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

Description

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

DESCRIPTION:

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

DL250-5/DL250TC-5.............................................................................................   0
	NOTICE....................................................................................................   7
	Table of Contents.........................................................................................   9
	Safety....................................................................................................  11
		Wheel Loader Safety...................................................................................  13
			Safety Instructions...............................................................................  17
			Safety Messages...................................................................................  17
			General...........................................................................................  19
				Safe Operation is Operator's Responsibility...................................................  19
				Know Your Machine.............................................................................  19
				Proper Work Tools and Attachments.............................................................  19
				Pressurized Fluids............................................................................  20
				Flying or Falling Objects.....................................................................  21
				Personal Protective Equipment (PPE)...........................................................  21
				Correction of Machine Problems................................................................  22
				Crushing and Cutting..........................................................................  22
				Hot Coolant and Oils - Burn Prevention........................................................  23
				Fire and Explosion Prevention.................................................................  23
				Fire Extinguisher and First-Aid Kit (Emergency Medical Kit)...................................  27
				Electrical System and Electrical Shock........................................................  27
				Roll-over Protective Structure (ROPS)/ Falling Object Protective Structure (FOPS).............  28
			Operation.........................................................................................  30
				Before Engine Starting........................................................................  30
				Work Site.....................................................................................  30
				Check Tire Pressure and Condition.............................................................  31
				Mounting/Dismounting..........................................................................  31
				Cleaning......................................................................................  32
				Operator Station..............................................................................  32
				Seat Belt.....................................................................................  33
				Visibility Information........................................................................  34
				Boost Starting or Charging Engine Batteries...................................................  35
				Starting Engine...............................................................................  36
				Traveling.....................................................................................  36
				Lifting and Digging...........................................................................  38
				Digging Beneath Overhangs.....................................................................  38
				Digging Beneath Wheel Loader..................................................................  38
				Operation on Slopes...........................................................................  39
				Attachment....................................................................................  40
				Equipment Lowering with Engine Stopped........................................................  40
				Preventing Risk of Injuries or Death From Boom and Bucket.....................................  40
				Engine Stop...................................................................................  42
				Parking Machine...............................................................................  42
			Maintenance.......................................................................................  43
				Cleaning......................................................................................  46
				Proper Tools and Clothing.....................................................................  46
				Disassembling Precautions.....................................................................  46
				Use of Lighting...............................................................................  47
				Fire and Explosion Prevention.................................................................  47
				Burn Prevention...............................................................................  48
				Rubber That Contains Fluorides................................................................  49
				Rubber and Plastics...........................................................................  50
				Welding Repairs...............................................................................  51
				Working on Machine............................................................................  52
				Lock Inspection Covers........................................................................  53
				Accumulator...................................................................................  53
				Compressed Air................................................................................  53
				Supports and Blocking for Work Equipment......................................................  54
				High-pressure Lines, Tubes and Hoses..........................................................  54
				Battery.......................................................................................  55
				Preservation/Storing Machine..................................................................  56
			Transportation....................................................................................  58
				Obey State and Local Over-the-Road Laws and Regulations.......................................  58
				Loading and Unloading.........................................................................  58
				Transporting Machine..........................................................................  59
			Environment and Circumstances.....................................................................  60
				Work Site Areas Requiring Extra Caution.......................................................  60
				High-voltage Cables...........................................................................  62
				Underground Operation.........................................................................  62
				Working in Water..............................................................................  63
				Working in Contaminated Environment...........................................................  63
				Operation in Extreme Conditions...............................................................  64
				Exhaust Ventilation...........................................................................  68
				Asbestos Information..........................................................................  68
				Silica Dust Information.......................................................................  69
				Disposal of Hazardous Materials...............................................................  69
				Sound.........................................................................................  69
				Vibration Information.........................................................................  70
	Specifications............................................................................................  73
		Specification.........................................................................................  75
			Safety Instructions...............................................................................  79
			General...........................................................................................  79
			Component Locations...............................................................................  80
			Working Range and Dimensions......................................................................  84
			Working Capacities................................................................................  88
				Bucket Capacity...............................................................................  88
				Stability.....................................................................................  88
			General Specifications............................................................................  90
			Performance Tests.................................................................................  92
				Purpose of Performance Tests..................................................................  92
				Kinds of Tests................................................................................  92
				Performance Standards.........................................................................  92
				Precautions for Evaluation of Test Data.......................................................  92
				Definition of "Performance Standard"..........................................................  92
			Preparation for Performance Tests.................................................................  93
				The Machine...................................................................................  93
				Test Area.....................................................................................  93
				Precautions...................................................................................  93
				Make Precise Measurement......................................................................  93
			Operational Performance Standard Table............................................................  94
			Operational Performance Test......................................................................  98
				Engine Speed..................................................................................  98
				Front Speed................................................................................... 100
				Natural Subsidence of Cylinder................................................................ 101
				Travel Speed - Acceleration and Deceleration.................................................. 102
				Steering Time................................................................................. 103
				Pressure Set.................................................................................. 104
			Approximate Weight of Workload Materials.......................................................... 107
				Material Weight............................................................................... 107
	General Maintenance....................................................................................... 109
		General Maintenance Instructions...................................................................... 111
			Safety Instructions............................................................................... 115
			Welding Precautions and Instructions.............................................................. 116
			Hydraulic System - General Precautions............................................................ 117
			Maintenance Service and Repair Procedure.......................................................... 119
				General Precautions........................................................................... 119
			Hydraulic System Cleanliness and Oil Leaks........................................................ 120
				Maintenance Precautions for Hydraulic System Service.......................................... 120
				Oil Leakage Precautions....................................................................... 121
			Cleaning and Inspection........................................................................... 122
				General Instructions.......................................................................... 122
				Bearing Inspection............................................................................ 123
		Standard Torques...................................................................................... 131
			Safety Instructions............................................................................... 135
			Torque Values for Standard Metric Fasteners....................................................... 136
			Torque Values for Standard U.S. Fasteners......................................................... 137
			Type 8 Phosphate Coated Hardware.................................................................. 139
			Torque Values for Hose Clamps..................................................................... 140
			ORFS Swivel Nut Recommended Torque................................................................ 140
			Torque Values for Split Flanges................................................................... 141
			Torque Wrench Extension Tools..................................................................... 142
				Torque Multiplication......................................................................... 142
				Other Uses for Torque Wrench Extension Tools.................................................. 143
				Tightening Torque Specifications (Metric)..................................................... 144
	Engine.................................................................................................... 147
		Engine................................................................................................ 149
			Safety Instructions............................................................................... 153
			Overview.......................................................................................... 154
			General Information............................................................................... 155
				General Description........................................................................... 155
				Engine Maintenance............................................................................ 159
				Inspection and Repair of the Engine........................................................... 162
			Engine Identification............................................................................. 164
				Engine Data Plate............................................................................. 164
			Engine Specification.............................................................................. 166
			Engine Performance Curves......................................................................... 167
			Special Tools..................................................................................... 168
			Tightening Torques................................................................................ 172
				Major Parts Tightening Torque................................................................. 172
				Tightening Torque for General Bolts........................................................... 174
				Tightening Torque of Plug Screw............................................................... 175
				Hollow Screw (4-Hole) Tightening Torque....................................................... 175
			Engine Disassembly................................................................................ 176
				Engine Disassembly............................................................................ 176
			Engine Assembly................................................................................... 191
				Engine Assembly............................................................................... 191
			Cylinder.......................................................................................... 214
				General Information........................................................................... 214
				Cylinder Head................................................................................. 214
				Valve Mechanism............................................................................... 220
			Actuating System.................................................................................. 232
				Camshaft...................................................................................... 232
				Timing Gear................................................................................... 245
			Lubrication system................................................................................ 246
				General Information........................................................................... 246
				Oil Pan....................................................................................... 250
				Oil Pump...................................................................................... 252
				Oil Filter.................................................................................... 254
			Exhaust System.................................................................................... 257
				Turbocharger.................................................................................. 257
				EGR (Exhaust Gas Recirculation) System........................................................ 269
				DNOx System................................................................................... 276
			Cooling System.................................................................................... 287
				General information........................................................................... 287
				Thermostat.................................................................................... 288
			Fuel System....................................................................................... 292
				General Information........................................................................... 292
				Fuel High-pressure System Components.......................................................... 293
				Injector...................................................................................... 294
				Common Rail................................................................................... 298
				Fuel Injection Pump........................................................................... 302
			Electrical System................................................................................. 306
				Electrical Parts.............................................................................. 306
				Switches and Sensors.......................................................................... 308
				ECU (Electronic Control Unit)................................................................. 312
				Starter....................................................................................... 314
				Exhaust Gas Reduction......................................................................... 316
				Circuit Diagram............................................................................... 320
			ECU Circuit....................................................................................... 325
	Drivetrain................................................................................................ 327
		Transmission.......................................................................................... 329
			Safety Instructions............................................................................... 333
			General........................................................................................... 333
				Specification................................................................................. 334
				Overview...................................................................................... 335
				Section View.................................................................................. 338
				Hydraulic Circuit (4-speed Transmission)...................................................... 340
				Electrohydraulic Control with Proportional Valves............................................. 344
				Controller.................................................................................... 345
				Electric Control System....................................................................... 346
				Speed Sensor.................................................................................. 349
			Measuring Points and Connections.................................................................. 352
			Transmission Electric Components.................................................................. 354
				Engine Pickup Sensor.......................................................................... 357
				Central Gear Pickup Sensor.................................................................... 357
				Turbine Pickup Sensor......................................................................... 357
				Output Speed Sensor........................................................................... 357
				Shift Lever Switch (DW-3)..................................................................... 358
				Transmission Shift Switch..................................................................... 361
				T/M Cutoff Sensor............................................................................. 361
				LIS Solenoid Valve............................................................................ 361
			Transmission Electrical Circuits.................................................................. 362
				Transmission Controller Circuit............................................................... 362
				Transmission Control Unit Terminal............................................................ 363
				Downshift..................................................................................... 371
				Transmission Cutoff Switch.................................................................... 378
			Torque Limits for Screws.......................................................................... 379
			Special Tools..................................................................................... 380
				List of Special Tools for Disassembly and Reassembly.......................................... 380
			Transmission Oil.................................................................................. 386
				Oil Grade of Transmission..................................................................... 386
			Disassembly....................................................................................... 387
				Electrohydraulic Control and Transmission Filter (Replaceable Filter)......................... 387
				Inductive Sensor, Hall Sensor, Breather, Oil Filler and Oil Drain Plug........................ 392
				Engine Connection, Oil Pressure Pump, Converter Back-pressure Valve and Temperature Sensor.... 393
				Outputs and Closure Parts Pump Shaft (PTO-Shaft).............................................. 397
				Clutches KV/KR/K1/K2/K3/K4 Input and Output Shaft............................................. 404
			Reassembly........................................................................................ 428
				Clutches KV/KR/K1/K2/K3/K4 Input and Output Shaft............................................. 428
				Outputs and Closure Parts Pump Shaft (PTO-shaft).............................................. 474
				Engine Connection, Oil Pressure Pump, Converter Back-pressure Valve and Temperature Sensor.... 477
				Emergency Steering Pump....................................................................... 481
				Inductive Sensor, Hall Sensor, Breather, Oil Filler and Oil Drain Plug........................ 482
				Electrohydraulic Control with Proportional Valves............................................. 483
			Failure Code...................................................................................... 491
		Front Axle............................................................................................ 517
			Safety Instructions............................................................................... 521
			General........................................................................................... 521
				Specification................................................................................. 521
				Overview...................................................................................... 522
				Parts List.................................................................................... 523
			Lubrication and Maintenance Instructions.......................................................... 525
				Oil Change.................................................................................... 525
				Carry Out Wear Measurement on the Multidisk Brake............................................. 527
				Tightening Torques for Screws................................................................. 528
			Differential System............................................................................... 529
				Theory of Differential Device................................................................. 529
				Structure of Differential Device.............................................................. 530
			LSD............................................................................................... 531
				Overview LSD (Limited Slip Differential)...................................................... 531
				LSD (Limited Slip Differential)............................................................... 532
			Axle Air Breathing................................................................................ 533
			Special Tools..................................................................................... 534
				List of Special Tools for Disassembly and Reassembly.......................................... 534
			Axle Oils......................................................................................... 541
				Oil Grade ZF-Powerfluid....................................................................... 541
			Removal........................................................................................... 542
			Disassembly....................................................................................... 546
				Output and Brake.............................................................................. 546
				Axle Housing.................................................................................. 552
				Input......................................................................................... 553
				Differentials................................................................................. 556
			Reassembly........................................................................................ 561
				Differentials................................................................................. 561
				Input......................................................................................... 569
				Axle Housing.................................................................................. 580
				Output and Brake.............................................................................. 581
		Rear Axle............................................................................................. 593
			Safety Instructions............................................................................... 597
			General........................................................................................... 597
				Specification................................................................................. 597
				Overview...................................................................................... 598
				Parts List.................................................................................... 599
			Lubrication and Maintenance Instructions.......................................................... 601
				Oil Change.................................................................................... 601
				Carry Out Wear Measurement on the Multidisk Brake............................................. 603
				Tightening Torques for Screws................................................................. 604
			Differential System............................................................................... 605
				Theory of Differential Device................................................................. 605
				Structure of Differential Device.............................................................. 606
			Axle Air Breathing................................................................................ 607
			Special Tools..................................................................................... 608
				List of Special Tools for Disassembly and Reassembly.......................................... 608
			Axle Oils......................................................................................... 615
				Oil Grade ZF-Powerfluid....................................................................... 615
			Removal........................................................................................... 616
			Installation...................................................................................... 621
			Completing Work................................................................................... 621
			Disassembly....................................................................................... 622
				Output and Brake.............................................................................. 622
				Axle Housing.................................................................................. 627
				Input......................................................................................... 629
				Differentials................................................................................. 631
			Reassembly........................................................................................ 634
				Differentials................................................................................. 634
				Input......................................................................................... 641
				Axle Housing.................................................................................. 649
				Output and Brake.............................................................................. 651
		Driveshaft............................................................................................ 663
			Safety Instructions............................................................................... 667
			General........................................................................................... 668
				Overview...................................................................................... 668
				Specification................................................................................. 668
			Removal (Front Driveshaft)........................................................................ 670
			Removal (Center Driveshaft)....................................................................... 673
			Removal (Rear Driveshaft)......................................................................... 676
			Installation (Rear DriveShaft).................................................................... 678
	Steering.................................................................................................. 679
		Power Steering System................................................................................. 681
			Safety Instructions............................................................................... 685
			General Description............................................................................... 685
				Overview...................................................................................... 686
				Hydraulic Circuit............................................................................. 687
				Theory of Operation........................................................................... 688
		Steering Unit......................................................................................... 691
			Safety Instructions............................................................................... 695
			General........................................................................................... 695
				General Description........................................................................... 695
				Specifications................................................................................ 697
				Overview...................................................................................... 698
				Theory of Operation........................................................................... 699
				Gerotor Operation............................................................................. 700
				Relief Valve.................................................................................. 700
		Priority Valve........................................................................................ 701
			Safety Instructions............................................................................... 705
			General........................................................................................... 705
				General Description........................................................................... 705
			Tool List......................................................................................... 706
			Removal........................................................................................... 707
			Installation...................................................................................... 712
			Completing Work................................................................................... 712
			Disassembly....................................................................................... 713
			Reassembly........................................................................................ 715
	Brake..................................................................................................... 717
		Service Brake......................................................................................... 719
			Safety Instructions............................................................................... 723
			General Description............................................................................... 724
			Service Brake System.............................................................................. 725
		Brake & Pilot Supply Valve............................................................................ 727
			Safety Instructions............................................................................... 731
			General Description............................................................................... 731
				Overview...................................................................................... 732
				Parts List.................................................................................... 734
			Removal........................................................................................... 735
		Charging Block........................................................................................ 741
			Safety Instructions............................................................................... 745
			General Description............................................................................... 746
				Parts List.................................................................................... 746
		Parking Brake......................................................................................... 749
			Safety Instructions............................................................................... 753
			General........................................................................................... 753
				Specification................................................................................. 753
				Overview...................................................................................... 753
				Parts List.................................................................................... 754
				Theory of Operation........................................................................... 755
			Installing and Setting Instructions............................................................... 757
				Installing the Brake.......................................................................... 757
				Clearance Adjusting........................................................................... 758
				Adjusting Instructions........................................................................ 759
			Emergency Release of the Parking Brake............................................................ 760
			Maintenance and Repair Work....................................................................... 761
				Maintenance and Replacement of the Lining Pads................................................ 761
				Replacing the Seals........................................................................... 764
		Brake Pedal Valve..................................................................................... 767
			Safety Instructions............................................................................... 771
			General Description............................................................................... 771
				Specification................................................................................. 771
				Theory of Operation........................................................................... 773
		Accumulator........................................................................................... 775
			Safety Instructions............................................................................... 779
			General...........................................................................................   0
				Layout........................................................................................ 782
				Specifications................................................................................ 782
	Cooling System............................................................................................ 783
		Cooling System........................................................................................ 785
			Safety Instructions............................................................................... 789
			General........................................................................................... 789
				General Description........................................................................... 789
				Function...................................................................................... 790
				Hydraulic Circuit............................................................................. 791
				Fan Motor Pressure and Fan Speed.............................................................. 792
					Checking Maximum Fan Speed................................................................ 793
		Fan and Brake Pump.................................................................................... 795
			Safety Instructions............................................................................... 799
			General........................................................................................... 799
				Specification................................................................................. 799
				Section View.................................................................................. 800
				EPPR Valve.................................................................................... 800
				Overview...................................................................................... 801
					Port and Hydraulic Circuit................................................................ 801
				Parts List.................................................................................... 802
				Theory of Operation........................................................................... 804
					Circuit................................................................................... 804
					Control Section........................................................................... 805
					Circuit Diagram Related to Fan Drive...................................................... 805
					Pump EPPR Valve........................................................................... 806
			Removal........................................................................................... 808
			Installation...................................................................................... 813
			Completing Work................................................................................... 813
			Maintenance Guidelines............................................................................ 814
				Sealing Control Valve......................................................................... 817
				Tools......................................................................................... 817
					Loctite Types............................................................................. 817
			Disassembly....................................................................................... 818
				Disassembly of Rotary Group................................................................... 819
				Disassembly of Shaft/Bearings................................................................. 821
			Reassembly........................................................................................ 825
		Fan Motor............................................................................................. 831
			Safety Instructions............................................................................... 835
			General........................................................................................... 836
				Specifications................................................................................ 836
				Overview...................................................................................... 836
					Port and Hydraulic Circuit................................................................ 836
		Fan Control Valve..................................................................................... 837
			Safety Instructions............................................................................... 841
			General........................................................................................... 841
				Specifications................................................................................ 841
					Port and Hydraulic Circuit................................................................ 842
		Radiator Assembly..................................................................................... 843
			Safety Instructions............................................................................... 847
			General........................................................................................... 847
				Overview...................................................................................... 847
				Structure..................................................................................... 848
			CAC (Charge Air Cooler)........................................................................... 850
				Overview...................................................................................... 850
			Radiator.......................................................................................... 853
				Overview...................................................................................... 853
				Theory of Operation........................................................................... 853
				Radiator Cap.................................................................................. 854
				Replacing - Radiator Cap...................................................................... 855
				Replacing Coolant............................................................................. 855
				Antifreeze Concentration Tables............................................................... 856
			Transmission Cooling.............................................................................. 857
				General Description........................................................................... 857
				Layout........................................................................................ 857
				Thermostat.................................................................................... 858
	Hydraulic System.......................................................................................... 859
		Main Pump............................................................................................. 861
			Safety Instructions............................................................................... 865
			General........................................................................................... 865
				General Description........................................................................... 865
				Specification................................................................................. 865
				Overview...................................................................................... 866
				Theory of Operation........................................................................... 867
				Parts List.................................................................................... 869
				Location...................................................................................... 872
			Removal........................................................................................... 873
			Installation...................................................................................... 879
			Completing Work................................................................................... 879
			Disassembly....................................................................................... 880
				Sealing Driveshaft............................................................................ 880
				Pump.......................................................................................... 881
			Reassembly........................................................................................ 887
				Pump.......................................................................................... 887
		Main Control Valve.................................................................................... 893
			Safety Instructions............................................................................... 897
			General........................................................................................... 897
				General Description........................................................................... 897
				Specification................................................................................. 898
				Overview...................................................................................... 900
				Hydraulic Circuit............................................................................. 902
				Parts List.................................................................................... 903
				Theory of Operation........................................................................... 904
			Removal........................................................................................... 917
			Disassembly/Reassembly............................................................................ 924
			Torque Table...................................................................................... 925
		Pilot System.......................................................................................... 929
			Safety Instructions............................................................................... 933
			General Description............................................................................... 933
			Fingertip Joystick................................................................................ 934
				Specification................................................................................. 934
				Port Name..................................................................................... 934
				Parts List - 2 Lever.......................................................................... 935
				Parts List - 3 Lever.......................................................................... 936
			FNR Joystick...................................................................................... 937
				Specification................................................................................. 937
				Port Name..................................................................................... 937
				Overview...................................................................................... 937
				Parts List.................................................................................... 938
		HydraulicSystem....................................................................................... 941
			Safety Instructions............................................................................... 945
			Hydraulic Component and Oil Flow.................................................................. 946
				Hydraulic Components.......................................................................... 946
			Fan Drive Operation............................................................................... 948
			Parking Brake Release Operation................................................................... 949
			Service Brake Operation........................................................................... 950
			Steering Operation................................................................................ 951
			Boom Raise Operation and Load Sensing............................................................. 952
			Boom Down Operation............................................................................... 954
			Boom Floating Operation........................................................................... 956
			Bucket Crowd Operation............................................................................ 958
			Bucket Dump Operation............................................................................. 960
			Combined Bucket Crowd and Boom Down Operation..................................................... 962
			Load Isolate System (LIS)......................................................................... 963
	Frame..................................................................................................... 965
		Articulation Center................................................................................... 967
			Safety Instructions............................................................................... 971
			General Description............................................................................... 971
				Maintenance Standard.......................................................................... 972
		Cabin................................................................................................. 975
			Safety Instructions............................................................................... 979
			Cabin Identification.............................................................................. 979
				Roll-over Protective Structure (ROPS)/Falling Object Protective Structure (FOPS).............. 979
			Dimensions of Cabin Glass......................................................................... 981
			Removal and Installation of Cabin Glass........................................................... 986
				Removal of Cabin Glass........................................................................ 986
				Installation of Cabin Glass................................................................... 988
		Counterweight......................................................................................... 993
			Safety Instructions............................................................................... 997
			General........................................................................................... 998
				Overview...................................................................................... 998
				Additional Counter Weight..................................................................... 999
		Oil Tank..............................................................................................1001
			Safety Instructions...............................................................................1005
			General...........................................................................................1005
				Specifications................................................................................1005
				Parts List....................................................................................1006
				Air Breather..................................................................................1008
		Fuel Tank.............................................................................................1009
			Safety Instructions...............................................................................1013
			General...........................................................................................1013
				Specifications................................................................................1013
				Parts List....................................................................................1014
		Cylinders.............................................................................................1017
			Safety Instructions...............................................................................1021
			General...........................................................................................1021
				General Description...........................................................................1021
				Specification.................................................................................1021
				Parts List....................................................................................1022
				Theory of Operation...........................................................................1034
				Seal of Cylinder..............................................................................1035
			Special Tools and Materials.......................................................................   0
				Rod Bushing (DD-bushing) Pushing-in Jig.......................................................1043
			Disassembly.......................................................................................1044
			Reassembly........................................................................................1049
			Troubleshooting...................................................................................1053
	Electrical System.........................................................................................1055
		Electrical System.....................................................................................1057
			Safety Instructions...............................................................................1061
			Overview..........................................................................................1061
			Electric Supply System............................................................................1062
			Engine Starting Circuit...........................................................................1064
				Operation During Start Process................................................................1064
				Operation After Start Process.................................................................1066
			Engine Stop System................................................................................1067
			Engine Emergency Start System.....................................................................1068
			Charging System...................................................................................1069
			Engine Control System.............................................................................1070
				Power Mode Control............................................................................1072
				Accelerator Pedal.............................................................................1073
				Auto Idle Control.............................................................................1074
			Electric Detent System............................................................................1075
				Electrical Circuit............................................................................1075
				Boom Kick-out.................................................................................1076
				Return to Dig.................................................................................1077
			Cooling Fan Control System........................................................................   0
				Electrical Diagram............................................................................1079
				Parts of Cooling Fan Control System...........................................................1080
				Operation of Cooling Fan Control System.......................................................1082
			Emergency Steering System (Option)................................................................1084
				Block Diagram.................................................................................1084
				Emergency Steering System Electrical Circuit..................................................1088
			Lighting System...................................................................................1090
				Light Circuit.................................................................................1090
			Monitoring System.................................................................................   0
				Instrument Panel..............................................................................1095
				Function Check................................................................................1095
				Monitoring System Schematic...................................................................1096
			Operation.........................................................................................   0
				Initial Operation.............................................................................1100
				Multifunction Display.........................................................................1101
			Warning and Indicator Lights......................................................................1104
				Indication of Warning Lights..................................................................1104
				Indication of Indicator Lights................................................................1106
			Graphic Information Area Display..................................................................   0
				User Menu.....................................................................................1109
				Information of Machine Operation..............................................................1136
			Failure Code......................................................................................1143
				Failure Code at Machine.......................................................................1143
				Failure Code at Engine Side...................................................................1146
				Failure Code at Transmission Side.............................................................1179
				FMIs (Failure Mode Identifier)................................................................1183
			Windshield Wiper..................................................................................1184
				Front Windshield Wiper........................................................................1184
				Rear Windshield Wiper.........................................................................1186
		Air Conditioner.......................................................................................1187
			Safety Instructions...............................................................................1191
			General Description...............................................................................1192
				Internal and External Filters.................................................................1193
				Air-conditioning System Layout................................................................1194
				Air Conditioner/Heater Unit...................................................................1196
				Ambient Air Temperature Sensor................................................................1201
				Compressor....................................................................................1209
				Receiver Dryer................................................................................1209
			Troubleshooting...................................................................................1210
			Refrigerant System Repairs........................................................................1212
				Refrigerant Safe Handling Procedures..........................................................1212
				Repair and Replacement Procedure..............................................................1213
				Refrigerant Recovery..........................................................................1215
				Vacuuming Refrigerant System..................................................................1215
				Leakage Check.................................................................................1217
				Refrigerant Charging..........................................................................1217
				Inspecting System for Leakage.................................................................1219
	Option....................................................................................................1221
		EmergencySteering.....................................................................................1223
			Safety Instructions...............................................................................1227
			General...........................................................................................1227
				General Description...........................................................................1227
				Specifications................................................................................1227
				Parts List....................................................................................1229
				Caution for Installation......................................................................1229
			Installation Procedure............................................................................1230
				Emergency Steering............................................................................1230
				Emergency Steering - Electric.................................................................1232
				After Installation Precautions................................................................1233
				Emergency Steering Function Test..............................................................1233
				Emergency Steering Automatic Test.............................................................1234
		Load Isolation System.................................................................................1235
			Safety Instructions...............................................................................1239
			General...........................................................................................1239
				General Description...........................................................................1239
				Overview......................................................................................1240
				Hydraulic Circuit.............................................................................1242
				Accumulator Charging Method...................................................................1242
			LIS Valve.........................................................................................1244
				Specification.................................................................................1244
				Parts List....................................................................................1245
			Accumulator.......................................................................................1246
				Specification.................................................................................1246
				Parts List....................................................................................1246
	Schematic.................................................................................................1247
		Hydraulic Schematic/ Electrical Schematic.............................................................1249

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• This is the SAME exact manual used by your dealers to fix your vehicle.
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• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

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