Doosan DL200 Operation And Maintenance Manual Download Page 235

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OP000040

6-1

Troubleshooting

OP000040

Troubleshooting

ENGINE

Problem

Possible Cause

Remedy

Starter does not operate.

Blown fuse.

Replace fuse.

Low battery power.

Charge battery.

Poor terminal contact.

Clean and tighten connections.

Starter switch failed.

Replace switch.

Starter relay failed.

Replace relay.

Starter control failed.

Replace controller.

Wiring harness faulty.

Replace harness.

Battery relay failed.

Replace relay.

Starter engages, engine does
not start.

Blown fuse.

Replace fuse.

Fuel gelled in cold weather.

Replace fuel.

Fuel filters plugged.

Replace filters.

Water or dirt in fuel system.

Clean system and add new
fuel.

Air in fuel system.

Purge air from system.

Engine stop control failed.

Replace stop control.

Engine stop relay failed.

Replace relay.

Engine starts, runs only at low
speed or shuts down.

Engine oil viscosity incorrect.

Change oil.

Clogged or dirty fuel injectors.

Clean injectors.

Fuel filters plugged.

Replace filters.

Engine stop motor cable out
of adjustment.

Readjust.

Engine speed control cable
out of adjustment.

Readjust.

Engine knocks, runs unevenly
or surges.

Low engine oil.

Add oil.

Plugged air intake system.

Clean system and replace
filter.

Injection pump out of
adjustment.

Contact your

DOOSAN

dealer.

Plugged fuel filter.

Replace fuel filter.

Water or dirt in fuel system.

Clean system and add new
fuel.

Clogged or dirty fuel injectors.

Clean injectors.

Summary of Contents for DL200

Page 1: ...ed 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 ...

Page 2: ......

Page 3: ...tion 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...

Page 4: ...chine 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 Se...

Page 5: ... 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 ...

Page 6: ...K1024537E Table of Contents IV ...

Page 7: ...K1024537E I I Presentation 1Presentation PRESENTATION FG008047 Figure 1 ...

Page 8: ...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 wi...

Page 9: ...rotective 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 Thi...

Page 10: ...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 pe...

Page 11: ...rference 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 elec...

Page 12: ...Reference Number Description 1 Primary Marking The machine PIN stamped into right side 2 Product Plate The manufacturer s name and address machine PIN 3 Additional 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 wei...

Page 13: ... page 1 13 4 General Hazard Information on page 1 13 5 Before Starting Engine on page 1 22 6 Machine Operation on page 1 26 7 Maintenance on page 1 34 8 Battery on page 1 44 9 Towing on page 1 46 10 Shipping and Transportation on page 1 47 DANGER Improper use of wheel loader could cause serious injury or death Before operating wheel loader or performing maintenance operator or technician must read...

Page 14: ...jury 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...

Page 15: ...fore 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 some procedures contact a DOOSAN distributor ...

Page 16: ...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 of 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 no...

Page 17: ...OP000506 1 5 Safety 1 3 10 12 6 4 11 5 9 8 3 7 10 9 4 6 2 FG008049 Figure 1 ...

Page 18: ... operating and make sure all persons are clear of area Always make sure when leaving operator s seat to Lower bucket or other working tools to ground LOCK transmission selector in NEUTRAL Set park brake Turn starter switch OFF Remove key from switch If hydraulic components and units are ABNORMAL consult nearest DOOSAN dealer or authorized service shop Do not attempt to make an overhaul ACO1360L WA...

Page 19: ... 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 ...

Page 20: ...able 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 or drill ACO1480L CAUTION Any raised attachment will lower to ground if accumulator holds a char...

Page 21: ...120 7 Warnings for High Temperature Hydraulic Oil 190 00691 190 00097 DANGER Keep out of steering turn area AMO0410L WARNING HYDRAULIC OIL To prevent hot oil from spurting out Turn engine off Allow oil to cool Slowly loosen cap to relieve pressure before removing ACO1410L ...

Page 22: ... sparks and flames away from batteries Always avoid storing metals like tools or inflammable materials around or on batteries Explosion or fire can be caused by short circuiting batteries Sulfuric acid in battery is poisonous It is strong enough to burn skin eat holes in clothing and cause blindness if splashed in eyes If you spill acid on yourself 1 Flush your skin with water 2 Apply baking soda ...

Page 23: ...hment 4190 2546A 190 00105 11 Warnings to Use Safety Lock 4190 1993 190 00121 DANGER To avoid injury securely brace lift arm before disassembly of valve or piping AMO0430L WARNING Safety lock must be in LOCK position when servicing pivot area or transporting machine AMO0440L ...

Page 24: ...OP000506 Safety 1 12 12 Warning Tag 190 00695 190 00098 WARNING Don t touch when performing inspection or maintenance ACO1450L ...

Page 25: ... you are taking medication that makes you feel sleepy if you have been drinking or if you are suffering from emotional problems These problems will interfere with your sense of judgement in emergencies and may cause accidents When working with another operator or with a person on work site traffic duty be sure that all personnel know the nature of the work and understand all hand signals that are ...

Page 26: ...ar telephones inside the operator s compartment when driving or operating the machine There is danger that this may lead to an unexpected accident Never bring any dangerous objects such as flammable or explosive items into the operator s cabin To ensure safety do not use the radio or music headphones when operating the machine There is danger that this may lead to a serious accident When operating...

Page 27: ...ds can cause disabling or permanent injuries NOTE The equivalent continuous A weighted sound pressure level at the workstation for this machine is 76 dB A Measurement is obtained on a dynamic machine following the procedures and cabin conditions as described in ISO 6396 NOTE The guaranteed sound power level emitted by the machinery for this machine is 104 dB A Measurement is obtained on a dynamic ...

Page 28: ...tes where the machine is working and traveling in good condition Remove any large rocks or obstacles Fill any ditches and holes Provide machines for and schedule time to maintain the terrain conditions 7 Travel over longer distance e g on public roads at adjusted medium speed Always adjust the speed for preventing bouncing Asbestos Dust Hazard Prevention Asbestos dust can be HAZARDOUS to your heal...

Page 29: ...gine is running Fuel Oil and Hydraulic Fluid Fire Hazards Fuel oil and antifreeze will catch fire if it is brought close to a flame Fuel is particularly flammable and can be hazardous Always strictly observe the following Add fuel oil antifreeze and hydraulic fluid to the machine only in a well ventilated area The machine must be parked with controls lights and switches turned OFF The engine must ...

Page 30: ...e coolant to cool then loosen the cap slowly to relieve the pressure To prevent hot oil from spurting out shut down engine wait for the oil to cool then loosen the cap slowly to relieve the pressure Injury from Work Equipment Do not enter or put your hand arm or any other part of your body between movable parts such as between the work equipment and cylinders or between the machine and work equipm...

Page 31: ...ous personal injury or death If a fire occurs during operation escape from the machine as follows Turn the starter switch to the O OFF position and shut down engine If there is time use the fire extinguisher to extinguish as much of the fire as possible Use the handrails and steps to escape from the machine The above is the basic method for escaping from the machine but changing the method may be ...

Page 32: ...re is any danger of getting hit by objects that could strike the operator s cabin Make sure that all other work site crew members are kept well away from wheel loader and safe from potential hazards Maintain Standard Safety Equipment in Good Condition Machinery guards and body panel covers must be in place at all times Keep well clear of rotating parts Pinch point hazards such as cooling fan and a...

Page 33: ...les in the accumulator or expose it any flame fire or heat source Do not weld on the accumulator or try attaching anything to it When carrying out disassembly or maintenance of the accumulator or when disposing of the accumulator the charged gas must be properly released Contact your DOOSAN distributor Wear safety goggles and protective gloves when working on an accumulator Hydraulic oil under pre...

Page 34: ...ntact each utility and identify their locations Be careful not to damage or cut any of these lines Check the condition of the river bed and the depth and flow of the water before operating in water or crossing a river NEVER be in water that is in excess of the permissible water depth Refer to Allowable Water Depth on page 3 22 Any type of object in the vicinity of the boom could represent a potent...

Page 35: ...rass paper and other flammable materials accumulated in the engine compartment and around the battery They could cause a fire Remove any dirt from the window glass mirrors handrails and steps Do not leave tools or spare parts laying around in the operator s compartment The vibration of the machine when traveling or during operations may cause them to fall and damage or break the control levers or ...

Page 36: ...vice work is in progress or if a warning tag is attached to controls in the cabin A machine that has not been used recently or is being operated in extremely cold temperatures could require a warm up or maintenance service before start up Check gauges and monitor displays for normal operation before starting the engine Listen for unusual noises and remain alert for other potentially hazardous cond...

Page 37: ...achine is used without repairing the problems it may lead to unexpected injury or failure Clear all personnel from directly around machine and from the area Clear all obstacles from the machine s path Beware of hazards Be sure that all windows are clean Secure the doors and the windows in the open position or in the shut position Adjust the rear view mirrors for best visibility close to the machin...

Page 38: ...t anyone operate machine unless they ve been fully and completely trained in safety and in operation of the machine Seat Belts Must Be Used at All Times Whenever engine is running operator must be seated at the control station with seat belt properly engaged Movement Alarms If wheel loader is equipped with an audible travel movement alarm test alarm on a daily basis Audible alarm should sound as s...

Page 39: ...ugh ground travel at low speed and avoid sudden changes in direction Always keep to the permissible water depth Refer to Allowable Water Depth on page 3 22 When traveling over bridges or structures on private land check first that the bridge or structure can withstand the weight of the machine When traveling on public roads check with the local authorities and follow their instructions Sloping Ter...

Page 40: ...that safety margin NOTE Before starting any type of operation near power lines either above ground or buried cable type you should always contact power utility directly and work out a safety plan with them Before Starting to Dig Contact Authorities Below ground hazards also include natural gas lines water mains tunnels and buried foundations Know what s underneath work site before starting to dig ...

Page 41: ... inadequate supports when work is being done Block wheels fore and aft to prevent any movement Digging Beneath Overhangs Digging beneath an overhang is dangerous Overhang could collapse on top of operator and cause serious injury or death Go on to another digging area before steep overhangs are formed Know height and reach limits of wheel loader and plan ahead while working Park wheel loader away ...

Page 42: ...also be guidelines standards or restrictions on equipment that may be used to perform certain kinds of work Check and follow all local requirements which may also be related to below ground hazards and power lines Never Use Ether Starting Aids An electric grid type manifold heater is used for cold starting Glowing heater element can cause ether or other starting fluid to detonate causing injury Ob...

Page 43: ... hitting the work equipment always do the following When working in tunnels on bridges under electric wires or when parking the machine or carrying out other operations in places with limited height be extremely careful not to hit the bucket or other parts To prevent collisions operate the machine at a safe speed when working in confined spaces indoors or in crowded areas Do not pass the bucket ov...

Page 44: ... becomes unstable In cold weather do not touch metal surfaces with your bare hands If you touch a metal surface in extremely cold weather your skin may freeze to the metal surface Parking Machine Avoid making sudden stops or parking the machine wherever it happens to be at the end of the work day Plan ahead so that the wheel loader will be on firm level ground away from traffic and away from high ...

Page 45: ...ll lock down security equipment that may have been installed on machine Never Let Anyone Ride on Attachment Never let anyone ride on any work attachment such as the bucket crusher grapple or clamshell grab bucket There is a danger of the person falling and suffering serious injury IMPORTANT When hydraulic system maintenance or service work must be performed be aware that accumulators in system sto...

Page 46: ...or that you may slip and injure yourself When washing the machine do the following Wear shoes with nonslip soles to prevent yourself from slipping and falling on wet places Wear safety glasses and protective clothing when washing the machine with high pressure steam Take action to prevent touching high pressure water and cutting your skin or having mud fly into your eyes Do not spray water directl...

Page 47: ...d explosion Fire Prevention and Explosion Prevention All fuels most lubricants and some coolant mixtures are flammable Leaking fuel or fuel that is spilled onto hot surfaces or onto electrical components can cause a fire Store all fuels and all lubricants in properly marked containers and away from all unauthorized persons Store oily rags and other flammable material in a protective container Do n...

Page 48: ...ali Alkali can cause personal injury Do not allow alkali to contact the skin the eyes or the mouth Allow cooling system components to cool before you drain the cooling system Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin Remove the hydraulic tank filter plug only after the engine has been stopped Make sure that the hydraulic tank fi...

Page 49: ...hat contain flammable fluids Do not flame cut on pipes or on tubes that contain flammable fluids Before you weld on pipes or on tubes or before you flame cut on pipes or on tubes clean the pipes or tubes thoroughly with a nonflammable solvent If heat is applied directly to rubber hoses or piping under pressure they may suddenly break so cover them with a fireproof covering Wear protective clothing...

Page 50: ...arried out with the inspection cover open but not locked there is danger that it may suddenly close and cause injury if there is a gust of wind Crushing Prevention and Cutting Prevention You should always have at least two people working together if the engine must be run during service One person needs to remain in the operator s seat ready to work the controls or stop the machine and shut off th...

Page 51: ... operation Park wheel loader on firm level ground and lower all equipment before shutting down and switching OFF controls When engine lube oil gearbox lubricant or other fluids require change wait for fluid temperatures to decrease to a moderate level before removing drain plugs NOTE Oil will drain more quickly and completely if it is warm Do not drain fluids at temperatures exceeding 95 C 203 F h...

Page 52: ... oil has enough force to pierce the skin and cause serious injury Always use a piece of wood or cardboard to check for suspected hydraulic leaks Never use your hands or expose your fingers Do not bend high pressure lines Do not strike high pressure lines Do not install lines tubes or hoses that are bent or damaged Make sure that all clamps guards and heat shields are installed correctly to prevent...

Page 53: ...tical Parts Must Be Replaced Periodically Replace following fire related components as soon as they begin to show any sign of wear or at regular periodic intervals whether or not deterioration is visible Fuel system flexible hoses the tank overflow drain hose and the fuel fill cap Hydraulic system hoses especially the pump outlet lines and front and rear pump branch hoses Keep mounting brackets an...

Page 54: ...s oil fuel solvent filters and batteries Check Tire Pressure and Condition Maintain tire pressure but do not overinflate Inspect tires and wheels daily When inflating tires follow procedures in Maintenance Section which include using an extension to allow you to avoid standing in front of or over a tire Do not change a tire unless you have both experience and proper equipment NOTE Refer to Recomme...

Page 55: ... structure verify that it can handle the load High pressure loads between the boom structure and support may cause the support to slip causing the boom to collapse leading to injuries or death Take the installation location of support and supporting surface into consideration A supporting structure must be used when disconnecting front hoses or removing any other mechanical component related to th...

Page 56: ...r vegetable oil Call a doctor or poison prevention center immediately When cleaning the top surface of the battery wipe it with a clean damp cloth Never use gasoline thinner or any other organic solvent or detergent Tighten the battery caps securely Explosive battery gas can be set off by sparks from accidental contact or static discharge Turn OFF all switches and engine when working on batteries ...

Page 57: ... or vehicle do not allow the two machines to touch Wear safety glasses or goggles while required battery connections are made 24 volt battery units consisting of two series connected twelve volt batteries have a cable connecting one positive terminal on one of the 12 volt batteries to a negative terminal on the other battery Booster or charger cable connections must be made between the nonseries c...

Page 58: ...ne the signals to use and follow these signals correctly If the engine on the problem machine will not start or there is a failure in the brake system always contact your DOOSAN distributor Never go between the towing machine and the towed machine during the towing operation It is dangerous to carry out towing on slopes so select a place where the slope is gradual If there is no place where the sl...

Page 59: ...aration for transport The hauling vehicle trailer and load must all be in compliance with local regulations governing the intended shipping route Partial disassembly or teardown of wheel loader may be necessary to meet travel restrictions or particular conditions at the work site Refer to Transportation on page 5 1 of this Operation and Maintenance Manual for information on loading unloading and t...

Page 60: ...OP000506 Safety 1 48 ...

Page 61: ...0 Seat Belt on page 2 55 11 Door Side Latch on page 2 56 12 Arm Rest on page 2 57 13 Fuse Box Relay Engine Emergency Stop Switch on page 2 58 Each group is explained with a point location drawing or photo and a brief description of each control switch gauge or valve Indicator lights work besides the gauges on the instrument panel The operator should monitor machine pressure on the instrument panel...

Page 62: ...OCATIONS DL200 The following figure identifies the location of major machine components 1 2 3 4 5 6 7 23 24 26 8 25 9 22 10 19 20 11 17 18 17 16 15 14 13 44 12 30 29 27 28 35 33 34 32 21 31 40 37 38 36 39 41 42 43 OPPOSITE SIDE FG008050 Figure 1 ...

Page 63: ...adder 17 Work Light 18 Operator s Cabin 19 Air Cleaner 20 Engine Air Intake Precleaner 21 Engine 22 Muffler 23 CAC Cooler 24 Radiator 25 Grille 26 Fan 27 Fuel Tank 28 Engine Oil Fill Cap 29 Engine Oil Filter 30 Engine Oil Level Dipstick 31 Rear Axle Pivot 32 Rear Axle 33 Drive Shaft Rear 34 Transmission 35 Transmission Oil Filter 36 Drive Shaft Center 37 Center Pin 38 Steering Wheel Cylinder 39 Bo...

Page 64: ...0TC The following figure identifies the location of major machine components 1 2 3 4 5 6 7 9 44 46 45 14 13 16 12 17 22 10 19 20 11 17 18 23 24 26 8 25 15 35 33 34 32 21 31 40 37 36 39 41 42 43 30 29 27 28 OPPOSITE SIDE FG008051 Figure 2 ...

Page 65: ...k Light 18 Operator s Cabin 19 Air Cleaner 20 Engine Air Intake Precleaner 21 Engine 22 Muffler 23 CAC Cooler 24 Radiator 25 Grille 26 Fan 27 Fuel Tank 28 Engine Oil Fill Cap 29 Engine Oil Filter 30 Engine Oil Level Dipstick 31 Rear Axle Pivot 32 Rear Axle 33 Drive Shaft Rear 34 Transmission 35 Transmission Oil Filter 36 Drive Shaft Center 37 Center Pin 38 Steering Wheel Cylinder 39 Lift Cylinder ...

Page 66: ...s controls in operator s cabin 1 3 4 FG006189 2 Figure 3 Reference Number Description 1 Steering Console and Pedal See page 2 7 2 Various Cabin Locations See page 2 42 3 Right Side Switch Panel See page 2 27 4 Seat Adjustment See page 2 53 Reference Number Description ...

Page 67: ...nce Number Description 1 Starter Switch 2 Horn Button 3 Combination Switch 4 Accelerator Pedal 5 Steering Wheel Adjustment Lever 6 Brake Pedals 7 Steering Wheel 8 Kick down Switch 9 Transmission Lever 10 Front Instrument Panel See page 2 16 11 Hour Meter 12 Hazard Warning Light Switch Reference Number Description ...

Page 68: ...ssure warning light should remain ON after the other four have turned OFF NOTE Preheat Indicator Light The operation of the preheat cycle depends on coolant temperature When the engine coolant is cold enough the preheat indicator light will remain ON until the engine preheat cycle is completed The preheat cycle takes about twenty seconds to complete and the indicator light will turn OFF When the l...

Page 69: ...sing the button at the end of the combination switch Figure 6 or the lowest button at the tip of the left pilot control valve lever joystick Figure 8 the horn will sound NOTE Starter switch must be ON Figure 6 AHO0890L FG003935 Figure 7 Optional FG003941 Figure 8 ...

Page 70: ...ate the windshield washer without any fluid If operate without any fluid the washer motor may be damaged Check level in washer tank and add fluid as required NOTE Using soapy water or synthetic detergent instead of window cleaning fluid may damage the wiper blade or painted surfaces Use standard window cleaning fluid SSK703 D Horn Button The center button on end of lever activates horn Only while ...

Page 71: ...l 2 Figure 13 to desired position Push lever down Tilt angle is 21 Adjusting Steering Wheel Telescopic Pull lever 1 Figure 13 upward and move wheel 2 Figure 13 to desired position Push lever down telescopic stroke is 80 mm FG003937 Figure 11 CAUTION The further the pedal is pressed the more engine speed increases However do not press the pedal more than necessary otherwise it will increase fuel co...

Page 72: ...ar This will allow the driver to perform a quick digging movement NOTE Kick down is RELEASED when transmission is placed in NEUTRAL position or the switch is pressed again Kick down function range Automatic 2nd 3rd 4th Manual 2nd FG002183 Figure 14 CAUTION When descending down an incline slow down the machine by using both the brake pedal and the engine as a brake by shifting the transmission to a...

Page 73: ... Neutral When the lever is returned to the center position between forward and reverse the transmission is in NEUTRAL R Reverse When the lever is pulled back transmission is in REVERSE 1st 2nd and 3rd are available Rotating the switch shifts transmission between 1st 2nd 3rd or 4th gears NOTE There is a transmission display on the dash that indicates gears direction of travel error codes and kick d...

Page 74: ...e moved from NEUTRAL to FORWARD and REVERSE 10 Front Instrument Panel See Front Instrument Panel on page 2 16 11 Hour Meter A LCD Meter that records total time When engine is running the hourglass icon blinks every four seconds This shows that the hour meter is working FG003943 Figure 20 CAUTION LOCK transmission lever Whenever machine is parked LOCK transmission lever in NEUTRAL to prevent accide...

Page 75: ...light up and flash warning others in the area At the same time the directional indicator lights on the instrument panel will turn ON to warn the operator The hazard warning lights operate independent of the starter switch O In this position this switch turns OFF hazard warning lights I In this position this switch turns ON all turn signals and they flash simultaneously NOTE Hazard warning lights w...

Page 76: ...OP000507 Operating Controls 2 16 FRONT INSTRUMENT PANEL 40 50 0 10 30 20 15 20 0 30 25 5 10 FG006054 12 11 2 7 4 13 10 14 8 22 23 21 16 24 1 5 6 18 20 17 15 9 19 3 Figure 24 ...

Page 77: ...nsmission Oil Temperature Gauge 7 Transmission Display Reference Number Description Reference Number Description 8 Preheat Indicator Light 9 Air Cleaner Clogged Warning Light 10 Battery Warning Light 11 Left Turn and Hazard Warning Light 12 High Beam Indicator Light 13 Right Turn and Hazard Warning Light 14 Work Light Indicator Light 15 Brake Fluid Pressure Warning Light 16 F R Forward Reverse Sel...

Page 78: ...ossible When the pointer comes close to the E red zone approximately 11 7l 3 U S gal of fuel remains 2 Speedometer This meter displays speed at which vehicle is traveling 3 Hour Meter A LCD meter that records total time When engine is running the hourglass icon blinks every four seconds This shows that the hour meter is working FG003948 Figure 25 10 0 50 40 20 30 FG004182 Figure 26 Figure 27 10 1 ...

Page 79: ...nd transmission circuit 15 20 10 5 0 30 25 FG004183 Figure 28 FG003949 Figure 29 CAUTION When the pointer indicates red zone it means the engine is overheated Stop the operation let the engine run at low rpm and wait for it to cool down Do not shut down engine If engine is shut down heat surge may occur FG003950 Figure 30 CAUTION When the pointer indicates red zone it means the transmission is ove...

Page 80: ...codes have occurred and are stored D Indicates that operation must be stopped immediately to prevent damage to transmission and hazardous operating condition The gear range indicator bars will indicate which gear is selected by displaying the corresponding number of bars The forward and reverse indicator bars will be OFF when the transmission is in MANUAL MODE When transmission is in AUTOMATIC MOD...

Page 81: ... the air filter and is beginning to restrict flow of air Clean or replace air filter before continuing to operate machine To turn indicator light OFF turn starter switch OFF and then back ON 10 Battery Warning Light When starter switch is first turned to ON position this red warning light should turn ON When engine is running this red light should turn OFF If light remains ON when engine is runnin...

Page 82: ...ing or flasher solenoid is damaged 12 High Beam Indicator Light This indicator light will turn ON when the headlights are turned to HIGH BEAM 13 Right Turn and Hazard Warning Light This light blinks when right turn signal is turned ON Both lights blink when warning lights are turned ON NOTE If left and right turn indicators blink together or if they blink faster than normal a light bulb is not ope...

Page 83: ...o sounds 16 F R Forward Reverse Selector Indicator Light Optional This indicator light will turn ON when the 2nd gear function is selected NOTE See F R Forward Reverse Travel Control System Option on page 3 16 for further information Figure 40 2658A Figure 41 HA0O2024 WARNING Never operate or travel machine when this light is ON or when alarm is sounding Always investigate cause of the drop in bra...

Page 84: ... Immediately stop any operation stop machine APPLY parking brake and shut down engine NOTE The light will also turn ON when the system is being tested Figure 43 P 0717A WARNING If vehicle is moved while this light is turned ON it could cause premature wear or damage the brake Always RELEASE parking brake and make sure this light is OFF before traveling machine Figure 44 AJO0450L DANGER Emergency s...

Page 85: ...r blinking check the engine as described under the engine diagnostic switch See page 2 37 Light turned ON nonfatal system error Light is BLINKING fatal system error NOTE The engine warning light flashes out the two digit fault code in the diagnostic mode 20 Not Used 21 Not Used 22 Mirror Heating Indicator Light This indicator light will turn ON when the mirror heater is operated AQO0040L Figure 45...

Page 86: ...ght This indicator light will turn ON when the cooling fan rotates in the reverse direction 24 Electric Steering Select Indicator Light Optional This indicator light will turn ON when the electric steering system is selected FG004185 Figure 48 FG004186 Figure 49 ...

Page 87: ...adlight Switch 8 Front Work Light Switch 9 Rear Work Light Switch 10 Rear Wiper Switch 11 Pilot Cutoff Switch 12 Parking Brake Switch 13 Transmission Cutoff Switch 14 Mirror Heating Switch 15 Reverse Fan Switch 16 Engine Diagnostic Switch 17 Boom Float Switch Optional 18 LIS Switch Optional 19 Seat Heater Switch Optional 20 Fuel Heater Switch Optional 21 Emergency Steering Test Switch Optional 22 ...

Page 88: ...pattern and description of operation A When the log forks control lever 6 Figure 51 is pushed forward the log forks are allowed to open B When the log forks control lever 6 Figure 51 is pulled back the log forks are allowed to close This lever is capable of forward travel and reverse travel 2nd gear function 1 Neutral Switch When this switch is pressed 2nd gear function will be operated and then 2...

Page 89: ...hile KD 5 Figure 51 switch is pressed machine can travel reverse When machine is travelled it can convert forward and reverse travel without pressing KD 5 Figure 51 switch 4 Horn Switch See page 2 31 5 Kick down Switch See page 2 31 NOTE Operating condition of 2nd gear function Start a engine Transmission lever is neutral Parking brake switch is off release NOTE Release condition of 2nd gear funct...

Page 90: ...rearward detent position 6 Figure 53 Bucket will return to set dig position Boom Height Kick out right lever in full rearward detent position 7 Figure 53 Lever will remain in this position until boom is at a preset height then will return to neutral automatically A Kick down Switch Two Places See page 2 12 B Horn Switch Two Places Log Fork Switch Option Horn switch function Log fork switch functio...

Page 91: ... Manual 2nd NOTE Kick down is RELEASED when transmission is placed in NEUTRAL position or the switch is pressed again A second kick down switch Figure 56 is on the end of the transmission lever 3 Horn Button Two Places Pressing the lowest button at the tip of the left pilot control valve lever joystick Figure 58 or the button at the end of the combination switch Figure 59 will sound the horn NOTE ...

Page 92: ...celerate the machine 4 Up and downshifts are made automatically between 1st 2nd 3rd 4th gears forward and between 2nd 3rd 4th in reverse 5 It is unnecessary to use kick down function for 1st gear Auto 2 4 mode Travel mode 1 1 3 is same as Auto 1 4 2 Up and downshifts are made automatically between 2nd 3rd 4th gears forward and between 2nd 3rd 4th in reverse 3 Kick down switch must be used for shif...

Page 93: ...nt panel switch and headlights NOTE If the switch is not in this position with the engine not running the pilot buzzer will sound to warn the operator that the batteries are being discharged I In this position this switch turns ON clearance tail instrument panel and switch lights II In this position this switch turns ON clearance tail instrument panel and headlights 8 Front Work Light Switch O In ...

Page 94: ...n this position windshield washer fluid sprays onto the rear windshield while running the rear wiper When released the switch returns to the O OFF position II In this position this switch turns ON windshield wiper mounted on rear windshield of operator s cabin Figure 65 AHO0850L O I II CAUTION Do not turn ON the work light when traveling on public roads Figure 66 HAOD421L O O I II CAUTION The wash...

Page 95: ...s APPLIED and the indicator light on the front instrument panel comes ON This brake can also be used as an emergency brake Figure 67 HBOI110L O I CAUTION When driving or parking the pilot cutoff switch must be changed to O OFF position Figure 68 HA0O2019 P O I WARNING Set the parking brake switch in the I APPLIED position before leaving the loader Make sure to APPLY the parking brake switch before...

Page 96: ...pressing the left brake pedal This mode is suitable for a load handling operation When the accelerator pedal is pressed in this setting more power is concentrated on the load handling system to quicken the boom lifting speed NOTE 1 Transmission CUTOFF function dose not operate at 3rd and 4th gear for protection of transmission 2 Despite transmission CUTOFF switch the right brake pedal has braking ...

Page 97: ...If the engine warning light turns ON or blinks when the engine is running it means a fault code has been recorded When this occurs the engine diagnostic switch allows the operator to view the fault codes The active fault code is started after this switch turns ON OFF if during the output of the fault code this switch turns ON OFF again the output of the current fault code is interrupted and the ne...

Page 98: ...g and working It improves dynamic stability machine life and comfortability It is most effective when traveling with load in the bucket O In this position the LIS turned OFF I In this position the LIS turned ON at all travel speeds II In this position the LIS will AUTOMATICALLY TURN ON if the forward travel speed exceed 6 km h 3 7 MPH or reverse travel speed exceed 4 km h 2 5 MPH LIS will automati...

Page 99: ... up procedure to ensure that the system is properly functioning Test emergency steering system using the following procedure A Turn starter switch to I ON position NOTE Do not start engine B Press emergency steering test switch and turn steering wheel at the same time If system is functioning properly the unit should steer The emergency steering indicator light should turn ON NOTE If unit does not...

Page 100: ...rging a cellular phone or powering a small 12V DC electrical device Open the cap when using it NOTE This socket is designed for small electrical capacity devices Do not use this socket for large electrical capacity devices Thus damage can be avoided 24 Cup Holder Place to put beverages WARNING Do not press this switch continuously Continuously pressing switch will cause heavy battery discharge The...

Page 101: ...ravel is again controlled by the transmission lever 26 F R Forward Reverse Control Switch Optional To be able to use the forward reverse function the F R selector switch must first be depressed When the switch is activated the F R selector indicator light will be turned ON in the instrument panel O In this position the machine is in NEUTRAL I In this position the machine travels FORWARD II In this...

Page 102: ...1 2 3 5 8 6 7 FG006505 Figure 83 Reference Number Description 1 Cabin Light 2 Stereo CD Player Optional 3 Heater and Air Conditioner Control Panel 4 Speakers 5 Storage Compartment 6 Windshield Washer Tank 7 Electrical Box 8 Fuse Box Reference Number Description ...

Page 103: ...ned ON and OFF irrespective of the position of the starter switch 2 Stereo CD Player Optional For operation of stereo see Stereo CD Player Optional on page 2 51 3 Heater and Air Conditioner Control Panel For operation of heater and air conditioner see Heater and Air Conditioner Operation on page 2 46 FG004192 Figure 84 V O E U M S U P N H O F F O SOUND TUNE L AM FM 1 4 3 2 5 6 SCAN PROGRAM AST FG0...

Page 104: ...ides behind of the operator s seat Keep the operation manual and other documents in this compartment 6 Windshield Washer Tank Contains windshield washer fluid It is located behind the operator s seat 3 Figure 88 7 Electrical Box Contains relays and electric components It is located on left side of cabin Figure 87 HBOM350L 3 2 1 FG003889 Figure 88 FG003956 Figure 89 ...

Page 105: ...0507 2 45 Operating Controls 8 Fuse Box The fuse box is on the upper side of electric box For a detailed explanation of fuses see Fuse Box Relay Engine Emergency Stop Switch on page 2 58 FG003959 Figure 90 ...

Page 106: ...ned into one unit to the right side of the operator s seat If necessary the operator can control interior cabin temperature using the operation panel 3 3 2 2 1 5 4 FG006506 Figure 91 Reference Number Description 1 Operation Panel 2 Front Nozzle Air Conditioner 3 Front Nozzle Defroster 4 Foot Nozzle 5 Rear Nozzle Reference Number Description ...

Page 107: ... Conditioner Switch A OFF Switch Turns OFF the heater and air conditioner unit B A C Switch Turns ON the air conditioner when one of the blower switches is activated FG003966 1 4 5 2 3 Figure 92 Reference Number Description 1 Fan and Air Conditioner Switch 2 Blower Fan Switches 3 Temperature Control Switch 4 Selector Switch for Wind Direction 5 Ventilation Selector Switch Reference Number Descript...

Page 108: ...tch The temperature control consists of 24 stages An LED is turned ON for every three stages Whenever pushing it it changes in stages Pushing it continuously it changes continuously A COOL Switch Lowers the temperature B WARM Switch Raises the temperature LED COLOR STATUS Green LED Air conditioner Full green maximum operation of air conditioner Red LED Heater Full red maximum operation of heater 4...

Page 109: ...t air flow for defrosting front window of operator s cabin 5 Ventilation Selector Switch A A Switch Draws fresh air into operator s compartment B B Switch Recirculates air within the operator s compartment Used to rapidly reduce condensation on windows FG006508 Figure 97 FG006509 Figure 98 Figure 99 HAOC981L A B ...

Page 110: ...or temperature Operate the air conditioner from twenty thirty minutes a week to circulate the refrigerant in the system NOTE The blower switch must be on LO speed NOTE The filter must be cleaned out every 500 hours and replaced with a new one every 1 000 hours NOTE In the event that the unit is being operated in a dusty environment the cleaning and replacement must be performed more frequently If ...

Page 111: ... V O E U M S U P N H O F F O SOUND TUNE L AM FM 1 4 3 2 5 6 SCAN PROGRAM AST FG000108 2 3 7 9 8 5 6 10 4 1 Figure 100 Reference Number Description 1 Power Volume Control 2 Sound Mode Selector 3 Band Selection 4 Tuning Up Down 5 Scan Function Auto Store 6 Preset Station 7 Tape Ejection 8 Fast Forward Rewind 9 Tape Loading Slot 10 LCD Reference Number Description ...

Page 112: ...OP000507 Operating Controls 2 52 CD Player Optional AST DIR FG000109 Figure 101 ...

Page 113: ...ment range is 60 mm 2 36 in for both front and rear 4 Weight Adjustment Knob Turning knob 4 Figure 103 to right makes suspension harder Turning knob to left makes suspension softer Adjust according to operator s weight by checking weight indicator dial Adjustment range is from 50 120 kg 110 265 lb 5 Backrest Adjustment Lever Pulling up right lever 5 Figure 103 allows seat backrest to be moved forw...

Page 114: ...ect and maintain the suspension and adjustment mechanisms of the seat regularly 3 Check that the machine is properly maintained Tire pressure brakes steering linkages etc 4 Steer brake accelerate shift gears move the attachments and load the attachments smoothly 5 Adjust the machine speed and travel path to reduce the vibration level Slow down if it is necessary when passing rough terrain Drive ar...

Page 115: ...osition for maximum comfort and machine control then fasten seat belt Seat belts must be worn across pelvic region and adjusted snugly to lessen chance and severity of injury in event of an accident Never fasten a seat belt across abdomen Under no circumstances should operator be standing in cabin when operating wheel loader Do not adjust seat position while vehicle is moving because a loss of con...

Page 116: ...s emergency exit from the cabin can be opened in two positions Position 1 ventilation position Open the window and secured it with the lock bar A Figure 109 Position 2 full opened position Open the window and push it to backward 3 To release doors from both sides of the cabin Pull the handles Figure 110 in the direction of arrows The handles are located on both sides of the operator s seat 1 FG003...

Page 117: ...ng Controls ARM REST Knob 1 Figure 111 is used to allow armrest to be moved to the most convenient position for the operator Loosen knob and move armrest 2 Figure 111 to desired position Tighten knob 1 2 FG003898 Figure 111 ...

Page 118: ...use is blown turn OFF the starter switch and shut off the power supply Remedy the cause if needed and replace the fuse with a new one FUSE BOX 1 FUSE BOX 2 FG003972 Figure 113 Fuse Box One No Name Capacity 1 Rear Wiper Window Washer 10A 2 Parking Brake Pilot Cut Off 10A 3 Rotating Beacon Optional 10A 4 CCTV Optional 10A 5 Spare 10A 6 Cigar Lighter 10A 7 Turn Signal Light Hazard Light Indicate Ligh...

Page 119: ...IS Optional 10A 4 Electric Steering Optional 10A 5 Emergency Steer Optional 10A 6 Horn Front Wiper 10A 7 Position Light Left 10A 8 Position Light Right 10A 9 Fuel Heater Optional 30A 10 Work Light Rear 20A 11 Mirror Heater 15A 12 Work Light Front 15A 13 Stereo Clock 12V Socket 15A 14 Memory Backup Pilot Buzzer 15A ...

Page 120: ...ng the fuse check the function of the relay Circuit Breaker A circuit breaker is next to the relay by the batteries at back of unit under engine compartment hood When a short circuit or an overload occurs the circuit breaker automatically cuts off current thus preventing electrical wires from burning FG003973 Figure 114 FG003974 Figure 115 FG003975 Figure 116 ...

Page 121: ...not shut down when using the starter switch it can be stopped by moving the engine emergency stop switch to the I Emergency Stop position O In this position the engine emergency stop system is OFF I In this position Emergency Stop is selected the engine will shut down NOTE When released the switch will return to O OFF position FG003978 Figure 117 HAOB100L A Figure 118 WARNING When changing the fus...

Page 122: ...OP000507 Operating Controls 2 62 ...

Page 123: ... BREAK IN PROCEDURES All wheel loaders are inspected and adjusted before leaving the factory However it is required that the operator follow these steps during initial break in period Failure to follow these steps may result in damage to equipment or reduced performance 1 Make sure to check all fluid levels before starting and every 8 10 operating hours 2 Do all Daily maintenance and service check...

Page 124: ...This will ensure that the parking brake is APPLIED 2 Move all control levers to NEUTRAL position 3 Make sure transmission neutral lock is in the N NEUTRAL LOCK position Figure 1 HA0O2019 P O I FG003979 Figure 2 IMPORTANT If transmission lever is not in NEUTRAL position engine will not start FG003980 Figure 3 ...

Page 125: ... I ON position All indicator lights should turn ON NOTE If unit is equipped with and emergency steering system Test system before starting engine If system does not function properly do not start unit Follow test procedure given with test switch 7 Rotate starter key to START position Starter motor should crank immediately and engine should start within a few seconds Figure 4 HBOI111L O I O I HAAH0...

Page 126: ...al engine vibration and noises If any are heard or felt investigate cause NOTE If engine coolant temperature gauge shows red while running take the following action Discontinue work and allow engine to run at LOW IDLE Open engine compartment cover for good ventilation Once engine temperature gauge returns to the green zone shut down engine After engine has cooled check coolant level look for signs...

Page 127: ...ntrol levers to NEUTRAL position 3 Make sure transmission neutral lock is in the N NEUTRAL LOCK position 4 Set pilot cutoff switch to O LOCKED position This will LOCK pilot control valve lever joystick HA0O2019 P O I Figure 9 FG003979 Figure 10 IMPORTANT If transmission lever is not in NEUTRAL position engine will not start FG003980 Figure 11 Figure 12 HBOI111L O I ...

Page 128: ...ter switch to the I ON position Figure 14 When preheat cycle is completed the preheat indicator light 1 Figure 15 will turn OFF 7 Rotate starter key to START position Starter motor should crank immediately and engine should start within a few seconds O I HAAH0040 Figure 13 FG000084 O I Figure 14 1 FG004193 CHECK F R Figure 15 FG000085 O I Figure 16 ...

Page 129: ... pressure oil temperature coolant temperature etc are in normal operating range If any engine system is not normal turn starter key to O OFF position 10 Perform Hydraulic System Warm up Cold Weather on page 3 10 FG003899 O I Figure 17 IMPORTANT If engine does not start after approximately fifteen seconds of cranking release starter key Wait five minutes for starter motor to cool down Repeat step 7...

Page 130: ...ERY TERMINAL 3 Follow normal engine starting procedures 4 After engine has started remove negative jumper cable and then positive cable WARNING Wear safety glasses Never connect negative leads to positive terminals and vice versa DO NOT connect auxiliary or booster battery ground terminal directly to battery terminal Locate and use a ground point on machine frame Depleted batteries generate hydrog...

Page 131: ...Set parking brake switch to the I APPLIED position This will ensure that the parking brake is APPLIED 4 Set bucket on ground 5 Put pilot cutoff switch to O LOCK position This will LOCK pilot control valve lever joystick 6 Allow engine to idle for one two minutes to cool down FG003979 Figure 19 FG003980 Figure 20 Figure 21 HA0O2019 P O I Figure 22 HBOI111L O I ...

Page 132: ...the oil through the system Do this for five minutes NOTE Do not allow cylinders to pass hydraulic oil over relief valve for more than twenty seconds at a time 5 Cycle boom and bucket about five times without a load to circulate oil through system Hydraulic System Warm up Cold Weather 1 Follow Steps 1 through 3 in Hydraulic System Warm up 2 Do not operate machine at full speed until system has full...

Page 133: ...e parking brake is engaged serious damage to parking brake disk will result Select a transmission gear that is appropriate for top speed that will be traveled Choosing a gear that is too high will reduce acceleration and will unnecessarily heat transmission converter oil Never place transmission in NEUTRAL when going down a hill Over speeding transmission can damage transmission gears Never change...

Page 134: ...ng travel as a result of accidentally touching pilot control valve lever joystick 4 Press brake pedal 5 Set transmission neutral lock is in the D DRIVE position 6 Set parking brake switch to the O RELEASE position This will RELEASE the parking brake Figure 26 HBOI111L O I FG002183 Figure 27 FG003980 Figure 28 Figure 29 HAOP043L P O I ...

Page 135: ...ORWARD position 9 Release the brake pedal while slowly pressing the accelerator pedal FG003979 Figure 30 FG003980 Figure 31 WARNING When traveling at high speed or on a steep hill do not make sharp changes in direction This could cause vehicle to overturn When traveling or changing direction always look carefully to be certain that no one is in path of vehicle ...

Page 136: ...k is in the N NEUTRAL LOCK position 4 Set parking brake switch to the I APPLIED position This will ensure that the parking brake is APPLIED Figure 32 FG002183 FG003979 Figure 33 FG003980 Figure 34 CAUTION LOCK transmission lever Whenever machine is parked LOCK transmission lever in NEUTRAL to prevent accidental machine movement Figure 35 HA0O2019 P O I ...

Page 137: ...rger 8 Rotate starter key to O OFF position Remove key 9 If machine is parked on a slope install wheel chocks in front of and behind vehicle wheels Figure 36 HBOI111L O I FG003900 O I Figure 37 Figure 38 2876A WARNING Always secure machine with wheel chocks when parked on a slope Leaving machine in gear will provide no braking effect because transmission clutch is hydraulically operated When engin...

Page 138: ...reverse To activate system perform the following steps 1 Place transmission lever in NEUTRAL NOTE Do not move the transmission lever out of NEUTRAL If the lever is moved the system will be deactivated 2 Press F R selector switch to the I position and then release The switch will return to the O position but the system will be activated When system is activated the F R selector indicator light Figu...

Page 139: ... starter switch is turned OFF When the system is deactivated the F R selector indicator light Figure 41 will be turned OFF ADDITIONAL BRAKING Machine hydraulic system can supply additional dynamic braking force during travel To accomplish this move pilot control valve lever joystick to crowd position and hold it there Hydraulic pump will be driven to supply output at maximum pressure relief pressu...

Page 140: ...r in Raise or Hold Raise position until boom has reached maximum height Then remove your hand from lever Lever will automatically return to NEUTRAL position This prevents hydraulic pump from working against relief valve maximum pressure BUCKET ANGLE INDICATOR Upper right side of bucket includes a bracket that indicates angle of bottom of bucket Top of bracket is parallel with bottom of bucket If b...

Page 141: ...ucket will automatically position itself to be in a preselected digging position usually flat To adjust bucket to desired preselected digging position perform the following steps 1 Operate controls to place bucket on ground and in desired digging position usually flat Return bucket lever to its NEUTRAL position 2 Shut down engine 3 Loosen bolts 1 Figure 47 on bracket 2 4 Position bracket 2 Figure ...

Page 142: ...the loader you are going to tow for steering it Before you tow a vehicle make sure you have checked the following Check the weights of your loader and the vehicle to be towed and make sure you loader has sufficient braking capacity to stop the towed load Check if the vehicle to be towed can be braked and steered If not do not allow anyone to ride on the towed vehicle Check the tow rope or tow bar ...

Page 143: ...t by a trailer truck to your nearest repair shop In addition to the above measures release the parking brake if the engine will not start or the hydraulic pumps are defective IF ENGINE STALLS WHILE TRAVELING BRAKE SYSTEM The brakes can be applied approximately 9 times by pressing the brake pedal due to the oil pressure stored in the accumulator after engine is turned OFF if the engine stalls while...

Page 144: ... housing As a rule of thumb the allowable water depth is about 400 mm This means that the loader should not be used in a river Observe the following conditions 1 Check the water depth in advance when crossing across a river 2 Use the same precautions before crossing across a swampy area 3 Do not enter rivers whose river bed is steep or has a rapid flow CAUTION Avoid use of the loader in salt water...

Page 145: ...The intervals recommended between checks oil changes and lubrication apply provided that the machine is used under normal environmental and operating conditions See Lubrication and Service Chart on page 4 17 Arrival and Delivery Inspection Before the machine leaves the factory it is tested and adjusted The dealer must also if the warranty is to apply carry out Arrival and Delivery Inspections acco...

Page 146: ...he warranties are to apply The first within 100 operating hours and the second at the latest at 1000 operating hours The carrying out of these inspections is a condition for the warranty to apply Condition Test A Condition Test is carried out at authorized dealer workshops and provides information about the general condition of the machine ...

Page 147: ...nt Fuel 6 Draining Coolant 7 Pre Fuel Filter 8 Filling Point Transmission 9 Draining Hydraulic Oil 10 Pilot Filter 11 Oil Dipstick 12 Oil Filter Engine 13 Draining Engine Oil 14 Filling Point Engine 15 Main Fuel Filter 16 Battery 17 Return Oil Filter 18 Filling Point Coolant 19 Filing Point Washer Fluid 20 Filling Point Hydraulic Oil 21 Ventilation Filters Cabin 22 Battery 23 Alternator Belt 24 Su...

Page 148: ...s lifting devices or working methods are used other than those described in this publication Further safety rules and information and warning texts are given within the respective section NOTE Lifting with a jack must only be carried out by trained personnel WARNING If work has to be carried out on the machine before it has cooled down care must be observed with regard to risk of burns from hot li...

Page 149: ...008055 Figure 3 Reference Number Description 1 The bucket attachment must be resting on the ground 2 Apply the parking brake 3 Shut down engine and take out the ignition key Does not apply when checking oil level in transmission 4 Carefully release the pressure in pressure lines and pressure vessels to avoid risks 5 Attach a black and yellow Warning Tag to the steering wheel 6 Connect the frame jo...

Page 150: ...an approved respirator or other protective articles when required Do not wear loose fitting clothing or jewelry Keep service surfaces and handholds clean from oil dirt and ice Use the stepping areas provided with antislip protection to avoid the risk of slipping Worn painted over or loose protections must be replaced Remember that high pressure water jets when washing and spilled oil can cause the...

Page 151: ... operating in an area which is contaminated or dangerous to one s health the machine must be especially equipped for this purpose Special local safety regulations apply within such areas and also when servicing the machine Shut down engine before opening engine covers etc Make sure that no tools or other objects which may cause damage have been forgotten in or on the machine Check that the equipme...

Page 152: ...he machine away from the fire sensitive area caused by the fire 2 Lower the lifting arms to the ground 3 Shut down engine by turning the ignition key to the 0 OFF position 4 Leave the cabin 5 Turn off the battery disconnect switch 6 Start putting out the fire and notify the fire brigade department if necessary It is forbidden to smoke or have an open flame near a machine when filling with fuel or ...

Page 153: ... red and marked R B and routed between the batteries between battery and starter motor between alternator and starter motor to the preheating element on the engine Electrical cables must not lie directly against oil or fuel lines The following applies for welding and grinding work A fire extinguisher must be kept near at hand The ventilation must be good when working indoors Approved respirator mu...

Page 154: ...which take a long time to heal It usually means that damaged tissue must be surgically removed Several hours may pass after contact with the acid before any symptoms appear and therefore one is not given any immediate warning The acid may remain on the machine parts for several years after a fire If swelling redness or a stinging feeling appears and one suspects that the cause may be contact with ...

Page 155: ...he environment must be taken care of in an environmentally safe way Check List After Fire When handling a machine which has been damaged by fire or been exposed to intense heat the following protective measures must under all circumstances be followed Use thick gloves made of rubber and wear goggles which are certain to protect your eyes Never touch burnt components with your bare hands as there i...

Page 156: ...itions Machines working in extremely hot or dusty conditions will require more frequent service checks Total hours of machine operation are determined by hour meter that is on the front instrument panel Product Identification Number P I N Location The PIN is stamped on the product identification plate Figure 9 on the right side of front frame above wheel cover NOTE Please make note of these number...

Page 157: ...recautions 1 Before performing any maintenance checks move pilot cutoff switch to LOCKED position Place a Warning Tag on controls so that no one begins to operate machine while maintenance checks are being performed 2 Clean up all fuel spills Fuel spills are hazardous especially around engine 3 Inspect all fuel lines for leakage Replace any lines fittings O rings or filters that show signs of wear...

Page 158: ...LTEX RANDO HD CZ 46 SIGMA DX 1 10W40 MULTIFAK EP 2 CHEVRON AW 32 BELOW 0 C AW 46 ABOVE 0 C DELO 400 15W40 DELO GREASE EP 2 DELO GEAR OIL or RPM UNIV GEAR 80W90 TEXACO RANDO HDZ 46 URSA SUPER PREMIUM 15W40 MULTIFAK ALL PURPOSE EP 2 MULTI GEAR EP SAE 80W90 ESSO UNIVIS N 46 ESSOLUBE XT 5 15W40 RONEX MP SPARTAN EP220 or EXXON GX 80W90 MOBIL MOBIL DTE 13M MOBIL DELVAC MX 15W40 RONEX MP LUBE SHC LS 15W9...

Page 159: ...ended Concentration Manufacturers Meeting ASTM D3306 50 Antifreeze 50 Distilled Water Dexcool ELC by Chevron Texaco Alugard G48 by BASF Others meeting or exceeding ASTM D3306 CAUTION Do not mix oils from different manufacturers DOOSAN does not endorse specific brands but does suggest that owners select quality oils whose suppliers provide assurance that required standards will always be met or exc...

Page 160: ...oils must be used make the oil drain intervals half of the API CI 4 values 3 Engine oil drain intervals need to be reduced by 50 when fuel sulfur content exceeds 0 5 5000 ppm Component Capacity Engine DL 06 Engine Oil Pan with Filter 27 liters 7 1 U S gal NOTE The filter holds an additional 1 liter 1 qt of oil Cooling System 40 liters 10 6 U S gal Fuel Tank 243 liters 64 U S gal Hydraulic Oil Tank...

Page 161: ...ing into the bearing Therefore grease the bearing until new clean grease is forced out through the outer seal Between 10 and 15 strokes with a normal handheld grease gun is required to grease one of the bearings for the lifting arms Wipe off grease fittings and grease gun before greasing so that dirt and sand is not introduced through the grease fittings Symbol key These standard symbols are used ...

Page 162: ...00509 Inspection Maintenance and Adjustment 4 18 Lubrication and Service Chart DL200 50h 1000h 2000h 1500h 250h 500h 10h FG008083 16 2 3 4 8 18 10 12 13 1 4 6 11 14 6 9 19 19 7 16 21 15 21 4 5 1 Figure 12 ...

Page 163: ...OP000509 4 19 Inspection Maintenance and Adjustment DL200TC 50h 1000h 2000h 1500h 250h 500h 10h FG008084 16 2 3 4 8 18 10 12 13 1 4 6 11 14 6 9 19 19 7 16 21 15 21 4 5 1 Figure 13 ...

Page 164: ...idge 1 F 15 Transmission Filter Cartridge 1 F 16 Full Flow Filter Element 1 F 17 Oil Suction Strainer Strainer 1 C 18 Brake and Pilot Filter Element 1 19 Air Cleaner Element Outer 1 C Element Inner 1 20 Air Intake Precleaner Case 1 C 21 Air Conditioner Filter Outer Cartridge 1 C Inner 1 C V Maintenance and Refill C Cleaning F First Time Exchange Only F100 Every 10 Hours for First 100 Hours W10 Eve...

Page 165: ...Lights 4 29 Start Engine Check Starting Ability and Observe Exhaust Color at Start up and at Normal Operating Temperature Listen for Any Abnormal Sounds 4 29 Check Operation of All Controls 4 29 Inspect Cooling Fan Blade 4 30 Check Engine Drive Belt Wear 4 30 Check Air Intake System 4 31 50 Hour Weekly Service Perform All Daily 10 Hour Service Checks 4 32 Grease Front Attachment Pins 4 32 Grease S...

Page 166: ...4 54 Air Cleaner 4 54 Replace Outer Air Cleaner Element 4 55 Drain and Replace Transmission Oil and Filter 4 56 Clean Fuel Tank and Strainer 4 58 Replace Air Conditioner Inner Filter 4 59 Check Air Conditioner Refrigerant 4 59 Check and Adjust Engine 4 60 Replace Hydraulic Full Flow Filter 4 61 1 500 Hour 9 Month Service Perform All Daily 10 50 250 and 500 Hour Service Checks 4 62 Replace Axle Dif...

Page 167: ...se Front Attachment Pins on page 4 32 Inspect All Tires for Correct Tire Pressure and Signs of Damage or Abnormal Wear 1 Inflate tires to proper operating pressure for working conditions See Tires on page 4 85 Check Engine Oil Level NOTE When checking level using a dipstick always remove and wipe it clean before making final level check 1 Check level of engine oil every day before starting engine ...

Page 168: ...ce transmission lever in NEUTRAL Apply parking brake Shut down engine 4 Block tires Once tires are blocked start engine and have a person remain in the cabin 5 Allow engine to idle until transmission temperature is to 80 C 176 F 6 Remove transmission dipstick Figure 17 Wipe dipstick clean and then insert it back into transmission 7 Remove dipstick and check oil level mark Oil level must be between...

Page 169: ...bled as shown in Figure 21 The hole 1 in the base of the filter fits over a circular base in the bottom of the tank The retaining rod 3 screws into the top of the filter 2 but the spring 4 slides over the top of the rod Be certain that this spring does not fall into the tank during reassembly 1 If filter assembly was removed insert assembly into the tank and check to make sure it is securely in pl...

Page 170: ...ion to make sure that the hoses piping fittings cylinders and hydraulic motors are not showing any signs of leakage If any is noted determine the source of the leak and repair Fill Fuel Tank 1 At end of each work day fill fuel tank Add fuel through fuel fill cap Figure 23 When working at a temperature of 0 C 32 F or higher use ASTM No 2 D or its equivalent At temperatures below 0 C 32 F use ASTM N...

Page 171: ...propylene glycol 1 Check sight gauge 1 Figure 27 that is attached to the radiator Coolant level must be visible in red centered circle shown on gauge To add coolant remove fill cap 2 Figure 27 of the radiator and add coolant to proper level by checking sight gauge 1 Figure 27 If temperature is below freezing see Antifreeze Concentration Tables on page 4 76 for antifreeze protection Use the table t...

Page 172: ...developed 2 Do not allow replaceable bucket teeth to wear down to the point that bucket base edge is exposed Figure 29 NOTE These instructions are only for DOOSAN OEM buckets If you are using other manufacturers buckets refer to their specific instructions Inspect Seat Belt for Proper Operation Inspect the Structure for Cracks and Faulty Welds 1 During the daily walk around inspection and when gre...

Page 173: ...isten for Any Abnormal Sounds Check Operation of All Controls 1 With engine at rated speed operate all of the controls 2 Follow cold weather hydraulic system warm up procedures 3 Note any slow operations or unusual movements Determine the cause and repair fault before operating IMPORTANT Cold weather operation requires that the operator fully warm up the hydraulic oil before beginning machine oper...

Page 174: ...yed or has pieces of material missing 2 Before installing new belts make sure all pulley grooves are clean and not worn Replace pulley if damaged or if the grooves are worn 3 All pulley support bearings shafts and brackets must be in working order 4 When replacing belts and pulleys pulley alignment must be checked with belts tensioned and brackets securely clamped A misalignment that can be detect...

Page 175: ...ed minimum the belt will be able to slip damaging the belts and pulley grooves NOTE When operating in abrasive conditions check tension every 100 hours Check Air Intake System 1 Park the machine on a level surface apply the parking brake lower the attachment to the ground and shut down engine 2 Check the engine intake hose and hose clamps for damage and tightness 3 If damaged wrinkled or loose rep...

Page 176: ...achment Pins DL200 1 Following fittings are greased daily or every 10 hours for first 100 hours of operation to comply with new machine break in requirements After that greasing must be done every 50 hours If bucket is being used in water grease fittings immediately after machine is removed from water A B C D E F FG008088 Figure 34 ...

Page 177: ...ucket hinge pins 2 locations Figure 35 Lever link connecting pin 1 location Figure 36 Bucket link connecting pin 1 location Figure 37 B Arm lever connecting pin 1 location Figure 38 FG008089 Figure 35 FG008090 Figure 36 FG008091 Figure 37 FG008092 Figure 38 ...

Page 178: ...der heads left right 2 locations Figure 40 Lift cylinder rod ends 2 locations Figure 41 E Remote location points Remote fittings for bucket cylinder head 50 HOUR 1 Figure 42 Remote fittings for loader arm foot end 50 HOUR 2 Figure 42 FG006252 Figure 39 FG006253 Figure 40 FG006254 Figure 41 FG006255 1 2 Figure42 ...

Page 179: ...ion Maintenance and Adjustment F Rear Axle pivot 1 Figure 43 3 locations on right side of machine Use remote grease fittings mounted on frame shown in Figure 44 1 FG008093 Figure 43 FRONT PIVOT REAR PIVOT FG008094 Figure 44 ...

Page 180: ...n to comply with new machine break in requirements After that greasing should be done every 50 hours If bucket is being used in water grease fittings immediately after machine is removed from water A Bucket hinge pins 2 locations on each side of bucket Arm link connecting pins 2 locations Figure 46 A B C D E F FG008095 Figure 45 FG008096 Figure 46 ...

Page 181: ... cylinder heads 2 locations Arm lever connecting pins 2 locations Lever link connecting pins 2 locations Figure 43 Link foot pins 2 locations D Lift cylinder heads left right 2 locations Lift cylinder rod ends 2 locations Figure 49 E Remote location points Remote fittings for loader arm foot end 50 HOUR Figure 50 FG008097 Figure 47 FG008098 Figure 48 FG008099 Figure 49 FG008100 Figure 50 ...

Page 182: ...aintenance and Adjustment 4 38 F Rear Axle pivot 1 Figure 51 3 locations on right side of machine Use remote grease fittings mounted on frame shown in Figure 52 1 FG008093 Figure 51 FRONT PIVOT REAR PIVOT FG008094 Figure 52 ...

Page 183: ...nds 2 locations Use remote grease fittings mounted on frame 1 and 2 Figure 54 Grease Upper and Lower Center Pins 1 Center pins upper Figure 55 and lower Figure 56 Two locations on right side of machine FG008101 Figure 53 2 3 1 FG001640 Figure 54 Reference Number Remote Grease Fittings 1 and 2 50 Hours Steering Cylinder Head Ends 3 250 Hours Drive Shaft Center Bearing FG001641 Figure 55 ...

Page 184: ... rebuild and every 1 000 Hours thereafter Follow procedure under 1 000 hour maintenance interval See page 4 61 Check Air Conditioner and Alternator Belt Tension After First 50 Hours 1 Air conditioner and alternator belt tension must be checked after first 50 hours of operation to comply with new machine break in requirements After first check air conditioner and alternator belt must be checked eve...

Page 185: ...ing circulated into operator s cabin They are located under the right side control panel 1 Open access cover on the lower right side of cabin on the outside to gain access filter 2 Remove filter 1 Figure 58 and inspect it for damage 3 Use compressed air to clean filter If element is very dirty use a mild soap and water solution to clean it NOTE Clean air conditioning filter every 50 hours and repl...

Page 186: ... Lower boom and position bucket on ground Shut down engine 2 Position a container under hydraulic tank drain plug Open tank breather cap See Figure 20 on page 4 25 Loosen drain valve at bottom of tank Figure 60 Allow all water and sediment to drain out Tighten drain valve NOTE Dispose of drained fluids according to local regulations Figure 59 WARNING Be certain that hydraulic oil has cooled before...

Page 187: ...e replaced at prescribed intervals the air cleaner is serviced regularly and that the exhaust system and lubricating oil lines do not leak In case jarring noises can be heard or if the turbocharger vibrates it must be reconditioned or replaced immediately Only authorized dealer workshops should carry out work on the turbocharger Check Air Conditioner and Alternator Belt Tension Loosen the tension ...

Page 188: ...n requirements NOTE After first change oil and filter must be changed every 1 000 hours Follow procedure under 1 000 hour maintenance interval See page 4 56 Replace Axle Differential and Planetaries Oil After First 250 Hours NOTE The differential and planetaries oil must be drained and refilled after first 250 hours of operation There after every 1 500 hours of operation See page 4 62 2 3 1 FG0016...

Page 189: ...ing 4 times or every 1 000 hours 6 months service 2 Remove and clean rubber evacuator valve 1 Figure 67 from bottom of air cleaner housing cover 2 Figure 67 Inspect seal lips for wear or damage Replace valve if necessary NOTE Install evacuator valve with lips parallel to the cover 3 Remove the access cover 2 Figure 67 by loosening the latches 3 4 Remove the outer filter 4 Figure 67 from the housin...

Page 190: ...and inner filters Do not clean inner filter Water Trap Take care of fuel spillage by using a vessel or a plastic hose Drain the water trap every 250 hours Draining water from the fuel has to be done by hand A nonreturn valve in the filter head prevents the fuel from running back to the tank As no fuel can run back the pressure will remain and as a consequence no water will be drained unless new fu...

Page 191: ...pilot filter Perform the following steps 1 Vent hydraulic oil tank 2 Unscrew element cover 5 Figure 73 Cover is filled with oil Dispose of oil 3 Remove O ring 3 Figure 73 and filter 4 4 Use a nonflammable nontoxic solvent to clean out cover 5 Figure 73 5 Insert a new filter 4 Figure 73 into cover 5 Install a new O ring 3 6 Screw cover 5 Figure 73 onto filter head 1 FG008104 Figure 72 Figure 73 ...

Page 192: ... clean fuel This will help reduce fuel system priming 5 Start engine After engine has run for a couple of minutes shut down engine and look for signs of leaks If engine does not start fuel system may need priming Prime fuel system using the following procedure A Loosen plug on top of fuel filter head B Unscrew and pump the hand operated primer pump near fuel injection pump Pump primer until fuel i...

Page 193: ... must have the following characteristics 5 micron rating engine mounted Remove Disconnect the wiring harness from the fuel heater if equipped Loosen and remove the fuel filter Make sure the seal ring does not stick to the filter head Remove the ring with an O ring pick if necessary NOTE Both fuel filters must be removed at the same time Install new filter Apply a small amount of oil around filter ...

Page 194: ...r gasket with fuel NOTE Fill fuel filter with clean fuel This will help reduce fuel system priming Clean Exterior of Radiator Oil Cooler and Air Conditioner Condenser 1 Dust and dirt accumulation on fins of radiator oil cooler and additional transmission cooler greatly reduce their cooling efficiency Use compressed air water and steam to clean fins on radiator oil cooler and transmission cooler NO...

Page 195: ... for damage 3 Use compressed air to clean filter If element is very dirty use a mild soap and water solution to clean it NOTE Clean air conditioning filter every 500 hours and replace with a new one every 1 000 hours of service NOTE If water was used to clean filter be sure it is completely dry before installation NOTE In the event that the unit it being operated in a dusty environment the cleanin...

Page 196: ... 104 F NOTE Dispose of drained fluids according to local regulations 2 Replace engine oil filter Figure 84 Engine oil filter is a spin on type Remove and discard filter 3 Install new filter Apply a small amount of oil around filter gasket Screw filter on head until gasket contacts head by hand turn filter 3 4 1 turn more with filter wrench NOTE See Fluid Capacities on page 4 16 for capacity and Ta...

Page 197: ...filter with clean 15W 40 oil Replace Air Conditioner Outer Filter Clean air conditioning outer filter every 50 hours and replace with a new one every 500 hours of service See Clean Air Conditioner Outer Filter on page 4 41 Figure 85 CAUTION The lubricating oil filter must be full of oil at start up to prevent engine damage ...

Page 198: ...acements vary depending on the working environment of the machine In certain environments the filter needs to be replaced more often The filter can be cleaned according to instructions which your authorized dealer will give you However after the filter has been cleaned five times or if it is damaged it must be replaced NOTE Make a mark on the decal at the end of the secondary filter every time the...

Page 199: ... The filter cannot be cleaned but must be replaced The secondary filter works as a protective filter if the main filter is damaged Never remove the secondary filter unless it is to be replaced Replace Outer Air Cleaner Element 1 Open the side access cover at the rear of the cabin 2 Remove the evacuator valve 1 Figure 89 and air cleaner cover 2 Figure 89 NOTE Inspect evacuator valve seal lips for w...

Page 200: ...o perform this operation 2 Start machine and drive it until transmission fluid has warmed to 80 C 176 F Park machine on firm level ground Lower bucket to ground 3 Place transmission lever in NEUTRAL Apply parking brake Shut down engine Block tires NOTE See Fluid Capacities on page 4 16 for capacity and Table of Recommended Lubricants on page 4 14 of this manual for recommended oil for the operatin...

Page 201: ...a person remain in the cabin 16 With engine idling have second person check transmission fluid level again Add fluid until level reaches high mark on dipstick 17 Idle engine until transmission fluid temperature reaches 80 C 176 F Check fluid level with engine idling Level must reach high mark on dipstick NOTE If oil level is above top high mark on dipstick drain oil until level is at high mark NOT...

Page 202: ... fluids according to local regulations 4 Remove bolts inspection cover and gasket Figure 95 from fuel tank 5 Clean inside of the tank and suction stainer 6 Install the inspection cover with a new gasket Tighten the bolts Do not overtighten 7 Close drain valve 8 Fill fuel tank 9 Check for any leaks at cover and plug WARNING Fuel is flammable and harmful to skin Do not smoke while draining moisture ...

Page 203: ...ioner Refrigerant 1 Apply the parking brake and lower attachment to the ground 2 Remove the cover 3 Press the HI flow control switch to set maximum air flow 4 Set the temperature control switch fully to the cool position and fully open the cabin doors 5 Slightly accelerate the engine to about the middle speed range compressor speed 1500 1800 rpm 6 Compare the flow of bubbles in the sight glass wit...

Page 204: ... the following items Engine Compression Pressure Injection Pressure Injection Timing Amount of Refrigerant Appearance of the Sight Glass Solutions Normal Almost clear Any bubbles disappear if the engine speed is increased to 1500 rpm High No bubbles are seen Contact your local DOOSAN loader dealer for inspection and recharging refrigerant Low A flow of bubbles is visible ...

Page 205: ...own onto its base until top of element is approximately 4 mm 0 157 below edge of tank 8 Install a new O ring 4 Figure 97 on cover 2 Set spring 3 into place on element 6 9 Set cover 2 Figure 97 into place over element 6 Install bolts 1 through cover 2 and tighten them 10 Tighten breather cap on tank WARNING The hydraulic oil will be hot after normal machine operation Allow system to cool before att...

Page 206: ... on the differential housing To drain and replace oil in an axle perform the following steps 1 Drive machine onto a level surface Position wheels on axle being drained so that axle end level plugs 1 Figure 98 are in the lowest position Apply parking brake Block wheels 2 Clean areas around drain plugs on both ends of axle Remove plugs NOTE See Fluid Capacities on page 4 16 for capacity and Table of...

Page 207: ...ighten level plugs at all three locations 7 Repeat procedure for other axle Axle Brake Disk Wear Measurement NOTE A wear measurement on the multidisk brake must be made at least once a year especially in case of a change in braking behavior like e g Braking noise Braking power reduced Deceleration changed Brake fluid level changed Braking pressure changed Insert feeler gauge into oil level check h...

Page 208: ... housing Do not use compressed air to blow out housing 4 Install new inner filter and secure it into position with wing nut Do not clean and reuse inner filter 5 Install new outer filter and secure it into position with wing nut 6 Install air cleaner cover NOTE Make sure that all gaskets on wing nuts and cover are properly installed and seated Check Steering Brake Drive Shaft Engine and Fuel Syste...

Page 209: ...y feel when pressing brake pedal is a sign that air is present in brake hydraulic system To bleed air out of brake hydraulic system perform the following steps Figure 102 1 Start engine and place transmission in NEUTRAL 2 Remove rubber cap from bleeder screw on wheel 3 Place one end of a plastic hose 2 over bleeder screw 1 Place other end of hose in a container 3 filled with brake fluid 4 Station ...

Page 210: ...page 4 16 for capacity 2 Place a container under the radiator and open the drain valve Figure 104 NOTE Dispose of drained fluids according to local regulations FG002206 Figure 103 WARNING Allow the engine to cool before releasing the radiator cap Make sure to loosen the cap slowly to release any remaining pressure Radiator cleaning is performed while the engine is running Take extreme caution when...

Page 211: ...ine NOTE See Fluid Capacities on page 4 16 for capacity 2 Position a catch tank beneath hydraulic tank drain plug Open tank breather cap See Figure 20 on page 4 25 Remove drain plug from bottom of tank Figure 106 Allow all hydraulic oil to drain out CAUTION Be certain that hydraulic oil has cooled before draining it Hot oil could splash and cause burns Figure 105 FG008102 Figure 106 Figure 107 ...

Page 212: ... up B Remove spring 2 Figure 109 and suction filter 4 by pulling on rod 3 C Clean in side and outside of strainer Replace strainer if it is broken D Position strainer on boss portion of suction pipe E Fill hydraulic oil tank Check level using sight gauge on side of tank F 6 Install tank drain plug Refill tank by pouring oil in through breather cap opening Install and tighten breather cap 7 Start e...

Page 213: ...l the brake accumulator with oil 3 Shut down engine 4 Turn the starter switch to ON position 5 Count the number of times you can depress the right hand brake pedal before the brake warning light comes on 6 If the number counted is less than five 5 there is some problem with the accumulator Contact your nearest DOOSAN dealer Figure 111 WARNING Pressurized Nitrogen gas in brake accumulator may explo...

Page 214: ...d more than 2 years before being discarded or installed on a machine In service lifetime of hoses fitted on a machine can never exceed 6 years but replace hoses described in Replace Pipes and Hoses on page 4 65 every year Always replace hoses having exceeded the allowed in service lifetime irrespective of the external appearance wear Always store hoses in a dark place at a maximum of 65 relative h...

Page 215: ...r and oil cooler fins to remove dirt and dust 3 Clean fuel system intake strainer and fuel filter more frequently 4 Inspect starter motor and alternator and clean as often as necessary Rocky Terrain 1 Check wheels tires rims and valve stems for damage or excessive wear 2 Inspect for loose or damaged fittings and bolts 3 On a more frequent basis inspect bucket and boom for damage or excessive wear ...

Page 216: ... 30 60 12 mm x std 8 57 62 11 89 86 14 52 105 12 mm x 1 5 9 00 65 12 59 91 14 94 108 14 mm x std 13 55 98 18 95 137 23 10 167 14 mm x 1 5 14 94 108 21 02 152 24 89 180 16 mm x std 20 88 151 29 46 213 35 54 257 16 mm x 1 5 22 54 163 31 53 228 38 03 275 18 mm x std 28 90 209 40 52 293 48 41 350 18 mm x 1 5 32 50 235 45 92 332 55 04 398 20 mm x std 40 94 296 57 95 419 69 01 499 20 mm x 1 5 46 05 333 ...

Page 217: ...e batteries create hydrogen gas An explosion hazard exists particularly with a deeply discharged battery Make sure that open flames burning objects or sparks are kept away from the battery compartment Battery electrolyte is diluted sulfuric acid Take extreme caution when handling the batteries The electrolyte can cause severe chemical burns If any electrolyte gets on your clothing or skin wash it ...

Page 218: ...rmal BLACK Insufficient charging check alternator TRANSPARENT Insufficient battery electrolyte replace with new battery NOTE Colors may vary from one battery manufacturer to another Always refer to instructions on battery The batteries should always be replaced in pairs Using an old battery with a new one will shorten the life span of the new battery ...

Page 219: ...t Engine overheating is often caused by bent or clogged radiator fins The spaces between the fins can be cleaned by use of air or water under pressure When straightening bent fins use care not to damage the tubes or break the bond between the fins and the tubes Heavy duty diesel engines require a balanced mixture of water and antifreeze Drain and replace the mixture every year or 2 000 hours of op...

Page 220: ...he blue green color makes it very difficult to tell the difference of what type of antifreeze is in a cooling system The colors are only a dye added to the clear antifreeze Do not rely on color Keep careful machine records of what brand and type of antifreeze is used in the unit If you are unsure of what type of antifreeze is in the system drain and flush the system NOTE Do not mix ethylene glycol...

Page 221: ...pilot system hoses until accumulator pressure has been released from the circuit To release pressure turn the starter switch to I ON position and operate pilot control valve lever and brake pedal Even though the engine is shut down hydraulic actuated components may move while releasing pilot pressure Keep all personnel away from machine while performing this operation Set pilot cutoff switch to O ...

Page 222: ...ure 1 Attach gauge to port 2 Figure 114 2 Adjust relief valve cartridge on brake pilot and fan motor supply valve Figure 116 Relief pressure Figure 116 for brake charging is 80 5 kg cm2 1 138 70 psi FG001653 1 3 2 4 5 Figure 114 Reference Number Description Pressure 1 Main Pump Pressure TPM 200 5 kg cm2 2 Brake Charge Pressure TP2 80 kg cm2 3 Steer Pump Pressure TPS at Only Steering Relief 200 5 k...

Page 223: ...is not impossible to adjust pressure NOTE Transmission clutch pressure is 16 kg cm2 228 psi Control Lever Activation Pressure 1 Attach gauge to port 5 Figure 114 2 Adjust relief cartridge Figure 118 on brake and pilot and fan motor supply valve Relief pressure must be set at 28 30 kg cm2 398 427 psi 3 Loosen lock nut on adjusting screw Turn adjusting screw clockwise to raise relief pressure Turn a...

Page 224: ...OP000509 Inspection Maintenance and Adjustment 4 80 Parking Brake Release Pressure 1 Attach pressure gauge to parking brake port 2 Figure 119 2 Parking brake pressure must be 52 65 kg cm2 740 925 psi ...

Page 225: ...rrent The proportional relief valve has a fail safe characteristic this means max relief valve setting is adjusted automatically if the voltage supply is interrupted e g broken wire This results in a max fan speed and therefore in a max cooling performance Fan Motor Pressure Standard 100 5 0 kg cm2 1 422 70 0 psi Fan rpm 1 200 7 8 4 3 2 9 1 6 5 FG001746 Figure 120 Reference Number Description 1 En...

Page 226: ...on the inlet hose 3 Check the maximum pressure by fully depressing the accelerator pedal and reading the pressure gauge Maximum fan motor pressure 100 2 kg cm2 The fan speed is approximately 1200 rpm at this time 6 3 4 5 2 1 8 7 FG008112 Figure 121 Reference Number Description 1 Fan Motor 2 Fan Guard 3 Inlet Line 4 Drain Line 5 Outlet Line 6 Relief Valve 7 Proportional Relief Valve 8 Reversable So...

Page 227: ...ht oil to all exposed cylinder rods Apply a coating of light oil to all control linkages and all control valve spools Check condition of oil coating each month and add to coating where necessary Battery Disconnect cables from battery or remove battery from machine If battery is removed fully charge battery and store it Cooling System Care If cooling system does not need antifreeze and is filled wi...

Page 228: ...g bolt 3 Figure 122 clockwise four turns 0 25 mm rotation to set the clearance to 1 mm 0 4 in 5 Install lock bracket 1 Figure 122 and bolt 2 Repeat steps 1 5 for other side Front Axle Parking Brake Emergency Release 1 Locate parking brake release bolt on the lower section on both sides of the housing 2 Loosen lock nut 4 Figure 122 from adjusting bolt 5 3 Tighten adjusting bolt 5 Figure 122 until i...

Page 229: ... tire tread as shown in the figure Tire installed on a split rim may explode causing injury or in the worst case death Use a long air hose with a self attaching air chuck which allows you to stand outside the danger area Tires on stored wheels spare wheels must be kept laying down on their side and only be inflated sufficiently to keep the rim parts in position Wheel Nut Tightening Check After hav...

Page 230: ...a wheel and tire must be removed from machine and replaced or if a tire must be replaced on wheel allow this task to be performed only by experienced service personnel A tire rim could be propelled off wheel and cause serious bodily injury or death See Figure 123 WARNING Improper servicing or changing tires and rims can cause explosion resulting in serious injury or death Do not service or change ...

Page 231: ...s the correct one for the load to be handled and transported over a particular distance If L5 tires are used for loading and carrying operations due attention must be paid to the transporting distances Radial tires are to be preferred for loading and carrying operation as the buildup of heat is less in this type of tire Tires Working Pressure Driving Pressure Remarks Front Rear Front Rear Bias Ply...

Page 232: ...OP000509 Inspection Maintenance and Adjustment 4 88 ...

Page 233: ...load the machine onto to the specified part of the trailer NOTE Have someone in clear view and in a safe position provide directions while loading 5 Lower the bucket and lock each control lever using the pilot cutoff switch 6 Apply the parking brake and set the articulation stopper in the LOCKED position 7 Tape over the exhaust stack outlet to prevent turbo Windmilling damage 8 Place blocks in fro...

Page 234: ...and work site crew Condition of ground support Wheel loader configuration and attachments Weight lifting height and lifting radius Safe rigging of load Proper handling of suspended load Tag lines on opposite sides of load can be very helpful in keeping a suspended load secure if they are anchored safely to control points on ground Figure 3 ...

Page 235: ...l system Clean system and add new fuel Air in fuel system Purge air from system Engine stop control failed Replace stop control Engine stop relay failed Replace relay Engine starts runs only at low speed or shuts down Engine oil viscosity incorrect Change oil Clogged or dirty fuel injectors Clean injectors Fuel filters plugged Replace filters Engine stop motor cable out of adjustment Readjust Engi...

Page 236: ...de oil for weather conditions change oil Clogged oil filter Change filter and oil Defective alarm switch Contact your DOOSAN dealer Oil leakage from pipe or joint Clogged suction strainer Excessive engine wear Defective oil pump Coolant temp warning light turns ON Low engine coolant level Add coolant Loose slipping broken fan belt Adjust or replace belt Clogged radiator fins Clean Scale or mineral...

Page 237: ...Remedy Problem Possible Cause Remedy None of the controls function loud noise from pumps Hydraulic pump failed Contact your DOOSAN dealer Low hydraulic oil level Add hydraulic oil as required Suction line plugged or damaged Clean or replace as required None of the controls function no noise from pumps Pilot pump failure Contact your DOOSAN dealer Cutoff solenoid valve failed Replace solenoid Relie...

Page 238: ... cooler Clean exterior of cooler Oil cooler faulty Contact your DOOSAN dealer Fan belt loose Tighten fan belting as required Actuators on one side of boom have little power or do not operate Overload relief valve is not operating properly Repair valve or replace Damaged hydraulic hose Replace hose Loose hydraulic fittings Tighten fittings Internal damage to control valve housing Replace control va...

Page 239: ...age to torque converter Repair or replace Engine malfunction See Engine Troubleshooting Table Brake valve Disassemble and clean Unusual transmission noise Low transmission fluid or low quality fluid Add fluid or change fluid Worn transmission parts Replace parts Broken gears or bearings Replace parts Transmission fails to operate Damaged transmission clutch disks Replace disks Damaged wires in tra...

Page 240: ...ng pump failure Repair or replace Leaking steering cylinder Repair cylinder Rust on steering column bearing and spline Lubricate Tire air pressure is low Inflate to proper pressure High initial resistance to movement of steering wheel Air in load sensing line inside priority valve Bleed system to remove air Sediment blocking orifice of load sensing line inside priority valve Clean and repair Sedim...

Page 241: ...r bleeding brakes brakes are not fully released Damaged brake disks Replace disks Damaged brake disk return spring Replace return springs Problem Possible Cause Remedy Battery has no power and will not accept a charge Damaged battery plates Replace battery Alternator not charging properly Repair or replace alternator Bad ground Clean and tighten Loose electrical connector Clean and tighten Alterna...

Page 242: ...OP000040 Troubleshooting 6 8 ...

Page 243: ... ps 118 kw 1800 rpm Rated Horse Power 145 ps 107 kw 2100 rpm Max Torque 70 kg m 686 N m 1400 rpm Transmission Full Automatic Power Shift Full Automatic Power Shift Speeds 4 Forward 3 Reverse Brake Systems Service Brakes Full Hydraulic Separate Dual Line Wet Discs Parking Brake Spring Applied Oil Released on Front Axle Wet Disc Performance Travel Speed 6 6 4 1 12 1 7 5 22 6 14 35 21 7 km h MPH Stee...

Page 244: ...1800 rpm Rated Horse Power 145 ps 107 kw 2100 rpm Max Torque 70 kg m 686 N m 1400 rpm Transmission Full Automatic Power Shift Full Automatic Power Shift Speeds 4 Forward 3 Reverse Brake Systems Service Brakes Full Hydraulic Separate Dual Line Wet Discs Parking Brake Spring Applied Oil Released on Front Axle Wet Disc Performance Travel Speed 6 6 4 1 12 1 7 5 22 6 14 35 21 7 km h MPH Steering Angle ...

Page 245: ...n WORKING RANGE AND DIMENSIONS DL200 Figure 1 illustrates exterior machine dimensions and working range of machine when it is equipped with a standard bucket 4 0 T R S Q P 4 5 15 B D E A G C L J M O N H I F K FG008113 Figure 1 ...

Page 246: ...t teeth with base edge H 2 850 mm 9 4 Dump Height at 45 with teeth I 2 730 mm 8 12 Dump Reach at 45 without teeth with base edge J 915 mm 3 Dump Reach at 45 with teeth K 1 000 mm 3 3 Digging Depth L 90 mm 4 Max Bucket Hinge Height M 3 830mm 12 7 Max Tilt Angle at Carry Position N 47 Max Tilt Angle at Ground O 41 Max Tilt Angle at Fully Raised P 63 Max Dump Angle at Fully Height Q 49 Turning Radius...

Page 247: ...5 Specification DL200TC Figure 1 illustrates exterior machine dimensions and working range of machine when it is equipped with a standard bucket 4 0 T R S Q P 4 5 15 B D E A G C L J M O N H I F K FG008114 Figure 1 ...

Page 248: ...t teeth with base edge H 2 780 mm 9 1 Dump Height at 45 with teeth I 2 650 mm 8 8 Dump Reach at 45 without teeth with base edge J 910 mm 2 12 Dump Reach at 45 with teeth K 990 mm 3 3 Digging Depth L 98 mm 4 Max Bucket Hinge Height M 3 813mm 12 6 Max Tilt Angle at Carry Position N 45 Max Tilt Angle at Ground O 44 Max Tilt Angle at Fully Raised P 51 Max Dump Angle at Fully Height Q 46 Turning Radius...

Page 249: ...rd of many types of workload materials APPROXIMATE WEIGHT OF WORKLOAD MATERIALS MATERIAL LOW WEIGHT OR DENSITY 1 100 KG M3 1 850 LB YD3 OR LESS MEDIUM WEIGHT OR DENSITY 1 600 KG M3 2 700 LB YD3 OR LESS HIGH WEIGHT OR DENSITY 2 000 KG M3 3 370 LB YD3 OR LESS Charcoal 401 kg m3 695 lb yd3 Coke blast furnace size 433 kg m3 729 lb yd3 Coke foundry size 449 kg m3 756 lb yd3 Coal bituminous slack piled ...

Page 250: ...61 kg m3 1 620 lb yd3 Gypsum crushed to 3 inch size 1 522 kg m3 2 565 lb yd3 Gravel DRY packed fragments 1 810 kg m3 3 051 lb yd3 Gravel WET packed fragments 1 922 kg m3 3 240 lb yd3 Limestone graded above 2 1 282 kg m3 2 160 lb yd3 Limestone graded 1 1 2 or 2 1 362 kg m3 2 295 lb yd3 Limestone crushed 1 522 kg m3 2 565 lb yd3 Limestone fine 1 602 kg m3 2 705 lb yd3 Phosphate rock 1 282 kg m3 2 16...

Page 251: ...WEIGHT OR DENSITY 1 100 KG M3 1 850 LB YD3 OR LESS MEDIUM WEIGHT OR DENSITY 1 600 KG M3 2 700 LB YD3 OR LESS HIGH WEIGHT OR DENSITY 2 000 KG M3 3 370 LB YD3 OR LESS IMPORTANT Weights are approximations of estimated average volume and mass Exposure to rain snow or ground water settling or compaction due to overhead weight and chemical or industrial processing or changes due to thermal or chemical t...

Page 252: ...OP000510 Specification 7 10 ...

Page 253: ...ickout 3 19 Raise Kickout 3 18 Boom Float Switch 2 38 Brake Charge Pressure 4 78 Brake Pedal 2 12 Brakes Accumulator 4 69 Bleeding 4 65 Brake Fluid Warning 2 23 Brake Fluid Warning Light 2 23 Brake Pedal 2 12 Troubleshooting 6 7 Bucket Angle Indicator 3 18 Capacity 7 7 Position Switch 3 19 Teeth and Side Cutters 4 28 C Cab Light 2 43 Center Pins 4 39 Cigar Lighter 2 32 Circuit Breaker 2 60 Clean E...

Page 254: ...ter 2 18 Hydraulic Oil Tank Drain Water 4 42 Hydraulic System Check Oil Level 4 25 Control Lever Activation Pressure 4 79 Fan Motor Pressure 4 82 Full Flow Filter Replace 4 40 4 61 Hydraulic Oil Replace 4 67 Hydraulic Pressures 4 78 Leaks in the Hydraulic System 4 26 Long Term Storage 4 83 Service Brake Outlet Pressure 4 79 Steering Pump Pressure 4 79 System Pilot Filter Replace 4 47 System Warm u...

Page 255: ... 53 Angle Adjustment of Armrest 2 54 Backrest Adjustment 2 53 Headrest 2 54 Weight Adjustment 2 53 Seat Belt 2 55 Seat Belt Inspection 4 28 Shipping and Transportation 1 47 Shutdown Engine Stop 3 9 Machine 3 14 Shutdown Control Functions 1 33 Sloping Terrain 1 27 Speakers 2 44 Speedometer 2 18 Starter Switch 2 8 Start up Cold Weather Engine Start 3 5 Engine Start 3 2 Hydraulic System Warm up 3 10 ...

Page 256: ... Oil Level Check 4 24 Oil Temperature Gauge 2 19 Transportation 5 1 Travel Precautions 1 27 Travel System Troubleshooting 6 5 Troubleshooting 6 1 U Unauthorized Modifications 1 13 Unloading and Loading 5 1 V Vibration 2 54 Vibration Level 1 15 Visibility 1 31 W Weight of Workload Materials 7 7 Wheel Nut Torque 4 86 Window Washer Liquid 4 28 Work Area 1 30 Work Light Indicator Light 2 23 Working Ca...

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Doosan DL200, Operation And Maintenance Manual

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