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