Doosan DL200 Manual
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Doosan DL200 Manual

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Summary of Contents for Doosan DL200

  • Page 1 Electrical System...
  • Page 3 SP001211 AIR CONDITIONER SP001211 Air Conditioner Edition 1 Air Conditioner SP001211 Page 1...
  • Page 4 MEMO Air Conditioner SP001211 Page 2...

  • Page 5: Table Of Contents

    Table of Contents Air Conditioner Safety Precautions..........5 Applicable Models..........5 General Description ..........6 Refrigerant Circulation ......... 8 Control Panel ............. 10 Control Specifications ........11 Temperature Level Control and Display ..12 Air Discharge According to Path Selection ..13 Air-conditioning System Circuit Diagram..
  • Page 6 MEMO Air Conditioner SP001211 Page 4...

  • Page 7: Safety Precautions

    Remember, that ultimately safety is your own personal responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DL200 5001 and Up Air Conditioner SP001211 Page 5...

  • Page 8: General Description

    GENERAL DESCRIPTION FG009195 Figure 1 The heater and air conditioner are combined into one blower unit in right control stand of operator's seat. If necessary, the operator can control inner temperature using the operation panel installed in the top of the right side door.
  • Page 9 The unit is equipped with an air filtration system which filters out dirt and dust particles from air being circulated into the operator's cab. This filter (1, Figure 2) should be cleaned out at approximately every 500 hours and replaced with a new one every 1,000 hours.

  • Page 10: Refrigerant Circulation

    REFRIGERANT CIRCULATION HBOI020L Figure 3 Reference Reference Description Description Number Number Evaporator Compressor Expansion Valve Blower Fan Condenser Receiver Dryer Condenser Fan Air Conditioner SP001211 Page 8...
  • Page 11 Shading Temperature Refrigerant State High High-pressure Gas High High-pressure Liquid Low-pressure Liquid High High-pressure Gas/Liquid Low-pressure Gas • Refrigerant (R134a) compressed approximately 15 kg/cm (213 psi) within the compressor. • compressed refrigerant flows into condenser high temperature (approximately 80°C (176°F)). •...

  • Page 12: Control Panel

    CONTROL PANEL FG004455 Figure 4 INPUT OUTPUT CONTROL PANEL DISPLAY TEMPERATURE SENSOR LOW SPEED RELAY BLOWER OFF SW MID SPEED RELAY MOTOR A / C SW VENT SW HIGH SPEED RELAY DEF. SW TEMP. CONTROL HEAT SW MIX DOOR ACTUATOR CONTROL FRE SW PANEL...

  • Page 13: Control Specifications

    CONTROL SPECIFICATIONS Control Item Control Switch Control Specifications Temperature "COOL" Switch MAX COOL Control "WARM" Switch 100% MAX HOT HDA6049L Figure 6 Temperature control switch consists of a 24 step variable selector. The display uses 7, Green / Red color LED's display selected...

  • Page 14: Temperature Level Control And Display

    TEMPERATURE LEVEL CONTROL AND DISPLAY Position Step LED 7 Sensor Remark Voltage Green Green Green Green Green Green Green 4.50 V ±0.2 MAX. COOL Green Green Green Green Green Green Green 4.33 V ±0.2 Green Green Green Green Green Green Green 4.15 V ±0.2 Green...

  • Page 15: Air Discharge According To Path Selection

    AIR DISCHARGE ACCORDING TO PATH SELECTION Face + Rear FG009196 Figure 9 Foot + Rear FG009197 Figure 10 Air Conditioner SP001211 Page 13...
  • Page 16 Defroster + Rear FG009198 Figure 11 Air Conditioner SP001211 Page 14...
  • Page 17 SP001211 Air Conditioner Page 15...

  • Page 18: Air-Conditioning System Circuit Diagram

    AIR-CONDITIONING SYSTEM CIRCUIT DIAGRAM 15-1 15-2 15-3 15-4 15-5 LED 1~12 HIGH 15-6 MODE SELECT VENT AIR MODE 15-7 RECIRCLE/FRESH FOOT BLOWER SPEED TEMP. CONTROL (WARM) (COOL) 15-8 15-9 FOOT HRS 26P AMP MIC 13P + 250 4P HRS NO.GT7A-26PD-DS 26P AMP MIC 13P 12 11 18 17...
  • Page 19 Reference Reference Description Description Number Number Battery A/C Control Panel Battery Relay A/C Unit Fusible Link 15-1 Blower Motor Circuit Breaker 15-2 Resister Fuse Box 15-3 High Speed Relay Headlight Switch 15-4 Mid Speed Relay Condenser Fan Relay 15-5 Low Speed Relay Condenser Fan Motor 15-6 Recirculate / Fresh Air Control...

  • Page 20: Troubleshooting

    TROUBLESHOOTING Refrigerant Pressure Check Figure 13 Open all doors and windows. Install manifold gauge set. Start engine and maintain engine speed at 1,800 - 2,000 rpm. Check high / low-pressure of refrigerant. High-pressure: 8 - 10 kg/cm (114 - 142 psi) Low-pressure: Approximately 1 kg/cm (14 psi) Possible Cause: Low Refrigerant Level...
  • Page 21 High-pressure: Approximately 20 - 25 kg/cm (284 - 356 psi) Low-pressure: Approximately 2.5 - 3.5 kg/cm (36 - 50 psi) Possible Cause: Air in system. Recover any remaining refrigerant. Vacuum out system. Recharge system. If the system has been exposed to the air for a long period of time, replace the receiver dryer. NOTE: High-pressure: Over 6 kg/cm (85 psi)

  • Page 22: Weight Of R134A Gas Used In Machines

    WEIGHT OF R134a GAS USED IN MACHINES Model Weight of Gas DL200 850 ±20 grams (30 ±0.7 oz) DL250 850 ±20 grams (30 ±0.7 oz) DL300 850 ±20 grams (30 ±0.7 oz) DL400 850 ±20 grams (30 ±0.7 oz) DL500 850 ±20 grams (30 ±0.7 oz)

  • Page 23: Refrigerant System Repairs

    REFRIGERANT SYSTEM REPAIRS WARNING! Always wear protective glasses gloves when handling refrigerant. If refrigerant comes in contact with the skin or eyes, immediately flush with clean, running water and consult a physician. Select a clean and well ventilated area to work. The refrigerant container is under high-pressure and should be stored below 40°C (104°F).

  • Page 24: Repair And Replacement Procedure

    Do not over tighten connections when working on refrigerant system. The new refrigerant system standards require new tools, equipment and parts. Do not attempt to use equipment use in servicing the old refrigerant system. The new refrigerant oil (PAG type) has a high moisture absorption characteristic.
  • Page 25 INSTALL REPAIR TOOL RECOVER REFRIGERANT REPAIR / REPLACE DEFECTIVE PARTS VACUUM SYSTEM (OVER 5 MINUTES) CHECK SYSTEM FOR AIR LEAKAGE REPAIR VACUUM SYSTEM (OVER 20 MINUTES) CHARGE SYSTEM (APPROXIMATELY 100 g) CHECK SYSTEM FOR REFRIGERANT LEAKAGE CHARGE SYSTEM TO PROPER LEVEL (Standard Capacity less Initial Charge) CHECK SYSTEM FOR REFRIGERANT LEAKAGE CHECK FOR PROPER REFRIGERANT LEVEL...

  • Page 26: Refrigerant Recovery

    Refrigerant Recovery Reference Description Number To Compressor Low-pressure Side High-pressure Side From Receiver Refrigerant Recovery Tank Attach the manifold gauges and the refrigerant recovery unit to the refrigerant lines as shown. HDA6067L Figure 16 Be careful not to switch the connections for the NOTE: low and high-pressure valves.
  • Page 27 Check system for vacuum leak. Allow system to sit for 10 minutes and check whether the system is holding the pressure. If the pressure has dropped, it must be repaired before proceeding to the next step. Vacuuming Procedure. If the system is holding the pressure and it has not changed for 10 minutes, vacuum out the system for an additional 20 minutes.

  • Page 28: Leakage Check

    Leakage Check Perform leakage check after completing NOTE: vacuuming process. After attaching the manifold gauge, open the high side valve. Charge system until the low side gauge dial indicates a pressure of 1 kg/cm (14 psi) and close the high side valve.
  • Page 29 Reference Description Number To Compressor Low-pressure Side High-pressure Side From Receiver Refrigerant Supply Container Charge the system by opening the manifold gauge low HDA6072L side valve. Figure 21 Initial charge amount: 100 g (3.5 ounces). If refrigerant does not flow freely into system, try starting engine first before operating air conditioner.

  • Page 30: Inspecting System For Leakage

    WARNING! • When outside temperature is low, warm the refrigerant supply container with warm water not exceeding 40°C (104°F). Do not allow water to come in contact with the charging adapter valve handle. • When outside temperature is high, cool off refrigerant supply container and condenser to aid the refrigerant charging process.
  • Page 31 Connection valve area. Inspect all valve areas. Verify all valves are capped to prevent leaking. Check for foreign material inside of valve cap. Interior of air conditioner unit. After stopping engine, insert detector probe into drain hose. (Leave inserted for 10 seconds minimum.) When inspecting leakage...
  • Page 32 Air Conditioner SP001211 Page 30...
  • Page 33 SP001095 ELECTRICAL SYSTEMSP001095 Electrical System Edition 1 Electrical System SP001095 Page 1...
  • Page 34 MEMO Electrical System SP001095 Page 2...
  • Page 35 Table of Contents Electrical System Safety Precautions..........5 Applicable Models..........5 Overview............... 6 Electric Supply System ........7 Engine Starting Circuit ........9 Operation During Start Process ........9 Operation After Start Process ........12 Engine Preheating System ....... 15 Engine Stop System .........
  • Page 36 Self Diagnosis and Display of Cooling Fan ....52 Failure Indications and Actions ........53 Emergency Steering System (Option)....54 Block Diagram .............. 54 Emergency Steering System Components ....55 Emergency Steering System Electric Circuit....58 Electric Detent System........59 Electric Circuit...............

  • Page 37: Safety Precautions

    Remember, that ultimately safety is your own personal responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DL200 5001 and Up Electrical System SP001095 Page 5...

  • Page 38: Overview

    OVERVIEW The electrical system for this equipment is DC 24 volts. The rated voltage for all electric components is 24 volts with the exception of the stereo and the air-conditioning control actuator. The system contains two 12 volt batteries connected in series and a three phase AC generator with a rectifier.

  • Page 39: Electric Supply System

    ELECTRIC SUPPLY SYSTEM The electric power circuit supplies electric current to each electric component. It consists of a battery, battery relay, starter switch, circuit breaker, fusible link and fuse box. The negative terminal of the battery is grounded to the vehicle body.
  • Page 40 STARTER SWITCH CONNECTION PREHEAT 0.5G START I(L) REG. FIELD FG006702 Figure 1 ELECTRICAL POWER CIRCUIT DIAGRAM Reference Reference Description Description Number Number Battery Starter Switch Battery Relay Fuse Box Fusible Link Alternator Circuit Breaker Diode Electrical System SP001095 Page 8...

  • Page 41: Engine Starting Circuit

    ENGINE STARTING CIRCUIT Operation During Start Process When the starter switch is turned to the start position, the safety start relay (14) is opened by the current flow from the connected "52" and "67" terminal of the transmission controller (13) and the "S"...
  • Page 42 I(L) REG. FIELD STARTER SWITCH CONNECTION VEHICLE ENGINE CONN CONN PREHEAT (CONN.2) 1-40 START CYLINDER CONN 1-05 1-06 1-10 1-11 1-02 1-03 1-08 1-09 (CONN.1) (CONN.3) FG006703 Figure 2 STARTER CIRCUIT (1) - WHILE STARTING Electrical System SP001095 Page 10...
  • Page 43 Reference Reference Description Description Number Number Battery Alternator Battery Relay Transmission Selector Switch Fusible Link Diode Circuit Breaker Transmission Controller Starter Switch Safety Starter Relay Fuse Box Engine Control Unit (ECU) Starter Controller Injector Solenoid Starter Relay Engine Sensor Starter Electrical System SP001095 Page 11...

  • Page 44: Operation After Start Process

    Operation After Start Process Once the engine has been started, the belt driven alternator (10) generates a current. The output generated by the alternator is a square wave pulse voltage through the "P" terminal and the frequency of the pulse voltage is proportional to the rotation of the alternator.
  • Page 45 I(L) REG. FIELD STARTER SWITCH CONNECTION VEHICLE ENGINE CONN CONN PREHEAT (CONN.2) 1-40 START CYLINDER CONN 1-05 1-06 1-10 1-11 1-02 1-03 1-08 1-09 (CONN.1) (CONN.3) FG008325 Figure 3 Electrical System SP001095 Page 13...
  • Page 46 Reference Reference Description Description Number Number Battery Alternator Battery Relay Transmission Selector Switch Fusible Link Diode Circuit Breaker Transmission Controller Starter Switch Safety Starter Relay Fuse Box Engine Control Unit (ECU) Starter Controller Injector Solenoid Starter Relay Engine Sensor Starter Electrical System SP001095 Page 14...

  • Page 47: Engine Preheating System

    ENGINE PREHEATING SYSTEM Intaking air heaters are implanted at two places. When the starter switch (5) is turned to the "ON" position, resistence equivalent to engine temperature sensor (11) is sent to engine control unit (8). The engine control unit (8) read the temperature according to the checked resistence.

  • Page 48: Engine Stop System

    ENGINE STOP SYSTEM This system has no engine stop system for special use like an engine stop motor or a fuel shutoff valve and so stops the engine by shutting off fuel when the fuel injector solenoid(9) controlling engine output acts opening and shutting movement according to the position of the starter switch(5).

  • Page 49: Charging System

    CHARGING SYSTEM When the starter switch (5) is turned to the "ON" position, an initial excited current flows to the battery relay(2), to the circuit breaker(4), to the "B" terminal of alternator(7), and to the field coil. When the engine is started from this condition the alternator (7) starts charging.

  • Page 50: Monitoring System

    MONITORING SYSTEM x100r/min km/h FG006500 Figure 7 Reference Reference Description Description Number Number Instrument Panel Turn Signal Light Switch Battery High Beam Switch Alternator Working Light Switch Speed Sensor Brake Oil Pressure Switch Coolant Temperature Sensor Parking Brake Pressure Switch Fuel Sensor Transmission Cutoff Switch Transmission Oil Temperature...

  • Page 51: Instrument Panel

    Instrument Panel x100r/min km/h HOURS < CONNECTOR AND TERMINAL NO.> AMP MIC 13P AMP MIC 17P 13 12 11 16 15 14 12 11 (CN1) (CN2) (CN3) FG006728 Figure 8 Gauges Warning Lights Speed Meter Turn and Hazard Warning Light Turn and Hazard Warning Light Tachometer...

  • Page 52: Monitoring System Schematic

    Function Check When the starter switch is turned to the "ON" position, all displays, switch lights and warning lights except turn and hazard warning light, high beam indicator, working light indicator and emergency steering indicator will be turned "ON" for two seconds and the warning buzzer will sound.
  • Page 53 Reference Reference Description Description Number Number Instrument Panel Air Cleaner Indicator Headlight Switch Engine Control Unit (ECU) Forward Lever Switch Brake Oil Pressure Switch Reverse Lever Switch Parking Brake Pressure Switch High Beam Switch Transmission Controller Left Turn Signal Switch Control Unit Right Turn Signal Switch Pilot Buzzer...

  • Page 54: Operation

    Operation Instruments Sensor Specification Input Function Display Input Specification Terminal 10 km/h- 905 Hz 20 km/h- 1811 Hz 30 km/h- 2716 Hz CN1-4 40 km/h- 3622 Hz Speedometer CN1-5 *ƒ = 90.55 V [Hz] ƒ : Frequency of T/M km/h Controller v : Speed [km/h] 500 rpm - 100 Hz...
  • Page 55 Sensor Specification Input Function Display Input Specification Terminal 50°C - Above 188.2 Ohm 67 C 105 C 67°C - 102 Ohm 50 C 125 C 105°C - 32 Ohm Engine Coolant CN1-6 Temperature Gauge 125°C - Below 19.8 Ohm 120 C 50 C 150 C 50°C - Above 188 Ohm...
  • Page 56 Indicator Lights Input Description Symbol Operation Remarks Terminal Lights up while the air heater is heated. (Terminal input is to CN2 - 1 24V.) Preheating CN1 - 5 Lights up when air cleaner is clogged. (When the terminal input is grounded.) Air Cleaner CN2 - 2 Lights up when the...
  • Page 57 Input Description Symbol Operation Remarks Terminal Lights up when high beam is operated. (Terminal input is to 24V) High Beam CN2 - 7 Lights up when work Light off when the light is operated. engine is started. (Terminal input is to 24 V) Work Light CN2 - 9...
  • Page 58 Input Description Symbol Operation Remarks Terminal Lights up when the F/ This is option parts. R switch is "ON" Forward / CN2 - 11 Reverse Lights up when the This is option parts. vehicle speed is above 5 km/h and the steering pressure is Emergency CN3 - 15...
  • Page 59 Control Unit Operation MIRROR HEATING AIR CLEANER F/R SELECT REVERSE FAN BUZZER CIRCUIT CHARGE BRAKE OIL PRESS PARK BRAKE AMP MIC 13P < CONNECTOR AND TERMINAL NO.> AMP MIC 13P FG008076 Figure 10 Reference Reference Description Description Number Number Instrument Panel Pilot Buzzer Starter Switch Alternator...

  • Page 60: Windshield Wiper

    WINDSHIELD WIPER Front windshield wiper You can control windshield wiper by operating wiper washer switch (2). Low speed wiper action (1st). Wiper acts in low speed through fuse box (1) to the 15,53 terminal of wiper switch (2) to the L,E terminal of wiper motor (5).
  • Page 61 Front Windshield Wiper Circuit + (F) CN5-6 15(53a) CN5-8 CN4-2 CN5-7 CN5-3 CN5-1 CN5-4 OFF ON WIPER WASHER HORN STOP B FG004463 Figure 11 Reference Reference Description Description Number Number Fuse Box 2 Wiper Motor Wiper Washer Switch Washer Tank Wiper Relay Diode Wiper Timer...

  • Page 62: Rear Windshield Wiper

    Rear Windshield wiper You can control rear windshield wiper by pressing wiper washer switch (2) in the switch panel. 1st wiper action (Wiper and washer activate the same time, automatic return). Fuse box (1), to the washer tank (4), to the 5,7 terminal of switch (20) are connected, then activates windshield washers.
  • Page 63 STOP + (R) FG004465 Figure 13 REAR WINDSHIELD WIPER STOP CIRCUIT Reference Reference Description Description Number Number Fuse Box 1 Washer Tank Wiper/washer Switch Diode Wiper Motor Electrical System SP001095 Page 31...

  • Page 64: Lighting System

    LIGHTING SYSTEM Light Circuit (RR) (FR) (RL) (FL) (CR) (CL) WORKING CN2-9 HI BEAM CN2-7 TURN SIGNAL (L) CN2-6 TURN SIGNAL (R) CN2-8 CN1-2 TURN SIGNAL HEAD LAMP CN4-8 CN4-4 CN4-1 CN4-5 CN4-6 CN4-7 CN4-9 15/1 FG004467 Figure 14 LIGHT CIRCUIT Electrical System SP001095 Page 32...
  • Page 65 Reference Reference Description Description Number Number Fuse Box 1 Instrument Panel Blinker Unit Diode Headlight Switch Front Working Light Switch Combination Switch Front Working Light Shift Lever Switch Rear Working Light Switch Hazard Switch Working Light Relay Stop Light Switch Rear Working Light 1 Headlight Relay Rear Working Light 2...
  • Page 66 Also if the combination switch (4) is in the "t " position, the current flows to the "56a" terminal and it allow the high light, which is in the headlight (L) (10) and the headlight (R) (11), to be light turns "ON." At the same time the current flows to the "CN2-7"...
  • Page 67 When the brake pedal is depressed and at the same time the stop light switch (7) is turned "ON," the current flows the from fuse box 1 (1), to the stop light switch (7) and to the "F" terminal of rear combination light (L) (14) and rear combination light (R) (15), and the stop light will be turned "ON."...

  • Page 68: Ecu System

    ECU SYSTEM Km/h e-doctor FG005280 Figure 15 Reference Reference Description Description Number Number ECU (Engine Control Unit) Tacho Meter Electronic Accelerator Pedal Transmission Controller Engine Diagnostic Connector Fuse Box Engine Check Warning Light Electrical System SP001095 Page 36...

  • Page 69: Ecu Electric Circuit

    ECU Electric Circuit ECU CONNECTOR DIAGNOSTIC CONN. 14P ECU CON.3 (16-PIN) ECU CON.2 ( PIN) ECU CON.1 (89-PIN) ENGINE CONN. CYLINDER CONN. VEHICLE CONN. (CN8) ENGINE VEHICLE CONN CONN GAUGE PANEL 2-32 DIAGNOSTIC LAMP (-) 0.5BW 1-30 P& OIL PRESSURE 2-27 DIAGNOSTIC LAMP (+) 1-22...

  • Page 70: Ecu System Component

    ECU System Component Engine Control Unit (ECU) Engine is automatic controled through all sorts of control devices after receiving all sorts of sensor input signals from engine. ECU is attached to engine and operates sensitively to circumferential temperature. ECU detects the abnormal conditions of engine system and give trouble position by self diagnostic code through a diagnostic lamp or an exclusive use diagnostic device.
  • Page 71 Economic Mode Switch This economic mode switch allows the operator to switch between 100% throttle torque and droop curve and about an 80% derated torque curve and droop. In the economy mode, fuel consumption is clearly reduced by utilising a reduced-power characteristic map for the engine.
  • Page 72 Electronic Accelerator ACCELERATOR ASS’Y 0.5R 0.5B POSITION SENSOR 0.5W IDLE 0.5G VALIDATION 0.5L 0.85Or FOOT PEDAL DETAIL "A" "A" Sig 3 Sig 2 PEDAL SENSOR IDLE VALIDATION SW. 100% Diagnostic Region WHITE BLACK BLUE ORANGE GREEN C.W. C.W. 70.63% IDLE ON IDLE OFF 1.3196% Deg.

  • Page 73: Engine Fault Code

    ENGINE FAULT CODE Current Value Blink Blink Failure Measuring Remarks Type Code Component Points Active Passive Coolant 2-15 R=186±5Ω Temperature 2-26 (100°C) Sensor Fuel Temperature 2-26 R=186±5Ω Sensor 2-35 (100°C) Boost Air 2-25 R=186±5Ω Temperature 2-36 (100°C) Sensor V=1,071±58mV It has to be Boost Air Pressure 2-33 (at 23°C and...
  • Page 74 Current Value Blink Blink Failure Measuring Remarks Type Code Component Points Active Passive It is a composite resistance of CAN line.This (1-53, 1-52) 60±5Ω Can Module value has to be (1-35, 1-34) (20°C) measured by connected condition of CAN line. Engine Over speed Main Relay...
  • Page 75 Current Value Blink Blink Failure Measuring Remarks Type Code Component Points Active Passive Solenoid Power 3-01 R=0.31~0.42Ω stage 5 (Cyl.5) 3-16 (20°C) Solenoid Power 3-02 R=0.31~0.42Ω stage 6 (Cyl.6) 3-15 (20°C) Fuel HI Pressure Pump (Current Fuel merering Controlled unit error of Lowside high pressure Powerstage 1)
  • Page 76 Current Value Blink Blink Failure Measuring Remarks Type Code Component Points Active Passive Fuel Pressure R=2.60~3.15Ω Monitoring 3-10 (20°C) MPROP HIGH 1. Active value : Starter switch has to be turned "ON" NOTE: Measuring points between component and wire harness have to be connected. 2.

  • Page 77: Cooling Fan Control System

    COOLING FAN CONTROL SYSTEM Outline It controls the speed of cooling fan according to temperature of coolant or transmission oil. Its reverse rotation function can be used for cleaning. Information on temperature of coolant and transmission oil are sent to the cooling fan controller via communication line (CAN). Electrical System SP001095 Page 45...

  • Page 78: Diagram

    Diagram FG005241 Figure 25 Reference Reference Description Description Number Number Cooling Fan Controller Fan Check Connector Reverse Rotation Lamp Cooling Fan Reverse Switch Transmission Controller (TCU) Cooling Fan Proportional Valve Transmission Oil Temperature Sensor Reverse Rotation Solenoid Coolant Temperature Sensor Fuse Box Electrical System SP001095...

  • Page 79: Electrical Diagram

    Electrical Diagram AMP 040 36P 16 15 12 11 (CN12) (CN11) CN1-1 CN2-13 1-35 J1939 (+) 1-34 J1939 (-) 120 OHM 1-33 1-53 1-52 1-51 CN11 CN12-1 CN12-4 CN12-2 CN11-1 CN11-2 CN11-3 CN12-11 CN12-12 CN11-4 BATTERY (+) CN11-5 BATTERY (-) CN11-6 CN11-7 CN11-13...

  • Page 80: Parts Of Cooling Fan Control System

    Parts of Cooling Fan Control System Cooling Fan Controller It controls the speed of the cooling fan according to temperature of coolant or transmission oil, reversing the rotation of the cooling fan. It is located in the electric box and has a self diagnosis function to check if it operates properly or fails.
  • Page 81 Cooling Fan Reverse Rotation Switch It is used to reverse the radiator cooling fan. Pressing the switch reverses the radiator cooling fan, which helps clean the radiator. To do so, put the Start switch OFF → ON and put this switch OFF (0) →...

  • Page 82: Operation Of Cooling Fan Control System

    Operation of Cooling Fan Control System Communication Monitoring Communication port SAE J1939 datalink CAN H, CAN L, SHIELD Communication failure E0, E1, or E2 is shown on the controller display. If there shows no error message, it means normal operation. Control of Cooling Fan The cooling fan controller controls the speed of the cooling fan according to temperature of transmission oil and...
  • Page 83 When the temperature sensor is opened: Minimum current is 220mA ± 10mA Fail safe function: When communication fails or temperature pressure is abnormal, minimum current is output (while the cooling fan operates at maximum speed). Fan reverse rotation control Fan Reverse Fan Reverse Cooling Fan Order of Input...

  • Page 84: Self Diagnosis And Display Of Cooling Fan

    Self Diagnosis and Display of Cooling Fan Normal Operation Display Operation mode display Categories LED Display System Status Minimumcurrent (cooling fan at high speed) 20 ~ 24% output of duty 25 ~ 34% output of duty 35 ~ 44% output of duty 45 ~ 54% output of duty Forward Prop.

  • Page 85: Failure Indications And Actions

    Failure Indications and Actions Inputs Outputs Detection Criteria Fault Location Fault Status Displays Actions Communication ECU / TCU Min. output of error J1939 communication proportional valve fault current Communication Min. output of error TCU communication proportional valve fault current Communication Min.

  • Page 86: Emergency Steering System (Option)

    EMERGENCY STEERING SYSTEM (OPTION) Block Diagram FG004925 Figure 33 EMERGENCY STEERING SYSTEM BLOCK DIAGRAM Reference Reference Description Description Number Number Fuse Box Emergency Steering Indicator Emergency Steering Switch Transmission Controller Emergency Steering Timer Battery Emergency Steering Pressure Main Steering Pressure Switch Switch Emergency Steering Pump When the speed of the vehicle exceeds 5 km/h and the main...

  • Page 87: Emergency Steering System Components

    Emergency Steering System Components Emergency Steering Timer Obtains signals from the main pressure switch (9) and the transmission controller (7), and play a role in operating the EMG STEERING TIMER emergency steering pump (5). PART NO. 537-00039B VOLT LOT NO. As the frequency signal of the transmission controller is differ from each machine, the reference frequency is 405 Hz which come under about 5 km/h.
  • Page 88 Emergency Steering Timer Circuit (28V) SPEED FG004923 Figure 36 Reference Reference Description Description Number Number Emergency Steering Timer Starter Switch "START" Emergency Steering Indicator Main Steering Pressure Switch Transmission Controller (TCU) Emergency Steering Pressure Switch Emergency Steering Pump Emergency Steering Switch Starter Switch "ON"...
  • Page 89 Operating Character when Emergency Steering Normal Mode Input Condition Output Remark Standard input Emergency Steering Pump Lamp Frequency putting out light Vp=20±5V Duty Cycle 50% will be lit only one time When above will be operated only one time for 60±10 seconds and 405±30 Hz for 60±10 seconds and stop.

  • Page 90: Emergency Steering System Electric Circuit

    Emergency Steering System Electric Circuit When the control signal, which is transmitted from the "36" terminal of the transmission controller, is inputted to the "2" terminal of the emergency steering timer (3) and the emergency steering pressure switch (4) is "OFF," the contact points "A" and "B"...

  • Page 91: Electric Detent System

    ELECTRIC DETENT SYSTEM The electric detent system separated into boom kick-out and return to dig. An each part consists of magnetic locking lever and proximity switch detecting the position of bucket or boom. Electric Circuit FG004461 Figure 40 ELECTRIC DETENT CIRCUIT Reference Reference Description...

  • Page 92: Boom Kick-Out

    Boom Kick-out When the work lever (joystick) is in the "FLOAT" (or "RAISE") position, lever is locked and boom is lowered (or lifted). When the boom is matched to setting position, lever locking is released and lever is returned to "NEUTRAL" position automatically and boom lowering (or lifting) is stopped.

  • Page 93: Return To Dig

    Return To Dig After dumping, if the work lever (joystick) is in the "CROWD" position, the work lever (joystick) will be locked and the bucket will be crowded. When the bucket is matched to setting position, the lever is returned to the "NEUTRAL" position and bucket crowding will be stopped.
  • Page 94 Electrical System SP001095 Page 62...
  • Page 95 SP000925 ELECTRICAL SCHEMATIC DL200/ DL250 SP000925 Electrical Schematic DL200/ DL250 Edition 1 Electrical Schematic DL200/ DL250 SP000925 Page 1...
  • Page 96 MEMO Electrical Schematic DL200/ DL250 SP000925 Page 2...
  • Page 97 Table of Contents Electrical Schematic DL200/ DL250 Safety Precautions..........5 Applicable Models..........5 DL200/ DL250............7 Electrical Schematic DL200/ DL250 SP000925 Page 3...
  • Page 98 MEMO Electrical Schematic DL200/ DL250 SP000925 Page 4...
  • Page 99 Remember, that ultimately safety is your own personal responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DL200 5001 and Up DL250 5001 and Up Electrical Schematic DL200/ DL250 SP000925 Page 5...
  • Page 100 Electrical Schematic DL200/ DL250 SP000925 Page 6...
  • Page 101 0.85WL AIR HEATER RELAY (+) 0.85WL 0.85W 0.85WL 0.85WL ACTUATOR (EPW) HRS 26P 154B 1-07 0.85BG AIR HEATER RELAY (-) 0.85BG 0.85BG 0.85BG 0.85BG 0.85LgB 0.85LgB 0.85V (CONN.3) (CONN.1) 0.85LY 0.85LY 0.85LY FG006730 Figure 1 Electrical Schematic DL200/ DL250 SP000925...

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