Daewoo Doosan DL200 DL200TC Wheel Loader Operation and Maintenance Manual

Copyright Doosan 2006 K1024537E Operation and Maintenance Manual DOOSAN reserves the right to improve its products continuously, delivering the best possible product to the marketplace. These improvements can be implemented at any time with no obligation to change materials previously sold. It is recommended that consumers periodically contact their distributors for most recent documentation on purchased equipment. This documentation may include attachments and optional equipment not available in your machine's package. Please call your distributor for additional items that you may require. Illustrations used throughout this manual are used only as a representation of the actual piece of equipment, and may vary from the actual item. Operation and Maintenance Manual K1024537E Serial Number 5001 and Up November 2006 DL200 DL200TC

K1024537E I Table of Contents Table of Contents Safety ..........................................................................................1-1 To the Operator of a DOOSAN Wheel Loader ................................... 1-1 General Safety Essentials .................................................................. 1-4 Location of Safety Labels ................................................................... 1-4 Unauthorized Modifications.............................................................. 1-13 General Hazard Information............................................................. 1-13 Before Starting Engine ..................................................................... 1-22 Machine Operation........................................................................... 1-26 Maintenance .................................................................................... 1-34 Battery ............................................................................................. 1-46 Towing .............................................................................................. 1-48 Shipping and Transportation ............................................................ 1-49 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 Various Cabin Locations .................................................................. 2-42 Heater and Air Conditioner Operation.............................................. 2-46 Stereo / CD Player (Optional) .......................................................... 2-51 Seat Adjustment............................................................................... 2-53 Seat Belt .......................................................................................... 2-55 Door Side Latch ............................................................................... 2-56 Arm Rest .......................................................................................... 2-57 Fuse Box/Relay/Engine Emergency Stop Switch ............................ 2-58

K1024537E II Table of Contents Operation ....................................................................................3-1 Instrument Panel Control Functions ................................................... 3-1 New Machine Break-in Procedures ................................................... 3-1 Engine Start and Stop........................................................................ 3-2 Machine Travel ................................................................................. 3-11 Machine Shut Down ......................................................................... 3-14 F/R (Forward/Reverse) Travel Control System (Optional) ................ 3-16 Additional Braking ............................................................................ 3-17 Boom Raise Kick-out........................................................................ 3-18 Bucket Angle Indicator ..................................................................... 3-18 Boom Lower Kick-out (Optional) ...................................................... 3-19 Adjustment of Bucket Position Switch .............................................. 3-19 Towing Machine ............................................................................... 3-20 If Engine Stalls While Traveling ........................................................ 3-21 Allowable Water Depth ..................................................................... 3-22 Inspection, Maintenance and Adjustment ...............................4-1 Basic Preventive Maintenance ........................................................... 4-1 Safety When Servicing....................................................................... 4-4 Preventive Maintenance................................................................... 4-12 Table of Recommended Lubricants ................................................. 4-14 Fluid Capacities ............................................................................... 4-16 Lubrication and Service Chart ......................................................... 4-17 Maintenance Intervals ...................................................................... 4-21 10 Hour / Daily Service .................................................................... 4-23 50 Hour / Weekly Service ................................................................ 4-33 250 Hour / Monthly Service ............................................................. 4-43 500 Hour / 3 Month Service ............................................................. 4-48 1,000 Hour / 6 Month Service .......................................................... 4-55 1,500 Hour / 9 Month Service .......................................................... 4-63 2,000 Hour / Yearly Service ............................................................. 4-65 12,000 Hour / Six Year Service ........................................................ 4-71 Bolt Torque Chart ............................................................................. 4-72

K1024537E III Table of Contents Electrical System ............................................................................. 4-73 Engine Cooling System.................................................................... 4-75 Handling of Accumulator .................................................................. 4-77 Hydraulic Pressure Checks .............................................................. 4-78 Long Term Storage .......................................................................... 4-83 Parking Brake Adjustment................................................................ 4-84 Severe Conditions Maintenance ...................................................... 4-85 Tires ................................................................................................. 4-86 Transmission Recalibration .............................................................. 4-89 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..................................................................................... 6-4 Steering ............................................................................................. 6-5 Braking ............................................................................................... 6-6 Electrical System ............................................................................... 6-6 Specification ..............................................................................7-1 General Specifications ....................................................................... 7-1 Working Range and Dimensions ....................................................... 7-4 Working Capacities ............................................................................ 7-8 Approximate Weight of Workload Materials ....................................... 7-8 Index ...........................................................................................8-1 Publication Request for Proposed Revision ...........................9-1

K1024537E Table of Contents IV

OP000506 1-1 Safety OP000506 1Safety TO THE OPERATOR OF A DOOSAN WHEEL LOADER Please respect the importance of taking responsibility for your own safety and that of other people who may be affected by your actions. The safety information on the following pages is organized into the following sections: 1. “General Safety Essentials” on page 1-4 2. “Location of Safety Labels” on page 1-4 3. “Unauthorized Modifications” on page 1-13 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 1-46 9. “Towing” on page 1-48 10. “Shipping and Transportation” on page 1-49 DANGER! Improper use of wheel loader could cause serious injury or death. Before operating wheel loader, or performing maintenance, operator or technician must read and understand entire Operation and Maintenance Manual. Any operation, maintenance, traveling or shipping methods that do not follow safety guidelines printed in this manual could cause serious injury or death.

OP000506 Safety 1-2 Learn Signal Words Used With Safety Alert Symbol The words "CAUTION," "WARNING," and "DANGER" used throughout this manual and on decals on the machine indicate degree of risk of hazards or unsafe practices. All three degrees of risk indicate that safety is involved. Observe precautions indicated whenever you see the Safety Alert "Triangle," no matter which signal word appears next to the "Exclamation Point" symbol. SAFETY ALERT SYMBOL Be Prepared – Get to Know All Operating and Safety Instructions. This is the Safety Alert Symbol. Wherever it appears – in this manual or on safety signs on the machine – you must be alert to potential threat of personal injury or accident. Always observe safety precautions and follow recommended procedures. CAUTION! This word is used on safety messages and safety labels and indicates potential threat of a hazardous situation that, if not avoided, could result in minor or moderate injury. It may also be used to alert against a generally unsafe practice. WARNING! This word is used on safety messages and safety labels and indicates potential threat of a hazardous situation that, if not avoided, could result in serious injury or death. It may also be used to alert against highly unsafe practice. DANGER! This word is used on safety messages and safety labels and indicates an imminent hazard of a situation that, if not avoided, is very likely to cause death or extremely serious injury. It may also be used to alert against equipment that may detonate or explode if handled or treated carelessly.

OP000506 1-3 Safety Safety precautions are described in SAFETY from page 1-4 on. DOOSAN cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore the safety messages in this manual and on the machine may not include all possible safety precautions. If any procedures or actions not specifically recommended or allowed in this manual are used, you must be sure that you and others can do such procedures and actions safely and without damaging the machine. If you are unsure about the safety of any procedures, contact a DOOSAN distributor.

OP000506 Safety 1-4 GENERAL SAFETY ESSENTIALS Accessory Applications The wheel loader has been designed primarily for moving earth with a bucket. For use as a grapple or for other object handling, contact DOOSAN. Lifting-work applications are permitted in approved lift configuration, to rated capacity only, with no side-loading (unless prohibited by local regulation). Do not use machine for activities for which it was not intended. Do not use bucket for lifting work, unless lift slings are used in approved configuration. LOCATION OF SAFETY LABELS The operator should know and pay attention to the information and warning plates/decals which are positioned on the machine. There are several specific warning signs on this machine. The exact location of hazards and the description of the hazards are reviewed in this section. Please become familiarized with all warning signs. Make sure that all the warning signs are legible. Clean the warning signs or replace the warning signs if you cannot read the words. Replace the illustrations if the illustrations are not visible. When you clean the warning signs, use a cloth, water and soap. Do not use solvent, gasoline, or other harsh chemicals to clean the safety signs. Solvents, gasoline, or other harsh chemicals could loosen the adhesive that secures the warning sign. Loose adhesive will allow the warning sign to fall off. Replace any safety sign that is damaged, or missing. If a safety sign is attached to a part that is replaced, install a safety sign on the replacement part.

Daewoo Doosan DL200 DL200TC Wheel Loader Operation and Maintenance Manual

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