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
VIDEO PREVIEW OF THE MANUAL:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
- The manual can be all yours – Once payment is complete, you will be taken to the download page from where you can download the manual. All in 2-5 minutes time!!
- Need any other service / repair / parts manual, please feel free to contact us at heydownloadss @gmail.com . We may surprise you with a nice offer
S.M