Daewoo Doosan WHEEL LOADER DL220-5 Shop Manual 950106-01724E-1 – PDF DOWNLOAD
DESCRIPTION:
Daewoo Doosan WHEEL LOADER DL220-5 Shop Manual 950106-01724E-1 – 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 DL220-5 Shop Manual 950106-01724E-1 – PDF DOWNLOAD
DL220-5....................................................................................................... 0 Table of Contents......................................................................................... 7 Safety.................................................................................................... 9 Wheel Loader Safety................................................................................... 11 Safety Instructions............................................................................... 11 Safety Messages................................................................................... 13 General........................................................................................... 15 Safe Operation is Operator's Responsibility................................................... 15 Know Your Machine............................................................................. 15 Proper Work Tools and Attachments............................................................. 15 Pressurized Fluids............................................................................ 16 Flying or Falling Objects..................................................................... 17 Personal Protective Equipment (PPE)........................................................... 17 Correction of Machine Problems................................................................ 18 Crushing and Cutting.......................................................................... 18 Hot Coolant and Oils - Burn Prevention........................................................ 19 Fire and Explosion Prevention................................................................. 19 Fire Extinguisher and First-Aid Kit (Emergency Medical Kit)................................... 23 Electrical System and Electrical Shock........................................................ 23 Roll-over Protective Structure (ROPS)/ Falling Object Protective Structure (FOPS)............. 24 Operation......................................................................................... 26 Before Engine Starting........................................................................ 26 Work Site..................................................................................... 26 Check Tire Pressure and Condition............................................................. 27 Mounting/Dismounting.......................................................................... 27 Cleaning...................................................................................... 28 Operator Station.............................................................................. 28 Seat Belt..................................................................................... 29 Visibility Information........................................................................ 30 Boost Starting or Charging Engine Batteries................................................... 31 Starting Engine............................................................................... 32 Traveling..................................................................................... 32 Lifting and Digging........................................................................... 34 Digging Beneath Overhangs..................................................................... 34 Digging Beneath Wheel Loader.................................................................. 34 Operation on Slopes........................................................................... 35 Attachment.................................................................................... 36 Equipment Lowering with Engine Stopped........................................................ 36 Preventing Risk of Injuries or Death From Boom and Bucket..................................... 36 Engine Stop................................................................................... 38 Parking Machine............................................................................... 38 Maintenance....................................................................................... 39 Warning Tag................................................................................... 41 Cleaning...................................................................................... 42 Proper Tools and Clothing..................................................................... 42 Disassembling Precautions..................................................................... 42 Use of Lighting............................................................................... 43 Fire and Explosion Prevention................................................................. 43 Burn Prevention............................................................................... 44 Rubber That Contains Fluorides................................................................ 45 Rubber and Plastics........................................................................... 46 Welding Repairs............................................................................... 47 Working on Machine............................................................................ 48 Lock Inspection Covers........................................................................ 49 Accumulator................................................................................... 49 Compressed Air................................................................................ 49 Supports and Blocking for Work Equipment...................................................... 50 High-pressure Lines, Tubes and Hoses.......................................................... 50 Battery....................................................................................... 51 Preservation/Storing Machine.................................................................. 52 Transportation.................................................................................... 54 Obey State and Local Over-the-Road Laws and Regulations....................................... 54 Loading and Unloading......................................................................... 54 Transporting Machine.......................................................................... 55 Environment and Circumstances..................................................................... 56 Work Site Areas Requiring Extra Caution....................................................... 56 High-voltage Cables........................................................................... 58 Underground Operation......................................................................... 58 Working in Water.............................................................................. 59 Working in Contaminated Environment........................................................... 59 Operation in Extreme Conditions............................................................... 60 Exhaust Ventilation........................................................................... 64 Asbestos Information.......................................................................... 64 Silica Dust Information....................................................................... 65 Disposal of Hazardous Materials............................................................... 65 Sound......................................................................................... 66 Vibration Information......................................................................... 66 Specifications............................................................................................ 69 Specification......................................................................................... 71 Safety Instructions............................................................................... 71 General........................................................................................... 73 General description........................................................................... 73 Component Locations............................................................................... 74 Working Range and Dimensions...................................................................... 78 Working Capacities................................................................................ 80 Bucket Capacity............................................................................... 80 Stability..................................................................................... 80 General Specifications............................................................................ 81 Performance Tests................................................................................. 82 Purpose of Performance Tests.................................................................. 82 Kinds of Tests................................................................................ 82 Performance Standards......................................................................... 82 Precautions for Evaluation of Test Data....................................................... 82 Definition of "Performance Standard".......................................................... 82 Preparation for Performance Tests................................................................. 83 The Machine................................................................................... 83 Test Area..................................................................................... 83 Precautions................................................................................... 83 Make Precise Measurement...................................................................... 83 Operational Performance Standard Table............................................................ 84 Operational Performance Test...................................................................... 86 Engine Speed.................................................................................. 86 Front Speed................................................................................... 88 Natural Subsidence of Cylinder................................................................ 89 Travel Speed - Acceleration and Deceleration.................................................. 90 Steering Time................................................................................. 91 Hydraulic Pressure Checks..................................................................... 92 Approximate Weight of Workload Materials.......................................................... 94 Material Weight............................................................................... 94 General Maintenance....................................................................................... 97 General Maintenance Instructions...................................................................... 99 Safety Instructions............................................................................... 99 Welding Precautions and Instructions.............................................................. 101 Hydraulic System - General Precautions............................................................ 102 Maintenance Service and Repair Procedure.......................................................... 104 General Precautions........................................................................... 104 Hydraulic System Cleanliness and Oil Leaks........................................................ 105 Maintenance Precautions for Hydraulic System Service.......................................... 105 Oil Leakage Precautions....................................................................... 106 Cleaning and Inspection........................................................................... 107 General Instructions.......................................................................... 107 Bearing Inspection............................................................................ 108 Standard Torques...................................................................................... 115 Safety Instructions............................................................................... 115 Torque Values for Standard Metric Fasteners....................................................... 117 Torque Values for Standard U.S. Fasteners......................................................... 118 Type 8 Phosphate Coated Hardware.................................................................. 120 Torque Values for Hose Clamps..................................................................... 121 ORFS Swivel Nut Recommended Torque................................................................ 121 Torque Values for Split Flanges................................................................... 122 Torque Wrench Extension Tools..................................................................... 123 Torque Multiplication......................................................................... 123 Other Uses for Torque Wrench Extension Tools.................................................. 124 Tightening Torque Specifications (Metric)..................................................... 125 Engine.................................................................................................... 129 Engine................................................................................................ 131 Safety Instructions............................................................................... 131 Overview.......................................................................................... 134 General Information............................................................................... 135 General Description........................................................................... 135 Engine Maintenance............................................................................ 139 Inspection and Repair of the Engine........................................................... 142 Engine Identification............................................................................. 144 Engine Data Plate............................................................................. 144 Engine Specification.............................................................................. 146 Engine Performance Curves......................................................................... 147 Special Tools..................................................................................... 148 Tightening Torques................................................................................ 152 Major Parts Tightening Torque................................................................. 152 Tightening Torque for General Bolts........................................................... 154 Tightening Torque of Plug Screw............................................................... 155 Hollow Screw (4-Hole) Tightening Torque....................................................... 155 Engine Disassembly................................................................................ 156 Engine Disassembly............................................................................ 156 Engine Assembly................................................................................... 171 Engine Assembly............................................................................... 171 Cylinder.......................................................................................... 194 General Information........................................................................... 194 Cylinder Head................................................................................. 194 Cylinder Block................................................................................ 198 Valve Mechanism............................................................................... 200 Actuating System.................................................................................. 212 Camshaft...................................................................................... 212 Piston........................................................................................ 214 Connecting Rod................................................................................ 218 Crankshaft.................................................................................... 220 Timing Gear................................................................................... 225 Lubrication system................................................................................ 226 General Information........................................................................... 226 Oil Pan....................................................................................... 230 Oil Pump...................................................................................... 232 Oil Filter.................................................................................... 234 Exhaust System.................................................................................... 237 Turbocharger.................................................................................. 237 EGR (Exhaust Gas Recirculation) System........................................................ 249 DNOx System................................................................................... 256 Cooling System.................................................................................... 267 General information........................................................................... 267 Thermostat.................................................................................... 268 Fuel System....................................................................................... 272 General Information........................................................................... 272 Fuel High-pressure System Components.......................................................... 273 Injector...................................................................................... 274 Common Rail................................................................................... 278 Fuel Injection Pump........................................................................... 282 Electrical System................................................................................. 286 Electrical Parts.............................................................................. 286 Switches and Sensors.......................................................................... 288 ECU (Electronic Control Unit)................................................................. 292 Starter....................................................................................... 294 Exhaust Gas Reduction......................................................................... 296 Circuit Diagram............................................................................... 300 Drivetrain................................................................................................ 305 Transmission.......................................................................................... 307 Safety Instructions............................................................................... 307 General........................................................................................... 311 General Description........................................................................... 311 Specification................................................................................. 312 Overview...................................................................................... 313 Section View.................................................................................. 316 Hydraulic Circuit (4-speed Transmission)...................................................... 318 Torque Convertor.............................................................................. 319 Electrohydraulic Control with Proportional Valves............................................. 322 Controller.................................................................................... 323 Electric Control System....................................................................... 324 Speed Sensor.................................................................................. 327 Measuring Points and Connections.................................................................. 330 Transmission Electric Components.................................................................. 332 TCU (Transmission Control Unit)............................................................... 334 Transmission Control Valve.................................................................... 334 Transmission Oil Temperature Sensor........................................................... 334 Engine Pickup Sensor.......................................................................... 335 Central Gear Pickup Sensor.................................................................... 335 Turbine Pickup Sensor......................................................................... 335 Output Speed Sensor........................................................................... 335 Shift Lever Switch (DW-3)..................................................................... 336 Forward, Reverse Switch Lever................................................................. 337 Fingertip Work Lever (Optional)............................................................... 337 Transmission Shift Switch..................................................................... 339 T/M Cutoff Sensor............................................................................. 339 LIS Solenoid Valve............................................................................ 339 Transmission Electrical Circuits.................................................................. 340 Transmission Controller Circuit............................................................... 340 Transmission Control Unit Terminal............................................................ 341 Downshift..................................................................................... 349 Transmission Cutoff Switch.................................................................... 356 Torque Limits for Screws.......................................................................... 357 Special Tools..................................................................................... 358 List of Special Tools for Disassembly and Reassembly.......................................... 358 Transmission Oil.................................................................................. 364 Oil Grade of Transmission..................................................................... 364 Disassembly....................................................................................... 365 Electrohydraulic Control and Transmission Filter (Replaceable Filter)......................... 365 Inductive Sensor, Hall Sensor, Breather, Oil Filler and Oil Drain Plug........................ 370 Engine Connection, Oil Pressure Pump, Converter Back-pressure Valve and Temperature Sensor.... 371 Outputs and Closure Parts Pump Shaft (PTO-Shaft).............................................. 375 Removal of Input Shaft, Output Shaft, Pump Shaft (PTO-shaft) and Clutches..................... 377 Clutches KV/KR/K1/K2/K3/K4 Input and Output Shaft............................................. 382 Reassembly........................................................................................ 406 Clutches KV/KR/K1/K2/K3/K4 Input and Output Shaft............................................. 406 Installation of Input Shaft, Output Shaft, Pump Shaft (Power-takeoff Shaft) and Clutches...... 445 Outputs and Closure Parts Pump Shaft (PTO-shaft).............................................. 452 Engine Connection, Oil Pressure Pump, Converter Back-pressure Valve and Temperature Sensor.... 455 Emergency Steering Pump....................................................................... 459 Inductive Sensor, Hall Sensor, Breather, Oil Filler and Oil Drain Plug........................ 460 Electrohydraulic Control with Proportional Valves............................................. 461 Failure Code...................................................................................... 469 Front Axle............................................................................................ 495 Safety Instructions............................................................................... 495 General........................................................................................... 498 Specification................................................................................. 498 Overview...................................................................................... 499 Parts List.................................................................................... 500 Lubrication and Maintenance Instructions.......................................................... 502 Oil Change.................................................................................... 502 Carry Out Wear Measurement on the Multidisk Brake............................................. 504 Tightening Torques for Screws................................................................. 505 Differential System............................................................................... 506 Theory of Differential Device................................................................. 506 Structure of Differential Device.............................................................. 507 LSD............................................................................................... 508 Overview LSD (Limited Slip Differential)...................................................... 508 LSD (Limited Slip Differential)............................................................... 509 Axle Air Breathing................................................................................ 510 Special Tools..................................................................................... 511 List of Special Tools for Disassembly and Reassembly.......................................... 511 Axle Oils......................................................................................... 518 Oil Grade ZF-Powerfluid....................................................................... 518 Removal........................................................................................... 519 Installation...................................................................................... 523 Completing Work................................................................................... 523 Disassembly....................................................................................... 524 Output and Brake.............................................................................. 524 Axle Housing.................................................................................. 529 Input......................................................................................... 530 Differentials................................................................................. 533 Reassembly........................................................................................ 537 Differentials................................................................................. 537 Input......................................................................................... 547 Axle Housing.................................................................................. 557 Output and Brake.............................................................................. 558 Rear Axle............................................................................................. 569 Safety Instructions............................................................................... 569 General........................................................................................... 571 Specification................................................................................. 571 Overview...................................................................................... 572 Parts List.................................................................................... 573 Lubrication and Maintenance Instructions.......................................................... 576 Oil Change.................................................................................... 576 Carry Out Wear Measurement on the Multidisk Brake............................................. 578 Tightening Torques for Screws................................................................. 579 Differential System............................................................................... 580 Theory of Differential Device................................................................. 580 Structure of Differential Device.............................................................. 581 Axle Air Breathing................................................................................ 582 Special Tools..................................................................................... 583 List of Special Tools for Disassembly and Reassembly.......................................... 583 Axle Oils......................................................................................... 590 Oil Grade ZF-Powerfluid....................................................................... 590 Removal........................................................................................... 591 Installation...................................................................................... 596 Completing Work................................................................................... 596 Disassembly....................................................................................... 597 Output and Brake.............................................................................. 597 Axle Housing.................................................................................. 602 Input......................................................................................... 604 Differentials................................................................................. 606 Reassembly........................................................................................ 609 Differentials................................................................................. 609 Input......................................................................................... 616 Axle Housing.................................................................................. 624 Output and Brake.............................................................................. 626 Driveshaft............................................................................................ 637 Safety Instructions............................................................................... 637 General........................................................................................... 639 Overview...................................................................................... 639 Specification................................................................................. 639 Removal (Front Driveshaft)........................................................................ 641 Installation (Front Driveshaft)................................................................... 644 Removal (Center Driveshaft)....................................................................... 645 Installation (Center Driveshaft).................................................................. 648 Removal (Rear Driveshaft)......................................................................... 649 Installation (Rear DriveShaft).................................................................... 651 Steering.................................................................................................. 653 Power Steering System................................................................................. 655 Safety Instructions............................................................................... 655 General........................................................................................... 657 General Description........................................................................... 657 Overview...................................................................................... 658 Hydraulic Circuit............................................................................. 659 Theory of Operation........................................................................... 660 Steering Unit......................................................................................... 663 Safety Instructions............................................................................... 663 General........................................................................................... 665 General Description........................................................................... 665 Specifications................................................................................ 667 Overview...................................................................................... 668 Theory of Operation........................................................................... 669 Gerotor Operation............................................................................. 670 Relief Valve.................................................................................. 670 Priority Valve........................................................................................ 671 Safety Instructions............................................................................... 671 General........................................................................................... 673 General Description........................................................................... 673 Tool List......................................................................................... 673 Removal........................................................................................... 674 Installation...................................................................................... 679 Completing Work................................................................................... 679 Disassembly....................................................................................... 680 Reassembly........................................................................................ 682 Brake..................................................................................................... 685 Service Brake......................................................................................... 687 Safety Instructions............................................................................... 687 General........................................................................................... 689 General Description........................................................................... 689 Service Brake System.............................................................................. 690 Brake & Pilot Supply Valve............................................................................ 693 Safety Instructions............................................................................... 693 General........................................................................................... 695 General Description........................................................................... 695 Overview...................................................................................... 696 Hydraulic Circuit............................................................................. 697 Parts List.................................................................................... 698 Removal........................................................................................... 699 Installation...................................................................................... 704 Completing Work................................................................................... 704 Charging Block........................................................................................ 705 Safety Instructions............................................................................... 705 General........................................................................................... 707 General Description........................................................................... 707 Parts List.................................................................................... 707 Hydraulic Circuit............................................................................. 708 Parking Brake......................................................................................... 709 Safety Instructions............................................................................... 709 General........................................................................................... 711 Specification................................................................................. 711 Overview...................................................................................... 711 Parts List.................................................................................... 712 Theory of Operation........................................................................... 713 Installing and Setting Instructions............................................................... 715 Installing the Brake.......................................................................... 715 Clearance Adjusting........................................................................... 716 Adjusting Instructions........................................................................ 717 Emergency Release of the Parking Brake............................................................ 718 Maintenance and Repair Work....................................................................... 719 Maintenance and Replacement of the Lining Pads................................................ 719 Replacing the Seals........................................................................... 722 Brake Pedal Valve..................................................................................... 725 Safety Instructions............................................................................... 725 General........................................................................................... 727 Specification................................................................................. 727 Parts List.................................................................................... 727 Theory of Operation........................................................................... 728 Accumulator........................................................................................... 731 Safety Instructions............................................................................... 731 General........................................................................................... 733 General Description........................................................................... 733 Layout........................................................................................ 735 Specifications................................................................................ 735 Cooling System............................................................................................ 737 Cooling System........................................................................................ 739 Safety Instructions............................................................................... 739 General........................................................................................... 741 General Description........................................................................... 741 Function...................................................................................... 742 Hydraulic Circuit............................................................................. 743 Fan Motor Pressure and Fan Speed.............................................................. 744 Fan and Brake Pump.................................................................................... 747 Safety Instructions............................................................................... 747 General........................................................................................... 749 Specification................................................................................. 749 Section View.................................................................................. 749 EPPR Valve.................................................................................... 750 Overview...................................................................................... 750 Parts List.................................................................................... 752 Theory of Operation........................................................................... 754 Removal........................................................................................... 758 Installation...................................................................................... 763 Completing Work................................................................................... 763 Maintenance Guidelines............................................................................ 764 Sealing Driveshaft............................................................................ 765 Sealing Control Valve......................................................................... 767 Tools......................................................................................... 767 Disassembly....................................................................................... 768 Disassembly of Rotary Group................................................................... 769 Disassembly of Control Device................................................................. 770 Disassembly of Shaft/Bearings................................................................. 771 Cleaning and Inspection........................................................................... 772 Reassembly........................................................................................ 775 Adjustment of Taper Roller Bearing............................................................ 776 Fan Motor............................................................................................. 781 Safety Instructions............................................................................... 781 General........................................................................................... 783 Specifications................................................................................ 783 Overview...................................................................................... 783 Fan Control Valve..................................................................................... 785 Safety Instructions............................................................................... 785 General........................................................................................... 787 Specifications................................................................................ 787 Radiator Assembly..................................................................................... 789 Safety Instructions............................................................................... 789 General........................................................................................... 791 Overview...................................................................................... 791 Structure..................................................................................... 792 Parts List.................................................................................... 793 CAC (Charge Air Cooler)........................................................................... 794 Overview...................................................................................... 794 Replacing - Hose/Pipe (Charge Air Cooler)..................................................... 795 Radiator.......................................................................................... 797 Overview...................................................................................... 797 Theory of Operation........................................................................... 797 Radiator Cap.................................................................................. 798 Replacing - Radiator Cap...................................................................... 799 Replacing Coolant............................................................................. 799 Antifreeze Concentration Tables............................................................... 800 Transmission Cooling.............................................................................. 801 General Description........................................................................... 801 Layout........................................................................................ 801 Thermostat.................................................................................... 802 Hydraulic System.......................................................................................... 803 Main Pump............................................................................................. 805 Safety Instructions............................................................................... 805 General........................................................................................... 807 General Description........................................................................... 807 Specification................................................................................. 807 Overview...................................................................................... 808 Hydraulic Circuit............................................................................. 809 Location...................................................................................... 810 Parts List.................................................................................... 811 Theory of Operation........................................................................... 814 Removal........................................................................................... 815 Installation...................................................................................... 821 Completing Work................................................................................... 821 Section View...................................................................................... 822 Disassembly....................................................................................... 823 Sealing Driveshaft............................................................................ 823 Pump.......................................................................................... 824 Inspection.................................................................................... 827 Reassembly........................................................................................ 830 Pump.......................................................................................... 830 Pressure and Flow Setting......................................................................... 834 Main Control Valve.................................................................................... 837 Safety Instructions............................................................................... 837 General........................................................................................... 839 General Description........................................................................... 839 Specification................................................................................. 840 Overview...................................................................................... 842 Hydraulic Circuit............................................................................. 844 Parts List.................................................................................... 845 Theory of Operation........................................................................... 846 Removal........................................................................................... 859 Installation...................................................................................... 865 Completing Work................................................................................... 865 Disassembly/Reassembly............................................................................ 866 Torque Table...................................................................................... 868 Pilot System.......................................................................................... 871 Safety Instructions............................................................................... 871 General........................................................................................... 873 General Description........................................................................... 873 Fingertip Joystick................................................................................ 874 Specification................................................................................. 874 Port Name..................................................................................... 874 Parts List - 2 Lever.......................................................................... 875 Parts List - 3 Lever.......................................................................... 876 FNR Joystick...................................................................................... 877 Specification................................................................................. 877 Port Name..................................................................................... 877 Overview...................................................................................... 877 Parts List.................................................................................... 878 Hydraulic System...................................................................................... 881 Safety Instructions............................................................................... 881 Hydraulic Component and Oil Flow.................................................................. 884 Hydraulic Components.......................................................................... 884 Fan Drive Operation............................................................................... 886 Parking Brake Release Operation................................................................... 887 Service Brake Operation........................................................................... 888 Steering Operation................................................................................ 889 Boom Raise Operation and Load Sensing............................................................. 890 Boom Down Operation............................................................................... 892 Boom Floating Operation........................................................................... 894 Bucket Crowd Operation............................................................................ 896 Bucket Dump Operation............................................................................. 898 Combined Bucket Crowd and Boom Down Operation..................................................... 900 Load Isolate System (LIS)......................................................................... 901 Frame..................................................................................................... 903 Articulation Center................................................................................... 905 Safety Instructions............................................................................... 905 General........................................................................................... 907 Maintenance Standard.......................................................................... 908 Cabin................................................................................................. 911 Safety Instructions............................................................................... 911 Cabin Identification.............................................................................. 913 Roll-over Protective Structure (ROPS)/Falling Object Protective Structure (FOPS).............. 913 Dimensions of Cabin Glass......................................................................... 915 Removal and Installation of Cabin Glass........................................................... 920 Removal of Cabin Glass........................................................................ 920 Installation of Cabin Glass................................................................... 922 Counterweight......................................................................................... 927 Safety Instructions............................................................................... 927 General........................................................................................... 929 Overview...................................................................................... 929 Oil Tank.............................................................................................. 931 Safety Instructions............................................................................... 931 General........................................................................................... 933 Specifications................................................................................ 933 Parts List.................................................................................... 934 Air Breather.................................................................................. 936 Fuel Tank............................................................................................. 937 Safety Instructions............................................................................... 937 General........................................................................................... 939 Specifications................................................................................ 939 Parts List.................................................................................... 940 Cylinders............................................................................................. 943 Safety Instructions............................................................................... 943 General........................................................................................... 945 General Description........................................................................... 945 Specification................................................................................. 945 Parts List.................................................................................... 946 Theory of Operation........................................................................... 952 Seal of Cylinder.............................................................................. 953 Special Tools and Materials....................................................................... 955 Piston Nut.................................................................................... 955 Piston Jig.................................................................................... 956 Steel Bushing Jig............................................................................. 957 Dust Wiper Jig................................................................................ 958 Slipper Seal Jig.............................................................................. 959 Slipper Seal Straightening Jig................................................................ 960 Rod Bushing (DD-bushing) Pushing-in Jig....................................................... 961 Disassembly....................................................................................... 962 Reassembly........................................................................................ 967 Troubleshooting................................................................................... 971 Electrical System......................................................................................... 973 Electrical System..................................................................................... 975 Safety Instructions............................................................................... 975 Overview.......................................................................................... 979 Electric Supply System............................................................................ 980 Engine Starting Circuit........................................................................... 982 Operation During Start Process................................................................ 982 Operation After Start Process................................................................. 984 Engine Stop System................................................................................ 985 Engine Emergency Start System..................................................................... 986 Charging System................................................................................... 987 Engine Control System............................................................................. 988 Power Mode Control............................................................................ 990 Accelerator Pedal............................................................................. 991 Auto Idle Control............................................................................. 992 Electric Detent System............................................................................ 993 Electrical Circuit............................................................................ 993 Boom Kick-out................................................................................. 994 Return to Dig................................................................................. 995 Cooling Fan Control System........................................................................ 996 Outline....................................................................................... 996 Diagram....................................................................................... 996 Electrical Diagram............................................................................ 997 Parts of Cooling Fan Control System........................................................... 998 Operation of Cooling Fan Control System.......................................................1000 Emergency Steering System (Option)................................................................1002 Block Diagram.................................................................................1002 Emergency Steering System Components..........................................................1003 Emergency Steering System Electrical Circuit..................................................1006 Lighting System...................................................................................1008 Light Circuit.................................................................................1008 Monitoring System.................................................................................1012 Instrument Panel..............................................................................1013 Function Check................................................................................1013 Monitoring System Schematic...................................................................1014 Operation.........................................................................................1016 Instruments Gauge.............................................................................1016 Indicator Lights..............................................................................1016 Initial Operation.............................................................................1018 Multifunction Display.........................................................................1019 Warning and Indicator Lights......................................................................1022 Indication of Warning Lights..................................................................1022 Indication of Indicator Lights................................................................1024 Graphic Information Area Display..................................................................1026 Overview......................................................................................1026 Main Menus for the Graphic Display Area.......................................................1026 Menu Selector Buttons.........................................................................1026 User Menu.....................................................................................1027 Service Menu..................................................................................1044 Information of Machine Operation..............................................................1054 Failure Code......................................................................................1061 Failure Code at Machine.......................................................................1061 Failure Code at Engine Side...................................................................1064 Failure Code at Transmission Side.............................................................1097 FMIs (Failure Mode Identifier)................................................................1101 Windshield Wiper..................................................................................1102 Front Windshield Wiper........................................................................1102 Rear Windshield Wiper.........................................................................1104 Air Conditioner.......................................................................................1105 Safety Instructions...............................................................................1105 General Description...............................................................................1107 Internal and External Filters.................................................................1108 Air-conditioning System Layout................................................................1109 Air Conditioner/Heater Circuit Diagram........................................................1110 Air Conditioner/Heater Unit...................................................................1111 Ambient Air Temperature Sensor................................................................1116 Sun Sensor....................................................................................1117 Control Panel.................................................................................1117 Compressor....................................................................................1124 Receiver Dryer................................................................................1124 Troubleshooting...................................................................................1125 Refrigerant System Repairs........................................................................1127 Refrigerant Safe Handling Procedures..........................................................1127 Repair and Replacement Procedure..............................................................1128 Refrigerant Recovery..........................................................................1130 Vacuuming Refrigerant System..................................................................1130 Leakage Check.................................................................................1132 Refrigerant Charging..........................................................................1132 Inspecting System for Leakage.................................................................1134 Option....................................................................................................1135 Emergency Steering....................................................................................1137 Safety Instructions...............................................................................1137 General...........................................................................................1139 General Description...........................................................................1139 Specifications................................................................................1139 Theory of Operation...........................................................................1140 Hydraulic Circuit.............................................................................1140 Parts List....................................................................................1141 Caution for Installation......................................................................1141 Installation Procedure............................................................................1142 Emergency Steering............................................................................1142 Emergency Steering - Electric.................................................................1144 After Installation Precautions................................................................1145 Emergency Steering Function Test..............................................................1145 Emergency Steering Automatic Test.............................................................1146 Load Isolation System.................................................................................1147 Safety Instructions...............................................................................1147 General...........................................................................................1149 General Description...........................................................................1149 Overview......................................................................................1150 Hydraulic Circuit.............................................................................1152 Accumulator Charging Method...................................................................1152 LIS Valve.........................................................................................1154 Specification.................................................................................1154 Parts List....................................................................................1155 Accumulator.......................................................................................1156 Specification.................................................................................1156 Parts List....................................................................................1156 Schematic.................................................................................................1157 Hydraulic Schematic / Electrical Schematic............................................................1159 Blank Page....................................................................................................1162 Blank Page....................................................................................................1164
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