Doosan DL220 User manual

Copyright Doosan 2010950106-00117E 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
950106-00117E
Serial Number 5001 and Up
May 2010
DL220

950106-00117E
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
Visibility Information......................................................................... 1-13
Unauthorized Modifications.............................................................. 1-15
General Hazard Information............................................................. 1-15
Before Starting Engine..................................................................... 1-24
Machine Operation........................................................................... 1-28
Maintenance .................................................................................... 1-36
Battery.............................................................................................. 1-46
Towing ............................................................................................. 1-48
Shipping and Transportation............................................................ 1-49
Operating Controls ....................................................................2-1
Component Locations........................................................................ 2-2
Operator's Area.................................................................................. 2-4
Steering Console and Pedals ............................................................ 2-5
Front Instrument Panel .................................................................... 2-14
Right Side Switch Panel................................................................... 2-25
Various Cabin Locations.................................................................. 2-40
Heater and Air Conditioner Operation.............................................. 2-44
Stereo / CD Player (Optional) .......................................................... 2-49
Seat Adjustment............................................................................... 2-51
Seat Belt .......................................................................................... 2-53
Door Side Latch ............................................................................... 2-54
Arm Rest.......................................................................................... 2-55
Fuse Box/Relay/Engine Emergency Stop Switch ............................ 2-56

950106-00117ETable of Contents
II
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 (Optional)............... 3-16
Additional Braking ............................................................................ 3-17
Boom Raise Kick-out ....................................................................... 3-18
Bucket Angle Indicator..................................................................... 3-18
Boom Lower Kick-out (Optional)...................................................... 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...................................................................... 4-20
10 Hour / Daily Service .................................................................... 4-22
50 Hour / Weekly Service ................................................................ 4-31
250 Hour / Monthly Service.............................................................. 4-38
500 Hour / 3 Month Service ............................................................. 4-43
1,000 Hour / 6 Month Service .......................................................... 4-50
1,500 Hour / 9 Month Service .......................................................... 4-58
2,000 Hour / Yearly Service............................................................. 4-60
12,000 Hour / 6 Year Service........................................................... 4-66
Severe Conditions Maintenance...................................................... 4-67

950106-00117E
III
Table of Contents
Bolt Torque Chart............................................................................. 4-68
Electrical System ............................................................................. 4-69
Engine Cooling System.................................................................... 4-71
Handling of Accumulator.................................................................. 4-74
Hydraulic Pressure Checks.............................................................. 4-75
Long Term Storage.......................................................................... 4-80
Parking Brake Adjustment ............................................................... 4-81
Tires................................................................................................. 4-82
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 ....................................................... 7-2
Working Capacities............................................................................ 7-4
Approximate Weight of Workload Materials....................................... 7-4
Index ...........................................................................................8-1

950106-00117ETable of Contents
IV

950106-00117E
I-I
Presentation
1Presentation
PRESENTATION
FG015573
Figure 1

950106-00117EPresentation
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 12,300 kg (27,116 lb)
for DL220. 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
DL220 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.

950106-00117E
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 gear pump. 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.

950106-00117EPresentation
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

950106-00117E
I-V
Presentation
A machine or device which meets the requirements must be CE
marked. Our machines have been tested particularly for
electromagnetic interference. The CE marking of the machine
and the declaration of conformity also cover the EMC directive.
If other electronic equipment is fitted to this machine, the
equipment must be CE marked and tested on the machine with
regard to electromagnetic interference.
COMMUNICATION EQUIPMENT
INSTALLATION
Protection Against Electromagnetic
Interference
This machine has been tested in accordance with EU directive
89/336/EEC governing electromagnetic interference. It is
therefore very important that all nonapproved electronic
accessories, such as communication equipment, must be tested
before installation and use, since they can cause interference to
the electronic systems of the machine.
IMPORTANT
All installation of optional communication equipment must
be carried out by trained professionals and in accordance
with the DOOSAN CE instructions applicable to the
machine.

950106-00117EPresentation
I-VI
PRODUCT PLATES
With the aid of the product plates, shown below, it is possible to
identify the machine and its components. The Product
Identification Number, PIN, indicates the model designation,
engine code and serial number of the machine. The Component
Identification Number, CIN, indicates the serial number of the
component. Make a note of the identification numbers.
When ordering spare parts, and in all telephone enquiries or
correspondence the PIN and CIN must always be quoted.
FG015627
6
8
1, 2
435
7
Figure 1
Reference
Number Description
1 Primary Marking The machine PIN (stamped into right side).
2 Product Plate The manufacturer's name and address, machine PIN.
3Additional Plate
for Product Plate
Machine weight, engine output year of manufacture, year of delivery
and position of CE mark (EU/EEA countries only).
4 Cabin
The manufacturer's name and address, product number, machine
model designation, max. machine weight, cabin serial number, ROPS/
FOPS number and ROPS/FOPS certificate number.
5 Engine The engine type designation and number.
6 Front Axle The manufacturer's name and address and front drive axle CIN.
7 Transmission The manufacturer's name and address and transmission CIN.
8 Rear Axle The manufacturer's name and address and rear drive axle CIN.

OP001012
1-1
Safety
OP001012
1Safety
TO THE OPERATOR OF A
WHEEL LOADER
Please respect the importance of taking responsibility for your
own safety, and that of other people who may be affected by
your actions.
The safety information on the following pages is organized into
the following sections:
1. “General Safety Essentials” on page 1-4
2. “Location of Safety Labels” on page 1-4
3. “Unauthorized Modifications” on page 1-15
4. “General Hazard Information” on page 1-15
5. “Before Starting Engine” on page 1-24
6. “Machine Operation” on page 1-28
7. “Maintenance” on page 1-36
8. “Battery” on page 1-46
9. “Towing” on page 1-48
10. “Shipping and Transportation” on page 1-49
DANGER
Improper use of wheel loader could cause serious injury or
death. Before operating wheel loader, or performing
maintenance, operator or technician must read and
understand entire Operation and Maintenance Manual.
Any operation, maintenance, traveling or shipping methods
that do not follow safety guidelines printed in this Manual
could cause serious injury or death.

OP001012Safety
1-2
Learn Signal Words Used With Safety Alert
Symbol
The words "CAUTION," "WARNING," and "DANGER" used
throughout this manual and on decals on the machine indicate
degree of risk of hazards or unsafe practices. All three degrees
of risk indicate that safety is involved. Observe precautions
indicated whenever you see the Safety Alert "Triangle," no
matter which signal word appears next to the "Exclamation
Point" symbol.
SAFETY ALERT SYMBOL
Be Prepared – Get to Know All Operating and Safety
Instructions.
This is the Safety Alert Symbol. Wherever it appears – in
this manual or on safety signs on the machine – you must
be alert to potential for personal injury or accidents. Always
observe safety precautions and follow recommended
procedures.
CAUTION
This word is used on safety messages and safety labels and
indicates potential of a hazardous situation that, if not
avoided, could result in minor or moderate injury. It may
also be used to alert against a generally unsafe practice.
WARNING
This word is used on safety messages and safety labels and
indicates potential threat of a hazardous situation that, if
not avoided, could result in serious injury or death. It may
also be used to alert against highly unsafe practice.
DANGER
This word is used on safety messages and safety labels and
indicates an imminent hazard of a situation that, if not
avoided, is very likely to cause death or extremely serious
injury. It may also be used to alert against equipment that
may detonate or explode if handled or treated carelessly.

OP001012
1-3
Safety
Safety precautions are described in SAFETY from page 1-4 on.
DOOSAN cannot predict every circumstance that might involve
a potential hazard in operation and maintenance. Therefore the
safety messages in this manual and on the machine may not
include all possible safety precautions. If any procedures or
actions not specifically recommended or allowed in this manual
are used, you must be sure that you and others can do such
procedures and actions safely and without damaging the
machine. If you are unsure about the safety of any procedures,
contact a DOOSAN distributor.

OP001012Safety
1-4
GENERAL SAFETY ESSENTIALS
Accessory Applications
The wheel loader has been designed primarily for moving earth
with a bucket. For use as a grapple or for other object handling,
contact DOOSAN. Lifting-work applications are permitted in
approved lift configuration, to rated capacity only, with no
side-loading (unless prohibited by local regulation). Do not use
machine for activities for which it was not intended. Do not use
bucket for lifting work, unless lift slings are used in approved
configuration.
LOCATION OF SAFETY LABELS
The operator should know and pay attention to the information
and warning plates/decals which are positioned on the machine.
There are several specific warning signs on this machine. The
exact location of hazards and the description of the hazards are
reviewed in this section.
Please become familiarized with all warning signs.
Make sure that all the warning signs are legible. Clean the
warning signs or replace the warning signs if you cannot read
the words. Replace the illustrations if the illustrations are not
visible. When you clean the warning signs, use a cloth, water
and soap. Do not use solvent, gasoline, or other harsh
chemicals to clean the safety signs. Solvents, gasoline, or other
harsh chemicals could loosen the adhesive that secures the
warning sign. Loose adhesive will allow the warning sign to fall
off.
Replace any safety sign that is damaged, or missing. If a safety
sign is attached to a part that is replaced, install a safety sign on
the replacement part.

OP001012
1-5
Safety
13
12
64115 9
10
83 7 10
946
2
FG015631
Figure 1

OP001012Safety
1-6
1. Warnings for Operation, Inspection
and Maintenance (4190-2545A,
190-00092)
2. Warnings for Cooling Fan (2190-3315,
190-00557)
WARNING
•AVOID DEATH OR SERIOUS INJURY - READ
AND UNDERSTAND THE INSTRUCTIONS
AND WARNINGS IN THE OPERATION AND
MAINTENANCE MANUALS prior to
operating this machine.
• Sound the horn to alert the people nearby
before operating, and sure all persons are
clear of area.
• Always make sure when leaving operator's
seat to:
– Lower bucket or other working tools to
the ground.
– Lock transmission selector in neutral.
– Set park brake.
– Turn key switch OFF. Remove key from switch.
• If hydraulic components and units are ABNORMAL, consult nearest DAEWOO dealer or
authorized service shop.
Do not attempt to make an overhaul.
ACO1360L
WARNING
Keep your hands away from the fan during
operation. Entanglement in the fan can cause
serious injury.
AMO0390L

OP001012
1-7
Safety
3. Warnings When Opening Engine Hood
(190-00095)
4. Warnings for Using Wheel Block
(4190-2547A, 190-00207)
WARNING
Before opening hood, shut down engine.
ACO1420L
WARNING
Block wheels to prevent machine movement
before disengaging park brake.
AMO0400L

OP001012Safety
1-8
5. Warnings for Handling Accumulator
(190-00703, 190-00099)
Accumulator
Wheel loader pilot control system is equipped with an
accumulator. Accumulator will store a pressure charge that may
enable hydraulic controls to be activated for a brief period of
time after engine has been shut down. Activation of any controls
may enable selected function to operate under force of gravity.
When shutting machine down, lower front attachment to ground.
After engine has been shut down, turn key to "ON" position and
move joystick controls to release pressure in accumulator.
Remove key.
WARNING
EXPLOSION HAZARD
• Keep away from flame.
• Do not weld on, or drill into the accumulator.
ACO1480L
CAUTION
Any raised attachment will lower to ground if accumulator
holds a charge.
IMPORTANT
Refer to Shop Manual for service procedures. Do not
release any pilot lines until pressure within accumulator
has been released.