Daewoo doosan WHEEL LOADER DL550-5 Shop Manual 950106-01246E-2 – PDF DOWNLOAD

Description

Daewoo doosan WHEEL LOADER DL550-5 Shop Manual 950106-01246E-2 – PDF DOWNLOAD

DESCRIPTION:

Daewoo doosan WHEEL LOADER DL550-5 Shop Manual 950106-01246E-2 – PDF DOWNLOAD

GENERAL

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

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

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

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

• Be sure that you understand the use and maintenance of all safety features such as pilot cutoff switch and seat belt. Use them always.

• Never remove, modify or disable any safety features. Always keep them in good operating condition.

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

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

Know Your Machine

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

Proper Work Tools and Attachments

• Only use work tools and attachments that are recommended by DOOSAN for use on DOOSAN machines. When installing and using optional attachments, read instruction manual for attachment, and general information related to attachments in this manual. Because DOOSAN cannot anticipate, identify or test all attachments that owners may want to install on their machines, contact DOOSAN for written authorization and approval of attachments, and their compatibility with optional kits.
• Attachments and attachment control systems that are compatible with the machine are required for safe and reliable machine operation. Do not exceed maximum operating weight (machine weight plus attachment) that is listed on ROPS certification plate.
• Make sure that all guards and shields are in place on machine and on work tool. Depending on type or combination of work equipment, there is a potential that work equipment could interfere with the cabin or other parts of machine. Before using unfamiliar work equipment, check if there is any potential for interference, and operate with caution.
• While you are performing any maintenance, testing, or adjustments to attachments, stay clear of the following areas: cutting edges, pinch points, and crushing surfaces. Never use attachment as a work platform or manlift. Contact your DOOSAN distributor about auxiliary hydraulic kits for attachments installation. If you are in doubt about the compatibility of a particular attachment with the machine, consult your DOOSAN distributor.

Pressurized Fluids

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

TABLE OF CONTENTS:

Daewoo doosan WHEEL LOADER DL550-5 Shop Manual 950106-01246E-2 – PDF DOWNLOAD

DL550-5…………………………………………………………………………………. 0
Table of Contents…………………………………………………………………….. 7
Safety………………………………………………………………………………. 9
Wheel Loader Safety……………………………………………………………….. 11
Safety Instructions……………………………………………………………. 15
Safety Messages……………………………………………………………….. 15
General………………………………………………………………………. 17
Safe Operation is Operator’s Responsibility…………………………………… 17
Know Your Machine………………………………………………………….. 17
Proper Work Tools and Attachments……………………………………………. 17
Pressurized Fluids…………………………………………………………. 18
Flying or Falling Objects…………………………………………………… 19
Personal Protective Equipment (PPE)………………………………………….. 19
Correction of Machine Problems………………………………………………. 20
Crushing and Cutting……………………………………………………….. 20
Hot Coolant and Oils – Burn Prevention……………………………………….. 21
Fire and Explosion Prevention……………………………………………….. 21
Fire Extinguisher and First-Aid Kit (Emergency Medical Kit)…………………….. 25
Electrical System and Electrical Shock……………………………………….. 25
Roll-over Protective Structure (ROPS)/ Falling Object Protective Structure (FOPS)…. 26
Operation…………………………………………………………………….. 28
Before Engine Starting……………………………………………………… 28
Work Site…………………………………………………………………. 28
Check Tire Pressure and Condition……………………………………………. 29
Mounting/Dismounting……………………………………………………….. 29
Cleaning………………………………………………………………….. 30
Operator Station…………………………………………………………… 30
Seat Belt…………………………………………………………………. 31
Visibility Information……………………………………………………… 32
Boost Starting or Charging Engine Batteries…………………………………… 33
Starting Engine……………………………………………………………. 34
Traveling…………………………………………………………………. 34
Lifting and Digging………………………………………………………… 36
Digging Beneath Overhangs…………………………………………………… 36
Digging Beneath Wheel Loader………………………………………………… 36
Operation on Slopes………………………………………………………… 37
Attachment………………………………………………………………… 38
Equipment Lowering with Engine Stopped……………………………………….. 38
Preventing Risk of Injuries or Death From Boom and Bucket………………………. 38
Engine Stop……………………………………………………………….. 40
Parking Machine……………………………………………………………. 40
Maintenance…………………………………………………………………… 41
Warning Tag……………………………………………………………….. 43
Cleaning………………………………………………………………….. 44
Proper Tools and Clothing…………………………………………………… 44
Disassembling Precautions…………………………………………………… 44
Use of Lighting……………………………………………………………. 45
Fire and Explosion Prevention……………………………………………….. 45
Burn Prevention……………………………………………………………. 46
Rubber That Contains Fluorides………………………………………………. 47
Rubber and Plastics………………………………………………………… 48
Welding Repairs……………………………………………………………. 49
Working on Machine…………………………………………………………. 50
Lock Inspection Covers……………………………………………………… 51
Accumulator……………………………………………………………….. 51
Compressed Air…………………………………………………………….. 51
Supports and Blocking for Work Equipment……………………………………… 52
High-pressure Lines, Tubes and Hoses…………………………………………. 52
Battery…………………………………………………………………… 53
Preservation/Storing Machine………………………………………………… 54
Transportation………………………………………………………………… 56
Obey State and Local Over-the-Road Laws and Regulations………………………… 56
Loading and Unloading………………………………………………………. 56
Transporting Machine……………………………………………………….. 57
Environment and Circumstances…………………………………………………… 58
Work Site Areas Requiring Extra Caution………………………………………. 58
High-voltage Cables………………………………………………………… 60
Underground Operation………………………………………………………. 60
Working in Water…………………………………………………………… 61
Working in Contaminated Environment………………………………………….. 61
Operation in Extreme Conditions……………………………………………… 62
Exhaust Ventilation………………………………………………………… 66
Asbestos Information……………………………………………………….. 66
Silica Dust Information…………………………………………………….. 67
Disposal of Hazardous Materials……………………………………………… 67
Sound…………………………………………………………………….. 67
Vibration Information………………………………………………………. 68
Specifications……………………………………………………………………….. 71
Specification…………………………………………………………………….. 73
Safety Instructions……………………………………………………………. 77
General………………………………………………………………………. 77
Component Locations……………………………………………………………. 78
Working Range and Dimensions……………………………………………………. 82
Working Capacities…………………………………………………………….. 84
Bucket Capacity……………………………………………………………. 84
Stability Data (EN – and ISO – Norms)………………………………………… 84
General Specifications…………………………………………………………. 85
Performance Tests……………………………………………………………… 86
Purpose of Performance Tests………………………………………………… 86
Kinds of Tests…………………………………………………………….. 86
Performance Standards………………………………………………………. 86
Precautions for Evaluation of Test Data………………………………………. 86
Definition of “Performance Standard”…………………………………………. 86
Preparation for Performance Tests……………………………………………….. 87
The Machine……………………………………………………………….. 87
Test Area…………………………………………………………………. 87
Precautions……………………………………………………………….. 87
Make Precise Measurement……………………………………………………. 87
Operational Performance Standard Table…………………………………………… 88
Operational Performance Test……………………………………………………. 90
Engine Speed………………………………………………………………. 90
Front Speed……………………………………………………………….. 92
Natural Subsidence of Cylinder………………………………………………. 93
Travel Speed – Acceleration and Deceleration………………………………….. 94
Steering Time……………………………………………………………… 95
Pressure Set………………………………………………………………. 96
Approximate Weight of Workload Materials…………………………………………. 98
Material Weight……………………………………………………………. 98
General Maintenance…………………………………………………………………… 101
GeneralMaintenanceInstructions……………………………………………………… 103
Safety Instructions……………………………………………………………. 107
Welding Precautions and Instructions…………………………………………….. 108
Hydraulic System – General Precautions…………………………………………… 109
Maintenance Service and Repair Procedure…………………………………………. 111
General Precautions………………………………………………………… 111
Hydraulic System Cleanliness and Oil Leaks……………………………………….. 112
Maintenance Precautions for Hydraulic System Service…………………………… 112
Oil Leakage Precautions…………………………………………………….. 113
Cleaning and Inspection………………………………………………………… 114
General Instructions……………………………………………………….. 114
Bearing Inspection…………………………………………………………. 115
Standard Torques………………………………………………………………….. 123
Safety Instructions……………………………………………………………. 127
Torque Values for Standard Metric Fasteners………………………………………. 128
Torque Values for Standard U.S. Fasteners………………………………………… 129
Type 8 Phosphate Coated Hardware………………………………………………… 131
Torque Values for Hose Clamps…………………………………………………… 132
ORFS Swivel Nut Recommended Torque………………………………………………. 132
Torque Values for Split Flanges…………………………………………………. 133
Torque Wrench Extension Tools…………………………………………………… 134
Torque Multiplication………………………………………………………. 134
Other Uses for Torque Wrench Extension Tools………………………………….. 135
Tightening Torque Specifications (Metric)…………………………………….. 136
Engine………………………………………………………………………………. 139
Engine…………………………………………………………………………… 141
Safety Instructions……………………………………………………………. 147
Overview……………………………………………………………………… 148
Inspection……………………………………………………………………. 149
Cleaning the Engine………………………………………………………… 149
Special Tools…………………………………………………………………. 149
Mounting the Engine in a Universal Stand……………………………………… 159
Engine Identification………………………………………………………….. 160
Engine Data Plate………………………………………………………….. 160
Engine Specification…………………………………………………………… 161
Engine Performance Curves………………………………………………………. 162
Tightening Torques…………………………………………………………….. 164
Normal Tightening Torque……………………………………………………. 164
Special Tightening Torque…………………………………………………… 168
Cylinder……………………………………………………………………… 194
Cylinder Head……………………………………………………………… 194
Valve Mechanism……………………………………………………………. 212
Cylinder Block…………………………………………………………….. 216
Cylinder Liner…………………………………………………………….. 231
Flywheel Housing…………………………………………………………… 238
Front Cover……………………………………………………………….. 241
Oil Mist Separator…………………………………………………………. 243
Actuating System………………………………………………………………. 249
Camshaft………………………………………………………………….. 249
Connecting Rod…………………………………………………………….. 256
Crankshaft………………………………………………………………… 259
Flywheel………………………………………………………………….. 268
Piston……………………………………………………………………. 273
Roller Tappet……………………………………………………………… 279
Intake Manifold……………………………………………………………. 280
Torsion Damper…………………………………………………………….. 281
Belt Circuit………………………………………………………………. 282
Timing Gear……………………………………………………………….. 288
Lubrication System…………………………………………………………….. 294
General Information………………………………………………………… 294
Centrifugal Oil Cleaner…………………………………………………….. 296
Oil Cooler………………………………………………………………… 301
Oil Filter………………………………………………………………… 304
Oil Pump………………………………………………………………….. 305
Oil Sump………………………………………………………………….. 307
Oil Pressure Sensor………………………………………………………… 309
Troubleshooting Chips Found in the Engine…………………………………….. 310
Troubleshooting the Lubrication System……………………………………….. 314
Lubrication Oil Consumption…………………………………………………. 315
Exhaust System………………………………………………………………… 318
General Information………………………………………………………… 318
T113, Exhaust Temperature Sensor Before Catalytic Converter…………………….. 334
T115, NOx Sensor…………………………………………………………… 335
T131 NOx Sensor……………………………………………………………. 337
T116, Reductant Pick-up Unit………………………………………………… 339
Evaporator………………………………………………………………… 344
V117 Reductant Doser……………………………………………………….. 345
V118, Coolant Valve for Heating the Reductant System…………………………… 350
V183 Reductant Pump………………………………………………………… 352
H25, H26 Electrically Heated Reductant Hose…………………………………… 363
M4000 Electric Exhaust Brake………………………………………………… 364
Reductant Tank…………………………………………………………….. 370
Oxidation Catalytic Converter……………………………………………….. 377
Exhaust Manifold…………………………………………………………… 379
Variable Geometry Turbocharger………………………………………………. 385
EGR System………………………………………………………………… 393
EGR Valve…………………………………………………………………. 399
EGR Cooler………………………………………………………………… 404
Cooling System………………………………………………………………… 406
Internal Cleaning of Cooling System………………………………………….. 409
Charge Air Cooler………………………………………………………….. 410
Charge Air Temperature Sensor……………………………………………….. 412
Charge Air Pressure Sensor………………………………………………….. 414
Thermostat………………………………………………………………… 415
Coolant Pump………………………………………………………………. 418
Coolant Temperature Sensor………………………………………………….. 419
Fuel System…………………………………………………………………… 421
General Information………………………………………………………… 421
Accumulator……………………………………………………………….. 427
Fuel Manifold……………………………………………………………… 428
Overflow Valve…………………………………………………………….. 435
Feed Pump…………………………………………………………………. 439
Injector………………………………………………………………….. 445
Fuel Filter……………………………………………………………….. 451
Fuel Heater……………………………………………………………….. 456
Fuel System Troubleshooting…………………………………………………. 457
Electrical System……………………………………………………………… 470
E44, Control Unit EMS………………………………………………………. 470
Control Unit EEC…………………………………………………………… 487
Clamping and Routing the Electrical Cables……………………………………. 492
Engine Speed Sensor………………………………………………………… 493
T110 Oil Level Sensor………………………………………………………. 495
T111, Fuel Pressure Sensor………………………………………………….. 496
T125, Exhaust Back Pressure Sensor…………………………………………… 498
T135, Camshaft Position Sensor………………………………………………. 499
V109, Solenoid Valve for Charge Pressure……………………………………… 501
V120, Fuel Inlet Metering Valve……………………………………………… 502
V141, V142, V143, V144, V145, V146 Solenoid Valve for Injector………………….. 504
T8, Coolant Level Monitor…………………………………………………… 505
P3, Alternator…………………………………………………………….. 506
M1, Starter Motor………………………………………………………….. 516
Electrical Parts…………………………………………………………… 519
EMS S8 (1/2)………………………………………………………………. 531
EMS S8 (2/2)………………………………………………………………. 533
EEC, EEC3 Exhaust Emission Control…………………………………………… 535
Drivetrain…………………………………………………………………………… 537
Transmission and Torque Converter (4WG)……………………………………………… 539
Safety Instructions……………………………………………………………. 545
General………………………………………………………………………. 546
Specification……………………………………………………………… 547
Outline…………………………………………………………………… 548
Overview………………………………………………………………….. 549
Section View………………………………………………………………. 550
Hydraulic Circuit (4-speed Transmission)……………………………………… 551
Torque Convertor…………………………………………………………… 552
Electrohydraulic Control with Proportional Valves……………………………… 555
Controller………………………………………………………………… 556
Electric Control System…………………………………………………….. 557
Speed Sensor………………………………………………………………. 560
Transmission Pressure Measuring Point and Connections………………………….. 562
Transmission Electric Components………………………………………………… 564
TCU (Transmission Control Unit)……………………………………………… 566
Transmission Control Valve………………………………………………….. 566
Transmission Oil Temperature Sensor………………………………………….. 566
Engine Pickup Sensor……………………………………………………….. 567
Central Gear Pickup Sensor………………………………………………….. 567
Turbine Pickup Sensor………………………………………………………. 567
Output Speed Sensor………………………………………………………… 567
Shift Lever Switch (DW-3)…………………………………………………… 568
Forward, Reverse Switch Lever……………………………………………….. 569
Fingertip Work Lever (Optional)……………………………………………… 569
Transmission Shift Switch…………………………………………………… 571
T/M Cutoff Sensor………………………………………………………….. 571
LIS Solenoid Valve…………………………………………………………. 571
Transmission Electrical Circuits………………………………………………… 572
Transmission Controller Circuit……………………………………………… 572
Traveling Circuits…………………………………………………………. 573
Downshift…………………………………………………………………. 581
Transmission Cutoff Switch………………………………………………….. 588
Torque Limits for Screws……………………………………………………….. 589
Transmission Oil………………………………………………………………. 590
Oil Grade of Transmission…………………………………………………… 590
Special Tools…………………………………………………………………. 591
List of Special Tools for Disassembly and Reassembly…………………………… 591
Transmission Control Valve……………………………………………………… 611
Disassembly……………………………………………………………….. 611
Reassembly………………………………………………………………… 614
Transmission………………………………………………………………….. 621
Disassembly……………………………………………………………….. 621
Reassembly………………………………………………………………… 647
Failure Code………………………………………………………………….. 733
Transmission and Torque Converter (5WG) (Option)……………………………………… 759
Safety Instructions……………………………………………………………. 763
General………………………………………………………………………. 764
Specification……………………………………………………………… 765
Overview………………………………………………………………….. 766
Hydraulic Circuit (5-speed Transmission)……………………………………… 767
Torque Convertor…………………………………………………………… 768
Transmission Pressure Measuring Point and Connections………………………….. 770
Transmission Electrical Circuits………………………………………………… 772
Transmission Controller Circuit……………………………………………… 772
Traveling Circuits…………………………………………………………. 773
Torque Converter Lockup…………………………………………………….. 774
Torque Limits for Screws……………………………………………………….. 776
Special Tools…………………………………………………………………. 777
List of Special Tools for Disassembly and Reassembly…………………………… 777
Transmission Control Valve……………………………………………………… 782
Disassembly……………………………………………………………….. 782
Reassembly………………………………………………………………… 787
Transmission………………………………………………………………….. 796
Disassembly……………………………………………………………….. 796
Reassembly………………………………………………………………… 822
Front Axle……………………………………………………………………….. 909
Safety Instructions……………………………………………………………. 913
General………………………………………………………………………. 913
Specification……………………………………………………………… 913
Overview………………………………………………………………….. 914
Parts List………………………………………………………………… 915
Lubrication and Maintenance Instructions…………………………………………. 917
Oil Grade…………………………………………………………………. 917
Oil Change………………………………………………………………… 917
Carry Out Wear Measurement on the Multidisk Brake……………………………… 919
Tightening Torques for Screws……………………………………………….. 920
Differential System……………………………………………………………. 921
Theory of Differential Device……………………………………………….. 921
Structure of Differential Device…………………………………………….. 922
LSD………………………………………………………………………….. 923
Overview LSD (Limited Slip Differential)……………………………………… 923
LSD (Limited Slip Differential)……………………………………………… 924
Axle Air Breathing…………………………………………………………….. 925
Special Tools…………………………………………………………………. 926
List of Special Tools for Disassembly and Reassembly…………………………… 926
Removal………………………………………………………………………. 932
Installation………………………………………………………………….. 935
Completing Work……………………………………………………………….. 935
Disassembly and Reassembly……………………………………………………… 936
Disassembly Output and Brake………………………………………………… 936
Disassembly Axle Housing……………………………………………………. 942
Disassembly Axle Drive Housing………………………………………………. 942
Disassembly Differentials…………………………………………………… 947
Reassembly Differentials……………………………………………………. 950
Reassembly Axle Drive Housing……………………………………………….. 956
Reassembly Axle Housing…………………………………………………….. 966
Reassembly Output and Brake…………………………………………………. 967
Rear Axle………………………………………………………………………… 977
Safety Instructions……………………………………………………………. 981
General………………………………………………………………………. 981
Specification……………………………………………………………… 981
Overview………………………………………………………………….. 982
Parts List………………………………………………………………… 983
Lubrication and Maintenance Instructions…………………………………………. 985
Oil Grade…………………………………………………………………. 985
Oil Change………………………………………………………………… 985
Carry Out Wear Measurement on the Multidisk Brake……………………………… 987
Tightening Torques for Screws……………………………………………….. 988
Differential System……………………………………………………………. 989
Theory of Differential Device……………………………………………….. 989
Structure of Differential Device…………………………………………….. 990
Axle Air Breathing…………………………………………………………….. 991
Special Tools…………………………………………………………………. 992
List of Special Tools for Disassembly and Reassembly…………………………… 992
Removal………………………………………………………………………. 998
Installation…………………………………………………………………..1003
Completing Work………………………………………………………………..1003
Disassembly and Reassembly………………………………………………………1004
Disassembly Output and Brake…………………………………………………1004
Disassembly Axle Housing…………………………………………………….1010
Disassembly Axle Drive Housing……………………………………………….1010
Disassembly Differentials……………………………………………………1015
Reassembly Differentials…………………………………………………….1018
Reassembly Axle Drive Housing………………………………………………..1024
Reassembly Axle Housing……………………………………………………..1034
Reassembly Output and Brake………………………………………………….1035
Driveshaft………………………………………………………………………..1045
Safety Instructions…………………………………………………………….1049
General……………………………………………………………………….1050
Overview…………………………………………………………………..1050
Specification………………………………………………………………1050
Removal (Front Drive Shaft)……………………………………………………..1052
Installation (Front Drive Shaft)…………………………………………………1053
Removal (Center Drive Shaft)…………………………………………………….1054
Installation (Center Drive Shaft)………………………………………………..1055
Removal (Rear Drive Shaft)………………………………………………………1056
Installation (Rear Drive Shaft)………………………………………………….1057
Steering……………………………………………………………………………..1059
Power Steering System………………………………………………………………1061
Safety Instructions…………………………………………………………….1065
General Description…………………………………………………………….1065
Overview…………………………………………………………………..1066
Hydraulic Circuit…………………………………………………………..1067
Theory of Operation…………………………………………………………1068
Steering Unit……………………………………………………………………..1071
Safety Instructions…………………………………………………………….1075
General Description…………………………………………………………….1075
Specifications……………………………………………………………..1077
Overview…………………………………………………………………..1078
Theory of Operation…………………………………………………………1079
Gerotor Operation…………………………………………………………..1080
Steering Pump……………………………………………………………………..1081
Safety Instructions…………………………………………………………….1085
General Description…………………………………………………………….1086
Specifications……………………………………………………………..1086
Overview…………………………………………………………………..1087
Parts List…………………………………………………………………1090
Theory of Operation…………………………………………………………1092
Removal……………………………………………………………………….1094
Installation…………………………………………………………………..1099
Completing Work………………………………………………………………..1099
Disassembly……………………………………………………………………1100
Assembly………………………………………………………………………1102
Flow Amplifier…………………………………………………………………….1105
Safety Instructions…………………………………………………………….1109
General Description…………………………………………………………….1109
Specifications……………………………………………………………..1110
Parts List…………………………………………………………………1112
Theory of Operation…………………………………………………………1113
Removal……………………………………………………………………….1115
Installation…………………………………………………………………..1119
Completing Work………………………………………………………………..1119
Tools…………………………………………………………………………1120
List of Required Tools………………………………………………………1120
Disassembly……………………………………………………………………1121
Assembly………………………………………………………………………1135
Cleaning and Inspection (Wear Limits and Tolerances)……………………………….1149
Cleaning…………………………………………………………………..1149
Inspection and Replacement…………………………………………………..1149
Lubrication………………………………………………………………..1149
Jerk Softener and Accumulator……………………………………………………….1151
Safety Instructions…………………………………………………………….1155
General Description…………………………………………………………….1155
Operation………………………………………………………………….1155
Accumulator……………………………………………………………………1156
Specifications……………………………………………………………..1156
Jerk Softener………………………………………………………………….1156
Specifications……………………………………………………………..1156
Parts List…………………………………………………………………1156
Function…………………………………………………………………..1156
Operating Principle…………………………………………………………1157
Brake………………………………………………………………………………..1159
Service Brake……………………………………………………………………..1161
Safety Instructions…………………………………………………………….1165
General Description…………………………………………………………….1166
Service Brake System……………………………………………………………1167
Brake and Pilot Supply Valve………………………………………………………..1169
Safety Instructions…………………………………………………………….1173
General Description…………………………………………………………….1173
Overview…………………………………………………………………..1174
Parts List…………………………………………………………………1176
Removal……………………………………………………………………….1177
Installation…………………………………………………………………..1182
Completing Work………………………………………………………………..1182
Charging Block…………………………………………………………………….1183
Safety Instructions…………………………………………………………….1187
General Description…………………………………………………………….1188
Parts List…………………………………………………………………1188
Hydraulic Circuit…………………………………………………………..1189
Parking Brake……………………………………………………………………..1191
Safety Instructions…………………………………………………………….1195
General Description…………………………………………………………….1195
Specification………………………………………………………………1195
Overview…………………………………………………………………..1196
Spring Applied Hydraulic Released Sliding Calliper……………………………..1197
Parts List…………………………………………………………………1199
Functional Description………………………………………………………1200
Mounting and Basic Setting Regulations………………………………………..1202
Adjusting Regulations……………………………………………………….1203
Emergency Release of Parking Brake……………………………………………1203
Maintenance and Repair Work………………………………………………….1204
General……………………………………………………………………1206
Brake Pedal Valve………………………………………………………………….1207
Safety Instructions…………………………………………………………….1211
General Description…………………………………………………………….1211
Specification………………………………………………………………1211
Parts List…………………………………………………………………1212
Theory of Operation…………………………………………………………1213
Accumulator……………………………………………………………………….1215
Safety Instructions…………………………………………………………….1219
General Description…………………………………………………………….1220
Layout…………………………………………………………………….1222
Specifications……………………………………………………………..1222
Brake Filter………………………………………………………………………1223
Safety Instructions…………………………………………………………….1227
General……………………………………………………………………….1227
General Description…………………………………………………………1227
Specification………………………………………………………………1227
Overview…………………………………………………………………..1228
Parts List…………………………………………………………………1228
Cooling System………………………………………………………………………..1229
Cooling System…………………………………………………………………….1231
Safety Instructions…………………………………………………………….1235
General Description…………………………………………………………….1235
Function…………………………………………………………………..1236
Hydraulic Circuit…………………………………………………………..1237
Fan Motor Pressure and Fan Speed……………………………………………..1238
Checking Maximum Fan Speed……………………………………………….1239
Fan and Brake Pump…………………………………………………………………1241
Safety Instructions…………………………………………………………….1245
General……………………………………………………………………….1245
Specification………………………………………………………………1245
Sectional View……………………………………………………………..1246
Overview…………………………………………………………………..1247
Port and Hydraulic Circuit……………………………………………….1247
Parts List…………………………………………………………………1248
Theory of Operation…………………………………………………………1250
Circuit………………………………………………………………..1250
Control Section…………………………………………………………1251
Circuit Diagram Related to Fan Drive………………………………………1251
Pump EPPR Valve…………………………………………………………1252
Removal……………………………………………………………………….1254
Installation…………………………………………………………………..1258
Completing Work………………………………………………………………..1258
Disassembly……………………………………………………………………1259
Assembly………………………………………………………………………1263
Tightening Torques………………………………………………………….1268
Sealing Driveshaft………………………………………………………….1268
Sealing Control Valve……………………………………………………….1270
Fan Motor…………………………………………………………………………1271
Safety Instructions…………………………………………………………….1275
Specifications……………………………………………………………..1276
Overview…………………………………………………………………..1276
Port and Hydraulic Circuit……………………………………………….1276
Fan Control Valve………………………………………………………………….1277
Safety Instructions…………………………………………………………….1281
General……………………………………………………………………….1281
Specifications……………………………………………………………..1281
Port and Hydraulic Circuit……………………………………………….1282
Radiator Assembly………………………………………………………………….1283
Safety Instructions…………………………………………………………….1287
General……………………………………………………………………….1287
Overview…………………………………………………………………..1287
Structure………………………………………………………………….1288
Parts List…………………………………………………………………1289
CAC (Charge Air Cooler)…………………………………………………………1290
Overview…………………………………………………………………..1290
Replacing – Hose/Pipe (Charge Air Cooler)……………………………………..1291
Radiator………………………………………………………………………1293
Overview…………………………………………………………………..1293
Theory of Operation…………………………………………………………1293
Radiator Cap……………………………………………………………….1294
Replacing – Radiator Cap…………………………………………………….1295
Replacing Coolant…………………………………………………………..1295
Antifreeze Concentration Tables………………………………………………1296
Transmission Cooling……………………………………………………………1297
General Description…………………………………………………………1297
Layout…………………………………………………………………….1297
Thermostat…………………………………………………………………1298
Hydraulic System………………………………………………………………………1299
Main Pump…………………………………………………………………………1301
Safety Instructions…………………………………………………………….1305
General Description…………………………………………………………….1306
Specifications……………………………………………………………..1306
Overview…………………………………………………………………..1307
Parts List…………………………………………………………………1308
Theory of Operation…………………………………………………………1310
Structure………………………………………………………………….1312
Removal……………………………………………………………………….1314
Installation…………………………………………………………………..1319
Completing work………………………………………………………………..1319
Disassembly……………………………………………………………………1320
Assembly………………………………………………………………………1322
Troubleshooting………………………………………………………………..1325
Maintenance Instructions………………………………………………………..1326
Main Control Valve…………………………………………………………………1327
Safety Instructions…………………………………………………………….1331
General Description…………………………………………………………….1332
Specification………………………………………………………………1333
Hydraulic Circuit…………………………………………………………..1334
Configuration (Port)………………………………………………………..1336
Theory of Operation…………………………………………………………1337
Section View……………………………………………………………….1345
Parts List…………………………………………………………………1346
Removal……………………………………………………………………….1350
Installation…………………………………………………………………..1356
Completing Work………………………………………………………………..1356
Pilot System………………………………………………………………………1357
Safety Instructions…………………………………………………………….1361
General Description…………………………………………………………….1361
Fingertip Joystick……………………………………………………………..1362
Specification………………………………………………………………1362
Port Name………………………………………………………………….1362
Parts List – 2 Lever………………………………………………………..1363
Parts List – 3 Lever………………………………………………………..1364
FNR Joystick…………………………………………………………………..1365
Specification………………………………………………………………1365
Port Name………………………………………………………………….1365
Overview…………………………………………………………………..1365
Parts List…………………………………………………………………1366
Hydraulic System…………………………………………………………………..1369
Safety Instructions…………………………………………………………….1373
Hydraulic Component and Circuit………………………………………………….1374
Hydraulic Components………………………………………………………..1374
Pilot Circuit………………………………………………………………1376
Main Circuit……………………………………………………………….1377
Return Circuit……………………………………………………………..1378
Load Sensing Circuit………………………………………………………..1379
Fan Drive Operation…………………………………………………………….1380
Parking Brake Release…………………………………………………………..1381
Service Brake Operation…………………………………………………………1382
Steering Operation……………………………………………………………..1383
Boom Raise Operation and Load Sensing…………………………………………….1384
Boom Down Operation…………………………………………………………….1385
Boom Floating Operation…………………………………………………………1386
Bucket Crowd Operation………………………………………………………….1387
Bucket Dump Operation…………………………………………………………..1388
Combined Bucket Crowd and Boom Down Operation……………………………………..1389
Load Isolation System (LIS)……………………………………………………..1390
Hydraulic System Troubleshooting…………………………………………………….1391
Safety Instructions…………………………………………………………….1395
Hydraulic System……………………………………………………………….1396
Engine Started but Machine Does Not Operate……………………………………1396
Hydraulic Oil Is Cloudy……………………………………………………..1397
Hydraulic Oil or Engine Overheated……………………………………………1398
Parking Brakes Does Not Work…………………………………………………1400
Service Brakes Does Not Work…………………………………………………1401
Boom, Bucket Speed Is Slow…………………………………………………..1402
Does Not Work the Boom Floating………………………………………………1404
Steering Wheel Is Heavy to Turn………………………………………………1406
Does Not Operated LIS……………………………………………………….1407
Frame………………………………………………………………………………..1409
Articulation Center………………………………………………………………..1411
Safety Instructions…………………………………………………………….1415
General Description…………………………………………………………….1415
Maintenance Standard………………………………………………………..1416
Cabin…………………………………………………………………………….1419
Safety Instructions…………………………………………………………….1423
Cabin Identification……………………………………………………………1423
Roll-over Protective Structure (ROPS)/Falling Object Protective Structure (FOPS)…..1423
Dimensions of Cabin Glass……………………………………………………….1425
Removal and Installation of Cabin Glass…………………………………………..1430
Removal of Cabin Glass………………………………………………………1430
Installation of Cabin Glass………………………………………………….1432
Counterweight……………………………………………………………………..1437
Safety Instructions…………………………………………………………….1441
General……………………………………………………………………….1442
Overview…………………………………………………………………..1442
Oil Tank………………………………………………………………………….1443
Safety Instructions…………………………………………………………….1447
General Description…………………………………………………………….1447
Specifications……………………………………………………………..1447
Parts List…………………………………………………………………1448
Air Breather……………………………………………………………….1450
Fuel Tank…………………………………………………………………………1451
Safety Instructions…………………………………………………………….1455
General Description…………………………………………………………….1455
Specifications……………………………………………………………..1455
Parts List…………………………………………………………………1456
Cylinders…………………………………………………………………………1459
Safety Instructions…………………………………………………………….1463
General……………………………………………………………………….1463
General Description…………………………………………………………1463
Specification………………………………………………………………1463
Parts List…………………………………………………………………1464
Theory of Operation…………………………………………………………1470
Seal of Cylinder……………………………………………………………1471
Special Tools and Materials……………………………………………………..1473
Piston Nut…………………………………………………………………1473
Piston Jig…………………………………………………………………1474
Steel Bushing Jig…………………………………………………………..1475
Dust Wiper Jig……………………………………………………………..1476
Slipper Seal Jig……………………………………………………………1477
Slipper Seal Straightening Jig……………………………………………….1478
Rod Bushing (DD-bushing) Pushing-in Jig……………………………………….1479
Disassembly……………………………………………………………………1480
Reassembly…………………………………………………………………….1485
Troubleshooting………………………………………………………………..1489
Electrical System……………………………………………………………………..1491
Electrical System………………………………………………………………….1611
Safety Instructions…………………………………………………………….1615
Overview………………………………………………………………………1615
Electric Supply System………………………………………………………….1616
Engine Starting Circuit…………………………………………………………1618
Operation During Start Process……………………………………………….1618
Operation After Start Process………………………………………………..1620
Engine Stop System……………………………………………………………..1621
Engine Emergency Start System……………………………………………………1622
Charging System………………………………………………………………..1623
Power Mode Control……………………………………………………………..1624
Engine Control System…………………………………………………………..1625
Accelerator Pedal…………………………………………………………..1626
Electrical Steering Control………………………………………………….1627
Electric Joystick…………………………………………………………..1628
Electric MCV Control………………………………………………………..1629
Electric Joystick (Boom)…………………………………………………….1630
Electric Joystick (Bucket)…………………………………………………..1631
Auto Idle Control…………………………………………………………..1632
Electric Detent System………………………………………………………….1633
Electrical Circuit………………………………………………………….1633
Boom Kick-out………………………………………………………………1634
Return to Dig………………………………………………………………1635
Cooling Fan Control System………………………………………………………1636
Outline……………………………………………………………………1636
Diagram……………………………………………………………………1636
Electrical Diagram………………………………………………………….1637
Parts of Cooling Fan Control System…………………………………………..1638
Operation of Cooling Fan Control System……………………………………….1640
Emergency Steering System (Option)……………………………………………….1642
Block Diagram………………………………………………………………1642
Emergency Steering System Components………………………………………….1643
Emergency Steering System Electrical Circuit…………………………………..1646
Lighting System………………………………………………………………..1648
Light Circuit………………………………………………………………1648
Monitoring System………………………………………………………………1652
Instrument Panel……………………………………………………………1653
Function Check……………………………………………………………..1653
Monitoring System Schematic………………………………………………….1654
Operation……………………………………………………………………..1656
Instruments Gauge…………………………………………………………..1656
Indicator Lights……………………………………………………………1656
Initial Operation…………………………………………………………..1658
Multifunction Display……………………………………………………….1659
Indication of Warning Lights…………………………………………………1662
Indication of Indicator Lights……………………………………………….1664
Graphic Information Area Display…………………………………………………1666
Overview…………………………………………………………………..1666
Main Menus for the Graphic Display Area……………………………………….1666
Menu Selector Buttons……………………………………………………….1666
User Menu………………………………………………………………….1667
Service Menu……………………………………………………………….1681
Information of Machine Operation……………………………………………..1691
Failure Code…………………………………………………………………..1698
Failure Code at Machine……………………………………………………..1698
Failure Code at Engine Side………………………………………………….1702
Failure Code at Transmission Side…………………………………………….1717
Failure Code at Electric Steering Side………………………………………..1721
FMIs (Failure Mode Identifier)……………………………………………….1723
Windshield Wiper……………………………………………………………….1724
Front Windshield Wiper………………………………………………………1724
Rear Windshield Wiper……………………………………………………….1726
Air Conditioner……………………………………………………………………1727
Safety Instructions…………………………………………………………….1731
General Description…………………………………………………………….1732
Internal and External Filters………………………………………………..1733
Air-conditioning System Layout……………………………………………….1734
Air Conditioner/Heater Circuit Diagram………………………………………..1735
Air Conditioner/Heater Unit………………………………………………….1736
Ambient Air Temperature Sensor……………………………………………….1741
Sun Sensor…………………………………………………………………1742
Control Panel………………………………………………………………1742
Compressor…………………………………………………………………1749
Receiver Dryer……………………………………………………………..1749
Troubleshooting………………………………………………………………..1750
Refrigerant System Repairs………………………………………………………1752
Refrigerant Safe Handling Procedures………………………………………….1752
Repair and Replacement Procedure……………………………………………..1753
Refrigerant Recovery………………………………………………………..1755
Vacuuming Refrigerant System…………………………………………………1755
Leakage Check………………………………………………………………1757
Refrigerant Charging………………………………………………………..1757
Inspecting System For Leakage………………………………………………..1759
Option……………………………………………………………………………….1761
EmergencySteering………………………………………………………………….1763
Safety Instructions…………………………………………………………….1767
General Description…………………………………………………………1767
Specifications……………………………………………………………..1767
Theory of Operation…………………………………………………………1768
Hydraulic Circuit…………………………………………………………..1768
Parts List…………………………………………………………………1769
Caution for Installation…………………………………………………….1769
Installation Procedure………………………………………………………….1770
Emergency Steering………………………………………………………….1770
Emergency Steering – Electric………………………………………………..1772
After Installation Precautions……………………………………………….1773
Emergency Steering Function Test……………………………………………..1773
Emergency Steering Automatic Test…………………………………………….1774
Load Isolation System………………………………………………………………1775
Safety Instructions…………………………………………………………….1779
General Description…………………………………………………………….1779
Overview…………………………………………………………………..1780
Hydraulic Circuit…………………………………………………………..1782
Accumulator Charging Method………………………………………………….1782
LIS Valve……………………………………………………………………..1784
Specification………………………………………………………………1784
Parts List…………………………………………………………………1785
Accumulator……………………………………………………………………1786
Specification………………………………………………………………1786
Parts List…………………………………………………………………1786
3rd Control Valve………………………………………………………………….1787
Safety Instructions…………………………………………………………….1791
General……………………………………………………………………….1791
Specification………………………………………………………………1791
Overview…………………………………………………………………..1792
Hydraulic Circuit…………………………………………………………..1792
Theory of Operation…………………………………………………………1793
Parts List…………………………………………………………………1794
Removal……………………………………………………………………….1795
Installation…………………………………………………………………..1798
Completing Work………………………………………………………………..1798
Disassembly and Assembly………………………………………………………..1799
General Cautions……………………………………………………………1799
Assembly and Disassembly of Spool and Over Load Relief Valve…………………….1800
Performance Tests………………………………………………………………1801
Auto Grease System…………………………………………………………………1803
Safety Instructions…………………………………………………………….1807
General Description…………………………………………………………….1807
Overview…………………………………………………………………..1808
Location…………………………………………………………………..1810
Theory of Operation…………………………………………………………1811
Pump Element……………………………………………………………1811
Grease Low Leveling……………………………………………………..1812
Feeder…………………………………………………………………1813
Error Sensing…………………………………………………………..1814
Pump………………………………………………………………………….1815
Overview…………………………………………………………………..1815
The Central Lubrication Pump……………………………………………..1815
Note on the Rating Plate…………………………………………………1816
Location…………………………………………………………………..1816
Specification………………………………………………………………1817
Parts List…………………………………………………………………1818
Pump Element……………………………………………………………1820
Check Valve…………………………………………………………….1821
Pressure Relief Valve……………………………………………………1821
Power Supply 24 VDC……………………………………………………..1822
Connectivity for Timer Operation with System Monitoring……………………..1822
Connector Pin Assignment in Timer Operation………………………………..1822
Pump Cable…………………………………………………………………1823
Overview……………………………………………………………….1823
Connector 1…………………………………………………………….1823
Connector 2…………………………………………………………….1824
Connector 3…………………………………………………………….1824
Fill Level Switch……………………………………………………….1824
Monitoring Lubrication Cycle by Piston Detector…………………………….1825
Approved Lubricants…………………………………………………………1826
Operation………………………………………………………………….1827
Pump…………………………………………………………………..1827
Fill Level Monitoring……………………………………………………1827
Malfunctions on Pump Unit in Progressive System…………………………….1827
Timer Operation…………………………………………………………1828
Maintenance, Repair…………………………………………………………1829
Maintenance…………………………………………………………….1829
Repair…………………………………………………………………1830
Feeder………………………………………………………………………..1831
Feeder (Front Frame)………………………………………………………..1831
General Description……………………………………………………..1831
Location and Parts List………………………………………………….1832
Dimension………………………………………………………………1833
Main Feeder Connector……………………………………………………1835
Feeder (Rear Frame)…………………………………………………………1835
General Description……………………………………………………..1835
Overview……………………………………………………………….1835
Location and Parts List………………………………………………….1836
Dimension………………………………………………………………1837
Feeder (Tilt lever)…………………………………………………………1838
General Description……………………………………………………..1838
Overview……………………………………………………………….1838
Location and Parts List………………………………………………….1840
Dimension………………………………………………………………1842
Replace Hose Using Service kit……………………………………………….1843
Hoses for Self Assembly………………………………………………….1843
Troubleshooting………………………………………………………………..1845
Grease Pump Fault…………………………………………………………..1847
Grease System Faults………………………………………………………..1847
Schematic…………………………………………………………………………….1849
Hydraulic Schematic / Electrical Schematic……………………………………………1851
Hydraulic Schematic…………………………………………………………….1853
Electrical Schematic……………………………………………………………1855

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