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Linkbelt 380X4-MH Excavator SERVICE MANUAL WLSM3807MH-LX – PDF DOWNLOAD
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Linkbelt Sumitomo 380X4-MH Excavator SERVICE MANUAL WLSM3807MH-LX – PDF DOWNLOAD
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Description
Linkbelt Sumitomo 380X4-MH Excavator SERVICE MANUAL WLSM3807MH-LX – PDF DOWNLOAD
FILE DETAILS:
Linkbelt Sumitomo 380X4-MH Excavator SERVICE MANUAL WLSM3807MH-LX – PDF DOWNLOAD
Language : English
Pages :1975
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Linkbelt Sumitomo 380X4-MH Excavator SERVICE MANUAL WLSM3807MH-LX – 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 380X4-MH Excavator SERVICE MANUAL WLSM3807MH-LX – PDF DOWNLOAD
Excavator 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 30
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
Idling Start 220
Auto Idle 220
One-touch Idle 221
Auto Warm-Up 222
Idle Shutdown 227
Idle Up 228
Work Mode Control 229
Engine Emergency Stop 230
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
Operation Explanation of SCR 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 344
Excessive White Smoke in Exhaust Gas 345
Excessive Black Smoke in Exhaust Gas 346
Abnormal Noise 346
High Fuel Consumption 347
High Oil Consumption 348
Engine Output Deficiency 349
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 391
Removal and Installation of Cylinder Head Cover 392
Cylinder head cover Removal 392
Cylinder head cover Installation 392
Removal and Installation of Cylinder Head 393
Removal of Cylinder head assembly 393
Cylinder head assembly Disassembly 402
Cylinder head assembly Reassembly 407
Installation of Cylinder head assembly 416
Cylinder head assembly Inspection 434
Removal and Installation of Cylinder Block 441
Removal of Cylinder block 441
Installation of Cylinder block 457
Cylinder block Inspection 495
Lubrication System 497
Removal and Installation of Oil Pan 497
Oil pan Removal 497
Oil pan Installation 497
Removal and Installation of Oil Level Switch 498
Oil level switch Removal 498
Oil level switch Installation 499
Removal and Installation of Oil Pump Assembly 499
Removal of Oil pump assembly 499
Disassembly of Oil Pump 512
Assembly of Oil Pump 513
Installation of Oil Pump 513
Inspection of Oil Pump 539
Inspection of Engine oil 540
Removal and Installation of Oil Port Cover 541
Removal of Oil port cover 541
Installation of Oil port cover 541
Removal and installation of Oil filter element 542
Removal of Oil filter element 542
Installation of Oil filter element 542
Cooling System 543
Removal and Installation of Water Pump Assembly 543
Removal of Water pump assembly 543
Installation of Water pump assembly 544
Inspection of Water pump assembly 548
Removal and Installation of Thermostat 548
Removal of Thermostat 548
Installation of Thermostat 549
Inspection of Thermostat 551
Inspection of Coolant 552
Inspection of Cooling Fan Belt 556
Removal and Installation of Overheat Switch 557
Removal of Overheat switch 557
Installation of Overheat switch 557
Induction System 559
Inspection of Air cleaner element 559
Exhaust System 560
Removal and installation of Oxidation Catalyst Assembly 560
Removal of Oxidation Catalyst Assembly 560
Installation of Oxidation Catalyst Assembly 561
Aux Emission Control Devices System 563
Removal and installation of Dosing Module 563
Removal of Dosing Module 563
Disassembly of Dosing Module 563
Assembly of Dosing Module 564
Installation of Dosing Module 564
Removal and installation of DEF Supply Module 566
Removal of DEF supply module 566
Disassembly of DEF Supply Module 567
Assembly of DEF Supply Module 567
Installation of DEF Supply Module 568
Removal and installation of Coolant Control Valve 570
Removal of Coolant Control Valve 570
Installation of Coolant Control Valve 571
Removal and Installation of DCU 573
Removal of DCU 573
Installation of DCU 573
Removal and installation of DEF Supply Module Filter 573
Removal of DEF Supply Module Filter 573
Installation of DEF Supply Module Filter 574
Removal and Installation of Exhaust Manifold 575
Removal of Exhaust manifold 575
Installation of Exhaust manifold 578
Exhaust manifold Inspection 584
Removal and Installation of Fuel Tank 585
Removal of Fuel Tank 585
Installation of fuel tank 588
Removal and Installation of Urea Pump 589
Removal of Urea Pump 589
Installation of Urea Pump 589
Removal and Installation of Urea Solution Tank 590
Removal of Urea Solution Tank 590
Installation of Urea Solution Tank 591
Removal and Installation of Fuel Supply Pump 592
Removal of Fuel Supply Pump 592
Fuel supply pump Installation 592
Removal and Installation of Common Rail Assembly 596
Removal of Common rail assembly 596
Installation of Common rail assembly 600
Removal and Installation of Injector 608
Injector Removal 608
Injector Installation 610
Removal and installation of Idle Gear 615
Removal of Idle Gear 615
Installation of Idle Gear 627
Inspection of Idle Gear 653
Removal and installation of Inlet Cover 655
Removal of Inlet Cover 655
Installation of Inlet Cover 659
Removal and installation of Crankshaft 668
Removal of Crankshaft 668
Installation of Crankshaft 684
Disassembly of Crankshaft 720
Assembly of Crankshaft 720
Inspection of Crankshaft 721
Removal and installation of Piston 727
Removal of Piston 727
Installation of Piston 738
Disassembly of Piston 760
Assembly of Piston 760
Inspection of Piston 762
Removal and installation of Camshaft 769
Removal of Camshaft 769
Disassembly of Camshaft 770
Installation of Camshaft 771
Assembly of Camshaft 775
Inspection of Camshaft 776
Removal and installation of Flywheel 778
Removal of Flywheel 778
Installation of Flywheel 779
Inspection of Flywheel 780
Removal and installation of Crankshaft Front Oil Seal 781
Removal of Crankshaft Front Oil Seal 781
Installation of Crankshaft Front Oil Seal 782
Removal and installation of Crankshaft Rear Oil Seal 786
Removal of Crankshaft Rear Oil Seal 786
Installation of Crankshaft Rear Oil Seal 787
Removal and installation of Rocker Arm Shaft 790
Removal of Rocker Arm Shaft 790
Installation of Rocker Arm Shaft 791
Disassembly of Rocker Arm Shaft 795
Assembly of Rocker Arm Shaft 795
Inspection of Rocker Arm Shaft 796
Removal and installation of Valve Spring 799
Removal of Valve Spring 799
Installation of Valve Spring 801
Inspection of Valve Spring 807
Removal and installation of Valve Stem Oil Seal 809
Removal of Valve Stem Oil Seal 809
Installation of Valve Stem Oil Seal 811
Removal and installation of Front Cover 818
Removal of Front Cover 818
Installation of Front Cover 820
Removal and installation of Intake Throttle Valve 827
Removal of Intake Throttle Valve 827
Installation of Intake Throttle Valve 827
Removal and Installation of Starter Motor 828
Removal of Starter Motor 828
Installation of Starter Motor 828
Disassembly of Starter Motor 829
Assembly of Starter Motor 830
Inspection of Starter Motor 834
Removal and Installation of Alternator 837
Removal of Alternator 837
Installation of Alternator 837
Disassembly of Alternator 837
Assembly of Alternator 839
Inspection of Alternator 840
Removal and Installation of Glow Plug 844
Removal of Glow Plug 844
Installation of Glow Plug 844
Glow Plug Inspection 845
Removal and Installation of Suction Control Valve 846
Suction control valve Removal 846
Suction control valve Installation 846
Removal and installation of Fuel Filter 849
Removal of Fuel Filter 849
Installation of Fuel Filter 849
Removal and installation of Relief Valve 852
Removal of Relief Valve 852
Installation of Relief Valve 852
Removal and installation of Fuel Filter Element 855
Removal of Fuel Filter Element 855
Installation of Fuel Filter Element 856
Removal and Installation of Fuel filter pressure 859
Fuel filter pressure sensor Removal 859
Fuel filter pressure sensor Installation 859
Removal and Installation of Engine coolant temperature sensor 860
Engine coolant temperature sensor Removal 860
Engine coolant temperature sensor Installation 860
Engine coolant temperature sensor Inspection 860
Removal and Installation of CKP sensor 861
Removal of CKP sensor 861
Installation of CKP sensor 861
CKP sensor Inspection 861
Removal and Installation of CMP sensor 862
CMP sensor Removal 862
CMP sensor Installation 862
CMP sensor Inspection 862
Removal and Installation of Oil pressure sensor 863
Removal of Oil pressure sensor 863
Installation of Oil pressure sensor 863
Inspection of Oil pressure sensor 863
Removal and installation of Pressure Sensor/Boost Temperature Sensor 864
Removal of Pressure sensor/boost temperature sensor 864
Installation of Pressure sensor/boost temperature sensor 864
Inspection of Pressure sensor/boost temperature sensor 864
Removal and Installation of IMT sensor 865
Removal of IMT sensor 865
Installation of IMT sensor 865
Removal and installation of Charge Air Cooler Temperature Sensor 1 866
Removal of Charge air cooler temperature sensor 1 866
Installation of Charge air cooler temperature sensor 1 866
Inspection of Charge air cooler temperature sensor 1 866
Sampling Procedure 867
Sampling of Engine Oil 867
Removal and Installation of Exhaust gas temperature sensor 868
Removal of Exhaust gas temperature sensor 868
Installation of Exhaust gas temperature sensor 868
Inspection of Exhaust gas temperature sensor 869
Removal and installation of EGR Gas Temperature Sensor 1 870
Removal of EGR Gas Temperature Sensor 1 870
Installation of EGR Gas Temperature Sensor 1 870
Inspection of EGR Gas Temperature Sensor 1 870
Removal and installation of EGR Gas Temperature Sensor 2 871
Removal of EGR Gas Temperature Sensor 2 871
Installation of EGR Gas Temperature Sensor 2 871
Inspection of EGR Gas Temperature Sensor 2 872
Removal and installation of NOx Sensor 873
Removal of NOx Sensor 873
Installation of NOx Sensor 873
Removal and Installation of Exhaust gas temperature sensor 3 876
Removal of Exhaust gas temperature sensor 3 876
Installation of Exhaust gas temperature sensor 3 876
Removal and installation of DEF Sensor 877
Removal of DEF Sensor 877
Installation of DEF Sensor 877
Engine-related Diagnostic Trouble Code List 878
Engine-side Trouble 885
ECM Trouble 885
DTC P0016 Crankshaft Position – Camshaft Position Correlation Error 885
DTC P0045 Turbocharger Boost Control VNT Error 885
DTC P0087 Fuel Rail/System Pressure – Too Low 886
DTC P0089 Fuel Pressure Regulator Performance 889
DTC P0091 Fuel Pressure Regulator Control Circuit Low 890
DTC P0092 Fuel Pressure Regulator Control Circuit High 891
DTC P0097 Intake Air Temperature (IAT) Sensor 2 Circuit Low Voltage 891
DTC P0098 Intake Air Temperature (IAT) Sensor 2 Circuit High Voltage 892
DTC P0102 Mass Air Flow Sensor Circuit Low Input 893
DTC P0103 Mass Air Flow Sensor Circuit High Input 894
DTC P0112 Intake Air Temperature Sensor Circuit Low 894
DTC P0113 Intake Air Temperature Sensor Circuit High 895
DTC P0117 Engine Coolant Temperature Sensor Circuit Low 896
DTC P0118 Engine Coolant Temperature Sensor Circuit High 896
DTC P0122 Throttle Position Sensor Circuit Low 898
DTC P0123 Throttle Position Sensor Circuit High 898
DTC P0182 Fuel Temperature Sensor Circuit Low 899
DTC P0183 Fuel Temperature Sensor Circuit High 900
DTC P0192 Fuel Rail Pressure Sensor Circuit Low 901
DTC P0193 Fuel Rail Pressure Sensor Circuit High 902
DTC P0201 Injector Circuit Open – Cylinder 1 903
DTC P0202 Injector Circuit Open – Cylinder 2 904
DTC P0203 Injector Circuit Open – Cylinder 3 904
DTC P0204 Injector Circuit Open – Cylinder 4 905
DTC P0205 Injector Circuit Open – Cylinder 5 906
DTC P0206 Injector Circuit Open – Cylinder 6 907
DTC P0217 Engine Coolant Over Temperature Condition 908
DTC P0219 Engine Overspeed Condition 908
DTC P0234 Turbocharger Overboost Condition 909
DTC P0237 Turbo Charger Boost Sensor Circuit Low 910
DTC P0238 Turbo Charger Boost Sensor Circuit High 911
DTC P0335 Crankshaft Position Sensor Circuit 912
DTC P0336 Crankshaft Position Sensor Circuit Range/Performance 913
DTC P0340 Camshaft Position Sensor Circuit 914
DTC P0380 Glow Relay Circuit Error 915
DTC P0401 EGR Flow Insufficient Detected 915
DTC P0404 EGR Control Circuit Range/Performance 916
DTC P0409 EGR Sensor Circuit 917
DTC P041C EGR Cooler Outlet 1 Temp Sensor Circuit Low 919
DTC P041D EGR Cooler Outlet 1 Temp Sensor Circuit High 919
DTC P0427 Catalyst Temperature Sensor Circuit Low Sensor 1 920
DTC P0428 Catalyst Temperature Sensor Circuit High Sensor 1 921
DTC P042C Catalyst Temperature Sensor Circuit Low Sensor 2 922
DTC P042D Catalyst Temperature Sensor Circuit High Sensor 2 923
DTC P0522 Engine Oil Pressure Sensor Circuit Low Input 924
DTC P0523 Engine Oil Pressure Sensor Circuit High Input 925
DTC P0545 EGR Cooler Inlet 1 Temp Sensor Circuit Low 925
DTC P0546 EGR Cooler Inlet 1Temp Sensor Circuit High 926
DTC P0560 12 Volt Circuit Error 927
DTC P0563 System Voltage High 927
DTC P0601 Internal Control Module Memory Check Sum Error 928
DTC P0602 Internal Control Module QR Code Error 928
DTC P0604 Internal Control Module RAM Error 929
DTC P0606 Internal Control Module CPU Error 929
DTC P060A Internal Control Module CPU IC Error 929
DTC P060C Internal Control Module A/D Processing Performance 930
DTC P0615 Starter Relay Circuit Error 930
DTC P0638 Throttle Actuator Control Range/Performance 931
DTC P0685 ECM Power Relay Control Circuit Open 932
DTC P0687 ECM Power Relay Control Circuit High 932
DTC P06A6 Sensor Reference Voltage 1 Circuit 933
DTC P06A7 Sensor Reference Voltage 2 Circuit 933
DTC P06A8 Sensor Reference Voltage 3 Circuit 934
DTC P06A9 Sensor Reference Voltage 4 Circuit 935
DTC P06AF Torque Management System – Forced Engine Shutdown 936
DTC P06D5 Sensor Reference Voltage 5 Circuit 936
DTC P1076 Charge Air Cooler (CAC) Temperature Sensor 1 Circuit Low Voltage 937
DTC P1077 Charge Air Cooler (CAC) Temperature Sensor 1 Circuit High Voltage 937
DTC P1093 Fuel Rail Pressure Too Low 939
DTC P1097 Compressor Outlet Temperature Sensor Circuit High 941
DTC P1098 Compressor Outlet Temperature Sensor Circuit High 942
DTC P1236 Charge Air Cooler Performance Failure 943
DTC P1261 Injector Positive Voltage Control Circuit Group 1 944
DTC P1262 Injector Positive Voltage Control Circuit Group 2 944
DTC P1404 EGR Position Fault 944
DTC P1606 SW-IC Internal failure 945
DTC P160B AD-IC Failure Error 945
DTC P160C AD-IC2 Failure Error 946
Diagnostic trouble code_P1621: EEPROM abnormality 946
DTC P1622 Control Module Long Term Memory Hardware 947
DTC P1669 DPD Lamp Control Circuit 948
DTC P204F SCR System Error (No Inducement) 949
DTC P207F Urea Fluid Concentration Too Low 949
DTC P20C9 SCR System Error 949
DTC P2122 Pedal Position Sensor 1 Circuit Low Input 949
DTC P2123 Pedal Position Sensor 1 Circuit High Input 950
DTC P2127 Pedal Position Sensor 2 Circuit Low Input 951
DTC P2128 Pedal Position Sensor 2 Circuit High Input 952
DTC P2138 Pedal Position Sensor 1 – 2 Voltage Correlation 952
DTC P2146 Fuel Injector Group 1 Supply Voltage Circuit 953
DTC P2149 Fuel Injector Group 2 Supply Voltage Circuit 954
DTC P2228 Barometric Pressure Sensor Circuit Low 956
DTC P2229 Barometric Pressure Sensor Circuit High 956
DTC P2457 Exhaust Gas Recirculation (EGR) Cooling System Performance 956
DTC P2458 Purge time Out Error 957
DTC P2BA7 Urea Fluid Quantity Too Low 957
DTC P2BAA SCR System Error (Inducement, No Purge) 958
DTC P3093 Fuel Rail Pressure Too Low 958
DTC U0001 CAN Bus Error (ISO-CAN) 961
DTC U0073 Control Module Communication Bus Off 962
DTC U0101 Lost Communication With CAN 964
DTC U010E Lost Communications With Dosing Control Module 965
DTC U0110 Lost Communication With VNT System 965
DTC U2106 Lost CAN Communications With Wheel Loader Transmission Control System 966
DTC U0411 Lost CAN Communications With VNT Control Module 966
DCU Trouble 967
DTC P0607 Control Module Performance 967
DTC P060B Internal Control Module A/D Processing Performance 967
DTC P062F Control Module EEPROM Error 968
DTC P0641 Sensor Reference Voltage 1 Circuit 969
DTC P0658 Actuator Supply Voltage Circuit 970
DTC P0659 Actuator Supply Voltage Circuit 971
DTC P1462 Urea Fluid Quality Sensor Timeout Error 972
DTC P1464 Main Relay Performance 973
DTC P1468 DCU Overtemperature 973
DTC P1491 Urea Fluid Overpressure 974
DTC P1493 DCU Driver Overtemperature 975
DTC P149C Urea Fluid Pressure Reduction Malfunction 976
DTC P149D Urea Fluid Tank Overtemperature 977
DTC P2000 Monitoring the NOx Efficiency 978
DTC P203B Urea Fluid Tank Level Sensor Stuck 980
DTC P203C Urea Fluid Tank Level Sensor Low Voltage 981
DTC P203D Urea Fluid Tank Level Sensor High Voltage 982
DTC P2048 Urea Fluid Injector Circuit Low Voltage 983
DTC P2049 Urea Fluid Injector Circuit High Voltage 984
DTC P204B Urea Fluid Pressure Sensor Performance 984
DTC P204C Urea Fluid Pressure Sensor Circuit Low Voltage 985
DTC P204D Urea Fluid Pressure Sensor Circuit High Voltage 986
DTC P205B Urea Fluid Tank Temperature Sensor Performance 987
DTC P205C Urea Fluid Tank Temperature Sensor Low Voltage 988
DTC P205D Urea Fluid Tank Temperature Sensor High Voltage 989
DTC P206A Urea Fluid Quality Sensor Circuit 989
DTC P206B Urea Sensor Over Temperature Condition 990
DTC P206C Urea Fluid Quality Sensor Circuit Low Voltage 991
DTC P206D Urea Fluid Quality Sensor Circuit High Voltage 992
DTC P207F Urea Fluid Concentration Too Low 992
DTC P208A Urea Fluid Pump Control Circuit 992
DTC P208B Usea Fluid Pump Performance 993
DTC P208C Urea Fluid Pump Control Circuit Low Voltage 994
DTC P208D Urea Fluid Pump Control Circuit High Voltage 995
DTC P208E Urea Fluid Injector Stuck 996
DTC P20A0 Urea Fluid Reverting Valve Circuit Open 997
DTC P20A2 Urea Fluid Reverting Valve Circuit Low Voltage 998
DTC P20A3 Urea Fluid Reverting Valve Circuit High Voltage 999
DTC P20AC Urea Fluid Pump Temperature Sensor Performance1000
DTC P20AD Urea Fluid Pump Module Temperature Sensor Performance1001
DTC P20B1 Urea Fluid Tank Heater Coolant Control Valve Circuit Open1002
DTC P20B3 Urea Fluid Tank Heater Coolant Control Valve Circuit Low Voltage1003
DTC P20B4 Urea Fluid Tank Heater Coolant Control Valve Circuit High Voltage1004
DTC P20E8 Urea Fluid Pressure Underpressure1004
DTC P20E9 Urea Fluid Overpressure1006
DTC P20EA Urea Fluid Pressure Reduction Malfunction1007
DTC P20FE Urea Fluid Pressure Build-Up Error1008
DTC P2201 Upstream Nox Sensor Performance1009
DTC P2206 Reading the error(open) information detected by Ft NOx sensor1010
DTC P2207 Reading the error(short) information detected by Ft NOx sensor1010
DTC P2210 Reading the error(open) information detected by Rr NOx sensor1011
DTC P2211 Reading the error(short) information detected by Rr NOx sensor1011
DTC P242B Exhaust Gas Temperature (EGT) Sensor 3 Performance1012
DTC P242C Exhaust Gas Temperature (EGT) Sensor 3 Circuit Low Voltage1012
DTC P242D Exhaust Gas Temperature (EGT) Sensor 3 Circuit High Voltage1013
DTC U0002 CAN Bus Off1014
DTC U0100 Lost Communication With ECM1015
DTC U029D CAN communication error between DCU and Ft NOx sensor1016
DTC U029E CAN communication error between DCU and Rr NOx sensor1018
Data Reference Values1020
Two Pump Relief1020
J HYDRAULIC EQUIPMENT (PUMP, OPERATION SYSTEM VALVE)1023
Main Equipment Table1030
Hydraulic Device1030
Hydraulic Pump1030
LM Pump1030
Motor for Generator1030
Control-related1032
Control valve1032
Solenoid Valve (5 Stack)1032
Solenoid Valve (2 stack) for EV Control1032
Solenoid Valve (for Generator)1033
Solenoid Valve (Single) for Free Swing1033
Remote Control Valve for Left/Right Operations1033
Remote Control Valve for Travel Operation1033
Remote Control Valve for Option Operations1033
Remote Control Valve Characteristic Diagram1033
Operation Remote Control Valve Control Diagram1034
Travel Remote Control Valve Control Diagram1035
1-pedal Travel Remote Control Valve Control Diagram1035
Reducing Valve (6 Stack Proportional Valve)1035
Reducing Valve (3 stack) for Interference Prevention1036
Cushion Valve (heat circuit, with shuttle valve)1036
Basic Functions1037
Oil temperature gauge1037
Static Horsepower Control1038
Pressure Boost Control1039
Stroke Control1041
Boom Down Energy Save1043
Pump Horsepower Cut Control1044
Pump Horsepower Boost Control1046
Arm 1 Semi-parallel Control1047
Arm 2 Semi-parallel Control1048
Gate Lock1049
Breaker Mode1050
Crusher Mode1050
Quick coupler1051
GCHC (Grapple Close Holding Circuit)1052
Hydraulic Fluid Filter Clogging1054
Solenoid Sticking Prevention1055
Port Diagram1056
Hydraulic Pump1056
LM Pump1057
Motor for Generator1058
Control Valve1059
Relief Valve1059
5 Stack Solenoid Valve1062
2 Stack Solenoid Valve (Elevator Control, 2nd Option)1064
Solenoid Valve (for Generator)1065
Solenoid Valve (for Free Swing)1066
Remote Control Valves (upper, travel)1066
Remote Control Valves (left-right)1066
Remote Control Valve (Travel)1067
Remote Control Valve (Option and 2nd Option)1068
Cushion Valve1069
Direction Valve1070
6 Stack Proportional Valve1071
Reducing Valve (3 stack) for Interference Prevention1073
Relief Valve (electromagnetic proportional)1074
Manifold Under Cab1075
Manifold (accumulator section)1076
Manifold (hydraulic oil tank section)1077
Hydraulic Pump1078
Structure and Operation Explanation1078
Hydraulic Pump Internal Structure Diagram1079
Overall View1079
Drive Shaft Front Side1080
Drive Shaft on Rear Side1081
Parts Table1082
Regulator1083
Regulator Operation Explanation1083
Regulator Operation Explanation Diagram1085
Internal Configuration Diagram of Regulator1087
Development Diagram of Regulator1089
Component Table1090
Gear Pump1092
Gear Pump Internal Structure Diagram1092
Structure and Operation Explanation1093
Operation Outline of Electronically-Controlled Pump1094
LM Pump1097
Overall View1097
Structural Diagram1099
Motor for Generator1101
Overall View1101
Structural Diagram1102
Control Valve1104
Basic Configuration1104
Operation1104
Operation of Main Unit1104
Activation of Relief Valve1124
5 Stack Solenoid Valve Operation Explanation1129
External Shape Diagram and Components1129
operation explanation1129
2 Stack Solenoid Valve1130
Structure1130
Single Proportional Valve1131
Structure1131
Operation Explanation1132
Upper Pilot Valve (remote control valve)1133
Structure1133
Function1133
Operation1133
Structural Diagram1137
Travel Pilot Valve (remote control valve)1138
Operation1138
Pressure Reducing Valve Section1138
Damping Mechanism in Operation Section1139
Structural Diagram1142
1-pedal Travel Pilot Valve (remote control valve)1144
Operation1144
Structural Diagram1146
Cushion Valve 1147
structure1147
operation explanation1147
Direction Valve (3-direction) 1152
Structure1152
Operation Explanation1153
6 Stack Proportional Valve (Pilot)1155
structure1155
operation principle1156
Reducing Valve1157
Structure1157
Operation Explanation1158
Electromagnetic Relief Valve1160
Structure1160
Operation Explanation1161
Operation of Check Valve1161
Operation of Electromagnetic Relief Valve1162
Removal and Installation of Hydraulic Reservoir1164
Removal of Hydraulic Reservoir1164
Installation of Hydraulic Oil Tank1167
Removal and Installation of Hydraulic Pump1168
Removal of Hydraulic Pump1168
Installation of Hydraulic Pump1171
Removal and Installation of LM Pump1172
Removal of LM Pump1172
Installation of LM Pump1172
Removal and Installation of Generator Motor1173
Removal of Motor for Generator1173
Installation of Motor for Generator1174
Removal and Installation of Control Valve1175
Removal of Control Valve1175
Installation of Control Valve1179
Removal and Installation of Travel Remote Control Valve1180
Removal of Travel Remote Control Valve1180
Installation of Travel Remote Control Valve1181
Removal and Installation of Operation Remote Control Valve1184
Removal of Operation Remote Control Valve (left side)1184
Installation of Operation Remote Control Valve (left side)1186
Removal of Operation Remote Control Valve (right side)1188
Installation of Operation Remote Control Valve (right side)1190
Removal and Installation of Option Remote Control Valve1192
Removal of Option Remote Control Valve1192
Installation of Option Remote Control Valve1193
Installation and Removal of 5 Stack Solenoid Valve1195
Removal of 5 Stack Solenoid Valve1195
Installation of 5 Stack Solenoid Valve1196
Removal and Installation of Cushion Valve1197
Removal of Cushion Valve1197
Installation of Cushion Valve1198
Procedures for Assembly and Disassembly of Hydraulic Pump Main Unit1200
Tools1200
Disassembly Procedure1200
Assembly Procedure1202
Regulator Maintenance Standards1205
Regulator Adjustment1205
Appendix Table and Drawings1206
Regulator Assembly and Disassembly Procedures1210
Tools1210
Preparations for Disassembly1210
Disassembly Procedure1210
Assembly Procedure1212
Internal Configuration Diagram of Regulator1216
Development Diagram of Regulator1218
Component Table1219
Assembly and Disassembly of Control Valve1221
Disassembly1221
Caution for Disassembly1221
Disassembly Procedure1221
Removal of Long Cap and Pulling Out of Main Spool1221
Disassembly of Arm 1, 2 Parallel-Tandem Spool, Neutral Cut Spool, Arm Regeneration Release Spool Section1222
Disassembly of Load Check Valve Section1222
Disassembly of Antidrift Valve Section (Sub Component in Assembly is Expressed by (Min Number – Sub Number))1223
Disassembly of Relief Valve1223
Disassembly of Option Section1223
Disassembly of Add-On Section1223
Disassembly of Valve Housing Coalescence Bolt1224
Cleaning1224
Inspection1224
assembly1224
Caution for Assembly1224
Caution for Handling O-ring1224
Caution for Handling Spool1224
Method to Apply Adhesive Agent (Male and Female Thread Section of Components Requiring Bonding)1224
Assembly Procedure of Sub-Assembly1225
Assembly of Spool Assembly (Main Spool)1225
Assembly of Arm 1, 2 Parallel-Tandem Spool, Neutral Cut Spool, Arm Regeneration Release Spool Assembly1225
Assembly of Antidrift Valve Assembly1226
Assembly Procedure of Control Valve Main Unit1226
Assembly of Relief Valve1226
Assembly of Load Check Valve1226
Assembly of Antidrift Valve1227
Assembly of Option Section1227
Assembly of Arm 1 Parallel-Tandem Spool1227
Assembly of Arm 2 Parallel-Tandem Spool, Neutral Cut Spool, Arm Regeneration Release Spool1227
Assembly of Main Spool1227
Assembly of Add-On Section1228
Assembly of Other Plugs1228
Internal Structural Diagram1229
Part List1235
Relief Valve1236
Assembly and Disassembly Procedure of Main Relief Valve1236
Assembly and Disassembly Procedures of Overload Relief1237
Assembly and Disassembly Procedure of Low-Pressure Relief Valve1238
Assembly and Disassembly Procedure of Main Relief Valve for Add-On1238
Adjustment of Relief Valve1239
Installation1240
Operation1240
Malfunction and Countermeasure1240
Procedures for Assembly and Disassembly of Operation Remote Control Valve1242
Maintenance Procedures1242
Required Tools and Tightening Torque1242
Maintenance Standards1242
Disassembly Procedures1243
Assembly Procedures1245
Causes of Trouble and Countermeasures1249
Procedures for Assembly and Disassembly of Travel Remote Control Valve1253
Maintenance Procedures1253
Disassembly Procedures1254
Assembly Procedures1258
Causes of Trouble and Countermeasures1263
Assembly and Disassembly Procedures of Option Remote Control Valve1266
Maintenance Procedures1266
Disassembly Procedures1266
Assembly Procedures1268
Causes of Trouble and Countermeasures1270
Assembly and Disassembly of Cushion Valve1274
Disassembly Procedures1274
Reverse Operation Spool Section1274
Check Plunger Section with Throttle1274
Shuttle Valve Section1274
Assembly Procedures1275
Reverse Operation Spool Section1275
Check Plunger Section with Throttle1275
Shuttle Valve Section1275
Written Materials1276
Procedures for Assembly and Disassembly of 6 Stack Proportional Valve (Pilot)1278
Development Diagram1278
Assembly and disassembly procedures1279
Precautions1279
Replacement of Proportional Solenoid1279
Disassembly1279
Assembly1279
Replacement of Sleeve and Spool1280
Disassembly1280
Assembly1281
Replacement of Poppet (Check Valve for Normally Open)1282
Disassembly1282
assembly1283
Maintenance Standards1283
Troubleshooting1283
Pressure Measurement and Adjustment Procedures1285
Procedures for Pressure Measurement from the Monitor Display1285
Monitor and Switch Panel1285
Pressure Measurement Method1285
Operating Method1285
PROCEDURES FOR MEASURING HYDRAULIC OIL TEMPERATURE FROM THE MONITOR DISPLAY1285
Hydraulic Oil Temperature Measurement Method1285
Operating Method1286
Procedures for Pressure Measurement by Installing Pressure Gauge1287
Preparations1287
Items to Prepare1287
Pressure Measuring Ports1288
Control Valve1290
Location of Relief Valves1290
Pressure Measurement Preparations1291
Pressure Measurement1293
Main Pressure Measurement1293
A Attachment Pressure Measurement1294
Boom-down Pressure Measurement1295
D Option Line Pressure Measurement1295
Pilot Pressure Measurement1295
Pressure Gauge Installation1295
Negative Control Pressure Measurement1296
Pressure Gauge Installation1296
Pressure Adjustment1296
Main Pressure Adjustment1296
Pressure Measurement and Adjustment Preparations1296
Main Relief Pressure Adjustment1298
Overload Relief Pressure Adjustment1299
Adjustment of Swing Relief Pressure1300
Pilot Pressure Adjustment1301
Power Generation Line Pressure Measurement Procedure, 2nd Option Pressure Measurement Procedure1302
A Generator Motor Pressure Measurement1302
Elevator Circuit Pressure Adjustment1303
Preparations1303
Elevator Up Circuit Pressure Adjustment1303
Elevator Down Circuit Pressure Adjustment1303
Hydraulic Pump Flow Measurement Procedures1304
Preparations1304
Items to Prepare1304
Work Preparations1304
Flow Measurement1306
LM Pump Flow Measurement Procedure1308
Preparations1308
Items to Prepare1308
Work Preparations1309
Flow Measurement1310
LM Pump Flow Adjustment Procedure1311
Drain Volume Measurement Procedures1311
Drain Volume Measurement of Motor for Generator1311
Air Bleed Procedure1313
Hydraulic Pump1313
Generator Motor1313
Sampling Procedure1315
Sampling of Hydraulic Fluid1315
Hydraulic Equipment Layout1316
Overall View1317
Pump Chamber Hydraulic Equipment Layout1318
Swing Body Center Section Hydraulic Equipment Layout1320
Housing Left Side Hydraulic Equipment Layout1322
Hydraulic Equipment Layout of Elevator Section1324
Hydraulic Equipment Layout of Generator-related Section1325
Layout of Hydraulic Equipment in Cab1326
N CAB1327
Removal and Installation of Operator’s Seat1330
Removal of Operator’s Seat1330
Installation of Operator’s Seat1330
Removal and Installation of Cab Assembly1331
Removal of Cab Assembly1331
Installation of Cab Assembly1335
Removal and Installation of Wiper1336
Removal of Wiper1336
Installation of wiper1336
Removal and Installation of Cab Front Glass1337
Removal of Cab Front Glass1337
Installation of Cab Front Glass1338
Window Lock Adjustment Procedures1339
Window Lock (front side)1339
Window Lock (rear side)1339
Removal and Installation of Housing Guardrail1341
Removal of Housing Guardrail1341
Installation of Housing Guardrail1343
Tightening Torque1344
R ELECTRICAL PARTS1345
Basic Functions1349
Monitor Control1349
Monitor Display Dimming1349
Diagnostic Trouble Code Indicator1350
Clock1350
Basic Operation1351
Battery Save1351
Accessories1353
Working Light1353
LED Light1354
Room Lamp1354
Radio Mute1356
Wiper and Washer1357
Safety1359
Horn1359
Back/Side View Monitor1360
Precautions for Camera Installation1361
Interference prevention1362
Maintenance1364
Anti-theft1364
Manual Lock1364
Service Support Screen Lock1365
Customer-specific System Information Screen Lock1365
Maintenance Information Screen Lock1365
Option Line Setting Screen Lock1365
Setting1366
Clock Adjustment1366
Option Flow Pressure Setting1366
Screen Brightness Setting1369
Interference prevention Setting1369
Battery Disconnect Switch1373
Explanation of Controller1374
Service Support1377
Screen Operations1377
Screen Display List1377
Service Monitor Structure1378
CHECK Screen List1379
MACHINE STATUS1380
HYDRAULIC STATUS1387
ENGINE STATUS1394
FAULT HISTORY1399
WORK HISTORY1399
HYDRAULIC HISTORY1407
ENGINE HISTORY1420
DEVICE TEST1443
ECM/DCU Memory Clear1443
SCR RE-GEN1444
Urea Line Leak Test1445
CCV Operation Test1445
Dosing Test1446
Reverting Valve Operation Test1447
Common Rail Pressure Test1448
Idle Speed Test / Injector Test1449
EGR Valve Control Test1451
VG Turbo Control Test1452
Intake Throttle Control Test1453
CONTROL UNIT Screen List1454
MCM-MAIN1454
MCM-SUB1458
COMMU TERMINAL1459
SETUP Screen List1461
MACHINE SELECT1461
DIMENSIONS1466
PARAMETERS1469
ENGINE INFORMATION1473
ENGINE INFORMATION1474
Data Confirmation1474
Data Transfer (Copy)1474
QR (INJECTOR) CODE1475
Injector number1475
Screen Layout1476
Data Source Selection1476
Manual Input1476
CAMERA1478
PASSWORD1481
CALIBRATE Screen List1483
THROTTLE VOLUME1484
OPTLINE RELIEF1485
PUMP FLOW1487
ANGLE SENSOR CALIBRATION1489
RESET Screen List1495
Checking the Operation of Abnormal End1497
Connection Connector Pin Layout1498
Main Controller1498
Monitor1499
Sequence Circuit Diagram1500
Code List1500
Overall1502
Block diagram1505
Main Controller1505
DCU1506
ECM1507
Monitor1508
Air Conditioner1509
Gate Lock1510
Horn1510
Working Light1510
Option1511
Other1512
Electrical Symbol List1512
Electrical Equipment Layout Diagram1514
Main Unit Left-side Layout Diagram1515
Engine Section Layout Diagram1517
Main Unit Right Side Layout Diagram (pump chamber)1520
Main Unit Center Section Layout Diagram1521
Cab Layout Diagram 11522
Cab Layout Diagram 21524
Layout Around Operator Seat1527
Anti-interference Sensor1529
LM-related Section1530
Stand Alone Parts Diagram1531
Removal and Installation of Wiper Controller1553
Removal of Wiper Controller1553
Installation of wiper controller1553
Removal and Installation of Wiper Motor1554
Removal of Wiper Motor1554
Installation of wiper motor1555
Removal and Installation of ECM1556
Removal of ECM1556
Installation of ECM1556
Removal and Installation of Main Controller1557
Removal of Main Controller1557
Installation of Main Controller1557
Removal and Installation of DCU1558
Removal of DCU1558
Installation of DCU1558
Removal and Installation of Monitor1559
Removal of Monitor1559
Installation of Monitor1560
Removal and Installation of Rear View Camera 1561
Removal of Rear View Camera1561
Installation of Rear View Camera1561
Removal and Installation of Side Camera (right)1562
Removal of Side Camera (Right)1562
Installation of Side Camera (Right)1562
Removal and Installation of Side Camera (Left)1563
Removal of Side Camera (Left)1563
Installation of Side Camera (Left)1563
Removal and Installation of FVM Controller1564
Removal of FVM Controller1564
Installation of FVM Controller1564
How to Set FVM1565
Air Conditioner Overall Diagram1569
Frame1569
Cab1572
Equipment Layout Diagram1575
Circuit Diagram1577
Air Conditioner Circuit Diagram1577
Explanation of Functions1579
Explanation of Control1579
Air Mix Motor Actuator Control1580
Blow Mode Motor Actuator Control1580
Refresh/Recirculate Switch Motor Actuator Control1581
Blower Amp Control1582
Compressor Clutch Control1584
COOLMAX Control and HOTMAX Control1585
Abnormality Detection and Control after Abnormality Detected1585
Monitor Mode1589
Door Switch Control1591
Actuator Inspection1592
Air Mix Motor Actuator Inspection1592
Refresh/Recirculate Switch Motor Actuator Inspection1593
Mode Motor Actuator Inspection1594
Self-diagnosis Function with Panel Display1595
Abnormality Display and Self-check Procedures1595
Abnormality Display Position1595
Explanation of Abnormality Display1595
Motor Actuator Abnormality1595
Sensor Abnormality1596
Explanation of Monitor Mode1596
Monitor Mode Display Position1596
Monitor Mode Display Operating Method1597
Display Contents in Monitor Mode1598
Part Function and Good/Poor Judgment1599
Control Panel1599
Blower Amp1599
Relay1600
Air Mix Actuator1601
Refresh/Recirculate Actuator1602
Blow Mode Actuator1602
Evaporator Sensor1603
Dual Pressure Switch1603
Solar Radiation Sensor1604
Inside Air Sensor1604
Assembly and Disassembly of Unit1606
Removal of Blower Unit1606
Replacement of Blower Motor1606
Replacement of Blower Amp1606
Removal of Heater Core1607
Removal of Heat Case Right/Left1607
Replacement of Evaporator and Expansion Valve1607
Installation of Evaporator Sensor1608
Replacement of Motor Actuator1608
Removal and Installation of Compressor1609
Removal of Compressor1609
Installation of Compressor1609
Removal and Installation of Condenser1610
Removal of Condenser1610
Installation of Condenser1610
Removal and Installation of Receiver Dryer1611
Removal of Receiver Dryer1611
Installation of Receiver Dryer1611
Work Precautions1612
Work Procedures1612
Air Conditioner Refrigerant Filling is Divided into the “Vacuum Operation” and “Gas Filling Operation”1612
Operation Chart1613
Tools1613
Filling Procedures1615
Charging Hose Connection Position1615
Connecting Gauge Manifold1615
Vacuuming1616
Gas Filling Operation, High-pressure Side1617
Gas Filling Work, Low Pressure Side1617
V ATTACHMENTS1621
Main Equipment Table1624
Backhoe Attachment1624
Cylinder1624
Maintenance Standards1625
Attachments (380X4-MH)1625
1 Boom and Swing Frame Installation Section1625
2 Boom Cylinder and Swing Frame Installation Section1626
3 Boom and Boom Cylinder Installation Section1626
4 Boom and Arm Cylinder Installation Section1627
5 Boom and Arm Installation Section1627
6 Arm and Arm Cylinder Installation Section1628
Removal and Installation of Arm Cylinder1629
Removal of Arm Cylinder1629
Installation of Arm Cylinder1631
Removal and Installation of Boom Cylinder1633
Removal of Boom Cylinder1633
Installation of Boom Cylinder1635
Removal and Installation of Elevator Cylinder1638
Removal of Elevator Cylinder1638
Installation of Elevator Cylinder1642
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder1647
Specifications and Structure Diagram (including the assembly diagram and parts table)1647
Basic Functions1647
Function of Each Location1647
Cylinder Head Assembly (made by KYB)1647
Piston Assembly (made by KYB)1648
Pipe Assembly (made by KYB)1650
Handling Precautions1650
Precautions for Installing the Cylinder on the Machine Body1650
Usage Cautions1651
Maintenance and Inspection Cautions1651
Maintenance Inspection and Service1653
Trouble Diagnostics1654
Storage Standards1659
Storing Parts Individually (In principle, store indoors)1659
When Mounted on Vehicle Body1659
Recommended Anti-rust Oil1659
Assembly and Disassembly Procedures1660
Preparations ····· Prepare the Following before Starting Disassembly1660
General Work Precautions1660
Maintenance Standards1660
Inspection after Assembly1660
Required Tool1661
General Tool1661
Special Jig (made by KYB)1662
Special Jig Parts Number List (made by KYB)1662
Disassembly Procedures (made by KYB)1663
Assembly Procedures (made by KYB)1666
Test Operation1671
Usage Limits1672
Structural Diagram (made by KYB)1673
Boom Cylinder1673
Arm Cylinder1675
Elevator Cylinder1677
HBCV1679
structure1679
Function1679
operation explanation1679
Port Diagram1694
HBCV1694
Air Bleed Procedure1695
HBCV1695
Boom Cylinder HBCV1695
Arm Cylinder HBCV1696
Removal and Installation of HBCV1697
Removal and Installation of Arm HBCV1698
Removal of Arm HBCV1698
Installation of Arm HBCV1698
Removal and Installation of Boom HBCV1700
Removal of Boom HBCV1700
Installation of Boom HBCV1701
Removal and Installation of Arm1703
Removal of Arm1703
Installation of Arm1704
Removal and Installation of Boom1706
Removal of Boom1706
Installation of Boom1710
Z OTHER1715
Change from Type 61721
Overall Layout1721
Lower1721
Swing Unit1722
Engine1722
hydraulic-related1724
Hydraulic Control1725
Cab, Housing1726
Electrical Data1728
Electric Control1729
Attachments1729
Specifications1730
ENGINE1730
HYDRAULIC SYSTEM1730
HYDRAULIC CONTROLS1731
ELECTRICAL SYSTEM1731
OPERATOR ENVIRONMENT1732
UNDERCARRIAGE1733
MASS1733
DIMENSIONS1733
WORKING RANGES1734
SYSTEM FLUID CAPACITIES AND SPECIFICATIONS1734
Arm Dimensions1735
Main Unit Weight1736
Divided Weight (MH Specifications)1736
Stand Alone Part Weight (MH Specifications)1737
Shoe Weight (per Side)1737
Arm Weight1737
Bolt Size and Torque Table1738
Special Torque Setting1738
Overall View1743
380X4-MH1743
Long Arm (67 m (2198 ft))1743
WORK RANGE DIAGRAM1744
380X4-MH1744
Long Arm (67 m (2198 ft))1744
New Machine Performance Judgment Table1746
Table of Standards1746
Measurement Method1748
Engine speed1748
Pressure at Each Part1749
Pump Command Displacement1749
Cylinder Down Amount1749
Attachment Speed1749
Swing Speed1750
Swing (180°) Brake Angle1751
Travel Speed1751
Off Travel Amount1751
Travel Sprocket Speed1752
Shoe Tension Amount1752
Swing Ball Race Bearing Movement Amount and Bucket Tip Movement Amount1753
FLUIDS AND LUBRICANTS1755
HYDRAULIC FLUID1755
Engine Oil1755
Fuel1755
Conditions applicable to diesel fuel1755
Recommended conditions applicable to diesel fuels1755
Main-Unit-related Diagnostic Trouble Code List1756
Main Unit-side Trouble1759
Diagnostic Trouble Code: 7000 Pressure Sensor P1 Abnormality1759
Diagnostic Trouble Code: 7001 Pressure Sensor P2 Abnormality1760
Diagnostic Trouble Code: 7002 Pressure Sensor N1 Abnormality1762
Diagnostic Trouble Code: 7003 Pressure Sensor N2 Abnormality1763
Diagnostic Trouble Code: 7004 Pressure Sensor Boom Cylinder Bottom Abnormality1765
Diagnostic Trouble Code: 7006 Pressure Sensor Boom Cylinder Rod Abnormality1766
Diagnostic Trouble Code: 7007 Pressure Sensor Arm Cylinder Rod Abnormality1768
Diagnostic Trouble Code: 7021 Pressure Sensor Swing Pilot Abnormality1769
Diagnostic Trouble Code: 7023 Pressure Sensor Arm-In Pilot Abnormality1771
Diagnostic Trouble Code: 7040 Level Sensor Fuel Abnormality1772
Diagnostic Trouble Code: 7041 Temperature Sensor Hydraulic Fluid Abnormality1773
Diagnostic Trouble Code: 7060 Boom Angle Sensor Signal Abnormality1775
Diagnostic Trouble Code: 7061 Arm Angle Sensor Signal Abnormality1776
Diagnostic Trouble Code: 7062 Elevator Angle Sensor Signal Abnormality1778
Diagnostic Trouble Code: 7065 Pressure Sensor Boom-Up Pilot Abnormality1779
Diagnostic Trouble Code: 7067 Pressure Sensor Bucket-Close Pilot Abnormality1781
Diagnostic Trouble Code: 7068 Pressure Sensor Boom-Down Pilot Abnormality1782
Diagnostic Trouble Code: 7069 Pressure Sensor Arm-Out Pilot Abnormality1784
Diagnostic Trouble Code: 7070 Pressure Sensor Bucket-Open Pilot Abnormality1785
Diagnostic Trouble Code: 7071 Pressure Sensor Travel Right Pilot Abnormality1787
Diagnostic Trouble Code: 7072 Pressure Sensor Travel Left Pilot Abnormality1789
Diagnostic Trouble Code: 7073 Pressure Sensor Travel 1 Pedal Abnormality1791
Diagnostic Trouble Code: 7074 Pressure Sensor 1st Option Pilot (Common/Front Pedal) Abnormality1792
Diagnostic Trouble Code: 7075 Pressure Sensor Arm Cylinder Bottom Abnormality1794
Diagnostic Trouble Code: 7078 Pressure Sensor 1st Option Pilot (Rear Pedal) Abnormality1796
Diagnostic Trouble Code: 7083 Bucket Cylinder Angle Sensor Deviation1798
Diagnostic Trouble Code: 7200 Swing Brake Solenoid Abnormality1798
Diagnostic Trouble Code: 7201 Travel 2nd-Speed Switchover Solenoid Abnormality1799
Diagnostic Trouble Code: 7202 Pressure Boost Solenoid Abnormality1800
Diagnostic Trouble Code: 7203 Travel Alarm Buzzer Abnormality1801
Diagnostic Trouble Code: 7206 Option Return Line Switchover Solenoid Abnormality1802
Diagnostic Trouble Code: 7207 Free Swing Solenoid Abnormality1804
Diagnostic Trouble Code: 7210 Liftcrane Buzzer Signal Abnormality1805
Diagnostic Trouble Code: 7211 Revolving Light, Bucket Lock Relay Signal Abnormality1806
Diagnostic Trouble Code: 7212 Gate Lock Solenoid Abnormality1807
Diagnostic Trouble Code: 7213 Quick Coupler Buzzer Abnormality1808
Diagnostic Trouble Code: 7214 Quick Coupler Solenoid Abnormality1810
Diagnostic Trouble Code: 7243 Boom Proportional Valve Signal Abnormality (interference prevention)1811
Diagnostic Trouble Code: 7244 Arm Proportional Valve Signal Abnormality (interference prevention)1813
Diagnostic Trouble Code: 7245 Offset Proportional Valve Signal Abnormality1814
Diagnostic Trouble Code: 7247 Boom 2-Down Pilot Proportional Valve Abnormality1815
Diagnostic Trouble Code: 7249 Bucket-Close Pilot Proportional Valve Abnormality1817
Diagnostic Trouble Code: 7250 Option Relief Pressure Proportional Valve Abnormality1818
Diagnostic Trouble Code: 7265 Arm 1 Semi-Parallel Proportional Valve Abnormality1819
Diagnostic Trouble Code: 7266 Arm 2 Semi-Parallel Proportional Valve Abnormality1820
Diagnostic Trouble Code: 7267 Arm 1 Regeneration Release Proportional Valve Abnormality1821
Diagnostic Trouble Code: 7270 Tilting 1 Proportional Valve Abnormality1823
Diagnostic Trouble Code: 7271 Tilting 2 Proportional Valve Abnormality1824
Diagnostic Trouble Code: 7273 Straight Travel Proportional Valve Abnormality1825
Diagnostic Trouble Code: 7400 Coolant Temperature Overheating 11826
Diagnostic Trouble Code: 7401 Coolant Temperature Overheating 21827
Diagnostic Trouble Code: 7404 Oil Temperature Overheating1828
Diagnostic Trouble Code: 7405 Boost Temperature Overheating 11829
Diagnostic Trouble Code: 7406 Boost Temperature Overheating 21830
Diagnostic Trouble Code: 7420 Alternator Power Generation Failure1831
Diagnostic Trouble Code: 7421 Coolant Level Decrease1832
Diagnostic Trouble Code: 7422 Engine Oil Pressure Decrease1833
Diagnostic Trouble Code: 7423 Air Cleaner Clogging1834
Diagnostic Trouble Code: 7424 Return Filter Clogging1835
Diagnostic Trouble Code: 7426 Fuel Filter Clogging 11836
Diagnostic Trouble Code: 7427 Fuel Filter Clogging 21837
Diagnostic Trouble Code: 7428 Inducement (Remaining Urea Level Low) – Warning1838
Diagnostic Trouble Code: 7429 Inducement (Remaining Urea Level Low) – Early1839
Diagnostic Trouble Code: 7430 Inducement (Remaining Urea Level Low) – Final1839
Diagnostic Trouble Code: 7602 ECM Communication Abnormality1840
Diagnostic Trouble Code: 7603 Computer S Communication Abnormality1841
Diagnostic Trouble Code: 7605 ECM Not-Matched1842
Diagnostic Trouble Code: 7606 EEPROM Abnormality1842
Diagnostic Trouble Code: 7608 Camera Abnormality1843
Diagnostic Trouble Code: 7612 Air Conditioner Communication Abnormality1844
Diagnostic Trouble Code: 7613 Monitor Communication (CAN) Abnormality1846
Diagnostic Trouble Code: 7614 Air Conditioner Panel Mismatch1847
Diagnostic Trouble Code: 7615 Sub-controller 1 Communication Abnormality1847
Diagnostic Trouble Code: 7618 DCU Communication Abnormality1849
Diagnostic Trouble Code: 7800 Signal Line Disconnection or Short Circuit1850
Diagnostic Trouble Code: 7801 Output Voltage Drop1851
Diagnostic Trouble Code: 7802 Magnet Overheat1853
Diagnostic Trouble Code: 7803 Generator Voltage Abnormality1854
Diagnostic Trouble Code: 7804 Magnet Overcurrent1856
Diagnostic Trouble Code: 7805 Control Panel Overheat1857
Diagnostic Trouble Code: 7806 Battery Voltage Drop1858
Diagnostic Trouble Code: 7807 Battery Overvoltage1858
Diagnostic Trouble Code: 7810 Short1859
Diagnostic Trouble Code: 7811 Control Panel Overheat1859
Diagnostic Trouble Code: 7812 Disconnection1860
Diagnostic Trouble Code: 7813 CPU Abnormality1861
Diagnostic Trouble Code: 7814 Condenser Overvoltage1861
List of special tools1863
NUMERICAL VALUE CONVERSION TABLE1863
Unit conversion rate1863
Length1863
Area1865
Volume1866
Weight1868
Pressure1869
Torque1870
Temperature1871
A1874
Travel Motor Special Tool1874
380X4-MH1874
Take-up Roller Special Tool1882
380X4-MH1882
Upper Roller Special Tool1883
380X4-MH1883
Lower Roller Special Tool1884
380X4-MH1884
Grease Cylinder Special Tool1884
380X4-MH1884
Center Joint Special Tool1885
380X4-MH1885
C1886
Swing Motor Special Tool1886
380X4-MH1886
H1888
Engine Oil Filter Special Tool1888
380X4-MH1888
Fuel Filter Special Tool1888
380X4-MH1888
Injector Special Tool1888
380X4-MH1888
Circuit Test Special Tool1889
380X4-MH1889
Valve Guide Special Tool1889
380X4-MH1889
Cylinder Head Special Tool1889
380X4-MH1889
Head Bolt Special Tool1892
380X4-MH1892
Crankshaft Special Tool1892
380X4-MH1892
Camshaft Special Tool1895
380X4-MH1895
Valve Spring Special Tool1895
380X4-MH1895
J1896
Remote Control Valve Special Tool1896
380X4-MH1896
R1897
Gas Filling Special Tool1897
380X4-MH1897
V1898
Attachment Special Tool (for Cylinder Assembly)1898
Special Jigs Part Number List1898
Attachment Special Tool (Other)1899
380X4-MH1899
Paint Colors1900
Abbreviation1902
SPS Maintenance Manual1906
Warnings for Preventing Accidents1906
Cautions for Safety1906
Magnetic Device1908
Electrical Schematic Diagrams (Comprehensive Wiring Diagram)1910
Generator1910
Control Panel1912
Operation Functions1916
Inspection1919
Troubleshooting1922
Investigation of Causes of Load Side Abnormality1926
Investigation of Causes of Generator Output Voltage Abnormality1927
Determining IGBT Module Abnormality1927
Basic Configurations1929
Troubleshooting1931
Simplified Table1931
Diagnostic Trouble Code: 78001940
Diagnostic Trouble Code: 78031942
Diagnostic Trouble Code: 7810 (1)1944
Diagnostic Trouble Code: 7810 (2)1946
Diagnostic Trouble Code: 7805/78111948
Diagnostic Trouble Code: 78121951
Trouble (Cannot Lift)1952
Magnet Wear Repair1953
Procedures for Removal and Installation of Components in Control Panel1956
Removal and Installation of Control Panel Door1956
Removal of Control Panel Door1956
Installation of Control Panel Door1956
Removal and Installation of Control Board1956
Removal of Control Board1956
Installation of Control Board1957
Control Board Terminal Number List1958
Removal and Installation of IGBT1959
Removal of IGBT1959
Installation of IGBT1960
Correspondence Table between Connector Cables and Terminals on IGBT1961
Removal and Installation of Fans1962
Removal of Fans1962
Installation of Fans1965
Construction machinery mounted magnet adsorption face repair1968
General information1968
General1968
Fundamental notes in repair work1968
Investigation before repair work1968
Preparation1969
Tool1969
Materials1970
Subsidiary materials1970
Repairing procedure1971
Check1975
The check after repair work1975
S.M 2/1/25
