Doosan DL200 Operation And Maintenance Manual
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Doosan DL200 Operation And Maintenance Manual

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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.
K1024537E Operation and Maintenance Manual
DL200
DL200TC
Operation and Maintenance Manual
K1024537E
Serial Number 5001 and Up
November 2006
Copyright Doosan 2006

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Summary of Contents for Doosan DL200

  • Page 1 Serial Number 5001 and Up November 2006 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.

  • Page 3: Table Of Contents

    Table of Contents Safety ..................1-1 To the Operator of a Wheel Loader ..........1-1 General Safety Essentials ..............1-4 Location of Safety Labels ..............1-4 Unauthorized Modifications............. 1-13 General Hazard Information ............1-13 Before Starting Engine ..............1-22 Machine Operation................1-26 Maintenance ..................
  • Page 4 Operation..................3-1 Instrument Panel Control Functions ..........3-1 New Machine Break-in Procedures ..........3-1 Engine Start and Stop ..............3-2 Machine Travel................3-11 Machine Shut Down ............... 3-14 F/R (Forward/Reverse) Travel Control System (Option)....3-16 Additional Braking ................3-17 Boom Raise Kick-out..............3-18 Bucket Angle Indicator ..............
  • Page 5 Bolt Torque Chart ................4-72 Electrical System................4-73 Engine Cooling System ..............4-75 Handling of Accumulator ..............4-77 Hydraulic Pressure Checks ............4-78 Long Term Storage ................ 4-83 Parking Brake Adjustment.............. 4-84 Tires ....................4-85 Transportation ................5-1 Loading and Unloading ..............5-1 Summary of Safety Precautions for Lifting........
  • Page 6 Table of Contents K1024537E...
  • Page 7 Presentation PRESENTATION FG008047 Figure 1 K1024537E Presentation...
  • Page 8 The machine is designed for a maximum machine weight (includes equipment attachments) 11,645 (25,673 lb) for DL200. 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 DL200 has a DOOSAN DL06 5.9 liter engine.
  • Page 9 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.
  • Page 10 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.
  • Page 11 INSTALLATION IMPORTANT All installation of optional communication equipment must be carried out by trained professionals and in accordance with the DOOSAN CE instructions applicable to the machine. Protection Against Electromagnetic Interference This machine has been tested in accordance with EU directive 89/336/EEC governing electromagnetic interference.
  • Page 12 PRODUCT PLATES With the aid of the product plates, shown below, it is possible to identify the machine and its components. The Product Identification Number, PIN, indicates the model designation, engine code and serial number of the machine. The Component Identification Number, CIN, indicates the serial number of the component.

  • Page 13: Safety

    OP000506 Safety TO THE OPERATOR OF A WHEEL LOADER 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. operation, maintenance, traveling...
  • Page 14 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 alert potential personal injury accidents.
  • Page 15 If you are unsure about the safety of some procedures, contact a DOOSAN distributor. Safety OP000506...

  • Page 16: 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...
  • Page 17 FG008049 Figure 1 OP000506 Safety...
  • Page 18 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. 2. Warnings for Cooling Fan...
  • Page 19 3. Warnings When Opening Engine Hood (190-00095) WARNING! Before opening hood, shut down engine. ACO1420L 4. Warnings for Using Wheel Block (4190-2547A, 190-00207) WARNING! Block wheels to prevent machine movement before disengaging park brake. AMO0400L Safety OP000506...
  • Page 20 5. Warnings for Handling Accumulator (190-00703, 190-00099) WARNING! Explosion hazard: • Keep away from flame. • Do not weld or drill. ACO1480L Accumulator Wheel loader pilot control system is equipped with an accumulator. Accumulator will store a pressure charge that may enable hydraulic controls to be activated for a brief period of time after engine has been shut down.
  • Page 21 6. Keep Out of Steering Turn Area (4190-1992A, 190-00120) DANGER! Keep out of steering turn area. AMO0410L 7. Warnings for High Temperature Hydraulic Oil (190-00691, 190-00097) WARNING! HYDRAULIC OIL To prevent hot oil from spurting out: • Turn engine off. •...
  • Page 22 8. Warnings for High Temperature Coolant (190-00692, 190-00097) WARNING! To prevent hot water from spurting out: • Turn engine "OFF." • Allow water to cool. • Slowly loosen relieve pressure before removing. ACO1410L 9. Warnings for Battery Maintenance (2190-2533A, 190-00100) DANGER! •...
  • Page 23 10. Warnings for Performing Maintenance On Front Attachment (4190-2546A, 190-00105) DANGER! To avoid injury, securely brace lift arm before disassembly of valve or piping. AMO0430L 11. Warnings to Use Safety Lock (4190-1993, 190-00121) WARNING! Safety lock must be in "LOCK" position when servicing pivot area or transporting machine.
  • Page 24 12. Warning Tag (190-00695, 190-00098) WARNING! Don't touch when performing inspection or maintenance. ACO1450L Safety OP000506 1-12...

  • Page 25: Unauthorized Modifications

    Any modification made without authorization or written approval from DOOSAN can create a safety hazard, for which the machine owner must be held responsible. For safety's sake, replace all OEM parts with the correct authorized or genuine DOOSAN part. For example, not...
  • Page 26 Inside Operator's Compartment When entering the operator's compartment, always remove all mud and oil from the soles of your shoes. If you operate the accelerator and brake pedals with mud or oil stuck to your shoes, your foot may slip and this may cause a serious accident.
  • Page 27 Clothing and Personal Protective Items Contain long hair, and avoid loose clothing and jewelry. They can catch on controls or in protruding parts and cause serious injury or death. Do not wear oily clothes. They are highly flammable. Full eye protection, a hard hat, safety shoes and gloves may be required at the work site.
  • Page 28 Recommendations for Limiting Vibrations Select the right machine, equipment and attachments for a particular application. Replace any damaged seat by a genuine DOOSAN part. Keep the seat maintained and adjusted. • Adjust the seat and suspension for the weight and size of the operator.
  • Page 29 Mounting and Dismounting Before getting on or off the machine, if there is any oil. grease, or mud on the handrails, steps, or track shoes, wipe it off immediately. Always keep these parts clean. Repair any damage and tighten any loose bolts. Never jump on or off the machine.
  • Page 30 Precautions When Handling Fluids at High Temperature Immediately after operations are stopped, the coolant, engine oil, and hydraulic oil are at high temperature and the radiator hydraulic tank still under pressure. Attempting to remove the cap, drain the oil or coolant, or replace the filters may lead to serious burns.
  • Page 31 Fire Extinguisher and First Aid Kit As a precaution if any injury or fire should occur, always do the following. • Be sure that fire extinguishers have been provided and read the labels to ensure that you know now them. recommended that appropriately...
  • Page 32 Contact your DOOSAN distributor for available safety guards and/or recommendations if there 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.
  • Page 33 • When carrying out disassembly or maintenance of accumulator, when disposing 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 pressure penetrate...

  • Page 34: Before Starting Engine

    BEFORE STARTING ENGINE Work Site Precautions Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous. Check the terrain and condition of the ground at the work site, and determine the best and safest method of operation. Make the ground surface as hard and horizontal as possible before carrying out operations.
  • Page 35 Avoid operating your machine to close to the edge of cliffs, overhangs, and deep ditches. The ground may be weak in such areas. If the ground should collapse, the machine could fall or tip over and this could result in serious injury or death.
  • Page 36 Engine Starting Walk around your machine before getting in the operator's cabin. Look for evidence of leaking fluid, loose fasteners, misaligned assemblies or any other indications of possible equipment hazard. All equipment covers and machinery safety guards must be in place, to protect against injury while the machine is being operated.
  • Page 37 Before Operating Machine If checks are not carried out properly after starting the engine, it may result in a delay in discovering abnormalities in the machine, and this may lead to personal injury or damage to the machine. Carry out the checks in an open area where there are no obstructions.

  • Page 38: Machine Operation

    IMPORTANT If you need more information or have any questions or concerns about safe operating procedures or working the wheel loader correctly in a particular application or in the specific conditions of your individual operating DOOSAN environment, please consult your local representative.
  • Page 39 Travel Precautions When traveling, wheel loader always keeps lights on; make sure that you are in compliance with all state and local regulations concerning warning flags and signs. Never turn the starter switch to the "O" (OFF) position when traveling. It is dangerous if the engine stops when the machine is traveling.
  • Page 40 Avoid High Voltage Cables Serious injury or death can result from contact or proximity to high voltage electric lines. The bucket does not have to make physical contact with power lines for current to be transmitted. Use a spotter and hand signals to stay away from power lines not clearly visible to operator.
  • Page 41 Use Care on Loose Support Working heavy loads over loose, soft ground or uneven, broken terrain can cause dangerous side load conditions and possible tipover and injury. Travel without a load or balanced load may also be hazardous. If temperatures are changing, be cautious of dark and wet patches when working or traveling over frozen ground.
  • Page 42 Stay Alert for People Moving Through Work Area When loading a truck you should always know where the driver is. Avoid loading over the cabin of a truck even if the driver is in a safe spot. Someone else could have gone inside, for any number of reasons.
  • Page 43 Take Time to Provide Good Visibility Be careful not to go close to the edge of a cliff by mistake. Use the machine only for its main purpose. Using it for other purposes will cause failures. To ensure an ample view, do as follows: •...
  • Page 44 Operate Carefully on Snow and Ice, In Very Cold Temperatures In icy cold weather avoid sudden travel movements and stay away from even very slight slopes. The machine could skid off to one side very easily. Snow accumulation could hide or obscure potential hazards. Use care while operating or while using the machine to clear snow.
  • Page 45 Shutdown Control Functions After bucket has been lowered to overnight storage position, move all switches and controls to "OFF" position. Pull parking brake knob to "APPLIED" position. This will apply parking brake. Move pilot cutoff switch to "LOCK" position. This will disable pilot control valve lever (joystick). Move key in starter switch to "OFF"...

  • Page 46: Maintenance

    Alert others that service or maintenance is being performed and tag operator's cabin controls - and other machine areas if required - with a warning notice. Warning tags for controls are available from DOOSAN WARNING distributors; see Figure 23. HAOC920L...
  • Page 47 Proper Tools Use only tools suited to the task. Using damaged, low qualify, faulty, or makeshift tools could cause personal injury. There is danger that pieces from, chisels with crushed heads, or hammers, may get into your eyes and cause blindness.
  • Page 48 Do not weld on pipes or on tubes that 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.
  • Page 49 Welding Repairs When carrying out welding repairs, carry out the welding in a properly equipped place. The welding must be performed by a qualified worker. During welding operations, there is the danger of, generation of gas, fire, or electric shock, so never let an unqualified worker do welding.
  • Page 50 Precautions When Working on Machine When carrying out maintenance operations on the machine, keep the area around your feet clean and tidy to prevent you from falling. Always do the following: • Do not spill oil or grease. • Do not leave tools laying about. •...
  • Page 51 95°C (203°F), however do not allow full cool down. Hydraulic Cylinder Seals Require Periodic Replacement Check cylinder drift rate at regular intervals. Overhaul seal kits are available through DOOSAN. High-pressure Hydraulic Lines Can Store a Great Deal of Energy Exposed hydraulic hoses on arm could react with explosive force if struck by a falling rock, overhead obstacle or other work site hazard.
  • Page 52 Cool Down Is Required Before Radiator or Reservoir Checks Shut down engine and allow heat to dissipate before performing service on engine radiator or hydraulic fluid reservoir. Both assemblies have air vent levers at or near fill cap for venting built-up air pressure. Release levers before trying to take off fill caps and LOOSEN CAPS SLOWLY, before removal.
  • Page 53 Obtain Immediate Medical Attention if Pressurized Oil Pierces Skin. WARNING! Failure to obtain prompt medical assistance could result in gangrene or other serious damage to tissue. Use Correct Replacement Fasteners Tightened to Proper Torque Refer to "General Maintenance" section of Shop Manual for information tightening torques...
  • Page 54 Dispose of All Petroleum Based Oils and Fluids Properly Physical contact with used motor oil may pose a health risk. Wipe oil from your hands promptly and wash off any remaining residue. Used motor oil is an environmental contaminant and may only be disposed of at approved collection facilities.
  • Page 55 While operating a machine, do not let people enter the operational area. The sudden collapse of the front structure caused from a hose failure may result in injuries or death. Figure 34 When stopping or parking the machine, lower the front structure to the ground.

  • Page 56: Battery

    BATTERY Battery Hazard Prevention Battery electrolyte contains diluted sulfuric acid and batteries generate hydrogen gas. Hydrogen gas is highly explosive, and mistakes in handling them can cause serious injury or fire. To prevent problems, always do the following: • Do not smoke or bring any flame near the battery. •...
  • Page 57 Disconnect Batteries Before Electrical Service or Electrical Welding Remove cable to negative terminal first when disconnecting cable. Connect positive terminal cables first when installing a battery. Use Low Heat Portable Lighting Hot surfaces on trouble lights or portable work lights can set off fuel or battery explosive gases.

  • Page 58: Towing

    • 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.

  • Page 59: Shipping And Transportation

    SHIPPING AND TRANSPORTATION Obey State and Local Over-the-Road Regulations Check state and local restrictions regarding weight, width and length of a load before making any other preparation for transport. The hauling vehicle, trailer and load must all be in compliance with local regulations governing the intended shipping route.
  • Page 60 Safety OP000506 1-48...

  • Page 61: Operating Controls

    OP000507 Operating Controls The "Operating Controls" section presented here consists of the following groups: “Component Locations” on page 2-2 “Operator's Area” on page 2-6 “Steering Console and Pedals” on page 2-7 “Front Instrument Panel” on page 2-16 “Right Side Switch Panel” on page 2-27 “Various Cabin Locations”...

  • Page 62: Component Locations

    COMPONENT LOCATIONS DL200 The following figure identifies the location of major machine components. 23 24 26 OPPOSITE SIDE 29 27 FG008050 Figure 1 Operating Controls OP000507...
  • Page 63 Reference Reference Description Description Number Number Bucket Teeth CAC Cooler Bucket Radiator Air Conditioner Condenser Grille Rear Wheel Cover Battery Box Fuel Tank Rear Light Engine Oil Fill Cap Counterweight Engine Oil Filter Fan Motor Engine Oil Level Dipstick Towing Pin Rear Axle Pivot Muffler Tail Pipe Rear Axle...
  • Page 64 DL200TC The following figure identifies the location of major machine components. 23 24 26 OPPOSITE SIDE 29 27 FG008051 Figure 2 Operating Controls OP000507...
  • Page 65 Reference Reference Description Description Number Number Bucket Teeth Radiator Bucket Grille Air Conditioner Condenser Rear Wheel Cover Fuel Tank Battery Box Engine Oil Fill Cap Rear Light Engine Oil Filter Counterweight Engine Oil Level Dipstick Fan Motor Rear Axle Pivot Towing Pin Rear Axle Muffler Tail Pipe...

  • Page 66: Operator's Area

    OPERATOR'S AREA Figure 3, identifies controls in operator's cabin. FG006189 Figure 3 Reference Reference Description Description Number Number Steering Console and Pedal Right Side Switch Panel (See page 2-7) (See page 2-27) Various Cabin Locations Seat Adjustment (See page 2-42) (See page 2-53) Operating Controls OP000507...

  • Page 67: Steering Console And Pedals

    STEERING CONSOLE AND PEDALS FG006191 Figure 4 Reference Reference Description Description Number Number Starter Switch Steering Wheel Horn Button Kick-down Switch Combination Switch Transmission Lever Accelerator Pedal Front Instrument Panel (See page 2-16) Steering Wheel Adjustment Lever Hour Meter Brake Pedals Hazard Warning Light Switch Operating Controls OP000507...
  • Page 68 1. Starter Switch A three-position starter switch is used to start or shut down engine for equipment operation. Turning the switch to this position turns the engine "OFF" along with its electrical system. In this position the engine is "OFF" but the interior cabin light fuel...
  • Page 69 2. Horn Button (Two Places) Pressing 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. Starter switch must be "ON." NOTE: AHO0890L Figure 6...
  • Page 70 3. Combination Switch Left Side Directional Switch - Pushing lever forward, activates left outside directional lights and directional indicator light on instrument panel. Right Side Directional Switch - Pulling lever back, activates right outside directional lights directional indicator light on instrument panel. When turn completed...
  • Page 71 4. Accelerator Pedal Controls the travel speed of loader and working speed of load handling system. 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 FG003937 consumption, cause short life on the engine, and in Figure 11...
  • Page 72 6. Brake Pedal (Right and Left Pedals) Pressing brake pedal will apply the brakes to the loader. The brake pedal modes can be switched from "INCHING" to "NO INCHING" or vice versa, by using the transmission cutoff switch (See page 2-36). CAUTION! FG002183 When descending down an incline, slow down the...
  • Page 73 A second kick-down switch (Figure 17) is on the right button in the tip of the pilot control valve lever (joystick) (Right one of two levers). FG003940 Figure 17 FG003936 Figure 18 9. Transmission Lever Forward - When the lever is pushed forward, transmission is in "FORWARD."...
  • Page 74 transmission neutral lever lock is in base transmission lever. This neutral lever lock prevents the transmission lever from being moved "NEUTRAL." "NEUTRAL LOCK" position. Prevents lever from being moved out of "NEUTRAL." "DRIVE" position. Allows lever to be moved from "NEUTRAL"...
  • Page 75 12. Hazard Warning Light Switch This warning light is used when the equipment is stopped due to a malfunction or when an emergency occurs. When this switch is pressed the directional indicator lights in front and back of the machine light up and flash, warning others in the area.

  • Page 76: Front Instrument Panel

    FRONT INSTRUMENT PANEL 21 16 FG006054 Figure 24 Operating Controls OP000507 2-16...
  • Page 77 Gauges Reference Reference Description Description Number Number Fuel Gauge Engine Coolant Temperature Gauge Speedometer Transmission Oil Temperature Hour Meter Gauge Tachometer Transmission Display Warning and Indicator Lights Reference Reference Description Description Number Number Preheat Indicator Light F/R (Forward/Reverse) Selector Indicator Light Air Cleaner Clogged Warning Light Parking Brake Indicator Light...
  • Page 78 1. Fuel Gauge This gauge displays amount of fuel in tank. "F" means the tank is "full"; "E" means the tank is "empty." If the pointer comes close to the "E" (red zone), add fuel as soon as possible. When the pointer comes close to the "E"...
  • Page 79 4. Tachometer This meter displays engine speed in revolutions per minute. FG004183 Figure 28 5. Engine Coolant Temperature Gauge This gauge displays temperature of engine coolant. 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.
  • Page 80 7. Transmission Display A transmission display is in the gauge panel on the dash. The LCD indicates, gears, direction of travel, error codes, and activated kick-down. FG006119 Figure 31 Figure 32, shows the transmission display in detail. Indicates travel direction and gear selection. See Figure 33 for more detailed information.
  • Page 81 8. Preheat Indicator Light This indicator light will turn "ON," when the engine preheat function is operating. Do not start engine as long as this light is "ON." HAOA639L Figure 34 9. Air Cleaner Clogged Warning Light This warning light will turn "ON," when dirt has built up in the air filter and is beginning to restrict flow of air.
  • Page 82 11. Left Turn and Hazard Warning Light This light blinks when left turn signal is turned "ON." Both lights blink when warning lights are turned "ON." If left and right turn indicators blink together, or if NOTE: they blink faster than normal, a light bulb is not operating or flasher solenoid is damaged.
  • Page 83 14. Work Light Indicator Light This indicator light will turn "ON," when the front and/or rear work lights are activated. 2658A Figure 40 15. Brake Fluid Pressure Warning Light This warning light will turn "ON," when pressure drops in brake fluid circuit. When light turns "ON," an alarm also sounds.
  • Page 84 17. Parking Brake Indicator Light This indicator light will turn "ON," when the parking brake is "APPLIED." If vehicle is moved while parking brake is applied, a warning alarm will sound. WARNING! If vehicle is moved while this light is turned "ON," it could cause premature wear or damage the 0717A brake.
  • Page 85 19. Engine Warning Light If a defect is present in the engine system, and it is recognized by the ECU and cause a malfunction in operation, it can be displayed with the engine warning light to indicate a warning to the operator. If this Light turns "ON"...
  • Page 86 23. Reverse Fan Indicator Light This indicator light will turn "ON," when the cooling fan rotates in the reverse direction. FG004185 Figure 48 24. Electric Steering Select Indicator Light (Optional) This indicator light will turn "ON," when the electric steering system is selected. FG004186 Figure 49 Operating Controls...

  • Page 87: Right Side Switch Panel

    RIGHT SIDE SWITCH PANEL < Two/Three Lever (Option) > FG006213 Figure 50 Reference Reference Description Description Number Number Pilot Control Valve Lever Reverse Fan Switch (Joystick) Engine Diagnostic Switch Pilot Control Valve Lever Boom Float Switch (Optional) (Two/Three Lever) (Optional) LIS Switch (Optional) Kick-down Switch Seat Heater Switch (Optional)
  • Page 88 1. Pilot Control Valve Lever (Joystick) (Optional) If loader is equipped with log forks this lever controls boom, bucket and log forks. Used to position bucket and boom. This lever is capable of raising or lowering boom, and crowding or dumping bucket.
  • Page 89 Forward Switch When this switch is pressed at forward traveling while "KD" (5, Figure 51) switch is pressed, machine can travel forward. When machine is travelled, it can convert forward and reverse travel without pressing "KD" (5, Figure 51) switch. Reverse Switch When this switch is pressed at reverse traveling while "KD"...
  • Page 90 1A. Pilot Control Valve Lever (Two/Three Lever) (Optional) Move left control lever forward (2, Figure 53) to dump bucket, or rearward (4, Figure 53) to roll back bucket. Move right control lever forward (3, Figure 53) to lower boom or rearward (5, Figure 53) to raise boom. Float (right lever in full forward detent position (1, Figure 53)): This position allows oil flow in and out FG003952...
  • Page 91 2. Kick-down Switch (Two Places) Kick-down Switch Function - When transmission is in 2nd gear, pressing this switch (Figure 57) will shift transmission into 1st gear. This will allow the driver to perform a quick digging movement. Kick-down function range: •...
  • Page 92 4. Cigar Lighter Push the lighter all the way into the socket and release your hand. After pushing it in, it will be ejected when it is heated. If it does not eject after a short time, pull it out and have it serviced. IMPORTANT The cigar lighter is powered by a 24 volt circuit.
  • Page 93 6. Economic Mode Switch This economic mode switch allows the operator to switch between 100% throttle torque and droop curve and about an 80% derated torque curve and droop. In the economy mode, fuel consumption is clearly reduced by utilising a reduced-power characteristic map for the engine.
  • Page 94 9. Rear Work Light Switch In this position, this switch turns "OFF" work lights mounted on the rear top of cabin and the sides of radiator. In this position, this switch turns "ON" work lights mounted on the sides of radiator. In this position, this switch turns "ON"...
  • Page 95 11. Pilot Cutoff Switch In this position the operator cannot operate the pilot control valve lever (joystick). In this position the operator can fully control the movement pilot control valve lever (joystick). CAUTION! HBOI110L Figure 67 When driving or parking, the pilot cutoff switch must be changed to "O"...
  • Page 96 13. Transmission Cutoff Switch This switch changes the mode of the brake pedal from "INCHING" to "NO INCHING." In this position, the "NO INCHING" mode is selected. "NO INCHING" mode, power transmission line is still connected when the brake pedal is pressed, thus, making it easier to start off on an incline.
  • Page 97 15. Reverse Fan Switch This switch causes the radiator cooling fan to rotate in the reverse direction. The function of reversing the direction of the radiator cooling fan is effective in cleaning the radiator. "OFF" position. "ON" position. Activate the switch for reverse rotation in the following FG004188 order;...
  • Page 98 17. Boom Float Switch (Optional) Boom float allows the bucket to follow the contour of the ground/working surface. When pressing this switch and setting work lever to float position, the lever is locked (detent) and boom is lowered. When boom is matched to setting position, the lever lock is released, and lever is returned to "NEUTRAL"...
  • Page 99 20. Fuel Heater Switch (Optional) This switch is used to operate the fuel heater. When the switch is pressed, the fuel heater starts to heat fuel. If the fuel temperature is 5°C and higher, the fuel heater does not operate, even if switch in "I " (ON) position In this position, this switch turns "OFF"...
  • Page 100 WARNING! press this switch continuously. Continuously pressing switch will cause heavy battery discharge. emergency steering motor has a high consumption of power. 22. Rotating Beacon Light Switch (Optional) In this position, this switch turns "OFF" rotating beacon light. In this position, this switch turns "ON" rotating beacon light.
  • Page 101 25. F/R (Forward/Reverse) Selector Switch (Optional) In this position, the F/R control switch is "OFF" In this position, the F/R control switch is activated. When released the switch returns to the "O" (OFF) position, but the system is still activated. When this switch is depressed again, F/R control switch is "OFF"...

  • Page 102: 2Various Cabin Locations

    VARIOUS CABIN LOCATIONS FG006505 Figure 83 Reference Reference Description Description Number Number Cabin Light Storage Compartment Stereo / CD Player (Optional) Windshield Washer Tank Heater and Air Conditioner Electrical Box Control Panel Fuse Box Speakers Operating Controls OP000507 2-42...
  • Page 103 1. Cabin Light Located in the middle of front cabin, it illuminates the cabin for night work. Light turns on when the switch is in the "ON" or "O" position but off in the "OFF" position. Cabin light may be turned "ON" and "OFF" irrespective of the position of the starter switch.
  • Page 104 4. Speakers Emits sound generated by stereo. HBOM350L Figure 87 5. Storage Compartments There are two storage compartments (1 and 2, Figure 88) located both sides behind of the operator's seat. Keep the operation manual and other documents in this compartment.
  • Page 105 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 Operating Controls OP000507 2-45...

  • Page 106: Heater And Air Conditioner Operation

    HEATER AND AIR CONDITIONER OPERATION Location of Controls and Vents FG006506 Figure 91 Reference Reference Description Description Number Number Operation Panel Foot Nozzle Front Nozzle (Air Conditioner) Rear Nozzle Front Nozzle (Defroster) The heater and air conditioner are combined into one unit to the right side of the operator's seat.
  • Page 107 Operation Panel FG003966 Figure 92 Reference Reference Description Description Number Number Fan and Air Conditioner Switch Selector Switch for Wind Direction Blower Fan Switches Ventilation Selector Switch Temperature Control Switch When a switch is selected, the LED above that switch will turn "ON"...
  • Page 108 2. Blower Fan Switches These switches are used to control the speed of the blower fan. "LO" Switch - Used for low blower speed. "MID" Switch - Used for intermediate blower speed. "HI" Switch - Used for high blower speed. If you do not select a blower speed the heater NOTE: HAOC940L...
  • Page 109 Used to direct air flow to lower portion of operator's cabin. FG006508 Figure 97 Used to direct air flow for defrosting front window of operator's cabin. FG006509 Figure 98 5. Ventilation Selector Switch "A" Switch - Draws fresh air into operator's compartment.
  • Page 110 Memory Function of Used Mode The air conditioner panel has a memory function. When the starter switch is turned "OFF" the settings for the panel will be stored. When the excavator is started, the last setting will be used. Additional Operating Instruction A proper interior temperature in summer is 5 - 6°...

  • Page 111: Stereo / Cd Player (Optional)

    STEREO / CD PLAYER (OPTIONAL) Before operating the stereo or CD player, read operation manual enclosed with stereo or CD player. Stereo PROGRAM AM/FM SCAN SOUND TUNE FG000108 Figure 100 Reference Reference Description Description Number Number Power / Volume Control Preset Station Sound Mode Selector Tape Ejection...
  • Page 112 CD Player (Optional) AST/DIR FG000109 Figure 101 Operating Controls OP000507 2-52...

  • Page 113: Seat Adjustment

    SEAT ADJUSTMENT WARNING! Whenever operator or operating condition has changed, check to see that seating position is suitable for the condition at hand. Always fasten your seat belt while operating vehicle. Adjust backrest so that the operator can fully reach and operate pedals. HAOB110L Figure 102 1.
  • Page 114 Recommendations for Limiting Vibrations Select the right machine, equipment and attachments for a particular application. Replace any damaged seat by a DOOSAN genuine part. Keep the seat maintained and adjusted. • Adjust the seat and suspension for the weight and size of the operator.

  • Page 115: Seat Belt

    SEAT BELT WARNING! Seat belt is for operator's safety and should always be worn. Before driving machine, adjust seat to desired position 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.

  • Page 116: Door Side Latch

    DOOR SIDE LATCH Door side latches (1. LH, Figure 107) and (2. RH, Figure 108) are used to secured the doors (RH, LH) to the side of the cabin when they are opened. Keep the door closed and locked when machine NOTE: is not in use.

  • Page 117: Arm Rest

    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. FG003898 Figure 111 Operating Controls OP000507 2-57...

  • Page 118: Fuse Box/Relay/Engine Emergency Stop Switch

    FUSE BOX/RELAY/ENGINE EMERGENCY STOP SWITCH Fuse Boxes There are two fuse boxes inside the cabin. Fuse boxes are on the upper side of the electric box. A usage diagram of fuses is shown inside of fuse box. Spare fuses are mounted on the inside of fuse box cover (10A - Qty.
  • Page 119 Fuse Box Two Name Capacity Gauge Panel Stop Light Auto-detent, LIS (Optional) Electric Steering (Optional) Emergency Steer (Optional) Horn, Front Wiper Position Light (Left) Position Light (Right) Fuel Heater (Optional) Work Light (Rear) Mirror Heater Work Light (Front) Stereo, Clock, 12V Socket Memory Backup, Pilot Buzzer Operating Controls OP000507...
  • Page 120 Relays The relays are in the electrical box on the left side in the operator's cabin. If the problem is not solved after replacing the fuse, check the function of the relay. FG003973 Figure 114 FG003974 Figure 115 Circuit Breaker A circuit breaker is next to the relay by the batteries at back of unit under engine compartment hood.
  • Page 121 Otherwise, a fire could break wiring harness and/or other components of the circuit. Always use original DOOSAN parts. HAOB100L Figure 118 Engine Emergency Stop Switch If the engine does not shut down when using the starter switch, it can be stopped by moving the engine emergency stop switch to the "I"...
  • Page 122 Operating Controls OP000507 2-62...

  • Page 123: Operation

    OP000508 Operation WARNING! Before operating any wheel loader, read and understand "Operating Controls" section of this manual. INSTRUMENT PANEL CONTROL FUNCTIONS Monitoring System Monitoring system uses network circuits between control system and sensors installed at various machine system locations to monitor selected conditions. The monitoring systems function is to continually inform the operator of machine's condition.

  • Page 124: Engine Start And Stop

    ENGINE START AND STOP Engine Start Set parking brake switch to "I" (APPLIED) position. This will ensure that the parking brake is "APPLIED." HA0O2019 Figure 1 Move all control levers to "NEUTRAL" position. IMPORTANT If transmission lever is not in "NEUTRAL" position, engine will not start.
  • Page 125 Set pilot cutoff switch to "O" (LOCK) position. This will "LOCK" pilot control valve lever (joystick). HBOI111L Figure 4 Set reverse fan switch to "O" (OFF) position. This will prevent damage to the cooling system during normal operation. HAAH0040 Figure 5 Rotate starter key to "I"...
  • Page 126 Release starter key when engine starts. Key will return to "I" (ON) position. 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. FG003899 Figure 8 After engine starts, check all indicator lights and...
  • Page 127 Cold Weather Engine Start Set parking brake switch to the "I" (APPLIED) position. This will ensure that the parking brake is "APPLIED." HA0O2019 Figure 9 Move all control levers to "NEUTRAL" position. IMPORTANT If transmission lever is not in "NEUTRAL" position, engine will not start.
  • Page 128 Set reverse fan switch to "O" (OFF) position. This will prevent damage to the cooling system during normal operation. HAAH0040 Figure 13 Turn starter switch to the "I" (ON) position (Figure 14). When preheat cycle is completed, the preheat indicator light (1, Figure 15) will turn "OFF."...
  • Page 129 Release starter key when engine starts. Key will return to "I" (ON) position. 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. FG003899 Figure 17 After engine starts, check all indicator lights and...
  • Page 130 Starting with Auxiliary Batteries 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 hydrogen gas.
  • Page 131 Engine Shut Down Move transmission lever to "NEUTRAL" position. FG003979 Figure 19 Make sure transmission neutral lock is in the "N" (NEUTRAL LOCK) position. FG003980 Figure 20 Set parking brake switch to the "I" (APPLIED) position. This will ensure that the parking brake is "APPLIED." HA0O2019 Figure 21 Set bucket on ground.
  • Page 132 Rotate starter key to "O" (OFF) position. Remove key. FG003900 Figure 23 Hydraulic System Warm-up Correct operating temperature of hydraulic oil is 50° - 80°C (120° - 175°F). Make sure to follow procedures listed below for hydraulic fluid warm-up. Run engine at idle (no load) for five minutes. Run engine for approximately five minutes at middle of speed range, without a load.

  • Page 133: Machine Travel

    MACHINE TRAVEL WARNING! If vehicle is moved while 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.
  • Page 134 Set pilot cutoff switch to "O" (LOCKED) position. This will prevent boom and bucket from accidentally moving during travel, as a result of accidentally touching pilot control valve lever (joystick). HBOI111L Figure 26 Press brake pedal. FG002183 Figure 27 Set transmission neutral lock is in the "D" (DRIVE) position.
  • Page 135 Place transmission lever in desired gear. Shift gears one by one. Do not skip from 1st to 3rd, for example. Shift transmission lever to "FORWARD" position. FG003979 Figure 30 Release the brake pedal while slowly pressing the accelerator pedal. WARNING! When traveling at high speed or on a steep hill, do not make sharp changes in direction.

  • Page 136: Machine Shut Down

    MACHINE SHUT DOWN Ease off throttle and apply travel brakes. FG002183 Figure 32 Put transmission lever in "NEUTRAL." FG003979 Figure 33 Set transmission neutral lock is in the "N" (NEUTRAL LOCK) position. CAUTION! "LOCK" transmission lever. Whenever machine is parked, "LOCK" transmission lever in "NEUTRAL" to prevent accidental machine movement.
  • Page 137 Set bucket on ground. Set pilot cutoff switch to "O" (LOCKED) position. This will lock pilot control valve lever (joystick). Allow engine to idle for one - two minutes to cool down. Stopping a turbocharged engine without a cool down period can seriously damage turbocharger. HBOI111L Figure 36 Rotate starter key to "O"...

  • Page 138: F/R (Forward/Reverse) Travel Control System (Option)

    F/R (FORWARD/REVERSE) TRAVEL CONTROL SYSTEM (OPTION) An optional F/R (Forward/Reverse) travel control system can be installed as an option on the machine. With this system installed, the operator's light-hand can remain on the steering wheel during operation, and not have to manually move the transmission lever between forward and reverse.

  • Page 139: Additional Braking

    The F/R control switch is then used to control the travel direction of the machine. In this position, the machine is in "NEUTRAL." In this position, the machine travels "FORWARD." this position, machine travels "REVERSE." The F/R travel control system will stay activated until one of two things happen.

  • Page 140: Boom Raise Kick-Out

    BOOM RAISE KICK-OUT Placing bucket lever in "Boom Raise Detent" position will lock bucket lever in raise boom position. Boom will raise until trip plate (1, Figure 43) makes contact with bucket height limit switch (2). When limit switch is tripped, boom will stop raising and bucket lever will automatically be returned to "NEUTRAL"...

  • Page 141: Boom Lower Kick-Out (Option)

    BOOM LOWER KICK-OUT (OPTION) Placing bucket lever in "L" position will lock control lever in lower boom position. Boom will move downward until trip plate (1, Figure 46) makes contact with bucket lower limit switch (2). When limit switch is tripped, boom will stop lowering and bucket lever will automatically be returned to "NEUTRAL"...

  • Page 142: Towing Machine

    TOWING MACHINE When necessary to tow another vehicle, the tow rope must be tied to the towing pin on the counterweight at the rear of vehicle. The loader must be used for towing only in an NOTE: emergency. WARNING! Do not tow machine at a speed over 10 km/h (6 MPH) FG001662 and do not tow machine farther than 10 km (6 mi).

  • Page 143: If Engine Stalls While Traveling

    When towing make sure you are doing the following: • Start slowly. A sudden start can lead to a broken tow rope. • The tow line must be along the center line of both your loader and the vehicle to be towed. •...

  • Page 144: Allowable Water Depth

    ALLOWABLE WATER DEPTH The water depth is an important factor to take into consideration when the loader is working in swampy areas. Do not enter water whose depth exceeds the loader's minimum ground clearance height or is high enough to wet the bottom of the axle housing.

  • Page 145: Inspection, Maintenance And Adjustment

    OP000509 Inspection, Maintenance and Adjustment BASIC PREVENTIVE MAINTENANCE For the machine to function satisfactorily and at lowest possible cost, a thorough maintenance program is required. This section of the manual describes the maintenance work which the operator can carry out. If certain operations require trained workshop personnel and special equipment, this will be indicated.
  • Page 146 Service Programmes Warranty Inspection Two Warranty Inspections must be carried out if the 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.
  • Page 147 Service Points FG008054 Figure 2 Reference Reference Description Description Number Number Level Sight Gauge Hydraulic Oil Filling Point, Engine Breather of Hydraulic Oil Main Fuel Filter Air Cleaner Battery Pre Cleaner Return Oil Filter Filling Point, Fuel Filling Point, Coolant Draining, Coolant Filing Point, Washer Fluid Pre Fuel Filter...

  • Page 148: Safety When Servicing

    DOOSAN disclaims all responsibility if other tools, 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.
  • Page 149 Service Position BEFORE beginning service work the machine must be parked on level ground and positioned as shown below. AFTER completing the service, all guards must be installed and all engine covers must be closed and locked. FG008055 Figure 3 Reference Description Number...
  • Page 150 Before Service Read • Read the Operator's Manual and the decals/labels and instructions found on the machine to obtain the required knowledge and information about the machine. • To be able to carry out the service work in a correct way, it is important that the correct tools and equipment be used.
  • Page 151 • Use a long handled window scraper and brush or ladder when cleaning outside windows. • The installation of two-way radio, lever steering or similar equipment must be carried out by a skilled person, faulty installation cause interference with electronic components controlling vital machine functions.
  • Page 152 Fire Prevention Measures There is always a risk of fire. It is important that you use a fire extinguisher that suits your machine and working environment and that you learn how to use it. The fire extinguisher must be placed behind the seat or externally in a lockable box.
  • Page 153 If a high-pressure jet is used for cleaning, take great NOTE: care as the insulation of electric leads can be damaged even at a moderately high-pressure and temperature. Protect electrical leads appropriate way. Take extra care when cleaning the machine after it has been used in a fire sensitive environment, e.g.
  • Page 154 Methods and Precautionary Measures When Removing Paint: Blasting • use respirator and eye protection Paint remover or other chemicals • portable extractor, respirator protective gloves Grinding machine • portable extractor, respirator protective gloves and eye protection Floor Rubber Observe extra great care when it is suspected that you may have to handle floor rubber.
  • Page 155 Rubber and Plastics Polymer materials when heated, can form compounds which are dangerous to health and environment and must therefore never be burned when scrapped. Also take care when handling machines which have been subjected to fire or other extreme heat. If gas cutting or welding is to be carried out near such materials, the following safety instructions must be followed: •...

  • Page 156: Preventive Maintenance

    PREVENTIVE MAINTENANCE Periodic checks and replacement of oil, grease, filters, etc. must be made at specific intervals, to keep machine in good working condition. The following pages describe items to be checked, lubricants to be used, and time interval between each check.
  • Page 157 The number is also stamped in the rear frame on the left side just below the cabin (Figure 10). FG008058 Figure 10 Engine Serial Number The engine name plate (identification label) is attached to engine headcover (1, Figure 11). The engine serial number is stamped on the right rear of the engine block, under exhaust manifold (2, Figure 11).

  • Page 158: Table Of Recommended Lubricants

    TABLE OF RECOMMENDED LUBRICANTS IMPORTANT Do not use lubricants other than those recommended, without prior written approval from DOOSAN. Refer to the Maintenance Intervals Table for NOTE: application points. LUBRICANT LUBRICANT HYDRAULIC OIL ENGINE OIL AXLE GEAR OIL MANUFACTURER GREASE...
  • Page 159 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 exceeded.

  • Page 160: Fluid Capacities

    DL06 Industrial Engines Oil Drain Intervals by Duty Cycle (Hours) Heavy ACEA E5 (API CI-4) CES 20078 NOTE: Limit oil change interval to 250 hour maximum for oil grades if 40% of the operating time is in ambient temperatures above 38°C (100°F) to prevent engine damage to oil degradation resulting from high oil temperature.

  • Page 161: Lubrication And Service Chart

    LUBRICATION AND SERVICE CHART Greasing Bearing The service life of bushings and pivot pins can be extended considerably, if the machine is greased regularly and in the correct way. The greasing of bearings has two main purposes: • Add grease to the bearing to reduce friction between pin and bushing.
  • Page 162 Lubrication and Service Chart DL200 2,3,4 250h 500h 1000h 1500h 2000h FG008083 Figure 12 Inspection, Maintenance and Adjustment OP000509 4-18...
  • Page 163 DL200TC 2,3,4 250h 500h 1000h 1500h 2000h FG008084 Figure 13 Inspection, Maintenance and Adjustment OP000509 4-19...
  • Page 164 Service Data Service Interval Items To Check Service Qty. 1000 1500 2000 Front Joint Pin Grease F100 Articulation Pin Grease Rear Axle Pivot Grease Steering Cylinder Grease Front Drive Shaft Grease Bearing Fuel Tank Diesel 243 L Hydraulic Hydraulic Oil Tank 115 L Engine Oil Engine Oil Pan...

  • Page 165: Maintenance Intervals

    MAINTENANCE INTERVALS SERVICE ITEM PAGE 10 Hour / Daily Service Grease Front Attachment Pins (for First 100 Hours) 4-23 Inspect All Tires for Correct Tire Pressure and Signs of Damage or Abnormal Wear 4-23 Check Engine Oil Level 4-23 Check Transmission Oil Level 4-24 Check Hydraulic System Oil Level 4-25...
  • Page 166 Replace Transmission Oil and Filter (After First 250 Hours) 4-44 Replace Axle Differential and Planetaries Oil (After First 250 Hours) 4-44 Clean Outer Filter of Air Cleaner 4-45 Water Trap 4-46 500 Hour / 3 Month Service Perform All Daily, 10, 50 and 250 Hour Service Checks 4-47 Replace Hydraulic System Brake and Pilot Filter 4-47...

  • Page 167: 10 Hour / Daily Service

    10 HOUR / DAILY SERVICE Grease Front Attachment Pins (for First 100 Hours) Fittings are greased daily, or every 10 hours, for the NOTE: 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.

  • Page 168: Check Transmission Oil Level

    Check Transmission Oil Level When checking level using a dipstick always remove NOTE: and wipe it clean before making final level check. Use two people to perform this operation. Start machine and drive it until transmission fluid has warmed to 80°C (176°F). Park machine on firm, level ground.

  • Page 169: Check Hydraulic System Oil Level

    Check Hydraulic System Oil Level WARNING! The hydraulic oil will be hot after normal machine operation. Allow system to cool before attempting to service any of the hydraulic components. The hydraulic tank is pressurized. Turn breather cap slowly to allow pressurized air to vent. After the HAOA060L Figure 18 pressure has been released, it is safe to remove either...

  • Page 170: Check For Leaks In Hydraulic System

    Check O-ring for damages and replace if necessary. Check position of O-ring at surface of hole. Place the cover on the access hole. Make sure the spring retaining cup (1, Figure 22) in the lower section of the cover is lined up with the spring. The filter assembly rod must be in a vertical position and perpendicular to the base of the tank.

  • Page 171: Check For Leaks In Fuel System

    Check for Leaks in Fuel System Perform an inspection of engine compartment to verify that fuel system is not leaking. If any is noted, determine the source of leak and repair. Drain Fuel Condensation Open fuel tank drain valve. (Figure 25). Allow any condensed water or sediment to drain out of tank.

  • Page 172: Check Level Of Windshield Washer Liquid

    Do not allow replaceable bucket teeth to wear down to the point that bucket base edge is exposed. (Figure These instructions are only for DOOSAN OEM NOTE: buckets. If you are using other manufacturers' buckets, refer to their specific instructions.

  • Page 173: Check The Operation Of All Exterior Lights, Horn And Control Console Indicator And

    Check the Operation of All Exterior Lights, Horn and Control Console Indicator and Monitor Lights Turn engine starter switch to "I" (ON) position and observe all indicator lights. Restore operation of any light bulbs that do not turn "ON" at this time. Sound the horn.

  • Page 174: Inspect Cooling Fan Blade

    Inspect Cooling Fan Blade WARNING! Personal injury can result from a fan blade failure. Never pull or pry on the fan. This can damage the fan blade(s) and cause fan failure. An inspection of the cooling fan is required daily. Check for cracks, loose rivets, bent or loose blades, Figure 30 and for contact between the blade tips and the fan...

  • Page 175: Check Air Intake System

    Check the engine intake hose, and hose clamps for damage and tightness. If damaged, wrinkled or loose, replace, tighten or contact your nearest DOOSAN loader dealer. IMPORTANT Severe engine damage will result from running with unfiltered air. Figure 33 Do not operate engine if any leaks or defects are found on air intake system.

  • Page 176: 50 Hour / Weekly Service

    50 HOUR / WEEKLY SERVICE Perform All Daily, 10 Hour Service Checks Grease Front Attachment Pins DL200 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.
  • Page 177 Bucket hinge pins, 2 locations (Figure 35). FG008089 Figure 35 Lever link connecting pin, 1 location (Figure 36). FG008090 Figure 36 Bucket link connecting pin, 1 location (Figure 37). FG008091 Figure 37 Arm-lever connecting pin, 1 location. (Figure 38). FG008092 Figure 38 Inspection, Maintenance and Adjustment OP000509...
  • Page 178 Bucket cylinder rod end, 1 location. (Figure 39). FG006252 Figure 39 Lift cylinder heads (left, right), 2 locations (Figure 40). FG006253 Figure 40 Lift cylinder rod ends, 2 locations. (Figure 41). FG006254 Figure 41 Remote location points. Remote fittings for bucket cylinder head (50 HOUR), (1, Figure 42).
  • Page 179 Rear Axle pivot (1, Figure 43), 3 locations on right side of machine. Use remote grease fittings mounted on frame shown in Figure 44. FG008093 Figure 43 REAR PIVOT FRONT PIVOT FG008094 Figure 44 Inspection, Maintenance and Adjustment OP000509 4-35...
  • Page 180 DL200TC 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 should be done every 50 hours. If bucket is being used in water, grease fittings immediately after machine is removed from water.
  • Page 181 Bucket lever connecting pins, 2 locations. Lever link connecting pins, 2 locations. Bucket cylinder rod ends, 2 locations. (Figure 47) FG008097 Figure 47 Bucket cylinder heads, 2 locations. Arm lever connecting pins, 2 locations. Lever link connecting pins, 2 locations. (Figure 43) Link foot pins, 2 locations.
  • Page 182 Rear Axle pivot (1, Figure 51), 3 locations on right side of machine. Use remote grease fittings mounted on frame shown in Figure 52. FG008093 Figure 51 REAR PIVOT FRONT PIVOT FG008094 Figure 52 Inspection, Maintenance and Adjustment OP000509 4-38...

  • Page 183: Grease Steering Cylinder Rod And Head Ends

    Grease Steering Cylinder Rod and Head Ends Steering cylinder rods, 2 locations, one on each side of machine. FG008101 Figure 53 Steering cylinder head ends, 2 locations. Use remote grease fittings mounted on frame. (1 and 2, Figure 54). Remote Grease Reference Number Fittings 1 and 2,...

  • Page 184: Replace Engine Oil And Filter (After First 50 Hours)

    FG001642 Figure 56 Replace Engine Oil and Filter (After First 50 Hours) Replace engine oil and filter after first 50 hours on a NOTE: new machine and every 500 hours thereafter.(See page 4-52) Replace Hydraulic Full Flow Filter (After First 50 Hours) Replace hydraulic full flow filter after first 50 hours of NOTE: operation...

  • Page 185: Clean Exterior Of Radiator, Oil Cooler And Air Conditioner Condenser

    Clean Exterior of Radiator, Oil Cooler and Air Conditioner Condenser Dust and dirt accumulation on fins of radiator (1), CAC cooler (4), oil cooler (2), and additional transmission cooler (3), greatly reduce their cooling efficiency. Use compressed air, water and steam to clean fins on radiator, oil cooler, and transmission cooler.

  • Page 186: 250 Hour / Monthly Service

    250 HOUR / MONTHLY SERVICE Perform All Daily, 10 Hour and 50 Hour Service Checks Check Engine Air Intake Precleaner The engine is equipped with a precleaner. Dust, insects, rainwater etc., can be present in the air. The precleaner collects this material and discharges it. This prevents material from being drawn into air cleaner.

  • Page 187: Turbocharger

    Turbocharger The turbocharger is lubricated and cooled by the engine lubrication system. Important for the function of the turbocharger is that: • lubrication and cooling is safeguarded by – not racing the engine immediately after it has been started. – the engine is allowed to run at low idle for a couple of minutes before it is turned off.

  • Page 188: Grease Drive Shafts

    Grease Drive Shafts Grease fitting for center bearing, 1 location. Use remote grease fitting mounted on front frame (3, Figure 63). Remote Grease Reference Number Fittings 1 and 2, Steering Cylinder 50 Hours Head Ends Drive Shaft FG001640 250 Hours Center Bearing Figure 63 FG002212...
  • Page 189 Clean Outer Filter of Air Cleaner Clean outer filter every 250 hours / monthly service. NOTE: If air cleaner clogged warning light (Figure 65) on NOTE: instrument panel comes "ON" the air cleaner must be serviced. When working in severely dusty conditions, the NOTE: service interval should be shortened.
  • Page 190 Clean the outer filter (4, Figure 67) by blowing compressed air from the inside of the filter towards the outside. Do not use more than 205 kPa (30 psi) air pressure. WARNING! If using compressed an to clean the filter, make sure that proper eye protection is worn.

  • Page 191: 500 Hour / 3 Month Service

    500 HOUR / 3 MONTH SERVICE Perform All Daily, 10, 50 and 250 Hour Service Checks Replace Hydraulic System Brake and Pilot Filter Replace filter in pilot filter. Perform the following steps: Vent hydraulic oil tank. FG008104 Figure 72 Unscrew element cover (5, Figure 73). Cover is filled with oil.
  • Page 192 Replace Fuel Prefilter WARNING! Exchange filter after waiting for engine to cool. Be careful of fire hazards. Do not smoke. Locate fuel filter inside engine compartment. Position a small container under prefilter. Drain fuel by opening drain valve on bottom of filter. Dispose of drained fluids according to local NOTE: regulations.
  • Page 193 Fuel Filter (Spin-On Type) General Information DOOSAN Common Rail Fuel System The DOOSAN Common Rail fuel system requires the use of fuel filters. prefuel filter have following characteristics: • water separating • 30-micron rating • hand priming pump • chassis mounted.
  • Page 194 Replace Fuel Filter WARNING! Exchange filter after waiting for engine to cool. Be careful of fire hazards. Do not smoke. Locate fuel filter inside engine compartment. Position a small container under fuel filter. FG006240 Figure 78 Unscrew fuel filter from head assembly. Discard fuel filter.
  • Page 195 FG002217 Figure 81 Clean Air Conditioner Inner Filter This unit is equipped with an air-conditioning system. There are two filters (1 and 2, Figure 82) for air conditioner. The filters out dirt and dust particles from air being circulated into operator's cabin. They are located under the right side control panel.
  • Page 196 Replace Engine Oil and Filter CAUTION! Never attempt to change oil or filter on a hot engine. Hot oil could splash and cause burns. Allow engine to cool down before changing oil or filter. Change engine oil and filter after first 50 hours on a NOTE: new machine and every 500 hours thereafter.
  • Page 197 CAUTION! The lubricating oil filter must be full of oil at start-up to prevent engine damage. Use clean 15W-40 oil to coat the gasket surface of the filter. Fill the filter with clean 15W-40 oil. Figure 85 Replace Air Conditioner Outer Filter Clean air-conditioning outer filter every 50 hours and replace with a new one every 500 hours of service.

  • Page 198: 1,000 Hour / 6 Month Service

    1,000 HOUR / 6 MONTH SERVICE Perform All Daily, 10, 50, 250 and 500 Hour Service Checks Air Cleaner CAUTION! Never remove air cleaner filter while engine is running. This will allow dirt to be sucked into engine and cause serious engine damage.
  • Page 199 • Check that all hose and pipe connections from the air cleaner to the engine induction manifold are tight. Check tightness of hose clamps. • If the alarm text remains after replacing the primary filter, also the secondary filter must be replaced.
  • Page 200 Remove outer filter (4, Figure 89) from the air cleaner housing. Clean the air cleaner cover and the inside of the air cleaner housing. Do not use compressed air to blow out housing. Install new outer filter. Install air cleaner cover and evacuator valve. Make sure that all gaskets on wing nuts and NOTE: cover are properly installed and seated.
  • Page 201 Rotate filter counterclockwise to remove it (Figure 91). 10. Clean filter head. 11. Grease filter gasket and gasket mating surface on filter head. 12. Thread filter onto filter head. Tighten filter 1/2 turn after filter gasket contacts filter head. Filter must be torque to 1.6 - 2.1 kg•m (11.5 - 15 ft lb).
  • Page 202 Clean Fuel Tank and Strainer WARNING! Fuel is flammable and harmful to skin. • Do not smoke while draining moisture and sediment from fuel tank. • Do not drain fuel with engine running. • Do not allow fuel to remain on skin for an extended period of time.
  • Page 203 Replace Air Conditioner Inner Filter This unit is equipped with an air filtration system NOTE: which filters out dirt and dust particles from air being circulated into operator's cabin. This filter must be cleaned out every 500 hours and replaced with a new one every 1,000 hours.
  • Page 204 A flow of bubbles is visible. Check and Adjust Engine Contact your nearest DOOSAN loader dealer. Contact engine manufacturer for checking and adjusting the following items: • Engine Compression Pressure. •...
  • Page 205 Replace Hydraulic Full Flow Filter WARNING! The hydraulic oil will be hot after normal machine operation. Allow system to cool before attempting to service any of the hydraulic components. The hydraulic tank is pressurized. Loosen hydraulic oil fill cap slightly to allow pressurized air to vent. After pressure has been released, it is safe to remove either the fill cap or service covers or drain water from the tank.

  • Page 206: 1,500 Hour / 9 Month Service

    1,500 HOUR / 9 MONTH SERVICE Perform All Daily, 10, 50, 250 and 500 Hour Service Checks Replace Axle Differential and Planetaries Oil in both front and rear axles must be replaced after NOTE: first 500 hours of operation to comply with new machine break-in requirements.
  • Page 207 Go to level plug holes (1, Figure 100) on axle ends. Add oil to these openings until oil level is even with bottom plug hole. Recheck level center differential. Add oil if necessary. When oil level is satisfactory at all three level plug holes, install and tighten level plugs at all three locations.

  • Page 208: 2,000 Hour / Yearly Service

    2,000 HOUR / YEARLY SERVICE Perform All Daily, 10, 50, 250, 500 and 1,000 Hour Service Checks Replace Inner Air Cleaner Element CAUTION! Never remove air cleaner element while engine is running. This will allow dirt to be sucked into engine and cause serious engine damage.
  • Page 209 Replace Pipes and Hoses Replace hoses that carry brake fluid to wheel brakes. Also replace hoses that carry hydraulic fluid to steering cylinders. It is difficult to determine condition of many hoses. The best way to ensure safe operation and to maintain maximum performance is to replace hoses on a regular basis.
  • Page 210 Replace Radiator Coolant Do not mix ethylene glycol and propylene glycol NOTE: antifreeze together. If the two are mixed, the protection level will be reduced to the level of the ethylene glycol. See “Engine Cooling System” on page 4-75, for further details. This unit was factory filled with propylene glycol.
  • Page 211 Replace Hydraulic Oil and Clean Oil Suction Strainer CAUTION! Be certain that hydraulic oil has cooled before draining it. Hot oil could splash and cause burns. Raise boom to its highest position. Tilt bucket back as far as possible, and shut down engine. “Fluid Capacities”...
  • Page 212 Figure 108 Without starting engine, operate controls to dump bucket. (Figure 107). Then operate controls to lower boom. (Figure 108). This will drain oil out of boom and bucket cylinders. Replace full flow hydraulic filters as described under “Loosen breather cap on hydraulic tank. (See Figure 20 on page 4-25).”...
  • Page 213 Count the number of times you can depress the right-hand brake pedal before the brake warning light comes on. If the number counted is less than five (5), there is some problem with the accumulator. Contact your nearest DOOSAN dealer. OP000509 Inspection, Maintenance and Adjustment 4-69...

  • Page 214: Hour / Six Year Service

    12,000 HOUR / SIX YEAR SERVICE Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 CEN) European regulations state that the in-service life of any DOOSAN hydraulic hose exceed years. recommends the following: • Hoses at the customer premises cannot be stored more than 2 years before being discarded or installed on a machine.

  • Page 215: Severe Conditions Maintenance

    SEVERE CONDITIONS MAINTENANCE Operating Condition Required Maintenance Mud, Water, Rain Check for loose fittings, obvious damage to machine, or any fluid leakage. After completing operations, clean mud, rocks, or debris from machine. Inspect for damage, cracked welds, or loosened parts. Perform all daily lubrication and service.

  • Page 216: Bolt Torque Chart

    BOLT TORQUE CHART Tightening Torque Specifications for Metric Bolts (For coated threads, prelubricated assemblies) Grade Gr. 8.8 Gr. 10.9 Gr. 12.9 Dia. kg•m ft lb kg•m ft lb kg•m ft lb 5 mm x std. 0.59 0.79 6 mm x std. 1.00 1.38 1.66...

  • Page 217: Electrical System

    ELECTRICAL SYSTEM Check Battery Condition WARNING! Before starting any battery service work, make sure to shut the engine off and turn the starter switch to the "I" (OFF) position. The 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.
  • Page 218 Inspect charge condition of battery by looking at the indicator light built into battery. • GREEN: Normal. • BLACK: Insufficient charging - check alternator. • TRANSPARENT: Insufficient battery electrolyte - replace with new battery. Colors may vary from one battery manufacturer NOTE: to another.

  • Page 219: Engine Cooling System

    ENGINE COOLING SYSTEM General Keeping an engine's cooling system in peak operating condition, can have many benefits to keeping a machine in good operating condition. A properly functioning cooling system will; improve fuel efficiency, reduce engine wear, and extend component life. Always use distilled water in the radiator.
  • Page 220 (extended life antifreeze) does. Ethylene glycol is also very hazardous to the environment, people and animals. DOOSAN recommends that ethylene glycol be replaced with propylene glycol. The newer propylene glycol antifreeze comes in many different colors.

  • Page 221: Handling Of Accumulator

    Do not weld on accumulator, or try attaching anything to it. • When replacing an accumulator, contact a DOOSAN distributor or sales agency so the gas can be properly released. • Wear safety goggles and protective gloves when working on an accumulator. Hydraulic oil under pressure can penetrate the skin and cause serious injuries.

  • Page 222: Hydraulic Pressure Checks

    HYDRAULIC PRESSURE CHECKS Hydraulic pressure for most systems can be check by using the remote test ports shown in (Figure 114). Reference Description Pressure Number Main Pump Pressure 200 ±5 kg/cm (TPM) Brake Charge Pressure 80 kg/cm (TP2) FG001653 Steer Pump Pressure Figure 114 (TPS) at Only Steering 200 ±5 kg/cm...
  • Page 223 Steering Pump Pressure Attach gauge to port (3, Figure 114). Adjust relief valve cartridge on steering valve (Figure 117). Cartridge must be adjusted to open at 200 ±5 (2,844 ±70 psi). Unscrew plug and washer. Adjust screw that is beneath plug.
  • Page 224 Parking Brake Release Pressure Attach pressure gauge to parking brake port (2, Figure 119). Parking brake pressure must be 52 - 65 kg/cm (740 - 925 psi). Inspection, Maintenance and Adjustment OP000509 4-80...
  • Page 225 Fan Motor Pressure and Fan rpm The motor intergrates a proportional pressure relief valve, the fan speed (and thus the cooling performance) can be infinitely controlled depending on two different simultaneous input signals from temperature sensors. The cooling fan controller processes the two input signals and controls the valve coil current.
  • Page 226 Checking the Relief Pressure of Fan Motor FG008112 Figure 121 Reference Reference Description Description Number Number Fan Motor Outlet Line Fan Guard Relief Valve Inlet Line Proportional Relief Valve Drain Line Reversable Solenoid Valve Maximum Fan Speed, Checking Open the radiator grille in order to connect the pressure gauge.

  • Page 227: Long Term Storage

    LONG TERM STORAGE Cleaning Pressure wash machine. Inspect machine for any damage or missing parts. Drive machine to check steering linkage for damage. Hydraulic System Start engine and allow it to idle for a few minutes. Drive machine around for two - three minutes. Raise and lower boom two - three times.

  • Page 228: Parking Brake Adjustment

    PARKING BRAKE ADJUSTMENT To adjust parking brake, perform the following steps: Jack up machine enough to allow tires to rotate freely. Turn “OFF” engine place transmission lever “NEUTRAL.” Turn ignition switch to “ON” position. Move parking brake switch to “UNLOCKED” position. Front Axle Service Brakes Checking clearance between brake pad and brake disc in the front axle.

  • Page 229: Tires

    TIRES Inflating Tires Recommended tire pressures should normally be followed. Special operations may justify a different pressure. In such cases, follow the instructions from the tire manufacturer and do not exceed the maximum permissible pressures, (See page 4-87) The tire pressure may have been raised before the machine was delivered from the factory.
  • Page 230 Stay away until tire and rim cool down. If the following defects are found in tires, for safety reasons the tires must be replaced with new tires. For the replacement contact DOOSAN loader dealer or a tire manufacturer's local dealer. •...
  • Page 231 • Tire layers are separated. • Radial cracks reach the carcass. • Deformation or damage which makes the tire unsuitable for use. Recommended Air Pressure Working Pressure Driving Pressure Tires Remarks Front Rear Front Rear +0.1 +0.1 +0.1 +0.1 20.5-25-16PR Bias Ply Tire (Standard) psi)
  • Page 232 Inspection, Maintenance and Adjustment OP000509 4-88...

  • Page 233: Transportation

    OP000039 Transportation LOADING AND UNLOADING When transporting the machine observe the various road rules, road transportation vehicle laws and vehicle limit ordinances, etc. It is a good idea to obtain special platform for loading and unloading the machine. Park the trailer on a flat firm roadbed. Keep a fairly long distance between the road shoulder and the machine.

  • Page 234: Summary Of Safety Precautions For Lifting

    SUMMARY OF SAFETY PRECAUTIONS FOR LIFTING To make safe lifts, the following items must be evaluated by operator and work site crew. • Condition of ground support. • Wheel loader configuration and attachments. • Weight, lifting height and lifting radius. •...

  • Page 235: Troubleshooting

    Low engine oil. Add oil. or surges. Plugged air intake system. Clean system and replace filter. Contact your DOOSAN dealer. Injection pump out of adjustment. Plugged fuel filter. Replace fuel filter. Water or dirt in fuel system. Clean system and add new fuel.
  • Page 236 Clogged or dirty fuel injectors. Clean injectors. Fuel filters plugged. Replace filters. Engine speed control cable Readjust. out of adjustment. Contact your DOOSAN dealer. Injection pump out of adjustment. Valve backlash faulty. Adjust backlash. Engine runs hot. Low coolant level.

  • Page 237: Hydraulic System

    Unstable (rough) idling. Air in fuel lines. Tighten fuel connections and filter. Fuel filter clogged. Replace fuel filter. Contact your DOOSAN dealer. Fuel pump failure. Incorrect fuel injection timing. Insufficient power. Air cleaner filter clogged. Clean or replace element. Fuel filer element clogged.
  • Page 238 Replace control valve. Wrong pilot line connection. Reconnect pilot lines. Oil temperature too high. Debris in exterior of cooler. Clean exterior of cooler. Contact your DOOSAN Oil cooler faulty. dealer. Fan belt loose. Tighten fan belting as required. Actuators on one side of Overload relief valve is not Repair valve or replace.

  • Page 239: Travel System

    TRAVEL SYSTEM General Problem Possible Cause Remedy Machine will not travel. Transmission clutch pressure Adjust pressure. incorrect. Transmission charge pump Replace pump. damaged. Damage to transmission control Repair wiring. valve wiring harness. Burned travel relay or fuse. Replace relay or fuse. Forward/Reverse solenoid for Clean and repair.

  • Page 240: Steering

    STEERING Problem Possible Cause Remedy Steering Wheel is hard to turn. Sediment blocking direction Clean and repair. change spool orifice, inside priority valve. Sediment blocking amplifying spool Clean and repair. orifice, inside priority valve. Sediment blocking load sensing Clean and repair. line orifice, inside priority valve.

  • Page 241: Braking

    BRAKING Problem Possible Cause Remedy Reduced brake action. Low secondary pressure in brake Repair or replace brake valve. valve. Worn brake disks. Replace brake disks. Damaged brake disks. Replace brake disks. Damaged brake valve block. Replace valve. Air in brake hydraulics due to leak Repair leak, bleed system.
  • Page 242 Troubleshooting OP000040...

  • Page 243: Specification

    OP000510 Specification GENERAL SPECIFICATIONS DL200 ITEM SPECIFICATION Standard Bucket Capacity (BOT / BOC) 1.9 m (2.5 yd ) / 2.0 m (2.62 yd Vehicle Weight (STD / OPT) 11,300 kg (24,912 lb) / 11,645 kg (25,673 lb) Engine (SAE J1995 Gross) Emission U.S EPA Tier3 (EU Stage IIIA)
  • Page 244 Vehicle Weight (STD / OPT) 11,300 kg (24,912 lb) / 11,580 kg (25,530 lb) Engine (SAE J1995 Gross) Emission U.S EPA Tier3 (EU Stage IIIA) DOOSAN DL06 Maker and Model Type Turbo Charged, Air to Air Intercooled Direct Injection Injection System Common-rail Controlled by Electronic ECM Max.

  • Page 245: Working Range And Dimensions

    WORKING RANGE AND DIMENSIONS DL200 Figure 1, illustrates exterior machine dimensions and working range of machine when it is equipped with a standard bucket. B (D) FG008113 Figure 1 Specification OP000510...
  • Page 246 CATEGORY DIMENSION Tire Size 20.5R25 (L2) 7,285 mm Overall Length (A) (23' 11") 2,550 mm Overall Width (B) (8' 4") 3,240 mm Overall Height (C) (10' 8") 2,550 mm Bucket Width (D) (8' 4") 2,900 mm Wheel Base (E) (9' 6") 1,930 mm Tread (F) (6' 4")
  • Page 247 DL200TC Figure 1, illustrates exterior machine dimensions and working range of machine when it is equipped with a standard bucket. B (D) FG008114 Figure 1 Specification OP000510...
  • Page 248 CATEGORY DIMENSION Tire Size 20.5R25 (L2) 7,335 mm Overall Length (A) (24' 1") 2,550 mm Overall Width (B) (8' 4") 3,240 mm Overall Height (C) (10' 8") 2,550 mm Bucket Width (D) (8' 4") 2,900 mm Wheel Base (E) (9' 6") 1,930 mm Tread (F) (6' 4")

  • Page 249: Working Capacities

    WORKING CAPACITIES Bucket Capacity Standard toothed bucket has a capacity of 1.9 m (2.5 yd Tipping Load Static Tipping Load with bucket in Over Front position is 8,870 kg (19,555 lb). With bucket in Fully Turned position, Static Tipping Load is 7,560 kg (16,667 lb). Material Weight The data below describes weight of a cubic meter (cubic yard) of many types of workload materials.
  • Page 250 LOW WEIGHT OR MEDIUM WEIGHT OR HIGH WEIGHT OR DENSITY DENSITY DENSITY MATERIAL 1,100 KG/M 1,600 KG/M 2,000 KG/M (1,850 LB/YD ), OR (2,700 LB/YD ), OR (3,370 LB/YD ), OR LESS LESS LESS Clay, DAMP, natural 1,746 kg/m --------------------- --------------------- (2,943 lb/yd Cement, Portland, DRY...
  • Page 251 LOW WEIGHT OR MEDIUM WEIGHT OR HIGH WEIGHT OR DENSITY DENSITY DENSITY MATERIAL 1,100 KG/M 1,600 KG/M 2,000 KG/M (1,850 LB/YD ), OR (2,700 LB/YD ), OR (3,370 LB/YD ), OR LESS LESS LESS 929 kg/m Salt --------------------- --------------------- (1,566 lb/yd 529 kg/m Snow, light density ---------------------...
  • Page 252 Specification OP000510 7-10...

  • Page 253: Index

    Index 4-69 Numerics Accumulator 4-65 4-54 Bleeding 1,000 Hour / 6 Month Service 2-23 Brake Fluid Warning 4-62 1,500 Hour / 9 Month Service 2-23 Brake Fluid Warning Light 4-70 12,000 Hour / Six Year Service 2-12 Brake Pedal 4-64 2,000 Hour / Annually Service Troubleshooting 4-32...
  • Page 254 40, 4-43 2-22 High Beam Indicator Light 4-60 2-9, 2-31 Check and Adjust Horn Button 2-37 2-18 Diagnostic Switch Hour Meter 4-30 Drive Belt Wear Hydraulic Oil Tank 4-52 4-42 Filter Change Drain Water 4-40 Oil and Filter Hydraulic System 4-52 4-25 Oil Change...
  • Page 255 2-53 Weight Adjustment Knob Seat Adjustment 2-53 Lifting Safety Precautions Adjusting Seat Forward/Backward 2-53 Loading and Unloading Adjusting Seat's Angle 2-28 2-54 Log Fork Control Lever Angle Adjustment of Armrest 4-83 2-53 Long Term Storage Backrest Adjustment 4-14 2-54 Lubricants Headrest 4-18 2-53...
  • Page 256 2-19 1-13 Tachometer Unauthorized Modifications Tipping Load Unloading and Loading 4-86 Tire Damage 4-23 Tire Pressure Inspection 3-20 Towing Machine 2-54 Vibration Transmission 1-15 Vibration Level 2-36 Cut-off Switch 1-31 Visibility 2-17 Display 2-13 Lever 4-44, 4-56 Oil - Drain and Replace Weight of Workload Materials 4-44, 4-56 Oil Filter Replacement...

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