TENDLLOD0011

System spec.
of DL Loader
All model
Jan., 24th,2007
Overseas P/S Team
Docu No : DLT 05 08 - Rev03

Machine system spec. & data
System pressure (DL200)
DL200 system pressure data.
Front relief 220 ± 5 kg/cm2
Steering relief ( LS, Pump) 190~195 kg/cm2 ,220 ± 5 kg/cm2
Pilot 30 ± 2 kg/cm2
Break accumulator charging 120~140 kg/cm2
Service brake 60 ± 3 kg/cm2
Fan motor (Opt :Tropical) 140 ± 5 kg/cm2 , 160kg/cm2
Parking brake 120 ± 5 kg/cm2
T/M Selection 17 ± 1 kg/cm2
1
2
3
4
5
4. Electric system
6
5. Electric system
Power supply system ?
??
7
5. Electric system
Start engine
¾ Key on position.
8
5. Electric system
Start engine
¾ Engine ignition.
9
5. Electric system
Start engine
¾ Starter controller.
① Direction signal
from safety relay (24 Volt)
② ALT signal
(Over than 500 rpm)
“S” is not connected with “E” when ① or ②
10
5. Electric system
Start engine
¾ Preheat.
11
5. Electric system
Start engine
¾ Preheating time.
DL200 / DL250 / DL300
Key position Coolant Temp’(℃) Heating time (sec) Remarks
Below 0 20
On Complete heating
5 10
(= preheating) Heating light is “on”
Above10 Not working
DL400
Key position Coolant Temp’(℃) Heating time (sec) Remarks
Below -12 30
On Complete heating
0 10
(= preheating) Heating light is “on”
Above19 Not working
12
5. Electric system
Start engine
¾ After heat.
13
5. Electric system
Start engine
¾ After heating time.

DL200 / DL250 / DL300
Coolant Temp’(℃) Heating time (sec)
Below 0 120
5 60
Above10 Not working
DL400
Coolant Temp’(℃) Heating time (sec)
Below -19 30
-19 ~ -8 20
-8 ~ 8 10
Above 8 Not working
14
5. Electric system
Control unit
Key S/W
Safety relay
Brake pressure S/W

Parking brake S/W
Alternator
Condition Operation
All lamp “On” with buzzer
Key S/W “On” (#1)
After 2 sec, All lamp and buzzer “Off”
Alternator charging voltage (Below 14.5 V) #2 Charging lamp “On”
Brake press S/W “Closed” (#6)
Alternator charging
Parking brake S/W “Closed” (#7) Buzzer
voltage (Above 14.5 V)
Safety relay “Closed” (#8)
15
5. Electric system
Proximity switch (Joystick lever detent function)
¾ Proximity switch.
(- Terminal)
( O output)
(+ Terminal)
Normal condition Approached condition
(O) and ( - ) Terminal : Opened (O) and ( - ) Terminal : Closed
16
5. Electric system
¾ Detent / release lever ( I )
← From Battery
Not approached
Not working Energize magnet
(Release lever) (Detent lever)
17
5. Electric system
¾ Detent / release lever ( II )
← From Battery
Approach lever Energize magnet Not working

(Detent lever) (Release lever)
18
5. Electric system
Air – conditioner
¾ Air-conditioner.
1.Battery. 2.Battery relay.

3.Fusible link. 4.Circuit breaker.
5.Fuse. 6.Lamp S/W.
7.Condenser fan relay.
8.Condenser motor.
9.Compressor relay.
10. Foot / defrost actuator.
11. Receiver drier. 12. Diode.
13. Compressor. 14. A/C controller.
15. A/C unit. 15-1. Blower motor.
15-2. Resister. 15-3. High speed relay.
15-4. Mid speed relay.
15-5. Low speed relay.
15-6. Recir / Fresh actuator.
15-7. Vent actuator.
15-8. Temp control actuator.
15-9. Temp sensor.
19
5. Electric system
Air – conditioner
15-2 Resister 15-8 Temp. control actuator

¾ Blower unit.
Fan speed relays

15-7 Vent actuator
15-9 Temp. sensor
15-6 Recirculation / Fresh actuator

20
5. Electric system
Air – conditioner
¾ A/C controller system.
21
5. Electric system
Air – conditioner
¾ Blower motor.
3.86Ω
1.28Ω
Low. speed
Θ
Θ Mid. speed
Θ
High speed
22
5. Electric system
Air – conditioner
¾ Recirculation / ventilation.
Θ
Θ Recirculation / Fresh air actuator
Θ
Θ Ventilation air actuator
23
5. Electric system
Air – conditioner
¾ Temp. control actuator.
12 Volt
24
5. Electric system
Air – condition system
¾ Condenser / air- compressor
25
5. Electric system
Air – condition system
¾ Foot / Defroster
24 Volt
26
5. Electric system
Cooling system
¾ Fan speed control system.
Reverse fan
S/W
T/M oil Temp.

Reverse fan sensor
warning lamp
Coolant Temp.
sensor
50mA ↔ 580mA
27
5. Electric system
Cooling system
¾ Operation controller.
Sensor Target temp. Fan speed Current of Proportional valve
Coolant Temp. 85℃ ~ 95℃ Low PRM : 580 mA (40 bar)

↕
400 ~ 1,200 RPM
Mission oil Temp. 95℃ ~ 103℃ Max PRM : 50 mA (140 bar)
(DL300 :120 mA)
Reverse fan
Low PRM : 580 mA ( 40 bar)
↓
Reverse S/W “on” Reverse Max RPM
Max PRM : 50 mA(140 bar)
(DL300 : 120 mA)
Before reversing fan,
Engine must be stop, key switch “on” condition and press reverse fan S/W.
Start engine, cooling fan will be reversing to max fan RPM for 5 Min.
28
5. Electric system
Cooling system
¾ Operation curve.
Coolant Temp.
T/M oil Temp.
Max. fan RPM

580mA
Reverse
“0” fan RPM

50m
A
Reverse fan
29
5. Electric system
Transmission
¾ Schematic of transmission system.
30
5. Electric system
Transmission
¾ Neutral position.
When measure currency,

#13 with # 10,56,32,55,9 and 51 are 100 mA
XXXXXX
31
5. Electric system
Transmission
¾ Traveling condition - Forward 1st
Engaged KV, K1 Clutch
z Y3, Y5 : 500 mA
#13 and#32,#13 and #9 : 9.5V
z Y1, Y2, Y4, Y6 : 100 mA
#13 and other : 1.9V
32
5. Electric system
Transmission
¾ Traveling condition - Reverse 1st
Engaged KR, K1 Clutch
z Y1, Y3 : 500 mA
#13 and#10,#13 and #32 : 9.5V
z Y2, Y4, Y5, Y6 : 100 mA
#13 and other : 1.9V
33
5. Electric system
Transmission
¾ Traveling condition (Traveling by F&R switch)
F&R select signal light on

(from gauge panel)
Condition of traveling by F&R switch

- DW-3 T/M selector SW : Neutral position and selected machine speed (1st,2nd,3rd or 4th)
Then, traveling machine by F&R switch without DW-3 T/M operation( F or R selection).
34
5. Electric system
Transmission
¾ Kick down - Manual mode : 2nd → 1st
When selected manual traveling mode and pressed kick down switch, the traveling gear is
shifted down ( 2nd speed gear → 1st speed gear).
And pressed kick down switch again, the traveling gear is shifted up ( 1st speed gear → 2nd
speed gear). It works for 1st and 2nd speed only ( not 3rd, 4th speed)
35
5. Electric system
Transmission
¾ Kick down - Auto mode.
Press down shift button , 4th → 3rd → 2nd → 1st or 1st

→ 2nd → 3rd → 4th
In order to change 4th → 3rd, engine speed must be
drop from normal engine RPM (RPM gap 200 ~ 300)
36
5. Electric system
Transmission
¾ Transmission cut – off function.
T/M Power cut off function is working

only forward & reverse 1st, 2nd speed
(Not 3rd,4th Speed)
X
X
T/M Cut off switch “On”
with press brake pedal
T/M controller cut forward or reverse

clutch power off.
37
5. Electric system
Transmission
¾ Automatic traveling (1-4)
~
~
~ Normal shifting range is 2nd ↔ 3rd ↔ 4th

~ If machine is on hard working condition
~ or traveling load, gear is shifted to
1st ↔ 2nd ↔ 3rd ↔ 4th automatically
Gear shifting is depended on traveling
load.
38
5. Electric system
Transmission
¾ Automatic traveling (2-4)
~
~
Normal shifting range is 2nd ↔ 3rd ↔ 4th.

~
~ If operator presses kick down switch ,
under 2nd , the gear will be shifted down
~ to 1st ↔ 2nd ↔ 3rd ↔ 4th.
39
5. Electric system
Transmission
¾ Control block.
Input current (mA) Resistance Voltage (VDC)

Regulator Output Press (bar)
Neutral Engaged (Ω) Neutral Engaged
Y1~Y6 100 500 19 1.9 9.5 0.8 ~ 8.3
Condition of Pressure Regulator Operation

1) Parking brake released 2) Transmission Oil Temperature : over – 10 degree C
40
5. Electric system
Transmission
¾ Temperature sensor in control block.
Condition Function Remark
Open or Short Circuit - Error code display only Resistance : 1000 ~ 1500 Ω
- Travels normally Sensing Temp. for AEB
No Buzzer
↓ -30 degree C (T/M oil) - Parking brake engaged
-30 ~ -10 degree C (T/M oil) - 1st, 2nd speed only
↑ -10 degree C (T/M oil) - Travels normally
41
5. Electric system
Transmission
¾ By pass fiter switch.
DL400, DL500
Normal condition Closed filter condition

Closed filter
By pass filter switch Normal Resistance (Ω) Resistance (Ω)
(= by pass oil)
Open
Closed 500 0
(Error code : BA)
42
5. Electric system
Transmission
¾ Location of transmitter.
Central
Engine Turbine Inductive
gear
transmitter
Engine
inductive
transmitter
Filter switch
Turbine
Out put Central gear Out put
speed sensor speed sensor
43
5. Electric system
Transmission
¾ Transmitter specification .
Specification
Sensor Remark
Frequency Resistance(Ω) Gap (mm)
Engine - Output torque Control signal
& 0.5~0.8 - Signal for AEB
Turbine 1050 ± 10% - Keep the original gap by shim
30Hz~50kHz
(20℃) (DL400)
Central 0.3 ~ 0.4 - No need gap adjustment(DL300)
- For high speed sensing
Output Propeller shaft speed
- Travel Speed display signal
- LIS system (over 6 km)
Speed 2Hz~5KHz - 1.0~1.3 - Keep the original gap by shim
(DL400)
- No need gap adjustment(DL300)
- For high & low speed sensing
44
5. Electric system
Transmission
¾ Working for each sensor.
1. Engine & turbine sensor :

Compare engine RPM & turbine RPM to get
working condition or engine load. Engine
2. Turbine & central sensor :

Compare turbine RPM & central gear RPM
to get clutch slipping condition or clutch Turbine
slipping time
Output
Central
45
5. Electric system
Transmission
¾ LIS system.
~
~
~
Machine speed
0 I II
Forward - Over 6 km/h : on, Below 4 km/h : off

LIS Sol valve off on
Reverse - Over 4 km/h : on, Below 2 km/h : off
46
5. Electric system
Transmission
¾ Emergency steering system.

From fuse box
From starter line
To warning
lamp
Condition
Emergency steering press Operation
Machine speed
S/W
Closed 0 km/h EMR motor is not working
Below 4 km/h EMR motor is not working
Open
EMR motor is working
(Brake press. drop) Over 5 km/h
for 60 sec with 1 time.
47
5. Electric system
Transmission
¾ AEB starter.
The AEB has the task to compensate tolerances

(plate clearance and pressure level)
which are influencing the filling procedure of the
clutches.
For each clutch,

the correct filling parameters are determined in one test
cycle for period of the quick-flling time
level of the filling compensating pressure
48
5. Electric system
Transmission
¾ AEB procedure.
Step Order Display Remarks
1 Warm up transmission about 10 to 20 minutes
2 Turn off ignition key
Plug in AEB starter to AEB connector located at

3
the seat base closest to the cab door
4 Put T/M gear selector lever to Neutral position
5 Engage park brake
TCU must recognize “PL” for at least 3 sec before

6 Start Engine “PL“
you press AEB starter button
7 On idling RPM “PL“
The button must not be released before TCU has

8 Press button of the AEB Starter “ST” started the AEB or quit with an error code
(see Error code list)
“K1” TCU has started the AEB, and goes on adjusting

9 Hold button until AEB has been started (Information about the AEB K1, K2,…, KR.
state) (Button may be released from starting)
“OK”
10 Wait until AEB has been finished
(AEB has been successful)
11 Turn off ignition and unplug AEB Starter
49
5. Electric system
Transmission
¾ AEB messages.
Symbol Meaning Remarks
PL AEB - Starter is plugged at the diagnostic plug
ST AEB Starter button is pressed
K1..K4,KV,KR Calibrating each clutch K1..K4,KV,KR
_ and Kx Wait for start, initialization of clutch Kx, x : 1, 2, 3, 4, V, R
fast fill time determination of clutch Kx compensating pressure determination of clutch
≡ and Kx Kx
calibration for all clutches finished Transmissions stays in neutral, have to
OK restart the TCU (ignition off/on) after
removing AEB-Starter
STOP AEB canceled (activation stopped) Transmissions stays in neutral, have to
restart the TCU (ignition off/on)
STOP and Kx AEB stopped, clutch Kx can't be Transmissions stays in neutral, have to
calibrated restart the TCU (ignition off/on)
Spanner and Kx couldn't be calibrated, AEB finished Transmissions stays in neutral, have to
Kx restart the TCU (ignition off/on)
↑E Engine speed too low E/G RPM should be raised
50
5. Electric system
Transmission
¾ AEB messages.
Symbol Meaning Remarks
↓E Engine speed too high E/G RPM should be down
↑T Transmission oil temperature too low Warm up Transmission
↓T Transmission oil temperature too high Cool down Transmission
FT T/M temp not in defined range during calibration T/M stays in neutral, have to restart the TCU
(key off/on)
FB Operating mode not NORMAL or T/M temp T/M stays in neutral, have to restart the TCU
sensor defective or storing of Calibrated values (key off/on)
to EEPROM-has failed
FO Output speed not zero Transmissions stays in neutral, have to
FN Shift lever not in Neutral position Transmissions stays in neutral, have to
FP Parking brake not applied Transmissions stays in neutral, have to
STOP AEB - Starter was used incorrect or is defective Transmissions stays in neutral, have to
51

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System spec.

Docu No : DLT 05 08 - Rev03

System pressure (DL200)

DL200 system pressure data.

Front relief 220 ± 5 kg/cm2

Steering relief ( LS, Pump) 190~195 kg/cm2 ,220 ± 5 kg/cm2

Break accumulator charging 120~140 kg/cm2

Service brake 60 ± 3 kg/cm2

Fan motor (Opt :Tropical) 140 ± 5 kg/cm2 , 160kg/cm2

Parking brake 120 ± 5 kg/cm2

T/M Selection 17 ± 1 kg/cm2

System pressure (DL250)

DL250 system pressure data.

Front relief 220 ± 5 kg/cm2

Steering relief ( LS, Pump) 190~195 kg/cm2 ,220 ± 5 kg/cm2

Break accumulator charging 120~140 kg/cm2

Service brake 60 ± 3 kg/cm2

Fan motor (Opt :Tropical) 140 ± 5 kg/cm2 , 160kg/cm2

Parking brake 120 ± 5 kg/cm2

T/M Selection 17 ± 1 kg/cm2

System pressure (DL300)

DL300 system pressure data.

Front relief 220 ± 5 kg/cm2

Steering relief ( LS, Pump) 190~195 kg/cm2 ,220 ± 5 kg/cm2

Break accumulator charging 120~140 kg/cm2

Service brake 60 ± 3 kg/cm2

Fan motor (Opt :Tropical) 140 ± 5 kg/cm2 , 160kg/cm2

Parking brake 120 ± 5 kg/cm2

T/M Selection 17 ± 1 kg/cm2

System pressure (DL400)

DL400 system pressure data.

Front relief 220 ± 5 kg/cm2

Steering relief ( LS, Pump) 190~195 kg/cm2 ,220 ± 5 kg/cm2

Break accumulator charging 120~140 kg/cm2

Service brake 60 ± 3 kg/cm2

Fan motor (Opt :Tropical) 140 ± 5 kg/cm2 , 160kg/cm2

Parking brake 120 ± 5 kg/cm2

T/M Selection 17 ± 1 kg/cm2

System pressure (DL500)

DL500 system pressure data.

Front relief 220 ± 5 kg/cm2

Steering relief ( LS, Pump) 190~195 kg/cm2 ,220 ± 5 kg/cm2

Break accumulator charging 120~140 kg/cm2

Service brake 60 ± 3 kg/cm2

Fan motor (Opt :Tropical) 140 ± 5 kg/cm2 , 160kg/cm2

Parking brake 120 ± 5 kg/cm2

T/M Selection 17 ± 1 kg/cm2

 Power supply system ?

“S” is not connected with “E” when ① or ②

DL200 / DL250 / DL300

Key position Coolant Temp’(℃) Heating time (sec) Remarks

Key position Coolant Temp’(℃) Heating time (sec) Remarks

¾ After heating time.

Coolant Temp’(℃) Heating time (sec)

Coolant Temp’(℃) Heating time (sec)

Brake pressure S/W

 Proximity switch (Joystick lever detent function)

Normal condition Approached condition

(O) and ( - ) Terminal : Opened (O) and ( - ) Terminal : Closed

 Proximity switch (Joystick lever detent function)

¾ Detent / release lever ( I )

(Release lever) (Detent lever)

 Proximity switch (Joystick lever detent function)

Power supply system ?

Proximity switch (Joystick lever detent function)

Proximity switch (Joystick lever detent function)

Proximity switch (Joystick lever detent function)

Air – condition system

Air – condition system