Daewoo Doosan WHEEL LOADER DL220-5 Shop Manual 950106-01724E-1 – PDF DOWNLOAD

Description

Daewoo Doosan WHEEL LOADER DL220-5 Shop Manual 950106-01724E-1 – PDF DOWNLOAD

DESCRIPTION:

Daewoo Doosan WHEEL LOADER DL220-5 Shop Manual 950106-01724E-1 – PDF DOWNLOAD

GENERAL

Safe Operation is Operator’s Responsibility Only trained and authorized personnel should operate and maintain the machine. Follow all safety rules, regulations and instructions when operating or performing maintenance on machine.

• Do not operate machine if you are under the influence of drugs or alcohol. An operator who is taking prescription drugs must get medical advice to determine if he or she can safely operate the machine.

• When working with other personnel on a work site, be sure that all personnel know the nature of work and understand all hand signals that are to be used.

• Be sure that all guards and shields are installed in their proper location. Have guards and shields repaired or replaced immediately if damaged.

• Be sure that you understand the use and maintenance of all safety features such as pilot cutoff switch and seat belt. Use them always.

• Never remove, modify or disable any safety features. Always keep them in good operating condition.

• Always check for and know the location of underground and overhead utility lines before working.

• Failure to use and maintain safety features according to instructions in this manual, Safety Manual and Shop Manual can result in death or serious injury.

Know Your Machine

Know how to operate your machine. Know the purpose of all controls, gauges, signals, indicators and monitor displays. Know the rated load capacity, speed range, braking and steering characteristics, turning radius and operating clearances. Keep in mind that rain, snow, ice, loose gravel, soft ground, slopes, etc., can change operating capabilities of your machine.

Proper Work Tools and Attachments

• Only use work tools and attachments that are recommended by DOOSAN for use on DOOSAN machines. When installing and using optional attachments, read instruction manual for attachment, and general information related to attachments in this manual. Because DOOSAN cannot anticipate, identify or test all attachments that owners may want to install on their machines, contact DOOSAN for written authorization and approval of attachments, and their compatibility with optional kits
• Attachments and attachment control systems that are compatible with the machine are required for safe and reliable machine operation. Do not exceed maximum operating weight (machine weight plus attachment) that is listed on ROPS certification plate. Make sure that all guards and shields are in place on machine and on work tool.
• Depending on type or combination of work equipment, there is a potential that work equipment could interfere with the cabin or other parts of machine. Before using unfamiliar work equipment, check if there is any potential for interference, and operate with caution. While you are performing any maintenance, testing, or adjustments to attachments, stay clear of the following areas: cutting edges, pinch points, and crushing surfaces. Never use attachment as a work platform or manlift. Contact your DOOSAN distributor about auxiliary hydraulic kits for attachments installation.
• If you are in doubt about the compatibility of a particular attachment with the machine, consult your DOOSAN distributor

Pressurized Fluids

• Pressurized air or fluids can cause debris and/or fluids to be blown out. This could result in death or serious injury. Immediately after operation is stopped, coolant, engine oil, and hydraulic oil are at their highest temperatures and the radiator and hydraulic tank are still under pressure.
• Always wait for temperature to cool down. Follow specified procedures when attempting to remove caps, drain oil or coolant, or replacing filters. Always wait for temperature to cool down, and follow specified procedures when performing these operations. Failure to do so can result in death or serious injury.
• When pressurized air and/or pressurized water is used for cleaning, wear protective clothing, protective shoes, and eye protection. Eye protection includes goggles or a protective face shield. Pressure can be trapped in a hydraulic system and must be relieved before maintenance is started.
• Releasing trapped pressure can cause sudden machine movement or attachment movement. Use caution if you disconnect hydraulic lines or fittings. High-pressure oil that is released can cause a hose to whip or oil to spray. Fluid penetration can result in death or serious injury.
• If fluid enters skin or eyes, get immediate medical attention from a physician familiar with this injury. Obey all local laws and regulations for disposal of liquids. To prevent hot coolant from spraying out, stop engine and wait for coolant to cool. Using gloves, slowly loosen cap to relieve pressure.

TABLE OF CONTENTS:

Daewoo Doosan WHEEL LOADER DL220-5 Shop Manual 950106-01724E-1 – PDF DOWNLOAD

DL220-5.......................................................................................................   0
	Table of Contents.........................................................................................   7
	Safety....................................................................................................   9
		Wheel Loader Safety...................................................................................  11
			Safety Instructions...............................................................................  11
			Safety Messages...................................................................................  13
			General...........................................................................................  15
				Safe Operation is Operator's Responsibility...................................................  15
				Know Your Machine.............................................................................  15
				Proper Work Tools and Attachments.............................................................  15
				Pressurized Fluids............................................................................  16
				Flying or Falling Objects.....................................................................  17
				Personal Protective Equipment (PPE)...........................................................  17
				Correction of Machine Problems................................................................  18
				Crushing and Cutting..........................................................................  18
				Hot Coolant and Oils - Burn Prevention........................................................  19
				Fire and Explosion Prevention.................................................................  19
				Fire Extinguisher and First-Aid Kit (Emergency Medical Kit)...................................  23
				Electrical System and Electrical Shock........................................................  23
				Roll-over Protective Structure (ROPS)/ Falling Object Protective Structure (FOPS).............  24
			Operation.........................................................................................  26
				Before Engine Starting........................................................................  26
				Work Site.....................................................................................  26
				Check Tire Pressure and Condition.............................................................  27
				Mounting/Dismounting..........................................................................  27
				Cleaning......................................................................................  28
				Operator Station..............................................................................  28
				Seat Belt.....................................................................................  29
				Visibility Information........................................................................  30
				Boost Starting or Charging Engine Batteries...................................................  31
				Starting Engine...............................................................................  32
				Traveling.....................................................................................  32
				Lifting and Digging...........................................................................  34
				Digging Beneath Overhangs.....................................................................  34
				Digging Beneath Wheel Loader..................................................................  34
				Operation on Slopes...........................................................................  35
				Attachment....................................................................................  36
				Equipment Lowering with Engine Stopped........................................................  36
				Preventing Risk of Injuries or Death From Boom and Bucket.....................................  36
				Engine Stop...................................................................................  38
				Parking Machine...............................................................................  38
			Maintenance.......................................................................................  39
				Warning Tag...................................................................................  41
				Cleaning......................................................................................  42
				Proper Tools and Clothing.....................................................................  42
				Disassembling Precautions.....................................................................  42
				Use of Lighting...............................................................................  43
				Fire and Explosion Prevention.................................................................  43
				Burn Prevention...............................................................................  44
				Rubber That Contains Fluorides................................................................  45
				Rubber and Plastics...........................................................................  46
				Welding Repairs...............................................................................  47
				Working on Machine............................................................................  48
				Lock Inspection Covers........................................................................  49
				Accumulator...................................................................................  49
				Compressed Air................................................................................  49
				Supports and Blocking for Work Equipment......................................................  50
				High-pressure Lines, Tubes and Hoses..........................................................  50
				Battery.......................................................................................  51
				Preservation/Storing Machine..................................................................  52
			Transportation....................................................................................  54
				Obey State and Local Over-the-Road Laws and Regulations.......................................  54
				Loading and Unloading.........................................................................  54
				Transporting Machine..........................................................................  55
			Environment and Circumstances.....................................................................  56
				Work Site Areas Requiring Extra Caution.......................................................  56
				High-voltage Cables...........................................................................  58
				Underground Operation.........................................................................  58
				Working in Water..............................................................................  59
				Working in Contaminated Environment...........................................................  59
				Operation in Extreme Conditions...............................................................  60
				Exhaust Ventilation...........................................................................  64
				Asbestos Information..........................................................................  64
				Silica Dust Information.......................................................................  65
				Disposal of Hazardous Materials...............................................................  65
				Sound.........................................................................................  66
				Vibration Information.........................................................................  66
	Specifications............................................................................................  69
		Specification.........................................................................................  71
			Safety Instructions...............................................................................  71
			General...........................................................................................  73
				General description...........................................................................  73
			Component Locations...............................................................................  74
			Working Range and Dimensions......................................................................  78
			Working Capacities................................................................................  80
				Bucket Capacity...............................................................................  80
				Stability.....................................................................................  80
			General Specifications............................................................................  81
			Performance Tests.................................................................................  82
				Purpose of Performance Tests..................................................................  82
				Kinds of Tests................................................................................  82
				Performance Standards.........................................................................  82
				Precautions for Evaluation of Test Data.......................................................  82
				Definition of "Performance Standard"..........................................................  82
			Preparation for Performance Tests.................................................................  83
				The Machine...................................................................................  83
				Test Area.....................................................................................  83
				Precautions...................................................................................  83
				Make Precise Measurement......................................................................  83
			Operational Performance Standard Table............................................................  84
			Operational Performance Test......................................................................  86
				Engine Speed..................................................................................  86
				Front Speed...................................................................................  88
				Natural Subsidence of Cylinder................................................................  89
				Travel Speed - Acceleration and Deceleration..................................................  90
				Steering Time.................................................................................  91
				Hydraulic Pressure Checks.....................................................................  92
			Approximate Weight of Workload Materials..........................................................  94
				Material Weight...............................................................................  94
	General Maintenance.......................................................................................  97
		General Maintenance Instructions......................................................................  99
			Safety Instructions...............................................................................  99
			Welding Precautions and Instructions.............................................................. 101
			Hydraulic System - General Precautions............................................................ 102
			Maintenance Service and Repair Procedure.......................................................... 104
				General Precautions........................................................................... 104
			Hydraulic System Cleanliness and Oil Leaks........................................................ 105
				Maintenance Precautions for Hydraulic System Service.......................................... 105
				Oil Leakage Precautions....................................................................... 106
			Cleaning and Inspection........................................................................... 107
				General Instructions.......................................................................... 107
				Bearing Inspection............................................................................ 108
		Standard Torques...................................................................................... 115
			Safety Instructions............................................................................... 115
			Torque Values for Standard Metric Fasteners....................................................... 117
			Torque Values for Standard U.S. Fasteners......................................................... 118
			Type 8 Phosphate Coated Hardware.................................................................. 120
			Torque Values for Hose Clamps..................................................................... 121
			ORFS Swivel Nut Recommended Torque................................................................ 121
			Torque Values for Split Flanges................................................................... 122
			Torque Wrench Extension Tools..................................................................... 123
				Torque Multiplication......................................................................... 123
				Other Uses for Torque Wrench Extension Tools.................................................. 124
				Tightening Torque Specifications (Metric)..................................................... 125
	Engine.................................................................................................... 129
		Engine................................................................................................ 131
			Safety Instructions............................................................................... 131
			Overview.......................................................................................... 134
			General Information............................................................................... 135
				General Description........................................................................... 135
				Engine Maintenance............................................................................ 139
				Inspection and Repair of the Engine........................................................... 142
			Engine Identification............................................................................. 144
				Engine Data Plate............................................................................. 144
			Engine Specification.............................................................................. 146
			Engine Performance Curves......................................................................... 147
			Special Tools..................................................................................... 148
			Tightening Torques................................................................................ 152
				Major Parts Tightening Torque................................................................. 152
				Tightening Torque for General Bolts........................................................... 154
				Tightening Torque of Plug Screw............................................................... 155
				Hollow Screw (4-Hole) Tightening Torque....................................................... 155
			Engine Disassembly................................................................................ 156
				Engine Disassembly............................................................................ 156
			Engine Assembly................................................................................... 171
				Engine Assembly............................................................................... 171
			Cylinder.......................................................................................... 194
				General Information........................................................................... 194
				Cylinder Head................................................................................. 194
				Cylinder Block................................................................................ 198
				Valve Mechanism............................................................................... 200
			Actuating System.................................................................................. 212
				Camshaft...................................................................................... 212
				Piston........................................................................................ 214
				Connecting Rod................................................................................ 218
				Crankshaft.................................................................................... 220
				Timing Gear................................................................................... 225
			Lubrication system................................................................................ 226
				General Information........................................................................... 226
				Oil Pan....................................................................................... 230
				Oil Pump...................................................................................... 232
				Oil Filter.................................................................................... 234
			Exhaust System.................................................................................... 237
				Turbocharger.................................................................................. 237
				EGR (Exhaust Gas Recirculation) System........................................................ 249
				DNOx System................................................................................... 256
			Cooling System.................................................................................... 267
				General information........................................................................... 267
				Thermostat.................................................................................... 268
			Fuel System....................................................................................... 272
				General Information........................................................................... 272
				Fuel High-pressure System Components.......................................................... 273
				Injector...................................................................................... 274
				Common Rail................................................................................... 278
				Fuel Injection Pump........................................................................... 282
			Electrical System................................................................................. 286
				Electrical Parts.............................................................................. 286
				Switches and Sensors.......................................................................... 288
				ECU (Electronic Control Unit)................................................................. 292
				Starter....................................................................................... 294
				Exhaust Gas Reduction......................................................................... 296
				Circuit Diagram............................................................................... 300
	Drivetrain................................................................................................ 305
		Transmission.......................................................................................... 307
			Safety Instructions............................................................................... 307
			General........................................................................................... 311
				General Description........................................................................... 311
				Specification................................................................................. 312
				Overview...................................................................................... 313
				Section View.................................................................................. 316
				Hydraulic Circuit (4-speed Transmission)...................................................... 318
				Torque Convertor.............................................................................. 319
				Electrohydraulic Control with Proportional Valves............................................. 322
				Controller.................................................................................... 323
				Electric Control System....................................................................... 324
				Speed Sensor.................................................................................. 327
			Measuring Points and Connections.................................................................. 330
			Transmission Electric Components.................................................................. 332
				TCU (Transmission Control Unit)............................................................... 334
				Transmission Control Valve.................................................................... 334
				Transmission Oil Temperature Sensor........................................................... 334
				Engine Pickup Sensor.......................................................................... 335
				Central Gear Pickup Sensor.................................................................... 335
				Turbine Pickup Sensor......................................................................... 335
				Output Speed Sensor........................................................................... 335
				Shift Lever Switch (DW-3)..................................................................... 336
				Forward, Reverse Switch Lever................................................................. 337
				Fingertip Work Lever (Optional)............................................................... 337
				Transmission Shift Switch..................................................................... 339
				T/M Cutoff Sensor............................................................................. 339
				LIS Solenoid Valve............................................................................ 339
			Transmission Electrical Circuits.................................................................. 340
				Transmission Controller Circuit............................................................... 340
				Transmission Control Unit Terminal............................................................ 341
				Downshift..................................................................................... 349
				Transmission Cutoff Switch.................................................................... 356
			Torque Limits for Screws.......................................................................... 357
			Special Tools..................................................................................... 358
				List of Special Tools for Disassembly and Reassembly.......................................... 358
			Transmission Oil.................................................................................. 364
				Oil Grade of Transmission..................................................................... 364
			Disassembly....................................................................................... 365
				Electrohydraulic Control and Transmission Filter (Replaceable Filter)......................... 365
				Inductive Sensor, Hall Sensor, Breather, Oil Filler and Oil Drain Plug........................ 370
				Engine Connection, Oil Pressure Pump, Converter Back-pressure Valve and Temperature Sensor.... 371
				Outputs and Closure Parts Pump Shaft (PTO-Shaft).............................................. 375
				Removal of Input Shaft, Output Shaft, Pump Shaft (PTO-shaft) and Clutches..................... 377
				Clutches KV/KR/K1/K2/K3/K4 Input and Output Shaft............................................. 382
			Reassembly........................................................................................ 406
				Clutches KV/KR/K1/K2/K3/K4 Input and Output Shaft............................................. 406
				Installation of Input Shaft, Output Shaft, Pump Shaft (Power-takeoff Shaft) and Clutches...... 445
				Outputs and Closure Parts Pump Shaft (PTO-shaft).............................................. 452
				Engine Connection, Oil Pressure Pump, Converter Back-pressure Valve and Temperature Sensor.... 455
				Emergency Steering Pump....................................................................... 459
				Inductive Sensor, Hall Sensor, Breather, Oil Filler and Oil Drain Plug........................ 460
				Electrohydraulic Control with Proportional Valves............................................. 461
			Failure Code...................................................................................... 469
		Front Axle............................................................................................ 495
			Safety Instructions............................................................................... 495
			General........................................................................................... 498
				Specification................................................................................. 498
				Overview...................................................................................... 499
				Parts List.................................................................................... 500
			Lubrication and Maintenance Instructions.......................................................... 502
				Oil Change.................................................................................... 502
				Carry Out Wear Measurement on the Multidisk Brake............................................. 504
				Tightening Torques for Screws................................................................. 505
			Differential System............................................................................... 506
				Theory of Differential Device................................................................. 506
				Structure of Differential Device.............................................................. 507
			LSD............................................................................................... 508
				Overview LSD (Limited Slip Differential)...................................................... 508
				LSD (Limited Slip Differential)............................................................... 509
			Axle Air Breathing................................................................................ 510
			Special Tools..................................................................................... 511
				List of Special Tools for Disassembly and Reassembly.......................................... 511
			Axle Oils......................................................................................... 518
				Oil Grade ZF-Powerfluid....................................................................... 518
			Removal........................................................................................... 519
			Installation...................................................................................... 523
			Completing Work................................................................................... 523
			Disassembly....................................................................................... 524
				Output and Brake.............................................................................. 524
				Axle Housing.................................................................................. 529
				Input......................................................................................... 530
				Differentials................................................................................. 533
			Reassembly........................................................................................ 537
				Differentials................................................................................. 537
				Input......................................................................................... 547
				Axle Housing.................................................................................. 557
				Output and Brake.............................................................................. 558
		Rear Axle............................................................................................. 569
			Safety Instructions............................................................................... 569
			General........................................................................................... 571
				Specification................................................................................. 571
				Overview...................................................................................... 572
				Parts List.................................................................................... 573
			Lubrication and Maintenance Instructions.......................................................... 576
				Oil Change.................................................................................... 576
				Carry Out Wear Measurement on the Multidisk Brake............................................. 578
				Tightening Torques for Screws................................................................. 579
			Differential System............................................................................... 580
				Theory of Differential Device................................................................. 580
				Structure of Differential Device.............................................................. 581
			Axle Air Breathing................................................................................ 582
			Special Tools..................................................................................... 583
				List of Special Tools for Disassembly and Reassembly.......................................... 583
			Axle Oils......................................................................................... 590
				Oil Grade ZF-Powerfluid....................................................................... 590
			Removal........................................................................................... 591
			Installation...................................................................................... 596
			Completing Work................................................................................... 596
			Disassembly....................................................................................... 597
				Output and Brake.............................................................................. 597
				Axle Housing.................................................................................. 602
				Input......................................................................................... 604
				Differentials................................................................................. 606
			Reassembly........................................................................................ 609
				Differentials................................................................................. 609
				Input......................................................................................... 616
				Axle Housing.................................................................................. 624
				Output and Brake.............................................................................. 626
		Driveshaft............................................................................................ 637
			Safety Instructions............................................................................... 637
			General........................................................................................... 639
				Overview...................................................................................... 639
				Specification................................................................................. 639
			Removal (Front Driveshaft)........................................................................ 641
			Installation (Front Driveshaft)................................................................... 644
			Removal (Center Driveshaft)....................................................................... 645
			Installation (Center Driveshaft).................................................................. 648
			Removal (Rear Driveshaft)......................................................................... 649
			Installation (Rear DriveShaft).................................................................... 651
	Steering.................................................................................................. 653
		Power Steering System................................................................................. 655
			Safety Instructions............................................................................... 655
			General........................................................................................... 657
				General Description........................................................................... 657
				Overview...................................................................................... 658
				Hydraulic Circuit............................................................................. 659
				Theory of Operation........................................................................... 660
		Steering Unit......................................................................................... 663
			Safety Instructions............................................................................... 663
			General........................................................................................... 665
				General Description........................................................................... 665
				Specifications................................................................................ 667
				Overview...................................................................................... 668
				Theory of Operation........................................................................... 669
				Gerotor Operation............................................................................. 670
				Relief Valve.................................................................................. 670
		Priority Valve........................................................................................ 671
			Safety Instructions............................................................................... 671
			General........................................................................................... 673
				General Description........................................................................... 673
			Tool List......................................................................................... 673
			Removal........................................................................................... 674
			Installation...................................................................................... 679
			Completing Work................................................................................... 679
			Disassembly....................................................................................... 680
			Reassembly........................................................................................ 682
	Brake..................................................................................................... 685
		Service Brake......................................................................................... 687
			Safety Instructions............................................................................... 687
			General........................................................................................... 689
				General Description........................................................................... 689
			Service Brake System.............................................................................. 690
		Brake & Pilot Supply Valve............................................................................ 693
			Safety Instructions............................................................................... 693
			General........................................................................................... 695
				General Description........................................................................... 695
				Overview...................................................................................... 696
				Hydraulic Circuit............................................................................. 697
				Parts List.................................................................................... 698
			Removal........................................................................................... 699
			Installation...................................................................................... 704
			Completing Work................................................................................... 704
		Charging Block........................................................................................ 705
			Safety Instructions............................................................................... 705
			General........................................................................................... 707
				General Description........................................................................... 707
				Parts List.................................................................................... 707
				Hydraulic Circuit............................................................................. 708
		Parking Brake......................................................................................... 709
			Safety Instructions............................................................................... 709
			General........................................................................................... 711
				Specification................................................................................. 711
				Overview...................................................................................... 711
				Parts List.................................................................................... 712
				Theory of Operation........................................................................... 713
			Installing and Setting Instructions............................................................... 715
				Installing the Brake.......................................................................... 715
				Clearance Adjusting........................................................................... 716
				Adjusting Instructions........................................................................ 717
			Emergency Release of the Parking Brake............................................................ 718
			Maintenance and Repair Work....................................................................... 719
				Maintenance and Replacement of the Lining Pads................................................ 719
				Replacing the Seals........................................................................... 722
		Brake Pedal Valve..................................................................................... 725
			Safety Instructions............................................................................... 725
			General........................................................................................... 727
				Specification................................................................................. 727
				Parts List.................................................................................... 727
				Theory of Operation........................................................................... 728
		Accumulator........................................................................................... 731
			Safety Instructions............................................................................... 731
			General........................................................................................... 733
				General Description........................................................................... 733
				Layout........................................................................................ 735
				Specifications................................................................................ 735
	Cooling System............................................................................................ 737
		Cooling System........................................................................................ 739
			Safety Instructions............................................................................... 739
			General........................................................................................... 741
				General Description........................................................................... 741
				Function...................................................................................... 742
				Hydraulic Circuit............................................................................. 743
				Fan Motor Pressure and Fan Speed.............................................................. 744
		Fan and Brake Pump.................................................................................... 747
			Safety Instructions............................................................................... 747
			General........................................................................................... 749
				Specification................................................................................. 749
				Section View.................................................................................. 749
				EPPR Valve.................................................................................... 750
				Overview...................................................................................... 750
				Parts List.................................................................................... 752
				Theory of Operation........................................................................... 754
			Removal........................................................................................... 758
			Installation...................................................................................... 763
			Completing Work................................................................................... 763
			Maintenance Guidelines............................................................................ 764
				Sealing Driveshaft............................................................................ 765
				Sealing Control Valve......................................................................... 767
				Tools......................................................................................... 767
			Disassembly....................................................................................... 768
				Disassembly of Rotary Group................................................................... 769
				Disassembly of Control Device................................................................. 770
				Disassembly of Shaft/Bearings................................................................. 771
			Cleaning and Inspection........................................................................... 772
			Reassembly........................................................................................ 775
				Adjustment of Taper Roller Bearing............................................................ 776
		Fan Motor............................................................................................. 781
			Safety Instructions............................................................................... 781
			General........................................................................................... 783
				Specifications................................................................................ 783
				Overview...................................................................................... 783
		Fan Control Valve..................................................................................... 785
			Safety Instructions............................................................................... 785
			General........................................................................................... 787
				Specifications................................................................................ 787
		Radiator Assembly..................................................................................... 789
			Safety Instructions............................................................................... 789
			General........................................................................................... 791
				Overview...................................................................................... 791
				Structure..................................................................................... 792
				Parts List.................................................................................... 793
			CAC (Charge Air Cooler)........................................................................... 794
				Overview...................................................................................... 794
				Replacing - Hose/Pipe (Charge Air Cooler)..................................................... 795
			Radiator.......................................................................................... 797
				Overview...................................................................................... 797
				Theory of Operation........................................................................... 797
				Radiator Cap.................................................................................. 798
				Replacing - Radiator Cap...................................................................... 799
				Replacing Coolant............................................................................. 799
				Antifreeze Concentration Tables............................................................... 800
			Transmission Cooling.............................................................................. 801
				General Description........................................................................... 801
				Layout........................................................................................ 801
				Thermostat.................................................................................... 802
	Hydraulic System.......................................................................................... 803
		Main Pump............................................................................................. 805
			Safety Instructions............................................................................... 805
			General........................................................................................... 807
				General Description........................................................................... 807
				Specification................................................................................. 807
				Overview...................................................................................... 808
				Hydraulic Circuit............................................................................. 809
				Location...................................................................................... 810
				Parts List.................................................................................... 811
				Theory of Operation........................................................................... 814
			Removal........................................................................................... 815
			Installation...................................................................................... 821
			Completing Work................................................................................... 821
			Section View...................................................................................... 822
			Disassembly....................................................................................... 823
				Sealing Driveshaft............................................................................ 823
				Pump.......................................................................................... 824
				Inspection.................................................................................... 827
			Reassembly........................................................................................ 830
				Pump.......................................................................................... 830
			Pressure and Flow Setting......................................................................... 834
		Main Control Valve.................................................................................... 837
			Safety Instructions............................................................................... 837
			General........................................................................................... 839
				General Description........................................................................... 839
				Specification................................................................................. 840
				Overview...................................................................................... 842
				Hydraulic Circuit............................................................................. 844
				Parts List.................................................................................... 845
				Theory of Operation........................................................................... 846
			Removal........................................................................................... 859
			Installation...................................................................................... 865
			Completing Work................................................................................... 865
			Disassembly/Reassembly............................................................................ 866
			Torque Table...................................................................................... 868
		Pilot System.......................................................................................... 871
			Safety Instructions............................................................................... 871
			General........................................................................................... 873
				General Description........................................................................... 873
			Fingertip Joystick................................................................................ 874
				Specification................................................................................. 874
				Port Name..................................................................................... 874
				Parts List - 2 Lever.......................................................................... 875
				Parts List - 3 Lever.......................................................................... 876
			FNR Joystick...................................................................................... 877
				Specification................................................................................. 877
				Port Name..................................................................................... 877
				Overview...................................................................................... 877
				Parts List.................................................................................... 878
		Hydraulic System...................................................................................... 881
			Safety Instructions............................................................................... 881
			Hydraulic Component and Oil Flow.................................................................. 884
				Hydraulic Components.......................................................................... 884
			Fan Drive Operation............................................................................... 886
			Parking Brake Release Operation................................................................... 887
			Service Brake Operation........................................................................... 888
			Steering Operation................................................................................ 889
			Boom Raise Operation and Load Sensing............................................................. 890
			Boom Down Operation............................................................................... 892
			Boom Floating Operation........................................................................... 894
			Bucket Crowd Operation............................................................................ 896
			Bucket Dump Operation............................................................................. 898
			Combined Bucket Crowd and Boom Down Operation..................................................... 900
			Load Isolate System (LIS)......................................................................... 901
	Frame..................................................................................................... 903
		Articulation Center................................................................................... 905
			Safety Instructions............................................................................... 905
			General........................................................................................... 907
				Maintenance Standard.......................................................................... 908
		Cabin................................................................................................. 911
			Safety Instructions............................................................................... 911
			Cabin Identification.............................................................................. 913
				Roll-over Protective Structure (ROPS)/Falling Object Protective Structure (FOPS).............. 913
			Dimensions of Cabin Glass......................................................................... 915
			Removal and Installation of Cabin Glass........................................................... 920
				Removal of Cabin Glass........................................................................ 920
				Installation of Cabin Glass................................................................... 922
		Counterweight......................................................................................... 927
			Safety Instructions............................................................................... 927
			General........................................................................................... 929
				Overview...................................................................................... 929
		Oil Tank.............................................................................................. 931
			Safety Instructions............................................................................... 931
			General........................................................................................... 933
				Specifications................................................................................ 933
				Parts List.................................................................................... 934
				Air Breather.................................................................................. 936
		Fuel Tank............................................................................................. 937
			Safety Instructions............................................................................... 937
			General........................................................................................... 939
				Specifications................................................................................ 939
				Parts List.................................................................................... 940
		Cylinders............................................................................................. 943
			Safety Instructions............................................................................... 943
			General........................................................................................... 945
				General Description........................................................................... 945
				Specification................................................................................. 945
				Parts List.................................................................................... 946
				Theory of Operation........................................................................... 952
				Seal of Cylinder.............................................................................. 953
			Special Tools and Materials....................................................................... 955
				Piston Nut.................................................................................... 955
				Piston Jig.................................................................................... 956
				Steel Bushing Jig............................................................................. 957
				Dust Wiper Jig................................................................................ 958
				Slipper Seal Jig.............................................................................. 959
				Slipper Seal Straightening Jig................................................................ 960
				Rod Bushing (DD-bushing) Pushing-in Jig....................................................... 961
			Disassembly....................................................................................... 962
			Reassembly........................................................................................ 967
			Troubleshooting................................................................................... 971
	Electrical System......................................................................................... 973
		Electrical System..................................................................................... 975
			Safety Instructions............................................................................... 975
			Overview.......................................................................................... 979
			Electric Supply System............................................................................ 980
			Engine Starting Circuit........................................................................... 982
				Operation During Start Process................................................................ 982
				Operation After Start Process................................................................. 984
			Engine Stop System................................................................................ 985
			Engine Emergency Start System..................................................................... 986
			Charging System................................................................................... 987
			Engine Control System............................................................................. 988
				Power Mode Control............................................................................ 990
				Accelerator Pedal............................................................................. 991
				Auto Idle Control............................................................................. 992
			Electric Detent System............................................................................ 993
				Electrical Circuit............................................................................ 993
				Boom Kick-out................................................................................. 994
				Return to Dig................................................................................. 995
			Cooling Fan Control System........................................................................ 996
				Outline....................................................................................... 996
				Diagram....................................................................................... 996
				Electrical Diagram............................................................................ 997
				Parts of Cooling Fan Control System........................................................... 998
				Operation of Cooling Fan Control System.......................................................1000
			Emergency Steering System (Option)................................................................1002
				Block Diagram.................................................................................1002
				Emergency Steering System Components..........................................................1003
				Emergency Steering System Electrical Circuit..................................................1006
			Lighting System...................................................................................1008
				Light Circuit.................................................................................1008
			Monitoring System.................................................................................1012
				Instrument Panel..............................................................................1013
				Function Check................................................................................1013
				Monitoring System Schematic...................................................................1014
			Operation.........................................................................................1016
				Instruments Gauge.............................................................................1016
				Indicator Lights..............................................................................1016
				Initial Operation.............................................................................1018
				Multifunction Display.........................................................................1019
			Warning and Indicator Lights......................................................................1022
				Indication of Warning Lights..................................................................1022
				Indication of Indicator Lights................................................................1024
			Graphic Information Area Display..................................................................1026
				Overview......................................................................................1026
				Main Menus for the Graphic Display Area.......................................................1026
				Menu Selector Buttons.........................................................................1026
				User Menu.....................................................................................1027
				Service Menu..................................................................................1044
				Information of Machine Operation..............................................................1054
			Failure Code......................................................................................1061
				Failure Code at Machine.......................................................................1061
				Failure Code at Engine Side...................................................................1064
				Failure Code at Transmission Side.............................................................1097
				FMIs (Failure Mode Identifier)................................................................1101
			Windshield Wiper..................................................................................1102
				Front Windshield Wiper........................................................................1102
				Rear Windshield Wiper.........................................................................1104
		Air Conditioner.......................................................................................1105
			Safety Instructions...............................................................................1105
			General Description...............................................................................1107
				Internal and External Filters.................................................................1108
				Air-conditioning System Layout................................................................1109
				Air Conditioner/Heater Circuit Diagram........................................................1110
				Air Conditioner/Heater Unit...................................................................1111
				Ambient Air Temperature Sensor................................................................1116
				Sun Sensor....................................................................................1117
				Control Panel.................................................................................1117
				Compressor....................................................................................1124
				Receiver Dryer................................................................................1124
			Troubleshooting...................................................................................1125
			Refrigerant System Repairs........................................................................1127
				Refrigerant Safe Handling Procedures..........................................................1127
				Repair and Replacement Procedure..............................................................1128
				Refrigerant Recovery..........................................................................1130
				Vacuuming Refrigerant System..................................................................1130
				Leakage Check.................................................................................1132
				Refrigerant Charging..........................................................................1132
				Inspecting System for Leakage.................................................................1134
	Option....................................................................................................1135
		Emergency Steering....................................................................................1137
			Safety Instructions...............................................................................1137
			General...........................................................................................1139
				General Description...........................................................................1139
				Specifications................................................................................1139
				Theory of Operation...........................................................................1140
				Hydraulic Circuit.............................................................................1140
				Parts List....................................................................................1141
				Caution for Installation......................................................................1141
			Installation Procedure............................................................................1142
				Emergency Steering............................................................................1142
				Emergency Steering - Electric.................................................................1144
				After Installation Precautions................................................................1145
				Emergency Steering Function Test..............................................................1145
				Emergency Steering Automatic Test.............................................................1146
		Load Isolation System.................................................................................1147
			Safety Instructions...............................................................................1147
			General...........................................................................................1149
				General Description...........................................................................1149
				Overview......................................................................................1150
				Hydraulic Circuit.............................................................................1152
				Accumulator Charging Method...................................................................1152
			LIS Valve.........................................................................................1154
				Specification.................................................................................1154
				Parts List....................................................................................1155
			Accumulator.......................................................................................1156
				Specification.................................................................................1156
				Parts List....................................................................................1156
	Schematic.................................................................................................1157
		Hydraulic Schematic / Electrical Schematic............................................................1159
Blank Page....................................................................................................1162
Blank Page....................................................................................................1164

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