DOOSAN DL200-3 WHEELED LOADER Service Repair Manual PDF [PDF]

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Fig. 001 CYLINDER BLOCK

DL200-3

Fig. 001 CYLINDER BLOCK Key No 1

Part No

Description

Qty S.C

150102-00004A

CYLINDER BLOCK ASS'Y

1

1A

-

CYLINDER BLOCK

1

D

1B

-

THRUST BEARING CAP ASS'Y

1

D

1BA

-

BEARING CAP;THRUST

1

D

1BB

65.91710-0001

RING;STOPPER

2

1C

-

BEARING CAP ASS'Y

6

D

1CA

-

BEARING CAP

1

D

1CB

65.91710-0001

RING;STOPPER

2

1D

65.90020-0066A

BOLT;BRG CAP

14

1E

65.04410-0021A

BUSH;CAMSHAFT

6

B

1F

65.04410-0022

BUSH;CAMSHAFT

1

B

1G

65.90302-0009

PLUG;CORE

2

1H

65.90302-0042

PLUG;CORE

8

1I

65.90302-0034

PLUG;CORE

5

1J

65.91606-0041

PLUG;CORE

2

1K

06.31641-0618

BALL;STEEL

1

20

65.90320-0022

PLUG SCREW PT1/8

1

21

65.91001-0013A

PIN;CORE

6

30

410127-00088

RELIEF VALVE ASS'Y

1

30A

06.56021-0102

O-RING

1

30B

-

RELIEF VALVE

1

33

06.22022-1063

PIN

2

34

65.91605-0002

COVER;CORE HOLE

1

35

65.90310-0134

SCREW;PLUG

2

36

06.56190-0732

SEAL;RING

2

40

65.01201-0075A

CYLINDER LINER-GRADE

6

41

65.01201-0076

LINER;CYLINDER-1A

6

42

65.01201-0077

LINER;CYLINDER-1B

6

43

65.01201-0078

LINER;CYLINDER-2A

6

44

65.01201-0079

LINER;CYLINDER-2B

6

DL200-3

1

D

D

Serial No

ICA

Replacable

Qty

Fig. 002 TIMING GEAR CASE

DL200-3

Fig. 002 TIMING GEAR CASE Key No

Part No

Description

Qty S.C

2

130405-00027A

CASE;TIMING GEAR

1

3

65.91710-0016

RING;STOPPER

2

4

65.01903-0034

GASKET

1

5

65.90020-0063B

BOLT;HEX M10X25

3

6

65.90020-0080

BOLT;COLLARED HEX.

1

7

65.98130-0241

ADAPTER

1

8

410127-00040

RELIEF VALVE ASS'Y

1

8A

65.96501-0074

O-RING

1

10

65.91601-0011

COVER

1

11

65.38901-0018A

GASKET;PTO

1

12

06.01943-3318

BOLT ASS'Y M12X1.5X35

2

DL200-3

1

Serial No

ICA

Replacable

Qty

Fig. 003 FLYWHEEL HOUSING

DL200-3

Fig. 003 FLYWHEEL HOUSING Key No 1

Part No

Description

Qty S.C

150114-00098A

FLYWHEEL HOUSING ASS'Y

1

1A

150114-00142

HOUSING,FLYWHEEL

1

1B

65.01414-0004A

COVER

1

1C

06.01923-3111

BOLT, M8X16

2

1D

65.96401-0014

CAP;RUBBER

1

5

65.01510-0040

SEAL;OIL

1

6

400613-00006

GASKET;F.W.H

1

7

65.90020-0100

BOLT, 103mm

9

8

65.90020-0101

BOLT, 57mm

4

9

65.90020-0105

BOLT, 67mm

4

10

65.91710-0009

RING;STOPPER

2

DL200-3

1

Serial No

ICA

Replacable

Qty

Fig. 004 OIL SEAL

DL200-3

Fig. 004 OIL SEAL Key No

Part No

Description

Qty S.C

1

65.01501-5003A

COVER;SEALING

1

2

65.01510-0157

SEAL;OIL

1

3

65.01905-0009

GASKET

1

4

06.01923-3116

BOLT ASS'Y M8X28

8

DL200-3

1

Serial No

ICA

Replacable

Qty

Fig. 005 OIL SPRAY NOZZLE

DL200-3

Fig. 005 OIL SPRAY NOZZLE Key No

Part No

Description

Qty S.C

1

65.01601-5020

OIL SPRAY NOZZLE ASS'Y

6

2

65.05401-5031

RELIEF VALVE ASS'Y

6

DL200-3

1

Serial No

ICA

Replacable

Qty

Fig. 006 BREATHER SYSTEM

DL200-3

Fig. 006 BREATHER SYSTEM Key No

Part No

Description

Qty S.C

1

110436-00094

BRACKET,BREATHER PIPE

1

2

06.01923-3114

BOLT ASS'Y M8X22

4

3

110972-00036

HOUSING;BREATHER

1

4

06.01923-3114

BOLT ASS'Y M8X22

4

5

420101-00503

HOSE,AIR

1

6

65.97402-0042

CLIP;HOSE

1

7

65.97402-0043

CLIP;HOSE

1

8

65.96301-0551

HOSE;RUBBER

1

9

65.97402-0025

CLAMP;HOSE

2

10

420215-00024

PIPE,OIL DRAIN

1

11

06.01923-3212

BOLT ASS'Y

2

12

65.96301-0422A

HOSE;RUBBER

1

13

65.97402-0025

CLAMP;HOSE

2

14

410104-00025

CHECK VALVE ASS'Y

1

15

65.96301-0535

HOSE;RUBBER

1

16

65.97402-0015

CLIP;HOSE

2

17

420215-00010

PIPE;OIL DRAIN

1

18

65.98150-0071

SCREW;HOLLOW

1

19

65.96507-0043

RING;SEAL A14X20

2

20

65.90201-0122

BOLT;STUD

1

21

65.97401-5019

CLIP;PIPE

1

22

06.16731-2107

WASHER

1

23

06.11063-8214

NUT

1

24

65.96301-0441

HOSE;RUBBER

1

25

06.67020-0105

CLAMP;HOSE

1

26

110972-00005

HOUSING;BREATHER

1

27

401002-00082

O-RING

1

28

06.01923-3113

BOLT ASS'Y M8X20

3

29

430201-00103

ADAPTER;OIL DRAIN BREATHER

1

30

06.56190-0719

RING;SEAL

1

DL200-3

1

Serial No

120822~

ICA

Replacable

Qty

Fig. 007 CRANKSHAFT

DL200-3

Fig. 007 CRANKSHAFT Key No

Part No

Description

Qty S.C

1

65.02101-0069A

CRANK SHAFT

1

2

06.22022-1018

PIN;DOWEL

1

3

65.02115-0016

GEAR;CRANKSHAFT

1

4

65.01110-6140A

METAL;MAIN

7

5

65.01150-6008

WASHER;THRUST

2

DL200-3

1

Serial No

ICA

Replacable

Qty

Fig. 008 VIBRATION DAMPER

DL200-3

Fig. 008 VIBRATION DAMPER Key No

Part No

Description

Qty S.C

1

65.02201-0002

DAMPER;VIBRATION

1

2

65.90020-0062B

BOLT;HEX M10X20

6

DL200-3

1

Serial No

ICA

Replacable

Qty

Fig. 009 FLYWHEEL

DL200-3

Fig. 009 FLYWHEEL Key No 1

Part No

Description

Qty S.C

150111-00049

FLYWHEEL SUB ASSY

1

-

FLYWHEEL ASS'Y

1

1AA

65.02301-0294

FLYWHEEL

1

1AB

65.02310-0006

GEAR;RING

1

1B

65.02130-0004

BUSH;DRIVING

1

65.90020-0140A

BOLT;COLLARED HEX.

8

1A

6

DL200-3

1

D

Serial No

ICA

Replacable

Qty

Fig. 010 CONNECTING ROD

DL200-3

Fig. 010 CONNECTING ROD Key No

Part No

Description

Qty S.C

1

65.02401-6035

CONNECTING ROD ASS'Y

6

1A

65.02411-0009

BOLT;CONNECTING ROD

2

6

65.02410-0040

METAL;CON-ROD(STD)

6

7

65.02410-0041

METAL;CON-ROD(0.25)

6

US

8

65.02410-0042

METAL;CON-ROD(0.50)

6

US

11

65.02410-0050

METAL;CON-ROD(STD)

6

12

65.02410-0051

METAL;CON-ROD(0.25)

6

US

13

65.02410-0052

METAL;CON-ROD(0.50)

6

US

DL200-3

1

Serial No

ICA

Replacable

Qty

Fig. 011 PISTON

DL200-3

Fig. 011 PISTON Key No

Part No

Description

Qty S.C

1

130602-00239

PISTON

6

2

401004-00097

PISTON RING KIT

1

2A

-

RING;TOP

6

K

2B

-

RING;SECOND

6

K

2C

-

RING;PISTON

6

K

5

65.02502-0017A

PIN;PISTON

6

8

06.29020-0125

RING;LOCK

12

DL200-3

1

Serial No

ICA

Replacable

Qty

Fig. 012 CRANK SHAFT PULLEY

DL200-3

Fig. 012 CRANK SHAFT PULLEY Key No

Part No

Description

Qty S.C

1

130711-00001A

PULLEY;CRANKSHAFT

1

2

65.90701-0099

WASHER

1

3

06.02106-0723

BOLT;SOCKET

8

DL200-3

1

Serial No

ICA

Replacable

Qty

Fig. 013 CYLINDER HEAD

DL200-3

Fig. 013 CYLINDER HEAD Key No 1

Part No

Description

Qty S.C

150113-00009

CYLINDER HEAD ASS'Y

1

1A

-

HEAD;CYLINDER

1

D

1B

65.03203-1062

SEAT;VALVE IN.

12

B

1C

65.03203-1063

SEAT;VALVE EX.

12

B

1D

65.03201-1016B

GUIDE;VALVE

24

B

1E

65.90302-0048

CORE;PLUG

10

1F

65.90302-0029

PLUG;CORE

21

1G

65.03205-0006B

BUSH;INJ. NOZZLE

6

1H

65.96501-0088

O-RING

12

10

65.91030-0005

PIN

2

11

65.90021-0009

BOLT;HEAD

26

12

65.90201-0134

BOLT;STUD

24

13

65.03901-0071

GASKET;CYLINDER HEAD

1

DL200-3

1

Serial No

ICA

Replacable

Qty

Fig. 014 CYLINDER HEAD COVER

DL200-3

Fig. 014 CYLINDER HEAD COVER Key No

Part No

Description

Qty S.C

1

150106-00064

CYL. HEAD COVER ASS'Y

1

2

65.90020-0109

BOLT;COLLARED HEX.

14

3

65.03905-0037A

GASKET;HEAD COVER

1

4

65.03905-5002

PACKING;HEAD COVER

14

5

65.03402-0009

COVER;INTERMEDIATE

1

6

400603-00050

GASKET;INTERMEDIATE

1

7

65.90020-0138

BOLT;COLLARED HEX.

16

8

65.01810-5011

CAP;OIL FILLER

1

DL200-3

1

Serial No

ICA

Replacable

Qty

Fig. 015 VALVE

DL200-3

Fig. 015 VALVE Key No

Part No

Description

Qty S.C

1

65.04101-0065B

VALVE;INTAKE

12

2

65.04101-0066B

VALVE;EXHAUST

12

3

65.04102-0024

SPRING;VALVE

24

6

65.04103-0018

PLATE;VALVE SPRING

24

7

65.04104-0009

COTTER;VALVE

48

8

65.90701-0098

WASHER

24

9

65.04902-0016

SEAL;VALVE STEM

24

10

65.04130-0009A

CALIPER;INTAKE

6

11

65.04130-0011

CALIPER;EXHAUST

6

DL200-3

1

Serial No

ICA

Replacable

Qty

Fig. 016 ROCKER ARM

DL200-3

Fig. 016 ROCKER ARM Key No

Part No

Description

Qty S.C

-

65.04200-6038D

R/A ARM SHAFT ASS'Y

2

2

65.04201-5042C

ROCKER ARM;INTAKE

3

3

65.04201-5043C

ROCKER ARM;EXHAUST

3

4

65.04203-5020A

SHAFT;ROCKER ARM

1

5

65.04202-0033

BRACKET;ROCKER ARM

1

6

65.04202-0034

BRACKET;ROCKER ARM

1

7

65.04202-0035

BRACKET;ROCKER ARM

2

8

65.97601-0124

SPRING;COMPESSION

3

9

65.90701-0136B

WASHER

6

10

06.29010-0120

RING;SNAP

2

11

65.90030-0018

BOLT;SOCKET

1

12

06.16110-0106

WASHER

1

13

65.04205-0014

SCREW;ADJUST

6

14

65.90501-0003

NUT

6

15

65.04209-5002

CAP;INTAKE

3

16

65.04209-0006

CAP;EXHAUST

3

17

65.90020-0120

BOLT;COLLARED HEX.

8

DL200-3

1

Serial No

ICA

Replacable

Qty

Fig. 017 VALVE TAPPET & PUSH ROD

DL200-3

Fig. 017 VALVE TAPPET & PUSH ROD Key No

Part No

Description

Qty S.C

1

65.04301-5003C

TAPPET;VALVE

12

2

65.04302-5015

ROD;PUSH

12

DL200-3

1

Serial No

ICA

Replacable

Qty

Fig. 018 CAM SHAFT

DL200-3

Fig. 018 CAM SHAFT Key No

Part No

Description

Qty S.C

1

65.04401-0046

CAM SHAFT

1

2

06.22022-1016

PIN;DOWEL

1

3

65.90720-0032

WASHER;THRUST

1

4

06.01913-2911

BOLT ASS'Y M6X16

2

DL200-3

1

Serial No

ICA

Replacable

Qty

Fig. 019 CAM SHAFT DRIVE

DL200-3

Fig. 019 CAM SHAFT DRIVE Key No

Part No

Description

Qty S.C

1

65.04501-0017

GEAR;CAM SHAFT

1

2

65.90020-0117

BOLT;COLLARED HEX.

4

3

65.04505-5018

GEAR;IDLE

1

4

65.04506-0016

PIN;IDLE GEAR

1

5

65.90720-0034B

WASHER;THRUST

1

6

65.90020-0118

BOLT;COLLARED HEX.

3

7

65.11301-5002

GEAR;DRIVE

2

8

65.04506-0015

PIN;IDLE GEAR

2

9

65.90720-0033A

WASHER;THRUST

1

10

65.90020-0118

BOLT;COLLARED HEX.

1

11

65.90020-0119

BOLT;COLLARED HEX.

1

DL200-3

1

Serial No

ICA

Replacable

Qty

Fig. 020 OIL PUMP

DL200-3

Fig. 020 OIL PUMP Key No 1

Part No

Description

Qty S.C

65.05100-6063A

OIL PUMP ASS'Y

1

1A

-

HOUSING;OIL PUMP

1

1B

65.05104-0023

GEAR;OIL PUMP

1

1C

65.05104-0022

GEAR;OIL PUMP

1

1D

65.05201-0016

GEAR;DRIVE;OIL PUMP

1

1E

06.22022-0907

PIN;DOWEL 6M6X10

1

1F

65.05103-0034

COVER;OIL PUMP

1

1G

06.01913-3114

BOLT ASS'Y M8X22

4

9

06.22022-0909

PIN;DOWEL 6M6X14

2

10

65.90020-0085

BOLT;COLLARED HEX.

2

DL200-3

1

D

Serial No

ICA

Replacable

Qty

Fig. 021 OIL COOLER & FILTER

DL200-3

Fig. 021 OIL COOLER & FILTER Key No 1

Part No

Description

Qty S.C

65.05601-7082

OIL COOLER ASS'Y

1

1A

65.05604-0030A

HOUSING;OIL COOLER

1

1B

65.05606-5032A

ELEMENT;OIL COOLER

1

1C

65.05902-0022

GASKET;OIL COOLER

2

1D

06.01923-3119

BOLT ASS'Y M8X40

4

1E

65.54109-0005A

SCREW;PLUG M22X1.5

1

1F

65.05610-0007A

GUIDER;WATER FLOW

1

1G

06.02097-8306

BOLT;SOCKET

2

1H

06.16731-2105

WASHER

2

2

65.05501-7099

OIL FILTER ASS'Y

1

2A

65.05503-0050

HEAD;OIL FILTER

1

2B

06.31641-0433

BALL;STEEL

1

2C

65.97601-0075

SPRING

1

2D

65.90310-0115

PLUG

1

2E

06.56190-0726

SEAL;RING

1

2F

65.05510-5032A

FILTER;OIL

1

3

06.01923-3123

BOLT ASS'Y M8X60

1

4

65.90201-0139

BOLT

1

5

06.15010-2311

WASHER

1

6

06.16731-2107

WASHER

1

7

65.05901-0031

GASKET;OIL FILTER

1

23

65.05902-0023

GASKET;OIL COOLER

1

24

06.01923-3117

BOLT ASS'Y M8X30

10

25

06.01923-3119

BOLT ASS'Y M8X40

10

26

06.01913-3128

BOLT M8X85

8

27

65.90201-0135

BOLT;STUD

3

28

06.15010-2311

WASHER

14

29

06.16731-2107

WASHER

5

30

65.90001-0098

BOLT

2

31

06.01913-3129

BOLT ASS'Y M8X90

1

DL200-3

1

Serial No

ICA

Replacable

Qty

Fig. 022 OIL PAN

DL200-3

Fig. 022 OIL PAN Key No

Part No

Description

Qty S.C

Serial No

1

65.05801-5249

PAN;OIL

1

4

65.05904-0035

GASKET;OIL PAN

1

~130603

4

400604-00026

GASKET,OIL PAN

1

130604~

5

06.01923-3120

BOLT ASS'Y M8X45

22

7

65.05806-5005A

TUBE;OIL LEVEL GAUGE

1

9

65.05805-5238

OIL LEVEL GAUGE

1

10

65.05701-6122

OIL PIPE ASS'Y

1

10A

65.05707-5011

COVER;STRAINER

1

10B

65.05740-0222

BRACKET;OIL SUCT.PIPE

1

10C

65.97401-0137

CLIP;PIPE

1

10D

06.01283-7115

BOLT M8X25

1

10E

06.15010-2311

WASHER

1

10F

65.90510-0012

NUT

1

17

65.05901-0032

GASKET

1

18

06.01913-3115

BOLT ASS'Y M8X25

1

19

06.01913-3119

BOLT ASS'Y M8X40

2

20

460102-00034

DRAIN ASSY

1

20A

65.96340-5013A

HOSE;DRAIN

1

20B

410202-00014

COCK ASSY;DRAIN

1

23

65.98130-0203

ADAPTER

1

24

06.56190-0732

SEAL;RING

1

25

65.01813-5019

PIPE;OIL FILLER

1

26

65.05903-0029A

GASKET

1

27

06.01913-3114

BOLT ASS'Y M8X22

4

28

65.01810-5011

CAP;OIL FILLER

1

DL200-3

1

ICA

I

Replacable

400604-00026

Qty

1

Fig. 023 COOLING WATER PIPE

DL200-3

Fig. 023 COOLING WATER PIPE Key No

Part No

Description

Qty S.C

Serial No

1

600102-00001

CONNECTION

1

2

420211-00039A

PIPE;COOLING WATER

1

3

65.98130-0143

ADAPTER

1

4

06.56180-0716

RING;SEAL

3

5

420101-00256

HOSE;RUBBER

1

6

06.08092-2402

SCREW;PLUG M10X1.25

2

7

120122-00003

BOLT;SPACER

3

~130418

7

120122-00003A

BOLT,SPACER

3

130419~

8

420108-00280

HOSE;RUBBER

1

9

06.56190-0728

RING;SEAL

1

10

65.98130-0068

NIPPLE

1

11

65.06301-0219A

PIPE;COOLING WATER

1

12

65.96501-0089A

O-RING

2

13

06.67020-0101

CLAMP;HOSE

2

14

06.67020-0105

CLAMP;HOSE

2

15

06.01923-3214

BOLT;HEX. M10X22

2

DL200-3

1

ICA

I

Replacable

120122-00003A

Qty

3

Fig. 024 THERMOSTAT

DL200-3

Fig. 024 THERMOSTAT Key No

Part No

Description

Qty S.C

1

300738-00009A

THERMOSTAT ASS'Y

1

1A

110980-00021A

HOUSING;THERMOSTAT

1

1B

300738-00010

THERMOSTAT

1

1C

401002-00055

O-RING

1

2

65.06904-0021

GASKET;THERMOSTAT

1

3

06.01013-9225

BOLT;HEX

6

40

06.16110-0107

WASHER;SPRING

6

41

06.15010-2312

WASHER;PLAIN

6

42

400602-00241

GASKET

1

43

600102-00003

CONNECTION

1

44

06.01923-3123

BOLT ASS'Y M8X60

3

45

06.01923-3131

BOLT;HEX.

1

46

430220-00008

OUTLET,WATER

1

47

400602-00316

GASKET;WATER PUMP

1

48

06.01923-3117

BOLT ASS'Y M8X30

2

49

65.90350-0005

SCREW;PLUG PT 3/8

1

DL200-3

1

Serial No

ICA

Replacable

Qty

Fig. 025 WATER PUMP

DL200-3

Fig. 025 WATER PUMP Key No

Part No

Description

Qty S.C

1

400921-00015B

WATER PUMP ASS'Y

1

1A

400923-00005A

HOUSING;WATER PUMP

1

1B

65.93410-0087

BEARING

1

1C

65.06520-6008

SEAL;MECHANICAL

1

1D

06.29020-0132

SNAP RING 55X2

1

1E

130707-00011A

PULLEY;BELT

1

1F

400902-00005

IMPELLER

1

10

06.22022-0907

PIN;DOWEL 6M6X10

2

11

06.01923-3126

BOLT;HEX. M8X75

9

12

110508-00182B

COVER,PUMP

1

13

06.01923-3119

BOLT ASS'Y M8X40

1

14

400602-00096

GASKET;WATER PUMP

1

15

06.01923-3124

BOLT ASS'Y M8X65

5

16

400602-00113A

GASKET;WATER PUMP

1

17

420211-00172

PIPE,COOLING WATER

1

18

400631-00003

GASKET;C/W PIPE

1

19

06.01923-3117

BOLT ASS'Y M8X30

2

20

130205-00059

BELT 5PK-1013L

1

21

110951-00327

SPACER

3

22

110417-00002

BRACKET;IDLE PULLEY

2

23

130710-00008

PULLEY;IDLE

1

24

65.91701-0154

SPACER

1

25

06.16731-2109

WASHER;SPRING A12

1

26

06.11063-8216

NUT;HEX

1

27

65.19103-6010A

EYE BOLT ASS'Y

1

32

06.01923-3223

BOLT ASSY

2

33

06.01923-3225

BOLT ASS'Y M10X70

1

34

06.16731-2108

WASHER;SPRING

1

35

06.11063-8215

NUT;HEX. M10

1

36

06.01923-3218

BOLT ASS'Y M10X35

1

DL200-3

1

D

Serial No

ICA

Replacable

Qty

Fig. 026 COOLING FAN

DL200-3

Fig. 026 COOLING FAN Key No

Part No

Description

Qty S.C

3

06.01913-3213

BOLT ASS`Y M10X20

6

7

130709-00020A

PULLEY;FAN

1

8

210101-00101

FAN DRIVE ASS'Y

1

9

06.01913-3219

BOLT ASS'Y M10X40

4

10

65.96801-0224

BELT 8PK-1735L

1

DL200-3

1

Serial No

ICA

Replacable

Qty

Fig. 027 EXHAUST MANIFOLD

DL200-3

Fig. 027 EXHAUST MANIFOLD Key No

Part No

Description

Qty S.C

1

240102-00096

EXHAUST MANIFOLD ASS'Y

1

1A

240102-00097

MANIFOLD;EXHAUST

1

1B

240102-00098

MANIFOLD;EXHAUST

1

1C

240102-00099

MANIFOLD;EXHAUST

1

1D

65.96507-0059A

RING;SEAL

8

5

65.08901-0045

GASKET;EXHAUST MANIFOLD

6

6

65.90535-0003

NUT

24

7

65.91701-0086

SPACER

24

10

65.90201-0076

BOLT;STUD

2

DL200-3

1

Serial No

ICA

Replacable

Qty

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