Doosan DL200-3 Install guide

Original InstructionsCopyright DOOSAN 2012
Serial Number 10001 and Up
Shop Manual
DL200-3 Wheel Loader
950106-00440E
June 2012
DOOSAN and the DOOSAN logo are registered
trademarks of DOOSAN Corporation in the United
States and various other countries around the
world.

Table of Contents
Page I
1Table of Contents
Safety
Wheel Loader Safety ............................................................................ SP002397
Specifications
Specification for DL200-3 ..................................................................... SP002595
General Maintenance
General Maintenance Instructions........................................................ SP002454
Standard Torques................................................................................. SP002404
Drivetrain
Transmission and Torque Converter (ZF 4WG-160) ............................ SP002596
Transmission Error Codes (ZF) ............................................................ SP002423
Axle (ZF-MT-L 3075 II) ......................................................................... SP002598
Driveshaft.............................................................................................. SP002663
Brake
Service Brake ....................................................................................... SP002426
Brake Supply Valve .............................................................................. SP002427
Charging Block ..................................................................................... SP002428
Parking Brake ....................................................................................... SP002429
Brake Pedal Valve ................................................................................ SP002430
Accumulator.......................................................................................... SP002464
Steering
Power Steering System ........................................................................ SP002599
Priority Valve......................................................................................... SP002600
Emergency Steering ............................................................................. SP002601

Table of Contents
Page II
Frame
Articulation Center ................................................................................ SP002767
Counterweight....................................................................................... SP002437
Tank
Oil Tank ................................................................................................ SP002664
Fuel Tank.............................................................................................. SP002665
Hydraulics
Main Pump............................................................................................ SP002440
Main Control Valve ............................................................................... SP002602
Load Isolation System .......................................................................... SP002603
Cooling System..................................................................................... SP002660
Pilot System.......................................................................................... SP002445
Hydraulic Schematic DL200-3 / DL220-3 ............................................. SP002661
Electrical System
Air Conditioner...................................................................................... SP002447
Electrical System .................................................................................. SP002662
Electrical Schematic DL200-3 / DL220-3.............................................. SP002666

SP002397
Page 1
Wheel Loader Safety
SP002397
WHEEL LOADER SAFETYSP002397
Wheel Loader
Safety
Edition 3

SP002397
Page 3
Wheel Loader Safety
Table of Contents
Wheel Loader Safety
Safety Instructions ................................................ 5
Applicable Models ................................................ 5
Safety Messages .................................................. 6
Safety Decals ....................................................... 7
General................................................................. 8
Transportation .................................................... 19
Operation............................................................ 21
Maintenance ....................................................... 39
Environment and Circumstances........................ 54

SP002397
Page 5
Wheel Loader Safety
SAFETY INSTRUCTIONS
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation and
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
MODEL SERIAL NUMBER RANGE
DL200-3 10001 and Up
DL220-3 10001 and Up
DL250-3 10001 and Up
DL300-3 10001 and Up
DL350-3 10001 and Up
DL420-3 10001 and Up
DL450-3 10001 and Up
DL550-3 10001 and Up

SP002397Wheel Loader Safety
Page 6
SAFETY MESSAGES
Safety messages and safety decals included in this manual and
on the machine provide instructions how to operate, service and
maintain the machine. Safety messages and safety decals
indicate potential hazards and describe safety precautions
required to avoid hazards. Operator and maintenance personnel
should read and understand these safety messages and decals
before beginning operation or maintenance.
Signal Words
The signal words "DANGER", "WARNING", "CAUTION" are
used throughout safety messages and safety decals in this
manual or on the machine. They indicate an existence of, and
the relative seriousness of a hazard. All three indicate that a
safety risk is involved. Observe the precautions indicated
whenever a Safety Alert Symbol is present, no matter which
signal word appears next to it.
SAFETY ALERT SYMBOL
Be Prepared -Get to Know All Operating and Safety
Instructions.
This is a Safety Alert Symbol. Wherever it appears in this
manual or on safety decals on the machine, you must be
alert to the potential for personal injury or accidents.
Always observe safety precautions and follow
recommended procedures.
DANGER
DANGER -This signal word is used on safety messages and
safety labels and indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
WARNING
WARNING -This signal word is used on safety messages and
safety labels and indicates a potentially hazardous situation
which, if not avoided, could result in death or serious injury.
CAUTION
CAUTION -This signal word is used on safety messages
and safety labels and indicates a potentially hazardous
situation which, if not avoided, could result in minor or
moderate injury.

SP002397
Page 7
Wheel Loader Safety
Other Signal Words
In addition to safety signal words, the following signal words are
used to indicate proper and effective use of machine.
NOTE: The word "NOTE" identifies information for effective
use.
SAFETY DECALS
Location of safety labels (decals) can vary from unit to unit.
Refer to appropriate Operation and Maintenance Manual, and
parts manual for your unit.
Always replace damaged or faded decals.
IMPORTANT
This signal word identifies procedures which must be
followed to avoid damage to machine.

SP002397Wheel Loader Safety
Page 8
GENERAL
Safe Operation is Operator's Responsibility
Only trained and authorized personnel should operate and
maintain the machine.
Follow all safety rules, regulations and instructions when
operating or performing maintenance on machine.
• Do not operate machine if you are under the
influence of drugs or alcohol. An operator who is
taking prescription drugs must get medical advice to
determine if he or she can safely operate the
machine.
• When working with other personnel on a work site, be
sure that all personnel know the nature of work and
understand all hand signals that are to be used.
• Be sure that all guards and shields are installed in
their proper location. Have guards and shields
repaired or replaced immediately if damaged.
• Be sure that you understand the use and
maintenance of all safety features such as pilot cutoff
switch and seat belt. Use them always.
• Never remove, modify or disable any safety features.
Always keep them in good operating condition.
• Always check for and know the location of
underground and overhead utility lines before working.
• Failure to use and maintain safety features according
to instructions in this manual, Safety Manual and
Shop Manual can result in death or serious injury.
Know Your Machine
Know how to operate your machine. Know the purpose of all
controls, gauges, signals, indicators and monitor displays. Know
the rated load capacity, speed range, braking and steering
characteristics, turning radius and operating clearances. Keep in
mind that rain, snow, ice, loose gravel, soft ground, slopes etc.,
can change operating capabilities of your machine.
Proper Work Tools and Attachments
Only use work tools and attachments that are recommended by
DOOSAN for use on DOOSAN machines. When installing and
using optional attachments, read instruction manual for
attachment, and general information related to attachments in
this manual. Because DOOSAN cannot anticipate, identify or
test all attachments that owners may want to install on their
machines, contact DOOSAN for written authorization and
approval of attachments, and their compatibility with optional
kits.

SP002397
Page 9
Wheel Loader Safety
Attachments and attachment control systems that are
compatible with the machine are required for safe and reliable
machine operation. Do not exceed maximum operating weight
(machine weight plus attachment) that is listed on ROPS
certification plate.
Make sure that all guards and shields are in place on machine
and on work tool. Depending on type or
combination of work
equipment, there is a potential that work
equipment could
interfere with the cabin or other parts of
machine. Before using
unfamiliar work equipment, check if there
is any potential of
interference, and operate with caution.
While you are performing any maintenance, testing, or
adjustments to attachments, stay clear of the following areas:
cutting edges, pinch points, and crushing surfaces.
Never use attachment as a work platform or manlift.
Contact your DOOSAN distributor about auxiliary hydraulic kits
for attachments installation. If you are in doubt about the
compatibility of a particular attachment with the machine, consult
your DOOSAN distributor.
Pressurized Fluids
Pressurized air or fluids can cause debris and/or fluids to be
blown out. This could result in death or serious injury.
Immediately after operations are stopped, coolant, engine oil,
and hydraulic oil are at their highest temperatures and the
radiator and hydraulic tank are still under pressure. Always wait
for temperature to cool down. Follow specified procedures when
attempting to remove caps, drain oil or coolant, or replacing
filters. Always wait for temperature to cool down, and follow
specified procedures when performing these operations. Failure
to do so can result in death or serious injury.
When pressurized air and/or pressurized water is used for
cleaning, wear protective clothing, protective shoes, and eye
protection. Eye protection includes goggles or a protective face
shield.
Pressure can be trapped in a hydraulic system and must be
relieved before maintenance is started.
Releasing trapped pressure can cause sudden machine
movement or attachment movement. Use caution if you
disconnect hydraulic lines or fittings.
High-pressure oil that is released can cause a hose to whip or oil
to spray. Fluid penetration can result in death or serious injury. If
fluid enters skin or eyes, get immediate medical attention from a
physician familiar with this injury.
Obey all local laws and regulations for disposal of liquids.
To prevent hot coolant from spraying out, stop engine and wait
for coolant to cool. Using gloves, slowly loosen cap to relieve
pressure.
FG018457
Figure 1

SP002397Wheel Loader Safety
Page 10
Flying or Falling Objects
On work sites where there is a potential hazard that flying or
falling objects can come in contact with operator's cabin, select
and use a guard to match operating conditions for additional
operator protection.
Working in mines, tunnels, deep pits, and loose or wet surfaces,
can produce hazard of falling rocks or flying objects. Additional
protection for operator's cabin may be required such as a Falling
Object Protective Structure (FOPS) or window guards. Contact
your DOOSAN distributor for information on available protective
guards.
To prevent personnel from being struck by flying objects, keep
personnel out of work area.
Personal Protective Equipment (PPE)
Do not wear loose clothing and accessories. Secure long hair.
These items can snag on controls or on other parts of equipment.
Do not wear oily clothes. They are highly flammable.
Do not forget that some risks to your health may not be
immediately apparent. Exhaust gases and noise pollution may not
be visible, but these hazards can cause disabling or permanent
injuries. Breathing masks and/or ear protection may be required.
Wear a hard hat, safety shoes, safety goggles, mask, leather
gloves, earplugs and other protective equipment, as required.
While working on machine, never use inadequate tools. They
could break or slip, or they may not adequately perform intended
functions.
Correction of Machine Problems
If any machine problems are found during operation and
maintenance (noise, vibration, smell, incorrect gauges, smoke,
oil leakage, etc.), or if any abnormal warming alerts are
displayed on display monitor, stop the machine immediately and
take the necessary corrective actions. Do not operate the
machine until problem has been corrected.
HAOA110L
Figure 2
HAOA100L
Figure 3
HAOA020L
Figure 4

SP002397
Page 11
Wheel Loader Safety
Crushing and Cutting
Keep objects away from moving fan blades. Fan blades can
throw and cut objects.
Do not use a wire rope that is kinked or frayed, or a wire rope
with any loss of diameter. Wear leather gloves when handling a
wire rope.
When striking a loose retainer pin, it can fly out and can cause a
serious injury. Make sure that area is clear of personnel when
striking a retainer pin. To avoid injury to your eyes, wear safety
goggles when striking a retainer pin.
Do not put your hand, arm or any other part of your body
between movable parts. If going between movable parts is
necessary, always position and secure work equipment so it
cannot move. Properly support equipment before performing
any work or maintenance under raised equipment.
If control levers are operated, clearance between machine and
work equipment will change and this may lead to serious
damage or can result in death or serious injury. Stay clear of
areas that may have a sudden change in clearance with
machine movement or equipment movement. Stay clear of all
rotating and moving parts. Unless instructed, never attempt
adjustments while machine is moving or while engine is running.
Do not depend on hydraulic cylinders to support raised
equipment. Equipment can fall if a control is moved, or if a
hydraulic line breaks, is loosened or disconnected.
If it is necessary to remove guards to perform maintenance,
always install guards after maintenance is completed.
Always have at least two people working together if the engine
must be running during service. One person needs to remain in
the operator's seat, ready to work the controls to stop the
machine or stop engine, if necessary.
HDO1010L
Figure 5

SP002397Wheel Loader Safety
Page 12
Hot Coolant and Oils - Burn Prevention
Do not touch any part of an operating engine. Immediately after
operations are stopped, coolant, engine oil, and hydraulic oil are
at their highest temperatures. The radiator and hydraulic tank
are still under pressure. Always wait for temperature to cool
down. Attempting to remove caps, drain oil or coolant, or
replacing filters may lead to serious burns, if done when hot.
Relieve all pressure in air system, hydraulic oil system,
lubrication system, fuel system, and cooling system, before any
lines, fittings or related items are disconnected.
To prevent hot oil or coolant from spraying out, stop engine and
wait for oil and coolant to cool. Using gloves, slowly loosen cap
to relieve pressure.
Fire and Explosion Prevention
All fuels, most lubricants and some coolant mixtures are
flammable and can cause a fire resulting in death or serious
injury, and property damage. Flammable fluids that are leaking
or spilled onto hot surfaces or onto electrical components can
cause fire.
Inspect for and remove all flammable materials such as spilled
fuel and oil, and debris from machine. Do not allow any
flammable materials to accumulate on machine.
Always observe the following:
• Add fuel, oil, antifreeze and hydraulic fluid to machine
only in a well ventilated area. Machine must be
parked with controls, lights and switches turned
"OFF." Engine must be "OFF" and any flames,
glowing embers, auxiliary heating units or spark
causing equipment must be extinguished, or turned
"OFF" and kept well clear of machine.
• Dust that is generated from repairing or grinding
nonmetallic hoods or nonmetallic fenders can be
toxic, flammable and explosive. Repair these
components in a well ventilated area away from
flames or sparks and wear a dust mask when
grinding painted parts.
FG019095
Figure 6
FG019096
Figure 7
HDO1015I
Figure 8
Figure 9
FG018458

SP002397
Page 13
Wheel Loader Safety
Maintenance
The machine and some attachments have components that
reach high temperatures under normal operating conditions. The
primary source of high temperatures are the engine and exhaust
system. If damaged or incorrectly maintained, the electrical
system can be a source of arcs or sparks.
Flammable debris (leaves, straw, etc.) must be removed
regularly. If flammable debris is allowed to accumulate, it can
cause a fire hazard. Clean machine often to avoid this
accumulation. Flammable debris in an engine compartment is a
potential fire hazard.
The operator's area, engine compartment and engine cooling
system must be inspected every day and cleaned. This is
necessary to prevent fire hazards and overheating.
Operation
Do not use machine where exhaust, arcs, sparks or hot
components can contact flammable material, explosive dust or
gases.
Do not operate machine near any flame.
Exhaust shields (if equipped) protect hot exhaust
components
from oil spray or fuel spray in case of a break in
a line, hose, or
seal. Exhaust shields must be correctly installed and maintained
properly.
Electrical
Check all electrical wiring and connections for damage daily.
Keep battery terminals clean and tight. Repair or replace any
damaged parts or wires that are loose or frayed. Clean all
electrical connections and tighten all electrical connections.
Never check battery charge by placing a metal object across
terminal posts. Use a voltmeter or a hydrometer.
Battery gas can explode and can result in death or serious
injury. Follow procedures in this manual for connecting battery
and for jump-starting. Do not jump-start or charge a frozen or
damaged battery. Keep all flames and sparks away from
batteries. Do not smoke in battery charging area.
Improper jumper cable connections can cause an explosion that
can result in death or serious injury. Refer to Operation and
Maintenance Manual for proper procedure in this manual.
Do not charge a frozen battery. This can cause an explosion.
After market radios or other electric operated equipment in cabin
must have a fuse in the electrical circuit.

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