Daewoo Doosan WHEEL LOADER DL200-3 DL200TC Shop Manual 950106-00985AE – PDF DOWNLOAD
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Daewoo Doosan WHEEL LOADER DL200-3 DL200TC Shop Manual 950106-00985AE – PDF DOWNLOAD
GENERAL
- 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 a 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 at all times.
- 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. SP003003 Page 9 Wheel Loader Safety 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 should 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.
Flying or Falling Objects
On work sites where there is a potential hazard that flying or falling objects can come in contact with operator’s cabin, select and use a guard to match operating conditions for additional operator protection. Working in mines, tunnels, deep pits, and loose or wet surfaces, can produce hazards of falling rocks or flying objects. Additional protection for operator’s cabin may be required such as a Falling Object Protective Structure (FOPS) or window guards. Contact your DOOSAN distributor for information on available protective guards. To prevent personnel from being struck by flying objects, keep personnel out of work area
Correction of Machine Problems
If any machine problems are found during operation and maintenance (noise, vibration, smell, incorrect gauges, smoke, oil leakage, etc.), or if any abnormal warming alerts are displayed on display monitor, stop the machine immediately and take the necessary corrective actions. Do not operate the machine until problem has been corrected
Crushing and Cutting
- Keep objects away from moving fan blades. Fan blades can throw and cut objects. Do not use a wire rope that is kinked or frayed, or a wire rope with any loss of diameter. Wear leather gloves when handling a wire rope. When striking a loose retainer pin, it can fly out and can cause a serious injury.
- Make sure that area is clear of personnel when striking a retainer pin. To avoid injury to your eyes, wear safety goggles when striking a retainer pin. Do not put your hand, arm or any other part of your body between movable parts. If going between movable parts is necessary, always position and secure work equipment so it cannot move.
- Properly support equipment before performing any work or maintenance under raised equipment. If control levers are operated, clearance between machine and work equipment will change and this may lead to serious damage or can result in death or serious injury.
- Stay clear of areas that may have a sudden change in clearance with machine movement or equipment movement. Stay clear of all rotating and moving parts. Unless instructed, never attempt adjustments while machine is moving or while engine is running.
- Do not depend on hydraulic cylinders to support raised equipment. Equipment can fall if a control is moved, or if a hydraulic line breaks, is loosened or disconnected. If it is necessary to remove guards to perform maintenance, always install guards after maintenance is completed. Always have at least two people working together if the engine must be runing during service.
- One person needs to remain in the operator’s seat, ready to work the controls to stop the machine or stop engine, if necessary.
TABLE OF CONTENTS:
Daewoo Doosan WHEEL LOADER DL200-3 DL200TC Shop Manual 950106-00985AE – PDF DOWNLOAD
sm_DL200-3 DL200TC-3(950106-00985AE)............................................................................ 0 Table of Contents........................................................................................... 7 Safety...................................................................................................... 9 Wheel Loader Safety..................................................................................... 11 Safety Instructions................................................................................. 15 Applicable Models................................................................................... 15 Safety Messages..................................................................................... 16 Signal Words.................................................................................... 16 Safety Decals....................................................................................... 17 General............................................................................................. 18 Know Your Machine............................................................................... 18 Proper Work Tools and Attachments............................................................... 18 Pressurized Fluids.............................................................................. 19 Flying or Falling Objects....................................................................... 20 Personal Protective Equipment (PPE)............................................................. 20 Correction of Machine Problems.................................................................. 21 Crushing and Cutting............................................................................ 21 Hot Coolant and Oils - Burn Prevention.......................................................... 22 Fire and Explosion Prevention................................................................... 22 Fire Extinguisher and First-Aid Kit (Emergency Medical Kit)..................................... 26 Electrical System and Electrical Shock.......................................................... 26 Roll-over Protective Structure (ROPS)/ Falling Object Protective Structure (FOPS)............... 27 Transportation...................................................................................... 29 Obey State and Local Over-the-Road Laws & Regulations........................................... 29 Loading and Unloading........................................................................... 29 Transporting Machine............................................................................ 30 Operation........................................................................................... 31 Before Engine Starting.......................................................................... 31 Work Site....................................................................................... 31 Check Tire Pressure and Condition............................................................... 32 Mounting/Dismounting............................................................................ 32 Cleaning........................................................................................ 33 Operator Station................................................................................ 33 Seat Belt....................................................................................... 34 Visibility Information.......................................................................... 35 Boost Starting or Charging Engine Batteries..................................................... 36 Starting Engine................................................................................. 37 Traveling....................................................................................... 38 Lifting and Digging............................................................................. 39 Digging Beneath Overhangs....................................................................... 40 Digging Beneath Wheel Loader.................................................................... 40 Operation on Slopes............................................................................. 40 Towing.......................................................................................... 42 Attachment...................................................................................... 43 Equipment Lowering with Engine Stopped.......................................................... 44 Preventing Risk of Injuries or Death From Boom and Bucket....................................... 44 Engine Stop..................................................................................... 45 Parking Machine................................................................................. 46 Preservation/Storing Machine.................................................................... 47 Maintenance......................................................................................... 49 Warning Tag..................................................................................... 52 Cleaning........................................................................................ 53 Proper Tools and Clothing....................................................................... 53 Disassembling Precautions....................................................................... 53 Use of Lighting................................................................................. 54 Fire and Explosion Prevention................................................................... 54 Burn Prevention................................................................................. 55 Rubber That Contains Fluorides.................................................................. 56 Rubber and Plastics............................................................................. 57 Welding Repairs................................................................................. 58 Working on Machine.............................................................................. 59 Lock Inspection Covers.......................................................................... 60 Accumulator..................................................................................... 60 Compressed Air.................................................................................. 60 High-pressure Lines, Tubes and Hoses............................................................ 61 Supports and Blocking for Work Equipment........................................................ 62 Battery......................................................................................... 62 Environment and Circumstances....................................................................... 64 Work Site Areas Requiring Extra Caution......................................................... 64 High-voltage Cables............................................................................. 66 Underground Operation........................................................................... 66 Working in Water................................................................................ 67 Working in Contaminated Environment............................................................. 67 Operation in Extreme Conditions................................................................. 68 Exhaust Ventilation............................................................................. 72 Asbestos Information............................................................................ 72 Silica Dust Information......................................................................... 73 Disposal of Hazardous Materials................................................................. 73 Sound........................................................................................... 73 Vibration....................................................................................... 74 Before Returning the Machine to the Customer.................................................... 74 Specifications.............................................................................................. 75 Specification for DL200-3 / DL200TC-3................................................................... 77 Safety Instructions................................................................................. 81 Applicable Models................................................................................... 81 Component Locations................................................................................. 82 General Specifications.............................................................................. 86 Engine Performance Curves (Per KS-R1004 Standard)................................................... 88 Working Range and Dimensions........................................................................ 90 Working Capacities.................................................................................. 94 Bucket Capacity................................................................................. 94 Stability....................................................................................... 94 Material Weight..................................................................................... 95 Approximate Weight of Workload Materials........................................................ 95 General Maintenance......................................................................................... 99 General Maintenance Instructions SP002454...............................................................101 Safety Instructions.................................................................................105 Applicable Models...................................................................................105 Welding Precautions and Instructions................................................................106 Hydraulic System - General Precautions..............................................................107 Maintenance Service and Repair Procedure............................................................109 General Precautions.............................................................................109 Hydraulic System Cleanliness and Oil Leaks..........................................................110 Maintenance Precautions for Hydraulic System Service............................................110 Oil Leakage Precautions.........................................................................111 Cleaning and Inspection.............................................................................112 General Instructions............................................................................112 Bearing Inspection..............................................................................113 Standard Torques........................................................................................121 Safety Instructions.................................................................................125 Applicable Models...................................................................................125 Torque Values for Standard Metric Fasteners.........................................................126 Torque Values for Standard U.S. Fasteners...........................................................127 Type 8 Phosphate Coated Hardware....................................................................129 Torque Values for Hose Clamps.......................................................................130 ORFS Swivel Nut Recommended Torque..................................................................130 Torque Values for Split Flanges.....................................................................131 Torque Wrench Extension Tools.......................................................................132 Torque Multiplication...........................................................................132 Other Uses for Torque Wrench Extension Tools....................................................133 Tightening Torque Specifications (Metric).......................................................134 Drivetrain..................................................................................................137 Transmission and Torque Converter (ZF 4WG-160)..........................................................139 Safety Instructions.................................................................................143 Applicable Models...................................................................................143 General.............................................................................................144 Torque Limits for Screws........................................................................145 Labeling of Identification Plate for ZF Powershift Transmission.....................................146 Configuration 4 WG-160..............................................................................147 Measuring Points and Connections 4 WG-160...........................................................150 Required Oil Grade..............................................................................151 Special Tools.......................................................................................152 List of Special Tools for Disassembly and Reassembly............................................152 Disassembly.........................................................................................158 Electro-hydraulic Control and Zf Fine Filter (Replaceable Filter)...............................158 Inductive Sensor, Hall Sensor, Breather, Oil Filler and Oil Drain Plug..........................163 Outputs and Closure Parts Pump Shaft (PTO-Shaft)................................................170 Removal of Input Shaft, Output Shaft, Pump Shaft (PTO-shaft) and Clutches.......................178 Clutches KV/KR/K1/K2/K3/K4 Input and Output Shaft...............................................182 Reassembly..........................................................................................205 Clutches KV/KR/K1/K2/K3/K4 Input and Output Shaft...............................................205 Installation of Input Shaft, Output Shaft, Pump Shaft (Power-takeoff Shaft) and Clutches............248 Assembly............................................................................................255 Outputs and Closure Parts Pump Shaft (PTO-shaft)................................................255 Reassembly..........................................................................................268 Converter Back-pressure Valve...................................................................268 Oil Pressure Pump...............................................................................269 Engine Connection (Direct Mount)................................................................271 Engine Connection (Remote Mount)................................................................272 Emergency Steering Pump.........................................................................275 Inductive Sensor, Hall Sensor, Breather, Oil Filler and Oil Drain Plug..........................276 Electro-hydraulic Control with Proportional Valves:.............................................278 Parking Brake.......................................................................................286 Functional Characteristics and Maintenance Instructions for Mechanical Sliding Caliper M90......286 Spring Applied Hydraulic Released Sliding Calliper FSG 75.......................................291 Spring Applied Hydraulic Released Sliding Calliper FSG 90 and FSG 110...........................299 Spring Applied Hydraulic Released Sliding Calliper FSG 88.......................................307 Transmission Error Codes (ZF) ..........................................................................319 Safety Instructions.................................................................................323 Applicable Models...................................................................................323 Definition of Operating Modes.......................................................................324 Normal..........................................................................................324 Substitute Clutch Control.......................................................................324 Limp-home.......................................................................................324 Transmission Shut Down..........................................................................324 TCU Shut Down...................................................................................325 TCU Key Off.....................................................................................325 TCU Idle........................................................................................325 Table of Fault Codes................................................................................326 Measurement of Resistance at Actuator/ Sensors and Cable............................................348 Actuator........................................................................................348 Cable...........................................................................................348 Axle (ZF-MT-L 3075 II)..................................................................................349 Safety Instructions.................................................................................353 Applicable Models...................................................................................353 Lubrication and Maintenance Instructions............................................................354 Oil Grade.......................................................................................354 Oil Change......................................................................................354 Make Wear Measurement on the Multidisk Brake....................................................356 Inscriptions on Model Identification Plate......................................................357 Tightening Torques for Screws...................................................................358 Special Tools.......................................................................................359 List of Special Tools for Disassembly and Reassembly............................................359 Disassembly Output and Brake....................................................................366 Disassembly Axle Housing........................................................................373 Disassembly Input...............................................................................375 Disassembly Differentials.......................................................................378 Reassembly Differentials........................................................................384 Reassembly Input................................................................................397 Reassembly Axle Housing.........................................................................406 Reassembly Output and Brake.....................................................................408 Driveshaft..............................................................................................419 Safety Instructions.................................................................................423 Applicable Models...................................................................................423 Driveshaft Weight...............................................................................424 Driveshaft Coupling Dimension...................................................................424 Driveshaft Tightening Torque....................................................................424 Brake.......................................................................................................425 Service Brake...........................................................................................427 Safety Instructions.................................................................................431 Applicable Models...................................................................................431 General Description.................................................................................432 Service Brake System................................................................................433 Brake Supply Valve......................................................................................435 Safety Instructions.................................................................................439 Applicable Models...................................................................................439 Supply Valve........................................................................................440 Charging Block..........................................................................................443 Safety Instructions.................................................................................447 Applicable Models...................................................................................447 Charging Block......................................................................................448 Parts List......................................................................................448 Parking Brake...........................................................................................451 Safety Instructions.................................................................................455 Applicable Models...................................................................................455 General Description.................................................................................456 Functional Characteristics and Maintenance Instructions.............................................457 Functional Characteristics of Spring Loaded Sliding Caliper Brakes..............................457 Mounting and Basic Setting Regulations..........................................................459 Adjusting Regulations...........................................................................460 Emergency Release of Parking Brake..............................................................460 Maintenance and Repair Work.....................................................................461 General.........................................................................................463 Brake Pedal Valve.......................................................................................465 Safety Instructions.................................................................................469 Applicable Models...................................................................................469 General Description.................................................................................470 Theory of Operation.............................................................................470 Specification...................................................................................472 Accumulator.............................................................................................473 Safety Instructions.................................................................................477 Applicable Models...................................................................................477 General Description.................................................................................478 Specifications..................................................................................480 Steering....................................................................................................481 Power Steering System...................................................................................483 Safety Instructions.................................................................................487 Applicable Models...................................................................................487 General Description.................................................................................488 Disassembly.........................................................................................489 Assembly............................................................................................496 Priority Valve..........................................................................................505 Safety Instructions.................................................................................509 Applicable Models...................................................................................509 General Description.................................................................................510 Tool List.......................................................................................510 Disassembly.........................................................................................511 Assembly............................................................................................513 Emergency Steering......................................................................................515 Safety Instructions.................................................................................519 Applicable Models...................................................................................519 General Description.................................................................................520 Emergency Steering Function Test................................................................522 Emergency Steering Automatic Test...............................................................522 Pump and DC Motor...................................................................................524 Frame.......................................................................................................525 Articulation Center.....................................................................................527 Safety Instructions.................................................................................531 Applicable Models...................................................................................531 General Description.................................................................................532 Maintenance Standard............................................................................532 Counterweight...........................................................................................535 Safety Instructions.................................................................................539 Applicable Models...................................................................................539 Specifications......................................................................................540 Counterweight.......................................................................................540 Tank........................................................................................................541 Oil Tank................................................................................................543 Safety Instructions.................................................................................547 Applicable Models...................................................................................547 General Description.................................................................................548 Parts List......................................................................................548 Specifications..................................................................................549 Fuel Tank...............................................................................................551 Safety Instructions.................................................................................555 Applicable Models...................................................................................555 General Description.................................................................................556 Parts List......................................................................................556 Specifications..................................................................................557 Fuel Sender Setting.........................................................................557 Hydraulics..................................................................................................559 Main Pump...............................................................................................561 Safety Instructions.................................................................................565 Applicable Models...................................................................................565 Specification.......................................................................................566 Sectional View......................................................................................566 General Repair Instructions.........................................................................567 Seal Kits and Subassemblies.........................................................................569 Sealing of the Driveshaft...........................................................................572 Sealing of the Regulator Housing....................................................................574 Projection of Pump Support/Checking of the Directional Valve........................................575 Removing of the Impeller............................................................................577 Disassembly of the Regulator........................................................................579 Removing of the Port Plate..........................................................................580 Removing of the Rotary Group........................................................................581 Disassembly of the Rotary Group.....................................................................583 Disassembly of the Hydraulic Control................................................................584 Inspection Notes....................................................................................585 Blind Threaded Hole in Driveshaft...............................................................586 Pump Assembly.......................................................................................601 Inspection Notes....................................................................................604 Pump Assembly.......................................................................................606 Tightening Torques..................................................................................613 Tightening Torques for Shaft Bolts (Metric ISO Standard Thread).................................613 Tightening Torques for Locking Screws VSTI (Metric ISO Fine Thread).............................613 Tightening Torques for Seal-lock Nuts (Metric ISO-Standard Thread)..............................614 Tightening Torques for Cross-slotted Lens Head Screws DIN 7985 (Metric ISO- Standard Thread)....614 Safety Instructions.................................................................................615 General Advice..................................................................................615 Before Starting.................................................................................615 Start...........................................................................................615 Attention.......................................................................................616 Hydraulic Equipment.............................................................................616 Main Control Valve......................................................................................617 Safety Instructions.................................................................................621 Applicable Models...................................................................................621 General Description.................................................................................622 Disassembly/Reassembly..............................................................................624 Load Isolation System...................................................................................635 Safety Instructions.................................................................................639 Applicable Models...................................................................................639 General Description.................................................................................640 Overview........................................................................................641 Hydraulic Circuit...............................................................................642 Accumulator Charging Method.....................................................................642 LIS Valve.......................................................................................644 Accumulator.....................................................................................646 Cooling System..........................................................................................647 Safety Instructions.................................................................................651 Applicable Models...................................................................................651 General.............................................................................................652 Function........................................................................................653 Fan Motor Pressure and Fan Speed................................................................654 Fan and Brake Pump..............................................................................656 Tightening Torques..............................................................................675 Fan Motor...........................................................................................676 Specifications..................................................................................676 Parts List......................................................................................676 Disassembly.....................................................................................677 Inspect Parts for Wear..........................................................................680 Reassembly......................................................................................681 Fan Control Valve...................................................................................684 Specifications..................................................................................684 Parts List......................................................................................684 Pilot System............................................................................................685 Safety Instructions.................................................................................689 Applicable Models...................................................................................689 Function............................................................................................690 Fingertip Joystick..................................................................................691 Specification...................................................................................691 Parts List......................................................................................692 Parts List......................................................................................696 Hydraulic Schematic DL200-3 / DL200TC-3 / DL220-3.......................................................699 Safety Instructions.................................................................................703 Applicable Models...................................................................................703 DL200-3 / DL220-3...................................................................................705 DL200TC-3...........................................................................................706 Electrical System...........................................................................................707 Air Conditioner.........................................................................................709 Safety Instructions.................................................................................713 Applicable Models...................................................................................713 General Description.................................................................................714 Internal and External Filters...................................................................715 Air-conditioning System Layout..................................................................716 Air Conditioner/heater Circuit Diagram..........................................................717 Air Conditioner/Heater Unit.....................................................................718 Ambient Air Temperature Sensor..................................................................723 Sun Sensor......................................................................................724 Control Panel...................................................................................724 Compressor......................................................................................731 Receiver Dryer..................................................................................731 Troubleshooting.....................................................................................732 Eight of R134a Gas Used In Machines.................................................................734 Refrigerant System Repairs..........................................................................735 Refrigerant Safe Handling Procedures............................................................735 Repair and Replacement Procedure................................................................736 Refrigerant Recovery............................................................................738 Vacuuming Refrigerant System....................................................................738 Leakage Check...................................................................................740 Refrigerant Charging............................................................................740 Inspecting System For Leakage...................................................................742 Electrical System.......................................................................................743 Safety Instructions.................................................................................748 Applicable Models...................................................................................748 Overview............................................................................................749 Electric Supply System..............................................................................750 Engine Starting Circuit.............................................................................752 Operation During Start Process..................................................................752 Operation After Start Process...................................................................754 Engine Stop System..................................................................................755 Charging System.....................................................................................756 Monitoring System...................................................................................757 Instrument Panel................................................................................758 Function Check..................................................................................760 Monitoring System Schematic.....................................................................760 Operation...........................................................................................762 Instruments Gauge...............................................................................762 Indicator Lights................................................................................762 Initial Operation...............................................................................764 Multifunction Display...........................................................................765 Indication of Warning Lights....................................................................767 Indication of Indicator Lights..................................................................769 Graphic Information Area Display....................................................................771 Overview........................................................................................771 Main Menus for the Graphic Display Area.........................................................771 Menu Selector Buttons...........................................................................772 User Menu...........................................................................................773 Service Menu........................................................................................780 Entering/Accessing and Exiting/Escaping Menus...................................................780 Service Menu Selections.........................................................................781 Windshield Wiper....................................................................................803 Front Windshield Wiper..........................................................................803 Rear Windshield Wiper...........................................................................805 Lighting System.....................................................................................808 Light Circuit...................................................................................808 Power Mode Control..................................................................................812 Engine Control System...............................................................................813 Accelerator Pedal...............................................................................814 Auto Idle Control...............................................................................815 Electric Detent System..............................................................................816 Electrical Circuit..............................................................................816 Boom Kick-out...................................................................................817 Return To Dig...................................................................................818 Cooling Fan Control System..........................................................................819 Outline.........................................................................................819 Diagram.........................................................................................819 Electrical Diagram..............................................................................820 Parts of Cooling Fan Control System.............................................................821 Operation of Cooling Fan Control System.........................................................823 Emergency Steering System (Option)..................................................................825 Block Diagram...................................................................................825 Emergency Steering System Components............................................................826 Emergency Steering System Electrical Circuit....................................................829 Electrical Schematic DL200-3 / DL200TC-3 / DL220-3 / DL250-3 / DL250TC-3................................831 Safety Instructions.................................................................................835 Applicable Models...................................................................................835 DL200-3 / DL200TC-3 / DL220-3 /DL250-3 / DL250TC-3..................................................837
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