Daewoo Doosan WHEEL LOADER DL550-5 Operation & Maintenance Manual – PDF DOWNLOAD

Description

Daewoo Doosan WHEEL LOADER DL550-5 Operation & Maintenance Manual – PDF DOWNLOAD

DESCRIPTION:

Daewoo doosan WHEEL LOADER DL550-5 Operation & Maintenance Manual – PDF DOWNLOAD

1Foreword

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.

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 DL550-5 Operation & Maintenance Manual – PDF DOWNLOAD

DL550-5……………………………………………………………………………………………………………………………………… 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
Sound…………………………………………………………………………………………………………………………….. 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 (Electric 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 Starter 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…………………………………………………………………………………………………………………..280
10 Hour / Daily Service…………………………………………………………………………………………………………………282
Grease Front Attachment Pins…………………………………………………………………………………………………………282
Check Engine Oil Level………………………………………………………………………………………………………………282
Check Transmission Oil Level…………………………………………………………………………………………………………283
Check Hydraulic System Oil Level……………………………………………………………………………………………………..284
Check for Leaks in Hydraulic System…………………………………………………………………………………………………..285
Fill Fuel Tank……………………………………………………………………………………………………………………..285
Check for Leaks in Fuel System……………………………………………………………………………………………………….286
Drain Fuel Condensation……………………………………………………………………………………………………………..286
Fill DEF (AdBlue) Tank………………………………………………………………………………………………………………286
Check Coolant Level…………………………………………………………………………………………………………………287
Check Level of Windshield Washer Liquid……………………………………………………………………………………………….287
Inspect Bucket Teeth and Side Cutters for Signs of Wear…………………………………………………………………………………288
Inspect Cooling Fan Blade……………………………………………………………………………………………………………288
Check Engine Air Intake Precleaner……………………………………………………………………………………………………288
Check Air Intake System……………………………………………………………………………………………………………..289
Inspect Seat Belt for Proper Operation………………………………………………………………………………………………..289
Inspect Mirrors for Damage and Adjust and Clean as Required……………………………………………………………………………..289
Inspect Structure for Cracks and Faulty Welds………………………………………………………………………………………….289
Check Operation of All Switches………………………………………………………………………………………………………290
Check Operation of All Exterior Lights, Horn and Control Console Indicator and Monitor Lights……………………………………………….290
Start Engine, Check Starting Ability, and Observe Exhaust Color at Start-up and at Normal Operating Temperature. Listen for Any Abnormal Sounds…..290
Check That Back up Alarm and Rear Camera (If equipped) is Working Properly………………………………………………………………..290
Inspect All Tires for Correct Tire Pressure and Signs of Damage or Abnormal Wear…………………………………………………………..290
Check Operation of All Controls and Linkages…………………………………………………………………………………………..291
50 Hour / Weekly Service………………………………………………………………………………………………………………..292
Perform All Daily Service Checks……………………………………………………………………………………………………..292
Grease Front Attachment Pins…………………………………………………………………………………………………………292
Grease Steering Cylinder Rod and Head Ends…………………………………………………………………………………………….293
Grease Upper and Lower Center Pins……………………………………………………………………………………………………294
Change Engine Oil and Filter (After First 50 Hours)…………………………………………………………………………………….295
Change Hydraulic Full Flow Filter (After First 50 Hours)………………………………………………………………………………..295
Check Air Conditioner and Alternator Belt Tension (After First 50 Hours)………………………………………………………………….295
Clean Exterior of Radiator, Oil Cooler and Air Conditioner Condenser……………………………………………………………………..295
Clean Air Conditioner Outer Filter……………………………………………………………………………………………………296
250 Hour / Monthly Service………………………………………………………………………………………………………………297
Perform All Daily and 50 Hour Service Checks…………………………………………………………………………………………..297
Braking – Test……………………………………………………………………………………………………………………..297
Drain Water From Hydraulic Oil Tank…………………………………………………………………………………………………..301
Grease Front Attachment Pins…………………………………………………………………………………………………………302
Check Air Conditioner Belt Tension……………………………………………………………………………………………………304
Grease Driveshafts………………………………………………………………………………………………………………….304
Change Transmission Oil and Filter (After First 250 Hours)………………………………………………………………………………305
Fuel Water Trap…………………………………………………………………………………………………………………….305
Auto Grease System (If Equipped)……………………………………………………………………………………………………..305
Clean Oil Bath Precleaner (Optional)………………………………………………………………………………………………….306
500 Hour / 3 Month Service………………………………………………………………………………………………………………308
Perform All Daily, 50 and 250 Hour Service Checks………………………………………………………………………………………308
Clean Outer Air Cleaner Filter……………………………………………………………………………………………………….308
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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• This is the SAME exact manual used by your dealers to fix your vehicle.
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S.M