Page 1 Serial Number 5001 and Up May 2010 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 Visibility Information ................. 1-13 Unauthorized Modifications.............. 1-15 General Hazard Information............. 1-15 Before Starting Engine..............1-24 Machine Operation................1-28 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 (Optional)....3-16 Additional Braking ................3-17 Boom Raise Kick-out ............... 3-18 Bucket Angle Indicator ..............
Page 5 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.........
Page 6 Table of Contents 950106-00117E...
Page 7 Presentation PRESENTATION FG015573 Figure 1 950106-00117E Presentation...
Page 8 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.
Page 9 DOOSAN Infracore Engineering Department. This department will decide whether the alteration may cause the approval to become void.
Page 10 Figure 2 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...
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
OP001012 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. Any operation, maintenance, traveling or shipping methods that do not follow safety guidelines printed in this Manual could cause serious injury or death.
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 be alert to potential for personal injury or accidents. Always observe safety precautions and follow recommended procedures.
Page 15 Safety precautions are described in SAFETY from page 1-4 on. DOOSAN cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore the safety messages in this manual and on the machine may not include all possible safety precautions. If any procedures or...
Page 16: General Safety Essentials
The wheel loader has been designed primarily for moving earth with a bucket. For use as a grapple or for other object handling, contact DOOSAN. Lifting-work applications are permitted in approved lift configuration, to rated capacity only, with no side-loading (unless prohibited by local regulation). Do not use machine for activities for which it was not intended.
Page 17 FG015631 Figure 1 OP001012 Safety...
Page 18 1. Warnings for Operation, Inspection and Maintenance (4190-2545A, 190-00092) WARNING • AVOID DEATH OR SERIOUS INJURY - READ AND UNDERSTAND THE INSTRUCTIONS AND WARNINGS IN THE OPERATION AND MAINTENANCE MANUALS prior operating this machine. • Sound the horn to alert the people nearby before operating, and sure all persons are clear of area.
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 OP001012...
Page 20 5. Warnings for Handling Accumulator (190-00703, 190-00099) WARNING • Keep away from flame. EXPLOSION HAZARD • Do not weld on, or drill into the accumulator. 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) WARNING Severe injury and death from crushing could occure in articulated area when machine turns. Make sure people are clear of machine before starting engine or moving steering wheel. Lock safety bar during servicing or transporting machine.
Page 22 8. Warnings for High Temperature Coolant (190-00692, 190-00097) WARNING COOLANT CAUSE INJURY BLINDNESS. Never loosen or open radiator cap when coolant is hot and under pressure. To open cap, stop engine, wait until radiator is cool. Then loosen cap slowly to relieve the pressure.
Page 23 10. Warnings for Performing Maintenance On Front Attachment (4190-2546A, 190-00105) WARNING Sudden or accidental movement of boom may cause injury or death. Securely brace boom before working or walking under raised boom. FG015713 11. Warnings to Use Safety Lock (4190-1993, 190-00121) WARNING Safety lock must be in "LOCK"...
Page 24 12. Warning Tag (190-00695A, 190-00098A) WARNING DO NOT OPERATE When Performing inspection or maintenance. FG013220 Safety OP001012 1-12...
Page 25: Visibility Information
VISIBILITY INFORMATION A rear view camera and mirrors ensure that visibility around the machine, from the operator's seat, meets the latest ISO standards for the region or marketplace that machine is sold into. NOTE: These devices may vary from one region to another, depending upon local and regional regulations.
Page 26 Inspect equipment and immediately report if there are problems with the visual aids. If machine cannot be fixed immediately, DO NOT use the machine. Contact your local DOOSAN distributor as soon as possible and ask for repairs. Guidelines •...
Page 27: Unauthorized Modifications
UNAUTHORIZED MODIFICATIONS Any modification made without authorization or written approval from DOOSAN can create a safety hazard, for which the machine owner will be held responsible. For safety's sake, replace all OEM parts with the correct authorized or genuine DOOSAN part. For example, not taking...
Page 28 Inside Operator's Cabin When entering the operator's cabin, 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. Clean grease and dirt from pedals and controls.
Page 29 Clothing and Personal Protective Items Secure long hair, and avoid loose clothing and jewelry. These items have the tendency to catch on controls or protrude into 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 30 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 31 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 32 Precautions When Handling Fluids at High Temperature Immediately after operations are stopped, the coolant, engine oil, and hydraulic oil are at highest temperatures and the radiator and hydraulic tank are still under pressure. Attempting to remove cap, drain the oil or coolant, or replace the filters may lead to serious burns.
Page 33 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 how to use them.
Page 34 Contact your DOOSAN distributor for available safety guards and/or recommendations to prevent 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 35 Attachment Precautions Option kits are available through your dealer. Contact DOOSAN for information on available one-way (single-acting) and two-way (double-acting) piping / valving / auxiliary control kits. Because DOOSAN cannot anticipate, identify or test all the attachments that owners may wish to install on their machines, please contact DOOSAN for authorization and approval of attachments, and their compatibility with optional kits.
Page 36: 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 sure the ground surface is as hard and horizontal as possible before carrying out operations.
Page 37 Remember that soil after heavy rain, blasting or after earthquakes, is weakened. Newly laid earth and the soil near ditches is typically loose. It can collapse under the weight of vibration of your machine and cause your machine to tip over. Install the safety guard if working in areas where there is a danger of falling rocks.
Page 38 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 39 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 40: Machine Operation
DOOSAN representative. Operate While Seated at Operator's Station Only Never reach in through a window to work a control. Do not try to operate wheel loader unless you're in command position - seated at controls. You should stay alert and focused on your work at all times.
Page 41 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 while the machine is traveling.
Page 42 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 43 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 44 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 45 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 46 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 47 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).
Page 48: 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 when performing inspection distributors; see Figure 24.
Page 49 Proper Tools Use only tools suited to the task. Using damaged, low quality, faulty, or makeshift tools could cause personal injury. There is a danger that pieces from, chisels with crushed heads, or hammers, may get into your eyes and cause blindness. HDO1037L Figure 26 Use of Lighting...
Page 50 Burn Prevention When checking the radiator coolant level, shut down engine, let the engine and radiator cool down, then check the coolant recovery tank. If the coolant level in the coolant recovery tank is near the upper limit, there is enough coolant in the radiator. Loosen the radiator cap gradually to release the internal pressure before removing the radiator cap.
Page 51 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 52 Precautions When Working on Machine When carrying out maintenance operations on the machine, keep area around your feet clean and tidy to prevent falls. Always do the following: • Do not spill oil or grease. • Do not leave tools laying about. •...
Page 53 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 54 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.
Page 55 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 on tightening torques and recommended assembly compounds and always use correct part.
Page 56 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 57 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 35 When stopping or parking the machine, lower the front structure to the ground.
Page 58: 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 59 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 60: 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 61: 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 62 Safety OP001012 1-50...
Page 63: Operating Controls
OP001013 Operating Controls The "Operating Controls" section presented here consists of the following groups: “Component Locations” on page 2-2 “Operator's Area” on page 2-4 “Steering Console and Pedals” on page 2-5 “Front Instrument Panel” on page 2-14 “Right Side Switch Panel” on page 2-25 “Various Cabin Locations”...
Page 64: Component Locations
COMPONENT LOCATIONS The following figure identifies the location of major machine components. 23 24 26 OPPOSITE SIDE 29 27 FG015574 Figure 1 Operating Controls OP001013...
Page 65 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 66: Operator's Area
OPERATOR'S AREA Figure 2, identifies controls in operator's cabin. FG006189 Figure 2 Reference Reference Description Description Number Number Steering Console and Pedal Right Side Switch Panel (See page 2-5) (See page 2-25) Various Cabin Locations Seat Adjustment (See page 2-40) (See page 2-51) Operating Controls OP001013...
Page 67: Steering Console And Pedals
STEERING CONSOLE AND PEDALS FG006191 Figure 3 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 2-14) Steering Wheel Adjustment Lever Hour Meter Brake Pedals Hazard Warning Light Switch Operating Controls OP001013...
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 and fuel tank transfer pump (if equipped) are functional.
Page 69 2. Horn Button (Two Places) Pressing the button at the end of the combination switch (Figure 5) or the lowest button at the tip of the left pilot control valve lever (joystick) (Figure 7), the horn will sound. NOTE: Starter switch must be "ON." AHO0890L Figure 5 FG003935...
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. NOTE: When turn...
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 10...
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 2-34). CAUTION When descending down an incline, slow down the FG002183...
Page 73 A second kick-down switch (Figure 16) is on the right button in the tip of the pilot control valve lever (joystick) (Right one of two levers). FG003940 Figure 16 FG003936 Figure 17 9. Transmission Lever Forward - When the lever is pushed forward, transmission is in "FORWARD."...
Page 74 A transmission neutral lever lock is in base of transmission lever. This neutral lever lock prevents the transmission lever from being moved out of "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 STOP 24 23 FG015582 Figure 23 Operating Controls OP001013 2-14...
Page 77 Gauges Reference Reference Description Description Number Number Hour Meter Transmission Oil Temperature Gauge Speedometer Tachometer Fuel Gauge Transmission Display Engine Coolant Temperature Gauge Warning and Indicator Lights Reference Reference Description Description Number Number Left Turn and Hazard Warning Right Turn and Hazard Warning Light Light High Beam Indicator Light...
Page 78 1. Hour Meter A LCD meter that records total time. When engine is running, the hourglass icon blinks every four seconds. This shows that the hour meter is working. HA0O2012 Figure 24 2. Speedometer This meter displays speed at which vehicle is traveling. FG004182 Figure 25 3.
Page 79 4. 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. FG003949 Do not shut down engine.
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. km/h x100r/min STOP FG015583 Figure 30 Figure 31, shows the transmission display in detail. Indicates travel direction and gear selection.
Page 81 9. High Beam Indicator Light This indicator light will turn "ON," when the headlights are turned to "HIGH BEAM." HAOD394L Figure 34 10. Work Light Indicator Light This indicator light will turn "ON," when the front and/or rear work lights are activated. 2658A Figure 35 11.
Page 82 12. Engine Coolant Temperature Warning Light If engine coolant overheats, this light will turn "ON", the engine speed will be automatically reduced, until coolant temperature drops. Do not turn engine "OFF" because this will cause coolant temperature to rise and may cause engine to siege due to heat surge.
Page 83 14. Engine Oil Pressure Warning This indicator Light will turn "ON" when the engine starter switch is turned "ON", and should go "OFF" after the engine starts. For example, if the engine oil pressure becomes too low, the light will turn "ON". If this happens, shut the engine down immediately and determine the cause of the problem.
Page 84 17. Right Turn and Hazard Warning Light This light blinks when right turn signal is turned "ON". Both lights blink when warning lights are turned "ON". NOTE: If left and right turn indicators blink together, or if they blink faster than normal, a light bulb is not operating or flasher solenoid is damaged.
Page 85 20. 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. WARNING Never operate or travel machine when this light is "ON" or when alarm is sounding. Always investigate HA0O2024 cause of the drop in brake fluid pressure, and repair Figure 45...
Page 86 23. Not Used 24. Emergency Steering Indicator Light (Optional) This indicator light will turn "ON", when the emergency steering system is activated due to a hydraulic failure. Immediately stop any operation, stop machine, "APPLY" parking brake, and shut down engine. DANGER AJO0450L Figure 49...
Page 87: Right Side Switch Panel
RIGHT SIDE SWITCH PANEL < Two/Three Lever (Option) > FG006213 Figure 51 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. When machine is being traveled, the lever (joystick) can be "LOCKED"...
Page 89 Forward Switch When this switch is pressed at forward traveling while "KD" (5, Figure 52) switch is pressed, machine can travel forward. When machine is travelled, it can convert forward and reverse travel without pressing "KD" (5, Figure 52) 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 54) to dump bucket, or rearward (4, Figure 54) to roll back bucket. Move right control lever forward (3, Figure 54) to lower boom or rearward (5, Figure 54) to raise boom. Float (right lever in full forward detent position (1, Figure 54)): This position allows oil flow in and out both ends of cylinders so the bucket can follow the contour of the...
Page 91 2. Kick-down Switch (Two Places) Kick-down Switch Function - When transmission is in 2nd gear, pressing this switch (Figure 58) 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.
Page 93 6. Economy Mode Switch This economy 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 of the pilot control valve lever (joystick). CAUTION HBOI110L When driving or parking, the pilot cutoff switch must Figure 68 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. In the "NO INCHING" mode, the 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 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 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. HAOA750L Figure 80 23. Power Socket for 12 Volt This is a power socket for only 12V DC devices. This socket can be used for charging a cellular phone or powering a small 12V DC electrical device.
Page 101 26. F/R (Forward/Reverse) Control Switch (Optional) To be able to use the forward/reverse function, the F/R selector switch must first be depressed. When the switch is activated, the F/R selector indicator light will be turned "ON" in the instrument panel. In this position, the machine is in "NEUTRAL"...
Page 102: Various Cabin Locations
VARIOUS CABIN LOCATIONS FG006505 Figure 84 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 OP001013 2-40...
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" "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 88 5. Storage Compartments There are two storage compartments (1 and 2, Figure 89) located both sides behind of the operator's seat. Keep the operation manual other documents this compartment. FG003889 Figure 89 6.
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 2-56. FG015587 Figure 91 Operating Controls OP001013 2-43...
Page 106: Heater And Air Conditioner Operation
HEATER AND AIR CONDITIONER OPERATION Location of Controls and Vents FG006506 Figure 92 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 93 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. NOTE: If you do not select a blower speed the heater and air conditioner will not work.
Page 109 Used to direct air flow to lower portion of operator's cabin. FG006508 Figure 98 Used to direct air flow for defrosting front window of operator's cabin. FG006509 Figure 99 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 101 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 102 Operating Controls OP001013 2-50...
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 103 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 108) and (2. RH, Figure 109) are used to secured the doors (RH, LH) to the side of the cabin when they are opened. NOTE: Keep the door closed and locked when machine is not in use.
Page 117: Arm Rest
ARM REST Knob (1, Figure 112) is used to allow armrest to be moved to the most convenient position for the operator. Loosen knob and move armrest (2, Figure 112) to desired position. Tighten knob. FG003898 Figure 112 Operating Controls OP001013 2-55...
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 OP001013...
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 SAFETY BACK DISPLAY MIRROR STEREO ALARM(1) ALARM(2) COMPRESSOR START ILL. HEATER SELECT fuse, check the function of the relay. HEAD REAR CONDENSER...
Page 121 When changing the fusible link, replace the fusible link with the same capacity part. Otherwise, a fire could break out in the wiring harness and/or other components of the circuit. Always use original DOOSAN parts. HAOB100L Figure 119 Engine Emergency Stop Switch...
Page 122 Battery Disconnect Switch A battery disconnect switch is located in the battery box. It is used for preventing the battery when the machine will not be used for a long time. If the machine will not be used for an extended period of a month or more, turn the battery disconnect switch to the "OFF"...
Page 123: Operation
OP001014 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.
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 gauges to...
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 gauges to...
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.
Page 138: F/R (Forward/Reverse) Travel Control System (Optional)
F/R (FORWARD/REVERSE) TRAVEL CONTROL SYSTEM (OPTIONAL) 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." In this position, the machine travels in "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 (Optional)
BOOM LOWER KICK-OUT (OPTIONAL) 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. NOTE: The loader must be used for towing only in an emergency. WARNING Do not tow machine at a speed over 10 km/h (6 MPH) 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. As a rule of thumb, the allowable water depth is about 460 mm.
Page 145: Inspection, Maintenance And Adjustment
OP001015 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 Figure 2 FG015604 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
SAFETY WHEN SERVICING This section deals with the safety rules which must be followed when checking and servicing the machine. DOOSAN disclaims all responsibility if other tools, lifting devices or working methods are used other than those described in this publication.
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. FG015607 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 • The installation of two-way radio, lever steering or similar equipment must be carried out by a skilled person, as faulty installation may cause interference with the electronic components controlling vital machine functions. • When carrying out service work below raised lifting arm system, the lifting arms must first have been secured (lifting arm support).
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. If the machine is to be provided with a handheld fire extinguisher, it must be of the ABE type (ABC in the USA), which means that it is possible to extinguish fires in both solid and liquid carbonaceous...
Page 153 Take extra care when cleaning the machine after it has been used in a fire sensitive environment, e.g. sawmill and refuse dumps. Reduce the risk of spontaneous combustion by installing for example silencer guard or high capacity cyclone precleaner. Sound absorbing material in the engine compartment must be kept clean to minimize the fire hazard.
Page 154 Methods and Precautionary Measures When Removing Paint: Blasting • use respirator and eye protection Paint remover or other chemicals • use a portable air extractor, respirator and protective gloves Grinding machine • use a portable air extractor, respirator and protective gloves and eye protection Floor Rubber Observe extra great care when it is suspected that you may...
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.
Page 156: Preventive Maintenance
Please make note of these numbers and their locations. These will be required whenever warranty or service work is requested. Keep this number on file, in case the mathine is stolen. Doosan Infracore Co., Ltd. 7-11, Hwasu-dong, Dong-gu, Incheon, Korea FG015608...
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 It is highly recommend to use the Doosan Genuine Products, or products which meet the specification below. Using other products may damage the equipment. NOTE: Refer to the Maintenance Intervals Table for application points. LUBRICANT...
Page 159 Mixing ratio is for reference purpose only and is not an absolute standard. 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 2000h 1500h 1000h 500h 250h 250h 500h 1000h 1500h 2000h 1, 4 FG015609 Figure 12 Inspection, Maintenance and Adjustment OP001015 4-18...
Page 163 F100: Every 10 Hours for First 100 Hours. W10: Every 10 Hours If Operating In Water. EG: Ethylene Glycol - Doosan Genuine Antifreeze Solution (Drain and replace using this interval.) See “Engine Cooling System” on page 4-73, for further explanation.
Page 164: Maintenance Intervals
MAINTENANCE INTERVALS SERVICE ITEM PAGE 10 Hour / Daily Service Grease Front Attachment Pins (for First 100 Hours) 4-22 Inspect All Tires for Correct Tire Pressure and Signs of Damage or Abnormal Wear 4-22 Check Engine Oil Level 4-22 Check Transmission Oil Level 4-23 Check Hydraulic System Oil Level 4-24...
Page 165 Replace Transmission Oil and Filter (After First 250 Hours) 4-40 Replace Axle Differential and Planetaries Oil (After First 250 Hours) 4-40 Clean Outer Filter of Air Cleaner 4-41 Water Trap 4-42 500 Hour / 3 Month Service Perform All Daily, 10, 50 and 250 Hour Service Checks 4-43 Replace Hydraulic System Brake and Pilot Filter 4-43...
Page 166: 10 Hour / Daily Service
10 HOUR / DAILY SERVICE Grease Front Attachment Pins (for First 100 Hours) NOTE: Fittings are greased daily, or every 10 hours, for the 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 167: Check Transmission Oil Level
Check Transmission Oil Level NOTE: When checking level using a dipstick always remove 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 168: 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 pressure has been HAOA060L Figure 17 released, it is safe to remove either the fill cap or service...
Page 169: 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 21) 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 170: 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 24). Allow any condensed water or sediment to drain out of tank.
Page 171: 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 28) NOTE: These instructions are only for DOOSAN OEM buckets. If you are using other manufacturers' FG001694 buckets, refer to their specific instructions.
Page 172: Check The Operation Of All Exterior Lights, Horn And Control Console Indicator And Monitor Lights
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 173: 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, and for contact Figure 29 between the blade tips and the fan shroud.
Page 174: 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 32 Do not operate engine if any leaks or defects are found on air intake system.
Page 175: 50 Hour / Weekly Service
50 HOUR / WEEKLY SERVICE Perform All Daily, 10 Hour Service Checks Grease Front Attachment Pins 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 176 Bucket hinge pins, 2 locations (Figure 34). FG015611 Figure 34 Lever link connecting pin, 1 location (Figure 35). FG015612 Figure 35 Bucket link connecting pin, 1 location (Figure 36). FG015613 Figure 36 Arm-lever connecting pin, 1 location. (Figure 37). FG015614 Figure 37 Inspection, Maintenance and Adjustment OP001015...
Page 177 Bucket cylinder rod end, 1 location. (Figure 38). FG006252 Figure 38 Lift cylinder heads (left, right), 2 locations (Figure 39). FG015622 Figure 39 Lift cylinder rod ends, 2 locations. (Figure 40). FG006254 Figure 40 Remote location points. Remote fittings for bucket cylinder head (50 HOUR), (1, Figure 41).
Page 178: Grease Steering Cylinder Rod And Head Ends
Rear Axle pivot (1, Figure 42), 3 locations on right side of machine. Use remote grease fittings mounted on frame shown in Figure 43. FG015615 Figure 42 REAR PIVOT FRONT PIVOT FG008094 Figure 43 Grease Steering Cylinder Rod and Head Ends Steering cylinder rods, 2 locations, one on each side of machine.
Page 179: Grease Upper And Lower Center Pins
Grease Upper and Lower Center Pins Center pins, upper (Figure 46) and lower (Figure 47). Two locations on right side of machine. FG001641 Figure 46 FG001642 Figure 47 Replace Engine Oil and Filter (After First 50 Hours) NOTE: Replace engine oil and filter after first 50 hours on a new machine and every 500 hours thereafter.(See page 4-48) Replace Hydraulic Full Flow Filter...
Page 180: Check Air Conditioner And Alternator Belt Tension (After First 50 Hours)
Check Air Conditioner and Alternator Belt Tension (After First 50 Hours) Air conditioner and alternator belt tension must be checked after first 50 hours of operation to comply with new machine break-in requirements. After first check, air conditioner and alternator belt must be checked every 250 hours.
Page 181: Clean Air Conditioner Outer Filter
Clean Air Conditioner Outer Filter This unit is equipped with an air-conditioning system. There are two filters (1 and 2, Figure 49) for air conditioner. They filter out dirt and dust particles from air being circulated into operator's cabin. They are located under the right side control panel. Open access cover on the lower right side of cabin on the outside, to gain access filter.
Page 182: 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 183: 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 184: Grease Drive Shafts
Grease Drive Shafts Grease fitting for center bearing, 1 location. Use remote grease fitting mounted on front frame (3, Figure 54). Remote Grease Reference Number Fittings 1 and 2, Steering Cylinder 50 Hours Head Ends Drive Shaft FG001640 250 Hours Center Bearing Figure 54 FG002212...
Page 185 Clean Outer Filter of Air Cleaner NOTE: Clean outer filter every 250 hours / monthly service. NOTE: If air cleaner clogged warning light (Figure 56) on instrument panel comes "ON" the air cleaner must be serviced. x100r/min km/h STOP NOTE: When working in severely dusty conditions, the service interval should be shortened.
Page 186 Clean the outer filter (4, Figure 58) 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 187: 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. FG015618 Figure 63 Unscrew element cover (5, Figure 64). Cover is filled with oil.
Page 188 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. NOTE: Dispose of drained fluids according to local regulations.
Page 189 Fuel Filter (Spin-On Type) General Information DOOSAN Common Rail Fuel System The DOOSAN Common Rail fuel system requires the use of two fuel filters. The prefuel filter have the following characteristics: • water separating • 30-micron rating • hand priming pump •...
Page 190 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 69 Unscrew fuel filter from head assembly. Discard fuel filter. NOTE: Dispose of drained fluids according to local regulations.
Page 191 FG002217 Figure 72 Clean Air Conditioner Inner Filter This unit is equipped with an air-conditioning system. There are two filters (1 and 2, Figure 73) for air conditioner. The filters out dirt and dust particles from air being circulated into operator's cabin.
Page 192 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. NOTE: Change engine oil and filter after first 50 hours on a new machine and every 500 hours thereafter.
Page 193 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 76 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 194: 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 195 • If the alarm text remains after replacing the primary filter, also the secondary filter must be replaced. See “21. Air Cleaner Clogged Warning Light” on page 2-23 Do not, under any circumstances, run the engine without a filter or with a damaged one. Always have a spare filter on hand and keep the filter well protected from dirt.
Page 196 Drain and Replace Transmission Oil and Filter NOTE: Transmission oil and filter must be changed after first 250 hours of operation to comply with new machine break-in requirements. After first change, oil and filter must be changed every 1,000 hours. Use two people to perform this operation.
Page 197 13. Fill transmission with fluid through transmission fill tube (Figure 82). FG008085 Figure 82 14. Add fluid until fluid level reaches low mark on dipstick (Figure 82). 15. Start engine. Idle engine for two minutes. Have a person remain in the cabin. 16.
Page 198 Park the machine on a level surface, apply the parking brake, lower the attachment to the ground, and shut down engine. Open the drain valve (Figure 84) on the bottom of the fuel tank. Drain the remaining fuel into a suitable container. NOTE: Dispose of drained fluids according to local regulations.
Page 199 Replace Air Conditioner Inner Filter NOTE: This unit is equipped with an air filtration system 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 200 Contact your local DOOSAN loader dealer inspection recharging refrigerant. 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 201 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 202 Change Fuel Cap Filter WARNING External shock or damages to fuel cap may lead to permanent damage to filter. FG015720 Figure 89 See under the fuel cap as shown on (Figure 90). Rotate bolt to CCW direction to loosen. FG015684 Figure 90 After disengaging it as shown on (Figure 91), carefully lay it on floor.
Page 203 After disengaging as shown on (Figure 92), you may now exchange it to a new filter as shown on (Figure 93). FG015687 Figure 93 After exchanging to a new filter, you may now assemble back in reverse order. FG015688 Figure 94 Inspection, Maintenance and Adjustment OP001015 4-59...
Page 204: 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 NOTE: Oil in both front and rear axles must be replaced after first 500 hours of operation to comply with new machine break-in requirements.
Page 205 Axle Brake Disk Wear Measurement NOTE: A wear measurement on the multidisk brake must be made at least once a year, especially in case of a change in braking behavior like, e.g. • Braking noise. • Braking power reduced. • Deceleration changed.
Page 206: 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 207 Bleed Brakes When brake hoses or brake tubes are replaced, air can be introduced into brake hydraulic system. Air can cause brakes to operate intermittently, which is a dangerous condition. Never operate machine with air in brake hydraulic system. A spongy feel when pressing brake pedal is a sign that air is present in brake hydraulic system.
Page 208 Do not mix antifreez solutions from different manufactures. Mixed solution may degrade the capabilities of the system. It is recommended to use the standard product from Doosan. In the bitterly cold area or weather, the customer should frequently check the performance of the coolant for appropriateness for the weather and then determine change cycle of the coolant.
Page 209 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. NOTE: “Fluid Capacities”...
Page 210 Without starting engine, operate controls to dump bucket. (Figure 103). Then operate controls to lower boom. (Figure 104). 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 19 on page 4-24).”...
Page 211 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. Inspection, Maintenance and Adjustment OP001015 4-67...
Page 212: 12,000 Hour / 6 Year Service
Standard ISO 8331 and EN982 CEN) European regulations state that the in-service life of any hydraulic hose exceed years. DOOSAN recommends the following: • Hoses at the customer premises cannot be stored more than 2 years before being discarded or installed on a machine.
Page 213: 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 214: 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 215: 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 216 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. NOTE: Colors may vary from one battery manufacturer to another.
Page 217: 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 218 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 219 Antifreeze Concentration Tables Ethylene Glycol - Doosan Genuine Antifreeze Solution (for all seasons) (2,000 Hour / Yearly) Ambient Temperature Cooling Water Antifreeze -10°C (14°F) -15°C (5°F) -20°C (-4°F) -25°C (-13°F) -30°C (-22°F) -40°C (-40°F) Propylene Glycol - Doosan Genuine Antifreeze Solution (for all seasons)
Page 220: 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 221: Hydraulic Pressure Checks
HYDRAULIC PRESSURE CHECKS Hydraulic pressure for most systems can be check by using the remote test ports shown in (Figure 110). Reference Description Pressure Number Main Pump Pressure (TPM) 210 ± 5 kg/cm Brake Charge Pressure 80 kg/cm (TP2) Steer Pump Pressure (TPS) FG015619 200 ±...
Page 222 Steering Pump Pressure Attach gauge to port (3, Figure 110). Adjust relief valve cartridge on steering valve (Figure 113). Cartridge must be adjusted to open at 200 ± 5 kg/cm (2,844 ± 70 psi). Unscrew plug and washer. Adjust screw that is beneath plug.
Page 223 Parking Brake Release Pressure Attach pressure gauge to parking brake port. Parking brake pressure must be 52 - 65 kg/cm (740 - 925 psi). Inspection, Maintenance and Adjustment OP001015 4-79...
Page 224 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 225 Checking the Relief Pressure of Fan Motor FG008112 Figure 117 Reference Reference Description Description Number Number Fan Motor Outlet Line Fan Guard Relief Valve Inlet Line Relief Valve Drain Line Reversable Solenoid Valve Maximum Fan Speed, Checking Open the radiator grille in order to connect the pressure gauge.
Page 226: 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 227: 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 and place transmission lever in “NEUTRAL.” Turn ignition switch to “ON” position. Move parking brake switch to “UNLOCKED”...
Page 228: 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 4-86) The tire pressure may have been raised before the machine was delivered from the factory.
Page 229 Stay away until tire and rim cool down. If the following defects are found in tires, for safety reasons the Tread tires must be replaced with new tires. For the replacement contact DOOSAN loader dealer or a tire Side walls manufacturer's local dealer. Breakers Carcass •...
Page 230 • 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) psi) psi) psi)
Page 231: Transportation
OP001016 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 232: 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 233: Troubleshooting
Add oil. or surges. Plugged air intake system. Clean system and replace filter. Injection pump out of Contact your DOOSAN dealer. adjustment. Plugged fuel filter. Replace fuel filter. Water or dirt in fuel system. Clean system and add new fuel.
Page 234 Clogged or dirty fuel injectors. Clean injectors. Fuel filters plugged. Replace filters. Engine speed control cable Readjust. out of adjustment. Injection pump out of Contact your DOOSAN dealer. adjustment. Valve backlash faulty. Adjust backlash. Engine runs hot. Low coolant level. Add coolant. Thermostat faulty.
Page 235: Hydraulic System
Air in fuel lines. Tighten fuel connections and filter. Fuel filter clogged. Replace fuel filter. Fuel pump failure. Contact your DOOSAN dealer. Incorrect fuel injection timing. Insufficient power. Air cleaner filter clogged. Clean or replace element. Fuel filer element clogged.
Page 236 Wrong pilot line connection. Reconnect pilot lines. Oil temperature too high. Debris in exterior of cooler. Clean exterior of cooler. Oil cooler faulty. Contact your DOOSAN dealer. Fan belt loose. Tighten fan belting as required. Actuators on one side of Overload relief valve is not Repair valve or replace.
Page 237: 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 238: 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 239: 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 240 Troubleshooting OP000040...
Page 241: Specification
OP001017 Specification GENERAL SPECIFICATIONS DL220 ITEM SPECIFICATION Standard Bucket Capacity (BOT / BOC) 2.2 m (2.88 yd ) / 2.3 m (3.01 yd Vehicle Weight (STD / OPT) 12,300 kg (27,116 lb) / 12,600 kg (27,778 lb) Engine (SAE J1995 Gross) Emission U.S EPA Tier3 (EU Stage IIIA)
Page 242: Working Range And Dimensions
WORKING RANGE AND DIMENSIONS Figure 1, illustrates exterior machine dimensions and working range of machine when it is equipped with a standard bucket. B (D) FG015634 Figure 1 Specification OP001017...
Page 243 CATEGORY DL220 Tire Size 20.5-25-16PR (L3) 20.5R25 (L3) 7,333 mm Overall Length (A) (24' 0") 2,550 mm Overall Width (B) (8' 4") 3,255 mm 3,245 mm Overall Height (C) (10' 8") (10' 8") 2,550 mm Bucket Width (D) (8' 4")
Page 244: Working Capacities
WORKING CAPACITIES Bucket Capacity Standard cutting edge bucket has a capacity of 2.3 m (3.0 yd Tipping Load Static Tipping Load with bucket in Over Front position is 10,079 kg (22,220 lb). With bucket in Fully Turned position, Static Tipping Load is 8,746 kg (19,281 lb).
Page 245 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 246 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 247: Index
Index 2-23 Numerics Brake Fluid Warning 2-23 4-50 Brake Fluid Warning Light 1,000 Hour / 6 Month Service 2-10 4-58 Brake Pedal 1,500 Hour / 9 Month Service 4-66 Troubleshooting 12,000 Hour / 6 Year Service Bucket 4-60 2,000 Hour / Yearly Service 3-18 Angle Indicator 4-31...
Page 248 2-35 2-19 Diagnostic Switch High Beam Indicator Light 4-29 2-7, 2-29 Drive Belt Wear Horn Button 4-48 Filter Change Hydraulic Oil Tank 4-35 4-38 Oil and Filter Drain Water 4-48 Oil Change Hydraulic System 4-22 4-24 Oil Level Check Check Oil Level 2-21 4-76 Oil Pressure Warning...
Page 249 2-51 Lifting Safety Precautions Adjusting Seat Forward/Backward 2-51 Loading and Unloading Adjusting Seat's Angle 2-26 2-52 Log Fork Control Lever Angle Adjustment of Armrest 4-80 2-51 Long Term Storage Backrest Adjustment 4-14 2-52 Lubricants Headrest 4-18 2-51 Lubrication and Service Chart Weight Adjustment 2-53 Seat Belt...
Page 250 2-17 1-15 Tachometer Unauthorized Modifications Tipping Load Unloading and Loading 4-83 Tire Damage 4-22 Tire Pressure Inspection 3-20 Towing Machine 2-52 Vibration Transmission 1-17 Vibration Level 2-34 Cut-off Switch 1-33 Visibility 2-15 Display 1-13 Visibility Information 2-11 Lever 4-40, 4-52 Oil - Drain and Replace 4-40, 4-52 Oil Filter Replacement...

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