Doosan DL200 User manual

Copyright Doosan 2006K1024537E Operation and Maintenance Manual
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.
Operation and Maintenance Manual
K1024537E
Serial Number 5001 and Up
November 2006
DL200
DL200TC

K1024537E
I
Table of Contents
Table of Contents
Safety..........................................................................................1-1
To the Operator of a Wheel Loader .............................................. 1-1
General Safety Essentials ................................................................ 1-4
Location of Safety Labels ................................................................ 1-4
Unauthorized Modifications............................................................. 1-13
General Hazard Information ........................................................... 1-13
Before Starting Engine ................................................................... 1-22
Machine Operation.......................................................................... 1-26
Maintenance .................................................................................... 1-34
Battery.............................................................................................. 1-44
Towing ............................................................................................. 1-46
Shipping and Transportation .......................................................... 1-47
Operating Controls ...................................................................2-1
Component Locations ....................................................................... 2-2
Operator's Area................................................................................. 2-6
Steering Console and Pedals .......................................................... 2-7
Front Instrument Panel................................................................... 2-16
Right Side Switch Panel ................................................................ 2-27
2Various Cabin Locations .............................................................. 2-42
Heater and Air Conditioner Operation .......................................... 2-46
Stereo / CD Player (Optional) ....................................................... 2-51
Seat Adjustment.............................................................................. 2-53
Seat Belt.......................................................................................... 2-55
Door Side Latch.............................................................................. 2-56
Arm Rest ......................................................................................... 2-57
Fuse Box/Relay/Engine Emergency Stop Switch ......................... 2-58

K1024537E
II
Table of Contents
Operation....................................................................................3-1
Instrument Panel Control Functions ................................................ 3-1
New Machine Break-in Procedures................................................. 3-1
Engine Start and Stop ..................................................................... 3-2
Machine Travel................................................................................ 3-11
Machine Shut Down ....................................................................... 3-14
F/R (Forward/Reverse) Travel Control System (Option).............. 3-16
Additional Braking ........................................................................... 3-17
Boom Raise Kick-out...................................................................... 3-18
Bucket Angle Indicator ................................................................... 3-18
Boom Lower Kick-out (Option) ...................................................... 3-19
Adjustment of Bucket Position Switch .......................................... 3-19
Towing Machine.............................................................................. 3-20
If Engine Stalls While Traveling.................................................... 3-21
Allowable Water Depth................................................................... 3-22
Inspection, Maintenance and Adjustment ............................4-1
Basic Preventive Maintenance......................................................... 4-1
Safety When Servicing ..................................................................... 4-4
Preventive Maintenance.................................................................. 4-12
Table of Recommended Lubricants............................................... 4-14
Fluid Capacities............................................................................... 4-16
Lubrication and Service Chart ....................................................... 4-17
Maintenance Intervals..................................................................... 4-21
10 Hour / Daily Service................................................................. 4-23
50 Hour / Weekly Service ............................................................. 4-32
250 Hour / Monthly Service .......................................................... 4-42
500 Hour / 3 Month Service ......................................................... 4-47
1,000 Hour / 6 Month Service ...................................................... 4-54
1,500 Hour / 9 Month Service ...................................................... 4-62
2,000 Hour / Yearly Service.......................................................... 4-64
12,000 Hour / Six Year Service.................................................... 4-70
Severe Conditions Maintenance .................................................... 4-71

K1024537E
III
Table of Contents
Bolt Torque Chart ........................................................................... 4-72
Electrical System............................................................................. 4-73
Engine Cooling System .................................................................. 4-75
Handling of Accumulator ................................................................ 4-77
Hydraulic Pressure Checks ............................................................ 4-78
Long Term Storage ........................................................................ 4-83
Parking Brake Adjustment.............................................................. 4-84
Tires................................................................................................. 4-85
Transportation ...........................................................................5-1
Loading and Unloading .................................................................... 5-1
Summary of Safety Precautions for Lifting..................................... 5-2
Troubleshooting ........................................................................6-1
Engine................................................................................................ 6-1
Hydraulic System .............................................................................. 6-3
Travel System ................................................................................... 6-5
Steering.............................................................................................. 6-6
Braking............................................................................................... 6-7
Electrical System............................................................................... 6-7
Specification ..............................................................................7-1
General Specifications ...................................................................... 7-1
Working Range and Dimensions..................................................... 7-3
Working Capacities ........................................................................... 7-7
Approximate Weight of Workload Materials.................................... 7-7
Index ...........................................................................................8-1

K1024537ETable of Contents
IV

K1024537E
I-I
Presentation
1Presentation
PRESENTATION
FG008047
Figure 1

K1024537EPresentation
I-II
Intended Use
The machine is intended to be used under normal conditions
for the applications described in the Operator's Manual. If it
is used for other purposes or in potentially dangerous
environments, for example explosive atmosphere or areas
with dust containing asbestos, etc., special safety regulations
must be followed and the machine must be equipped for
such use. Contact the manufacturer/dealer for further
information.
The machine is designed for a maximum machine weight
(includes equipment and attachments) of 11,645 kg
(25,673 lb) for DL200. If the maximum weight is exceeded,
no warranties on the part of the manufacturer will apply.
However, always pay attention to national regulations for
traveling on public roads.
Engine
DL200 has a DOOSAN DL06 5.9 liter engine. The engine
has intercooling and is fitted with a common rail system.
The common rail system is positioned at an angle above the
pistons and are controlled via the camshaft and a electronic
control module (ECM).
The cylinder head covers all cylinders.
The engine has four valves per cylinder.
The accelerator position is transferred electrically from
accelerator pedal.
Electrical System
The machine has three control units. The Gauge Panel for
the instrumentation is integrated with the display unit,
warning lights and instruments and provides the operator
with information via there. The Control Unit (for the machine)
receives signals from sensors on the machine and these are
passed to the Gauge Panel. The ECU controls the engine.
Power Transmission
The transmission is electrohydraulically controlled, where all
gears are in constant mesh. The gear ranges are achieved
by applying different combinations of clutches. Between the
engine and transmission gears there is a hydraulic torque
converter, which controls the output torque. The front and
rear axles have planetary gears in the wheel hubs and this
reduces the strain on the respective drive shafts.

K1024537E
I-III
Presentation
Brake System
The machine is provided with a dual circuit, all hydraulic,
brake system with one circuit for each axle. Each circuit
meets the requirements for secondary brake capability.
Parking Brake
The parking brake is a wet disk brake built into the front
axle. The brake is applied by spring force and is released
hydraulically.
Steering System
The machine uses a load sensing, hydrodynamic steering
system. It has a steering arc of 40°.
Cabin
The cabin has a heating and ventilation system with
defrosting for front and rear windows. Air-conditioning is
standard. The cabin has two emergency exits, the door and
right side window.
FOPS and ROPS
The cabin is approved as a protective cabin according to
FOPS and ROPS standards. FOPS is an abbreviation of
Falling Object Protective Structure (roof protection) and
ROPS is an abbreviation of Roll Over Protective Structure
(roll over protection).
Never carry out any unauthorized alterations to the cabin,
e.g. lowering the roof height, drilling, welding on brackets for
fire extinguisher, radio aerial or other equipment, without first
having discussed the alteration with personnel at the
DOOSAN Infracore Engineering Department. This department
will decide whether the alteration may cause the approval to
become void. It is important that all parties concerned are
aware of these regulations.
Hydraulic System
The hydraulic system use a triple vane pump which contains
three pumping sections. The first pumping section supplies
oil for the front attachment. The second pumping section
supplies oil for the steering cylinders. Surplus oil which is
not necessary for the steering function is directed into
control valve to join the first pump is oil by the priority
valve. Pilot pump oil is used for brake and pilot line
operation.

K1024537EPresentation
I-IV
Equipment
The machine can be provided with different types of optional
equipment, depending on the requirements of different
markets. Examples of such equipment are lever steering,
Boom Suspension System (LIS), secondary steering,
separate attachment locking, automatic greasing.
CE MARKING, EMC DIRECTIVE
CE Marking
(Declaration of Conformity)
(Only applies to machines marketed within the EU/EEA.)
This machine is CE marked. This means that when
delivered the machine meets the applicable "Essential Health
and Safety Requirements," which are given in the Machinery
Safety Directive, 98/37EC.
Any person carrying out changes that affect the safety of
the machine, is also responsible for the same.
As proof that the requirements are met, the machine is
supplied with an EU Declaration of Conformity, issued by
DOOSAN CE for each separate machine. This EU
declaration also covers attachments manufactured by
DOOSAN CE. The documentation is a valuable document,
which must be kept safe and retained for at least ten years.
The document should always accompany the machine when
it is sold.
If the machine is used for other purposes or with other
attachments than described in this manual, safety must at all
times and in each separate case be maintained. The person
carrying out such action is also responsible for the action
which, in some cases, may require a new CE marking and
the issue of a new EU Declaration of Conformity.
The EU EMC Directive
The electronic equipment of the machine may in some
cases cause interference to other electronic equipment, or
suffer from external electromagnetic interference, which may
constitute safety risks.
The EU EMC directive on "Electromagnetic Compatibility,"
89/336/EEC, provides a general description of what
demands can be made on the machine out of a safety point
of view, where permitted limits have been determined and
given according to international standards.
FG001781
Figure 2