Daewoo Doosan WHEEL LOADER DL200-5DL200TC-5 Shop Manual 950106-01249E – PDF DOWNLOAD
DESCRIPTION:
Daewoo Doosan WHEEL LOADER DL200-5DL200TC-5 Shop Manual 950106-01249E – 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.
Flying or Falling Objects
On work sites where there is a potential hazard that flying or falling objects can come in contact with operator’s cabin, select and use a guard to match operating conditions for additional operator protection. Working in mines, tunnels, deep pits, and loose or wet surfaces, can produce hazards of falling rocks or flying objects. Additional protection for operator’s cabin could be required such as an Operator Protection Guard (OPG) or window guards. Contact your DOOSAN distributor for information on available protective guards. To prevent personnel from being struck by flying objects, keep personnel out of work area.
TABLE OF CONTENTS:
Daewoo Doosan WHEEL LOADER DL200-5DL200TC-5 Shop Manual 950106-01249E – PDF DOWNLOAD
DL200-5/DL200TC-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............................................................... 52 Accumulator.......................................................................... 53 Compressed Air....................................................................... 53 Supports and Blocking for Work Equipment............................................. 53 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................................................................................ 70 Vibration Information................................................................ 70 Specifications................................................................................... 73 Specification................................................................................ 75 Safety Instructions...................................................................... 79 General.................................................................................. 79 Component Locations...................................................................... 80 Working Range and Dimensions............................................................. 86 Working Capacities....................................................................... 90 Bucket Capacity...................................................................... 90 Stability............................................................................ 90 General Specifications................................................................... 92 Performance Tests........................................................................ 94 Purpose of Performance Tests......................................................... 94 Kinds of Tests....................................................................... 94 Performance Standards................................................................ 94 Precautions for Evaluation of Test Data.............................................. 94 Definition of "Performance Standard"................................................. 94 Preparation for Performance Tests........................................................ 95 The Machine.......................................................................... 95 Test Area............................................................................ 95 Precautions.......................................................................... 95 Make Precise Measurement............................................................. 95 Operational Performance Standard Table................................................... 96 Operational Performance Test............................................................. 100 Engine Speed......................................................................... 100 Front Speed.......................................................................... 102 Natural Subsidence of Cylinder....................................................... 103 Travel Speed - Acceleration and Deceleration......................................... 104 Steering Time........................................................................ 105 Hydraulic Pressure Checks................................................................ 106 Steering Pump Load Sensing Pressure.................................................. 106 Pilot Supply Pressure................................................................ 106 Main Pump Pressure................................................................... 107 Brake Charging Pressure.............................................................. 107 Clutch Pressure...................................................................... 107 Parking Brake Pressure............................................................... 108 HST Charging Pump Pressure........................................................... 108 HST Pump Control Pressure............................................................ 108 Approximate Weight of Workload Materials................................................. 109 Material Weight...................................................................... 109 General Maintenance.............................................................................. 111 General Maintenance Instructions............................................................. 113 Safety Instructions...................................................................... 117 Welding Precautions and Instructions..................................................... 118 Hydraulic System - General Precautions................................................... 119 Maintenance Service and Repair Procedure................................................. 121 General Precautions.................................................................. 121 Hydraulic System Cleanliness and Oil Leaks............................................... 122 Maintenance Precautions for Hydraulic System Service................................. 122 Oil Leakage Precautions.............................................................. 123 Cleaning and Inspection.................................................................. 124 General Instructions................................................................. 124 Bearing Inspection................................................................... 125 Standard Torques............................................................................. 133 Safety Instructions...................................................................... 137 Torque Values for Standard Metric Fasteners.............................................. 138 Torque Values for Standard U.S. Fasteners................................................ 139 Type 8 Phosphate Coated Hardware......................................................... 141 Torque Values for Hose Clamps............................................................ 142 ORFS Swivel Nut Recommended Torque....................................................... 142 Torque Values for Split Flanges.......................................................... 143 Torque Wrench Extension Tools............................................................ 144 Torque Multiplication................................................................ 144 Other Uses for Torque Wrench Extension Tools......................................... 145 Tightening Torque Specifications (Metric)............................................ 146 Engine........................................................................................... 149 Engine....................................................................................... 151 Safety Instructions...................................................................... 155 Overview................................................................................. 156 General Information...................................................................... 157 Major Component Location............................................................. 157 Engine Identification................................................................ 162 Engine Lifting....................................................................... 164 Maintenance and Storage.............................................................. 166 Engine Specification..................................................................... 169 General Specification................................................................ 169 Engine Performance Curves............................................................ 170 Basic Engine............................................................................. 171 Cylinder Block....................................................................... 171 Cylinder Head........................................................................ 173 Valve Mechanism Cover................................................................ 185 Crankcase Breather................................................................... 190 Flywheel and Flywheel Housing........................................................ 194 Actuating System......................................................................... 206 Pistons, Rings, and Connecting Rods.................................................. 206 Crankshaft........................................................................... 221 Gears and Timing Gear Case........................................................... 240 Camshaft............................................................................. 260 Rocker Shaft......................................................................... 270 Lubricant System......................................................................... 280 Overview............................................................................. 280 Engine Oil Pump...................................................................... 282 Engine Oil Filter.................................................................... 286 Engine Oil Pan....................................................................... 289 Engine Oil Pressure - Test........................................................... 296 Excessive Bearing Wear - Inspect..................................................... 296 Excessive Engine Oil Consumption - Inspect........................................... 297 Increased Engine Oil Temperature - Inspect........................................... 297 Cooling System........................................................................... 298 Overview............................................................................. 298 Water Pump........................................................................... 299 Water Temperature Regulator.......................................................... 304 Engine Oil Cooler.................................................................... 308 Piston Cooling Jets.................................................................. 314 Fuel System.............................................................................. 316 Overview............................................................................. 316 High-pressure Fuel System............................................................ 317 Water Separator & Pre Fuel Filter (Fuel Prefilter)................................... 319 Main Fuel Filter..................................................................... 321 Fuel Injection Pump.................................................................. 323 Fuel Injection Lines................................................................. 331 Fuel Injectors....................................................................... 343 Fuel System - Inspect................................................................ 350 Air in Fuel - Test................................................................... 351 Finding Top Center Position for No. 1 Piston......................................... 353 Fuel Injection Timing - Check........................................................ 354 Fuel Quality - Test.................................................................. 355 Fuel System - Prime.................................................................. 356 Cleanliness of Fuel System........................................................... 357 Air Inlet and Exhaust System............................................................. 358 Exhaust System....................................................................... 358 DEF Dosing Control System............................................................ 417 Electrical System........................................................................ 439 Electrical Control System............................................................ 439 Sensor Locations for the Engine...................................................... 442 Electronic Control Module (ECM)...................................................... 446 Electric Component - Remove and Install.............................................. 453 Drivetrain....................................................................................... 483 Transmission................................................................................. 485 Safety Instructions...................................................................... 489 General.................................................................................. 489 General Description.................................................................. 489 Overview............................................................................. 490 Specification........................................................................ 490 Hydraulic Circuit.................................................................... 492 Clutch Operation..................................................................... 493 Parts List........................................................................... 494 Transmission Electric Components......................................................... 496 HST Controller....................................................................... 497 Traction Mode/Level Select Switch.................................................... 497 Variable Speed Control............................................................... 497 Controller........................................................................... 498 Speed Sensor......................................................................... 498 Transmission Electrical Circuits......................................................... 500 Transmission Controller Circuit...................................................... 500 Downshift............................................................................ 510 Section View............................................................................. 512 Disassembly.............................................................................. 513 Sensor............................................................................... 527 Special Tools............................................................................ 552 T1................................................................................... 552 T2................................................................................... 553 T3................................................................................... 553 Axle......................................................................................... 555 Safety Instructions...................................................................... 559 General.................................................................................. 560 Overview............................................................................. 560 Specification........................................................................ 561 Parts List........................................................................... 562 Differential (Standard).............................................................. 565 Lubrication and Maintenance.............................................................. 566 Oil Change Intervals................................................................. 566 Adjustment and Checks................................................................ 566 Recommended Lubricants for Axles..................................................... 566 Removal (Front Axle)..................................................................... 568 Removal (Rear Axle)...................................................................... 572 Installation (Rear Axle)................................................................. 577 Completing Work (Rear Axle).............................................................. 577 Disassembly and Reassembly............................................................... 578 Planetary Reduction and Axle Shaft (Front and Rear).................................. 578 Differential Unit (Front and Rear)................................................... 606 Bevel Pinion......................................................................... 614 Driveshaft................................................................................... 625 Safety Instructions...................................................................... 629 General.................................................................................. 630 Overview............................................................................. 630 Specification........................................................................ 630 Removal (Front Driveshaft)............................................................... 632 Removal (Center Driveshaft).............................................................. 635 Removal (Rear Driveshaft)................................................................ 638 Installation (Rear DriveShaft)........................................................... 640 Steering......................................................................................... 641 Power Steering System........................................................................ 643 Safety Instructions...................................................................... 647 General.................................................................................. 647 General Description.................................................................. 647 Overview............................................................................. 648 Hydraulic Circuit.................................................................... 649 Theory of Operation.................................................................. 650 Steering Unit................................................................................ 653 Safety Instructions...................................................................... 657 General.................................................................................. 657 General Description.................................................................. 657 Overview............................................................................. 659 Specifications....................................................................... 660 Port and Hydraulic Circuit........................................................... 660 Theory of Operation.................................................................. 661 Gerotor Operation.................................................................... 662 Relief Valve......................................................................... 662 Priority Valve............................................................................... 663 Safety Instructions...................................................................... 667 General.................................................................................. 667 Overview............................................................................. 667 Hydraulic Circuit.................................................................... 667 Theory of Operation.................................................................. 668 Removal.................................................................................. 669 Installation............................................................................. 673 Completing Work.......................................................................... 673 Brake............................................................................................ 675 Service Brake................................................................................ 677 Safety Instructions...................................................................... 681 General.................................................................................. 682 General Description.................................................................. 682 Service Brake System..................................................................... 683 Brake Pilot Supply Valve..................................................................... 685 Safety Instructions...................................................................... 689 General.................................................................................. 689 General Description.................................................................. 689 Overview............................................................................. 690 Hydraulic Circuit.................................................................... 691 Functions............................................................................ 691 Parts List........................................................................... 692 Removal.................................................................................. 693 Accumulator Charging Valve................................................................... 699 Safety Instructions...................................................................... 703 General.................................................................................. 704 General Description.................................................................. 704 Overview............................................................................. 704 Hydraulic Circuit.................................................................... 705 Function............................................................................. 705 Parts List........................................................................... 706 Removal.................................................................................. 707 Parking Brake................................................................................ 713 Safety Precautions....................................................................... 717 General.................................................................................. 718 General Description.................................................................. 718 Parking Brake............................................................................ 719 Front Axle Parking Brake Emergency Release........................................... 719 Front Axle Parking Brake Adjustment.................................................. 720 Applying Parking Brake............................................................... 721 Releasing Parking Brake.............................................................. 722 Brake Pedal Valve............................................................................ 723 Safety Instructions...................................................................... 727 General.................................................................................. 727 Overview............................................................................. 727 Specification........................................................................ 727 Theory of Operation.................................................................. 728 Accumulator.................................................................................. 731 Safety Instructions...................................................................... 735 General.................................................................................. 0 Layout............................................................................... 738 Specifications....................................................................... 738 Cooling System................................................................................... 739 Cooling System............................................................................... 741 Safety Instructions...................................................................... 745 General.................................................................................. 745 General Description.................................................................. 745 Hydraulic Circuit.................................................................... 746 Function............................................................................. 747 Fan Motor Pressure and Fan Speed..................................................... 748 Checking Maximum Fan Speed....................................................... 749 Fan Motor.................................................................................... 751 Safety Instructions...................................................................... 755 General.................................................................................. 756 Overview............................................................................. 756 Specifications....................................................................... 756 Port and Hydraulic Circuit........................................................... 756 Fan Control Valve............................................................................ 757 Safety Instructions...................................................................... 761 General.................................................................................. 761 Specifications....................................................................... 761 Port and Hydraulic Circuit........................................................... 762 Removal.................................................................................. 763 Installation............................................................................. 767 Completing Work.......................................................................... 767 Radiator Assembly............................................................................ 769 Safety Instructions...................................................................... 773 General.................................................................................. 773 Overview............................................................................. 773 Structure............................................................................ 774 CAC (Charge Air Cooler).................................................................. 776 Overview............................................................................. 776 Radiator................................................................................. 779 Overview............................................................................. 779 Theory of Operation.................................................................. 779 Radiator Cap......................................................................... 780 Replacing - Radiator Cap............................................................. 781 Replacing Coolant.................................................................... 781 Antifreeze Concentration Tables...................................................... 782 HST (Hydro-Static Transmission).................................................................. 783 HST Pump..................................................................................... 785 Safety Instructions...................................................................... 789 General.................................................................................. 790 Layout............................................................................... 790 Specification........................................................................ 791 Overview............................................................................. 792 Hydraulic Circuit.................................................................... 794 Parts List........................................................................... 800 HST Pump - Rotary Group.......................................................... 800 HST Pump - Control............................................................... 802 Section View............................................................................. 804 Removal.................................................................................. 805 Installation............................................................................. 812 Completing Work.......................................................................... 812 Disassembly and Reassembly............................................................... 813 Controller........................................................................... 813 Removing controller.............................................................. 813 Sealing Controller............................................................... 814 Installing the Controller........................................................ 815 Setting Controller (Hydraulic Neutral Position).................................. 816 Internal Gear Pump (Boost Pump)...................................................... 817 Remove Internal Gear Pump Cover.................................................. 817 Seal/Install Internal Gear Pump Cover............................................ 819 Shaft Seal........................................................................... 820 Exchange Shaft Seal.............................................................. 820 Valves............................................................................... 821 Seal/Replace the High-pressure Relief Valve...................................... 821 Seal/Replace Boost Relief Valve.................................................. 823 Seal/Replace Pressure Cut-off.................................................... 824 Set Pressure Cut-off............................................................. 825 Seal Shuttle Valve............................................................... 826 Pump Case/Rotary Group/Stroke Piston................................................. 827 Pump Case........................................................................ 827 Demount Rotary Group............................................................. 828 Demount Swashplate............................................................... 829 Replacing/Installing Swashplate.................................................. 829 Removing Driveshaft with Bearing................................................. 830 Replacing/Installing Driveshaft with Bearing..................................... 831 Replacing/Installing Rotary Group................................................ 832 Sealing Cover on Stroke Piston................................................... 833 Sealing Stroke Piston............................................................ 835 Installing Stroke Piston......................................................... 836 Pressure Setting......................................................................... 837 Low-pressure (Boost Relief Valve).................................................... 837 High-pressure........................................................................ 837 Travel Motor................................................................................. 839 Safety Instructions...................................................................... 843 General.................................................................................. 843 General Description.................................................................. 843 Layout............................................................................... 844 Specification........................................................................ 845 Overview............................................................................. 846 Theory of Operation.................................................................. 848 Parts List........................................................................... 852 Removal.................................................................................. 854 Installation............................................................................. 861 Completing Work.......................................................................... 861 Disassembly and Reassembly............................................................... 0 Cover (Motor 1)...................................................................... 866 Flushing and Boost Pressure Valve (Motor 2).......................................... 868 Driveshaft........................................................................... 870 Rotary Group......................................................................... 876 HST Filter................................................................................... 879 Safety Instructions...................................................................... 883 General.................................................................................. 883 General Description.................................................................. 883 Overview............................................................................. 883 Specification........................................................................ 883 Parts List........................................................................... 884 Hydraulic System................................................................................. 885 Main Pump.................................................................................... 887 Safety Instructions...................................................................... 891 General.................................................................................. 891 General Description.................................................................. 891 Overview............................................................................. 892 Specification........................................................................ 893 Hydraulic Circuit.................................................................... 893 Parts List........................................................................... 894 Location............................................................................. 895 Removal.................................................................................. 896 Installation............................................................................. 902 Completing Work.......................................................................... 902 Disassembly.............................................................................. 903 Reassembly............................................................................... 906 Main Control Valve........................................................................... 909 Safety Instructions...................................................................... 913 General.................................................................................. 913 General Description.................................................................. 913 Overview............................................................................. 914 Specification........................................................................ 915 Hydraulic Circuit.................................................................... 916 Theory of Operation.................................................................. 918 Removal.................................................................................. 932 Disassembly and Reassembly............................................................... 939 Unloader Valve............................................................................... 943 Safety Instructions...................................................................... 947 General.................................................................................. 947 General Description.................................................................. 947 Overview............................................................................. 948 Hydraulic Circuit.................................................................... 949 Function............................................................................. 949 Parts List........................................................................... 950 Removal.................................................................................. 951 Installation............................................................................. 955 Completing Work.......................................................................... 955 Clutch and Pilot Supply Valve................................................................ 957 Safety Instructions...................................................................... 961 General.................................................................................. 961 General Description.................................................................. 961 Overview............................................................................. 962 Hydraulic Circuit.................................................................... 963 Function............................................................................. 963 Parts List........................................................................... 964 Removal.................................................................................. 965 Pilot System................................................................................. 971 Safety Instructions...................................................................... 975 General.................................................................................. 975 General Description.................................................................. 975 Fingertip Joystick....................................................................... 976 Specification........................................................................ 976 Port Name............................................................................ 976 Parts List - 2 Lever................................................................. 977 Parts List - 3 Lever................................................................. 978 FNR Joystick............................................................................. 979 Overview............................................................................. 979 Specification........................................................................ 979 Port Name............................................................................ 979 Parts List........................................................................... 980 Hydraulic System............................................................................. 983 Safety Instructions...................................................................... 987 Hydraulic Component and Oil Flow......................................................... 988 Hydraulic Components................................................................. 988 Fan Drive Operation...................................................................... 990 Parking Brake Release Operation.......................................................... 991 Service Brake Operation.................................................................. 992 Steering Operation....................................................................... 993 Boom Raise Operation..................................................................... 994 Boom Down Operation...................................................................... 996 Boom Floating Operation.................................................................. 998 Bucket Crowd Operation...................................................................1000 Bucket Dump Operation....................................................................1002 Load Isolate System (LIS)................................................................1004 Frame............................................................................................1005 Articulation Center..........................................................................1007 Safety Instructions......................................................................1011 General..................................................................................1011 General Description..................................................................1011 Maintenance Standard.................................................................1012 Cabin........................................................................................1015 Safety Instructions......................................................................1019 Cabin Identification.....................................................................1019 Roll-over Protective Structure (ROPS)/Falling Object Protective Structure (FOPS).....1019 Dimensions of Cabin Glass................................................................1021 Removal and Installation of Cabin Glass..................................................1026 Removal of Cabin Glass...............................................................1026 Installation of Cabin Glass..........................................................1028 Counterweight................................................................................1033 Safety Instructions......................................................................1037 General..................................................................................1038 Overview.............................................................................1038 Oil Tank.....................................................................................1039 Safety Instructions......................................................................1043 General..................................................................................1043 Specifications.......................................................................1043 Parts List...........................................................................1044 Air Breather.........................................................................1046 Fuel Tank....................................................................................1047 Safety Instructions......................................................................1051 General..................................................................................1051 Specifications.......................................................................1051 Parts List...........................................................................1052 Cylinders....................................................................................1055 Safety Instructions......................................................................1059 General..................................................................................1059 General Description..................................................................1059 Specification........................................................................1059 Parts List...........................................................................1060 Theory of Operation..................................................................1072 Seal of Cylinder.....................................................................1073 Special Tools and Materials.............................................................. 0 Rod Bushing (DD-bushing) Pushing-in Jig..............................................1081 Disassembly..............................................................................1082 Reassembly...............................................................................1087 Troubleshooting..........................................................................1091 Electrical System................................................................................1093 Electrical System............................................................................1095 Safety Instructions......................................................................1099 Overview.................................................................................1099 Electric Supply System...................................................................1100 Engine Starting Circuit..................................................................1102 Operation During Start Process.......................................................1102 Operation After Start Process........................................................1104 Engine Stop System.......................................................................1106 Engine Emergency Start System............................................................1108 Charging System..........................................................................1110 Engine Control System.................................................................... 0 Acceleration Behavior Mode Control...................................................1114 Accelerator Pedal....................................................................1115 Throttle Lock Up/Down................................................................1116 Auto Idle Control....................................................................1117 Electric Detent System...................................................................1118 Electrical Circuit...................................................................1118 Boom Kick-out........................................................................1119 Return to Dig........................................................................1120 Cooling Fan Control System...............................................................1121 Outline..............................................................................1121 Diagram..............................................................................1121 Electrical Diagram...................................................................1122 Parts of Cooling Fan Control System..................................................1123 Operation of Cooling Fan Control System..............................................1125 Emergency Steering System (Option).......................................................1127 Block Diagram........................................................................1127 Emergency Steering System Electrical Circuit.........................................1131 Lighting System..........................................................................1134 Light Circuit........................................................................1134 Monitoring System........................................................................ 0 Instrument Panel.....................................................................1139 Function Check.......................................................................1139 Monitoring System Schematic..........................................................1140 Operation................................................................................ 0 Initial Operation....................................................................1144 Multifunction Display................................................................1145 Warning and Indicator Lights.............................................................1148 Indication of Warning Lights.........................................................1148 Indication of Indicator Lights.......................................................1149 Graphic Information Area Display......................................................... 0 User Menu............................................................................1153 Failure Code.............................................................................1185 Failure Code at Machine..............................................................1185 Failure Code at Engine Side..........................................................1188 Failure Code at HST Pump Side........................................................1196 FMIs (Failure Mode Identifier).......................................................1199 Windshield Wiper.........................................................................1200 Front Windshield Wiper...............................................................1200 Rear Windshield Wiper................................................................1202 Air Conditioner..............................................................................1203 Safety Instructions......................................................................1207 General..................................................................................1208 General Description..................................................................1208 Internal and External Filters........................................................1209 Air-conditioning System Layout.......................................................1210 Air Conditioner/Heater Unit..........................................................1212 Ambient Air Temperature Sensor.......................................................1217 Receiver Dryer.......................................................................1225 Troubleshooting..........................................................................1226 Refrigerant System Repairs...............................................................1228 Refrigerant Safe Handling Procedures.................................................1228 Repair and Replacement Procedure.....................................................1229 Refrigerant Recovery.................................................................1231 Vacuuming Refrigerant System.........................................................1231 Leakage Check........................................................................1233 Refrigerant Charging.................................................................1233 Inspecting System for Leakage........................................................1235 Option...........................................................................................1237 Emergency Steering...........................................................................1239 Safety Instructions......................................................................1243 General..................................................................................1243 General Description..................................................................1243 Specifications.......................................................................1243 Parts List...........................................................................1245 Caution for Installation.............................................................1245 Installation Procedure...................................................................1246 Emergency Steering...................................................................1246 Emergency Steering - Electric........................................................1248 After Installation Precautions.......................................................1249 Emergency Steering Function Test.....................................................1249 Emergency Steering Automatic Test....................................................1250 Load Isolation System........................................................................1251 Safety Instructions......................................................................1255 General..................................................................................1255 General Description..................................................................1255 Overview.............................................................................1256 Hydraulic Circuit....................................................................1258 Accumulator Charging Method..........................................................1258 LIS Valve................................................................................1260 Specification........................................................................1260 Parts List...........................................................................1261 Accumulator..............................................................................1262 Specification........................................................................1262 Parts List...........................................................................1262 Schematic........................................................................................1263 Hydraulic Schematic / Electrical Schematic...................................................1265 Blank Page...........................................................................................1268 Blank Page...........................................................................................1270
VIDEO PREVIEW OF THE MANUAL:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- 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