Daewoo Doosan WHEEL LOADER DL250-5DL250TC-5 SHOP MANUAL 950106-01253E – PDF DOWNLOAD
DESCRIPTION:
Daewoo Doosan WHEEL LOADER DL250-5DL250TC-5 SHOP MANUAL 950106-01253E – PDF DOWNLOAD
GENERAL
Safe Operation is Operator’s Responsibility Only trained and authorized personnel should operate and maintain the machine. Follow all safety rules, regulations and instructions when operating or performing maintenance on machine.
• Do not operate machine if you are under the influence of drugs or alcohol. An operator who is taking prescription drugs must get medical advice to determine if he or she can safely operate the machine.
• When working with other personnel on a work site, be sure that all personnel know the nature of work and understand all hand signals that are to be used.
• Be sure that all guards and shields are installed in their proper location. Have guards and shields repaired or replaced immediately if damaged.
• Be sure that you understand the use and maintenance of all safety features such as pilot cutoff switch and seat belt. Use them always.
• Never remove, modify or disable any safety features. Always keep them in good operating condition.
• Always check for and know the location of underground and overhead utility lines before working.
• Failure to use and maintain safety features according to instructions in this manual, Safety Manual and Shop Manual can result in death or serious injury.
Know Your Machine
Know how to operate your machine. Know the purpose of all controls, gauges, signals, indicators and monitor displays. Know the rated load capacity, speed range, braking and steering characteristics, turning radius and operating clearances. Keep in mind that rain, snow, ice, loose gravel, soft ground, slopes, etc., can change operating capabilities of your machine.
Proper Work Tools and Attachments
- Only use work tools and attachments that are recommended by DOOSAN for use on DOOSAN machines. When installing and using optional attachments, read instruction manual for attachment, and general information related to attachments in this manual. Because DOOSAN cannot anticipate, identify or test all attachments that owners may want to install on their machines, contact DOOSAN for written authorization and approval of attachments, and their compatibility with optional kits
- Attachments and attachment control systems that are compatible with the machine are required for safe and reliable machine operation.
- Do not exceed maximum operating weight (machine weight plus attachment) that is listed on ROPS certification plate. Make sure that all guards and shields are in place on machine and on work tool. Depending on type or combination of work equipment, there is a potential that work equipment could interfere with the cabin or other parts of machine.
- Before using unfamiliar work equipment, check if there is any potential for interference, and operate with caution. While you are performing any maintenance, testing, or adjustments to attachments, stay clear of the following areas: cutting edges, pinch points, and crushing surfaces.
- Never use attachment as a work platform or manlift. Contact your DOOSAN distributor about auxiliary hydraulic kits for attachments installation. If you are in doubt about the compatibility of a particular attachment with the machine, consult your DOOSAN distributor
Pressurized Fluids
- Pressurized air or fluids can cause debris and/or fluids to be blown out. This could result in death or serious injury. Immediately after operation is stopped, coolant, engine oil, and hydraulic oil are at their highest temperatures and the radiator and hydraulic tank are still under pressure. Always wait for temperature to cool down. Follow specified procedures when attempting to remove caps, drain oil or coolant, or replacing filters.
- Always wait for temperature to cool down, and follow specified procedures when performing these operations. Failure to do so can result in death or serious injury. When pressurized air and/or pressurized water is used for cleaning, wear protective clothing, protective shoes, and eye protection.
- Eye protection includes goggles or a protective face shield. Pressure can be trapped in a hydraulic system and must be relieved before maintenance is started. Releasing trapped pressure can cause sudden machine movement or attachment movement. Use caution if you disconnect hydraulic lines or fittings. High-pressure oil that is released can cause a hose to whip or oil to spray. Fluid penetration can result in death or serious injury.
- If fluid enters skin or eyes, get immediate medical attention from a physician familiar with this injury. Obey all local laws and regulations for disposal of liquids. To prevent hot coolant from spraying out, stop engine and wait for coolant to cool. Using gloves, slowly loosen cap to relieve pressure.
TABLE OF CONTENTS:
Daewoo Doosan WHEEL LOADER DL250-5DL250TC-5 SHOP MANUAL 950106-01253E – PDF DOWNLOAD
DL250-5/DL250TC-5............................................................................................. 0 NOTICE.................................................................................................... 7 Table of Contents......................................................................................... 9 Safety.................................................................................................... 11 Wheel Loader Safety................................................................................... 13 Safety Instructions............................................................................... 17 Safety Messages................................................................................... 17 General........................................................................................... 19 Safe Operation is Operator's Responsibility................................................... 19 Know Your Machine............................................................................. 19 Proper Work Tools and Attachments............................................................. 19 Pressurized Fluids............................................................................ 20 Flying or Falling Objects..................................................................... 21 Personal Protective Equipment (PPE)........................................................... 21 Correction of Machine Problems................................................................ 22 Crushing and Cutting.......................................................................... 22 Hot Coolant and Oils - Burn Prevention........................................................ 23 Fire and Explosion Prevention................................................................. 23 Fire Extinguisher and First-Aid Kit (Emergency Medical Kit)................................... 27 Electrical System and Electrical Shock........................................................ 27 Roll-over Protective Structure (ROPS)/ Falling Object Protective Structure (FOPS)............. 28 Operation......................................................................................... 30 Before Engine Starting........................................................................ 30 Work Site..................................................................................... 30 Check Tire Pressure and Condition............................................................. 31 Mounting/Dismounting.......................................................................... 31 Cleaning...................................................................................... 32 Operator Station.............................................................................. 32 Seat Belt..................................................................................... 33 Visibility Information........................................................................ 34 Boost Starting or Charging Engine Batteries................................................... 35 Starting Engine............................................................................... 36 Traveling..................................................................................... 36 Lifting and Digging........................................................................... 38 Digging Beneath Overhangs..................................................................... 38 Digging Beneath Wheel Loader.................................................................. 38 Operation on Slopes........................................................................... 39 Attachment.................................................................................... 40 Equipment Lowering with Engine Stopped........................................................ 40 Preventing Risk of Injuries or Death From Boom and Bucket..................................... 40 Engine Stop................................................................................... 42 Parking Machine............................................................................... 42 Maintenance....................................................................................... 43 Cleaning...................................................................................... 46 Proper Tools and Clothing..................................................................... 46 Disassembling Precautions..................................................................... 46 Use of Lighting............................................................................... 47 Fire and Explosion Prevention................................................................. 47 Burn Prevention............................................................................... 48 Rubber That Contains Fluorides................................................................ 49 Rubber and Plastics........................................................................... 50 Welding Repairs............................................................................... 51 Working on Machine............................................................................ 52 Lock Inspection Covers........................................................................ 53 Accumulator................................................................................... 53 Compressed Air................................................................................ 53 Supports and Blocking for Work Equipment...................................................... 54 High-pressure Lines, Tubes and Hoses.......................................................... 54 Battery....................................................................................... 55 Preservation/Storing Machine.................................................................. 56 Transportation.................................................................................... 58 Obey State and Local Over-the-Road Laws and Regulations....................................... 58 Loading and Unloading......................................................................... 58 Transporting Machine.......................................................................... 59 Environment and Circumstances..................................................................... 60 Work Site Areas Requiring Extra Caution....................................................... 60 High-voltage Cables........................................................................... 62 Underground Operation......................................................................... 62 Working in Water.............................................................................. 63 Working in Contaminated Environment........................................................... 63 Operation in Extreme Conditions............................................................... 64 Exhaust Ventilation........................................................................... 68 Asbestos Information.......................................................................... 68 Silica Dust Information....................................................................... 69 Disposal of Hazardous Materials............................................................... 69 Sound......................................................................................... 69 Vibration Information......................................................................... 70 Specifications............................................................................................ 73 Specification......................................................................................... 75 Safety Instructions............................................................................... 79 General........................................................................................... 79 Component Locations............................................................................... 80 Working Range and Dimensions...................................................................... 84 Working Capacities................................................................................ 88 Bucket Capacity............................................................................... 88 Stability..................................................................................... 88 General Specifications............................................................................ 90 Performance Tests................................................................................. 92 Purpose of Performance Tests.................................................................. 92 Kinds of Tests................................................................................ 92 Performance Standards......................................................................... 92 Precautions for Evaluation of Test Data....................................................... 92 Definition of "Performance Standard".......................................................... 92 Preparation for Performance Tests................................................................. 93 The Machine................................................................................... 93 Test Area..................................................................................... 93 Precautions................................................................................... 93 Make Precise Measurement...................................................................... 93 Operational Performance Standard Table............................................................ 94 Operational Performance Test...................................................................... 98 Engine Speed.................................................................................. 98 Front Speed................................................................................... 100 Natural Subsidence of Cylinder................................................................ 101 Travel Speed - Acceleration and Deceleration.................................................. 102 Steering Time................................................................................. 103 Pressure Set.................................................................................. 104 Approximate Weight of Workload Materials.......................................................... 107 Material Weight............................................................................... 107 General Maintenance....................................................................................... 109 General Maintenance Instructions...................................................................... 111 Safety Instructions............................................................................... 115 Welding Precautions and Instructions.............................................................. 116 Hydraulic System - General Precautions............................................................ 117 Maintenance Service and Repair Procedure.......................................................... 119 General Precautions........................................................................... 119 Hydraulic System Cleanliness and Oil Leaks........................................................ 120 Maintenance Precautions for Hydraulic System Service.......................................... 120 Oil Leakage Precautions....................................................................... 121 Cleaning and Inspection........................................................................... 122 General Instructions.......................................................................... 122 Bearing Inspection............................................................................ 123 Standard Torques...................................................................................... 131 Safety Instructions............................................................................... 135 Torque Values for Standard Metric Fasteners....................................................... 136 Torque Values for Standard U.S. Fasteners......................................................... 137 Type 8 Phosphate Coated Hardware.................................................................. 139 Torque Values for Hose Clamps..................................................................... 140 ORFS Swivel Nut Recommended Torque................................................................ 140 Torque Values for Split Flanges................................................................... 141 Torque Wrench Extension Tools..................................................................... 142 Torque Multiplication......................................................................... 142 Other Uses for Torque Wrench Extension Tools.................................................. 143 Tightening Torque Specifications (Metric)..................................................... 144 Engine.................................................................................................... 147 Engine................................................................................................ 149 Safety Instructions............................................................................... 153 Overview.......................................................................................... 154 General Information............................................................................... 155 General Description........................................................................... 155 Engine Maintenance............................................................................ 159 Inspection and Repair of the Engine........................................................... 162 Engine Identification............................................................................. 164 Engine Data Plate............................................................................. 164 Engine Specification.............................................................................. 166 Engine Performance Curves......................................................................... 167 Special Tools..................................................................................... 168 Tightening Torques................................................................................ 172 Major Parts Tightening Torque................................................................. 172 Tightening Torque for General Bolts........................................................... 174 Tightening Torque of Plug Screw............................................................... 175 Hollow Screw (4-Hole) Tightening Torque....................................................... 175 Engine Disassembly................................................................................ 176 Engine Disassembly............................................................................ 176 Engine Assembly................................................................................... 191 Engine Assembly............................................................................... 191 Cylinder.......................................................................................... 214 General Information........................................................................... 214 Cylinder Head................................................................................. 214 Valve Mechanism............................................................................... 220 Actuating System.................................................................................. 232 Camshaft...................................................................................... 232 Timing Gear................................................................................... 245 Lubrication system................................................................................ 246 General Information........................................................................... 246 Oil Pan....................................................................................... 250 Oil Pump...................................................................................... 252 Oil Filter.................................................................................... 254 Exhaust System.................................................................................... 257 Turbocharger.................................................................................. 257 EGR (Exhaust Gas Recirculation) System........................................................ 269 DNOx System................................................................................... 276 Cooling System.................................................................................... 287 General information........................................................................... 287 Thermostat.................................................................................... 288 Fuel System....................................................................................... 292 General Information........................................................................... 292 Fuel High-pressure System Components.......................................................... 293 Injector...................................................................................... 294 Common Rail................................................................................... 298 Fuel Injection Pump........................................................................... 302 Electrical System................................................................................. 306 Electrical Parts.............................................................................. 306 Switches and Sensors.......................................................................... 308 ECU (Electronic Control Unit)................................................................. 312 Starter....................................................................................... 314 Exhaust Gas Reduction......................................................................... 316 Circuit Diagram............................................................................... 320 ECU Circuit....................................................................................... 325 Drivetrain................................................................................................ 327 Transmission.......................................................................................... 329 Safety Instructions............................................................................... 333 General........................................................................................... 333 Specification................................................................................. 334 Overview...................................................................................... 335 Section View.................................................................................. 338 Hydraulic Circuit (4-speed Transmission)...................................................... 340 Electrohydraulic Control with Proportional Valves............................................. 344 Controller.................................................................................... 345 Electric Control System....................................................................... 346 Speed Sensor.................................................................................. 349 Measuring Points and Connections.................................................................. 352 Transmission Electric Components.................................................................. 354 Engine Pickup Sensor.......................................................................... 357 Central Gear Pickup Sensor.................................................................... 357 Turbine Pickup Sensor......................................................................... 357 Output Speed Sensor........................................................................... 357 Shift Lever Switch (DW-3)..................................................................... 358 Transmission Shift Switch..................................................................... 361 T/M Cutoff Sensor............................................................................. 361 LIS Solenoid Valve............................................................................ 361 Transmission Electrical Circuits.................................................................. 362 Transmission Controller Circuit............................................................... 362 Transmission Control Unit Terminal............................................................ 363 Downshift..................................................................................... 371 Transmission Cutoff Switch.................................................................... 378 Torque Limits for Screws.......................................................................... 379 Special Tools..................................................................................... 380 List of Special Tools for Disassembly and Reassembly.......................................... 380 Transmission Oil.................................................................................. 386 Oil Grade of Transmission..................................................................... 386 Disassembly....................................................................................... 387 Electrohydraulic Control and Transmission Filter (Replaceable Filter)......................... 387 Inductive Sensor, Hall Sensor, Breather, Oil Filler and Oil Drain Plug........................ 392 Engine Connection, Oil Pressure Pump, Converter Back-pressure Valve and Temperature Sensor.... 393 Outputs and Closure Parts Pump Shaft (PTO-Shaft).............................................. 397 Clutches KV/KR/K1/K2/K3/K4 Input and Output Shaft............................................. 404 Reassembly........................................................................................ 428 Clutches KV/KR/K1/K2/K3/K4 Input and Output Shaft............................................. 428 Outputs and Closure Parts Pump Shaft (PTO-shaft).............................................. 474 Engine Connection, Oil Pressure Pump, Converter Back-pressure Valve and Temperature Sensor.... 477 Emergency Steering Pump....................................................................... 481 Inductive Sensor, Hall Sensor, Breather, Oil Filler and Oil Drain Plug........................ 482 Electrohydraulic Control with Proportional Valves............................................. 483 Failure Code...................................................................................... 491 Front Axle............................................................................................ 517 Safety Instructions............................................................................... 521 General........................................................................................... 521 Specification................................................................................. 521 Overview...................................................................................... 522 Parts List.................................................................................... 523 Lubrication and Maintenance Instructions.......................................................... 525 Oil Change.................................................................................... 525 Carry Out Wear Measurement on the Multidisk Brake............................................. 527 Tightening Torques for Screws................................................................. 528 Differential System............................................................................... 529 Theory of Differential Device................................................................. 529 Structure of Differential Device.............................................................. 530 LSD............................................................................................... 531 Overview LSD (Limited Slip Differential)...................................................... 531 LSD (Limited Slip Differential)............................................................... 532 Axle Air Breathing................................................................................ 533 Special Tools..................................................................................... 534 List of Special Tools for Disassembly and Reassembly.......................................... 534 Axle Oils......................................................................................... 541 Oil Grade ZF-Powerfluid....................................................................... 541 Removal........................................................................................... 542 Disassembly....................................................................................... 546 Output and Brake.............................................................................. 546 Axle Housing.................................................................................. 552 Input......................................................................................... 553 Differentials................................................................................. 556 Reassembly........................................................................................ 561 Differentials................................................................................. 561 Input......................................................................................... 569 Axle Housing.................................................................................. 580 Output and Brake.............................................................................. 581 Rear Axle............................................................................................. 593 Safety Instructions............................................................................... 597 General........................................................................................... 597 Specification................................................................................. 597 Overview...................................................................................... 598 Parts List.................................................................................... 599 Lubrication and Maintenance Instructions.......................................................... 601 Oil Change.................................................................................... 601 Carry Out Wear Measurement on the Multidisk Brake............................................. 603 Tightening Torques for Screws................................................................. 604 Differential System............................................................................... 605 Theory of Differential Device................................................................. 605 Structure of Differential Device.............................................................. 606 Axle Air Breathing................................................................................ 607 Special Tools..................................................................................... 608 List of Special Tools for Disassembly and Reassembly.......................................... 608 Axle Oils......................................................................................... 615 Oil Grade ZF-Powerfluid....................................................................... 615 Removal........................................................................................... 616 Installation...................................................................................... 621 Completing Work................................................................................... 621 Disassembly....................................................................................... 622 Output and Brake.............................................................................. 622 Axle Housing.................................................................................. 627 Input......................................................................................... 629 Differentials................................................................................. 631 Reassembly........................................................................................ 634 Differentials................................................................................. 634 Input......................................................................................... 641 Axle Housing.................................................................................. 649 Output and Brake.............................................................................. 651 Driveshaft............................................................................................ 663 Safety Instructions............................................................................... 667 General........................................................................................... 668 Overview...................................................................................... 668 Specification................................................................................. 668 Removal (Front Driveshaft)........................................................................ 670 Removal (Center Driveshaft)....................................................................... 673 Removal (Rear Driveshaft)......................................................................... 676 Installation (Rear DriveShaft).................................................................... 678 Steering.................................................................................................. 679 Power Steering System................................................................................. 681 Safety Instructions............................................................................... 685 General Description............................................................................... 685 Overview...................................................................................... 686 Hydraulic Circuit............................................................................. 687 Theory of Operation........................................................................... 688 Steering Unit......................................................................................... 691 Safety Instructions............................................................................... 695 General........................................................................................... 695 General Description........................................................................... 695 Specifications................................................................................ 697 Overview...................................................................................... 698 Theory of Operation........................................................................... 699 Gerotor Operation............................................................................. 700 Relief Valve.................................................................................. 700 Priority Valve........................................................................................ 701 Safety Instructions............................................................................... 705 General........................................................................................... 705 General Description........................................................................... 705 Tool List......................................................................................... 706 Removal........................................................................................... 707 Installation...................................................................................... 712 Completing Work................................................................................... 712 Disassembly....................................................................................... 713 Reassembly........................................................................................ 715 Brake..................................................................................................... 717 Service Brake......................................................................................... 719 Safety Instructions............................................................................... 723 General Description............................................................................... 724 Service Brake System.............................................................................. 725 Brake & Pilot Supply Valve............................................................................ 727 Safety Instructions............................................................................... 731 General Description............................................................................... 731 Overview...................................................................................... 732 Parts List.................................................................................... 734 Removal........................................................................................... 735 Charging Block........................................................................................ 741 Safety Instructions............................................................................... 745 General Description............................................................................... 746 Parts List.................................................................................... 746 Parking Brake......................................................................................... 749 Safety Instructions............................................................................... 753 General........................................................................................... 753 Specification................................................................................. 753 Overview...................................................................................... 753 Parts List.................................................................................... 754 Theory of Operation........................................................................... 755 Installing and Setting Instructions............................................................... 757 Installing the Brake.......................................................................... 757 Clearance Adjusting........................................................................... 758 Adjusting Instructions........................................................................ 759 Emergency Release of the Parking Brake............................................................ 760 Maintenance and Repair Work....................................................................... 761 Maintenance and Replacement of the Lining Pads................................................ 761 Replacing the Seals........................................................................... 764 Brake Pedal Valve..................................................................................... 767 Safety Instructions............................................................................... 771 General Description............................................................................... 771 Specification................................................................................. 771 Theory of Operation........................................................................... 773 Accumulator........................................................................................... 775 Safety Instructions............................................................................... 779 General........................................................................................... 0 Layout........................................................................................ 782 Specifications................................................................................ 782 Cooling System............................................................................................ 783 Cooling System........................................................................................ 785 Safety Instructions............................................................................... 789 General........................................................................................... 789 General Description........................................................................... 789 Function...................................................................................... 790 Hydraulic Circuit............................................................................. 791 Fan Motor Pressure and Fan Speed.............................................................. 792 Checking Maximum Fan Speed................................................................ 793 Fan and Brake Pump.................................................................................... 795 Safety Instructions............................................................................... 799 General........................................................................................... 799 Specification................................................................................. 799 Section View.................................................................................. 800 EPPR Valve.................................................................................... 800 Overview...................................................................................... 801 Port and Hydraulic Circuit................................................................ 801 Parts List.................................................................................... 802 Theory of Operation........................................................................... 804 Circuit................................................................................... 804 Control Section........................................................................... 805 Circuit Diagram Related to Fan Drive...................................................... 805 Pump EPPR Valve........................................................................... 806 Removal........................................................................................... 808 Installation...................................................................................... 813 Completing Work................................................................................... 813 Maintenance Guidelines............................................................................ 814 Sealing Control Valve......................................................................... 817 Tools......................................................................................... 817 Loctite Types............................................................................. 817 Disassembly....................................................................................... 818 Disassembly of Rotary Group................................................................... 819 Disassembly of Shaft/Bearings................................................................. 821 Reassembly........................................................................................ 825 Fan Motor............................................................................................. 831 Safety Instructions............................................................................... 835 General........................................................................................... 836 Specifications................................................................................ 836 Overview...................................................................................... 836 Port and Hydraulic Circuit................................................................ 836 Fan Control Valve..................................................................................... 837 Safety Instructions............................................................................... 841 General........................................................................................... 841 Specifications................................................................................ 841 Port and Hydraulic Circuit................................................................ 842 Radiator Assembly..................................................................................... 843 Safety Instructions............................................................................... 847 General........................................................................................... 847 Overview...................................................................................... 847 Structure..................................................................................... 848 CAC (Charge Air Cooler)........................................................................... 850 Overview...................................................................................... 850 Radiator.......................................................................................... 853 Overview...................................................................................... 853 Theory of Operation........................................................................... 853 Radiator Cap.................................................................................. 854 Replacing - Radiator Cap...................................................................... 855 Replacing Coolant............................................................................. 855 Antifreeze Concentration Tables............................................................... 856 Transmission Cooling.............................................................................. 857 General Description........................................................................... 857 Layout........................................................................................ 857 Thermostat.................................................................................... 858 Hydraulic System.......................................................................................... 859 Main Pump............................................................................................. 861 Safety Instructions............................................................................... 865 General........................................................................................... 865 General Description........................................................................... 865 Specification................................................................................. 865 Overview...................................................................................... 866 Theory of Operation........................................................................... 867 Parts List.................................................................................... 869 Location...................................................................................... 872 Removal........................................................................................... 873 Installation...................................................................................... 879 Completing Work................................................................................... 879 Disassembly....................................................................................... 880 Sealing Driveshaft............................................................................ 880 Pump.......................................................................................... 881 Reassembly........................................................................................ 887 Pump.......................................................................................... 887 Main Control Valve.................................................................................... 893 Safety Instructions............................................................................... 897 General........................................................................................... 897 General Description........................................................................... 897 Specification................................................................................. 898 Overview...................................................................................... 900 Hydraulic Circuit............................................................................. 902 Parts List.................................................................................... 903 Theory of Operation........................................................................... 904 Removal........................................................................................... 917 Disassembly/Reassembly............................................................................ 924 Torque Table...................................................................................... 925 Pilot System.......................................................................................... 929 Safety Instructions............................................................................... 933 General Description............................................................................... 933 Fingertip Joystick................................................................................ 934 Specification................................................................................. 934 Port Name..................................................................................... 934 Parts List - 2 Lever.......................................................................... 935 Parts List - 3 Lever.......................................................................... 936 FNR Joystick...................................................................................... 937 Specification................................................................................. 937 Port Name..................................................................................... 937 Overview...................................................................................... 937 Parts List.................................................................................... 938 HydraulicSystem....................................................................................... 941 Safety Instructions............................................................................... 945 Hydraulic Component and Oil Flow.................................................................. 946 Hydraulic Components.......................................................................... 946 Fan Drive Operation............................................................................... 948 Parking Brake Release Operation................................................................... 949 Service Brake Operation........................................................................... 950 Steering Operation................................................................................ 951 Boom Raise Operation and Load Sensing............................................................. 952 Boom Down Operation............................................................................... 954 Boom Floating Operation........................................................................... 956 Bucket Crowd Operation............................................................................ 958 Bucket Dump Operation............................................................................. 960 Combined Bucket Crowd and Boom Down Operation..................................................... 962 Load Isolate System (LIS)......................................................................... 963 Frame..................................................................................................... 965 Articulation Center................................................................................... 967 Safety Instructions............................................................................... 971 General Description............................................................................... 971 Maintenance Standard.......................................................................... 972 Cabin................................................................................................. 975 Safety Instructions............................................................................... 979 Cabin Identification.............................................................................. 979 Roll-over Protective Structure (ROPS)/Falling Object Protective Structure (FOPS).............. 979 Dimensions of Cabin Glass......................................................................... 981 Removal and Installation of Cabin Glass........................................................... 986 Removal of Cabin Glass........................................................................ 986 Installation of Cabin Glass................................................................... 988 Counterweight......................................................................................... 993 Safety Instructions............................................................................... 997 General........................................................................................... 998 Overview...................................................................................... 998 Additional Counter Weight..................................................................... 999 Oil Tank..............................................................................................1001 Safety Instructions...............................................................................1005 General...........................................................................................1005 Specifications................................................................................1005 Parts List....................................................................................1006 Air Breather..................................................................................1008 Fuel Tank.............................................................................................1009 Safety Instructions...............................................................................1013 General...........................................................................................1013 Specifications................................................................................1013 Parts List....................................................................................1014 Cylinders.............................................................................................1017 Safety Instructions...............................................................................1021 General...........................................................................................1021 General Description...........................................................................1021 Specification.................................................................................1021 Parts List....................................................................................1022 Theory of Operation...........................................................................1034 Seal of Cylinder..............................................................................1035 Special Tools and Materials....................................................................... 0 Rod Bushing (DD-bushing) Pushing-in Jig.......................................................1043 Disassembly.......................................................................................1044 Reassembly........................................................................................1049 Troubleshooting...................................................................................1053 Electrical System.........................................................................................1055 Electrical System.....................................................................................1057 Safety Instructions...............................................................................1061 Overview..........................................................................................1061 Electric Supply System............................................................................1062 Engine Starting Circuit...........................................................................1064 Operation During Start Process................................................................1064 Operation After Start Process.................................................................1066 Engine Stop System................................................................................1067 Engine Emergency Start System.....................................................................1068 Charging System...................................................................................1069 Engine Control System.............................................................................1070 Power Mode Control............................................................................1072 Accelerator Pedal.............................................................................1073 Auto Idle Control.............................................................................1074 Electric Detent System............................................................................1075 Electrical Circuit............................................................................1075 Boom Kick-out.................................................................................1076 Return to Dig.................................................................................1077 Cooling Fan Control System........................................................................ 0 Electrical Diagram............................................................................1079 Parts of Cooling Fan Control System...........................................................1080 Operation of Cooling Fan Control System.......................................................1082 Emergency Steering System (Option)................................................................1084 Block Diagram.................................................................................1084 Emergency Steering System Electrical Circuit..................................................1088 Lighting System...................................................................................1090 Light Circuit.................................................................................1090 Monitoring System................................................................................. 0 Instrument Panel..............................................................................1095 Function Check................................................................................1095 Monitoring System Schematic...................................................................1096 Operation......................................................................................... 0 Initial Operation.............................................................................1100 Multifunction Display.........................................................................1101 Warning and Indicator Lights......................................................................1104 Indication of Warning Lights..................................................................1104 Indication of Indicator Lights................................................................1106 Graphic Information Area Display.................................................................. 0 User Menu.....................................................................................1109 Information of Machine Operation..............................................................1136 Failure Code......................................................................................1143 Failure Code at Machine.......................................................................1143 Failure Code at Engine Side...................................................................1146 Failure Code at Transmission Side.............................................................1179 FMIs (Failure Mode Identifier)................................................................1183 Windshield Wiper..................................................................................1184 Front Windshield Wiper........................................................................1184 Rear Windshield Wiper.........................................................................1186 Air Conditioner.......................................................................................1187 Safety Instructions...............................................................................1191 General Description...............................................................................1192 Internal and External Filters.................................................................1193 Air-conditioning System Layout................................................................1194 Air Conditioner/Heater Unit...................................................................1196 Ambient Air Temperature Sensor................................................................1201 Compressor....................................................................................1209 Receiver Dryer................................................................................1209 Troubleshooting...................................................................................1210 Refrigerant System Repairs........................................................................1212 Refrigerant Safe Handling Procedures..........................................................1212 Repair and Replacement Procedure..............................................................1213 Refrigerant Recovery..........................................................................1215 Vacuuming Refrigerant System..................................................................1215 Leakage Check.................................................................................1217 Refrigerant Charging..........................................................................1217 Inspecting System for Leakage.................................................................1219 Option....................................................................................................1221 EmergencySteering.....................................................................................1223 Safety Instructions...............................................................................1227 General...........................................................................................1227 General Description...........................................................................1227 Specifications................................................................................1227 Parts List....................................................................................1229 Caution for Installation......................................................................1229 Installation Procedure............................................................................1230 Emergency Steering............................................................................1230 Emergency Steering - Electric.................................................................1232 After Installation Precautions................................................................1233 Emergency Steering Function Test..............................................................1233 Emergency Steering Automatic Test.............................................................1234 Load Isolation System.................................................................................1235 Safety Instructions...............................................................................1239 General...........................................................................................1239 General Description...........................................................................1239 Overview......................................................................................1240 Hydraulic Circuit.............................................................................1242 Accumulator Charging Method...................................................................1242 LIS Valve.........................................................................................1244 Specification.................................................................................1244 Parts List....................................................................................1245 Accumulator.......................................................................................1246 Specification.................................................................................1246 Parts List....................................................................................1246 Schematic.................................................................................................1247 Hydraulic Schematic/ Electrical Schematic.............................................................1249
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PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
S.M