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Link-Belt 380 X4MH MATERIAL HANDLER SERVICE MANUAL WLSM3807MH-01LX PDF
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Link-Belt 380 X4MH MATERIAL HANDLER SERVICE MANUAL WLSM3807MH-01LX – PDF DOWNLOAD
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Description
Link-Belt 380 X4MH MATERIAL HANDLER SERVICE MANUAL WLSM3807MH-01LX – PDF DOWNLOAD
FILE DETAILS:
Link-Belt 380 X4MH MATERIAL HANDLER SERVICE MANUAL WLSM3807MH-01LX – PDF DOWNLOAD
Language : English
Pages :2213
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Link-Belt 380 X4MH MATERIAL HANDLER SERVICE MANUAL WLSM3807MH-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 380 X4MH MATERIAL HANDLER SERVICE MANUAL WLSM3807MH-01LX – PDF DOWNLOAD
MATERIAL HANDLER 1
SAFETY 9
Safety, general information and standard torque data 12
General Information 13
Safety 13
ROPS 15
Non-ROPS Application 15
Standard Torque Data For Cap Screws And Nuts 16
Bolt and Nut Tightening 16
Removal of Under Cover 17
A LOWER 21
Main Equipment Table 25
Lower Component 25
Travel Unit 25
Take-up roller 25
Upper roller 25
Lower Roller 25
Recoil spring 25
Shoe 25
Center joint 26
Main Equipment Structure and Operation Explanation 27
Travel Motor 27
Travel motor operation explanation 27
Structure 27
Summary explanation of component parts 28
Rotary group 28
Parking Brake 28
Variable Capacity Mechanism Section 28
Overload Relief Valve 29
Brake Valve Section 29
Function 31
Motor operation 31
Parking Brake Operation 32
Operation of Variable Capacity Mechanism Section 33
Overload Relief Valve Operation 34
Brake Valve Operation 35
Port Diagram 40
Travel Motor 40
Center Joint 41
Basic Functions 42
Travel Speed Selection 42
Travel Alarm 42
Removal and Installation of Track 44
Removal and Installation of Shoe Assembly 45
Removal of Shoe Assembly 45
Installation of Shoe Assembly 47
Removal and Installation of Shoe Plate 49
Removal of Shoe Plate 49
Installation of Shoe Plate 49
Removal and Installation of Roller 50
Removal and Installation of Upper Roller 51
Removal of Upper Roller 51
Installation of Upper Roller 52
Assembly and Disassembly of Upper Roller 53
Configuration Diagram 53
Dimension Diagram 54
Jig Dimension Diagram 54
Disassembly Procedures 54
Assembly Procedures 57
Removal and Installation of Lower Roller 59
Removal of Lower Roller 59
Installation of Lower Roller 60
Assembly and Disassembly of Lower Roller 61
Configuration Diagram 61
Dimension Diagram 62
Jig Dimension Diagram 62
Disassembly Procedures 62
Assembly Procedures 65
Removal and Installation of Drive Sprocket 67
Removal of Drive Sprocket 67
Installation of Drive Sprocket 68
Removal and Installation of Take-up Roller 69
Removal of Take-up Roller 69
Installation of Take-up Roller 70
Assembly and Disassembly of Take-up Roller 71
Configuration Diagram 71
Dimension Diagram 72
Jig Dimension Diagram 72
Disassembly Procedures 72
Assembly Procedures 74
Removal and Installation of Grease Cylinder 77
Removal of Grease Cylinder 77
Installation of Grease Cylinder 78
Assembly and Disassembly of Grease Cylinder 79
Configuration Diagram 79
Dimension Diagram 79
Jig Dimension Diagram 80
Disassembly Procedures 80
Assembly Procedures 81
Removal and Installation of Center Joint 83
Removal of Center Joint 83
Installation of Center Joint 85
Assembly and Disassembly of Center Joint 86
Configuration Diagram 87
Dimension Diagram 88
Jig Dimension Diagram 89
Disassembly Procedures 89
Assembly Procedures 90
Removal and Installation of Travel Motor 94
Removal of Travel Motor 94
Installation of Travel Motor 96
Assembly and Disassembly of Travel Motor 99
Tools for Assembly and Disassembly 99
Standard tools 99
Secondary Materials 99
Special Tool (jig) 100
Measurement Device 103
Motor Disassembly Procedures 103
Precautions before motor disassembly 103
Tightening Torque 104
Disassembly procedure 104
Removal of supplied valves 104
Disassembly of motor 105
Disassembly of overload relief valve 108
Reduction gear disassembly procedures 109
Disassembly preparations 109
Disassembly procedure 109
Installation to Receiving Platform Of Reduction Gear (unit) 109
Removal of Reduction Gear Cover 110
Removal of carrier 1 assembly 110
Removal of carrier 2 assembly 110
Removal of housing assembly 110
Disassembly of Housing Assembly 111
Removal of floating seal from motor 112
Disassembly of carrier 1 assembly 112
Disassembly of Carrier 2 Assembly 113
Maintenance standards 115
Motor Parts Maintenance Standards 115
Reduction gear parts maintenance standards 117
Inspection prior to reassembly 117
Thrust washer 117
Gears 118
Bearing 118
Floating seal 118
Parts Maintenance 118
Assembly of motor 120
Precautions before Motor Assembly 120
Assembly procedure 120
Motor Assembly Procedures 120
Motor assembly procedure 123
Assembly of the Carrier 2 Assembly 123
Assembly of the carrier 1 assembly 124
Installation of bearing and floating seal 125
Assembly of the housing assembly 125
Determining the thickness of the angular bearing shim 126
Installation of housing assembly 126
Installation of Carrier 2 Assembly 127
Installation of carrier 1 assembly 128
Cover Attachment 129
Gear Oil Filling 129
Initial pre-conditioning operation 129
Drain charge 129
Performing initial operation (pre-conditioning operation) 129
Troubleshooting 130
General cautions 130
Causes of troubles and countermeasures 130
Structural diagram 132
Maintenance Standards 133
Drive sprocket 133
Take-up roller 134
Upper roller 135
Lower Roller 136
Track Shoe (Grouser Shoe) 137
Inspection Gauge 138
For Drive Sprocket 138
For Take-up Roller 138
For Upper Roller 139
For Lower Roller 139
Pressure Measurement and Adjustment Procedures 140
Main Pressure Measurement 140
B Travel Pressure Measurement 140
Drain Volume Measurement Procedures 141
Preparations 141
Travel Motor Drain Volume Measurement 141
Air Bleed Procedure 143
Travel Motor 143
B C SWING UNIT, COUNTERWEIGHT 145
Main Equipment Table 148
Upper Component 148
Swing Unit 148
Main Equipment Structure and Operation Explanation 149
Swing Motor 149
Swing Motor Operation Explanation 149
Hydraulic motor operation explanation 149
Mechanical brake operation explanation 149
Make-up valve operation explanation 149
Relief valve operation explanation (relief valve internal structure diagram) 150
Bypass valve operation explanation (bypass valve internal structure diagram) 151
Swing motor internal diagram 153
Port Diagram 155
Swing motor 155
Basic Functions 156
Swing brake 156
Swing Lock 156
Swing Speed Limit 157
Swing Relief Cut 159
Free Swing (Option) 160
Removal and Installation of Swing Unit 162
Removal of Swing Unit 162
Installation of Swing Unit 164
Assembly and Disassembly of Swing Unit 165
Disassembly 165
Assembly 166
Assembly and Disassembly of Swing Motor 168
Causes of Trouble and Solutions 168
Maintenance Standard Table 170
Jig 172
Disassembly 172
Assembly 177
Swing Motor Internal Structural Diagram 184
Removal and Installation of Counterweight 186
Removal of Counterweight 186
Installation of Counterweight 187
Pressure Measurement and Adjustment Procedures 188
Main Pressure Measurement 188
C Swing Pressure Measurement 188
Drain Volume Measurement Procedures 189
Preparations 189
Swing Motor Drain Volume Measurement 189
Air Bleed Procedure 190
Swing Motor 190
Check 191
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 204
SCR Gauge 206
Fuel Economy Gauge 209
Neutral start 210
Power-cut Delay 211
Preheat 212
Throttle 213
Throttle Volume Position Detection 214
Idle start 220
Auto Idle 221
One-touch Idle 221
Auto Warm-Up 222
Idle Shutdown 227
Idle up 228
Work Mode Control 228
Engine Emergency Stop 229
SCR RE-GEN 230
Inducement 235
Feed Pump Automatic Stop 239
Coolant Level Decrease 241
Air Filter Clogging 242
Fuel Filter Clogging 243
Battery Charge Abnormality 244
Horsepower Reduction Control (in Uplands) 245
Horsepower Reduction Control (at Engine Failure) 245
Main Data 248
Function, Structure, Operation 251
Function, structure, operation (SCR) 305
SCR Control System Inspection 332
Explanation of SCR Operation 333
Diagnosis for Each Symptom 335
Intermittent conditions of urea selective catalytic reduction system 335
Urea fluid consumption too high 338
Ammonia smell noticeable 338
White crystalline powder visible 339
Symptom 340
Engine Start Problem 340
Engine Stalling 342
Engine Hunting, Rough Idling 343
Excessive White Smoke in Exhaust Gas 344
Excessive Black Smoke in Exhaust Gas 345
Abnormal Noise 346
High Fuel Consumption 346
High Oil Consumption 348
Engine Output Deficiency 348
Functional Inspection 351
Engine Compression Pressure Inspection 351
Fuel System Inspection 352
Lubrication System Inspection 352
Suction air system inspection 353
Exhaust System Inspection 353
EGR Control System Inspection 353
Start System Inspection 354
Glow Control System Inspection 354
OBD System Inspection 355
Monitor Warning Light Lighting Circuit System Inspection 356
Inspection of the monitor warning light blinking circuit system 357
Start Circuit System Inspection 357
Removal and Installation of Engine Assembly 359
Removal of Engine Assembly 359
Installation of Engine Assembly 362
Removal and Installation of Fuel Cooler, Engine Intercooler, Radiator, and Oil Cooler 363
Removal and Installation of Fuel Cooler 363
Removal of Fuel Cooler 363
Installation of Fuel Cooler 363
Removal and Installation of Engine Intercooler 363
Removal of Intercooler 363
Installation of Inter Cooler 364
Inspection of Intercooler 364
Removal and Installation of Radiator 365
Removal of Radiator 365
Installation of Radiator 368
Inspection of Radiator 368
Removal and Installation of Oil Cooler 369
Removal of Oil Cooler 369
Installation of oil cooler 371
Removal and Installation of Turbo Charger 372
Removal of Turbo Charger 372
Installation of Turbo Charger 373
Inspection of Turbo Charger 375
Removal and Installation of EGR Valve 377
Removal of EGR Valve 377
Installation of EGR Valve 379
Inspection of EGR Valve 383
Removal and Installation of Engine Hood 384
Removal of Engine Hood 384
Installation of Engine Hood 384
Removal and Installation of SCR 385
Removal of SCR 385
Installation of SCR 385
Removal and installation of Silicon Controlled Rectifier Catalyst 386
Removal of Silicon Controlled Rectifier Catalyst 386
Installation of Silicon Controlled Rectifier Catalyst 387
Disassembly of Silicon Controlled Rectifier Catalyst 390
Assembly of Silicon Controlled Rectifier Catalyst 390
Inspection of Silicon Controlled Rectifier Catalyst 390
Removal and Installation of Cylinder Head Cover 391
Cylinder head cover Removal 391
Cylinder head cover Installation 391
Removal and Installation of Cylinder Head 392
Removal of Cylinder head assembly 392
Cylinder head assembly Disassembly 401
Cylinder head assembly Reassembly 406
Installation of Cylinder head assembly 415
Cylinder head assembly Inspection 433
Removal and Installation of Cylinder Block 440
Removal of Cylinder block 440
Installation of Cylinder block 456
Cylinder block Inspection 494
Lubrication System 496
Removal and Installation of Oil Pan 496
Oil pan Removal 496
Oil pan Installation 496
Removal and Installation of Oil Level Switch 497
Oil level switch Removal 497
Oil level switch Installation 498
Removal and Installation of Oil Pump Assembly 498
Removal of Oil pump assembly 498
Disassembly of Oil Pump 511
Assembly of Oil Pump 512
Installation of Oil Pump 512
Inspection of Oil Pump 538
Inspection of Engine oil 539
Removal and Installation of Oil Port Cover 540
Removal of Oil port cover 540
Installation of Oil port cover 540
Removal and installation of Oil filter element 541
Removal of Oil filter element 541
Installation of Oil filter element 541
Cooling System 542
Removal and Installation of Water Pump Assembly 542
Removal of Water pump assembly 542
Installation of Water pump assembly 543
Inspection of Water pump assembly 547
Removal and Installation of Thermostat 547
Removal of Thermostat 547
Installation of Thermostat 548
Inspection of Thermostat 550
Inspection of Coolant 551
Inspection of Cooling Fan Belt 555
Removal and Installation of Overheat Switch 556
Removal of Overheat switch 556
Installation of Overheat switch 556
Induction System 558
Inspection of Air cleaner element 558
Exhaust System 559
Removal and installation of Oxidation Catalyst Assembly 559
Removal of Oxidation Catalyst Assembly 559
Installation of Oxidation Catalyst Assembly 560
Aux Emission Control Devices System 562
Removal and installation of Dosing Module 562
Removal of Dosing Module 562
Disassembly of Dosing Module 562
Assembly of Dosing Module 563
Installation of Dosing Module 563
Removal and installation of DEF Supply Module 565
Removal of DEF supply module 565
Disassembly of DEF Supply Module 566
Assembly of DEF Supply Module 566
Installation of DEF Supply Module 567
Removal and installation of Coolant Control Valve 569
Removal of Coolant Control Valve 569
Installation of Coolant Control Valve 570
Removal and Installation of DCU 572
Removal of DCU 572
Installation of DCU 572
Removal and installation of DEF Supply Module Filter 572
Removal of DEF Supply Module Filter 572
Installation of DEF Supply Module Filter 573
Removal and Installation of Exhaust Manifold 574
Removal of Exhaust manifold 574
Installation of Exhaust manifold 577
Exhaust manifold Inspection 583
Removal and Installation of Fuel Tank 584
Removal of Fuel Tank 584
Installation of fuel tank 587
Removal and Installation of Urea Pump 588
Removal of Urea Pump 588
Installation of Urea Pump 588
Removal and Installation of Urea Solution Tank 589
Removal of Urea Solution Tank 589
Installation of Urea Solution Tank 590
Removal and Installation of Fuel Supply Pump 591
Removal of Fuel Supply Pump 591
Fuel supply pump Installation 591
Removal and Installation of Common Rail Assembly 595
Removal of Common rail assembly 595
Installation of Common rail assembly 599
Removal and Installation of Injector 607
Injector Removal 607
Injector Installation 609
Removal and installation of Idle Gear 614
Removal of Idle Gear 614
Installation of Idle Gear 626
Inspection of Idle Gear 652
Removal and installation of Inlet Cover 654
Removal of Inlet Cover 654
Installation of Inlet Cover 658
Removal and installation of Crankshaft 667
Removal of Crankshaft 667
Installation of Crankshaft 683
Disassembly of Crankshaft 719
Assembly of Crankshaft 719
Inspection of Crankshaft 720
Removal and installation of Piston 726
Removal of Piston 726
Installation of Piston 737
Disassembly of Piston 759
Assembly of Piston 759
Inspection of Piston 761
Removal and installation of Camshaft 768
Removal of Camshaft 768
Disassembly of Camshaft 769
Installation of Camshaft 770
Assembly of Camshaft 774
Inspection of Camshaft 775
Removal and installation of Flywheel 777
Removal of Flywheel 777
Installation of Flywheel 778
Inspection of Flywheel 779
Removal and installation of Crankshaft Front Oil Seal 780
Removal of Crankshaft Front Oil Seal 780
Installation of Crankshaft Front Oil Seal 781
Removal and installation of Crankshaft Rear Oil Seal 785
Removal of Crankshaft Rear Oil Seal 785
Installation of Crankshaft Rear Oil Seal 786
Removal and installation of Rocker Arm Shaft 789
Removal of Rocker Arm Shaft 789
Installation of Rocker Arm Shaft 790
Disassembly of Rocker Arm Shaft 794
Assembly of Rocker Arm Shaft 794
Inspection of Rocker Arm Shaft 795
Removal and installation of Valve Spring 798
Removal of Valve Spring 798
Installation of Valve Spring 800
Inspection of Valve Spring 806
Removal and installation of Valve Stem Oil Seal 808
Removal of Valve Stem Oil Seal 808
Installation of Valve Stem Oil Seal 810
Removal and installation of Front Cover 817
Removal of Front Cover 817
Installation of Front Cover 819
Removal and installation of Intake Throttle Valve 826
Removal of Intake Throttle Valve 826
Installation of Intake Throttle Valve 826
Removal and Installation of Starter Motor 827
Removal of Starter Motor 827
Installation of Starter Motor 827
Disassembly of Starter Motor 828
Assembly of Starter Motor 829
Inspection of Starter Motor 833
Removal and Installation of Alternator 836
Removal of Alternator 836
Installation of Alternator 836
Disassembly of Alternator 836
Assembly of Alternator 838
Inspection of Alternator 839
Removal and Installation of Glow Plug 843
Removal of Glow Plug 843
Installation of Glow Plug 843
Glow Plug Inspection 844
Removal and Installation of Suction Control Valve 845
Suction control valve Removal 845
Suction control valve Installation 845
Removal and installation of Fuel Filter 848
Removal of Fuel Filter 848
Installation of Fuel Filter 848
Removal and installation of Relief Valve 851
Removal of Relief Valve 851
Installation of Relief Valve 851
Removal and installation of Fuel Filter Element 854
Removal of Fuel Filter Element 854
Installation of Fuel Filter Element 855
Removal and Installation of Fuel filter pressure 858
Fuel filter pressure sensor Removal 858
Fuel filter pressure sensor Installation 858
Removal and Installation of Engine coolant temperature sensor 859
Engine coolant temperature sensor Removal 859
Engine coolant temperature sensor Installation 859
Engine coolant temperature sensor Inspection 859
Removal and Installation of CKP sensor 860
Removal of CKP sensor 860
Installation of CKP sensor 860
CKP sensor Inspection 860
Removal and Installation of CMP sensor 861
CMP sensor Removal 861
CMP sensor Installation 861
CMP sensor Inspection 861
Removal and Installation of Oil pressure sensor 862
Removal of Oil pressure sensor 862
Installation of Oil pressure sensor 862
Inspection of Oil pressure sensor 862
Removal and installation of Pressure Sensor/Boost Temperature Sensor 863
Removal of Pressure sensor/boost temperature sensor 863
Installation of Pressure sensor/boost temperature sensor 863
Inspection of Pressure sensor/boost temperature sensor 863
Removal and Installation of IMT sensor 864
Removal of IMT sensor 864
Installation of IMT sensor 864
Removal and installation of Charge Air Cooler Temperature Sensor 1 865
Removal of Charge air cooler temperature sensor 1 865
Installation of Charge air cooler temperature sensor 1 865
Inspection of Charge air cooler temperature sensor 1 865
Sampling Procedure 866
Sampling of Engine Oil 866
Removal and Installation of Exhaust gas temperature sensor 867
Removal of Exhaust gas temperature sensor 867
Installation of Exhaust gas temperature sensor 867
Inspection of Exhaust gas temperature sensor 868
Removal and installation of EGR Gas Temperature Sensor 1 869
Removal of EGR Gas Temperature Sensor 1 869
Installation of EGR Gas Temperature Sensor 1 869
Inspection of EGR Gas Temperature Sensor 1 869
Removal and installation of EGR Gas Temperature Sensor 2 870
Removal of EGR Gas Temperature Sensor 2 870
Installation of EGR Gas Temperature Sensor 2 870
Inspection of EGR Gas Temperature Sensor 2 871
Removal and installation of NOx Sensor 872
Removal of NOx Sensor 872
Installation of NOx Sensor 872
Removal and Installation of Exhaust gas temperature sensor 3 875
Removal of Exhaust gas temperature sensor 3 875
Installation of Exhaust gas temperature sensor 3 875
Removal and installation of DEF Sensor 876
Removal of DEF Sensor 876
Installation of DEF Sensor 876
Engine-related Diagnostic Trouble Code List 877
Engine-side Trouble 886
ECM Trouble 886
DTC P0016 Crankshaft Position – Camshaft Position Correlation Error 886
DTC P0045 Turbocharger Boost Control VNT Error 887
DTC P0087 Fuel Rail/System Pressure – Too Low 888
DTC P0089 Fuel Pressure Regulator Performance 891
DTC P0091 Fuel Pressure Regulator Control Circuit Low 892
DTC P0092 Fuel Pressure Regulator Control Circuit High 893
DTC P0097 Intake Air Temperature (IAT) Sensor 2 Circuit Low Voltage 894
DTC P0098 Intake Air Temperature (IAT) Sensor 2 Circuit High Voltage 895
DTC P0102 Mass Air Flow Sensor Circuit Low Input 896
DTC P0103 Mass Air Flow Sensor Circuit High Input 897
DTC P0112 Intake Air Temperature Sensor Circuit Low 898
DTC P0113 Intake Air Temperature Sensor Circuit High 899
DTC P0117 Engine Coolant Temperature Sensor Circuit Low 900
DTC P0118 Engine Coolant Temperature Sensor Circuit High 901
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 908
DTC P0201 Injector Circuit Open – Cylinder 1 910
DTC P0202 Injector Circuit Open – Cylinder 2 911
DTC P0203 Injector Circuit Open – Cylinder 3 912
DTC P0204 Injector Circuit Open – Cylinder 4 913
DTC P0205 Injector Circuit Open – Cylinder 5 914
DTC P0206 Injector Circuit Open – Cylinder 6 915
DTC P0217 Engine Coolant Over Temperature Condition 916
DTC P0219 Engine Overspeed Condition 917
DTC P0234 Turbocharger Overboost Condition 918
DTC P0237 Turbo Charger Boost Sensor Circuit Low 919
DTC P0238 Turbo Charger Boost Sensor Circuit High 920
DTC P0335 Crankshaft Position Sensor Circuit 921
DTC P0336 Crankshaft Position Sensor Circuit Range/Performance 923
DTC P0340 Camshaft Position Sensor Circuit 924
DTC P0380 Glow Relay Circuit Error 925
DTC P0401 EGR Flow Insufficient Detected 926
DTC P0404 EGR Control Circuit Range/Performance 927
DTC P0409 EGR Sensor Circuit 928
DTC P041C EGR Cooler Outlet 1 Temp Sensor Circuit Low 930
DTC P041D EGR Cooler Outlet 1 Temp Sensor Circuit High 931
DTC P0427 Catalyst Temperature Sensor Circuit Low Sensor 1 932
DTC P0428 Catalyst Temperature Sensor Circuit High Sensor 1 933
DTC P042C Catalyst Temperature Sensor Circuit Low Sensor 2 934
DTC P042D Catalyst Temperature Sensor Circuit High Sensor 2 935
DTC P0522 Engine Oil Pressure Sensor Circuit Low Input 937
DTC P0523 Engine Oil Pressure Sensor Circuit High Input 938
DTC P0545 EGR Cooler Inlet 1 Temp Sensor Circuit Low 939
DTC P0546 EGR Cooler Inlet 1Temp Sensor Circuit High 940
DTC P0560 12 Volt Circuit Error 941
DTC P0563 System Voltage High 942
DTC P0601 Internal Control Module Memory Check Sum Error 942
DTC P0602 Internal Control Module QR Code Error 943
DTC P0604 Internal Control Module RAM Error 944
DTC P0606 Internal Control Module CPU Error 944
DTC P060A Internal Control Module CPU IC Error 945
DTC P060C Internal Control Module A/D Processing Performance 945
DTC P0615 Starter Relay Circuit Error 946
DTC P0638 Throttle Actuator Control Range/Performance 947
DTC P0685 ECM Power Relay Control Circuit Open 948
DTC P0687 ECM Power Relay Control Circuit High 949
DTC P06A6 Sensor Reference Voltage 1 Circuit 950
DTC P06A7 Sensor Reference Voltage 2 Circuit 951
DTC P06A8 Sensor Reference Voltage 3 Circuit 952
DTC P06A9 Sensor Reference Voltage 4 Circuit 953
DTC P06AF Torque Management System – Forced Engine Shutdown 954
DTC P06D5 Sensor Reference Voltage 5 Circuit 954
DTC P1076 Charge Air Cooler (CAC) Temperature Sensor 1 Circuit Low Voltage 955
DTC P1077 Charge Air Cooler (CAC) Temperature Sensor 1 Circuit High Voltage 956
DTC P1093 Fuel Rail Pressure Too Low 957
DTC P1097 Compressor Outlet Temperature Sensor Circuit High 960
DTC P1098 Compressor Outlet Temperature Sensor Circuit High 961
DTC P1236 Charge Air Cooler Performance Failure 962
DTC P1261 Injector Positive Voltage Control Circuit Group 1 963
DTC P1262 Injector Positive Voltage Control Circuit Group 2 964
DTC P1404 EGR Position Fault 964
DTC P1606 SW-IC Internal failure 965
DTC P160B AD-IC Failure Error 966
DTC P160C AD-IC2 Failure Error 966
Diagnostic trouble code_P1621: EEPROM abnormality 967
DTC P1622 Control Module Long Term Memory Hardware 968
DTC P1669 DPD Lamp Control Circuit 969
DTC P204F SCR System Error (No Inducement) 970
DTC P207F Urea Fluid Concentration Too Low 970
DTC P20C9 SCR System Error 971
DTC P2122 Pedal Position Sensor 1 Circuit Low Input 971
DTC P2123 Pedal Position Sensor 1 Circuit High Input 972
DTC P2127 Pedal Position Sensor 2 Circuit Low Input 973
DTC P2128 Pedal Position Sensor 2 Circuit High Input 974
DTC P2138 Pedal Position Sensor 1 – 2 Voltage Correlation 975
DTC P2146 Fuel Injector Group 1 Supply Voltage Circuit 976
DTC P2149 Fuel Injector Group 2 Supply Voltage Circuit 978
DTC P2228 Barometric Pressure Sensor Circuit Low 979
DTC P2229 Barometric Pressure Sensor Circuit High 980
DTC P2457 Exhaust Gas Recirculation (EGR) Cooling System Performance 980
DTC P2458 Purge time Out Error 981
DTC P2BA7 Urea Fluid Quantity Too Low 982
DTC P2BAA SCR System Error (Inducement, No Purge) 982
DTC P3093 Fuel Rail Pressure Too Low 983
DTC U0001 CAN Bus Error (ISO-CAN) 986
DTC U0073 Control Module Communication Bus Off 987
DTC U0101 Lost Communication With CAN 989
DTC U010E Lost Communications With Dosing Control Module 990
DTC U0110 Lost Communication With VNT System 991
DTC U2106 Lost CAN Communications With Wheel Loader Transmission Control System 992
DTC U0411 Lost CAN Communications With VNT Control Module 992
DCU Trouble 993
Diagnostic Trouble Code_P0607: Control Module Characteristic Abnormality 993
Diagnostic trouble code_P060B: Control Module A/D Conversion Processing Device Abnormality 994
Diagnostic trouble code_P062F: Control Module EEPROM Abnormality 994
Diagnostic trouble code_P0641: Sensor Reference Voltage Abnormality 995
Diagnostic trouble code_P0658: Actuator Supply Power Feed System Abnormality 997
Diagnostic trouble code_P0659: Actuator Supply Power Feed System Abnormality 998
Diagnostic trouble code_P1462: Urea Solution Quality Sensor Time-Out Abnormality1000
Diagnostic trouble code_P1464: Main Relay Abnormality (Early OPEN Error/Sticking Error of Main Relay)1001
Diagnostic trouble code_P1468: Urea Solution Injection Control Module (DCM) High Temperature Abnormality1002
Diagnostic trouble code_P1491: Urea Solution High Pressure Abnormality1002
Diagnostic trouble code_P1493: Urea Solution Injection Control Module (DCM) Screwdriver High Temperature Abnormality1004
Diagnostic trouble code_P149C: Urea Solution Reducing Pressure Abnormality1004
DTC P149D Urea Fluid Tank Overtemperature1006
Diagnostic trouble code_P2000: Cleaning Ratio Abnormality1007
Diagnostic trouble code_P203B: Urea Solution Tank Level Sensor1009
Diagnostic trouble code_P203C: Urea Solution Tank Level Sensor Low Voltage Potential1010
Diagnostic trouble code_P203D: Urea Solution Tank Level Sensor High Voltage Potential1011
Diagnostic trouble code_P2048: Urea Solution Injector System Low Voltage Potential1012
Diagnostic trouble code_P2049: Urea Solution Injector System High Voltage Potential1014
Diagnostic trouble code_P204B: Urea Solution Pressure Sensor System Characteristic Abnormality1015
Diagnostic trouble code_P204C: Urea Solution Pressure Sensor System Low Voltage Potential1016
Diagnostic trouble code_P204D: Urea Solution Pressure Sensor System High Voltage Potential1017
Diagnostic trouble code_P205B: Urea Solution Tank Temperature Sensor Characteristic Abnormality1018
Diagnostic trouble code_P205C: Urea Solution Tank Temperature Sensor Low Voltage Potential1019
Diagnostic trouble code_P205D: Urea solution tank temperature sensor high voltage potential1020
DTC P206A Urea Fluid Quality Sensor Circuit1021
Diagnostic trouble code_P206B: Urea Sensor High Temperature Abnormality1022
DTC P206C Urea Fluid Quality Sensor Circuit Low Voltage1023
DTC P206D Urea Fluid Quality Sensor Circuit High Voltage1024
Diagnostic trouble code_P207F: Urea Solution Concentration Low1025
Diagnostic trouble code_P208A: Urea Solution Pump Control System1026
Diagnostic trouble code_P208B: Urea Solution Pump Characteristic Abnormality1027
Diagnostic trouble code_P208C: Urea Solution Pump Control System Low Voltage Potential1028
Diagnostic trouble code_P208D: Urea Solution Pump Control System High Voltage Potential1029
Diagnostic trouble code_P208E: Urea Solution Injector Attachment1030
Diagnostic trouble code_P20A0: Urea Solution Reverting Valve System Disconnection1032
Diagnostic trouble code_P20A2: Urea Solution Reverting Valve System Low Voltage Potential1033
Diagnostic trouble code_P20A3: Urea Solution Reverting Valve System High Voltage Potential1034
Diagnostic trouble code_P20AC: Urea Solution Pump Temperature Sensor Characteristic Abnormality1035
Diagnostic trouble code_P20AD: Urea Solution Pump Module Temperature Sensor Function1036
Diagnostic trouble code_P20B1: Urea Solution Tank Heater Coolant Control Valve System Disconnection1037
Diagnostic trouble code_P20B3: Urea Solution Tank Heater Coolant Control Valve System Low Voltage Potential1038
Diagnostic trouble code_P20B4: Urea solution tank heater coolant control valve system high voltage potential1039
Diagnostic trouble code_P20E8: Urea Solution Low Pressure Abnormality1040
Diagnostic trouble code_P20E9: Urea Solution High Pressure Abnormality1042
Diagnostic trouble code_P20EA: Urea Solution Reducing Pressure Abnormality1044
Diagnostic trouble code_P20FE: Urea Solution Build-Up Abnormality1045
Diagnostic trouble code_P2201: NOx Sensor Upstream Function1047
Diagnostic trouble code_P2206: Ft NOx Sensor Disconnection1048
Diagnostic trouble code_P2207: Ft NOx Sensor Short-Circuit1048
Diagnostic trouble code_P2210: Rr NOx Sensor Disconnection1049
Diagnostic trouble code_P2211: Rr NOx Sensor Short-Circuit1049
Diagnostic trouble code_P242B: Exhaust Gas Temperature (EGT) Sensor 3 System Function1050
Diagnostic trouble code_P242C: Exhaust Gas Temperature (EGT) Sensor 3 System Low Voltage Potential1051
Diagnostic trouble code_P242D: Exhaust Gas Temperature (EGT) Sensor 3 System High Voltage Potential1052
DTC U0002 CAN Bus Off1053
DTC U0100 Lost Communication With ECM1054
Diagnostic trouble code_U029D: CAN Communication Error Between DCU-Ft NOx Sensors1055
Diagnostic trouble code_U029E: CAN Communication Error Between DCU-Rr NOx Sensors1058
Data Reference Values1059
Two Pump Relief1059
J HYDRAULIC EQUIPMENT (PUMP, OPERATION SYSTEM VALVE)1061
Main Equipment Table1068
Hydraulic Device1068
Hydraulic Pump1068
LM Pump1068
Motor for Generator1068
Control-related1070
Control valve1070
Solenoid Valve (5 Stack)1070
Solenoid Valve (2 stack) for EV Control1070
Solenoid Valve (for Generator)1071
Solenoid Valve (Single) for Free Swing1071
Remote Control Valve for Left/Right Operations1071
Remote Control Valve for Travel Operation1071
Remote Control Valve for Option Operations1071
Remote Control Valve Characteristic Diagram1072
Operation Remote Control Valve Control Diagram1072
Travel Remote Control Valve Control Diagram1073
1-pedal Travel Remote Control Valve Control Diagram1073
Reducing Valve (6 Stack Proportional Valve)1074
Reducing Valve (3 stack) for Interference Prevention1075
Cushion Valve (with Heat Circuit, Shuttle Valve)1076
Basic Functions1077
Oil temperature gauge1077
Static Horsepower Control1078
Pressure Boost Control1079
Stroke Control1081
Boom Down Energy Save1083
Pump Horsepower Cut Control1084
Pump Horsepower Boost Control1086
Arm 1 Semi-parallel Control1087
Arm 2 Semi-parallel Control1088
CAVIS (CAB ANTI VIBRATION INTELLIGENT SYSTEM)1088
Hot Shutdown Warning1094
Gate Lock1096
Breaker Mode1097
Crusher Mode1097
Quick coupler1098
Hydraulic Fluid Filter Clogging1099
Solenoid Sticking Prevention1100
Port Diagram1101
Hydraulic Pump1101
LM Pump1102
Motor for Generator1103
Control Valve1104
Relief Valve1104
5 stack solenoid valve1107
2 Stack Solenoid Valve (Elevator Control, 2nd Option)1108
Solenoid Valve (for Generator)1109
Solenoid Valve (for Free Swing)1110
Remote Control Valves (upper, travel)1110
Remote Control Valves (left-right)1110
Remote control valve (travel)1111
Remote Control Valve (Option and 2nd Option)1112
Cushion valve1113
Direction Valve1114
6 Stack Proportional Valve1115
Reducing Valve (3 stack) for Interference Prevention1117
Relief Valve (electromagnetic proportional)1118
Manifold Under Cab1119
Manifold (accumulator section)1120
Manifold (hydraulic oil tank section)1121
Hydraulic Pump1122
Structure and Operation Explanation1122
Hydraulic Pump Internal Structure Diagram1123
Overall View1123
Drive Shaft Front Side1124
Drive Shaft on Rear Side1125
Parts Table1126
Regulator1127
Regulator Operation Explanation1127
Regulator Operation Explanation Diagram1129
Internal Configuration Diagram of Regulator1131
Development Diagram of Regulator1133
Component Table1134
Gear Pump1136
Gear Pump Internal Structure Diagram1136
Structure and Operation Explanation1137
Operation Outline of Electronically-Controlled Pump1138
LM Pump1141
Overall View1141
Structural Diagram1143
Motor for Generator1145
Overall View1145
Structural Diagram1146
Control Valve1148
Basic Configuration1148
Operation1148
Operation of Main Unit1148
Activation of Relief Valve1168
5 Stack Solenoid Valve Operation Explanation1173
External Shape Diagram and Components1173
operation explanation1173
2 Stack Solenoid Valve1174
Structure1174
Single Proportional Valve1175
Structure1175
Operation Explanation1176
Upper Pilot Valve (remote control valve)1177
Structure1177
Function1177
Operation1177
Structural Diagram1181
Travel Pilot Valve (remote control valve)1182
Operation1182
Pressure Reducing Valve Section1182
Damping Mechanism in Operation Section1183
Structural Diagram1186
1-pedal Travel Pilot Valve (remote control valve)1188
Operation1188
Structural Diagram1190
Cushion Valve 1191
Structure1191
operation explanation1191
Direction Valve (3-direction) 1196
Structure1196
Operation Explanation1197
6 Stack Proportional Valve (Pilot)1199
structure1199
operation principle1200
Reducing Valve1201
Structure1201
Operation Explanation1202
Electromagnetic Relief Valve1204
Structure1204
Operation Explanation1205
Operation of Check Valve1205
Operation of Electromagnetic Relief Valve1206
Removal and Installation of Hydraulic Reservoir1208
Removal of Hydraulic Reservoir1208
Installation of Hydraulic Oil Tank1211
Removal and Installation of Hydraulic Pump1212
Removal of Hydraulic Pump1212
Installation of Hydraulic Pump1215
Removal and Installation of LM Pump1216
Removal of LM Pump1216
Installation of LM Pump1216
Removal and Installation of Generator Motor1217
Removal of Motor for Generator1217
Installation of Motor for Generator1218
Removal and Installation of Control Valve1219
Removal of Control Valve1219
Installation of Control Valve1223
Removal and Installation of Travel Remote Control Valve1224
Removal of Travel Remote Control Valve1224
Installation of Travel Remote Control Valve1225
Removal and Installation of Operation Remote Control Valve1228
Removal of Operation Remote Control Valve (left side)1228
Installation of Operation Remote Control Valve (left side)1230
Removal of Operation Remote Control Valve (right side)1232
Installation of Operation Remote Control Valve (right side)1234
Removal and Installation of Option Remote Control Valve1236
Removal of Option Remote Control Valve1236
Installation of Option Remote Control Valve1237
Installation and Removal of 5 Stack Solenoid Valve1239
Removal of 5 Stack Solenoid Valve1239
Installation of 5 Stack Solenoid Valve1240
Removal and Installation of Cushion Valve1241
Removal of Cushion Valve1241
Installation of Cushion Valve1242
Procedures for Assembly and Disassembly of Hydraulic Pump Main Unit1244
Tools1244
Disassembly Procedure1244
Assembly Procedure1246
Regulator Maintenance Standards1249
Regulator Adjustment1249
Appendix Table and Drawings1250
Regulator Assembly and Disassembly Procedures1254
Tools1254
Preparations for Disassembly1254
Disassembly Procedure1254
Assembly Procedure1256
Internal Configuration Diagram of Regulator1260
Development Diagram of Regulator1262
Component Table1263
Assembly and Disassembly of Control Valve1265
Disassembly1265
Caution for Disassembly1265
Disassembly Procedure1265
Removal of Long Cap and Pulling Out of Main Spool1265
Disassembly of Arm 1, 2 Parallel-Tandem Spool, Neutral Cut Spool, Arm Regeneration Release Spool Section1266
Disassembly of Load Check Valve Section1266
Disassembly of Antidrift Valve Section (Sub Component in Assembly is Expressed by (Min Number – Sub Number))1267
Disassembly of Relief Valve1267
Disassembly of Option Section1267
Disassembly of Add-On Section1267
Disassembly of Valve Housing Coalescence Bolt1268
Cleaning1268
Inspection1268
assembly1268
Caution for Assembly1268
Caution for Handling O-ring1268
Caution for Handling Spool1268
Method to Apply Adhesive Agent (Male and Female Thread Section of Components Requiring Bonding)1268
Assembly Procedure of Sub-Assembly1269
Assembly of Spool Assembly (Main Spool)1269
Assembly of Arm 1, 2 Parallel-Tandem Spool, Neutral Cut Spool, Arm Regeneration Release Spool Assembly1269
Assembly of Antidrift Valve Assembly1270
Assembly Procedure of Control Valve Main Unit1270
Assembly of Relief Valve1270
Assembly of Load Check Valve1270
Assembly of Antidrift Valve1271
Assembly of Option Section1271
Assembly of Arm 1 Parallel-Tandem Spool1271
Assembly of Arm 2 Parallel-Tandem Spool, Neutral Cut Spool, Arm Regeneration Release Spool1271
Assembly of Main Spool1271
Assembly of Add-On Section1272
Assembly of Other Plugs1272
Internal Structural Diagram1273
Part List1279
Relief Valve1280
Assembly and Disassembly Procedure of Main Relief Valve1280
Assembly and Disassembly Procedures of Overload Relief1281
Assembly and Disassembly Procedure of Low-Pressure Relief Valve1282
Assembly and Disassembly Procedure of Main Relief Valve for Add-On1282
Adjustment of Relief Valve1283
Installation1284
Operation1284
Malfunction and Countermeasure1284
Procedures for Assembly and Disassembly of Operation Remote Control Valve1286
Maintenance Procedures1286
Required Tools and Tightening Torque1286
Maintenance Standards1286
Disassembly Procedures1287
Assembly Procedures1289
Causes of Trouble and Countermeasures1293
Procedures for Assembly and Disassembly of Travel Remote Control Valve1297
Maintenance Procedures1297
Disassembly Procedures1298
Assembly Procedures1302
Causes of Trouble and Countermeasures1307
Assembly and Disassembly Procedures of Option Remote Control Valve1310
Maintenance Procedures1310
Disassembly Procedures1310
Assembly Procedures1312
Causes of Trouble and Countermeasures1314
Assembly and Disassembly of Cushion Valve1318
Disassembly Procedures1318
Reverse Operation Spool Section1318
Check Plunger Section with Throttle1318
Shuttle Valve Section1318
Assembly Procedures1319
Reverse Operation Spool Section1319
Check Plunger Section with Throttle1319
Shuttle Valve Section1319
Document1320
Procedures for Assembly and Disassembly of 6 Stack Proportional Valve (Pilot)1322
Development Diagram1322
Assembly and disassembly procedures1323
Precautions1323
Replacement of Proportional Solenoid1323
Disassembly1323
Assembly1323
Replacement of Sleeve and Spool1324
Disassembly1324
Assembly1325
Replacement of Poppet (Check Valve for Normally Open)1326
Disassembly1326
assembly1326
Maintenance Standards1327
Troubleshooting1327
Pressure Measurement and Adjustment Procedures1328
Procedures for Pressure Measurement from the Monitor Display1328
Monitor and Switch Panel1328
Pressure Measurement Method1328
Operating Method1328
PROCEDURES FOR MEASURING HYDRAULIC OIL TEMPERATURE FROM THE MONITOR DISPLAY1329
Hydraulic Oil Temperature Measurement Method1329
Operating Method1329
Procedures for Pressure Measurement by Installing Pressure Gauge1330
Preparations1330
Items to Prepare1330
Pressure Measuring Ports1331
Control Valve1333
Location of Relief Valves1333
Pressure Measurement Preparations1334
Pressure Measurement1336
Main Pressure Measurement1336
A Attachment Pressure Measurement1337
Boom-down Pressure Measurement1338
D Option Line Pressure Measurement1338
Pilot Pressure Measurement1338
Pressure Gauge Installation1338
Negative Control Pressure Measurement1339
Pressure Gauge Installation1339
Pressure Adjustment1339
Main Pressure Adjustment1339
Pressure Measurement and Adjustment Preparations1339
Main Relief Pressure Adjustment1341
Overload Relief Pressure Adjustment1342
Adjustment of Swing Relief Pressure1343
Pilot Pressure Adjustment1344
Power Generation Line Pressure Measurement Procedure, 2nd Option Pressure Measurement Procedure1345
A Generator Motor Pressure Measurement1345
Elevator Circuit Pressure Adjustment1346
Preparations1346
Elevator Up Circuit Pressure Adjustment1346
Elevator Down Circuit Pressure Adjustment1346
Hydraulic Pump Flow Measurement Procedures1347
Preparations1347
Items to Prepare1347
Work Preparations1347
Flow Measurement1349
LM Pump Flow Measurement Procedure1351
Preparations1351
Items to Prepare1351
Work Preparations1352
Flow Measurement1353
LM Pump Flow Adjustment Procedure1354
Drain Volume Measurement Procedures1354
Drain Volume Measurement of Motor for Generator1354
Air Bleed Procedure1356
Hydraulic Pump1356
Generator Motor1356
Sampling Procedure1358
Sampling of Hydraulic Fluid1358
Hydraulic Equipment Layout1359
Overall View1360
Pump Chamber Hydraulic Equipment Layout1361
Swing Body Center Section Hydraulic Equipment Layout1363
Housing Left Side Hydraulic Equipment Layout1365
Hydraulic Equipment Layout of Elevator Section1367
Hydraulic Equipment Layout of Generator-related Section1368
Layout of Hydraulic Equipment in Cab1369
J_EXPLANATION OF HYDRAULIC CIRCUIT AND OPERATIONS COMBINEDpdf1371
N CAB1448
Removal and Installation of Operator’s Seat1451
Removal of Operator’s Seat1451
Installation of Operator’s Seat1451
Removal and Installation of Cab Assembly1452
Removal of Cab Assembly1452
Installation of Cab Assembly1456
Removal and Installation of Wiper1457
Removal of Wiper1457
Installation of wiper1457
Removal and Installation of Cab Front Glass1458
Removal of Cab Front Glass1458
Installation of Cab Front Glass1459
Window Lock Adjustment Procedures1460
Window Lock (front side)1460
Window Lock (rear side)1460
Removal and Installation of Housing Guardrail1462
Removal of Housing Guardrail1462
Installation of Housing Guardrail1464
Tightening Torque1465
R ELECTRICAL PARTS1466
Basic Functions1470
Monitor Control1470
Monitor Display Dimming1470
Diagnostic Trouble Code Indicator1471
Clock1471
Basic Operation1472
Battery save1472
Accessories1474
Working Light1474
LED Light1475
Room Lamp1475
Radio Mute1477
Wiper and Washer1478
Safety1480
Horn1480
Back/Side View Monitor1481
Precautions for Camera Installation1482
Interference prevention1482
Maintenance1484
Anti-theft1484
Manual Lock1485
Service Support Screen Lock1485
Customer-specific System Information Screen Lock1485
Maintenance Information Screen Lock1486
Option Line Setting Screen Lock1486
Setting1486
Clock Adjustment1486
Auxiliary hydraulics configuration1487
Screen Brightness Setting1488
Interference prevention Setting1488
Battery Disconnect Switch1493
Explanation of Controller1494
Service Support1497
Screen Operations1497
Screen Display List1497
Service Monitor Structure1498
CHECK Screen List1499
MACHINE STATUS1500
HYDRAULIC STATUS1507
ENGINE STATUS1515
FAULT HISTORY1520
WORK HISTORY1520
HYDRAULIC HISTORY1529
ENGINE HISTORY1543
DEVICE TEST1565
ECM/DCU Memory Clear1565
SCR RE-GEN1566
Urea line leak test1567
CCV operation test1567
Dosing test1568
Reverting valve test1569
Common rail pressure test1570
Idle speed test/injector test1571
EGR valve control test1573
VG turbo control test1574
Intake throttle control test1575
CONTROL UNIT Screen List1576
MCM-MAIN1576
MCM-SUB1581
COMMU TERMINAL1582
SETUP Screen List1585
MACHINE SELECT1585
DIMENSIONS1590
PARAMETERS1592
ENGINE INFORMATION1596
ENGINE INFORMATION1597
Data check1597
Data transfer (copy)1598
QR (INJECTOR) CODE1599
Injector number1599
Screen Layout1599
Data Source Selection1599
Manual Input1600
CAMERA1601
PASSWORD1604
CALIBRATE Screen List1606
THROTTLE VOLUME1607
PUMP FLOW1608
ANGLE SENSOR CALIBRATION1610
RESET Screen List1614
Checking the Operation of Abnormal End1616
Connection Connector Pin Layout1618
Main controller1618
Monitor1620
Sequence Circuit Diagram1621
Code List1621
Overall1624
Block diagram1628
Main controller1628
DCU1629
ECM1630
Sub-controller1631
Monitor1632
Air conditioner1633
Gate Lock1634
Horn1634
Working Light1635
Others1636
Electrical Symbol List1637
Electrical Equipment Layout Diagram1638
Main Unit Left-side Layout Diagram1639
Engine Section Layout Diagram1641
Main Unit Right Side Layout Diagram (pump chamber)1644
Main Unit Center Section Layout Diagram1645
Cab Layout Diagram 11646
Cab Layout Diagram 21648
Layout Around Operator Seat1651
Anti-interference Sensor1653
LM-related Section1654
Automatic Greasing Device1655
Stand Alone Parts Diagram1656
Removal and Installation of Wiper Controller1680
Removal of Wiper Controller1680
Installation of wiper controller1680
Removal and Installation of Wiper Motor1681
Removal of Wiper Motor1681
Installation of wiper motor1682
Removal and Installation of ECM1683
Removal of ECM1683
Installation of ECM1683
Removal and Installation of Main Controller1684
Removal of Main Controller1684
Installation of Main Controller1684
Removal and Installation of DCU1685
Removal of DCU1685
Installation of DCU1685
Removal and Installation of Monitor1686
Removal of Monitor1686
Installation of Monitor1687
Removal and Installation of Rear View Camera 1688
Removal of Rear View Camera1688
Installation of Rear View Camera1688
Removal and Installation of Side Camera (right)1689
Removal of Side Camera (Right)1689
Installation of Side Camera (right)1689
Removal and Installation of Side Camera (Left)1690
Removal of Side Camera (Left)1690
Installation of Side Camera (left)1690
Removal and Installation of FVM Controller1691
Removal of FVM Controller1691
Installation of FVM Computer1691
How to Set FVM1692
Air Conditioner Overall Diagram1696
Frame1696
Cab1699
Equipment Layout Diagram1702
Circuit Diagram1704
Air Conditioner Circuit Diagram1704
Explanation of Functions1706
Explanation of Control1706
Air Mix Motor Actuator Control1707
Blow Mode Motor Actuator Control1707
Refresh/Recirculate Switch Motor Actuator Control1708
Blower Amp Control1709
Compressor Clutch Control1711
COOLMAX Control and HOTMAX Control1712
Abnormality Detection and Control after Abnormality Detected1712
Monitor Mode1716
Door Switch Control1718
Actuator Inspection1719
Air Mix Motor Actuator Inspection1719
Refresh/Recirculate Switch Motor Actuator Inspection1720
Mode Motor Actuator Inspection1721
Self-diagnosis Function with Panel Display1722
Abnormality Display and Self-check Procedures1722
Abnormality Display Position1722
Explanation of Abnormality Display1722
Motor Actuator Abnormality1722
Sensor Abnormality1723
Explanation of Monitor Mode1723
Monitor Mode Display Position1723
Monitor Mode Display Operating Method1724
Display Contents in Monitor Mode1725
Part Function and Good/Poor Judgment1726
Control Panel1726
Blower Amp1726
Relay1727
Air Mix Actuator1728
Refresh/Recirculate Actuator1729
Blow Mode Actuator1729
Evaporator Sensor1730
Dual Pressure Switch1730
Solar Radiation Sensor1731
Inside Air Sensor1731
Assembly and Disassembly of Unit1733
Removal of Blower Unit1733
Replacement of Blower Motor1733
Replacement of Blower Amp1733
Removal of Heater Core1734
Removal of Heat Case Right/Left1734
Replacement of Evaporator and Expansion Valve1734
Installation of Evaporator Sensor1735
Replacement of Motor Actuator1735
Removal and Installation of Compressor1736
Removal of Compressor1736
Installation of Compressor1736
Removal and Installation of Condenser1737
Removal of Condenser1737
Installation of Condenser1737
Removal and Installation of Receiver Dryer1738
Removal of Receiver Dryer1738
Installation of Receiver Dryer1738
Work Precautions1739
Work Procedures1739
Air Conditioner Refrigerant Filling is Divided into the “Vacuum Operation” and “Gas Filling Operation”1739
Operation Chart1740
Tools1740
Filling Procedures1742
Charging Hose Connection Position1742
Connecting Gauge Manifold1742
Vacuuming1743
Gas Filling Operation, High-pressure Side1744
Gas Filling Work, Low Pressure Side1744
R_ELECTRICAL PARTS AND WIRING DIAGRAMS COMBINEDpdf1748
004_R_Electrical Parts and Wiring Assembly Diagram_380X4-MH1748
R1748
Electrical Parts and Wiring Assembly Diagram1750
Frame (main unit right side, main unit center section)1751
Frame (main unit left side)1753
Engine and Pump1755
Battery1757
Cab1759
003_R_Electrical Connector Wiring Diagram_380X4-MH1762
R1762
Electrical Connector Wiring Diagram1764
Frame Main Harness1765
Control Valve Harness1767
SCR Harness1769
Light Harness (cab light)1771
Light Harness (cab light) (LED)1773
Light Harness (cab light) (with guard)1775
Light Harness (rear cab light) (LED)1777
Travel Harness1779
Cab Main Harness1781
Indicator Jumper1783
Console Harness1785
GPS Harness1787
Computer S Harness1789
Free Swing Harness1791
Camera Harness1793
Camera Harness [700 mm (27559 in)]1795
Camera Harness [2050 mm (80709 in)]1797
Camera Harness [3050 mm (120079 in)]1799
Camera Harness [4000 mm (157480 in)]1801
Camera Harness (WAVES)1803
Boom Harness (lamp and angle sensor)1805
Arm Harness (lamp and angle sensor)1807
US Control Panel Harness1809
Panel Board Select Harness1811
Option Harness (SV)1813
V ATTACHMENTS1816
Main Equipment Table1819
Backhoe Attachment1819
Cylinder1819
Maintenance Standards1820
Attachments (380X4-MH)1820
1 Boom and Swing Frame Installation Section1820
2 Boom Cylinder and Swing Frame Installation Section1821
3 Boom and Boom Cylinder Installation Section1821
4 Boom and Arm Cylinder Installation Section1822
5 Boom and Arm Installation Section1822
6 Arm and Arm Cylinder Installation Section1823
Removal and Installation of Arm Cylinder1824
Removal of Arm Cylinder1824
Installation of Arm Cylinder1826
Removal and Installation of Boom Cylinder1828
Removal of Boom Cylinder1828
Installation of Boom Cylinder1830
Removal and Installation of Boom Cylinder (Automatic Greasing Device)1833
Removal of Boom Cylinder (Automatic Greasing Device)1833
Installation of Boom Cylinder (Automatic Greasing Device)1836
Removal and Installation of Elevator Cylinder1839
Removal of Elevator Cylinder1839
Installation of Elevator Cylinder1843
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder1848
Specifications and Structure Diagram (including the assembly diagram and parts table)1848
Basic Functions1848
Function of Each Location1848
Cylinder Head Assembly (made by KYB)1848
Piston Assembly (made by KYB)1849
Pipe Assembly (made by KYB)1851
Handling Precautions1851
Precautions for Installing the Cylinder on the Machine Body1851
Usage Cautions1852
Maintenance and Inspection Cautions1852
Maintenance Inspection and Service1854
Trouble Diagnostics1855
Storage Standards1860
Storing Parts Individually (In principle, store indoors)1860
When Mounted on Vehicle Body1860
Recommended Anti-rust Oil1860
Assembly and Disassembly Procedures1861
Preparations ····· Prepare the Following before Starting Disassembly1861
General Work Precautions1861
Maintenance Standards1861
Inspection after Assembly1861
Required Tool1862
General Tool1862
Special Jig (made by KYB)1863
Special Jig Parts Number List (made by KYB)1863
Disassembly Procedures (made by KYB)1864
Assembly Procedures (made by KYB)1867
Test Operation1872
Usage Limits1873
Structural Diagram (made by KYB)1874
Boom Cylinder1874
Arm Cylinder1876
Elevator Cylinder1878
HBCV1880
structure1880
Function1880
operation explanation1880
Port Diagram1895
HBCV1895
Air Bleed Procedure1896
HBCV1896
Boom Cylinder HBCV1896
Arm Cylinder HBCV1897
Removal and Installation of HBCV1898
Removal and Installation of Arm HBCV1899
Removal of Arm HBCV1899
Installation of Arm HBCV1899
Removal and Installation of Boom HBCV1901
Removal of Boom HBCV1901
Installation of Boom HBCV1902
Removal and Installation of Arm1904
Removal of Arm1904
Installation of Arm1905
Removal and Installation of Boom1907
Removal of Boom1907
Installation of Boom1911
Z OTHER1916
Change from Type 61921
Overall Layout1921
Lower1921
Swing Unit1922
Engine1923
Hydraulic-related Data1925
Oil Pressure Control1926
Cab, House1928
Electrical Data1929
Electric Control1930
Specifications1931
ENGINE1931
HYDRAULIC SYSTEM1931
HYDRAULIC CONTROLS1932
ELECTRICAL SYSTEM1932
OPERATOR ENVIRONMENT1933
UNDERCARRIAGE1934
MASS1934
DIMENSIONS1934
WORKING RANGES1935
SYSTEM FLUID CAPACITIES AND SPECIFICATIONS1935
Arm Dimension1936
Long Arm [670 m (2198 ft)]1936
Main Unit Weight1937
Divided Weight (MH Specifications)1937
Stand Alone Part Weight (MH Specifications)1938
Shoe Weight (per Side)1938
Arm Weight1938
Bolt Size and Torque Table1939
Special Torque Setting1939
Overall View1944
380X4-MH1944
Long Arm (67 m (2198 ft))1944
WORK RANGE DIAGRAM1945
380X4-MH1945
Long Arm (67 m (2198 ft))1945
New Machine Performance Judgment Table1947
Table of Standards1947
Measurement Method1950
Engine speed1950
Pressure at Each Part1950
Pump Command Displacement1951
Cylinder Down Amount1951
Attachment Speed1951
Swing Speed1952
Swing (180°) Brake Angle1952
Travel Speed1952
Off Travel Amount1953
Travel Sprocket Speed1953
Shoe Tension Amount1953
Swing Ball Race Bearing Movement Amount1954
FLUIDS AND LUBRICANTS1956
HYDRAULIC FLUID1956
Engine Oil1956
Fuel1956
Conditions applicable to diesel fuel1956
Recommended conditions applicable to diesel fuels1956
Main-Unit-related Diagnostic Trouble Code List1957
Main Unit-side Trouble1960
Diagnostic Trouble Code: 7000 Pressure Sensor P1 Abnormality1960
Diagnostic Trouble Code: 7001 Pressure Sensor P2 Abnormality1962
Diagnostic Trouble Code: 7002 Pressure Sensor N1 Abnormality1964
Diagnostic Trouble Code: 7003 Pressure Sensor N2 Abnormality1966
Diagnostic Trouble Code: 7004 Pressure Sensor Boom Cylinder Bottom Abnormality1968
Diagnostic Trouble Code: 7007 Pressure sensor arm cylinder rod abnormality1970
Diagnostic Trouble Code: 7021 Pressure Sensor Swing Pilot Abnormality1972
Diagnostic Trouble Code: 7023 Pressure Sensor Arm-In Pilot Abnormality1974
Diagnostic Trouble Code: 7040 Level sensor fuel abnormality1976
Diagnostic Trouble Code: 7041 Temperature Sensor Hydraulic Fluid Abnormality1978
Diagnostic Trouble Code: 7060 Boom Angle Sensor Signal Abnormality1980
Diagnostic Trouble Code: 7061 Arm Angle Sensor Signal Abnormality1982
Diagnostic Trouble Code: 7062 Elevator Angle Sensor Signal Abnormality1984
Diagnostic Trouble Code: 7065 Pressure Sensor Boom-Up Pilot Abnormality1986
Diagnostic Trouble Code: 7067 Pressure Sensor Bucket-Close Pilot Abnormality1988
Diagnostic Trouble Code: 7068 Pressure Sensor Boom-Down Pilot Abnormality1990
Diagnostic Trouble Code: 7069 Pressure Sensor Arm-Out Pilot Abnormality1992
Diagnostic Trouble Code: 7070 Pressure Sensor Bucket-Open Pilot Abnormality1994
Diagnostic Trouble Code: 7071 Pressure Sensor Travel Right Pilot Abnormality1996
Diagnostic Trouble Code: 7072 Pressure Sensor Travel Left Pilot Abnormality1998
Diagnostic Trouble Code: 7073 Pressure Sensor Travel 1 Pedal Abnormality2000
Diagnostic Trouble Code: 7075 Pressure Sensor Arm Cylinder Bottom Abnormality2002
Diagnostic Trouble Code: 7080: Pressure Sensor Grapple Cylinder Bottom Abnormality2004
Diagnostic Trouble Code: 7083 Bucket Cylinder Angle Sensor Deviation2006
Diagnostic Trouble Code: 7200 Swing Brake Solenoid Abnormality2007
Diagnostic Trouble Code: 7201 Travel 2nd-Speed Switchover Solenoid Abnormality2009
Diagnostic Trouble Code: 7202 Pressure Boost Solenoid Abnormality2010
Diagnostic Trouble Code: 7203 Travel Alarm Buzzer Abnormality2011
Diagnostic Trouble Code: 7207 Free Swing Solenoid Abnormality2012
Diagnostic Trouble Code: 7212 Gate Lock Solenoid Abnormality2013
Diagnostic Trouble Code: 7243 Boom Proportional Valve Signal Abnormality (interference prevention)2015
Diagnostic Trouble Code: 7244 Arm Proportional Valve Signal Abnormality (interference prevention)2017
Diagnostic Trouble Code: 7245 Offset Proportional Valve Signal Abnormality2019
Diagnostic Trouble Code: 7247 Boom 2-Down Pilot Proportional Valve Abnormality2021
Diagnostic Trouble Code: 7249 Bucket-Close Pilot Proportional Valve Abnormality2023
Diagnostic Trouble Code: 7265 Arm 1 Semi-Parallel Proportional Valve Abnormality2025
Diagnostic Trouble Code: 7266 Arm 2 Semi-Parallel Proportional Valve Abnormality2027
Diagnostic Trouble Code: 7267 Arm 1 Regeneration Release Proportional Valve Abnormality2029
Diagnostic Trouble Code: 7270 Tilting 1 Proportional Valve Abnormality2031
Diagnostic Trouble Code: 7271 Tilting 2 Proportional Valve Abnormality2033
Diagnostic Trouble Code: 7273 Straight Travel Proportional Valve Abnormality2035
Diagnostic Trouble Code: 7400 Coolant Temperature Overheating 12037
Diagnostic Trouble Code: 7401 Coolant Temperature Overheating 22038
Diagnostic Trouble Code: 7404 Oil Temperature Overheating2039
Diagnostic Trouble Code: 7405 Boost Temperature Overheating 12040
Diagnostic Trouble Code: 7406 Boost Temperature Overheating 22041
Diagnostic Trouble Code: 7420 Alternator Power Generation Defect2042
Diagnostic Trouble Code: 7421 Coolant Level Decrease2044
Diagnostic Trouble Code: 7422 Decrease in Engine Oil Pressure2045
Diagnostic Trouble Code: 7423 Air Cleaner Clogging2046
Diagnostic Trouble Code: 7426 Fuel Filter Clogging 12047
Diagnostic Trouble Code: 7427 Fuel Filter Clogging 22049
Diagnostic Trouble Code: 7428 Inducement (Remaining Urea Level Low) – Warning2051
Diagnostic Trouble Code: 7429 Inducement (Remaining Urea Level Low) – Early2052
Diagnostic Trouble Code: 7430 Inducement (Remaining Urea Level Low) – Final2053
Diagnostic Trouble Code: 7602 ECM Communication Abnormality2054
Diagnostic Trouble Code: 7605 ECM Not-Matched2056
Diagnostic Trouble Code: 7606 EEPROM Abnormality2057
Diagnostic Trouble Code: 7608 Camera Abnormality2058
Diagnostic Trouble Code: 7612 Air Conditioner Communication Abnormality2061
Diagnostic Trouble Code: 7613 Monitor communication (CAN) abnormality2063
Diagnostic Trouble Code: 7614 Air Conditioner Panel Mismatch2065
Diagnostic Trouble Code: 7615 Sub-controller 1 Communication Abnormality2066
Diagnostic Trouble Code: 7618 DCU Communication Abnormality2068
Diagnostic Trouble Code: 7800 Signal Line Disconnection or Short Circuit2070
Diagnostic Trouble Code: 7801 Output Voltage Drop2071
Diagnostic Trouble Code: 7802 Magnet Overheat2073
Diagnostic Trouble Code: 7803 Generator Voltage Abnormality2075
Diagnostic Trouble Code: 7804 Magnet Overcurrent2078
Diagnostic Trouble Code: 7805 Control Panel Overheat2079
Diagnostic Trouble Code: 7806 Battery Voltage Drop2080
Diagnostic Trouble Code: 7807 Battery Overvoltage2081
Diagnostic Trouble Code: 7810 Short2082
Diagnostic Trouble Code: 7811 Control Panel Overheat2083
Diagnostic Trouble Code: 7812 Disconnection2084
Diagnostic Trouble Code: 7813 CPU Abnormality2085
Diagnostic Trouble Code: 7814 Condenser Overvoltage2086
List of special tools2087
NUMERICAL VALUE CONVERSION TABLE2087
Unit conversion rate2087
Length2087
Area2089
Volume2090
Weight2092
Pressure2093
Torque2094
Temperature2095
A2098
Travel Motor Special Tool2098
380X4-MH2098
Take-up Roller Special Tool2106
380X4-MH2106
Upper Roller Special Tool2107
380X4-MH2107
Lower Roller Special Tool2108
380X4-MH2108
Grease Cylinder Special Tool2108
380X4-MH2108
Center Joint Special Tool2109
380X4-MH2109
C2110
Swing Motor Special Tool2110
380X4-MH2110
H2112
Engine Oil Filter Special Tool2112
380X4-MH2112
Fuel Filter Special Tool2112
380X4-MH2112
Injector Special Tool2112
380X4-MH2112
Circuit Test Special Tool2113
380X4-MH2113
Valve Guide Special Tool2113
380X4-MH2113
Cylinder Head Special Tool2113
380X4-MH2113
Head Bolt Special Tool2116
380X4-MH2116
Crankshaft Special Tool2116
380X4-MH2116
Camshaft Special Tool2119
380X4-MH2119
Valve Spring Special Tool2119
380X4-MH2119
J2120
Remote Control Valve Special Tool2120
380X4-MH2120
R2121
Gas Filling Special Tool2121
380X4-MH2121
V2122
Attachment Special Tool (for Cylinder Assembly)2122
Special Jigs Part Number List2122
Attachment Special Tool (Other)2123
380X4-MH2123
Paint Colors2124
Abbreviation2126
Magnet Unit2130
SPS Maintenance Manual2130
Warnings for Preventing Accidents2130
Cautions for Safety2130
Magnetic Device2132
Electrical Schematic Diagrams (Comprehensive Wiring Diagram)2134
Generator2134
Control Panel2136
Operation Functions2140
Inspection2143
Troubleshooting2146
Investigation of Causes of Load Side Abnormality2150
Investigation of Causes of Generator Output Voltage Abnormality2151
Determining IGBT Module Abnormality2151
Basic Configurations2153
Troubleshooting2153
Simplified Table2153
Diagnostic Trouble Code: 78002163
Diagnostic Trouble Code: 78032166
Diagnostic Trouble Code: 7810 (1)2169
Diagnostic Trouble Code: 7810 (2)2172
Diagnostic Trouble Code: 7805/78112175
Diagnostic Trouble Code: 78122178
Trouble (Cannot Lift)2179
Magnet Wear Repair2180
Procedures for Removal and Installation of Components in Control Panel2182
Removal and Installation of Control Panel Door2182
Removal of Control Panel Door2182
Installation of Control Panel Door2182
Removal and Installation of Control Board2183
Removal of Control Board2183
Installation of Control Board2183
Control Board Terminal Number List2185
Removal and Installation of IGBT2185
Removal of IGBT2185
Installation of IGBT2186
Correspondence Table between Connector Cables and Terminals on IGBT2188
Removal and Installation of Fans2189
Removal of Fans2189
Installation of Fans2191
Construction machinery mounted magnet adsorption face repair2194
General information2194
General2194
Fundamental notes in repair work2194
Investigation before repair work2194
Preparation2195
Tool2195
Materials2196
Subsidiary materials2196
Repairing procedure2197
Check2201
The check after repair work2201
Automatic Greasing Device2202
Removal and Installation of Grease Tank and Pump2202
Removal of Grease Tank and Pump2202
Installation of Grease Tank and Pump2202
Removal and Installation of Main Distributor2203
Removal of Main Distributor2203
Installation of Main Distributor2203
Removal and Installation of Upper Distributor2203
Removal of Upper Distributor2203
Installation of Upper Distributor2204
Removal and Installation of Boom Distributor2204
Removal of Boom Distributor2204
Installation of Boom Distributor2204
Removal and Installation of Grease Line of Automatic Greasing Device2204
Removal of Grease Line of Automatic Greasing Device2204
Installation of Grease Line of Automatic Greasing Device2205
Filling the Grease of Automatic Greasing Device2205
Troubleshooting2206
Diagnosis of Fault of Automatic Greasing Device2206
Remedial Actions at the time of Clogging of Pump2210
Remedial Actions at the time of Clogging of Grease Line and Distributor2211
S.M 3/1/25
