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

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

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