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Linkbelt 160X4 Excavator SERVICE MANUAL WLSM1607-02LX – PDF DOWNLOAD
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Description
Linkbelt 160X4 Excavator SERVICE MANUAL WLSM1607-02LX – PDF DOWNLOAD
FILE DETAILS:
Linkbelt 160X4 Excavator SERVICE MANUAL WLSM1607-02LX – PDF DOWNLOAD
Language : English
Pages :1711
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Linkbelt 160X4 Excavator SERVICE MANUAL WLSM1607-02LX – 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:
Linkbelt 160X4 Excavator SERVICE MANUAL WLSM1607-02LX – PDF DOWNLOAD
Excavator 1
SAFETY 9
Safety, general information and standard torque data 12
General Information 13
Safety 13
ROPS 15
ROPS Judgment 15
Standard Torque Data For Cap Screws And Nuts 19
Bolt and Nut Tightening 19
A LOWER 21
Main Equipment Table 25
Lower Component 25
Travel Unit 25
Take-up Roller 25
Upper Roller 25
Lower Roller 25
Recoil Spring 25
Shoe 26
Center Joint 26
Main Equipment Structure and Operation Explanation 27
Travel Motor 27
Travel motor operation explanation 27
Port Diagram 41
Travel Motor 41
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 46
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 55
Assembly Procedures 57
Removal and Installation of Lower Roller 60
Removal of Lower Roller 60
Installation of Lower Roller 61
Assembly and Disassembly of Lower Roller 62
Configuration Diagram 62
Dimension Diagram 63
Jig Dimension Diagram 63
Disassembly Procedures 63
Assembly Procedures 66
Removal and Installation of Drive Sprocket 68
Removal of Drive Sprocket 68
Installation of Drive Sprocket 70
Removal and Installation of Take-up Roller 71
Removal of Take-up Roller 71
Installation of Take-up Roller 72
Assembly and Disassembly of Take-up Roller 73
Configuration Diagram 73
Dimension Diagram 74
Jig Dimension Diagram 74
Disassembly Procedures 74
Assembly Procedures 77
Removal and Installation of Grease Cylinder 81
Removal of Grease Cylinder 81
Installation of grease cylinder 82
Assembly and Disassembly of Tension Shock Absorber 83
Configuration Diagram 83
Dimension diagram 83
Jig dimension diagram 84
Disassembly procedures 84
Assembly procedures 84
Removal and Installation of Center Joint 87
Removal of Center Joint 87
Installation of Center Joint 89
Assembly and Disassembly of Center Joint 91
Configuration Diagram 92
Dimension Diagram 93
Jig Dimension Diagram 94
Disassembly Procedures 94
Assembly Procedures 95
Removal and Installation of Travel Motor 98
Removal of Travel Motor 98
Installation of Travel Motor 100
Assembly and Disassembly of Travel Motor 103
Tools for Assembly and Disassembly 103
Standard tools 103
Secondary materials 104
Special tools 105
Measurement device 105
Motor Disassembly Procedures 105
Precautions before motor disassembly 105
Tightening torque 106
Disassembly procedure 107
Maintenance Standards 116
Motor parts maintenance standards 116
Reduction gear parts maintenance standards 119
Precautions before motor assembly 122
Assembly procedures 122
Installation of Motor 135
Motor inspection 135
Operation Check 136
Motor operation check 137
Troubleshooting 138
Motor Repair Kit 146
Travel Motor Internal Structure Diagram 149
Travel Motor Part Table 150
Component Table 152
Maintenance Standards 153
Drive Sprocket 153
Take-up Roller 154
Upper Roller 155
Lower Roller 156
Track Shoe (grouser shoe) 158
Inspection Gauge 159
For Drive Sprocket 159
For Take-up Roller 160
For Upper Roller 160
For Lower Roller 161
Pressure Measurement and Adjustment Procedures 162
Main Pressure Measurement 162
Travel Pressure Measurement 162
Drain Volume Measurement Procedures 163
Preparations 163
Travel Motor Drain Volume Measurement 163
Air Bleed Procedure 165
Travel Motor 165
B C SWING UNIT, COUNTERWEIGHT 167
Main Equipment Table 170
Upper Component 170
Swing Unit 170
Main Equipment Structure and Operation Explanation 171
Swing Motor 171
Swing Motor Operation Explanation 171
Equipment configuration 171
Internal Structure Diagram 174
Swing reduction gear internal structure diagram 175
Relief valve internal structure diagram 175
Swing Motor Part Table 176
Port Diagram 178
Swing Motor 178
Basic Functions 179
Swing Brake 179
Swing Lock 179
Swing Relief Cut 180
Removal and Installation of Swing Unit 182
Removal of Swing Unit 182
Installation of Swing Unit 184
Assembly and Disassembly of Swing Motor 185
Causes of Trouble and Solutions 185
Jig 187
Disassembly 188
Assembly 193
Swing Motor Internal Structure Diagram 203
Assembly and Disassembly of Swing Unit 205
Disassembly 205
Assembly 206
Removal and Installation of Counterweight 208
Removal of Counterweight 208
Installation of Counterweight 209
Pressure Measurement and Adjustment Procedures 211
Main Pressure Measurement 211
C Swing Pressure Measurement 211
Drain Volume Measurement Procedures 212
Preparations 212
Swing Motor Drain Volume Measurement 212
Air Bleed Procedure 213
Swing Motor 213
Check 213
H ENGINE 215
Main Equipment Table 222
Engine-related 222
Engine 222
Air Cleaner (double element) 222
Radiator 222
SCR 222
Basic Functions 223
Fuel Gauge 223
Coolant Temperature Gauge 224
SCR Gauge 226
Fuel Economy Gauge 229
Neutral Start 230
Power-cut Delay 231
Preheat 231
Throttle 232
Throttle Volume Position Detection 233
Idling Start 239
Auto Idle 239
One-touch Idle 240
Auto Warm-Up 241
Idle Shutdown 246
Idle Up 247
Work Mode Control 248
Engine Emergency Stop 249
SCR RE-GEN 249
Inducement 254
Feed Pump Automatic Stop 258
Coolant Level Decrease 260
Air Filter Clogging 261
Fuel Filter Clogging 262
Battery Charge Abnormality 263
Horsepower Reduction Control (in Uplands) 264
Horsepower Reduction Control (at Engine Failure) 264
Primary specifications 267
Function, Structure, Operation 269
Function, structure, operation (SCR) 315
SCR Control System Inspection 341
Operation Explanation of SCR 342
Diagnosis for Each Symptom 344
Intermittent conditions of urea selective catalytic reduction system 344
Urea fluid consumption too high 347
Ammonia smell noticeable 347
White crystalline powder visible 348
Diagnosis for Each Symptom 349
Engine Start Problem 349
Engine Stalling 351
Engine Hunting, Rough Idling 353
Excessive White Smoke in Exhaust Gas 355
Excessive Black Smoke in Exhaust Gas 355
Abnormal Noise 356
High Fuel Consumption 357
High Oil Consumption 358
Engine Output Deficiency 359
Functional Inspection 361
Engine Compression Pressure Inspection 361
Fuel System Inspection 362
Lubrication system check 362
Suction air system inspection 363
Exhaust system inspection 363
EGR Control System Inspection 363
Start System Inspection 364
Glow control system check 364
OBD system check 366
Inspection of the monitor warning light illumination circuit system 366
Inspection of the monitor warning light blinking circuit system 367
Inspection of the starter circuit system 367
Removal and Installation of Engine Assembly 369
Removal of Engine Assembly 369
Installation of Engine Assembly 374
Removal and Installation of Fuel Cooler, Engine Intercooler, Radiator, and Oil Cooler 375
Removal and Installation of Fuel Cooler 375
Removal of Fuel Cooler 375
Installation of Fuel Cooler 375
Removal and Installation of Engine Intercooler 375
Removal of Intercooler 376
Installation of Inter Cooler 376
Inspection of Intercooler 377
Removal and Installation of Radiator 377
Removal of Radiator 378
Installation of Radiator 381
Inspection of Radiator 381
Removal and Installation of Oil Cooler 382
Removal of Oil Cooler 382
Installation of oil cooler 384
Removal and Installation of Turbo Charger 385
Turbocharger assembly Removal 385
Turbocharger assembly Installation 386
Inspection of Turbo Charger 387
Removal and Installation of EGR Valve 388
Removal 388
Installation 388
Inspection 388
Removal and Installation of EGR Cooler 389
Removal 389
Installation 390
Inspection 392
Removal and Installation of Engine Hood 394
Removal of Engine Hood 394
Installation of Engine Hood 395
Removal and Installation of SCR 396
Removal of SCR 396
Installation of SCR 397
Removal and Installation of SCR Catalyst 398
Removal 398
Installation 400
Disassembly 403
Assembly 403
Inspection 404
Removal and Installation of Cylinder Head Cover 405
Cylinder head cover Removal 405
Installation of Cylinder Head Cover 406
Removal and Installation of Cylinder Head 407
Removal of Cylinder Head 407
Disassembly of Cylinder Head 416
Assembly of Cylinder Head 418
Installation of Cylinder Head 421
Inspection 438
Removal and Installation of Cylinder Block 444
Removal of Cylinder Block 444
Installation of Cylinder Block 460
Inspection 492
Lubrication System 493
Removal and Installation of Oil Pan and Crank Case 493
Removal of Oil Pan and Crank Case 493
Installation of Oil Pan and Crank Case 507
Removal and Installation of Oil Level Switch 534
Removal of Oil Level Switch 534
Installation of Oil Level Switch 534
Removal and Installation of Oil Pump Assembly 535
Removal of Oil Pump Assembly 535
Disassembly of Oil Pump Assembly 538
Assembly of Oil Pump Assembly 538
Installation of Oil Pump Assembly 538
Inspection 542
Engine oil Inspection 543
Removal and Installation of Oil Port Cover 543
Removal of Oil Port Cover 543
Installation of Oil Port Cover 544
Cooling System 545
Removal and Installation of Water Pump Assembly 545
Removal of Water Pump Assembly 545
Installation of Water Pump Assembly 546
Inspection 547
Removal and Installation of Thermostat 548
Removal of Thermostat 548
Installation of Thermostat 548
Inspection 549
InspectionInspection of Coolant 549
Inspection of Cooling Fan Belt 550
Removal and Installation of Overheat Switch 550
Removal of Overheat Switch 550
Installation of Overheat Switch 551
Induction System 552
Inspection of Air Cleaner Element 552
Exhaust System 553
Removal and installation of Oxidation Catalyst Assembly 553
Removal 553
Installation 555
Aux Emission Control Devices System 558
Removal and installation of Dosing Module 558
Removal 558
Disassembly 558
Assembly 559
Installation 559
Removal and installation of DEF Supply Module 560
Removal 560
Disassembly 560
Assembly 561
Installation 561
Removal and installation of Coolant Control Valve 562
Removal 562
Installation 562
Removal and Installation of DCU 563
Removal 563
Installation 563
Removal and installation of DEF Supply Module Filter 563
Removal 563
Installation 564
Appendixes 565
Removal and Installation of Exhaust Manifold 571
Removal of Exhaust Manifold 571
Installation of Exhaust Manifold 572
Inspection 575
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 582
Removal of Urea Solution Tank 582
Installation of Urea Solution Tank 582
Removal and Installation of Fuel Supply Pump 584
Removal of Fuel Supply Pump 584
Installation of Fuel Supply Pump 589
Removal and Installation of Common Rail Assembly 597
Removal of Common Rail Assembly 597
Installation of Common Rail Assembly 598
Removal and Installation of Injector 600
Removal of Injector 600
Installation of Injector 602
Removal and Installation of Starter Motor 606
Removal of Starter Motor 606
Installation of Starter Motor 607
Disassembly of Starter Motor 607
Assembly of Starter Motor 608
Inspection of Starter Motor 610
Removal and Installation of Alternator 614
Removal of Alternator 614
Installation of Alternator 614
Removal and Installation of Glow Plug 615
Removal of Glow Plug 615
Installation of Glow Plug 615
Inspection 616
Removal and Installation of Suction Control Valve 617
Removal of Suction Control Valve 617
Installation of Suction Control Valve 617
Removal and installation of Fuel Filter 619
Removal of Fuel Filter 619
Installation of Fuel Filter 619
Removal and Installation of Fuel filter pressure 622
Fuel filter pressure sensor Removal 622
Fuel filter pressure sensor Installation 622
Removal and Installation of Engine coolant temperature sensor 623
Engine coolant temperature sensor Removal 623
Engine coolant temperature sensor Installation 623
Inspection 623
Removal and Installation of CKP sensor 625
CKP sensor Removal 625
CKP sensor Installation 625
Inspection 625
Removal and Installation of CMP sensor 626
CMP sensor Removal 626
CMP sensor Installation 626
Inspection 626
Removal and Installation of Oil pressure sensor 627
Oil pressure sensor Removal 627
Oil pressure sensor Installation 627
Inspection 627
Removal and installation of Pressure Sensor/Boost Temperature Sensor 629
Removal of Pressure Sensor/Boost Temperature Sensor 629
Installation of Pressure Sensor/Boost Temperature Sensor 629
Inspection of Pressure Sensor/Boost Temperature Sensor 629
Removal and Installation of IMT sensor 630
IMT sensor Removal 630
IMT sensor Installation 630
Removal and installation of Charge Air Cooler Temperature Sensor 1 631
Removal of Charge Air Cooler Temperature Sensor 1 631
Installation of Charge Air Cooler Temperature Sensor 1 631
Inspection of Charge Air Cooler Temperature Sensor 1 631
Sampling Procedure 632
Sampling of Engine Oil 632
Removal and Installation of Exhaust gas temperature sensor 633
Removal 633
Installation 633
Inspection 634
Removal and installation of EGR Gas Temperature Sensor 1 635
Removal 635
Installation 635
Inspection 635
Removal and installation of EGR Gas Temperature Sensor 2 636
Removal 636
Installation 636
Inspection 636
Removal and installation of NOx Sensor 637
Removal 637
Installation 637
Removal and installation of EGR Gas Temperature Sensor 3 639
Removal 639
Installation 639
Removal and installation of DEF Sensor 641
Removal 641
Installation 641
Engine-related Diagnostic Trouble Code List 642
Engine-side Trouble 647
ECM Trouble 647
DTC U0001 CAN Bus Error (ISO-CAN) 647
DTC P0016 Crankshaft Position – Camshaft Position Correlation Error 648
DTC P0045 Turbocharger Boost Control VNT Error 648
DTC U0073 Control Module Communication Bus Off 650
DTC P0087 Fuel Rail/System Pressure – Too Low 651
DTC P0089 Fuel Pressure Regulator Performance 654
DTC P0091 Fuel Pressure Regulator Control Circuit Low 655
DTC P0092 Fuel Pressure Regulator Control Circuit High 656
DTC P0097 Intake Air Temperature (IAT) Sensor 2 Circuit Low Voltage 657
DTC P0098 Intake Air Temperature (IAT) Sensor 2 Circuit High Voltage 657
DTC U0101 Lost Communication With CAN 658
DTC P0102 Mass Air Flow Sensor Circuit Low Input 659
DTC P0103 Mass Air Flow Sensor Circuit High Input 660
DTC U010E Lost Communications With Dosing Control Module 660
DTC U0110 Lost Communication With VNT System 661
DTC P0112 Intake Air Temperature Sensor Circuit Low 661
DTC P0113 Intake Air Temperature Sensor Circuit High 662
DTC P0117 Engine Coolant Temperature Sensor Circuit Low 663
DTC P0118 Engine Coolant Temperature Sensor Circuit High 663
DTC P0122 Throttle Position Sensor Circuit Low 664
DTC P0123 Throttle Position Sensor Circuit High 665
DTC P0182 Fuel Temperature Sensor Circuit Low 666
DTC P0183 Fuel Temperature Sensor Circuit High 667
DTC P0192 Fuel Rail Pressure Sensor Circuit Low 668
DTC P0193 Fuel Rail Pressure Sensor Circuit High 668
DTC P0201 Injector Circuit Open – Cylinder 1 670
DTC P0202 Injector Circuit Open – Cylinder 2 670
DTC P0203 Injector Circuit Open – Cylinder 3 671
DTC P0204 Injector Circuit Open – Cylinder 4 672
DTC P0217 Engine Coolant Over Temperature Condition 673
DTC P0219 Engine Overspeed Condition 673
DTC P0234 Turbocharger Overboost Condition 674
DTC P0237 Turbo Charger Boost Sensor Circuit Low 675
DTC P0238 Turbo Charger Boost Sensor Circuit High 675
DTC P0335 Crankshaft Position Sensor Circuit 676
DTC P0336 Crankshaft Position Sensor Circuit Range/Performance 677
DTC P0340 Camshaft Position Sensor Circuit 678
DTC P0380 Glow Relay Circuit Error 679
DTC P0401 EGR Flow Insufficient Detected 680
DTC P0404 EGR Control Circuit Range/Performance 681
DTC P0409 EGR Sensor Circuit 681
DTC U0411 Lost CAN Communications With VNT Control Module 683
DTC P041C EGR Cooler Outlet 1 Temp Sensor Circuit Low 683
DTC P041D EGR Cooler Outlet 1 Temp Sensor Circuit High 684
DTC P0427 Catalyst Temperature Sensor Circuit Low Sensor 1 685
DTC P0428 Catalyst Temperature Sensor Circuit High Sensor 1 685
DTC P042C Catalyst Temperature Sensor Circuit Low Sensor 2 686
DTC P042D Catalyst Temperature Sensor Circuit High Sensor 2 687
DTC P0522 Engine Oil Pressure Sensor Circuit Low Input 688
DTC P0523 Engine Oil Pressure Sensor Circuit High Input 689
DTC P0545 EGR Cooler Inlet 1 Temp Sensor Circuit Low 690
DTC P0546 EGR Cooler Inlet 1Temp Sensor Circuit High 690
DTC P0560 12 Volt Circuit Error 691
DTC P0563 System Voltage High 691
DTC P0601 Internal Control Module Memory Check Sum Error 692
DTC P0602 Internal Control Module QR Code Error 692
DTC P0604 Internal Control Module RAM Error 693
DTC P0606 Internal Control Module CPU Error 693
DTC P060A Internal Control Module CPU IC Error 693
DTC P060C Internal Control Module A/D Processing Performance 693
DTC P0615 Starter Relay Circuit Error 694
DTC P0638 Throttle Actuator Control Range/Performance 694
DTC P0685 ECM Power Relay Control Circuit Open 695
DTC P0687 ECM Power Relay Control Circuit High 696
DTC P06A6 Sensor Reference Voltage 1 Circuit 696
DTC P06A7 Sensor Reference Voltage 2 Circuit 697
DTC P06A8 Sensor Reference Voltage 3 Circuit 698
DTC P06A9 Sensor Reference Voltage 4 Circuit 698
DTC P06AF Torque Management System – Forced Engine Shutdown 699
DTC P06D5 Sensor Reference Voltage 5 Circuit 700
DTC P1076 Charge Air Cooler (CAC) Temperature Sensor 1 Circuit Low Voltage 700
DTC P1077 Charge Air Cooler (CAC) Temperature Sensor 1 Circuit High Voltage 700
DTC P1093 Fuel Rail Pressure Too Low 701
DTC P1097 Compressor Outlet Temperature Sensor Circuit High 704
DTC P1098 Compressor Outlet Temperature Sensor Circuit High 705
DTC P1236 Charge Air Cooler Performance Failure 706
DTC P1261 Injector Positive Voltage Control Circuit Group 1 706
DTC P1262 Injector Positive Voltage Control Circuit Group 2 707
DTC P1404 EGR Position Fault 707
DTC P1606 SW-IC Internal failure 708
DTC P160B AD-IC Failure Error 708
DTC P160C AD-IC2 Failure Error 708
DTC P1621 Control Module Long Term Memory Performance 708
DTC P1669 DPD Lamp Control Circuit 709
DTC P204F SCR System Error (No Inducement) 710
DTC P207F Urea Fluid Concentration Too Low 710
DTC P20C9 SCR System Error 710
DTC U2106 Lost CAN Communications With Wheel Loader Transmission Control System 710
DTC P2122 Pedal Position Sensor 1 Circuit Low Input 711
DTC P2123 Pedal Position Sensor 1 Circuit High Input 711
DTC P2127 Pedal Position Sensor 2 Circuit Low Input 712
DTC P2128 Pedal Position Sensor 2 Circuit High Input 713
DTC P2138 Pedal Position Sensor 1 – 2 Voltage Correlation 713
DTC P2146 Fuel Injector Group 1 Supply Voltage Circuit 714
DTC P2149 Fuel Injector Group 2 Supply Voltage Circuit 715
DTC P2228 Barometric Pressure Sensor Circuit Low 716
DTC P2229 Barometric Pressure Sensor Circuit High 717
DTC P2457 Exhaust Gas Recirculation (EGR) Cooling System Performance 717
DTC P2458 Purge time Out Error 718
DTC P2BA7 Urea Fluid Quantity Too Low 718
DTC P2BAA SCR System Error (Inducement, No Purge) 718
DTC P3093 Fuel Rail Pressure Too Low 718
DCU Trouble 721
DTC U0002 CAN Bus Off 721
DTC U0100 Lost Communication With ECM 722
DTC U029D Lost Communication With NOx Sensor 1 723
DTC P0607 Control Module Performance 725
DTC P060B Internal Control Module A/D Processing Performance 726
DTC P062F Control Module EEPROM Error 726
DTC P0641 Sensor Reference Voltage 1 Circuit 727
DTC P0658 Actuator Supply Voltage Circuit 728
DTC P0659 Actuator Supply Voltage Circuit 729
DTC P1462 Urea Fluid Quality Sensor Timeout Error 730
DTC P1464 Main Relay Performance 730
DTC P1468 DCU Overtemperature 731
DTC P1491 Urea Fluid Overpressure 731
DTC P1493 DCU Driver Overtemperature 733
DTC P149C Urea Fluid Pressure Reduction Malfunction 733
DTC P149D Urea Fluid Tank Overtemperature 734
DTC P203B Urea Fluid Tank Level Sensor Stuck 735
DTC P203C Urea Fluid Tank Level Sensor Low Voltage 736
DTC P203D Urea Fluid Tank Level Sensor High Voltage 737
DTC P2048 Urea Fluid Injector Circuit Low Voltage 738
DTC P2049 Urea Fluid Injector Circuit High Voltage 739
DTC P204B Urea Fluid Pressure Sensor Performance 739
DTC P204C Urea Fluid Pressure Sensor Circuit Low Voltage 740
DTC P204D Urea Fluid Pressure Sensor Circuit High Voltage 741
DTC P205B Urea Fluid Tank Temperature Sensor Performance 742
DTC P205C Urea Fluid Tank Temperature Sensor Low Voltage 743
DTC P205D Urea Fluid Tank Temperature Sensor High Voltage 743
DTC P206A Urea Fluid Quality Sensor Circuit 744
DTC P206B Urea Sensor Over Temperature Condition 744
DTC P206C Urea Fluid Quality Sensor Circuit Low Voltage 745
DTC P206D Urea Fluid Quality Sensor Circuit High Voltage 746
DTC P207F Urea Fluid Concentration Too Low 746
DTC P208A Urea Fluid Pump Control Circuit 747
DTC P208B Usea Fluid Pump Performance 747
DTC P208C Urea Fluid Pump Control Circuit Low Voltage 748
DTC P208D Urea Fluid Pump Control Circuit High Voltage 749
DTC P208E Urea Fluid Injector Stuck 750
DTC P20A0 Urea Fluid Reverting Valve Circuit Open 751
DTC P20A2 Urea Fluid Reverting Valve Circuit Low Voltage 751
DTC P20A3 Urea Fluid Reverting Valve Circuit High Voltage 752
DTC P20AC Urea Fluid Pump Temperature Sensor Performance 753
DTC P20AD Urea Fluid Pump Module Temperature Sensor Performance 754
DTC P20B1 Urea Fluid Tank Heater Coolant Control Valve Circuit Open 755
DTC P20B3 Urea Fluid Tank Heater Coolant Control Valve Circuit Low Voltage 756
DTC P20B4 Urea Fluid Tank Heater Coolant Control Valve Circuit High Voltage 756
DTC P20E8 Urea Fluid Pressure Underpressure 757
DTC P20E9 Urea Fluid Overpressure 758
DTC P20EA Urea Fluid Pressure Reduction Malfunction 760
DTC P20FE Urea Fluid Pressure Build-Up Error 760
DTC P2201 Upstream Nox Sensor Performance 762
DTC P2206 NOx Sensor Heater Control Circuit Low Voltage Sensor 1 762
DTC P2207 NOx Sensor Heater Control Circuit High Voltage Sensor 1 763
DTC P242B Exhaust Gas Temperature (EGT) Sensor 3 Performance 763
DTC P242C Exhaust Gas Temperature (EGT) Sensor 3 Circuit Low Voltage 763
DTC P242D Exhaust Gas Temperature (EGT) Sensor 3 Circuit High Voltage 764
Data Reference Values 766
Idle Speed 766
Two Pump Relief 767
J HYDRAULIC EQUIPMENT (PUMP, OPERATION SYSTEM VALVE) 769
Main Equipment Table 775
Hydraulic Device 775
Hydraulic Pump 775
Pump P – Q Diagram 776
Control-related 777
Control Valve 777
Solenoid Valve (4 stack) 777
Remote Control Valve for Left/Right Operations 777
Remote Control Valve for Travel Operation 777
Remote Control Valve Characteristic Diagram 778
Operation Remote Control Valve Control Diagram 778
Travel Remote Control Valve Control Diagram 779
Cushion Valve (heat circuit, with shuttle valve) 779
Selector Valve 779
Basic Functions 780
Oil Temperature Gauge 780
Static Horsepower Control 781
Overload Warning (Function for Europe Only) 782
Pressure Boost Control 782
Stroke Control 784
Boom Down Energy Save 786
Pump Horsepower Boost Control 787
Arm 1 Semi-parallel Control 787
Arm 2 Semi-parallel Control 788
Hot Shutdown Warning 789
Gate Lock 790
Breaker Mode 791
Crusher Mode 791
Quick coupler 792
Hydraulic Filter Clogging 793
Solenoid Sticking Prevention 794
Port Diagram 795
Hydraulic Pump (Standard Model) 795
Control Valve 796
Relief Valve 796
Relief Valve (blade) 799
4 Stack Solenoid Valve 802
2 Stack Solenoid Valve 804
Remote Control Valves (upper, travel) 804
Remote Control Valves (left-right) 804
Remote Control Valve (Travel) 805
Cushion Valve 806
2-way Selector Valve 807
Direction Valve 808
Reducing Valve (3 stack) 809
Relief Valve (electromagnetic proportional) 810
Manifold Under Cab 811
Manifold (accumulator section) 812
Hydraulic oil tank 813
Hydraulic Pump 814
Type Indication 814
Specifications 814
Structure and Operation Explanation 814
Hydraulic Circuit Diagram 816
Hydraulic Pump Internal Structure Diagram 817
Overall View 817
Drive Shaft Front Side 821
Drive Shaft Rear Side 822
Development Diagram 823
Part Table 825
Regulator 825
Regulator Operation Explanation 825
Regulator Operation Explanation Diagram 828
Internal Configuration Diagram of Regulator 831
Development Diagram of Regulator 833
Component Table 834
Operation Outline of Electronically-Controlled Pump 836
Control Valve 839
Basic configuration 839
Operation 852
4 Stack Solenoid Valve Operation Explanation 877
External Shape Diagram and Component Parts 877
Operation Explanation 878
Upper Pilot Valve (remote control valve) 879
Structure 879
Function 879
Operation 880
Structural Diagram 883
Travel Pilot Valve (remote control valve) 884
Operation 884
Pressure Reducing Valve Section 884
Damping Mechanism in Operation Section 885
Structural Diagram 888
Cushion Valve 890
structure 890
operation explanation 890
Selector Valve (2-way) 895
Structure 895
Operation Explanation 896
Development Diagram 897
Direction Valve (3-direction) 898
Structure 898
Operation Explanation 899
3 Stack Proportional Valve (for pilot) 901
Structure 901
Operation Explanation 901
SOL1, 2 901
SOL3 903
Electromagnetic Relief Valve 905
Structure 905
Operation Explanation 906
Operation of Check Valve 906
Operation of Electromagnetic Relief Valve 907
Removal and Installation of Hydraulic Reservoir 909
Removal of Hydraulic Reservoir 909
Installation of Hydraulic Tank 912
Removal and Installation of Hydraulic Pump 913
Removal of Hydraulic Pump 913
Installation of hydraulic pump 916
Removal and Installation of Control Valve 917
Removal of Control Valve 917
Installation of Control Valve 920
Removal and Installation of Travel Remote Control Valve 921
Removal of Travel Remote Control Valve 921
Installation of Travel Remote Control Valve 922
Removal and Installation of Operation Remote Control Valve 925
Removal of Operation Remote Control Valve (Left) 925
Installation of Operation Remote Control Valve (Left) 927
Removal of Operation Remote Control Valve (Right) 929
Installation of Operation Remote Control Valve (Right) 931
Removal and Installation of 4 Stack Solenoid 934
Removal of 4 Stack Solenoid 934
Installation of 4 Stack Solenoid Valve 935
Removal and Installation of Cushion Valve 938
Removal of Cushion Valve 938
Installation of Cushion Valve 939
Procedures for Assembly and Disassembly of Hydraulic Pump Main Unit 942
Tools 942
Disassembly Procedure 943
Assembly Procedure 945
Pump Main Unit Maintenance Standards 949
Replacement standards for worn parts 949
Standards for repairing cylinders, valve plates, and swash plates (shoe plates) 949
Tightening torque 950
Overall View 950
Drive Shaft Front Side 954
Drive Shaft Rear Side 955
Development Diagram 956
Part Table 958
Causes of Failures, and Actions 959
Regulator Maintenance Standards 961
Regulator Adjustment 961
Appendix Table and Drawings 962
Regulator Assembly and Disassembly Procedures 966
Tools 966
Preparations for Disassembly 966
Disassembly Procedure 966
Assembly Procedures 968
Internal Configuration Diagram of Regulator 971
Development Diagram of Regulator 973
Component Table 974
Procedures for Assembly and Disassembly of Control Valve 976
Main plunger section 976
Foot relief valve 978
Main relief valve 979
Disassembly 979
Assembly and pressure setting 981
Pressure setting 982
Overload relief valve 983
Center bypass valve 985
Arm regeneration check 986
Boom back pressure check 987
Load hold valve 988
Boom regeneration check 991
Check valve 992
Swing priority valve 994
Check valve (swing priority path) 996
Arm regeneration valve 998
Travel signal switchover spool 999
Procedures for Assembly and Disassembly of Operation Remote Control Valve1000
Maintenance Procedures1000
Required Tools and Tightening Torque1000
Maintenance Standards1000
Disassembly Procedures1001
Assembly Procedures1004
Causes of Trouble and Countermeasures1007
Procedures for Assembly and Disassembly of Travel Remote Control Valve1011
Maintenance Procedures1011
Disassembly Procedures1012
Assembly Procedures1016
Causes of Trouble and Countermeasures and Cross-section Diagram1021
Assembly and Disassembly of Cushion Valve1024
Disassembly Procedures1024
Reverse Operation Spool Section1024
Check Plunger Section with Throttle1024
Shuttle Valve Section1024
Assembly Procedures1025
Reverse Operation Spool Section1025
Check Plunger Section with Throttle1025
Shuttle Valve Section1025
Written Materials1026
Pressure Measurement and Adjustment Procedures1028
Procedures for Pressure Measurement from the Monitor Display1028
Monitor and Switch Panel1028
Pressure Measurement Method1028
Operating Method1028
PROCEDURES FOR MEASURING HYDRAULIC OIL TEMPERATURE FROM THE MONITOR DISPLAY1028
Hydraulic Oil Temperature Measurement Method1028
Operating Method1029
Procedures for Pressure Measurement by Installing Pressure Gauge1030
Preparations1030
Items to prepare1030
Pressure Measuring Ports1031
Control Valve1033
Location of Relief Valves1033
Pressure Measurement Preparations1034
Pressure Measurement1036
Main Pressure Measurement1036
A Attachment Pressure Measurement1036
Boom-down pressure measurement1038
D Option Line Pressure Measurement1038
Pilot Pressure Measurement1038
Pressure Gauge Installation1038
Negative Control Pressure Measurement1039
Pressure Gauge Installation1039
Pressure Adjustment1039
Main Pressure Adjustment1039
Pressure Measurement and Adjustment Preparations1039
Main Relief Pressure Adjustment1041
Overload Relief Pressure Adjustment1041
Swing Relief Pressure Adjustment1043
Pilot Pressure Adjustment1044
Hydraulic Pump Flow Measurement Procedures1045
Preparations1045
Items to Prepare1045
Work Preparations1046
Flow Measurement1047
Air Bleed Procedure1049
Hydraulic Pump1049
Sampling Procedure1050
Sampling of Hydraulic Fluid1050
Hydraulic Equipment Layout1051
Overall View1052
Pump Chamber Hydraulic Equipment Layout1053
Swing Body Center Section Hydraulic Equipment Layout1054
Housing Left Side Hydraulic Equipment Layout1056
Layout of Hydraulic Equipment in Cab1057
N CAB1139
Removal and Installation of Operator’s Seat1142
Removal of Operator’s Seat1142
Installation of Operator’s Seat1142
Removal and Installation of Cab Assembly1143
Removal of Cab Assembly1143
Installation of Cab Assembly1147
Removal and Installation of Wiper1148
Removal of Wiper1148
Installation of wiper1148
Removal and Installation of Cab Front Glass1149
Removal of Cab Front Glass1149
Installation of Cab Front Glass1150
Window Lock Adjustment Procedures1151
Window Lock (front side)1151
Window Lock (rear side)1151
Removal and Installation of Housing Guardrail1153
Removal of Housing Guardrail1153
Installation of Housing Guardrail1153
Tightening torque1154
R ELECTRICAL PARTS1155
Basic Functions1159
Monitor Control1159
Monitor Display Dimming1159
Diagnostic Trouble Code Indicator1160
Clock1160
Basic Operation1161
Battery Save1161
Accessories1163
Working Light1163
LED Light1164
Room Lamp1164
Radio Mute1166
Wiper and Washer1167
Safety1169
Horn1169
Back/Side View Monitor1170
Precautions for Camera Installation1171
Maintenance1171
Anti-theft1171
Manual Lock1172
Service Support Screen Lock1172
Customer-specific System Information Screen Lock1172
Maintenance Information Screen Lock1173
Option Line Setting Screen Lock1173
Setting1173
Clock Adjustment1173
Screen Brightness Setting1174
Battery Disconnect Switch1175
Explanation of Controller1176
Service Support1178
Screen Operations1178
Screen Display List1178
Service Monitor Structure1179
CHECK Screen List1180
MACHINE STATUS1181
HYDRAULIC STATUS1187
ENGINE STATUS1194
FAULT HISTORY1198
WORK HISTORY1198
HYDRAULIC HISTORY1207
ENGINE HISTORY1219
DEVICE TEST1240
ECM/DCU Memory Clear1240
SCR RE-GEN1241
Urea Line Leak Test1242
CCV Operation Test1243
Dosing Test1244
Reverting Valve Operation Test1245
Common Rail Pressure Test1246
Idle Speed Test / Injector Test1247
EGR Valve Control Test1248
VG Turbo Control Test1249
Intake Throttle Control Test1250
CONTROL UNIT Screen List1252
MCM-MAIN1252
MCM-SUB1256
COMMU TERMINAL1257
SETUP Screen List1259
MACHINE SELECT1259
DIMENSIONS1264
PARAMETERS1265
ENGINE INFORMATION1268
ENGINE INFORMATION1269
Data Confirmation1269
Data Transfer (Copy)1270
QR (INJECTOR) CODE1271
Injector number1271
Screen Layout1271
Data Source Selection1271
Manual Input1272
CAMERA1273
PASSWORD1276
CALIBRATE Screen List1278
THROTTLE VOLUME1279
OPTLINE RELIEF1280
PUMP FLOW1282
Connection Connector Pin Layout1285
Main Controller1285
Monitor1286
Sequence Circuit Diagram1287
Code List1287
Overall1290
Block diagram1293
Main Controller1293
DCU1294
ECM1295
Monitor1296
Air Conditioner1297
Gate Lock1298
Horn1298
Working Light1299
Option1300
Other1301
Electrical Symbol List1301
Electrical Equipment Layout Diagram1304
Main Unit Left-side Layout Diagram1305
Engine Section Layout Diagram1308
Main Unit Right Side Layout Diagram (pump chamber)1311
Main Unit Center Section Layout Diagram1312
Cab Layout Diagram 11313
Cab Layout Diagram 21315
Layout Around Operator Seat1318
Stand Alone Parts Diagram1319
Removal and Installation of Wiper Controller1338
Removal of Wiper Controller1338
Installation of wiper controller1338
Removal and Installation of Wiper Motor1339
Removal of Wiper Motor1339
Installation of wiper motor1340
Removal and Installation of ECM1341
Removal of ECM1341
Installation of ECM1341
Removal and Installation of Main Controller1342
Removal of Main Controller1342
Installation of Main Controller1342
Removal and Installation of DCU1343
Removal of DCU1343
Installation of DCU1343
Removal and Installation of Monitor1344
Removal of Monitor1344
Installation of Monitor1344
Removal and Installation of Rear View Camera 1345
Removal of Rear View Camera1345
Installation of Rear View Camera1345
Removal and Installation of Side Camera (right)1346
Removal of Side Camera (Right)1346
Installation of Side Camera (right)1346
Removal and Installation of Side Camera (Left)1347
Removal of Side Camera (Left)1347
Installation of Side Camera (Left)1347
Removal and Installation of FVM Controller1348
Removal of FVM Controller1348
Installation of FVM Controller1348
How to Set FVM1349
Air Conditioner Overall Diagram1353
Frame1353
Cab1356
Equipment Layout Diagram1359
Circuit Diagram1361
Air Conditioner Circuit Diagram1361
Explanation of Functions1363
Explanation of Control1363
Air Mix Motor Actuator Control1364
Blow Mode Motor Actuator Control1364
Refresh/Recirculate Switch Motor Actuator Control1365
Blower Amp Control1366
Compressor Clutch Control1368
COOLMAX Control and HOTMAX Control1369
Abnormality Detection and Control after Abnormality Detected1369
Monitor Mode1373
Door Switch Control1375
Actuator Inspection1376
Air Mix Motor Actuator Inspection1376
Refresh/Recirculate Switch Motor Actuator Inspection1377
Mode Motor Actuator Inspection1378
Self-diagnosis Function with Panel Display1379
Abnormality Display and Self-check Procedures1379
Abnormality Display Position1379
Explanation of Abnormality Display1379
Motor Actuator Abnormality1379
Sensor Abnormality1380
Explanation of Monitor Mode1380
Monitor Mode Display Position1381
Monitor Mode Display Operating Method1381
Display Contents in Monitor Mode1382
Part Function and Good/Poor Judgment1388
Control Panel1388
Blower Amp1388
Relay1389
Air Mix Actuator1390
Refresh/Recirculate Actuator1391
Blow Mode Actuator1391
Evaporator Sensor1392
Dual Pressure Switch1392
Solar Radiation Sensor1393
Inside Air Sensor1393
Assembly and Disassembly of Unit1395
Removal of Blower Unit1395
Replacement of Blower Motor1395
Replacement of Blower Amp1395
Removal of Heater Core1396
Removal of Heat Case Right/Left1396
Replacement of Evaporator and Expansion Valve1396
Installation of Evaporator Sensor1397
Replacement of Motor Actuator1397
Removal and Installation of Compressor1398
Removal of Compressor1398
Installation of Compressor1398
Removal and Installation of Condenser1399
Removal of Condenser1399
Installation of Condenser1400
Removal and Installation of Receiver Dryer1401
Removal of Receiver Dryer1401
Installation of Receiver Dryer1401
Work Precautions1403
Work Procedures1403
Air Conditioner Refrigerant Filling is Divided into the “Vacuum Operation” and “Gas Filling Operation”1403
Operation Chart1404
Tools1404
Filling Procedures1406
Charging Hose Connection Position1406
Connecting Gauge Manifold1406
Vacuuming1407
Gas Filling Operation, High-pressure Side1408
Gas Filling Work, Low Pressure Side1408
V ATTACHMENTS1461
Main Equipment Table1465
Backhoe Attachment1465
Cylinder1465
Maintenance Standards1466
Attachment (Backhoe)1466
1 Boom and Swing Frame Installation Section1466
2 Boom Cylinder and Swing Frame Installation Section1467
3 Boom and Boom Cylinder Installation Section1467
4 Boom and Arm Cylinder Installation Section1468
5 Boom and Arm Installation Section1469
6 Arm and Arm Cylinder Installation Section1469
7 Arm and Bucket Cylinder Installation Section1470
8 Arm and Arm Link Installation Section1471
9 Bucket and Bucket Link Installation Section1471
10 Bucket Link and Bucket Cylinder Installation Section1472
11 Bucket and Arm Installation Section1473
Removal and Installation of Bucket Cylinder1474
Removal of Bucket Cylinder1474
Installation of Bucket Cylinder1476
Removal and Installation of Arm Cylinder1478
Removal of Arm Cylinder1478
Installation of Arm Cylinder1480
Removal and Installation of Boom Cylinder1483
Removal of Boom Cylinder1483
Installation of Boom Cylinder1485
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder1488
Specifications and Structure Diagram (including the assembly diagram and parts table)1488
Basic functions1488
Function of Each Location1488
Cylinder Head Assembly1488
Piston Assembly1489
Pipe Assembly1491
Handling Precautions1491
Precautions for Installing the Cylinder on the Machine Body1491
Usage Cautions1492
Maintenance and Inspection Cautions1492
Maintenance Inspection and Service1494
Trouble Diagnostics1495
Storage Standards1499
Storing Parts Individually (In principle, store indoors)1499
When Mounted on Vehicle Body1499
Recommended Anti-rust Oil1500
Assembly and Disassembly Procedures1500
Preparations ····· Prepare the Following before Starting Disassembly1500
General Work Precautions1500
Maintenance Standards1500
Inspection after Assembly1500
Required Tool1501
General Tool1501
Special Jig1502
Special Jigs Part Number List1503
Disassembly Procedures1504
Assembly Procedures1507
Test Operation1511
Usage Limits1512
Structural Diagram1513
Boom Cylinder1513
Arm Cylinder1515
Bucket Cylinder1517
HBCV1519
structure1519
Function1519
operation explanation1519
Port Diagram1534
HBCV1534
Air Bleed Procedure1535
HBCV1535
Boom Cylinder HBCV1535
Arm Cylinder HBCV1536
Removal and Installation of HBCV1537
Removal and Installation of Arm HBCV1538
Removal of arm HBCV1538
Installation of arm HBCV1538
Removal and Installation of Boom HBCV1539
Removal of Boom HBCV1539
Installation of boom HBCV1540
Removal and Installation of Bucket1541
Removal of Bucket1541
Installation of Bucket1541
Removal and Installation of Bucket Link1543
Removal of Bucket Link1543
Installation of Bucket Link1543
Removal and Installation of Arm1545
Removal of Arm1545
Installation of Arm1546
Removal and Installation of Boom1547
Removal of Boom1547
Installation of Boom1549
Z OTHER1553
Changes from Model -61558
Overall Layout1558
Lower1559
Swing Unit1559
Engine1559
Hydraulic-related Data1561
Hydraulic Control1561
Cab, House1562
Electrical Data1563
Electric Control1564
Attachments1564
Specifications1565
ENGINE1565
HYDRAULIC SYSTEM1565
HYDRAULIC CONTROLS1566
ELECTRICAL SYSTEM1566
OPERATOR ENVIRONMENT1567
UNDERCARRIAGE1568
MASS1568
DIGGING FORCE (with 062 m3 Sumitomo Bucket) (ISO 6015)1568
DIMENSIONS1568
WORKING RANGES1569
SYSTEM FLUID CAPACITIES AND SPECIFICATIONS1569
Arm Dimension1570
Main Unit Weight1572
Divided Weight (standard specifications)1572
Stand Alone Part Weight1573
Shoe Weight (per Side)1573
Arm Weight1573
Bucket Weight1573
Bolt Size and Torque Table1575
Special Torque Setting1575
Overall View1579
160X41579
Standard Arm [262 m (8596 ft)]1579
Long Arm [305m (10007 ft)]1580
WORK RANGE DIAGRAM1581
160X41581
Standard Arm [262 m (8596 ft)]1581
Long Arm [305m (10007 ft)]1583
New Machine Performance Judgment Table1585
Table of Standards1585
Measurement Method1587
Engine speed1587
Pressure at Each Part1588
Pump Command Displacement1588
Cylinder Down Amount1588
Attachment Speed1588
Swing Speed1589
Swing (180°) Brake Angle1590
Travel Speed1590
Off Travel Amount1590
Travel Sprocket Speed1591
Shoe Tension Amount1591
Swing Ball Race Bearing Movement Amount and Bucket Tip Movement Amount1592
FLUIDS AND LUBRICANTS1594
HYDRAULIC FLUID1594
Engine Oil1594
Fuel1594
Conditions applicable to diesel fuel1594
Recommended Conditions Applicable to Diesel Fuel1594
Main-unit-related Diagnostic Trouble Code List1595
Main Unit-side Trouble1598
Diagnostic Trouble Code: 7000 Pressure Sensor P1 Abnormality1598
Diagnostic Trouble Code: 7001 Pressure Sensor P2 Abnormality1599
Diagnostic Trouble Code: 7002 Pressure Sensor N1 Abnormality1601
Diagnostic Trouble Code: 7003 Pressure Sensor N2 Abnormality1602
Diagnostic Trouble Code: 7004 Pressure Sensor Boom Cylinder Bottom Abnormality1604
Diagnostic Trouble Code: 7007 Pressure Sensor Arm Cylinder Rod Abnormality1605
Diagnostic Trouble Code: 7021 Pressure Sensor Swing Pilot Abnormality1607
Diagnostic Trouble Code: 7023 Pressure Sensor Arm-In Pilot Abnormality1608
Diagnostic Trouble Code: 7040 Level Sensor Fuel Abnormality1610
Diagnostic Trouble Code: 7041 Temperature Sensor Hydraulic Fluid Abnormality1611
Diagnostic Trouble Code: 7065 Pressure Sensor Boom-Up Pilot Abnormality1612
Diagnostic Trouble Code: 7067 Pressure Sensor Bucket-Close Pilot Abnormality1614
Diagnostic Trouble Code: 7068 Pressure Sensor Boom-Down Pilot Abnormality1616
Diagnostic Trouble Code: 7069 Pressure Sensor Arm-Out Pilot Abnormality1617
Diagnostic Trouble Code: 7070 Pressure Sensor Bucket-Open Pilot Abnormality1619
Diagnostic Trouble Code: 7071 Pressure Sensor Travel Right Pilot Abnormality1620
Diagnostic Trouble Code: 7072 Pressure Sensor Travel Left Pilot Abnormality1622
Diagnostic Trouble Code: 7073 Pressure Sensor Travel 1 Pedal Abnormality1624
Diagnostic Trouble Code: 7074 Pressure Sensor 1st Option Pilot (Common/Front Pedal) Abnormality1626
Diagnostic Trouble Code: 7075 Pressure Sensor Arm Cylinder Bottom Abnormality1627
Diagnostic Trouble Code: 7078 Pressure Sensor 1st Option Pilot (Rear Pedal) Abnormality1629
Diagnostic Trouble Code: 7200 Swing Brake Solenoid Abnormality1631
Diagnostic Trouble Code: 7201 Travel 2nd-Speed Switchover Solenoid Abnormality1632
Diagnostic Trouble Code: 7202 Pressure Boost Solenoid Abnormality1633
Diagnostic Trouble Code: 7203 Travel Alarm Buzzer Abnormality1634
Diagnostic Trouble Code: 7206 Option Return Line Switchover Solenoid Abnormality1635
Diagnostic Trouble Code: 7207 Free Swing Solenoid Abnormality1636
Diagnostic Trouble Code: 7213 Quick Coupler Buzzer Abnormality1637
Diagnostic Trouble Code: 7214 Quick Coupler Solenoid Abnormality1639
Diagnostic Trouble Code: 7247 Boom 2-Down Pilot Proportional Valve Abnormality1640
Diagnostic Trouble Code: 7249 Bucket-Close Pilot Proportional Valve Abnormality1641
Diagnostic Trouble Code: 7250 Option Relief Pressure Proportional Valve Abnormality1643
Diagnostic Trouble Code: 7265 Arm 1 Semi-Parallel Proportional Valve Abnormality1644
Diagnostic Trouble Code: 7266 Arm 2 Semi-Parallel Proportional Valve Abnormality1645
Diagnostic Trouble Code: 7267 Arm 1 Regeneration Release Proportional Valve Abnormality1646
Diagnostic Trouble Code: 7270 Tilting 1 Proportional Valve Abnormality1647
Diagnostic Trouble Code: 7271 Tilting 2 Proportional Valve Abnormality1649
Diagnostic Trouble Code: 7273 Straight Travel Proportional Valve Abnormality1650
Diagnostic Trouble Code: 7400 Coolant Temperature Overheating 11651
Diagnostic Trouble Code: 7401 Coolant Temperature Overheating 21652
Diagnostic Trouble Code: 7404 Oil Temperature Overheating1653
Diagnostic Trouble Code: 7405 Boost Temperature Overheating 11654
Diagnostic Trouble Code: 7406 Boost Temperature Overheating 21655
Diagnostic Trouble Code: 7420 Alternator Power Generation Failure1656
Diagnostic Trouble Code: 7421 Coolant Level Decrease1657
Diagnostic Trouble Code: 7422 Engine Oil Pressure Decrease1658
Diagnostic Trouble Code: 7423 Air Cleaner Clogging1659
Diagnostic Trouble Code: 7424 Return Filter Clogging1660
Diagnostic Trouble Code: 7426 Fuel Filter Clogging 11661
Diagnostic Trouble Code: 7427 Fuel Filter Clogging 21662
Diagnostic Trouble Code: 7428 Inducement (Remaining Urea Level Low) – Warning1663
Diagnostic Trouble Code: 7429 Inducement (Remaining Urea Level Low) – Early1664
Diagnostic Trouble Code: 7430 Inducement (Remaining Urea Level Low) – Final1664
Diagnostic Trouble Code: 7602 ECM Communication Abnormality1665
Diagnostic Trouble Code: 7605 ECM Not-Matched1666
Diagnostic Trouble Code: 7606 EEPROM Abnormality1667
Diagnostic Trouble Code: 7608 Camera Abnormality1667
Diagnostic Trouble Code: 7612 Air Conditioner Communication Abnormality1669
Diagnostic Trouble Code: 7613 Monitor Communication (CAN) Abnormality1670
Diagnostic Trouble Code: 7615 Sub-Controller Communication Abnormality1671
Diagnostic Trouble Code: 7618 DCU Communication Abnormality1673
List of special tools1675
NUMERICAL VALUE CONVERSION TABLE1675
Unit conversion rate1675
Length1675
Area1677
Volume1678
Weight1680
Pressure1681
Torque1682
Temperature1683
A1686
Travel Motor Special Tool1686
160X41686
Take-up Roller Special Tool1689
160X41689
Upper Roller Special Tool1690
160X41690
Lower Roller Special Tool1691
160X41691
C1692
Swing Motor Special Tool1692
160X41692
H1695
Engine Oil Filter Special Tool1695
160X41695
Fuel Filter Special Tool1695
160X41695
Injector Special Tool1695
160X41695
Circuit Test Special Tool1696
160X41696
Valve Guide Special Tool1696
160X41696
Cylinder Head Special Tool1696
160X41696
Head Bolt Special Tool1699
160X41699
Crankshaft Special Tool1699
160X41699
Valve Spring Special Tool1701
160X41701
J1702
Remote Control Valve Special Tool1702
160X41702
R1704
Gas Filling Special Tool1704
160X41704
V1704
Attachment Special Tool (for Cylinder Assembly)1704
Special Jigs Part Number List1704
Paint Colors1706
Abbreviation1708
001_J_Explanation of Hydraulic Circuit and Operations (standard model)_160X4pdf 0
J1059
Explanation of Hydraulic Circuit and Operations (standard model)1061
Travel Circuit1062
Travel Low-speed Circuit1062
Travel High-speed Circuit1064
Straight Travel Circuit (with HBCV)1066
Swing Circuit1068
Swing Relief Cut Control Circuit1068
Swing Priority Circuit (with HBCV)1070
Swing Brake Circuit1072
Swing Parking Circuit (lever in neutral)1074
Swing Parking Circuit (brake release)1076
Swing Parking Circuit (machine stop)1078
Boom Circuit1080
Boom-up Circuit (independent operation) (with HBCV)1080
Boom-up Spool Stroke Control Circuit (compound boom-up + arm-in) (with HBCV)1082
Boom-up Circuit (compound boom-up + arm-in) (with HBCV)1084
Boom-down Regenerative Circuit (with HBCV)1086
Boom-down Tilting Prevention Circuit (with HBCV)1088
Boom-down Load Holding Valve Circuit (with HBCV)1090
Arm Circuit1092
Arm-out Circuit (with HBCV)1092
Arm-in Regenerative Circuit (with HBCV)1094
Arm-in Load Holding Valve Circuit (with HBCV)1096
Bucket Circuit1098
Bucket-open Circuit1098
Bucket-close Regenerative Circuit1100
Bucket-close Spool Stroke Control Circuit1102
Negative Control Circuit1104
Negative Control Circuit1104
Other Circuits1106
Cushion Circuit (arm-out operation)1107
Cushion Circuit (when arm-out operation stopped)1110
Cushion Circuit (arm-out → arm-in operation)1112
Heat Circuit (lever in neutral)1114
Auto Pressure Boost Circuit (bucket close)1116
002_J_Explanation of Hydraulic Circuit and Operations (option)_160X4pdf 0
J1119
Explanation of Hydraulic Circuit and Operations (option)1121
Option Circuits1122
Single Breaker Circuit (pedal type)1122
Single Breaker Circuit (switch type)1124
Single Breaker Circuit (proportional control type)1126
Single Double-acting Circuit (switch type) (1 pump hydraulic fork)1128
Single Double-acting Circuit (proportional control type) (1 pump hydraulic fork)1130
Multi-purpose Circuit (proportional control type) (breaker)1132
Multi-purpose Circuit (proportional control type) (2 pumps flow crusher)1134
2nd Option Circuit (proportional control type) (hydraulic rotation fork)1136
003_R_Electrical Connector Wiring Diagram_160X4pdf 0
R1411
Electrical Connector Wiring Diagram1413
Frame Main Harness1414
SCR Harness1416
Light Harness (boom light)1418
Light Harness (cab light)1420
Light Harness (cab light) (with guard)1422
Travel Harness1424
Cab Main Harness1426
Indicator Jumper1428
Console Harness1430
GPS Computer Harness1432
GPS Computer Intermediate Harness1434
Feed Pump Harness1436
Camera Harness (FVM)1438
Camera Harness (rear view camera)1440
Camera Intermediate Harness [8000 mm (314961 in)]1442
Camera Intermediate Harness (left camera)1444
004_R_Electrical Parts and Wiring Assembly Diagram_160X4pdf 0
R1445
Electrical Parts and Wiring Assembly Diagram1447
Frame1448
Engine and Pump1452
Attachments1454
Battery1456
Cab1458
S.M 3/1/25
