Test1442
Reverting Valve Operation Test1443
Common Rail Pressure Test1444
Idle Speed Test / Injector Test1445
EGR Valve Control Test1446
VG Turbo Control Test1447
Intake Throttle Control Test1448
CONTROL UNIT Screen List1450
MCM-MAIN1450
MCM-SUB1454
COMMU TERMINAL1455
SETUP Screen List1457
MACHINE SELECT1458
DIMENSIONS1462
PARAMETERS1463
ENGINE INFORMATION1465
ENGINE INFORMATION1466
Data Confirmation1466
Data Transfer (Copy)1467
QR (INJECTOR) CODE1468
Injector number1468
Screen Layout1468
Data Source Selection1468
Manual Input1469
CAMERA1470
PASSWORD1473
CALIBRATE Screen List1475
THROTTLE VOLUME1476
OPTLINE RELIEF1477
PUMP FLOW1479
Connection Connector Pin Layout1482
Main Controller1482
Monitor1483
Sequence Circuit Diagram1484
Code List1484
Overall1486
Block diagram1489
Main Controller1489
DCU1490
ECM1491
Monitor1492
Air Conditioner1493
Gate Lock1494
Horn1494
Working Light1494
Option1495
Other1496
Electrical Symbol List1496
Electrical Equipment Layout Diagram1498
Main Unit Left-side Layout Diagram1499
Engine Section Layout Diagram1501
Main Unit Right Side Layout Diagram (pump chamber)1504
Main Unit Center Section Layout Diagram1505
Cab Layout Diagram 11506
Cab Layout Diagram 21508
Layout Around Operator Seat1511
Stand Alone Parts Diagram1512
Removal and Installation of Wiper Controller1534
Removal of Wiper Controller1534
Installation of wiper controller1534
Removal and Installation of Wiper Motor1535
Removal of Wiper Motor1535
Installation of wiper motor1536
Removal and Installation of ECM1537
Removal of ECM1537
Installation of ECM1537
Removal and Installation of Main Controller1538
Removal of Main Controller1538
Installation of Main Controller1538
Removal and Installation of DCU1539
Removal of DCU1539
Installation of DCU1539
Removal and Installation of Monitor1540
Removal of Monitor1540
Installation of Monitor1541
How to Set FVM1542
Air Conditioner Overall Diagram1546
Frame1546
Cab1549
Equipment Layout Diagram1552
Circuit Diagram1554
Air Conditioner Circuit Diagram1554
Explanation of Functions1556
Explanation of Control1556
Air Mix Motor Actuator Control1557
Blow Mode Motor Actuator Control1557
Refresh/Recirculate Switch Motor Actuator Control1558
Blower Amp Control1559
Compressor Clutch Control1561
COOLMAX Control and HOTMAX Control1562
Abnormality Detection and Control after Abnormality Detected1562
Monitor Mode1566
Door Switch Control1568
Actuator Inspection1569
Air Mix Motor Actuator Inspection1569
Refresh/Recirculate Switch Motor Actuator Inspection1570
Mode Motor Actuator Inspection1571
Self-diagnosis Function with Panel Display1572
Abnormality Display and Self-check Procedures1572
Abnormality Display Position1572
Explanation of Abnormality Display1572
Motor Actuator Abnormality1572
Sensor Abnormality1573
Explanation of Monitor Mode1573
Monitor Mode Display Position1574
Monitor Mode Display Operating Method1574
Display Contents in Monitor Mode1575
Part Function and Good/Poor Judgment1581
Control Panel1581
Blower Amp1581
Relay1582
Air Mix Actuator1583
Refresh/Recirculate Actuator1584
Blow Mode Actuator1584
Evaporator Sensor1585
Dual Pressure Switch1585
Solar Radiation Sensor1586
Inside Air Sensor1586
Assembly and Disassembly of Unit1588
Removal of Blower Unit1588
Replacement of Blower Motor1588
Replacement of Blower Amp1588
Removal of Heater Core1589
Removal of Heat Case Right/Left1589
Replacement of Evaporator and Expansion Valve1589
Installation of Evaporator Sensor1590
Replacement of Motor Actuator1590
Removal and Installation of Compressor1591
Removal of Compressor1591
Installation of Compressor1591
Removal and Installation of Condenser1592
Removal of Condenser1592
Installation of Condenser1592
Removal and Installation of Receiver Dryer1593
Removal of Receiver Dryer1593
Installation of Receiver Dryer1593
Work Precautions1594
Work Procedures1594
Air Conditioner Refrigerant Filling is Divided into the “Vacuum Operation” and “Gas Filling Operation”1594
Operation Chart1595
Tools1595
Filling Procedures1597
Charging Hose Connection Position1597
Connecting Gauge Manifold1597
Vacuuming1598
Gas Filling Operation, High-pressure Side1599
Gas Filling Work, Low Pressure Side1599
V ATTACHMENTS1633
Main Equipment Table1637
Backhoe Attachment1637
Cylinder1637
Maintenance Standards1638
Attachment (Backhoe)1638
1 Boom and swing frame mounting area1638
2 Boom Cylinder and Swing Frame Installation Section1639
3 Boom and Boom Cylinder Installation Section1640
4 Boom and Arm Cylinder Installation Section1640
5 Boom and Arm Installation Section1641
6 Arm and Arm Cylinder Installation Section 1642
7 Arm and Bucket Cylinder Installation Section1642
8 Arm and Arm Link Installation Section1643
9 Bucket and Bucket Link Installation Section1644
10 Bucket Link and Bucket Cylinder Installation Section1644
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 Cylinder1651
Removal of Arm Cylinder1651
Installation of Arm Cylinder1653
Removal and Installation of Boom Cylinder1656
Removal of Boom Cylinder1656
Installation of Boom Cylinder1658
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder1660
Specifications and Structure Diagram (including the assembly diagram and parts table)1660
Basic Functions1660
Function of Each Location1660
Cylinder Head Assembly (made by KYB)1660
Piston Assembly (made by KYB)1661
Pipe Assembly (made by KYB)1663
Handling Precautions1663
Precautions for Installing the Cylinder on the Machine Body1663
Usage Cautions1664
Maintenance and Inspection Cautions1664
Maintenance Inspection and Service1666
Trouble Diagnostics1667
Storage Standards1672
Storing Parts Individually (In principle, store indoors)1672
When Mounted on Vehicle Body1672
Recommended Anti-rust Oil1672
Assembly and Disassembly Procedures1673
Preparations ····· Prepare the Following before Starting Disassembly1673
General Work Precautions1673
Maintenance Standards1673
Inspection after Assembly1673
Required Tool1674
General Tool1674
Special Jig (made by KYB)1675
Special Jig Parts Number List (made by KYB)1675
Disassembly Procedures (made by KYB)1676
Assembly Procedures (made by KYB)1679
Test Operation1684
Usage Limits1685
Structural Diagram (made by KYB)1686
Boom Cylinder1686
Arm Cylinder1688
Bucket Cylinder1690
HBCV1692
structure1692
Function1692
operation explanation1692
Port Diagram1707
HBCV1707
Air Bleed Procedure1708
HBCV1708
Boom Cylinder HBCV1708
Arm Cylinder HBCV1709
Removal and Installation of HBCV1710
Removal and Installation of Arm HBCV1711
Removal of Arm HBCV1711
Installation of Arm HBCV1711
Removal and Installation of Boom HBCV1713
Removal of Boom HBCV1713
Installation of Boom HBCV1714
Removal and Installation of Bucket1716
Removal of Bucket1716
Installation of Bucket1716
Removal and Installation of Bucket Link1718
Removal of Bucket Link1718
Installation of Bucket Link1718
Removal and Installation of Arm1720
Removal of Arm1720
Installation of Arm1721
Removal and Installation of Boom1722
Removal of Boom1722
Installation of Boom1724
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
UNDERCARRIAGE1744
MASS1744
DIGGING FORCE (with 14 m3 Sumitomo Bucket) (ISO 6015)1744
DIMENSIONS1744
WORKING RANGES1745
SYSTEM FLUID CAPACITIES AND SPECIFICATIONS1745
Arm Dimensions1747
Main Unit Weight1749
Divided Weight (Standard Specifications)1749
Stand Alone Part Weight1749
Shoe Weight (per side)1750
Arm Weight1750
Bucket Weight1750
Bolt Size and Torque Table1752
Special Torque Setting1752
Overall View1756
350X41756
Standard Arm (325 m (1066 ft))1756
Short Arm (263 m (863 ft))1757
Long Arm (404 m (1325 ft))1758
WORK RANGE DIAGRAM1759
350X41759
Standard Arm (325 m (1066 ft))1759
Short Arm (263 m (863 ft))1761
Long Arm (404 m (1325 ft))1763
New Machine Performance Judgment Table1765
Table of Standards1765
Measurement Method1767
Engine speed1767
Pressure at Each Part1768
Pump Command Displacement1768
Cylinder Down Amount1768
Attachment Speed1768
Swing Speed1769
Swing (180°) Brake Angle1770
Travel Speed1770
Off Travel Amount1770
Travel Sprocket Speed1771
Shoe Tension Amount1771
Swing Ball Race Bearing Movement Amount and Bucket Tip Movement Amount1772
FLUIDS AND LUBRICANTS1774
HYDRAULIC FLUID1774
Engine Oil1774
Fuel1774
Conditions applicable to diesel fuel1774
Recommended Conditions Applicable to Diesel Fuel1774
Main-unit-related Diagnostic Trouble Code List1775
Main Unit-side Trouble1778
Diagnostic Trouble Code: 7000 Pressure Sensor P1 Abnormality1778
Diagnostic Trouble Code: 7001 Pressure Sensor P2 Abnormality1779
Diagnostic Trouble Code: 7002 Pressure Sensor N1 Abnormality1781
Diagnostic Trouble Code: 7003 Pressure Sensor N2 Abnormality1782
Diagnostic Trouble Code: 7004 Pressure Sensor Boom Cylinder Bottom Abnormality1784
Diagnostic Trouble Code: 7006 Rod Pressure Sensor Signal Abnormality1785
Diagnostic Trouble Code: 7007 Pressure Sensor Arm Cylinder Rod Abnormality1787
Diagnostic Trouble Code: 7021 Pressure Sensor Swing Pilot Abnormality1788
Diagnostic Trouble Code: 7023 Pressure Sensor Arm-In Pilot Abnormality1790
Diagnostic Trouble Code: 7040 Level Sensor Fuel Abnormality1791
Diagnostic Trouble Code: 7041 Temperature Sensor Hydraulic Fluid Abnormality1792
Diagnostic Trouble Code: 7065 Pressure Sensor Boom-Up Pilot Abnormality1794
Diagnostic Trouble Code: 7067 Pressure Sensor Bucket-Close Pilot Abnormality1795
Diagnostic Trouble Code: 7068 Pressure Sensor Boom-Down Pilot Abnormality1797
Diagnostic Trouble Code: 7069 Pressure Sensor Arm-Out Pilot Abnormality1799
Diagnostic Trouble Code: 7070 Pressure Sensor Bucket-Open Pilot Abnormality1800
Diagnostic Trouble Code: 7071 Pressure Sensor Travel Right Pilot Abnormality1802
Diagnostic Trouble Code: 7072 Pressure Sensor Travel Left Pilot Abnormality1804
Diagnostic Trouble Code: 7073 Pressure Sensor Travel 1 Pedal Abnormality1806
Diagnostic Trouble Code: 7074 Pressure Sensor 1st Option Pilot (Common/Front Pedal) Abnormality1807
Diagnostic Trouble Code: 7075 Pressure Sensor Arm Cylinder Bottom Abnormality1809
Diagnostic Trouble Code: 7078 Pressure Sensor 1st Option Pilot (Rear Pedal) Abnormality1811
Diagnostic Trouble Code: 7200 Swing Brake Solenoid Abnormality1813
Diagnostic Trouble Code: 7201 Travel 2nd-Speed Switchover Solenoid Abnormality1814
Diagnostic Trouble Code: 7202 Pressure Boost Solenoid Abnormality1815
Diagnostic Trouble Code: 7203 Travel Alarm Buzzer Abnormality1816
Diagnostic Trouble Code: 7206 Option Return Line Switchover Solenoid Abnormality1817
Diagnostic Trouble Code: 7207 Free Swing Solenoid Abnormality1818
Diagnostic Trouble Code: 7212 Shut-off Solenoid Signal Abnormality1819
Diagnostic Trouble Code: 7213 Quick Coupler Buzzer Abnormality1820
Diagnostic Trouble Code: 7214 Quick Coupler Solenoid Abnormality1822
Diagnostic Trouble Code: 7247 Boom 2-Down Pilot Proportional Valve Abnormality1824
Diagnostic Trouble Code: 7249 Bucket-Close Pilot Proportional Valve Abnormality1825
Diagnostic Trouble Code: 7250 Option Relief Pressure Proportional Valve Abnormality1826
Diagnostic Trouble Code: 7265 Arm 1 Semi-Parallel Proportional Valve Abnormality1828
Diagnostic Trouble Code: 7266 Arm 2 Semi-Parallel Proportional Valve Abnormality1829
Diagnostic Trouble Code: 7267 Arm 1 Regeneration Release Proportional Valve Abnormality1830
Diagnostic Trouble Code: 7270 Tilting 1 Proportional Valve Abnormality1831
Diagnostic Trouble Code: 7271 Tilting 2 Proportional Valve Abnormality1833
Diagnostic Trouble Code: 7273 Straight Travel Proportional Valve Abnormality1834
Diagnostic Trouble Code: 7400 Coolant Temperature Overheating 11835
Diagnostic Trouble Code: 7401 Coolant Temperature Overheating 21836
Diagnostic Trouble Code: 7404 Oil Temperature Overheating1837
Diagnostic Trouble Code: 7405 Boost Temperature Overheating 11838
Diagnostic Trouble Code: 7406 Boost Temperature Overheating 21839
Diagnostic Trouble Code: 7420 Alternator Power Generation Failure1840
Diagnostic Trouble Code: 7421 Coolant Level Decrease1841
Diagnostic Trouble Code: 7422 Engine Oil Pressure Decrease1842
Diagnostic Trouble Code: 7423 Air Cleaner Clogging1843
Diagnostic Trouble Code: 7424 Return Filter Clogging1844
Diagnostic Trouble Code: 7426 Fuel Filter Clogging 11845
Diagnostic Trouble Code: 7427 Fuel Filter Clogging 21846
Diagnostic Trouble Code: 7428 Inducement (Remaining Urea Level Low) – Warning1847
Diagnostic Trouble Code: 7429 Inducement (Remaining Urea Level Low) – Early1848
Diagnostic Trouble Code: 7430 Inducement (Remaining Urea Level Low) – Final1848
Diagnostic Trouble Code: 7602 ECM Communication Abnormality1849
Diagnostic Trouble Code: 7603 Computer S Communication Abnormality1850
Diagnostic Trouble Code: 7605 ECM Not-Matched1851
Diagnostic Trouble Code: 7606 EEPROM Abnormality1851
Diagnostic Trouble Code: 7608 Camera Abnormality1852
Diagnostic Trouble Code: 7612 Air Conditioner Communication Abnormality1853
Diagnostic Trouble Code: 7613 Monitor Communication (CAN) Abnormality1855
Diagnostic Trouble Code: 7615 Sub-Controller Communication Abnormality1856
Diagnostic Trouble Code: 7618 DCU Communication Abnormality1857
List of special tools1859
NUMERICAL VALUE CONVERSION TABLE1859
Unit conversion rate1859
Length1859
Area1861
Volume1862
Weight1864
Pressure1865
Torque1866
Temperature1867
A1870
Travel Motor Special Tool1870
350X41870
Take-up Roller Special Tool1877
350X41877
Upper Roller Special Tool1878
350X41878
Lower Roller Special Tool1879
350X41879
Grease Cylinder Special Tool1879
350X41879
Center Joint Special Tool1880
350X41880
C1881
Swing Motor Special Tool1881
350X41881
H1883
Engine Oil Filter Special Tool1883
350X41883
Fuel Filter Special Tool1883
350X41883
Injector Special Tool1883
350X41883
Circuit Test Special Tool1884
350X41884
Valve Guide Special Tool1884
350X41884
Cylinder Head Special Tool1884
350X41884
Head Bolt Special Tool1887
350X41887
Crankshaft Special Tool1887
350X41887
Camshaft Special Tool1890
350X41890
Valve Spring Special Tool1890
350X41890
J1891
Remote Control Valve Special Tool1891
350X41891
R1892
Gas Filling Special Tool1892
350X41892
V1893
Attachment Special Tool (for Cylinder Assembly)1893
Special Jigs Part Number List1893
Attachment Special Tool (Other)1894
350X41894
Paint Colors1895
Abbreviation1897
WLSM3507-00LX-A3-Jpdf 0
A3 Assembly Diagrams 0
J1261
Explanation of Hydraulic Circuit and Operations (standard model)1263
Travel Circuit1264
Travel Low-speed Circuit1264
Travel High-speed Circuit1266
Straight Travel Circuit (with HBCV)1268
Swing Circuit1270
Swing Speed Limit Control Circuit1270
Swing Relief Cut Control Circuit1272
Swing Brake Circuit1274
Swing Parking Circuit (lever in neutral)1276
Swing Parking Circuit (brake release)1278
Swing Parking Circuit (machine stop)1280
Boom Circuit1282
Boom-up Circuit (independent operation) (with HBCV)1282
Boom-up Spool Stroke Control Circuit (compound boom-up + arm-in) (with HBCV)1284
Boom-down Regenerative Circuit (with HBCV)1286
Boom-down Tilting Prevention Circuit (with HBCV)1288
Boom-down Load Holding Valve Circuit (with HBCV)1290
Arm Circuit1292
Arm-out Circuit (with HBCV)1292
Arm Semi-Parallel 1 Circuit1294
Arm Semi-Parallel 2 Circuit1296
Arm-in Regenerative Circuit (with HBCV)1298
Arm-in Load Holding Valve Circuit (with HBCV)1300
Bucket Circuit1302
Bucket-open Circuit1302
Bucket-close Regenerative Circuit1304
Bucket-Close Spool Stroke Control Circuit1306
Negative Control Circuit1308
Negative Control Circuit1308
Other Circuits1310
Cushion Circuit (arm-out operation)1310
Cushion Circuit (when arm-out operation stopped)1312
Cushion Circuit (arm-out → arm-in operation)1314
Heat Circuit (lever in neutral)1316
Auto Pressure Boost Circuit (arm in)1318
J1321
Explanation of Hydraulic Circuit and Operations (option)1323
Option Circuits1324
Breaker Circuit (independent operation)1324
Double-acting Circuit (hydraulic fork)1326
Multi-purpose Circuit (breaker Q control)1328
Multi-purpose Circuit (2 pumps flow crusher)1330
2nd Option Circuit (hydraulic rotation fork)1332
R 0
Electrical Connector Wiring Diagram 0
Main Frame 0
Control Valve 0
SCR 0
Cab Main Harness 0
Console 0
EST-A 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
WLSM3507-00LX-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
R1603
Electrical Connector Wiring Diagram1605
Main Frame1606
Control Valve1608
SCR1610
Cab Main Harness1612
Console1614
EST-A1616
Indicator Jumper1618
R1619
Electrical Parts and Wiring Assembly Diagram1621
Frame1622
Engine and Pump1624
Attachments1626
Battery1628
Cab1630
S.M 3/1/25
