Daewoo Doosan DL220 Operator's Manual

Copyright Doosan 2010 950106-00117E Operation and Maintenance Manual DOOSAN reserves the right to improve our products in a continuing process to provide the best possible product to the market place. These improvements can be implemented at any time with no obligation to change materials on previously sold products. It is recommended that consumers periodically contact their distributors for recent documentation on purchased equipment. This documentation may include attachments and optional equipment that is not available in your machine's package. Please call your distributor for additional items that you may require. Illustrations used throughout this manual are used only as a representation of the actual piece of equipment, and may vary from the actual item. Operation and Maintenance Manual 950106-00117E Serial Number 5001 and Up May 2010 DL220

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

950106-00117E Table of Contents II Operation ....................................................................................3-1 Instrument Panel Control Functions................................................... 3-1 New Machine Break-in Procedures ................................................... 3-1 Engine Start and Stop........................................................................ 3-2 Machine Travel ................................................................................ 3-11 Machine Shut Down......................................................................... 3-14 F/R (Forward/Reverse) Travel Control System (Optional) ............... 3-16 Additional Braking ............................................................................ 3-17 Boom Raise Kick-out ....................................................................... 3-18 Bucket Angle Indicator ..................................................................... 3-18 Boom Lower Kick-out (Optional) ...................................................... 3-19 Adjustment of Bucket Position Switch.............................................. 3-19 Towing Machine ............................................................................... 3-20 If Engine Stalls While Traveling ....................................................... 3-21 Allowable Water Depth .................................................................... 3-22 Inspection, Maintenance and Adjustment ...............................4-1 Basic Preventive Maintenance........................................................... 4-1 Safety When Servicing....................................................................... 4-4 Preventive Maintenance .................................................................. 4-12 Table of Recommended Lubricants ................................................. 4-14 Fluid Capacities ............................................................................... 4-16 Lubrication and Service Chart.......................................................... 4-17 Maintenance Intervals ...................................................................... 4-20 10 Hour / Daily Service .................................................................... 4-22 50 Hour / Weekly Service ................................................................ 4-31 250 Hour / Monthly Service.............................................................. 4-38 500 Hour / 3 Month Service ............................................................. 4-43 1,000 Hour / 6 Month Service .......................................................... 4-50 1,500 Hour / 9 Month Service .......................................................... 4-58 2,000 Hour / Yearly Service ............................................................. 4-60 12,000 Hour / 6 Year Service........................................................... 4-66 Severe Conditions Maintenance ...................................................... 4-67

950106-00117E III Table of Contents Bolt Torque Chart............................................................................. 4-68 Electrical System ............................................................................. 4-69 Engine Cooling System.................................................................... 4-71 Handling of Accumulator .................................................................. 4-74 Hydraulic Pressure Checks.............................................................. 4-75 Long Term Storage .......................................................................... 4-80 Parking Brake Adjustment ............................................................... 4-81 Tires ................................................................................................. 4-82 Transportation ...........................................................................5-1 Loading and Unloading ...................................................................... 5-1 Summary of Safety Precautions for Lifting......................................... 5-2 Troubleshooting ........................................................................6-1 Engine ................................................................................................ 6-1 Hydraulic System ............................................................................... 6-3 Travel System .................................................................................... 6-5 Steering.............................................................................................. 6-6 Braking............................................................................................... 6-7 Electrical System ............................................................................... 6-7 Specification ..............................................................................7-1 General Specifications ....................................................................... 7-1 Working Range and Dimensions ....................................................... 7-2 Working Capacities ............................................................................ 7-4 Approximate Weight of Workload Materials ....................................... 7-4 Index ...........................................................................................8-1

950106-00117E Table of Contents IV

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

950106-00117E Presentation I-II Intended Use The machine is intended to be used under normal conditions for the applications described in the Operator's Manual. If it is used for other purposes or in potentially dangerous environments, for example explosive atmosphere or areas with dust containing asbestos, etc., special safety regulations must be followed and the machine must be equipped for such use. Contact the manufacturer/dealer for further information. The machine is designed for a maximum machine weight (includes equipment and attachments) of 12,300 kg (27,116 lb) for DL220. If the maximum weight is exceeded, no warranties on the part of the manufacturer will apply. However, always pay attention to national regulations for traveling on public roads. Engine DL220 has a DOOSAN DL06 5.9 liter engine. The engine has intercooling and is fitted with a common rail system. The common rail system is positioned at an angle above the pistons and are controlled via the camshaft and a electronic control module (ECM). The cylinder head covers all cylinders. The engine has four valves per cylinder. The accelerator position is transferred electrically from accelerator pedal. Electrical System The machine has three control units. The Gauge Panel for the instrumentation is integrated with the display unit, warning lights and instruments and provides the operator with information via there. The Control Unit (for the machine) receives signals from sensors on the machine and these are passed to the Gauge Panel. The ECU controls the engine. Power Transmission The transmission is electrohydraulically controlled, where all gears are in constant mesh. The gear ranges are achieved by applying different combinations of clutches. Between the engine and transmission gears there is a hydraulic torque converter, which controls the output torque. The front and rear axles have planetary gears in the wheel hubs and this reduces the strain on the respective drive shafts.

950106-00117E I-III Presentation Brake System The machine is provided with a dual circuit, all hydraulic, brake system with one circuit for each axle. Each circuit meets the requirements for secondary brake capability. Parking Brake The parking brake is a wet disk brake built into the front axle. The brake is applied by spring force and is released hydraulically. Steering System The machine uses a load sensing, hydrodynamic steering system. It has a steering arc of 40°. Cabin The cabin has a heating and ventilation system with defrosting for front and rear windows. Air-conditioning is standard. The cabin has two emergency exits, the door and right side window. FOPS and ROPS The cabin is approved as a protective cabin according to FOPS and ROPS standards. FOPS is an abbreviation of Falling Object Protective Structure (roof protection) and ROPS is an abbreviation of Roll Over Protective Structure (roll over protection). Never carry out any unauthorized alterations to the cabin, e.g. lowering the roof height, drilling, welding on brackets for fire extinguisher, radio aerial or other equipment, without first having discussed the alteration with personnel at the DOOSAN Infracore Engineering Department. This department will decide whether the alteration may cause the approval to become void. It is important that all parties concerned are aware of these regulations. Hydraulic System The hydraulic system use a gear pump. The first pumping section supplies oil for the front attachment. The second pumping section supplies oil for the steering cylinders. Surplus oil which is not necessary for the steering function is directed into control valve to join the first pump is oil by the priority valve. Pilot pump oil is used for brake and pilot line operation.

950106-00117E Presentation I-IV Equipment The machine can be provided with different types of optional equipment, depending on the requirements of different markets. Examples of such equipment are lever steering, Boom Suspension System (LIS), secondary steering, separate attachment locking, automatic greasing. CE MARKING, EMC DIRECTIVE CE Marking (Declaration of Conformity) (Only applies to machines marketed within the EU/EEA.) This machine is CE marked. This means that when delivered the machine meets the applicable "Essential Health and Safety Requirements," which are given in the Machinery Safety Directive, 98/37EC. Any person carrying out changes that affect the safety of the machine, is also responsible for the same. As proof that the requirements are met, the machine is supplied with an EU Declaration of Conformity, issued by DOOSAN CE for each separate machine. This EU declaration also covers attachments manufactured by DOOSAN CE. The documentation is a valuable document, which must be kept safe and retained for at least ten years. The document should always accompany the machine when it is sold. If the machine is used for other purposes or with other attachments than described in this manual, safety must at all times and in each separate case be maintained. The person carrying out such action is also responsible for the action which, in some cases, may require a new CE marking and the issue of a new EU Declaration of Conformity. The EU EMC Directive The electronic equipment of the machine may in some cases cause interference to other electronic equipment, or suffer from external electromagnetic interference, which may constitute safety risks. The EU EMC directive on "Electromagnetic Compatibility," 89/ 336/EEC, provides a general description of what demands can be made on the machine out of a safety point of view, where permitted limits have been determined and given according to international standards. FG001781 Figure 2

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Daewoo Doosan DL220 Operator's Manual

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