Daewoo Doosan WHEEL LOADER DL250-5DL250TC-5 SHOP MANUAL 950106-01253E-1 – PDF DOWNLOAD
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Daewoo Doosan WHEEL LOADER DL250-5DL250TC-5 SHOP MANUAL 950106-01253E-1 – 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 injur
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
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-1 – PDF DOWNLOAD
DL250-5/DL250TC-5............................................................................................. 0 Table of Contents......................................................................................... 7 Safety.................................................................................................... 9 Wheel Loader Safety................................................................................... 11 Safety Instructions............................................................................... 15 Safety Messages................................................................................... 15 General........................................................................................... 17 Safe Operation is Operator's Responsibility................................................... 17 Know Your Machine............................................................................. 17 Proper Work Tools and Attachments............................................................. 17 Pressurized Fluids............................................................................ 18 Flying or Falling Objects..................................................................... 19 Personal Protective Equipment (PPE)........................................................... 19 Correction of Machine Problems................................................................ 20 Crushing and Cutting.......................................................................... 20 Hot Coolant and Oils - Burn Prevention........................................................ 21 Fire and Explosion Prevention................................................................. 21 Fire Extinguisher and First-Aid Kit (Emergency Medical Kit)................................... 25 Electrical System and Electrical Shock........................................................ 25 Roll-over Protective Structure (ROPS)/ Falling Object Protective Structure (FOPS)............. 26 Operation......................................................................................... 28 Before Engine Starting........................................................................ 28 Work Site..................................................................................... 28 Check Tire Pressure and Condition............................................................. 29 Mounting/Dismounting.......................................................................... 29 Cleaning...................................................................................... 30 Operator Station.............................................................................. 30 Seat Belt..................................................................................... 31 Visibility Information........................................................................ 32 Boost Starting or Charging Engine Batteries................................................... 33 Starting Engine............................................................................... 34 Traveling..................................................................................... 34 Lifting and Digging........................................................................... 36 Digging Beneath Overhangs..................................................................... 36 Digging Beneath Wheel Loader.................................................................. 36 Operation on Slopes........................................................................... 37 Attachment.................................................................................... 38 Equipment Lowering with Engine Stopped........................................................ 38 Preventing Risk of Injuries or Death From Boom and Bucket..................................... 38 Engine Stop................................................................................... 40 Parking Machine............................................................................... 40 Maintenance....................................................................................... 41 Warning Tag................................................................................... 43 Cleaning...................................................................................... 44 Proper Tools and Clothing..................................................................... 44 Disassembling Precautions..................................................................... 44 Use of Lighting............................................................................... 45 Fire and Explosion Prevention................................................................. 45 Burn Prevention............................................................................... 46 Rubber That Contains Fluorides................................................................ 47 Rubber and Plastics........................................................................... 48 Welding Repairs............................................................................... 49 Working on Machine............................................................................ 50 Lock Inspection Covers........................................................................ 51 Accumulator................................................................................... 51 Compressed Air................................................................................ 51 Supports and Blocking for Work Equipment...................................................... 52 High-pressure Lines, Tubes and Hoses.......................................................... 52 Battery....................................................................................... 53 Preservation/Storing Machine.................................................................. 54 Transportation.................................................................................... 56 Obey State and Local Over-the-Road Laws and Regulations....................................... 56 Loading and Unloading......................................................................... 56 Transporting Machine.......................................................................... 57 Environment and Circumstances..................................................................... 58 Work Site Areas Requiring Extra Caution....................................................... 58 High-voltage Cables........................................................................... 60 Underground Operation......................................................................... 60 Working in Water.............................................................................. 61 Working in Contaminated Environment........................................................... 61 Operation in Extreme Conditions............................................................... 62 Exhaust Ventilation........................................................................... 66 Asbestos Information.......................................................................... 66 Silica Dust Information....................................................................... 67 Disposal of Hazardous Materials............................................................... 67 Sound......................................................................................... 67 Vibration Information......................................................................... 68 Specifications............................................................................................ 71 Specification......................................................................................... 73 Safety Instructions............................................................................... 77 General........................................................................................... 77 Component Locations............................................................................... 78 Working Range and Dimensions...................................................................... 82 Working Capacities................................................................................ 86 Bucket Capacity............................................................................... 86 Stability..................................................................................... 86 General Specifications............................................................................ 88 Performance Tests................................................................................. 90 Purpose of Performance Tests.................................................................. 90 Kinds of Tests................................................................................ 90 Performance Standards......................................................................... 90 Precautions for Evaluation of Test Data....................................................... 90 Definition of "Performance Standard".......................................................... 90 Preparation for Performance Tests................................................................. 91 The Machine................................................................................... 91 Test Area..................................................................................... 91 Precautions................................................................................... 91 Make Precise Measurement...................................................................... 91 Operational Performance Standard Table............................................................ 92 Operational Performance Test...................................................................... 96 Engine Speed.................................................................................. 96 Front Speed................................................................................... 98 Natural Subsidence of Cylinder................................................................ 99 Travel Speed - Acceleration and Deceleration.................................................. 100 Steering Time................................................................................. 101 Pressure Set.................................................................................. 102 Approximate Weight of Workload Materials.......................................................... 105 Material Weight............................................................................... 105 General Maintenance....................................................................................... 107 General Maintenance Instructions...................................................................... 109 Safety Instructions............................................................................... 113 Welding Precautions and Instructions.............................................................. 114 Hydraulic System - General Precautions............................................................ 115 Maintenance Service and Repair Procedure.......................................................... 117 General Precautions........................................................................... 117 Hydraulic System Cleanliness and Oil Leaks........................................................ 118 Maintenance Precautions for Hydraulic System Service.......................................... 118 Oil Leakage Precautions....................................................................... 119 Cleaning and Inspection........................................................................... 120 General Instructions.......................................................................... 120 Bearing Inspection............................................................................ 121 Standard Torques...................................................................................... 129 Safety Instructions............................................................................... 133 Torque Values for Standard Metric Fasteners....................................................... 134 Torque Values for Standard U.S. Fasteners......................................................... 135 Type 8 Phosphate Coated Hardware.................................................................. 137 Torque Values for Hose Clamps..................................................................... 138 ORFS Swivel Nut Recommended Torque................................................................ 138 Torque Values for Split Flanges................................................................... 139 Torque Wrench Extension Tools..................................................................... 140 Torque Multiplication......................................................................... 140 Other Uses for Torque Wrench Extension Tools.................................................. 141 Tightening Torque Specifications (Metric)..................................................... 142 Engine.................................................................................................... 145 Engine................................................................................................ 147 Safety Instructions............................................................................... 151 Overview.......................................................................................... 152 General Information............................................................................... 153 General Description........................................................................... 153 Engine Maintenance............................................................................ 157 Inspection and Repair of the Engine........................................................... 160 Engine Identification............................................................................. 162 Engine Data Plate............................................................................. 162 Engine Specification.............................................................................. 164 Engine Performance Curves......................................................................... 165 Special Tools..................................................................................... 166 Tightening Torques................................................................................ 170 Major Parts Tightening Torque................................................................. 170 Tightening Torque for General Bolts........................................................... 172 Tightening Torque of Plug Screw............................................................... 173 Hollow Screw (4-Hole) Tightening Torque....................................................... 173 Engine Disassembly................................................................................ 174 Engine Disassembly............................................................................ 174 Engine Assembly................................................................................... 189 Engine Assembly............................................................................... 189 Cylinder.......................................................................................... 212 General Information........................................................................... 212 Cylinder Head................................................................................. 212 Cylinder Block................................................................................ 216 Valve Mechanism............................................................................... 218 Actuating System.................................................................................. 230 Camshaft...................................................................................... 230 Piston........................................................................................ 232 Connecting Rod................................................................................ 236 Crankshaft.................................................................................... 238 Timing Gear................................................................................... 243 Lubrication system................................................................................ 244 General Information........................................................................... 244 Oil Pan....................................................................................... 248 Oil Pump...................................................................................... 250 Oil Filter.................................................................................... 252 Exhaust System.................................................................................... 255 Turbocharger.................................................................................. 255 EGR (Exhaust Gas Recirculation) System........................................................ 267 DNOx System................................................................................... 274 Cooling System.................................................................................... 285 General information........................................................................... 285 Thermostat.................................................................................... 286 Fuel System....................................................................................... 290 General Information........................................................................... 290 Fuel High-pressure System Components.......................................................... 291 Injector...................................................................................... 292 Common Rail................................................................................... 296 Fuel Injection Pump........................................................................... 300 Electrical System................................................................................. 304 Electrical Parts.............................................................................. 304 Switches and Sensors.......................................................................... 306 ECU (Electronic Control Unit)................................................................. 310 Starter....................................................................................... 312 Exhaust Gas Reduction......................................................................... 314 Circuit Diagram............................................................................... 318 Drivetrain................................................................................................ 325 Transmission.......................................................................................... 327 Safety Instructions............................................................................... 331 General........................................................................................... 331 Specification................................................................................. 332 Overview...................................................................................... 333 Section View.................................................................................. 336 Hydraulic Circuit (4-speed Transmission)...................................................... 338 Torque Convertor.............................................................................. 339 Electrohydraulic Control with Proportional Valves............................................. 342 Controller.................................................................................... 343 Electric Control System....................................................................... 344 Speed Sensor.................................................................................. 347 Measuring Points and Connections.................................................................. 350 Transmission Electric Components.................................................................. 352 TCU (Transmission Control Unit)............................................................... 354 Transmission Control Valve.................................................................... 354 Transmission Oil Temperature Sensor........................................................... 354 Engine Pickup Sensor.......................................................................... 355 Central Gear Pickup Sensor.................................................................... 355 Turbine Pickup Sensor......................................................................... 355 Output Speed Sensor........................................................................... 355 Shift Lever Switch (DW-3)..................................................................... 356 Forward, Reverse Switch Lever................................................................. 357 Fingertip Work Lever (Optional)............................................................... 357 Transmission Shift Switch..................................................................... 359 T/M Cutoff Sensor............................................................................. 359 LIS Solenoid Valve............................................................................ 359 Transmission Electrical Circuits.................................................................. 360 Transmission Controller Circuit............................................................... 360 Transmission Control Unit Terminal............................................................ 361 Downshift..................................................................................... 369 Transmission Cutoff Switch.................................................................... 376 Torque Limits for Screws.......................................................................... 377 Special Tools..................................................................................... 378 List of Special Tools for Disassembly and Reassembly.......................................... 378 Transmission Oil.................................................................................. 384 Oil Grade of Transmission..................................................................... 384 Disassembly....................................................................................... 385 Electrohydraulic Control and Transmission Filter (Replaceable Filter)......................... 385 Inductive Sensor, Hall Sensor, Breather, Oil Filler and Oil Drain Plug........................ 390 Engine Connection, Oil Pressure Pump, Converter Back-pressure Valve and Temperature Sensor.... 391 Outputs and Closure Parts Pump Shaft (PTO-Shaft).............................................. 395 Removal of Input Shaft, Output Shaft, Pump Shaft (PTO-shaft) and Clutches..................... 397 Clutches KV/KR/K1/K2/K3/K4 Input and Output Shaft............................................. 402 Reassembly........................................................................................ 426 Clutches KV/KR/K1/K2/K3/K4 Input and Output Shaft............................................. 426 Installation of Input Shaft, Output Shaft, Pump Shaft (Power-takeoff Shaft) and Clutches...... 465 Outputs and Closure Parts Pump Shaft (PTO-shaft).............................................. 472 Engine Connection, Oil Pressure Pump, Converter Back-pressure Valve and Temperature Sensor.... 475 Emergency Steering Pump....................................................................... 479 Inductive Sensor, Hall Sensor, Breather, Oil Filler and Oil Drain Plug........................ 480 Electrohydraulic Control with Proportional Valves............................................. 481 Failure Code...................................................................................... 489 Front Axle............................................................................................ 515 Safety Instructions............................................................................... 519 General........................................................................................... 519 Specification................................................................................. 519 Overview...................................................................................... 520 Parts List.................................................................................... 521 Lubrication and Maintenance Instructions.......................................................... 523 Oil Change.................................................................................... 523 Carry Out Wear Measurement on the Multidisk Brake............................................. 525 Tightening Torques for Screws................................................................. 526 Differential System............................................................................... 527 Theory of Differential Device................................................................. 527 Structure of Differential Device.............................................................. 528 LSD............................................................................................... 529 Overview LSD (Limited Slip Differential)...................................................... 529 LSD (Limited Slip Differential)............................................................... 530 Axle Air Breathing................................................................................ 531 Special Tools..................................................................................... 532 List of Special Tools for Disassembly and Reassembly.......................................... 532 Axle Oils......................................................................................... 539 Oil Grade ZF-Powerfluid....................................................................... 539 Removal........................................................................................... 540 Installation...................................................................................... 543 Completing Work................................................................................... 543 Disassembly....................................................................................... 544 Output and Brake.............................................................................. 544 Axle Housing.................................................................................. 550 Input......................................................................................... 551 Differentials................................................................................. 554 Reassembly........................................................................................ 559 Differentials................................................................................. 559 Input......................................................................................... 567 Axle Housing.................................................................................. 578 Output and Brake.............................................................................. 579 Rear Axle............................................................................................. 591 Safety Instructions............................................................................... 595 General........................................................................................... 595 Specification................................................................................. 595 Overview...................................................................................... 596 Parts List.................................................................................... 597 Lubrication and Maintenance Instructions.......................................................... 599 Oil Change.................................................................................... 599 Carry Out Wear Measurement on the Multidisk Brake............................................. 601 Tightening Torques for Screws................................................................. 602 Differential System............................................................................... 603 Theory of Differential Device................................................................. 603 Structure of Differential Device.............................................................. 604 Axle Air Breathing................................................................................ 605 Special Tools..................................................................................... 606 List of Special Tools for Disassembly and Reassembly.......................................... 606 Axle Oils......................................................................................... 613 Oil Grade ZF-Powerfluid....................................................................... 613 Removal........................................................................................... 614 Installation...................................................................................... 619 Completing Work................................................................................... 619 Disassembly....................................................................................... 620 Output and Brake.............................................................................. 620 Axle Housing.................................................................................. 625 Input......................................................................................... 627 Differentials................................................................................. 629 Reassembly........................................................................................ 632 Differentials................................................................................. 632 Input......................................................................................... 639 Axle Housing.................................................................................. 647 Output and Brake.............................................................................. 649 Driveshaft............................................................................................ 661 Safety Instructions............................................................................... 665 General........................................................................................... 666 Overview...................................................................................... 666 Specification................................................................................. 666 Removal (Front Driveshaft)........................................................................ 668 Installation (Front Driveshaft)................................................................... 670 Removal (Center Driveshaft)....................................................................... 671 Installation (Center Driveshaft).................................................................. 673 Removal (Rear Driveshaft)......................................................................... 674 Installation (Rear DriveShaft).................................................................... 676 Steering.................................................................................................. 677 Power Steering System................................................................................. 679 Safety Instructions............................................................................... 683 General Description............................................................................... 683 Overview...................................................................................... 684 Hydraulic Circuit............................................................................. 685 Theory of Operation........................................................................... 686 Steering Unit......................................................................................... 689 Safety Instructions............................................................................... 693 General........................................................................................... 693 General Description........................................................................... 693 Specifications................................................................................ 695 Overview...................................................................................... 696 Theory of Operation........................................................................... 697 Gerotor Operation............................................................................. 698 Relief Valve.................................................................................. 698 Priority Valve........................................................................................ 699 Safety Instructions............................................................................... 703 General........................................................................................... 703 General Description........................................................................... 703 Tool List......................................................................................... 704 Removal........................................................................................... 705 Installation...................................................................................... 710 Completing Work................................................................................... 710 Disassembly....................................................................................... 711 Reassembly........................................................................................ 713 Brake..................................................................................................... 715 Service Brake......................................................................................... 717 Safety Instructions............................................................................... 721 General Description............................................................................... 722 Service Brake System.............................................................................. 723 Brake & Pilot Supply Valve............................................................................ 725 Safety Instructions............................................................................... 729 General Description............................................................................... 729 Overview...................................................................................... 730 Parts List.................................................................................... 732 Removal........................................................................................... 733 Installation...................................................................................... 737 Completing Work................................................................................... 737 Charging Block........................................................................................ 739 Safety Instructions............................................................................... 743 General Description............................................................................... 744 Parts List.................................................................................... 744 Hydraulic Circuit............................................................................. 745 Parking Brake......................................................................................... 747 Safety Instructions............................................................................... 751 General........................................................................................... 751 Specification................................................................................. 751 Overview...................................................................................... 751 Parts List.................................................................................... 752 Theory of Operation........................................................................... 753 Installing and Setting Instructions............................................................... 755 Installing the Brake.......................................................................... 755 Clearance Adjusting........................................................................... 756 Adjusting Instructions........................................................................ 757 Emergency Release of the Parking Brake............................................................ 758 Maintenance and Repair Work....................................................................... 759 Maintenance and Replacement of the Lining Pads................................................ 759 Replacing the Seals........................................................................... 762 Brake Pedal Valve..................................................................................... 765 Safety Instructions............................................................................... 769 General Description............................................................................... 769 Specification................................................................................. 769 Parts List.................................................................................... 770 Theory of Operation........................................................................... 771 Accumulator........................................................................................... 773 Safety Instructions............................................................................... 777 General........................................................................................... 778 General Description........................................................................... 778 Layout........................................................................................ 780 Specifications................................................................................ 780 Cooling System............................................................................................ 781 Cooling System........................................................................................ 783 Safety Instructions............................................................................... 787 General........................................................................................... 787 General Description........................................................................... 787 Function...................................................................................... 788 Hydraulic Circuit............................................................................. 789 Fan Motor Pressure and Fan Speed.............................................................. 790 Checking Maximum Fan Speed................................................................ 791 Fan and Brake Pump.................................................................................... 793 Safety Instructions............................................................................... 797 General........................................................................................... 797 Specification................................................................................. 797 Section View.................................................................................. 798 EPPR Valve.................................................................................... 798 Overview...................................................................................... 799 Port and Hydraulic Circuit................................................................ 799 Parts List.................................................................................... 800 Theory of Operation........................................................................... 802 Circuit................................................................................... 802 Control Section........................................................................... 803 Circuit Diagram Related to Fan Drive...................................................... 803 Pump EPPR Valve........................................................................... 804 Removal........................................................................................... 806 Installation...................................................................................... 811 Completing Work................................................................................... 811 Maintenance Guidelines............................................................................ 812 Sealing Driveshaft............................................................................ 813 Sealing Control Valve......................................................................... 815 Tools......................................................................................... 815 Loctite Types............................................................................. 815 Disassembly....................................................................................... 816 Disassembly of Rotary Group................................................................... 817 Disassembly of Control Device................................................................. 818 Disassembly of Shaft/Bearings................................................................. 819 Cleaning and Inspection........................................................................... 820 Reassembly........................................................................................ 823 Adjustment of Taper Roller Bearing............................................................ 824 Taper Roller Bearing Pretension........................................................... 824 Fan Motor............................................................................................. 829 Safety Instructions............................................................................... 833 General........................................................................................... 834 Specifications................................................................................ 834 Overview...................................................................................... 834 Port and Hydraulic Circuit................................................................ 834 Fan Control Valve..................................................................................... 835 Safety Instructions............................................................................... 839 General........................................................................................... 839 Specifications................................................................................ 839 Port and Hydraulic Circuit................................................................ 840 Radiator Assembly..................................................................................... 841 Safety Instructions............................................................................... 845 General........................................................................................... 845 Overview...................................................................................... 845 Structure..................................................................................... 846 Parts List.................................................................................... 847 CAC (Charge Air Cooler)........................................................................... 848 Overview...................................................................................... 848 Replacing - Hose/Pipe (Charge Air Cooler)..................................................... 849 Radiator.......................................................................................... 851 Overview...................................................................................... 851 Theory of Operation........................................................................... 851 Radiator Cap.................................................................................. 852 Replacing - Radiator Cap...................................................................... 853 Replacing Coolant............................................................................. 853 Antifreeze Concentration Tables............................................................... 854 Transmission Cooling.............................................................................. 855 General Description........................................................................... 855 Layout........................................................................................ 855 Thermostat.................................................................................... 856 Hydraulic System.......................................................................................... 857 Main Pump............................................................................................. 859 Safety Instructions............................................................................... 863 General........................................................................................... 863 General Description........................................................................... 863 Specification................................................................................. 863 Overview...................................................................................... 864 Theory of Operation........................................................................... 865 Parts List.................................................................................... 867 Location...................................................................................... 870 Removal........................................................................................... 871 Installation...................................................................................... 877 Completing Work................................................................................... 877 Disassembly....................................................................................... 878 Sealing Driveshaft............................................................................ 878 Pump.......................................................................................... 879 Inspection.................................................................................... 882 Reassembly........................................................................................ 885 Pump.......................................................................................... 885 Pressure and Flow Setting......................................................................... 889 Main Control Valve.................................................................................... 891 Safety Instructions............................................................................... 895 General........................................................................................... 895 General Description........................................................................... 895 Specification................................................................................. 896 Overview...................................................................................... 898 Hydraulic Circuit............................................................................. 900 Parts List.................................................................................... 901 Theory of Operation........................................................................... 902 Removal........................................................................................... 915 Installation...................................................................................... 921 Completing Work................................................................................... 921 Disassembly/Reassembly............................................................................ 922 Torque Table...................................................................................... 923 Pilot System.......................................................................................... 927 Safety Instructions............................................................................... 931 General Description............................................................................... 931 Fingertip Joystick................................................................................ 932 Specification................................................................................. 932 Port Name..................................................................................... 932 Parts List - 2 Lever.......................................................................... 933 Parts List - 3 Lever.......................................................................... 934 FNR Joystick...................................................................................... 935 Specification................................................................................. 935 Port Name..................................................................................... 935 Overview...................................................................................... 935 Parts List.................................................................................... 936 Hydraulic System...................................................................................... 939 Safety Instructions............................................................................... 943 Hydraulic Component and Oil Flow.................................................................. 944 Hydraulic Components.......................................................................... 944 Fan Drive Operation............................................................................... 946 Parking Brake Release Operation................................................................... 947 Service Brake Operation........................................................................... 948 Steering Operation................................................................................ 949 Boom Raise Operation and Load Sensing............................................................. 950 Boom Down Operation............................................................................... 952 Boom Floating Operation........................................................................... 954 Bucket Crowd Operation............................................................................ 956 Bucket Dump Operation............................................................................. 958 Combined Bucket Crowd and Boom Down Operation..................................................... 960 Load Isolate System (LIS)......................................................................... 961 Frame..................................................................................................... 963 Articulation Center................................................................................... 965 Safety Instructions............................................................................... 969 General Description............................................................................... 969 Maintenance Standard.......................................................................... 970 Cabin................................................................................................. 973 Safety Instructions............................................................................... 977 Cabin Identification.............................................................................. 977 Roll-over Protective Structure (ROPS)/Falling Object Protective Structure (FOPS).............. 977 Dimensions of Cabin Glass......................................................................... 979 Removal and Installation of Cabin Glass........................................................... 984 Removal of Cabin Glass........................................................................ 984 Installation of Cabin Glass................................................................... 986 Counterweight......................................................................................... 991 Safety Instructions............................................................................... 995 General........................................................................................... 996 Overview...................................................................................... 996 Additional Counter Weight..................................................................... 997 Oil Tank.............................................................................................. 999 Safety Instructions...............................................................................1003 General...........................................................................................1003 Specifications................................................................................1003 Parts List....................................................................................1004 Air Breather..................................................................................1006 Fuel Tank.............................................................................................1007 Safety Instructions...............................................................................1011 General...........................................................................................1011 Specifications................................................................................1011 Parts List....................................................................................1012 Cylinders.............................................................................................1015 Safety Instructions...............................................................................1019 General...........................................................................................1019 General Description...........................................................................1019 Specification.................................................................................1019 Parts List....................................................................................1020 Theory of Operation...........................................................................1032 Seal of Cylinder..............................................................................1033 Special Tools and Materials.......................................................................1035 Piston Nut....................................................................................1035 Piston Jig....................................................................................1036 Steel Bushing Jig.............................................................................1037 Dust Wiper Jig................................................................................1038 Slipper Seal Jig..............................................................................1039 Slipper Seal Straightening Jig................................................................1040 Rod Bushing (DD-bushing) Pushing-in Jig.......................................................1041 Disassembly.......................................................................................1042 Reassembly........................................................................................1047 Troubleshooting...................................................................................1051 Electrical System.........................................................................................1053 Electrical System.....................................................................................1055 Safety Instructions...............................................................................1059 Overview..........................................................................................1059 Electric Supply System............................................................................1060 Engine Starting Circuit...........................................................................1062 Operation During Start Process................................................................1062 Operation After Start Process.................................................................1064 Engine Stop System................................................................................1065 Engine Emergency Start System.....................................................................1066 Charging System...................................................................................1067 Engine Control System.............................................................................1068 Power Mode Control............................................................................1070 Accelerator Pedal.............................................................................1071 Auto Idle Control.............................................................................1072 Electric Detent System............................................................................1073 Electrical Circuit............................................................................1073 Boom Kick-out.................................................................................1074 Return to Dig.................................................................................1075 Cooling Fan Control System........................................................................1076 Outline.......................................................................................1076 Diagram.......................................................................................1076 Electrical Diagram............................................................................1077 Parts of Cooling Fan Control System...........................................................1078 Operation of Cooling Fan Control System.......................................................1080 Emergency Steering System (Option)................................................................1082 Block Diagram.................................................................................1082 Emergency Steering System Components..........................................................1083 Emergency Steering System Electrical Circuit..................................................1086 Lighting System...................................................................................1088 Light Circuit.................................................................................1088 Monitoring System.................................................................................1092 Instrument Panel..............................................................................1093 Function Check................................................................................1093 Monitoring System Schematic...................................................................1094 Operation.........................................................................................1096 Instruments Gauge.............................................................................1096 Indicator Lights..............................................................................1096 Initial Operation.............................................................................1098 Multifunction Display.........................................................................1099 Warning and Indicator Lights......................................................................1102 Indication of Warning Lights..................................................................1102 Indication of Indicator Lights................................................................1104 Graphic Information Area Display..................................................................1106 Overview......................................................................................1106 Main Menus for the Graphic Display Area.......................................................1106 Menu Selector Buttons.........................................................................1106 User Menu.....................................................................................1107 Service Menu..................................................................................1124 Information of Machine Operation..............................................................1134 Failure Code......................................................................................1141 Failure Code at Machine.......................................................................1141 Failure Code at Engine Side...................................................................1144 Failure Code at Transmission Side.............................................................1177 FMIs (Failure Mode Identifier)................................................................1181 Windshield Wiper..................................................................................1182 Front Windshield Wiper........................................................................1182 Rear Windshield Wiper.........................................................................1184 Air Conditioner.......................................................................................1185 Safety Instructions...............................................................................1189 General Description...............................................................................1190 Internal and External Filters.................................................................1191 Air-conditioning System Layout................................................................1192 Air Conditioner/Heater Circuit Diagram........................................................1193 Air Conditioner/Heater Unit...................................................................1194 Ambient Air Temperature Sensor................................................................1199 Sun Sensor....................................................................................1200 Control Panel.................................................................................1200 Compressor....................................................................................1207 Receiver Dryer................................................................................1207 Troubleshooting...................................................................................1208 Refrigerant System Repairs........................................................................1210 Refrigerant Safe Handling Procedures..........................................................1210 Repair and Replacement Procedure..............................................................1211 Refrigerant Recovery..........................................................................1213 Vacuuming Refrigerant System..................................................................1213 Leakage Check.................................................................................1215 Refrigerant Charging..........................................................................1215 Inspecting System for Leakage.................................................................1217 Option....................................................................................................1219 Emergency Steering....................................................................................1221 Safety Instructions...............................................................................1225 General...........................................................................................1225 General Description...........................................................................1225 Specifications................................................................................1225 Theory of Operation...........................................................................1226 Hydraulic Circuit.............................................................................1226 Parts List....................................................................................1227 Caution for Installation......................................................................1227 Installation Procedure............................................................................1228 Emergency Steering............................................................................1228 Emergency Steering - Electric.................................................................1230 After Installation Precautions................................................................1231 Emergency Steering Function Test..............................................................1231 Emergency Steering Automatic Test.............................................................1232 Load Isolation System.................................................................................1233 Safety Instructions...............................................................................1237 General...........................................................................................1237 General Description...........................................................................1237 Overview......................................................................................1238 Hydraulic Circuit.............................................................................1240 Accumulator Charging Method...................................................................1240 LIS Valve.........................................................................................1242 Specification.................................................................................1242 Parts List....................................................................................1243 Accumulator.......................................................................................1244 Specification.................................................................................1244 Parts List....................................................................................1244 Schematic.................................................................................................1245 Blank Page....................................................................................................1250 Blank Page....................................................................................................1252
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- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
S.M