Daewoo Doosan DL200 Wheel Loader Service Repair Manual (Serial Number 5001 and Up)

1. DL200 DL200TC Shop Manual K1024538E Serial Number 5001 and Up DOOSAN reserves the right to improve our products in a continuing process to provide the best possible product to the market place. These improvements can be implemented at any time with no obligation to change materials on previously sold products. It is recommended that consumers periodically contact their distributors for recent documentation on purchased equipment. This documentation may include attachments and optional equipment that is not available in your machine's package. Please call your distributor for additional items that you may require. Illustrations used throughout this manual are used only as a representation of the actual piece of equipment, and may vary from the actual item. K1024538E Shop Manual Copyright 2006 Doosan

2. 1Table of Contents 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 Table of Contents Page I

3. 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 Table of Contents Page II

4. PRIORITY VALVE Theory of Operation Oil output from the steering pump flows through the priority valve to both the loader supply line and to the steering circuit. During operation of the steering wheel, the priority valve shifts and supplies pump flow only to the steering circuit. This results in smooth operation of the steering circuit. At rest, the spool (1, Figure 4) maintains an open path between inlet port P and steering outlet port CF. Port EF is kept closed by the force from spring (2, Figure 4). The spool (1, Figure 4) contains a drilled passage. The passage is open to port CF and is also open to both ends of the spool. At the neutral position of the steering unit, oil from port P flows through port CF and into the drilled passage in the spool. At this time, oil flowing out of CF is blocked at the control spool of the steering unit. This raises the pressure in port CF. At this time, port LS is open to the chamber on the far right side of the priority valve. Port LS is not open to the chamber on the far left side of the valve. As oil flows through the drilled passage in the spool, pressure builds on the left side of the spool but pressure is low on the right side of the spool because oil can drain into port LS. When oil pressure on the left side of the spool rises above the force of spring (2, Figure 4), the spool (1, Figure 4) shifts the right. This allows pump flow at port P to flow out both ports CF and EF. Now both the loader supply line and the steering supply line are charged with flow from the steering pump. Whenever the steering wheel is turned, the spool in the steering unit directs some oil flow back to port LS. This equalizes the oil pressure on both ends of the spool (1, Figure 4). The spring now shifts the spool to the left. This closes off the passage from port P to port EF. This makes all steering pump flow now available only to the steering circuit from port CF. Figure 3 Steering Page 8 SP001085

5. Figure 4 Reference Number Reference Number Description Description 1 Spool CF Steering Supply Port 2 Spring ED Loader Supply Port P Pressure Port LS Pilot Port SP001085 Page 9 Steering

6. Parts List Figure 5 Reference Number Reference Number Description Description 1 Plug 5 Spring 2 O-ring 6 Plug 3 Spool 7 Orifice 4 Housing Specifications Priority Valve Specification Model Danfoss OLS 120 Control Pressure 7 kg/cm2 (100 psi) Rated Flow 120 lpm (32 gpm) Steering Page 10 SP001085

7. SPECIAL TOOLS 1. The following tools are necessary to repair the priority valve. See Figure 6. Open end wrench - 27 mm Slip joint pliers Nylon rod Allen wrenches - 5 mm, 8 mm and 10 mm Figure 6 DISASSEMBLY 1. Use open end wrench to loosen PP plug. See Figure 7. Remove O-ring. Figure 7 2. Use open end wrench to loosen LS plug. See Figure 8. Remove O-ring. Figure 8 SP001085 Page 11 Steering

8. 3. Remove spring. See Figure 9. Figure 9 4. Use a nylon rod to push spool out of bore. See Figure 10. Figure 10 5. Use an 8 mm allen wrench to remove plug from pressure relief valve. See Figure 11 Figure 11 6. Use a 10 mm allen wrench to unscrew pressure relief valve from its bore. See Figure 12. Figure 12 Steering Page 12 SP001085

9. 7. Hold pressure relief valve with a pliers and use a 5 mm allen wrench to remove set screw. See Figure 13. Figure 13 8. The pressure relief valve is composed of a valve housing, valve needle, spring and set screw. See Figure 14. Figure 14 CLEANING AND INSPECTION (WEAR LIMITS AND TOLERANCES) For general cleaning and inspection procedures, refer to "General Maintenance Procedures" section. Clean all parts with a nonflammable, nontoxic solvent. Carefully inspect all parts. Replace all worn or broken parts. Use only new O-rings to assemble the valve. Cost all parts with oil before assembling them. SP001085 Page 13 Steering

10. REASSEMBLY The relief valve pressure can be changed by changing springs. The following table displays the characteristics of the three springs available. See Figure 15. NOTE: Wire Diameter (A) Coil Spring Height (C) Pressure in Bars Diameter (B) 4.0 bar (58 psi) 2.5 mm (0.0984") 12.5 mm (0.4921") 50.0 mm (1.9685") 7.0 bar (100 psi) 3.0 mm (0.1181") 12.5 mm (0.4921") 50.0 mm (1.9685") 10.0 bar (145psi) 3.2 mm (0.1260") 12.5 mm (0.4921") 50.0 mm (1.9685") Figure 15 1. Figure 16, shows PP plug and spool. Figure 16 Steering Page 14 SP001085

11. 2. Figure 17, shows outer spool and outer PP plug. Plug is installed with spool. Figure 17 3. Install spool into bore. See Figure 18. Use a nylon rod to position spool in neutral position. Figure 18 4. Install spring and LS plug into bore. See Figure 19. Use a new O-ring on plug. Figure 19 5. Use a 27 mm wrench to tighten PP plug and LS plug to 6 kg•m (44 ft lb). See Figure 20. Figure 20 SP001085 Page 15 Steering

12. 6. Assemble valve needle, spring and set screw into pressure relief valve housing. See Figure 21. Thread pressure relief valve into body of priority valve and tighten it. See Figure 21. Figure 21 7. Install plug into pressure relief valve bore. Tighten plug to 5 kg•m (36 ft lb). See Figure 22. Figure 22 Steering Page 16 SP001085

13. STEERING UNIT Power Steering System Power Steering Unit. The machine contains a fully hydraulic steering unit. See Figure 23. Rotating the steering wheel controls hydraulic flow through the steering valve. The steering valve meters the volume of pump flow that is supplied to the steering cylinders Reference Number Description 1 Bearing 2 Centering Springs 3 Sleeve 4 Center Pin 5 Check Valve 6 Gerotor 7 End Cap 8 Spool 9 Drive Shaft 10 Housing The steering unit contains a gerotor. This allows the operator to steer the machine when the engine is not running or when the steering pump has failed. The gerotor functions as a manual hydraulic pump that is powered by the rotation of the steering wheel. Rotating the steering wheel will cause the gerotor to draw oil from the hydraulic tank and send this oil to the steering cylinders. Figure 23 The shaft that is rotated by the steering wheel is attached to the spool (8, Figure 23) by the engagement of a spline. The spool is surrounded by a sleeve (3). The spool and sleeve are connected by the centering spring (2). At the steering wheel neutral position, the center pin does not contact the spool. A drive shaft (9) extends through the spool. The upper end of the drive shaft engages the center pin (4). The lower end of the drive shaft engages the spline in the gerotor (6). SP001085 Page 17 Steering

14. Neutral Operation With the steering wheel in the neutral position (wheels turned neither right nor left), the spool (2, Figure 24) and sleeve (1, Figure 24) are stationary at the position where the center pin (6, Figure 24) becomes centered in the spool space by the centering springs (3, Figure 24). Oil flow through the load sensing line (LS), port L, port R, and port T are bypassed to the tank line and the oil supply (P) is blocked by the directional spool in the steering unit (2, Figure 2). Even if an external force is applied to the steering cylinder, the steering unit is protected because the oil path is blocked by the directional spool. Reference Number Description 1 Sleeve 2 Spool 3 Centering Spring 4 Spool 5 Sleeve 6 Center Pin 7 Drive shaft Figure 24 Right Turn The spool (2, Figure 24) is engaged with the spline of the steering shaft. When the steering wheel is turned to the right, the spool turns. The sleeve (1, Figure 24) is connected to the spool (2, Figure 24) by centering springs (3, Figure 24). When spool turns, the sleeve turns. The sleeve turning angle is about 10° less than the spool turning angle. This allows the longitudinal slots in the spool to align with the ports in the sleeve. Oil from port P on the steering unit (2, Figure 2) travels through the control spool and is directed to port R which directs the oil to the steering cylinders (6, Figure 2). The amount of flow metered to port R is controlled by the amount of steering wheel rotation. Excess oil flow through port P that is not metered to port R, is directed by the spool to port T and is then directed through the il cooler and into the tank. Steering Page 18 SP001085

15. Left Turn The spool (2, Figure 23) is engaged with the spline of the steering shaft. When the steering wheel is connected to the spool (2, Figure 24) by centering springs (3, Figure 24). When the spool turns, the sleeve turns. The sleeve turning angle is about 10° less than the spool turning angle. This allows the longitudinal slots in the spool to align with the ports in the sleeve. When the steering wheel is turned to the left, oil from port P on the steering unit (2, Figure 2) is directed through the control spool in the steering unit, out port L and into the steering cylinders (6, Figure 2). The amount of oil flow metered to port L is controlled by the amount of steering wheel rotation. Excess oil flow through port P that is not metered to port L, is directed by the spool to port T and is then directed through the oil cooler and into the tank. Gerotor Operation If the engine or pump is not operating, the steering unit (2, Figure 2) works as a manual pump when the steering wheel is turned. The gerotor will work when the input torque to the steering wheel is less than 12 kg•m (87 ft lb). If the necessary input torque is greater than this, the gerotor will not function. When the steering wheel is turned, the gerotor creates a vacuum that draws oil from port T. See Figure 1. The gerotor pumps this oil through the control spool and into the steering cylinders. Return oil flows back to the spool and is used to lubricate the steering unit (2, Figure 2). The return oil then flows back into the tank line and is recirculated back to the gerotor and the steering cylinders. SP001085 Page 19 Steering

16. Parts List An exploded view of the steering unit is shown in Figure 25. Figure 25 1 Seal Ring 1 Seal Ring 2 Housing 15 Spacer - 13.8 mm (If equipped) 3 Spool 16 Spacer - 25 mm (If equipped) 4 Sleeve 17 Spacer Bushing (If equipped) 5 Ball 18 O-ring 80.5 x 1.5 mm 6 Threaded Bushing 19 Middle Plate 7 O-ring 20 Distributor Plate 8 Backing Ring (If equipped) 21 Rotor 9 Thrust Washers 22 O-ring - 79.92 x 1.78 mm 10 Thrust Bearing 23 Cylinder Gear 11 Spacer Ring 24 End Cover 12 Cross Pin 25 Washer 13 Neutral Springs 26 Roll Pin 2.5 x 32 mm 14 Shaft 27 Bolt Steering Page 20 SP001085

17. Specifications Specification Steering Unit DL200 Type Load Sensing, Dynamic Signal, Nonreaction Gerotor Displacement 630 cc/rev (38.44 in3/rev) Rated Flow 80 liter/min (21.12 U.S. gal) SPECIAL TOOLS The tools necessary for steering unit repair are illustrated below. 1. Stabilizing base. See Figure 26. Figure 26 2. O-ring assembly tool. See Figure 27. Figure 27 SP001085 Page 21 Steering

18. 3. Seal driver. See Figure 28. Figure 28 4. Torque wrench, 0 - 5 kg•m (0 - 35 ft lb). See Figure 29. 13 mm socket. Ratchet handle. 12 mm screwdriver. 6 mm screwdriver. 2 mm screwdriver. Plastic hammer. Figure 29 Steering Page 22 SP001085

19. DISASSEMBLY It is very important to keep the inside of the steering unit clean. Make sure that the outside of the steering unit is clean before opening the unit. Use a wire brush and solvent to clean the entire unit. 1. Remove steering column from steering unit. Bolt steering unit to stabilizing base. Bolt base to work bench. 2. Remove bolts from steering unit end cover. See Figure 30. Figure 30 3. Remove end cover from unit. See Figure 31. Figure 31 4. Lift cylinder gear off unit. See Figure 32. Remove two O-rings. Figure 32 Steering Page 24 SP001085

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21. 5. Remove spacer bushing and spacer from cylinder gear (If equipped). See Figure 33. Refer to parts manual for our unit to determine if these parts are installed. NOTE: Figure 33 6. Remove shaft from housing. See Figure 34. Figure 34 7. Remove distributor plate from housing. See Figure 35. Figure 35 8. Remove O-ring from top of middle plate. See Figure 36. Figure 36 SP001085 Page 25 Steering

22. 9. Lift middle plate off housing. See Figure 37. Figure 37 10. Remove O-ring from housing. See Figure 38. Figure 38 11. Unscrew threaded bushing and remove it. See Figure 39. Figure 39 12. Remove cross pin. See Figure 40. Figure 40 Steering Page 26 SP001085