DAEWOO DOOSAN WHEEL LOADER DL420-5 Operation & Maintenance ManualSerial Number 10001 and Up – PDF DOWNLOAD

Description

DAEWOO DOOSAN WHEEL LOADER DL420-5 Operation & Maintenance ManualSerial Number 10001 and Up – PDF DOWNLOAD

DESCRIPTION:

DAEWOO DOOSAN WHEEL LOADER DL420-5 Operation & Maintenance ManualSerial Number 10001 and Up – PDF DOWNLOAD

Foreword

• This Operation & Maintenance Manual was written to give owner or operator instructions on safe operation and maintenance of DOOSAN equipment. READ AND UNDERSTAND THIS OPERATION AND MAINTENANCE MANUAL BEFORE OPERATING YOUR DOOSAN EQUIPMENT. Keep this manual in the cabin so it is always available.
• If it is lost, order another one from your DOOSAN distributor. If there are any questions, contact your DOOSAN distributor. This manual may illustrate options and accessories not installed on your equipment.
• Any modification made without written authorization or approval from DOOSAN can create a safety hazard. Always replace parts with genuine DOOSAN parts or DOOSAN authorized replacement parts

SAFETY MESSAGES

Safety messages and safety decals included in this manual and on the machine provide instructions how to operate, service and maintain the machine. Safety messages and safety decals indicate potential hazards and describe safety precautions required to avoid hazards. Operator and maintenance personnel should read and understand these safety messages and decals before beginning operation or maintenance.

Signal Words

The signal words “DANGER”, “WARNING”, “CAUTION” are used throughout safety messages and safety decals in this manual or on the machine. They indicate an existence of, and the relative seriousness of, a hazard. All three indicate that a safety risk is involved. Observe the precautions indicated whenever a Safety Alert Symbol is present, no matter which signal word appears next to it.

PRODUCT INFORMATION

Intended Use The machine is intended to be used under normal conditions for applications described in this manual. If it is used for other purposes, or in potentially hazardous environments, special precautions must be followed and the machine must be equipped for such use. Examples include, but are not limited: falling object guards, work lights, etc. Do not engage in prohibited uses as described in this manual. Contact your DOOSAN distributor for further information.

Machine Capacity

Do not exceed machine capacity by modifying machine or using unapproved attachments. Exceeding machine capacity can adversely affect machine performance characteristics such as: stability, system certifications such as brakes and steering, the Roll-over Protective Structure (ROPS) and can result in death or serious injury. Contact your DOOSAN distributor for further information

Engine and Emission Control System Maintenance

Proper inspection, maintenance and repair is essential to keeping engine and machine systems properly operating. This includes proper inspection and maintenance of the machine’s emission control system. This could include machine and engine components, such as an EGR (Exhaust Gas Recirculation) system, fuel system, turbocharger, electrical system, air intake system and/or cooling system. As a heavy-duty off-road diesel engine owner, you are responsible for performing required maintenance. The required maintenance procedures are outlined in this Operation & Maintenance Manual, or Shop Manual. Do not remove, alter, or render inoperative, any emission control system

TABLE OF CONTENTS:

DAEWOO DOOSAN WHEEL LOADER DL420-5 Operation & Maintenance ManualSerial Number 10001 and Up – PDF DOWNLOAD

DL420-5……………………………………………………………………………………………………………………………………… 0 Table of Contents…………………………………………………………………………………………………………………………. 5 Foreword…………………………………………………………………………………………………………………………………. 9 Safety Messages……………………………………………………………………………………………………………………….. 10 AEM Safety Manual (North America Only)…………………………………………………………………………………………………… 11 Product Information……………………………………………………………………………………………………………………. 12 Intended Use………………………………………………………………………………………………………………………. 12 Machine Capacity…………………………………………………………………………………………………………………… 12 Engine and Emission Control System Maintenance………………………………………………………………………………………… 12 Product Identification…………………………………………………………………………………………………………………. 13 Federal Emission Control Systems………………………………………………………………………………………………………… 14 Emission Control System Warranty Statement……………………………………………………………………………………………. 14 Catalytic Converter………………………………………………………………………………………………………………… 19 California Emission Control Warranty Statement………………………………………………………………………………………… 21 Your Warranty Rights and Obligations…………………………………………………………………………………………………. 21 Manufacturer’s Warranty Coverage…………………………………………………………………………………………………….. 22 Owner’s Warranty Responsibilities……………………………………………………………………………………………………. 22 Safety…………………………………………………………………………………………………………………………………… 23 Safety Decals…………………………………………………………………………………………………………………………. 24 Information and Location for Safety Decals……………………………………………………………………………………………. 26 General………………………………………………………………………………………………………………………………. 36 Safe Operation is Operator’s Responsibility…………………………………………………………………………………………… 36 Know Your Machine………………………………………………………………………………………………………………….. 36 Proper Work Tools and Attachments……………………………………………………………………………………………………. 36 Pressurized Fluids…………………………………………………………………………………………………………………. 37 Flying or Falling Objects…………………………………………………………………………………………………………… 38 Personal Protective Equipment (PPE)………………………………………………………………………………………………….. 38 Correction of Machine Problems………………………………………………………………………………………………………. 39 Crushing and Cutting……………………………………………………………………………………………………………….. 39 Hot Coolant and Oils – Burn Prevention……………………………………………………………………………………………….. 40 Fire and Explosion Prevention……………………………………………………………………………………………………….. 40 Fire Extinguisher and First-Aid Kit (Emergency Medical Kit)…………………………………………………………………………….. 44 Electrical System and Electrical Shock……………………………………………………………………………………………….. 44 Operation…………………………………………………………………………………………………………………………….. 47 Before Engine Starting……………………………………………………………………………………………………………… 47 Work Site…………………………………………………………………………………………………………………………. 47 Check Tire Pressure and Condition……………………………………………………………………………………………………. 48 Mounting/Dismounting……………………………………………………………………………………………………………….. 48 Cleaning………………………………………………………………………………………………………………………….. 49 Operator Station…………………………………………………………………………………………………………………… 49 Seat Belt…………………………………………………………………………………………………………………………. 50 Visibility Information……………………………………………………………………………………………………………… 51 Boost Starting or Charging Engine Batteries…………………………………………………………………………………………… 52 Starting Engine……………………………………………………………………………………………………………………. 53 Traveling…………………………………………………………………………………………………………………………. 53 Lifting and Digging………………………………………………………………………………………………………………… 55 Digging Beneath Overhangs…………………………………………………………………………………………………………… 55 Digging Beneath Wheel Loader………………………………………………………………………………………………………… 55 Operation on Slopes………………………………………………………………………………………………………………… 56 Attachment………………………………………………………………………………………………………………………… 57 Equipment Lowering with Engine Stopped……………………………………………………………………………………………….. 57 Preventing Risk of Injuries or Death From Boom and Bucket………………………………………………………………………………. 57 Engine Stop……………………………………………………………………………………………………………………….. 59 Parking Machine……………………………………………………………………………………………………………………. 59 Maintenance…………………………………………………………………………………………………………………………… 60 Cleaning………………………………………………………………………………………………………………………….. 63 Proper Tools and Clothing…………………………………………………………………………………………………………… 63 Disassembling Precautions…………………………………………………………………………………………………………… 63 Use of Lighting……………………………………………………………………………………………………………………. 64 Fire and Explosion Prevention……………………………………………………………………………………………………….. 64 Burn Prevention……………………………………………………………………………………………………………………. 65 Rubber That Contains Fluorides………………………………………………………………………………………………………. 66 Rubber and Plastics………………………………………………………………………………………………………………… 67 Welding Repairs……………………………………………………………………………………………………………………. 68 Working on Machine…………………………………………………………………………………………………………………. 69 Lock Inspection Covers……………………………………………………………………………………………………………… 70 Accumulator……………………………………………………………………………………………………………………….. 70 Compressed Air…………………………………………………………………………………………………………………….. 70 Supports and Blocking for Work Equipment……………………………………………………………………………………………… 71 High-pressure Lines, Tubes and Hoses…………………………………………………………………………………………………. 71 Battery…………………………………………………………………………………………………………………………… 72 Preservation/Storing Machine………………………………………………………………………………………………………… 73 Transportation………………………………………………………………………………………………………………………… 75 Obey State and Local Over-the-Road Laws and Regulations………………………………………………………………………………… 75 Loading and Unloading………………………………………………………………………………………………………………. 75 Transporting Machine……………………………………………………………………………………………………………….. 76 Environment and Circumstances…………………………………………………………………………………………………………… 77 Work Site Areas Requiring Extra Caution………………………………………………………………………………………………. 77 High-voltage Cables………………………………………………………………………………………………………………… 79 Underground Operation………………………………………………………………………………………………………………. 79 Working in Water…………………………………………………………………………………………………………………… 80 Working in Contaminated Environment………………………………………………………………………………………………….. 80 Operation in Extreme Conditions……………………………………………………………………………………………………… 81 Exhaust Ventilation………………………………………………………………………………………………………………… 85 Asbestos Information……………………………………………………………………………………………………………….. 85 Silica Dust Information…………………………………………………………………………………………………………….. 86 Disposal of Hazardous Materials……………………………………………………………………………………………………… 86 Vibration…………………………………………………………………………………………………………………………. 87 Operating Controls………………………………………………………………………………………………………………………… 89 Component Locations……………………………………………………………………………………………………………………. 90 Steering Console and Pedals…………………………………………………………………………………………………………….. 94 1. Horn Button (Two Places)…………………………………………………………………………………………………………. 95 2. Combination Switch………………………………………………………………………………………………………………. 96 3. Accelerator Pedal……………………………………………………………………………………………………………….. 97 4. Steering Wheel Adjustment Lever…………………………………………………………………………………………………… 97 5. Brake Pedal (Right and Left Pedals)……………………………………………………………………………………………….. 98 6. Steering Wheel………………………………………………………………………………………………………………….. 98 7. Kick-down Button (Two Places)…………………………………………………………………………………………………….. 99 8. Transmission Lever………………………………………………………………………………………………………………. 99 9. Front Instrument Panel……………………………………………………………………………………………………………100 10. Hour Meter……………………………………………………………………………………………………………………..100 12. Hazard Warning Light Switch………………………………………………………………………………………………………103 Front Instrument Panel…………………………………………………………………………………………………………………. 0 Password Activated………………………………………………………………………………………………………………….106 1. Speedometer……………………………………………………………………………………………………………………..106 2. Multifunction Gauge and Graphic Information Display………………………………………………………………………………….106 3. Left Turn and Hazard Warning Light…………………………………………………………………………………………………107 4. Parking Brake Indicator Light……………………………………………………………………………………………………..107 5. Right Turn and Hazard Warning Light………………………………………………………………………………………………..107 10. Emergency Steering Indicator Light (Optional)………………………………………………………………………………………109 11. Mirror Heater Indicator Light…………………………………………………………………………………………………….109 12. Work Light Indicator Light……………………………………………………………………………………………………….109 Multifunction Gauge and Graphic Information Display……………………………………………………………………………………….. 0 Multifunction Gauge and Graphic Information Display…………………………………………………………………………………….112 Warning Pop-up……………………………………………………………………………………………………………………..124 User Menu………………………………………………………………………………………………………………………….126 Right Side Switch Panel…………………………………………………………………………………………………………………140 1. FNR Lever (Standard)……………………………………………………………………………………………………………..141 1A. Finger Tip Lever (Optional)………………………………………………………………………………………………………142 1B. Pilot Control Valve Lever (Elec. Lever) (Optional)………………………………………………………………………………….144 2. Kick-down Button (Two Places)……………………………………………………………………………………………………..144 3. Horn Button (Two Places)………………………………………………………………………………………………………….145 4. Starter Switch…………………………………………………………………………………………………………………..145 5. Parking Brake Switch……………………………………………………………………………………………………………..146 6. Pilot Cutoff Switch………………………………………………………………………………………………………………146 7. Headlight Switch…………………………………………………………………………………………………………………147 8. Stand Keypad…………………………………………………………………………………………………………………….147 9. Hands-free Control Panel………………………………………………………………………………………………………….152 10. Power Socket for 12 Volt…………………………………………………………………………………………………………155 11. Cigarette Lighter……………………………………………………………………………………………………………….155 12. F/R (Forward/Reverse) Selector Switch……………………………………………………………………………………………..155 13. F/R (Forward/Reverse) Control Switch………………………………………………………………………………………………156 Left Side Electric Steering Control Unit (Optional)………………………………………………………………………………………..157 1. Electric Steering Selector Switch………………………………………………………………………………………………….158 2. 3rd FNR Control Switch……………………………………………………………………………………………………………158 3. Kick-down Button…………………………………………………………………………………………………………………158 4. Electric Steering Joystick………………………………………………………………………………………………………..159 5. Armrest Cutoff Switch…………………………………………………………………………………………………………….159 Various Cabin Locations………………………………………………………………………………………………………………… 0 9. Emergency Start Switch……………………………………………………………………………………………………………163 Heater and Air Conditioner Operation……………………………………………………………………………………………………..164 Location of Controls and Vents……………………………………………………………………………………………………….164 Control Panel………………………………………………………………………………………………………………………165 Memory Function…………………………………………………………………………………………………………………….169 Additional Operating Instructions…………………………………………………………………………………………………….169 Seat Adjustment W/Air Suspension (Standard)……………………………………………………………………………………………….171 1. Adjusting Seat Forward/Backward Lever………………………………………………………………………………………………171 2. Seat Height and Weight Adjustment Knob……………………………………………………………………………………………..171 3. Backrest Adjustment Lever…………………………………………………………………………………………………………171 4. Lumbar Control Knob………………………………………………………………………………………………………………171 5. Angle Adjustment of Armrest……………………………………………………………………………………………………….172 6. Adjustment of Upper Backrest………………………………………………………………………………………………………172 7. Heating Operator’s Seat (Optional)…………………………………………………………………………………………………172 Recommendations for Limiting Vibrations……………………………………………………………………………………………….173 Seat Adjustment W/Air Suspension and Heater……………………………………………………………………………………………….174 1. Adjusting Seat Forward/Backward Lever………………………………………………………………………………………………174 2. Seat Height and Firmness/Adjustment Knob……………………………………………………………………………………………174 3. Backrest Adjustment Lever…………………………………………………………………………………………………………174 4. Lumbar Control Knob………………………………………………………………………………………………………………174 5. Angle Adjustment of Armrest……………………………………………………………………………………………………….175 6. Adjustment of Upper Backrest………………………………………………………………………………………………………175 7. Heating Operator’s Seat (Optional)…………………………………………………………………………………………………175 Seat Belt……………………………………………………………………………………………………………………………..176 Seat Belt Locking and Unlocking………………………………………………………………………………………………………176 Door Side Latch………………………………………………………………………………………………………………………..177 Arm Rest………………………………………………………………………………………………………………………………178 Fuse Box/Relay…………………………………………………………………………………………………………………………179 Fuse Boxes…………………………………………………………………………………………………………………………179 Relays…………………………………………………………………………………………………………………………….181 Circuit Breaker…………………………………………………………………………………………………………………….181 Fusible Link……………………………………………………………………………………………………………………….181 Wheel Chocks…………………………………………………………………………………………………………………………..182 Operation…………………………………………………………………………………………………………………………………183 To Operate a New Wheel Loader……………………………………………………………………………………………………………183 Monitoring System…………………………………………………………………………………………………………………..183 New Machine Break-in Procedures………………………………………………………………………………………………………183 Starting and Stopping Engine…………………………………………………………………………………………………………….184 Inspection Before Starting Engine…………………………………………………………………………………………………….184 Operational Checks Before Starting Engine……………………………………………………………………………………………..187 Engine Start……………………………………………………………………………………………………………………….188 After Start Limit Logic……………………………………………………………………………………………………………..192 Automatic Warming Up Operation……………………………………………………………………………………………………….192 Fuel Heater Switch………………………………………………………………………………………………………………….193 Plug Heater (Optional)………………………………………………………………………………………………………………193 Check Oil Bath Precleaner (Optional)………………………………………………………………………………………………….194 Emission Control System…………………………………………………………………………………………………………………195 Reaction at Low Reductant Level………………………………………………………………………………………………………195 Reaction to Faults in SCR System (Only EPA)……………………………………………………………………………………………195 Coolant Temperature…………………………………………………………………………………………………………………196 Engine Oil Pressure…………………………………………………………………………………………………………………197 Charging Indicator Light…………………………………………………………………………………………………………….197 Stopping Engine…………………………………………………………………………………………………………………….197 Checks and Maintenance After Stopping Engine…………………………………………………………………………………………..199 Machine Travel…………………………………………………………………………………………………………………………200 If Engine Stalls While Traveling…………………………………………………………………………………………………………203 Working in Water……………………………………………………………………………………………………………………….203 Towing………………………………………………………………………………………………………………………………..204 F/R (Forward/Reverse) Travel Control System……………………………………………………………………………………………….206 Machine Shut Down………………………………………………………………………………………………………………………207 Operation of Attachment…………………………………………………………………………………………………………………209 Arm Angle Sensor Switch……………………………………………………………………………………………………………..209 Bucket Angle Indicator………………………………………………………………………………………………………………….209 Adjustment of Bucket Position Switch……………………………………………………………………………………………………..210 Bucket Angle Sensor Switch (Optional)…………………………………………………………………………………………………210 Operation Under Abnormal Conditions………………………………………………………………………………………………………211 Operation in Extreme Cold……………………………………………………………………………………………………………211 Operation in Extreme Heat……………………………………………………………………………………………………………212 Operation in Dusty and Sandy Areas……………………………………………………………………………………………………213 Operation in Rainy or Humid Conditions………………………………………………………………………………………………..214 Operation in Saltwater Areas…………………………………………………………………………………………………………214 Operation at High Altitudes………………………………………………………………………………………………………….215 Operation During Electrical Storms……………………………………………………………………………………………………215 Long Term Storage………………………………………………………………………………………………………………………216 Before Storage……………………………………………………………………………………………………………………..216 During Storage……………………………………………………………………………………………………………………..217 After Storage………………………………………………………………………………………………………………………217 Auto Grease System (Optional)…………………………………………………………………………………………………………… 0 Location…………………………………………………………………………………………………………………………..220 Lubricants…………………………………………………………………………………………………………………………221 Pump Display and Control Elements of Control Screen…………………………………………………………………………………….227 Pump Display Mode…………………………………………………………………………………………………………………..231 Pump Programming……………………………………………………………………………………………………………………233 Maintenance………………………………………………………………………………………………………………………..237 Troubleshooting…………………………………………………………………………………………………………………….240 Inspection, Maintenance and Adjustment……………………………………………………………………………………………………….247 Maintenance Information…………………………………………………………………………………………………………………247 Safety Precautions………………………………………………………………………………………………………………….250 Arrival Inspections and Delivery Instructions………………………………………………………………………………………….250 Machine Setup Position for Maintenance……………………………………………………………………………………………………251 Maintenance Handling Access……………………………………………………………………………………………………………..253 Entering/Leaving/Climbing On Machine………………………………………………………………………………………………….253 Service Position……………………………………………………………………………………………………………………254 Service Points……………………………………………………………………………………………………………………..255 Handling Oil, Fuel, DEF (AdBlue) Coolant………………………………………………………………………………………………….256 Oil……………………………………………………………………………………………………………………………….256 Fuel………………………………………………………………………………………………………………………………256 DEF (AdBlue)……………………………………………………………………………………………………………………….258 Coolant and Water for Dilution……………………………………………………………………………………………………….259 Grease…………………………………………………………………………………………………………………………….259 Filters……………………………………………………………………………………………………………………………260 Electrical System Maintenance……………………………………………………………………………………………………………260 Recommend Fuel, Coolant, and Lubricant……………………………………………………………………………………………………261 Lubrication………………………………………………………………………………………………………………………..261 Before Service Instructions………………………………………………………………………………………………………….262 Fire Prevention Measures…………………………………………………………………………………………………………….264 Working on Painted Surfaces………………………………………………………………………………………………………….265 Methods and Precautionary Measures When Removing Paint………………………………………………………………………………….266 Rubber That Contains Fluorides……………………………………………………………………………………………………….266 Rubber and Plastics…………………………………………………………………………………………………………………267 Preventive Maintenance…………………………………………………………………………………………………………………. 0 Component Serial Numbers…………………………………………………………………………………………………………….269 Engine Identification……………………………………………………………………………………………………………….269 Table of Recommended Lubricants………………………………………………………………………………………………………….270 Transmission Oil……………………………………………………………………………………………………………………….273 Oil Grade of Transmission……………………………………………………………………………………………………………273 Axle Oils……………………………………………………………………………………………………………………………..274 Oil Grade ZF-Powerfluid……………………………………………………………………………………………………………..274 Engine Oil Drain Intervals by Duty Cycle (Hours)……………………………………………………………………………………….275 Fluid Capacities……………………………………………………………………………………………………………………….275 Lubrication and Service Chart……………………………………………………………………………………………………………276 Greasing Bearings…………………………………………………………………………………………………………………..276 Maintenance Intervals…………………………………………………………………………………………………………………..281 10 Hour / Daily Service…………………………………………………………………………………………………………………283 Grease Front Attachment Pins…………………………………………………………………………………………………………283 Check Engine Oil Level………………………………………………………………………………………………………………283 Check Transmission Oil Level…………………………………………………………………………………………………………284 Check Hydraulic System Oil Level……………………………………………………………………………………………………..285 Check for Leaks in Hydraulic System…………………………………………………………………………………………………..286 Fill Fuel Tank……………………………………………………………………………………………………………………..286 Check for Leaks in Fuel System……………………………………………………………………………………………………….287 Drain Fuel Condensation……………………………………………………………………………………………………………..287 Fill DEF (AdBlue) Tank………………………………………………………………………………………………………………287 Check Coolant Level…………………………………………………………………………………………………………………288 Check Level of Windshield Washer Liquid……………………………………………………………………………………………….288 Inspect Bucket Teeth and Side Cutters for Signs of Wear…………………………………………………………………………………289 Inspect Cooling Fan Blade……………………………………………………………………………………………………………289 Check Engine Air Intake Precleaner……………………………………………………………………………………………………289 Check Air Intake System……………………………………………………………………………………………………………..290 Inspect Seat Belt for Proper Operation………………………………………………………………………………………………..290 Inspect Mirrors for Damage and Adjust and Clean as Required……………………………………………………………………………..290 Inspect Structure for Cracks and Faulty Welds………………………………………………………………………………………….290 Check Operation of All Switches………………………………………………………………………………………………………291 Check Operation of All Exterior Lights, Horn and Control Console Indicator and Monitor Lights……………………………………………….291 Start Engine, Check Starting Ability, and Observe Exhaust Color at Start-up and at Normal Operating Temperature. Listen for Any Abnormal Sounds…..291 Check That Back up Alarm and Rear Camera (If equipped) is Working Properly………………………………………………………………..291 Inspect All Tires for Correct Tire Pressure and Signs of Damage or Abnormal Wear…………………………………………………………..291 Check Operation of All Controls and Linkages…………………………………………………………………………………………..292 50 Hour / Weekly Service………………………………………………………………………………………………………………..293 Perform All Daily Service Checks……………………………………………………………………………………………………..293 Grease Front Attachment Pins…………………………………………………………………………………………………………293 Grease Steering Cylinder Rod and Head Ends…………………………………………………………………………………………….294 Grease Upper and Lower Center Pins……………………………………………………………………………………………………295 Change Engine Oil and Filter (After First 50 Hours)…………………………………………………………………………………….296 Change Hydraulic Full Flow Filter (After First 50 Hours)………………………………………………………………………………..296 Check Air Conditioner and Alternator Belt Tension (After First 50 Hours)………………………………………………………………….296 Clean Exterior of Radiator, Oil Cooler and Air Conditioner Condenser……………………………………………………………………..296 Clean Air Conditioner Outer Filter……………………………………………………………………………………………………297 250 Hour / Monthly Service………………………………………………………………………………………………………………298 Perform All Daily and 50 Hour Service Checks…………………………………………………………………………………………..298 Braking – Test……………………………………………………………………………………………………………………..298 Drain Water From Hydraulic Oil Tank…………………………………………………………………………………………………..302 Grease Front Attachment Pins…………………………………………………………………………………………………………303 Check Air Conditioner Belt Tension……………………………………………………………………………………………………305 Grease Driveshafts………………………………………………………………………………………………………………….305 Change Transmission Oil and Filter (After First 250 Hours)………………………………………………………………………………306 Fuel Water Trap…………………………………………………………………………………………………………………….306 Auto Grease System (If Equipped)……………………………………………………………………………………………………..306 Clean Oil Bath Precleaner (Optional)………………………………………………………………………………………………….307 500 Hour / 3 Month Service………………………………………………………………………………………………………………309 Perform All Daily, 50 and 250 Hour Service Checks………………………………………………………………………………………309 Clean Outer Air Cleaner Filter……………………………………………………………………………………………………….309 Change Hydraulic System Brake and Pilot Filter…………………………………………………………………………………………310 Change Engine Oil…………………………………………………………………………………………………………………..311 Change Engine Oil Filter…………………………………………………………………………………………………………….312 Clean Centrifugal Oil Cleaner………………………………………………………………………………………………………..313 Clean Exterior of Radiator, Oil Cooler and Air Conditioner Condenser……………………………………………………………………..315 Check and Adjust Valve Clearance……………………………………………………………………………………………………..315 Clean Air Conditioner Inner Filter……………………………………………………………………………………………………316 Change Axle Differential and Planetaries Oil (After First 500 Hours)……………………………………………………………………..316 Change Air Conditioner Outer Filter…………………………………………………………………………………………………..316 Check Hydraulic Oil Contamination…………………………………………………………………………………………………….317 1,000 Hour / 6 Month Service…………………………………………………………………………………………………………….318 Perform All Daily, 50, 250, and 500 Hour Service Checks…………………………………………………………………………………318 Change Water Separator………………………………………………………………………………………………………………318 Change Fuel Filter………………………………………………………………………………………………………………….319 Change DEF (AdBlue) Breather Filter…………………………………………………………………………………………………..322 Change DEF (AdBlue) Filter…………………………………………………………………………………………………………..323 Drain and Change Transmission Oil and Filter…………………………………………………………………………………………..324 Change Air Conditioner Inner Filter…………………………………………………………………………………………………..325 Check and Adjust Engine……………………………………………………………………………………………………………..325 Clean Fuel Tank and Strainer…………………………………………………………………………………………………………326 Check Air Conditioner Refrigerant…………………………………………………………………………………………………….327 Change Air Breather Filter…………………………………………………………………………………………………………..328 Change Hydraulic Full Flow Filter…………………………………………………………………………………………………….329 Change Fuel Cap Filter………………………………………………………………………………………………………………330 Check Drive Belt……………………………………………………………………………………………………………………332 1,500 Hour / 9 Month Service…………………………………………………………………………………………………………….333 Perform All Daily, 50, 250 and 500 Hour Service Checks………………………………………………………………………………….333 Change Axle Differential and Planetaries Oil…………………………………………………………………………………………..333 2,000 Hour / Yearly Service……………………………………………………………………………………………………………..335 Perform All Daily, 50, 250, 500 and 1,000 Hour Service Checks……………………………………………………………………………335 Change Outer Air Cleaner Filter………………………………………………………………………………………………………335 Change Inner Air Cleaner Filter………………………………………………………………………………………………………335 Check Steering, Brake, Driveshaft, Engine, and Fuel System………………………………………………………………………………335 Change Pipes and Hoses………………………………………………………………………………………………………………335 Change Radiator Coolant……………………………………………………………………………………………………………..336 Change Hydraulic Oil and Clean Oil Suction Strainer…………………………………………………………………………………….337 Bleed Brakes……………………………………………………………………………………………………………………….339 Check Brake Accumulator……………………………………………………………………………………………………………..340 12,000 Hour / 6 Year Service…………………………………………………………………………………………………………….341 Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 CEN)…………………………………………………………………341 Standard Bolt Torque Chart………………………………………………………………………………………………………………342 Tightening Torque Specifications for Metric Bolts (For coated threads, prelubricated assemblies)…………………………………………….342 Electrical System………………………………………………………………………………………………………………………343 Check Battery Condition……………………………………………………………………………………………………………..343 Engine Cooling System…………………………………………………………………………………………………………………..344 General……………………………………………………………………………………………………………………………344 Antifreeze Concentration Tables………………………………………………………………………………………………………346 Table of Standards for Allowed Tap Water………………………………………………………………………………………………346 Handling of Accumulator…………………………………………………………………………………………………………………347 Pilot Accumulator…………………………………………………………………………………………………………………..347 Brake Accumulators………………………………………………………………………………………………………………….348 LIS Accumulator…………………………………………………………………………………………………………………….348 Steering Accumulator………………………………………………………………………………………………………………..348 Hydraulic Pressure Checks……………………………………………………………………………………………………………….349 Steering Pump Load Sensing Pressure…………………………………………………………………………………………………..349 Pilot Supply Pressure……………………………………………………………………………………………………………….349 Main Pump Pressure………………………………………………………………………………………………………………….350 Brake Charging Pressure……………………………………………………………………………………………………………..350 Transmission Clutch Pressure…………………………………………………………………………………………………………351 Main Pump Load Sensing Pressure………………………………………………………………………………………………………351 Fan Motor Pressure and Fan Speed……………………………………………………………………………………………………..352 Long Term Storage………………………………………………………………………………………………………………………354 Cleaning…………………………………………………………………………………………………………………………..354 Hydraulic System……………………………………………………………………………………………………………………354 Lubrication………………………………………………………………………………………………………………………..354 Battery……………………………………………………………………………………………………………………………354 Cooling System Care…………………………………………………………………………………………………………………354 Parking Brake Adjustment………………………………………………………………………………………………………………..355 Emergency Release of Parking Brake……………………………………………………………………………………………………355 Adjustment Procedure for Parking Brake………………………………………………………………………………………………..356 Severe Conditions Maintenance……………………………………………………………………………………………………………357 Tires…………………………………………………………………………………………………………………………………358 Inflating Tires…………………………………………………………………………………………………………………….358 Wheel Nut, Tightening Check………………………………………………………………………………………………………….358 Wheel Nut Torque……………………………………………………………………………………………………………………359 Check Tire for Damage……………………………………………………………………………………………………………….359 Recommended Air Pressure…………………………………………………………………………………………………………….360 Transmission Recalibration………………………………………………………………………………………………………………361 Transportation…………………………………………………………………………………………………………………………….363 Transporting Machine……………………………………………………………………………………………………………………363 Unloading………………………………………………………………………………………………………………………….366 Lifting Machine………………………………………………………………………………………………………………………..367 Troubleshooting……………………………………………………………………………………………………………………………369 Braking……………………………………………………………………………………………………………………………….369 Electrical System………………………………………………………………………………………………………………………370 Engine………………………………………………………………………………………………………………………………..370 Hydraulic System……………………………………………………………………………………………………………………….373 Steering………………………………………………………………………………………………………………………………375 Travel System………………………………………………………………………………………………………………………….376 General……………………………………………………………………………………………………………………………376 Specification……………………………………………………………………………………………………………………………..379 General Specifications………………………………………………………………………………………………………………….379 Working Range and Dimensions…………………………………………………………………………………………………………….380 Working Capacities……………………………………………………………………………………………………………………..382 Bucket Capacity…………………………………………………………………………………………………………………….382 Stability Data (EN – and ISO – Norms)…………………………………………………………………………………………………382 Approximate Weight of Workload Materials………………………………………………………………………………………………….383 Material Weight…………………………………………………………………………………………………………………….383 Index…………………………………………………………………………………………………………………………………….385

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