Doosan DL200 & DL200TC Wheel Loader Workshop Repair Service Manual PDF - MDSDL200OPES.zip

A full-service repair manual, complete with electrical wiring diagrams, for the Doosan DL200 and DL200TC Wheel Loaders — packed with workshop details that let you maintain, troubleshoot, and overhaul the machine the way professional technicians do.

This workshop service and repair manual for the Doosan DL200 and DL200TC Wheel Loaders covers:

* Numbered table of contents easy to use so that you can find the information you need fast.

* Detailed sub-steps expand on repair procedure information

* Numbered instructions guide you through every repair procedure step by step.

* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.

* Notes, cautions and warnings throughout each chapter pinpoint critical information.

* Bold figure number help you quickly match illustrations with instructions.

* Detailed illustrations, drawings and photos guide you through every procedure.

* Enlarged inset helps you identify and examine parts in detail.

MAIN SECTIONS

Safety

Wheel Loader Safety.. SP000865

Specifications

Specification for DL200/ DL200TC.. SP000914

General Maintenance

General Maintenance Procedures ... SP001055

Standard Torques .. SP000813

Drive Train

Transmission and Torque Converter... SP001011

Transmission Error Codes (ZF)... SP001056

Axle... SP001018

Drive Shaft ... SP001019

Brake

Service Brake... SP001080

Brake Supply Valve.. SP001081

Parking Brake .. SP001082

Brake Pedal Valve.. SP001083

Accumulator.. SP001084

Steering

Steering .. SP001085

Cushion Valve.. SP000328

Emergency Steering ... SP001086

Frame

Articulation Center .. SP001087

Counterweight... SP000130

Tank

Oil Tank.. SP001088

Fuel Tank... SP001089

Hydraulics

Cylinders... SP001027

Main Pump... SP001212

Main Control Valve... SP001090

Load Isolation System.. SP001091

Cooling System.. SP001092

Pilot System... SP001093

Hydraulic Schematic DL200... SP001094

Electrical System

Air Conditioner ... SP001211

Electrical System ... SP001095

Electrical Schematic DL200/ DL250.. SP000925

Total Pages: 688 pages

File Format: PDF (bookmarked, Searchable, Printable, high quality)

Language: English

Table of Contents......3

Safety......5

Wheel Loader Safety......7

Safety Precautions......11

Applicable Models......11

To the Operator of a Wheel Loader......12

Learn the Signal Words Used with the Safety Alert Symbol......14

General Safety Essentials......16

Accessory Applications......16

Location of Safety Labels......16

Unauthorized Modifications......17

General Hazard Information......17

Safety Rules......17

Safety Features......17

Inside Operator's Compartment......18

Clothing and Personal Protective Items......19

Breathing Masks, Ear Protection May Be Required......19

Vibration Level Information......19

Asbestos Dust Hazard Prevention......20

Mounting and Dismounting......20

Fuel, Oil and Hydraulic Fluid Fire Hazards......21

Precautions When Handling Fluids at High Temperature......21

Injury from Work Equipment......22

Fire Extinguisher and First Aid Kit......22

Protection from Falling or Flying Objects......23

Install Additional Safety Equipment If Conditions Require......23

Maintain Standard Safety Equipment in Good Condition......23

Attachment Precautions......24

Accumulator......24

Engine Ventilation......24

Before Starting Engine......25

Work Site Precautions......25

Checks Before Starting Engine......26

Engine Starting......27

Before Operating Machine......28

Machine Operation......29

Operate While Seated at Operator's Station ONLY......29

Seat Belts Should Be Used at All Times......29

Movement Alarms......29

Travel Precautions......30

Sloping Terrain Requires Caution......30

Avoid High Voltage Cables......31

Before Starting to Dig, Contact Authorities......31

Be Aware of Height Obstacles......31

Use Care on Loose Support......32

Use Solid Support Blocking......32

Digging Beneath Overhangs......32

Digging Beneath Wheel Loader......32

Stay Alert for People Moving Through Work Area......33

Be Aware of and Conform to Local Regulations......33

Never Use Ether Starting Aids......33

Observe General Safety Rules......34

Take Time to Provide Good Visibility......34

Keep "Pinch Point" Areas Clear Use Caution in Reverse......35

Operate Carefully on Snow and Ice and in Very Cold Temperatures......35

Parking Machine......36

Shutdown Control Functions......36

Never Let Anyone Ride on Attachment......36

Maintenance......37

Use Warning Tag During Service......37

Clean Before Inspection or Maintenance......37

Proper Tools......38

Use of Lighting......38

Fire Prevention and Explosion Prevention......38

Burn Prevention......39

Welding Repairs......40

Treatment for Electrical Welding to the Body Structure......41

Precautions for Removal, Installation, and Storage of Attachments......41

Precautions When Working on Machine......41

Lock Inspection Covers......42

Crushing Prevention and Cutting Prevention......42

Do Not Run Engine If Repairs or Work Are Being Performed Alone......42

Always Use Adequate Equipment Supports and Blocking......42

Do Not Work on Hot Engines or Hot Cooling or Hydraulic Systems......43

Hydraulic Cylinder Seals Require Periodic Replacement......43

Highpressure Hydraulic Lines Can Store a Great Deal of Energy......43

Precautions with Highpressure Line, Tubes and Hoses......44

Obtain Immediate Medical Attention if Pressurized Oil Pierces Skin......44

Use Correct Replacement Fasteners Tightened to Proper Torque......45

Safety Critical Parts Must Be Replaced Periodically......45

Dispose of All Petroleum Based Oils and Fluids Properly......45

Check Tire Pressure and Condition......45

Battery......46

Battery Hazard Prevention......46

Disconnect Batteries Before Electrical Service or Electrical Welding......46

Use Low Heat Portable Lighting......47

Boost Starting or Charging Engine Batteries......47

Towing......48

Precautions When Towing......48

Shipping and Transportation......49

Obey State and Local OvertheRoad Regulations......49

Summary of Safety Precautions for Lifting......49

Specifications......51

Specification for DL200/ DL200TC......53

Safety Precautions......57

Applicable Models......57

Component Locations......58

DL200......58

DL200TC......60

General Specifications......62

Engine Performance Curves......64

Working Range and Dimensions......66

Working Capacities......71

Bucket Capacity......71

Tipping Load......71

Material Weight......71

Approximate Weight of Workload Materials......71

General Maintenance......75

General Maintenance Procedures SP001055......77

Safety Precautions......81

Applicable Models......81

Welding Precautions and Guidelines......82

Hydraulic System General Precautions......83

Maintenance Service and Repair Procedure......85

General Precautions......85

Hydraulic System Cleanliness and Oil Leaks......86

Maintenance Precautions for Hydraulic System Service......86

Oil Leakage Precautions......87

Cleaning and Inspection......88

General Guidelines......88

Bearing inspection......89

Normal Bearing......90

Bent Cage......90

Galling......91

Abrasive Step Wear......91

Etching......92

Misalignment......92

Indentations......92

Fatigue Spalling......93

Brinelling......93

Cage Wear......93

Abrasive Roller Wear......94

Cracked Inner Race......94

Smears......94

Frettage......95

Heat Discoloration......95

Stain Discoloration......95

Standard Torques......97

Safety Precautions......101

Applicable Models......101

Torque Values for Standard Metric Fasteners......102

Torque Values for Standard U.S. Fasteners......103

Type 8 Phosphate Coated Hardware......105

Torque Values for Hose Clamps......106

Torque Values for Split Flanges......107

Torque Wrench Extension Tools......108

Torque Multiplication......108

Other Uses for Torque Wrench Extension Tools......109

Tightening Torque Specifications (Metric)......110

I. "Loctite" Fastener Adhesives......111

II. "Loctite" Pipe Thread Sealant......111

III. "Loctite" gasket/flange sealer......111

IV. "Loctite" retaining compounds......112

V. "Loctite" Adhesives......112

Drive Train......113

Transmission and Torque Converter......115

Safety Precautions......121

Applicable Models......121

General......122

Transmission and Torque Converter......124

Powershift Transmission......125

Transmission Control......125

The Chart of Measuring Points and Connection 4 WG160......127

Oil Circuit Diagram 4WG160......129

Transmission Electrical Components......132

TCU (Transmission Control Unit)......134

Transmission Control Valve......134

Transmission Oil Temperature Sensor......134

Engine Pickup Sensor......135

Central Gear Pickup Sensor......135

Turbine Pickup Sensor......135

Output Speed Sensor......136

Shift Lever Switch (DW3)......136

Forward, Reverse Switch Lever (Optional)......137

Finger Tip Work Lever......138

2-Lever (Optional)......138

3-Lever (Optional)......138

Switch Circuit......139

Auto Selector Switch......139

Display......140

Transmission Faults Codes......141

Fault Display......141

CAN Message......141

Description of Fault Codes......141

Abbreviations......142

Definition of Operation Modes......142

Normal......142

Substitute Clutch Control......142

Limphome......142

Transmission Shut Down......143

TCU Shut Down......143

Table of Fault Codes......143

Measurement of Resistance at Actuator/ sensors and Cable......143

Actuator......143

Cable......143

Transmission Electrical Circuits......144

T/M Controller Circuit......144

Traveling Circuits......145

Neutral......146

Forward First Gear......147

Forward Second Gear......148

Forward Third Gear......149

Forward Fourth Gear......150

Reverse First Gear......151

Reverse Second Gear......152

Reverse Third Gear......153

Downshift......153

Overview......153

Kickdown: Forward Second Gear to Forward First Gear (Auto Selector Switch "O" Manual Mode)......154

Downshift (Auto Selector Switch "Second Gear" Auto Mode)......155

Downshift (Auto Selector Switch "Third Gear" Auto Mode)......156

Transmission Cutoff......157

LIS (Load Isolation System) Optional......158

Aeb Starter......159

Introduction......159

Procedure to Start AEB......160

Display During AEB-mode......160

Installation View......162

Inner Section......162

Front View......164

Side View......165

Rear View......166

Special Tools......167

Engine Connection......167

Input......168

Gearbox Housing......169

Coupling......170

Coupling K1......170

Coupling K2......171

Coupling K4......172

Coupling KV......173

Coupling KR......174

Output......175

Gearshift System......176

Pressure Regulator......179

Pressure Oil Pump......180

Filter......181

Oil Pipes......182

Hydraulic Control Unit (HSG94)......183

Disassembly......185

Reassembly......188

Transmission Disassembly......193

Remove Filter Unit......193

Remove Hydraulic Control Unit (HGS-94) and Duct Plate from Gearbox Housing......194

Remove and Dismantle Converter Safety Valve......195

Engine Connection Converter......196