Daewoo Doosan Powershift Trans. 3WG 116 161 Fault Codes Manual SB4121E00

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Daewoo Doosan Powershift Trans. 3WG 116 161 Fault Codes Manual SB4121E00 – PDF DOWNLOAD

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Daewoo Doosan Powershift Trans. 3WG 116 161 Fault Codes Manual SB4121E00 – PDF DOWNLOAD

Language :English
Pages :58
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Daewoo Doosan Powershift Trans. 3WG 116 161 Fault Codes Manual SB4121E00 – PDF DOWNLOAD

SB4125E00 0
SB2003E00 0
SB2004E00 0
SB4118E00 0
CONTENTS 6
1 GENERAL INFORMATION 8
11 Engine specifications 8
1 2 Performance curve 9
1 21 Performance curve (ECRFA), D50/60/70/80S-2 (3 speed) 9
1 22 Performance curve (ECRFB), D35/40/45S-2, D50C-2 10
1 23 Performance curve (ECRFC), D50/60/70S-2 (2 speed) 11
13 Engine assembly 12
131 Engine assembly view (ECRFA), D50/60/70/80S-2 (3 speed) 12
132 Engine assembly view (ECRFB), D35/40/45S-2, D50C-2 13
133 Engine assembly views (ECRFC), D50/60/70S-2 (2 speed) 14
14 Safety regulations 15
141 General notes 15
142 Regulations designed to prevent accidents 15
143 Regulations designed to prevent damage to engine and premature wear 16
144 Regulations designed to prevent pollution 17
145 General repair instructions 18
2 TECHNICAL INFORMATION 19
21 Engine model and serial number 19
22 Engine type 20
221 Cylinder block 20
222 Piston con-rod / crankshaft 20
23 Engine timing 20
24 Valves 21
25 Lubrication system 21
251 Recommend of lubricating oil 22
252 Oil cooler 23
253 Oil filter 23
26 Air cleaner 24
27 Fuel system 24
271 Injection pump 25
272 Fuel filter 25
273 Fuel requirements 25
274 How to select fuel oil 26
28 Cooling system 27
281 Anti-freeze 28
282 Cooling water 28
29 V-belt tension check and adjust 30
210 Valve clearance and adjustment 31
211 Cylinder compression pressure 32
212 Injection nozzle 33
213 Battery 33
214 Starting motor 33
215 Diagnosis and remedy 34
216 Engine inspection 43
2161 Stopping engine 43
2162 General engine inspection cycle 43
217 Use of original parts for repair and replacement 44
3 Maintenance 45
31 Engine Disassembly 45
311 Major part fixing nuts and bolts 45
312 Main structure parts (1) 56
313 Main structure parts (2) 58
314 Rocker arm disassembly 60
315 Cylinder head disassembly 61
316 Piston and connecting rod disassembly 62
32 Engine Inspection 64
321 Cylinder block 64
322 Cylinder head 64
323 Valve stem and valve guide clearance 65
324 Valve spring 69
325 Tappet 70
326 Push rod 70
327 Rocker arm correction 71
328 Idler gear and shaft 72
329 Camshaft 72
3210 Cylinder liner 74
3211 Cylinder block 75
3212 Piston 78
3213 Maintenance of cylinder block, cylinder liner and piston 81
3214 Connecting rod 82
3215 Crankshaft 84
3216 Flywheel and flywheel housing 88
33 Engine Reassembly 89
331 Piston and connecting rod assembly 89
332 Cylinder head assembly parts 91
333 Rocker arm and shaft assembly 94
334 Main components 95
335 Major component assembly101
336 External parts105
4 Commissioning and Operation110
41 Preparation110
411 Starting110
42 Starting and operation111
421 Operation of a new engine (Break-In)111
422 Check points for break-in111
43 Inspections after starting113
44 Operation in winter time113
441 Prevention against the freeze of cooling water113
442 Prevention against excessive cooling113
443 Lubricating oil114
444 Starting of engine in winter114
445 Tuning the engine114
45 Maintenance and care115
451 Periodical inspection and maintenance115
452 Exchanging of lubrication oil115
453 Oil level115
454 Oil exchange procedure115
455 Replacement of oil filter cartridge116
46 Cooling system117
461 Coolant draining117
462 Cleaning of the cooling inside system circuit118
47 Valve clearance and adjustment118
48 Injection timing120
49 Tightening the cylinder head bolts123
410 Fuel injection pump123
411 Feed pump strainer124
412 Separator (Add if necessary)124
413 Air bleeding125
414 Belts125
5 Maintenance of Major Components128
51 Lubrication system128
511 Oil pump128
512 Oil cooler130
52 Cooling system131
521 Water pump131
522 Thermostat135
53 Fuel system136
531 Fuel filter136
532 Injection nozzle137
533 Injection Pump Calibration141
534 Precautions for operation144
535 Walk-around check and servicing145
536 Diagnostics and troubleshooting146
6 Special Tool List147
Appendix149
SB2134E00 0
Index 4
Specifications 6
Alternator 6
Systems Operation 7
Alternator 7
HC45 Alternator Operation 7
Alternator Components 8
Alternator Operation Schematic 10
Introduction 7
Testing And Adjusting 11
Alternator 12
Alternator Output Test 12
Machine Test 12
Troubleshooting 11
Troubleshooting Problem List 11
Troubleshooting Problems 11
SB2135E00 0
Index 4
Specification 6
Starting Motor 6
Systems Operation 8
Starting Motor 8
Introduction 8
Starting Motor Components 9
Testing And Adjusting 14
Starting Motor 15
Off Machine No Load Test 18
On Machine Starting Motor Diagnosis Procedure 15
Starting Motor Component Tests 19
Troubleshooting 14
Troubleshooting Problem List 14
Troubleshooting Problems 14
Disassembly And Assembly 24
Starting Motor 24
Assemble Starting Motor 27
Disassemble Starting Motor 24
SB4126E00 0
Index 4
Specifications 6
Brake Drum Diameter 10
Brakes 9
Differential 7
Drive Axle 7
General Tightening Torque 6
Power Transfer Group 10
Torque Converter 7
Wheel Bearings And Drive Wheels 8
Systems Operation 11
Differential And Drive Axles 12
Automatic Adjustment 14
Brake Components 13
Differential 12
Wheel Hubs 12
General Information 11
Testing And Adjusting 15
Troubleshooting 15
Checks During Operation 15
Visual Checks 15
Power Shift Transmission 20
Converter Stall Test 22
Inching Pedal Adjustment 24
ODB Brake Lever Adjustment 24
Pressure Tap Locations 21
Transmission Pressure Tests 20
Wheel Brakes Adjustment 23
SB4127E00 0
Index 4
Disassembly 6
Removal And Strip Down Of the Axle Housing 15
Removal And Strip Down Of The Brake 9
Removal And Strip Down Of Wheel Hub 6
Removal And Strip Down Of Wheel Hub And Brake 10
Reassembly 18
Adjustment Of Bearing Preload On Bevel Pinion Shaft 20
Assembly Of Axle Housing Into Input Housing 24
Contact Pattern Check 24
Determination of Installation Dimension For Bevel Pinion Shaft 19
Measurement Bearing Play of Bevel Pinion Shaft 20
Mounting Of Brake And Wheel Hub to The Axle Housing 25
Preassembly Differential 21
SB4152E00 0
Index 4
Vechicle Systems 6
Specifications 6
Booster-Brake 6
Hydraulic Pump 6
Systems Operation 7
Brake System 7
Drive Axle Cooling System 8
Testing & Adjusting 9
Brake System Air Removal 9
Disassembly & Assembly 10
Brake Hydraulic Booster 10
Power Train 11
Exploded and Cross-Section Views 11
Axle Cross-Section View 11
Brake and Wheel End Parts Nomenclature 11
Differential Carrier Components Nomenclature 12
Introduction 13
Description 13
Disassembly 14
Disassembling the Axle 14
Disassembling the Differential Carrier Assembly 17
Disassembling the Differential Case 19
Disassembling the Pinion Bearing Cage 19
Disassembling the Wet Disc Brake 16
Disassembling the Wheel End 16
Measuring Total Bearing Preload and Gearset Backlash and Runout 17
Removing the Axle From the Vehicle 14
Prepare Parts for Assembly 20
Applying Liquid Gasket Material 23
Cleaning Axle Assemblies 20
Cleaning Ground or Polished Parts 20
Cleaning Parts With Rough Finishes 20
Cleaning the Breather 20
Drying Cleaned Parts 20
Flush Lube From the Axle 24
Gearset Information (Drive Pinion and Ring Gear Marks) 24
Inspecting Parts 20
Inspecting Parts 21
Tapered Roller Bearings 21
Pinions and Gears 22
Main Differential Assembly 22
Axle Shafts 22
Installing Fasteners With Pre- Applied Adhesive, Loctite Liquid Adhesive or Equivalent 23
Installing New Fasteners With Pre-Applied Adhesive Patches 23
Installing Original or Used Fasteners Using Three Bond 1305 and 1334, Loctite 241, 242, 243, 271 and 273 or Equivalent 23
Preventing Corrosion 20
Removing Dri-Loc Fasteners 23
Repairing or Replacing Parts 22
Welding Repair 22
Assembly 26
Assembling the Carrier Into the Axle Housing 33
Assembling the Differential Case 26
Assembling the Park Brake Actuator 30
Assembling the Pinion Bearing Cage 26
Assembling the Service Brake Actuator 30
Assembling the Wheel End 31
Assembling the Wheel End Into the Axle Housing 33
Adjusting the Parking Brake Lever 34
Functional Test of Hydraulic Apply Brake 34
Installing the Differential Case Assembly 28
Installing the Drive Pinion 27
Adjustments 36
Adjusting the Gearset Backlash 36
Adjusting Tooth Contact Pattern of the Gearset 37
Checking the Ring Gear Backface Runout 36
Diagnostics 40
Specifications 42
Torque Table 42
Special Service Tools 43
SB4121E00 0
Index 4
IMPORTANT INSTRUCTIONS 6
Systems Operation 7
Controller DW-3 9
Display 9
Error code definition 12
Possible Indications on the Display 9
Electronic Control unit TCU 12
Electronic Controls for Powershift transmissions 13
Description of the Basic functions 13
Independent calibration of the Shifting elements (AEB) 14
Inching device 15
Function of the Converter 7
Function of a hydrodynamic Torque converter (Schematic view) 7
Powershift transmission 8
Transmission control 8
Operation 16
AEB STARTER 18
– Introduction 18
– List of abbreviations 18
– Procedure to start AEB 18
– Display during AEB-Mode 19
– Procedure to start ISK 20
– Display during ISK mode 20
Cold start 17
Controller DW – 3 (Table -11) 33
Driving and Shifting 16
Driving preparation and Maintenance 16
Electro – Hydraulic control with proportional valves (Table – 9) 30
Fully – Automatic control EST – 37A Circuit diagram standard (Table -10) 31
Gearbox Diagram (Table – 6) 27
Installation Front view (Table – 2) 22
Installation Rear view (Table – 3) 23
Layout (Table – 1) 21
Oil circuit diagram Forward 1st Speed (Table – 5) 26
Oil temperature 17
Schedule of measuring points and connections (Table – 4) 24
Stopping and Parking 17
Power flow Forward speed (Table – 7) 28
Power flow Reverse speed (Table – 8) 29
Towing 17
Transmission control in the Driving mode Automatic 17
Description of Fault Codes 34
Definition of operating modes 38
Limp-Home 38
Normal 38
Substitute Clutch Control 38
Table of fault codes 39
TCU-Shutdown 38
Tranmission-Shutdown 38
Introduction 34
Abbreviations 34
Display 34
Display during AEB-Mode 35
Display during Inchpedal Calibration 37
Display during operation 35
Measuring of resistance at actuator/sensors and cable 57
actuator 57
cable 57
SB4122E00 0
Index 2
Important information on industrial safety 3
LIST OF SPECIAL TOOLS FOR DIS- AND REASSEMBLY 5
COUPLING K1 14
COUPLING K2 15
COUPLING K3 16
COUPLING KV 17
COUPLING KR 18
ENGINE CONNECT 9
FILTER 12
GEARSHIFT SYS 19
INPUT 10
POWER TAKE OFF 11
PRESS REGULATOR 13
1 DISASSEMBLY 21
Electro-Hydraulic Control And Micro Filter (Exchange Filter) 21
11 Removal of the Filter 21
12 Removal of the Electric Shift System 22
2 DISASSEMBLY 26
Inductive transmitters, Valves, Oil Filler and Oil Drain Plug, Screw Plugs 26
3 DISASSEMBLY 27
Engine Connection, Pressure Oil Pump and Removal of the Clutches 27
4 DISASSEMBLY 32
Clutches KV/KR/K1/K2/K3 and Input 32
41 Clutch KV 32
42 Clutch KR 34
43 Clutch K1 37
44 Clutch K2 39
45 Clutch K3 41
46 Input 43
5 REASSEMBLY 44
Clutches KV/KR/K1/K2/K3 and Input 44
51 Clutch KV 44
52 Clutch KR 47
53 Clutch K1 50
54 Clutch K2 53
55 Clutch K3 56
56 Input 60
6 REASSEMBLY 61
Engine Connection, Pressure Oil Pump and Installation of the Clutches 61
7 REASSEMBLY 69
Inductive Transmitters, Valves, Oil Filler and Oil Drain Plug, Screw Plugs 69
8 REASSEMBLY 71
Electro-hydraulic control unit with proportional valves 71
81 Mounting of the Electric Control Unit 72
82 Mounting of Micro Filter (Pressure Filter) 77
SB4128E00 0
Index 3
Specifications 5
Hydraulic Control Valve 5
Hydraulic Pump 6
Steering Gear 7
Steering Wheel And Gear Group 7
Steer Wheels And Steer Axle 7
Tilt Cylinder 6
Tilt Cylinder Installation 6
Systems Operation 8
Brake System 21
Control Valves 10
Hydraulic System 8
Oil Flow 18
Steering System 17
Steering Unit 18
Testing And Adjusting 23
Brake System 34
Brake System Air Removal 34
Parking Brake Adjustment 35
Parking Brake Test 35
Hydraulic System 31
Steering System 32
Tilt Cylinder Alignment 36
Troubleshooting 23
Brake System 29
Hydraulic System and Mast 24
Operation Checks 23
Steering System 28
Visual Checks 23
SB4129E00 0
Index 4
Brake Hydraulic Booster 22
Counterweight 9
Hood 9
Hydraulic Control Valve 10
Hydraulic Oil Filter Assembly 21
Hydraulic Pump 16
Overhead Guard 10
Seat 10
Steer Axle 23
Steering Column And Gear Assembly 29
Steering Wheel 29
Tilt Cylinders 6
Tires And Rims (Steer) 34
SB4130E00 0
SB4131E00 0
SB4132E00 0
Index 4
Disassembly & Assembly 6
Carriage 6
Carriage Rollers 7
Mast 9
Specifications 13
Carriage 13
Lift Chains 13
Mast 13
Systems Operations 14
Lift Cylinder & Mast 14
Testing & Adjusting 15
Carriage Adjustment 16
Chain Adjustment Check 17
Chain Adjustment 17
Chain Adjustments 17
Chain Wear Test 17
Cylinder Adjustment 15
Drift Test 19
Mast Adjustment 15
Mast And Carriage 15
Measurement Of Carriage And Forks 18
Tilt Angle Check 18
SB2144E04 0
Table of Contents 2
Information Section 3
Foreword 3
Safety Section 5
Important Safety Information 5
Safety 6
Warning Signs and Labels 6
General Hazard Information 10
Operation Information 11
Maintenance Information 14
Operator Restraint System(If Equipped) 17
Avoiding Lift Truck Tipovers 21
Safety Rules 23
How to Survive in a Tipover 28
General Section 29
Specifications 29
Noise &Vibration 35
Capacity Chart – Without Side Shifter 36
Serial Number 38
Operator’s Warning and Identification Plate 40
Operation Section 42
Operator’s Station and Monitoring Systems 42
Lift Truck Controls 47
Refueling 51
Before Starting the Engine 54
Starting the Engine 57
After Starting the Engine 60
Lift Truck Operation 61
Auto Shift Controller ASC-200/201 (If Equipped) 63
Operating Techniques 68
Parking the Lift Truck 72
Lift Fork Adjustment 73
Storage Information 74
Transportation Hints 75
Towing Information 76
Maintenance Section 77
Inspection, Maintenance and Repair of Lift Truck Forks 77
Tire Inflation Information 81
Torque Specifications 82
Cooling System Specifications 84
Fuel Specifications 86
Lubricant Specifications 88
Lubricant Viscosities and Refill Capacities 91
Maintenance Intervals 92
When Required 95
Every 10 Service Hours or Daily102
First 50-100 Service Hours or a Week107
First 250 Service Hours or a Month114
Every 250 Service Hours or Monthly115
Every 500 Service Hours or 3 Months123
Every 1000 Service Hours or 6 Months127
Every 1500 Service Hours or 9 Months134
Every 2000 Service Hours or Yearly135
Every 3000 Service Hours or 18 Months142
Environment Protection Section143
Environment Protection143
Index Section144
Index144

S.M 20/2/2025