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1. K1024538E Shop Manual
Copyright 2006 Doosan
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.
Shop Manual
K1024538E
Serial Number 5001 and Up
DL200
DL200TC

2. Table of Contents
Page I
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

3. Table of Contents
Page II
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

4. SP001085Steering
Page 8
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

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

6. SP001085Steering
Page 10
Parts List
Specifications
Figure 5
Reference
Number
Description
1 Plug
2 O-ring
3 Spool
4 Housing
5 Spring
6 Plug
7 Orifice
Reference
Number
Description
Priority Valve Specification
Model Danfoss OLS 120
Control Pressure 7 kg/cm2 (100 psi)
Rated Flow 120 lpm (32 gpm)

7. SP001085
Page 11
Steering
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
DISASSEMBLY
1. Use open end wrench to loosen PP plug. See Figure
7. Remove O-ring.
2. Use open end wrench to loosen LS plug. See Figure
8. Remove O-ring.
Figure 6
Figure 7
Figure 8

8. SP001085Steering
Page 12
3. Remove spring. See Figure 9.
4. Use a nylon rod to push spool out of bore. See Figure
10.
5. Use an 8 mm allen wrench to remove plug from
pressure relief valve. See Figure 11
6. Use a 10 mm allen wrench to unscrew pressure relief
valve from its bore. See Figure 12.
Figure 9
Figure 10
Figure 11
Figure 12

9. SP001085
Page 13
Steering
7. Hold pressure relief valve with a pliers and use a 5
mm allen wrench to remove set screw. See Figure 13.
8. The pressure relief valve is composed of a valve housing,
valve needle, spring and set screw. See 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.
Figure 13
Figure 14

10. SP001085Steering
Page 14
REASSEMBLY
NOTE: The relief valve pressure can be changed by
changing springs. The following table displays the
characteristics of the three springs available. See
Figure 15.
1. Figure 16, shows PP plug and spool.
Figure 15
Pressure
in Bars
Wire
Diameter
(A)
Coil
Diameter
(B)
Spring
Height
(C)
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 16

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

12. SP001085Steering
Page 16
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.
7. Install plug into pressure relief valve bore. Tighten plug
to 5 kg•m (36 ft lb). See Figure 22.
Figure 21
Figure 22

13. SP001085
Page 17
Steering
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
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.
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).
Figure 23
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

14. SP001085Steering
Page 18
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.
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.
Figure 24
Reference
Number
Description
1 Sleeve
2 Spool
3 Centering Spring
4 Spool
5 Sleeve
6 Center Pin
7 Drive shaft

15. SP001085
Page 19
Steering
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.

16. SP001085Steering
Page 20
Parts List
An exploded view of the steering unit is shown in Figure 25.
Figure 25
1 Seal Ring
2 Housing
3 Spool
4 Sleeve
5 Ball
6 Threaded Bushing
7 O-ring
8 Backing Ring (If equipped)
9 Thrust Washers
10 Thrust Bearing
11 Spacer Ring
12 Cross Pin
13 Neutral Springs
14 Shaft
15 Spacer - 13.8 mm (If equipped)
16 Spacer - 25 mm (If equipped)
17 Spacer Bushing (If equipped)
18 O-ring 80.5 x 1.5 mm
19 Middle Plate
20 Distributor Plate
21 Rotor
22 O-ring - 79.92 x 1.78 mm
23 Cylinder Gear
24 End Cover
25 Washer
26 Roll Pin 2.5 x 32 mm
27 Bolt
1 Seal Ring

17. SP001085
Page 21
Steering
Specifications
SPECIAL TOOLS
The tools necessary for steering unit repair are illustrated
below.
1. Stabilizing base. See Figure 26.
2. O-ring assembly tool. See Figure 27.
Steering Unit
Specification
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)
Figure 26
Figure 27

18. SP001085Steering
Page 22
3. Seal driver. See 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 28
Figure 29

19. SP001085Steering
Page 24
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.
3. Remove end cover from unit. See Figure 31.
4. Lift cylinder gear off unit. See Figure 32. Remove two
O-rings.
Figure 30
Figure 31
Figure 32

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

22. SP001085Steering
Page 26
9. Lift middle plate off housing. See Figure 37.
10. Remove O-ring from housing. See Figure 38.
11. Unscrew threaded bushing and remove it. See Figure
39.
12. Remove cross pin. See Figure 40.
Figure 37
Figure 38
Figure 39
Figure 40