DAEWOO DOOSAN WHEEL LOADER DL420-5 Shop Manual Serial Number 10001 and Up – PDF DOWNLOAD

Description

DAEWOO DOOSAN WHEEL LOADER DL420-5 Shop Manual Serial Number 10001 and Up – PDF DOWNLOAD

DESCRIPTION:

DAEWOO DOOSAN WHEEL LOADER DL420-5 Shop Manual Serial Number 10001 and Up – PDF DOWNLOAD

SAFETY INSTRUCTIONS

AVOID DEATH OR SERIOUS INJURY

Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments repairs or service. Untrained operators and failure to follow instructions can cause death or serious injur

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.

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 DL420-5 Shop Manual Serial Number 10001 and Up – PDF DOWNLOAD

DL420-5..............................................................................................   0
	Table of Contents................................................................................   7
	Safety...........................................................................................   9
		Wheel Loader Safety..........................................................................  11
			Safety Instructions......................................................................  15
			Safety Messages..........................................................................  15
			General..................................................................................  17
				Safe Operation is Operator's Responsibility..........................................  17
				Know Your Machine....................................................................  17
				Proper Work Tools and Attachments....................................................  17
				Pressurized Fluids...................................................................  18
				Flying or Falling Objects............................................................  19
				Personal Protective Equipment (PPE)..................................................  19
				Correction of Machine Problems.......................................................  20
				Crushing and Cutting.................................................................  20
				Hot Coolant and Oils - Burn Prevention...............................................  21
				Fire and Explosion Prevention........................................................  21
				Fire Extinguisher and First-Aid Kit (Emergency Medical Kit)..........................  25
				Electrical System and Electrical Shock...............................................  25
				Roll-over Protective Structure (ROPS)/ Falling Object Protective Structure (FOPS)....  26
			Operation................................................................................  28
				Before Engine Starting...............................................................  28
				Work Site............................................................................  28
				Check Tire Pressure and Condition....................................................  29
				Mounting/Dismounting.................................................................  29
				Cleaning.............................................................................  30
				Operator Station.....................................................................  30
				Seat Belt............................................................................  31
				Visibility Information...............................................................  32
				Boost Starting or Charging Engine Batteries..........................................  33
				Starting Engine......................................................................  34
				Traveling............................................................................  34
				Lifting and Digging..................................................................  36
				Digging Beneath Overhangs............................................................  36
				Digging Beneath Wheel Loader.........................................................  36
				Operation on Slopes..................................................................  37
				Towing...............................................................................  38
				Attachment...........................................................................  39
				Equipment Lowering with Engine Stopped...............................................  40
				Preventing Risk of Injuries or Death From Boom and Bucket............................  40
				Engine Stop..........................................................................  41
				Parking Machine......................................................................  42
			Maintenance..............................................................................  43
				Warning Tag..........................................................................  45
				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.......................................................................  86
				Bucket Capacity......................................................................  86
				Stability Data (EN - and ISO - Norms)................................................  86
			General Specifications...................................................................  87
			Performance Tests........................................................................  88
				Purpose of Performance Tests.........................................................  88
				Kinds of Tests.......................................................................  88
				Performance Standards................................................................  88
				Precautions for Evaluation of Test Data..............................................  88
				Definition of "Performance Standard".................................................  88
			Preparation for Performance Tests........................................................  89
				The Machine..........................................................................  89
				Test Area............................................................................  89
				Precautions..........................................................................  89
				Make Precise Measurement.............................................................  89
			Operational Performance Standard Table...................................................  90
			Operational Performance Test.............................................................  92
				Engine Speed.........................................................................  92
				Front Speed..........................................................................  94
				Natural Subsidence of Cylinder.......................................................  95
				Travel Speed - Acceleration and Deceleration.........................................  96
				Steering Time........................................................................  97
				Pressure Set.........................................................................  98
			Approximate Weight of Workload Materials................................................. 100
				Material Weight...................................................................... 100
	General Maintenance.............................................................................. 103
		General Maintenance Instructions............................................................. 105
			Safety Instructions...................................................................... 109
			Welding Precautions and Instructions..................................................... 110
			Hydraulic System - General Precautions................................................... 111
			Maintenance Service and Repair Procedure................................................. 113
				General Precautions.................................................................. 113
			Hydraulic System Cleanliness and Oil Leaks............................................... 114
				Maintenance Precautions for Hydraulic System Service................................. 114
				Oil Leakage Precautions.............................................................. 115
			Cleaning and Inspection.................................................................. 116
				General Instructions................................................................. 116
				Bearing Inspection................................................................... 117
		Standard Torques............................................................................. 125
			Safety Instructions...................................................................... 129
			Torque Values for Standard Metric Fasteners.............................................. 130
			Torque Values for Standard U.S. Fasteners................................................ 131
			Type 8 Phosphate Coated Hardware......................................................... 133
			Torque Values for Hose Clamps............................................................ 134
			ORFS Swivel Nut Recommended Torque....................................................... 134
			Torque Values for Split Flanges.......................................................... 135
			Torque Wrench Extension Tools............................................................ 136
				Torque Multiplication................................................................ 136
				Other Uses for Torque Wrench Extension Tools......................................... 137
				Tightening Torque Specifications (Metric)............................................ 138
	Engine........................................................................................... 141
		Engine....................................................................................... 143
			Safety Instructions...................................................................... 149
			Overview................................................................................. 150
			Inspection............................................................................... 151
				Cleaning the Engine.................................................................. 151
			Special Tools............................................................................ 151
				Mounting the Engine in a Universal Stand............................................. 161
			Engine Identification.................................................................... 162
				Engine Data Plate.................................................................... 162
			Engine Specification..................................................................... 163
			Engine Performance Curves................................................................ 164
			Tightening Torques....................................................................... 166
				Normal Tightening Torque............................................................. 166
				Special Tightening Torque............................................................ 170
			Cylinder................................................................................. 196
				Cylinder Head........................................................................ 196
				Valve Mechanism...................................................................... 214
				Cylinder Block....................................................................... 218
				Cylinder Liner....................................................................... 232
				Flywheel Housing..................................................................... 239
				Front Cover.......................................................................... 242
				Oil Mist Separator................................................................... 244
			Actuating System......................................................................... 250
				Camshaft............................................................................. 250
				Connecting Rod....................................................................... 257
				Crankshaft........................................................................... 260
				Flywheel............................................................................. 269
				Piston............................................................................... 274
				Roller Tappet........................................................................ 280
				Intake Manifold...................................................................... 281
				Torsion Damper....................................................................... 282
				Belt Circuit......................................................................... 283
				Timing Gear.......................................................................... 289
			Lubrication System....................................................................... 295
				General Information.................................................................. 295
				Centrifugal Oil Cleaner.............................................................. 297
				Oil Cooler........................................................................... 302
				Oil Filter........................................................................... 305
				Oil Pump............................................................................. 306
				Oil Sump............................................................................. 308
				Oil Pressure Sensor.................................................................. 310
				Troubleshooting Chips Found in the Engine............................................ 311
				Troubleshooting the Lubrication System............................................... 315
				Lubrication Oil Consumption.......................................................... 316
			Exhaust System........................................................................... 319
				General Information.................................................................. 319
				T113, Exhaust Temperature Sensor Before Catalytic Converter.......................... 335
				T115, NOx Sensor..................................................................... 336
				T131 NOx Sensor...................................................................... 338
				T116, Reductant Pick-up Unit......................................................... 340
				Evaporator........................................................................... 345
				V117 Reductant Doser................................................................. 346
				V118, Coolant Valve for Heating the Reductant System................................. 351
				V183 Reductant Pump.................................................................. 353
				H25, H26 Electrically Heated Reductant Hose.......................................... 364
				M4000 Electric Exhaust Brake......................................................... 365
				Reductant Tank....................................................................... 371
				Oxidation Catalytic Converter........................................................ 378
				Exhaust Manifold..................................................................... 380
				Variable Geometry Turbocharger....................................................... 386
				EGR System........................................................................... 394
				EGR Valve............................................................................ 401
				EGR Cooler........................................................................... 406
			Cooling System........................................................................... 408
				Internal Cleaning of Cooling System.................................................. 411
				Charge Air Cooler.................................................................... 412
				Charge Air Temperature Sensor........................................................ 414
				Charge Air Pressure Sensor........................................................... 416
				Thermostat........................................................................... 417
				Coolant Pump......................................................................... 420
				Coolant Temperature Sensor........................................................... 421
			Fuel System.............................................................................. 423
				General Information.................................................................. 423
				Accumulator.......................................................................... 429
				Fuel Manifold........................................................................ 430
				Overflow Valve....................................................................... 437
				Feed Pump............................................................................ 441
				Injector............................................................................. 447
				Fuel Filter.......................................................................... 453
				Fuel Heater.......................................................................... 459
				Fuel System Troubleshooting.......................................................... 460
			Electrical System........................................................................ 473
				E44, Control Unit EMS................................................................ 473
				Control Unit EEC..................................................................... 490
				Clamping and Routing the Electrical Cables........................................... 495
				Engine Speed Sensor.................................................................. 496
				T110 Oil Level Sensor................................................................ 498
				T111, Fuel Pressure Sensor........................................................... 499
				T125, Exhaust Back Pressure Sensor................................................... 501
				T135, Camshaft Position Sensor....................................................... 502
				V109, Solenoid Valve for Charge Pressure............................................. 504
				V120, Fuel Inlet Metering Valve...................................................... 505
				V141, V142, V143, V144, V145, V146 Solenoid Valve for Injector....................... 507
				T8, Coolant Level Monitor............................................................ 508
				P3, Alternator....................................................................... 509
				M1, Starter Motor.................................................................... 519
				Electrical Parts..................................................................... 522
				EMS S8 (1/2)......................................................................... 533
				EMS S8 (2/2)......................................................................... 535
				EEC, EEC3 Exhaust Emission Control................................................... 537
	Drivetrain....................................................................................... 539
		Transmission and Torque Converter (4WG)...................................................... 541
			Safety Instructions...................................................................... 547
			General.................................................................................. 548
				Specification........................................................................ 549
				Outline.............................................................................. 550
				Overview............................................................................. 551
				Section View......................................................................... 552
				Hydraulic Circuit (4-speed Transmission)............................................. 553
				Torque Convertor..................................................................... 554
				Electrohydraulic Control with Proportional Valves.................................... 557
				Controller........................................................................... 558
				Electric Control System.............................................................. 559
				Speed Sensor......................................................................... 562
				Transmission Pressure Measuring Point and Connections................................ 564
			Transmission Electric Components......................................................... 566
				TCU (Transmission Control Unit)...................................................... 568
				Transmission Control Valve........................................................... 568
				Transmission Oil Temperature Sensor.................................................. 568
				Engine Pickup Sensor................................................................. 569
				Central Gear Pickup Sensor........................................................... 569
				Turbine Pickup Sensor................................................................ 569
				Output Speed Sensor.................................................................. 569
				Shift Lever Switch (DW-3)............................................................ 570
				Forward, Reverse Switch Lever........................................................ 571
				Fingertip Work Lever (Optional)...................................................... 571
				Transmission Shift Switch............................................................ 573
				T/M Cutoff Sensor.................................................................... 573
				LIS Solenoid Valve................................................................... 573
				DHL Solenoid Valve................................................................... 574
				T/M Converter Lockup P/V............................................................. 574
			Transmission Electrical Circuits......................................................... 576
				Transmission Controller Circuit...................................................... 576
				Traveling Circuits................................................................... 577
				Downshift............................................................................ 586
				Transmission Cutoff.................................................................. 592
				LIS (Load Isolation System) - Option................................................. 593
				Torque Converter Lockup (Option)..................................................... 594
				DHL (Differential Lock-auto) - Option................................................ 595
				DHL (Differential Lock-manual) - Option.............................................. 596
			Torque Limits for Screws................................................................. 597
			Special Tools............................................................................ 598
				List of Special Tools for Disassembly and Reassembly................................. 598
				Disassembly.......................................................................... 618
				Reassembly........................................................................... 621
			Transmission............................................................................. 628
				Disassembly.......................................................................... 628
				Reassembly........................................................................... 654
			Failure Code............................................................................. 739
		Transmission and Torque Converter (5WG) (Option)............................................. 765
			Safety Instructions...................................................................... 769
			General.................................................................................. 769
				Specification........................................................................ 770
				Overview............................................................................. 771
				Hydraulic Circuit (5-speed Transmission)............................................. 772
				Torque Convertor..................................................................... 773
			Transmission Electrical Circuits......................................................... 774
				T/M Controller Circuit............................................................... 774
			Torque Limits for Screws................................................................. 776
			Special Tools............................................................................ 777
				List of Special Tools for Disassembly and Reassembly................................. 777
			Electrohydraulic Control with Proportional Valves........................................ 782
				Disassembly.......................................................................... 782
				Reassembly........................................................................... 787
			Transmission............................................................................. 796
				Disassembly.......................................................................... 796
				Reassembly........................................................................... 823
		Front Axle................................................................................... 913
			Safety Instructions...................................................................... 917
			General.................................................................................. 917
				Specification........................................................................ 917
				Overview............................................................................. 918
				Parts List........................................................................... 919
			Lubrication and Maintenance Instructions................................................. 921
				Oil Grade............................................................................ 921
				Oil Change........................................................................... 921
				Carry Out Wear Measurement on the Multidisk Brake.................................... 923
				Tightening Torques for Screws........................................................ 924
			Differential System...................................................................... 925
				Theory of Differential Device........................................................ 925
				Structure of Differential Device..................................................... 926
			LSD...................................................................................... 927
				Overview LSD (Limited Slip Differential)............................................. 927
				LSD (Limited Slip Differential)...................................................... 928
			Axle Air Breathing....................................................................... 929
			Special Tools............................................................................ 930
				List of Special Tools for Disassembly and Reassembly................................. 930
			Removal.................................................................................. 937
			Installation............................................................................. 940
			Completing Work.......................................................................... 940
			Disassembly and Reassembly............................................................... 941
				Disassembly of Output and Brake...................................................... 941
				Disassembly Axle Housing............................................................. 947
				Disassembly Input.................................................................... 948
				Disassembly Differentials............................................................ 951
				Reassembly Differentials............................................................. 958
				Reassembly Input..................................................................... 970
				Reassembly Axle Housing.............................................................. 978
				Reassembly Output and Brake.......................................................... 980
		Rear Axle.................................................................................... 993
			Safety Instructions...................................................................... 997
			General.................................................................................. 997
				Specification........................................................................ 997
				Overview............................................................................. 998
				Parts List........................................................................... 999
			Lubrication and Maintenance Instructions.................................................1001
				Oil Grade............................................................................1001
				Oil Change...........................................................................1001
				Carry Out Wear Measurement on the Multidisk Brake....................................1003
				Tightening Torques for Screws........................................................1004
			Differential System......................................................................1005
				Theory of Differential Device........................................................1005
				Structure of Differential Device.....................................................1006
			Axle Air Breathing.......................................................................1007
			Special Tools............................................................................1008
				List of Special Tools for Disassembly and Reassembly.................................1008
			Removal..................................................................................1014
			Installation.............................................................................1018
			Completing Work..........................................................................1018
			Disassebmbly and Reassembly..............................................................1019
				Disassembly Output and Brake.........................................................1019
				Disassembly Axle Housing.............................................................1025
				Disassembly Input....................................................................1026
				Disassembly Differentials............................................................1029
				Reassembly Differentials.............................................................1036
				Reassembly Input.....................................................................1048
				Reassembly Axle Housing..............................................................1056
				Reassembly Output and Brake..........................................................1058
		Driveshaft...................................................................................1071
			Safety Instructions......................................................................1075
			General..................................................................................1076
				Overview.............................................................................1076
				Specification........................................................................1076
			Removal (Front DriveShaft)...............................................................1078
			Installation (Front DriveShaft)..........................................................1079
			Removal (Center DriveShaft)..............................................................1080
			Installation (Center DriveShaft).........................................................1081
			Removal (Rear DriveShaft)................................................................1082
			Installation (Rear DriveShaft)...........................................................1083
	Steering.........................................................................................1085
		Power Steering System........................................................................1087
			Safety Instructions......................................................................1091
			General Description......................................................................1091
				Overview.............................................................................1092
				Hydraulic Circuit....................................................................1093
				Theory of Operation..................................................................1094
		Steering Unit................................................................................1097
			Safety Instructions......................................................................1101
			General Description......................................................................1101
				Specifications.......................................................................1103
				Overview.............................................................................1104
				Theory of Operation..................................................................1105
				Gerotor Operation....................................................................1106
				Relief Valve.........................................................................1106
		Steering Pump................................................................................1107
			Safety Instructions......................................................................1111
			General Description......................................................................1112
				Specifications.......................................................................1112
				Overview.............................................................................1113
				Theory of Operation..................................................................1116
			Removal..................................................................................1118
			Installation.............................................................................1122
			Completing Work..........................................................................1122
			Disassembly..............................................................................1123
			Assembly.................................................................................1125
		Flow Amplifier...............................................................................1129
			Safety Instructions......................................................................1133
			General Description......................................................................1133
				Specifications.......................................................................1134
				Parts List...........................................................................1136
				Theory of Operation..................................................................1137
			Removal..................................................................................1139
			Installation.............................................................................1141
			Completing Work..........................................................................1141
			Tools....................................................................................1142
				List of Required Tools...............................................................1142
			Disassembly..............................................................................1143
			Assembly.................................................................................1157
			Cleaning and Inspection (Wear Limits and Tolerances).....................................1171
				Cleaning.............................................................................1171
				Inspection and Replacement...........................................................1171
				Lubrication..........................................................................1171
		Jerk Softener and Accumulator................................................................1173
			Safety Instructions......................................................................1177
			General Description......................................................................1177
				Operation............................................................................1177
			Accumulator..............................................................................1178
				Specifications.......................................................................1178
			Jerk Softener............................................................................1178
				Specifications.......................................................................1178
				Parts List...........................................................................1178
	Brake............................................................................................1179
		Service Brake................................................................................1181
			Safety Instructions......................................................................1185
			General Description......................................................................1186
			Service Brake System.....................................................................1187
		Brake and Pilot Supply Valve.................................................................1189
			Safety Instructions......................................................................1193
			General Description......................................................................1193
				Overview.............................................................................1194
				Parts List...........................................................................1196
			Removal..................................................................................1197
			Installation.............................................................................1200
			Completing Work..........................................................................1200
		Charging Block...............................................................................1201
			Safety Instructions......................................................................1205
			General Description......................................................................1206
				Parts List...........................................................................1206
				Hydraulic Circuit....................................................................1207
		Parking Brake................................................................................1209
			Safety Instructions......................................................................1213
			General Description......................................................................1213
				Specification........................................................................1213
				Overview.............................................................................1214
			Functional Characteristics and Maintenance Instructions..................................1215
				Functional Characteristics of Spring Loaded Sliding Caliper Brakes...................1215
				Mounting and Basic Setting Regulations...............................................1217
				Adjusting Regulations................................................................1218
				Emergency Release of Parking Brake...................................................1218
				Maintenance and Repair Work..........................................................1219
				General..............................................................................1221
		Brake Pedal Valve............................................................................1223
			Safety Instructions......................................................................1227
			General Description......................................................................1227
				Specification........................................................................1227
				Parts List...........................................................................1228
				Theory of Operation..................................................................1229
		Accumulator..................................................................................1231
			Safety Instructions......................................................................1235
			General Description......................................................................1236
				Layout...............................................................................1238
				Specifications.......................................................................1238
		Brake Filter.................................................................................1239
			Safety Instructions......................................................................1243
				Specification........................................................................1244
				Overview.............................................................................1244
				Parts List...........................................................................1244
	Cooling System...................................................................................1245
		Cooling System...............................................................................1247
			Safety Instructions......................................................................1251
			General Description......................................................................1251
				Function.............................................................................1252
				Hydraulic Circuit....................................................................1253
				Fan Motor Pressure and Fan Speed.....................................................1254
					Checking Maximum Fan Speed.......................................................1255
		Fan and Brake Pump...........................................................................1257
			Safety Instructions......................................................................1261
			General..................................................................................1261
				Specification........................................................................1261
				Sectional View.......................................................................1262
				Overview.............................................................................1263
					Port and Hydraulic Circuit.......................................................1263
				Parts List...........................................................................1264
				Theory of Operation..................................................................1266
					Circuit..........................................................................1266
					Control Section..................................................................1267
					Circuit Diagram Related to Fan Drive.............................................1267
					Pump EPPR Valve..................................................................1268
			Removal..................................................................................1270
			Installation.............................................................................1272
			Completing Work..........................................................................1272
			Disassembly..............................................................................1273
			Assembly.................................................................................1277
				Tightening Torques...................................................................1282
				Sealing Driveshaft...................................................................1282
				Sealing Control Valve................................................................1284
		Fan Motor....................................................................................1285
			Safety Instructions......................................................................1289
				Specifications.......................................................................1290
				Overview.............................................................................1290
					Port and Hydraulic Circuit.......................................................1290
		Fan Control Valve............................................................................1291
			Safety Instructions......................................................................1295
			General..................................................................................1295
				Specifications.......................................................................1295
					Port and Hydraulic Circuit.......................................................1296
		Radiator Assembly............................................................................1297
			Safety Instructions......................................................................1301
			General..................................................................................1301
				Overview.............................................................................1301
				Structure............................................................................1302
				Parts List...........................................................................1303
			CAC (Charge Air Cooler)..................................................................1304
				Overview.............................................................................1304
				Replacing - Hose/Pipe (Charge Air Cooler)............................................1305
			Radiator.................................................................................1307
				Overview.............................................................................1307
				Theory of Operation..................................................................1307
				Radiator Cap.........................................................................1308
				Replacing - Radiator Cap.............................................................1309
				Replacing Coolant....................................................................1309
				Antifreeze Concentration Tables......................................................1310
			Transmission Cooling.....................................................................1311
				General Description..................................................................1311
				Layout...............................................................................1311
				Thermostat...........................................................................1312
	Hydraulic System.................................................................................1313
		Main Pump....................................................................................1315
			Safety Instructions......................................................................1319
			General..................................................................................1319
				Specifications.......................................................................1319
				Overview.............................................................................1320
				Theory of Operation..................................................................1322
				Parts List...........................................................................1324
				Structure............................................................................1328
			Removal..................................................................................1330
			Installation.............................................................................1333
			Completing work..........................................................................1333
			Disassembly..............................................................................1334
			Assembly.................................................................................1337
			Troubleshooting..........................................................................1340
			Maintenance Instructions.................................................................1341
		Main Control Valve...........................................................................1343
			Safety Instructions......................................................................1347
			General Description......................................................................1348
				Specification........................................................................1349
				Hydraulic Circuit....................................................................1350
				Configuration (Port).................................................................1352
				Theory of Operation..................................................................1353
				Section View.........................................................................1361
				Parts List...........................................................................1362
			Removal..................................................................................1366
			Installation.............................................................................1371
			Completing Work..........................................................................1371
		Pilot System.................................................................................1373
			Safety Instructions......................................................................1377
			General Description......................................................................1377
			Fingertip Joystick.......................................................................1378
				Specification........................................................................1378
				Port Name............................................................................1378
				Parts List - 2 Lever.................................................................1379
				Parts List - 3 Lever.................................................................1380
			FNR Joystick.............................................................................1381
				Specification........................................................................1381
				Port Name............................................................................1381
				Overview.............................................................................1381
				Parts List...........................................................................1382
		Hydraulic System.............................................................................1385
			Safety Instructions......................................................................1389
			Hydraulic Component and Circuit..........................................................1390
				Hydraulic Components.................................................................1390
				Pilot Circuit........................................................................1392
				Main Circuit.........................................................................1393
				Return Circuit.......................................................................1394
				Load Sensing Circuit.................................................................1395
			Fan Drive Operation......................................................................1396
			Parking Brake Release....................................................................1397
			Service Brake Operation..................................................................1398
			Steering Operation.......................................................................1399
			Boom Raise Operation and Load Sensing....................................................1400
			Boom Down Operation......................................................................1401
			Boom Floating Operation..................................................................1402
			Bucket Crowd Operation...................................................................1403
			Bucket Dump Operation....................................................................1404
			Combined Bucket Crowd and Boom Down Operation............................................1405
			Load Isolation System (LIS)..............................................................1406
		Hydraulic System Troubleshooting.............................................................1407
			Safety Instructions......................................................................1411
			Hydraulic System.........................................................................1412
				Engine Started but Machine Does Not Operate..........................................1412
				Hydraulic Oil Is Cloudy..............................................................1413
				Hydraulic Oil or Engine Overheated...................................................1414
				Parking Brakes Does Not Work.........................................................1415
				Service Brakes Does Not Work.........................................................1416
				Boom, Bucket Speed Is Slow...........................................................1417
				Does Not Work the Boom Floating......................................................1418
				Steering Wheel Is Heavy to Turn......................................................1419
				Does Not Operated LIS................................................................1420
	Frame............................................................................................1421
		Articulation Center..........................................................................1423
			Safety Instructions......................................................................1427
			General Description......................................................................1427
				Maintenance Standard.................................................................1428
		Cabin........................................................................................1431
			Safety Instructions......................................................................1435
			Cabin Identification.....................................................................1435
				Roll-over Protective Structure (ROPS)/Falling Object Protective Structure (FOPS).....1435
			Dimensions of Cabin Glass................................................................1437
			Removal and Installation of Cabin Glass..................................................1442
				Removal of Cabin Glass...............................................................1442
				Installation of Cabin Glass..........................................................1444
		Counterweight................................................................................1449
			Safety Instructions......................................................................1453
			General..................................................................................1454
				Overview.............................................................................1454
		Oil Tank.....................................................................................1455
			Safety Instructions......................................................................1459
			General Description......................................................................1459
				Specifications.......................................................................1459
				Parts List...........................................................................1460
				Air Breather.........................................................................1462
		Fuel Tank....................................................................................1463
			Safety Instructions......................................................................1467
			General Description......................................................................1467
				Specifications.......................................................................1467
				Parts List...........................................................................1468
		Cylinders....................................................................................1471
			Safety Instructions......................................................................1475
			General..................................................................................1475
				General Description..................................................................1475
				Specification........................................................................1475
				Parts List...........................................................................1476
				Theory of Operation..................................................................1482
				Seal of Cylinder.....................................................................1483
			Special Tools and Materials..............................................................1485
				Piston Nut...........................................................................1485
				Piston Jig...........................................................................1486
				Steel Bushing Jig....................................................................1487
				Dust Wiper Jig.......................................................................1488
				Slipper Seal Jig.....................................................................1489
				Rod Bushing (DD-bushing) Pushing-in Jig..............................................1490
			Disassembly..............................................................................1491
			Reassembly...............................................................................1496
			Troubleshooting..........................................................................1500
	Electrical System................................................................................1503
		Electrical System............................................................................1505
			Safety Instructions......................................................................1509
			Overview.................................................................................1509
			Electric Supply System...................................................................1510
			Engine Starting Circuit..................................................................1512
				Operation During Start Process.......................................................1512
				Operation After Start Process........................................................1514
			Engine Stop System.......................................................................1515
			Engine Emergency Start System............................................................1516
			Charging System..........................................................................1517
			Power Mode Control.......................................................................1518
			Engine Control System....................................................................1519
				Accelerator Pedal....................................................................1520
				Electrical Steering Control..........................................................1521
				Electric Joystick....................................................................1522
				Electric MCV Control.................................................................1523
				Electric Joystick (Boom).............................................................1524
				Electric Joystick (Bucket)...........................................................1525
				Auto Idle Control....................................................................1526
			Electric Detent System...................................................................1527
				Electrical Circuit...................................................................1527
				Boom Kick-out........................................................................1528
				Return to Dig........................................................................1529
			Cooling Fan Control System...............................................................1530
				Outline..............................................................................1530
				Diagram..............................................................................1530
				Electrical Diagram...................................................................1531
				Parts of Cooling Fan Control System..................................................1532
				Operation of Cooling Fan Control System..............................................1534
			Emergency Steering System (Option).......................................................1536
				Block Diagram........................................................................1536
				Emergency Steering System Components.................................................1537
				Emergency Steering System Electrical Circuit.........................................1540
			Lighting System..........................................................................1542
				Light Circuit........................................................................1542
			Monitoring System........................................................................1546
				Instrument Panel.....................................................................1547
				Function Check.......................................................................1547
				Monitoring System Schematic..........................................................1548
			Operation................................................................................1550
				Instruments Gauge....................................................................1550
				Indicator Lights.....................................................................1550
				Initial Operation....................................................................1552
				Multifunction Display................................................................1553
				Indication of Warning Lights.........................................................1556
				Indication of Indicator Lights.......................................................1558
			Graphic Information Area Display.........................................................1560
				Overview.............................................................................1560
				Main Menus for the Graphic Display Area..............................................1560
				Menu Selector Buttons................................................................1560
				User Menu............................................................................1561
				Service Menu.........................................................................1575
				Information of Machine Operation.....................................................1585
			Failure Code.............................................................................1592
				Failure Code at Machine..............................................................1592
				Failure Code at Engine Side..........................................................1596
				Failure Code at Transmission Side....................................................1611
				Failure Code at Electric Steering Side...............................................1615
				FMIs (Failure Mode Identifier).......................................................1617
			Windshield Wiper.........................................................................1618
				Front Windshield Wiper...............................................................1618
				Rear Windshield Wiper................................................................1620
		Air Conditioner..............................................................................1621
			Safety Instructions......................................................................1625
			General Description......................................................................1626
				Internal and External Filters........................................................1627
				Air-conditioning System Layout.......................................................1628
				Air Conditioner/Heater Circuit Diagram...............................................1629
				Air Conditioner/Heater Unit..........................................................1630
				Ambient Air Temperature Sensor.......................................................1635
				Sun Sensor...........................................................................1636
				Control Panel........................................................................1636
				Compressor...........................................................................1643
				Receiver Dryer.......................................................................1643
			Troubleshooting..........................................................................1644
			Refrigerant System Repairs...............................................................1646
				Refrigerant Safe Handling Procedures.................................................1646
				Repair and Replacement Procedure.....................................................1647
				Refrigerant Recovery.................................................................1649
				Vacuuming Refrigerant System.........................................................1649
				Leakage Check........................................................................1651
				Refrigerant Charging.................................................................1651
				Inspecting System For Leakage........................................................1653
	Option...........................................................................................1655
		Emergency Steering...........................................................................1657
			Safety Instructions......................................................................1661
				General Description..................................................................1661
				Specifications.......................................................................1661
				Theory of Operation..................................................................1662
				Hydraulic Circuit....................................................................1662
				Parts List...........................................................................1663
				Caution for Installation.............................................................1663
			Installation Procedure...................................................................1664
				Emergency Steering...................................................................1664
				Emergency Steering - Electric........................................................1666
				After Installation Precautions.......................................................1667
				Emergency Steering Function Test.....................................................1667
				Emergency Steering Automatic Test....................................................1668
		Load Isolation System........................................................................1669
			Safety Instructions......................................................................1673
			General Description......................................................................1673
				Overview.............................................................................1674
				Hydraulic Circuit....................................................................1676
				Accumulator Charging Method..........................................................1676
			LIS Valve................................................................................1678
				Specification........................................................................1678
				Parts List...........................................................................1679
			Accumulator..............................................................................1680
				Specification........................................................................1680
				Parts List...........................................................................1680
		3rd Control Valve............................................................................1681
			Safety Instructions......................................................................1685
			General..................................................................................1685
				Specification........................................................................1685
				Overview.............................................................................1686
				Hydraulic Circuit....................................................................1686
				Theory of Operation..................................................................1687
				Parts List...........................................................................1688
			Removal..................................................................................1689
			Installation.............................................................................1692
			Completing Work..........................................................................1692
			Disassembly and Assembly.................................................................1693
				General Cautions.....................................................................1693
				Assembly and Disassembly of Spool and Over Load Relief Valve.........................1694
			Performance Tests........................................................................1695
		Auto Grease System...........................................................................1697
			Safety Instructions......................................................................1701
			General Description......................................................................1701
				Overview.............................................................................1702
				Location.............................................................................1704
				Theory of Operation..................................................................1705
					Pump Element.....................................................................1705
					Grease Low Leveling..............................................................1706
					Feeder...........................................................................1707
					Error Sensing....................................................................1708
			Pump.....................................................................................1709
				Overview.............................................................................1709
					The Central Lubrication Pump.....................................................1709
					Note on the Rating Plate.........................................................1710
				Location.............................................................................1710
				Specification........................................................................1711
				Parts List...........................................................................1712
					Pump Element.....................................................................1714
					Check Valve......................................................................1715
					Pressure Relief Valve............................................................1715
					Power Supply 24 VDC..............................................................1716
					Connectivity for Timer Operation with System Monitoring..........................1716
					Connector Pin Assignment in Timer Operation......................................1716
				Pump Cable...........................................................................1717
					Overview.........................................................................1717
					Connector 1......................................................................1717
					Connector 2......................................................................1718
					Connector 3......................................................................1718
					Fill Level Switch................................................................1718
					Monitoring Lubrication Cycle by Piston Detector..................................1719
				Approved Lubricants..................................................................1720
				Operation............................................................................1721
					Pump.............................................................................1721
					Fill Level Monitoring............................................................1721
					Malfunctions on Pump Unit in Progressive System..................................1721
					Timer Operation..................................................................1722
				Maintenance, Repair..................................................................1723
					Maintenance......................................................................1723
					Repair...........................................................................1724
			Feeder...................................................................................1725
				Feeder (Front Frame).................................................................1725
					General Description..............................................................1725
					Location and Parts List..........................................................1726
					Dimension........................................................................1727
					Main Feeder Connector............................................................1729
				Feeder (Rear Frame)..................................................................1729
					General Description..............................................................1729
					Overview.........................................................................1729
					Location and Parts List..........................................................1730
					Dimension........................................................................1731
				Feeder (Tilt lever)..................................................................1732
					General Description..............................................................1732
					Overview.........................................................................1732
					Location and Parts List..........................................................1733
					Dimension........................................................................1734
				Replace Hose Using Service kit.......................................................1735
					Hoses for Self Assembly..........................................................1735
			Troubleshooting..........................................................................1737
				Grease Pump Fault....................................................................1739
				Grease System Faults.................................................................1739
	Schematic........................................................................................1741
		Hydraulic Schematic/ Electrical Schematic....................................................1743
			Hydraulic Schematic......................................................................1745
			Electrical Schematic.....................................................................1747

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