Daewoo Doosan WHEEL LOADER DL250-5DL250TC-5 SHOP MANUAL 950106-01253E-1 – PDF DOWNLOAD

Description

Daewoo Doosan WHEEL LOADER DL250-5DL250TC-5 SHOP MANUAL 950106-01253E-1 – PDF DOWNLOAD

DESCRIPTION:

Daewoo Doosan WHEEL LOADER DL250-5DL250TC-5 SHOP MANUAL 950106-01253E-1 – PDF DOWNLOAD

GENERAL

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

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

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

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

• Be sure that you understand the use and maintenance of all safety features such as pilot cutoff switch and seat belt. Use them always. • Never remove, modify or disable any safety features. Always keep them in good operating condition.

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

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

Know Your Machine

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

Proper Work Tools and Attachments

Only use work tools and attachments that are recommended by DOOSAN for use on DOOSAN machines. When installing and using optional attachments, read instruction manual for attachment, and general information related to attachments in this manual. Because DOOSAN cannot anticipate, identify or test all attachments that owners may want to install on their machines, contact DOOSAN for written authorization and approval of attachments, and their compatibility with optional kits

Pressurized Fluids

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

TABLE OF CONTENTS:

Daewoo Doosan WHEEL LOADER DL250-5DL250TC-5 SHOP MANUAL 950106-01253E-1 – PDF DOWNLOAD

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

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