Doosan DL220. Operation and Maintenance Manual (2010)

26. F/R (Forward/Reverse) Control Switch

(Optional)

To be able to use the forward/reverse function, the F/R

selector switch must first be depressed. When the switch is

activated, the F/R selector indicator light will be turned

"ON" in the instrument panel.

O. In this position, the machine is in "NEUTRAL"

In this position, the machine travels "FORWARD"

BSO0410L

II.

In this position, the machine travels "REVERSE"

Figure 83

NOTE: If the transmission lever is moved out of

"NEUTRAL" while operating the F/R control

switch, the transmission lever will override the

switch. The F/R control switch system will

require, that the F/R selector switch to be

pressed again, with the transmission lever in

"NEUTRAL."

Operating Controls

OP001013

2-39

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.

FG004192

Figure 85

2. Stereo / CD Player (Optional)

For operation of stereo see “Stereo / CD Player (Optional)”

on page 2-49.

PROGRAM

AST

SOUND

AM/FM

SCAN

TUNE

FG004057

Figure 86

3. Heater and Air Conditioner Control

Panel

For operation of heater and air conditioner see “Heater and

Air Conditioner Operation” on page 2-44.

FG003955

Figure 87

Operating Controls

OP001013

2-41

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 and other documents in this

compartment.

FG003889

Figure 89

6. Windshield Washer Tank

Contains windshield washer fluid. It is located behind the

operator's seat. (3, Figure 89)

7. Electrical Box

Contains relays and electric components. It is located on

left side of cabin.

FG015585

Figure 90

Operating Controls

OP001013

2-42

HEATER AND AIR CONDITIONER

OPERATION

Location of Controls and Vents

FG006506

Figure 92

Reference

Description

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. If necessary, the operator can

control interior cabin temperature using the operation panel.

Operating Controls

OP001013

2-44

Operation Panel

FG003966

Figure 93

Reference

Description

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" and give an activation sound.

When the light switch is turned "ON," the panel LED's will turn

"ON."

1. Fan and Air Conditioner Switch

A. "OFF" Switch

- Turns "OFF" the heater and air

conditioner unit.

B. "A/C" Switch - Turns "ON" the air conditioner when

one of the blower switches is activated.

HAOC930L

Figure 94

Operating Controls

OP001013

2-45

2. Blower Fan Switches

These switches are used to control the speed of the blower

fan.

A. "LO" Switch - Used for low blower speed.

B. "MID" Switch - Used for intermediate blower speed.

C. "HI" Switch - Used for high blower speed.

NOTE: If you do not select a blower speed the heater

and air conditioner will not work.

HAOC940L

Figure 95

3. Temperature Control Switch

The temperature control consists of 24 stages. An LED is

turned "ON" for every three stages. Whenever pushing it, it

changes in stages. Pushing it continuously, it changes

continuously.

A. "COOL" Switch - Lowers the temperature.

B. "WARM" Switch - Raises the temperature.

LED COLOR STATUS

HAOA860I

Green LED - Air conditioner. Full green, maximum

Figure 96

operation of air conditioner.

Red LED - Heater. Full red, maximum operation of

heater.

4. Selector Switch for Wind Direction

A. Used to direct air flow to upper portion of operator's

cabin.

FG006507

Figure 97

Operating Controls

OP001013

2-46

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° C (10 - 12°F)

less than the outdoor temperature.

Operate the air conditioner from twenty - thirty minutes a week

to circulate the refrigerant in the system.

NOTE: The blower switch must be on "LO" speed.

NOTE: The filter must be cleaned out every 500 hours and

replaced with a new one every 1,000 hours.

NOTE: In the event that the unit is being operated in a dusty

environment, the cleaning and replacement must be

performed more frequently.

If operating the air conditioner or heater for a long time, operate

the ventilation switch, and when smoking, vent the air to the

outside to prevent irritation to eyes.

Operating Controls

OP001013

2-48

STEREO / CD PLAYER (OPTIONAL)

Before operating the stereo or CD player, read operation manual

enclosed with stereo or CD player.

Stereo

PROGRAM

AST

SOUND

AM/FM

SCAN

TUNE

FG000108

Figure 101

Reference

Description

Number

Power / Volume Control

Preset Station

Sound Mode Selector

Tape Ejection

Band Selection

Fast Forward / Rewind

Tuning Up / Down

Tape Loading Slot

Scan Function / Auto Store

LCD

Operating Controls

OP001013

2-49

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. Adjusting Seat Forward/Backward

Lever

Holding lever (3, Figure 104), raise it, while pushing or

pulling seat to desired position. Release lever once desired

position is reached. Adjustment range is 160 mm (6.3 in).

2 and 3. Adjusting Seat's Angle and Height

Lever

HBOI350L

Figure 104

Pulling left lever (3, Figure 104) up allows rear part of seat

to be moved up or down. Pulling lever (2) up allows front

part of seat to be moved up or down. Adjust seat according

to operator's size and work conditions. Adjustment range is

60 mm (2.36 in) for both front and rear.

4. Weight Adjustment Knob

Turning knob (4, Figure 104) to right makes suspension

harder. Turning knob to left makes suspension softer.

Adjust according to operator's weight by checking weight

indicator dial. Adjustment range is from 50 - 120 kg (110 -

265 lb).

5. Backrest Adjustment Lever

Pulling up right lever (5, Figure 104) allows seat backrest

to be moved forward or backward.

Operating Controls

OP001013

2-51

6. Angle Adjustment of Armrest

Adjustment angle of left and right armrest (6, Figure 105) is

done by turning a dial in bottom of armrest. When you

adjust angle, manually raise armrest before turning dial.

7. Headrest

Headrest

(7, Figure

105) can be adjusted forward/

backward and up/down. Move it by holding both sides.

HAOB130L

Figure 105

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.

•

Inspect and maintain the suspension and adjustment

mechanisms of the seat regularly.

Check that the machine is properly maintained.

•

Tire pressure, brakes, steering, linkages, etc.

Steer, brake, accelerate, shift gears, move the

attachments and load the attachments smoothly.

Adjust the machine speed and travel path to reduce the

vibration level.

•

Slow down if it is necessary when passing rough

terrain.

•

Drive around obstacles and excessive rough terrain

conditions.

Keep the terrain on work sites where the machine is

working and traveling in good condition.

•

Remove any large rocks or obstacles.

•

Fill any ditches and holes.

•

Provide machines for and schedule time to maintain

the terrain conditions.

Travel over longer distance

(e.g. on public roads) at

adjusted (medium) speed.

•

Always adjust the speed for preventing bouncing.

Operating Controls

OP001013

2-52

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. Never fasten a seat belt

across abdomen.

Under no circumstances should operator be standing in

cabin when operating wheel loader.

Do not adjust seat position while vehicle is moving because

a loss of control may result. Stop machine, apply parking

brake, and then adjust seat.

Always, check condition of seat belt and belt bracket before

fastening it. Do not use it with twists in it. Replace belt or

bracket if damaged or worn.

Seat Belt Locking and Unlocking

Insert belt end (1, Figure 106) into buckle (2). Pull belt to check

that belt end is locked into buckle.

Adjust belt length so that it comfortably tight against operator's

pelvic region (hipbone).

HAOB140L

Figure 106

Press button (3, Figure 107) in center of buckle (2) and pull out

belt (1) to unlock.

HAOB150L

Figure 107

Operating Controls

OP001013

2-53

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.

FG003894

Figure 108

FG003895

Figure 109

The RH side door, which is emergency exit from the cabin,

can be opened in two positions.

Position 1. (ventilation position)

•

Open the window and secured it with the lock bar. (A,

Figure 110)

Position 2. (full opened position)

•

Open the window and push it to backward

FG003896

Figure 110

To release doors from both sides of the cabin. Pull the

handles

(Figure

111) in the direction of arrows. The

handles are located on both sides of the operator's seat.

FG003897

Figure 111

Operating Controls

OP001013

2-54

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. 1, 15A - Qty.

1, 20A - Qty. 1 and 30A - Qty. 1).

WARNING

If any fuse is blown, turn "OFF" the starter switch and shut

off the power supply. Remedy the cause

if needed and

replace the fuse with a new one.

FG003971

Figure 113

Fuse Box One

FUSE BOX (1)

FUSE BOX (2)

No.

Name

Capacity

Rear Wiper, Window Washer

10A

Parking Brake, Pilot Cut Off

10A

Rotating Beacon (Optional)

10A

CCTV (Optional)

10A

FG003972

Spare

10A

Figure 114

Cigar Lighter

10A

Turn Signal Light, Hazard Light,

10A

Indicate Light

Starter Switch, Hour Meter,

10A

Cabin Light

Air Conditioner, Heater

30A

Headlight

20A

Transmission

15A

Condenser Fan, Cooling Fan

15A

ECU (1)

15A

ECU (2)

15A

Operating Controls

OP001013

2-56

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

FNR

START

COMPRESSOR

STEREO

ILL.

ALARM(1)

ALARM(2)

HEATER

LIS

SELECT

fuse, check the function of the relay.

HEAD

REAR

WIPER

CONDENSER

RETURN TO

RAISE

FLOAT

HORN

FUEL

LAMP

FAN

DIG

HEATER

FG015589

Figure 115

FG015591

Figure 116

Circuit Breaker

A circuit breaker is next to the relay by the batteries at back of

unit under engine compartment hood. When a short circuit or an

overload occurs, the circuit breaker automatically cuts off

current, thus preventing electrical wires from burning.

FG003975

Figure 117

Operating Controls

OP001013

2-58

Fusible Link

A fusible link (Figure 118) is in the battery box.

If the engine does not crank, first check that the starter switch is

turned "ON" and that no power is available (No indicator lights

will light.). Check that the "A" portion (Figure 119) of the fusible

link is not broken or burned through. Replace the fusible link if

damage and investigate cause.

FG003978

Figure 118

WARNING

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

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" (Emergency Stop) position.

O. In this position, the engine emergency stop system is

"OFF"

In this position, "Emergency Stop" is selected the engine

will shut down

NOTE: When released, the switch will return to "O"

FG015592

(OFF) position

Figure 120

FG015593

Figure 121

Operating Controls

OP001013

2-59

OP001014

3Operation

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.

Displays and gauge readouts on instrument panel provide

information such as engine speed, engine coolant temperature,

transmission oil pressure, and electrical charge status.

NEW MACHINE BREAK-IN

PROCEDURES

All wheel loaders are inspected and adjusted before leaving the

factory. However, it is required that the operator follow these

steps during initial break-in period. Failure to follow these steps

may result in damage to equipment or reduced performance.

Make sure to check all fluid levels before starting and every

8 - 10 operating hours.

Do all Daily maintenance and service checks.

For first 50 operational hours, as shown by hour meter on

control console, do not exceed 80% of maximum rated

engine speed.

At end of first

50 operational hours, drain engine oil.

Replace engine oil filter and engine oil.

Operation

OP001014

3-1

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" (ON) position. All indicator lights

should turn "ON."

NOTE: If unit is equipped with and emergency steering

system. Test system before starting engine. If

system does not function properly, do not start

unit. Follow test procedure given with test

switch.

FG000084

Figure 6

Rotate starter key to "START" position. Starter motor

should crank immediately, and engine should start within a

few seconds.

FG000085

Figure 7

Operation

OP001014

3-3

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

be certain that all engine systems

(oil pressure, oil

temperature, coolant temperature, etc.) are in normal

operating range. If any engine system is not normal, turn

starter key to "OFF" position.

Instrument Panel Light or Gauge

Indicator Reading

Fuel Gauge

Engine Coolant Temperature Gauge

WHITE RANGE

Transmission Oil Temperature Gauge

Engine Oil Pressure Warning Light

Charging Warning Light

OFF

Brake Oil Pressure Warning Light

Parking Brake Light

NOTE: Parking brake indicator light turns "ON" or

"OFF" according to parking brake operation

regardless of engine starting.

10.

Perform “Hydraulic System Warm-up” on page 3-10.

11.

Check color of exhaust smoke:

•

No color or light blue - Engine is running in good

condition.

•

Black - Incomplete combustion. Check cause.

•

White or dark blue - Engine is burning engine oil.

Check cause.

12.

Check for usual engine vibration and noises. If any are

heard or felt, investigate cause.

NOTE: If engine coolant temperature gauge shows red

while running, take the following action;

Discontinue work and allow engine to run at

"LOW IDLE." Open engine compartment cover

for good ventilation. Once engine temperature

gauge returns to the green zone, shut down

engine. After engine has cooled, check coolant

level, look for signs of leaks, clogged or dirty

radiator fins (radiator core), and fan belt tension.

Operation

OP001014

3-4

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.

FG003979

Figure 10

Make sure transmission neutral lock is in the "N"

(NEUTRAL LOCK) position.

FG003980

Figure 11

Set pilot cutoff switch to "O" (LOCKED) position. This will

"LOCK" pilot control valve lever (joystick).

HBOI111L

Figure 12

Operation

OP001014

3-5

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."

FG000084

Figure 14

F/R

FG015594

Figure 15

Rotate starter key to "START" position. Starter motor

should crank immediately, and engine should start within a

few seconds.

FG000085

Figure 16

Operation

OP001014

3-6

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

After engine starts, check all indicator lights and gauges to

Figure 17

be certain that all engine systems

(oil pressure, oil

temperature, coolant temperature, etc.) are in normal

operating range. If any engine system is not normal, turn

starter key to "O" (OFF) position.

10. Perform “Hydraulic System Warm-up - Cold Weather” on

page 3-10.

Operation

OP001014

3-7

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. Electrical

sparks around or near batteries can cause an explosion.

Figure 18

Reference

Description

Number

Auxiliary Batteries

Ground Auxiliary Batteries to

Machine Frame

Depleted Batteries

If batteries are drained during starting procedures, you can jump

start engine using auxiliary or booster batteries according to

following procedures:

Connect positive jumper cable from auxiliary batteries to

depleted batteries (Figure 18).

Connect negative jumper cable from auxiliary batteries to a

ground point on machine frame. DO NOT CONNECT

DIRECTLY TO NEGATIVE BATTERY TERMINAL.

Follow normal engine starting procedures.

After engine has started, remove negative jumper cable,

and then positive cable.

Operation

OP001014

3-8

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.

Put pilot cutoff switch to "O"

(LOCK) position. This will

"LOCK" pilot control valve lever (joystick).

Allow engine to idle for one - two minutes to cool down.

HBOI111L

Figure 22

Operation

OP001014

3-9

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.

Cycle bucket until bucket cylinder bottoms out (extended

and retracted) without a load to circulate the oil through the

system. Do this for five minutes.

NOTE: Do not allow cylinders to pass hydraulic oil over

relief valve for more than twenty seconds at a

time.

Cycle boom, and bucket about five times without a load to

circulate oil through system.

Hydraulic System Warm-up - Cold

Weather

Follow Steps 1 through 3 in "Hydraulic System Warm-up."

Do not operate machine at full speed until system has fully

warmed up.

If working speeds continue to be slow, repeat initial

hydraulic warm-up procedures again. If repeating warm-up

procedures does not improve working speeds, continue to

operate, but use extreme caution because machine

function may be erratic.

Operation

OP001014

3-10

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.

Never place transmission in "NEUTRAL" when going

down a hill. Over speeding transmission can damage

transmission gears.

Never change direction of vehicle travel at high speed.

Serious damage to transmission will result.

Unlatch frame lock plate between front and rear frames

before traveling. Secure lock plate to rear frame (Figure

24).

FG008052

Figure 24

Set pilot cutoff switch to "I" (UNLOCKED) position. Raise

bucket to a height of 20 - 30 cm (8 - 12 in) above the

ground. Tilt bucket completely back.

HBOI110L

Figure 25

Operation

OP001014

3-11

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.

FG003980

Figure 28

Set parking brake switch to the "O" (RELEASE) position.

This will "RELEASE" the parking brake.

HAOP043L

Figure 29

Operation

OP001014

3-12

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. This could

cause vehicle to overturn.

When traveling or changing direction, always look

FG003980

carefully to be certain that no one is in path of

Figure 31

vehicle.

Operation

OP001014

3-13

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.

FG003980

Figure 34

Set parking brake switch to the "I" (APPLIED) position.

This will ensure that the parking brake is "APPLIED."

HA0O2019

Figure 35

Operation

OP001014

3-14

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" (OFF) position. Remove key.

FG003900

Figure 37

If machine is parked on a slope, install wheel chocks in

front of and behind vehicle wheels.

WARNING

Always secure machine with wheel chocks when

parked on a slope. Leaving machine in gear will

provide no braking effect because transmission

clutch is hydraulically operated. When engine is

turned "OFF," there is no hydraulic pressure in

2876A

transmission and clutch is not engaged.

Figure 38

Operation

OP001014

3-15

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.

To activate system perform the following steps:

Place transmission lever in "NEUTRAL."

NOTE: Do not move the transmission lever out of

"NEUTRAL." If the lever is moved, the system

will be deactivated.

FG005290

Figure 39

Press F/R selector switch to the "I" position, and then

release. The switch will return to the "O" position, but the

system will be activated. When system is activated, the F/

R selector indicator light (Figure 41) will be turned "ON."

FG003977

Figure 40

km/h

x100r/min

F/R

FG015597

Figure 41

Operation

OP001014

3-16

The F/R control switch is then used to control the travel

direction of the machine.

O. In this position, the machine is in "NEUTRAL."

In this position, the machine travels "FORWARD."

II.

In this position, the machine travels in "REVERSE."

The F/R travel control system will stay activated until one

of two things happen.

A. The transmission lever is moved out of "NEUTRAL"

into "FORWARD" or "REVERSE."

BSO0410L

Figure 42

B. The starter switch is turned "OFF."

When the system is deactivated, the F/R selector indicator

light (Figure 41) will be turned "OFF."

ADDITIONAL BRAKING

Machine hydraulic system can supply additional dynamic

braking force during travel. To accomplish this, move pilot

control valve lever (joystick) to crowd position and hold it there.

Hydraulic pump will be driven to supply output at maximum

pressure (relief pressure). Energy expended to drive pump, will

slow engine speed. Additional dynamic braking, along with

proper gear selection, can be used to slow a vehicle that is being

driven down an incline.

Operation

OP001014

3-17

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"

position. Trip plate can be adjusted to control maximum height

that boom can be raised.

FG015598

Figure 43

IMPORTANT

Trip plate (1, Figure 43) must always be set to contact limit

switch

(2) before boom cylinders reach maximum

extension. Maximum extension causes pump to force

fluid over relief valve.

To raise boom to maximum height, past preset height, hold

boom and bucket lever in "Raise" or "Hold Raise" position until

FG015599

boom has reached maximum height. Then remove your hand

Figure 44

from lever. Lever will automatically return to "NEUTRAL"

position. This prevents hydraulic pump from working against

relief valve (maximum pressure).

BUCKET ANGLE INDICATOR

Upper right side of bucket includes a bracket that indicates angle

of bottom of bucket. Top of bracket is parallel with bottom of

bucket. If bottom of bucket is not visible, top of bracket will be

visible.

FG015600

Figure 45

Operation

OP001014

3-18

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" position. Trip

plate can be adjusted to control maximum height that boom can

be lowered.

IMPORTANT

FG015602

Trip plate must always be set to contact limit switch

Figure 46

before boom cylinders reach maximum extension.

Maximum extension causes pump to force fluid over

relief valve.

ADJUSTMENT OF BUCKET

POSITION SWITCH

When bucket lever is held in crowd detent position, after bucket

has been dumped, bucket will pivot toward crowd position. Once

full crowd position has been reached, bucket lever will

automatically return to "NEUTRAL" position. If bucket is lowered

after lever returns to "NEUTRAL," bucket will automatically

position itself to be in a preselected digging position (usually

flat). To adjust bucket to desired preselected digging position,

perform the following steps.

Operate controls to place bucket on ground and in desired

digging position (usually flat). Return bucket lever to its

"NEUTRAL" position.

FG015603

Figure 47

Shut down engine.

Loosen bolts (1, Figure 47) on bracket (2).

Position bracket (2, Figure 47) so that end of arm (3) is

aligned with center of magnetic switch (4).

Tighten bolts (1, Figure 47).

Start engine. Raise boom, dump bucket, then move bucket

lever into crowd detent position. Now lower boom and

check to see that bucket has stopped at required position.

A small readjustment of bracket (2, Figure 47) may be

necessary.

Operation

OP001014

3-19

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). This

FG001662

will prevent damage to machine transmission that would

Figure 48

result from lack of lubrication.

WARNING

When towing another vehicle on a public road, take

necessary measures to let other vehicles and people

know that you are towing another vehicle. Use a flag,

rotating beacon light, or hazard light.

NOTE: There are several requirements you must abide by

when towing another vehicle. Learn the regulations

and rules about towing another vehicle and observe

them.

If the loader is being towed by another vehicle and the engine

will not start, remove the front and rear drive shafts; otherwise

the transmission will rotate without being properly lubricated,

causing seizure. Before removing them, apply the parking

brakes and block the wheels securely.

If the engine can be started and the steering wheel and brakes

function normally, have someone get on the loader you are

going to tow for steering it.

Before you tow a vehicle make sure you have checked the

following:

•

Check the weights of your loader and the vehicle to

be towed and make sure you loader has sufficient

braking capacity to stop the towed load.

•

Check if the vehicle to be towed can be braked and

steered. If not, do not allow anyone to ride on the

towed vehicle.

•

Check the tow rope or tow bar for damage and make

sure it has sufficient strength for the work.

•

When necessary to descend a grade, another towing

vehicle must be used in the rear to retard.

Operation

OP001014

3-20

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.

•

If you use any other towing device, refer to the

Instruction Manual supplied with the towing device.

•

If it is difficult to tow the loader, transport it by a trailer

truck to your nearest repair shop.

•

In addition to the above measures, release the

parking brake if the engine will not start or the

hydraulic pumps are defective.

IF ENGINE STALLS WHILE

TRAVELING

BRAKE SYSTEM: The brakes can be applied approximately 9

times by pressing the brake pedal due to the oil pressure

stored in the accumulator after engine is turned "OFF" if

the engine stalls while traveling, move to an out of traffic

area and park. Do not pump the brake pedal at this time;

otherwise the brake oil pressure will be used up, thus

causing the brakes to fail.

Operation

OP001014

3-21

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.

(It can be different according to type of tires.) This means that

the loader should not be used in a river.

Observe the following conditions:

Check the water depth in advance when crossing across a

river.

Use the same precautions before crossing across a

swampy area.

Do not enter rivers whose river bed is steep or has a rapid

flow.

CAUTION

Avoid use of the loader in salt water. Salt water

will cause the development of rust which will

shorten the life of the loader.

Operation

OP001014

3-22

OP001015

4Inspection, 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.

The intervals recommended between checks, oil changes and

lubrication apply provided that the machine is used under

normal environmental and operating conditions. See

“Lubrication and Service Chart” on page 4-17

Arrival and Delivery Inspection

Before the machine leaves the factory, it is tested and adjusted.

The dealer must also, if the warranty is to apply, carry out

"Arrival and Delivery Inspections" according to applicable form,

which must be signed.

Delivery Instructions

Figure 1

When handing the machine over, the dealer must give the buyer

"Delivery Instructions" according to applicable form, which must

be signed, if the warranty is to apply.

Inspection, Maintenance and Adjustment

OP001015

4-1

Service Points

15 12

Figure 2

FG015604

Reference

Description

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

Filling Point, Hydraulic Oil

Filling Point, Transmission

Ventilation Filters, Cabin

Draining, Hydraulic Oil

Battery

Pilot Filter

Alternator Belt

Oil Dipstick

Suction Strainer, Transmission

Oil Filter, Engine

Oil Filter, Transmission

Draining, Engine Oil

Inspection, Maintenance and Adjustment

OP001015

4-3

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.

Further safety rules and information and warning texts are given

within the respective section.

NOTE: Lifting with a jack must only be carried out by trained

personnel.

WARNING

If work has to be carried out on the machine before it has

cooled down, care must be observed with regard to risk of

burns from hot liquids and hot machine parts.

Inspection, Maintenance and Adjustment

OP001015

4-4

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

The bucket/attachment must be resting on the ground.

Apply the parking brake.

Shut down engine and take out the ignition key. (Does not apply when checking oil level in

transmission).

Carefully release the pressure in pressure lines and pressure vessels to avoid risks.

Attach a black and yellow "Warning Tag" to the steering wheel.

Connect the frame joint lock.

Block the wheels in a suitable way (with, for example, wedges).

Allow the machine to cool.

Inspection, Maintenance and Adjustment

OP001015

4-5

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. Replace or repair broken tools

and faulty equipment.

•

When lifting the machine, the frame joint must be

locked and the machine lifted at the eyes intended for

this purpose. See “Summary of Safety Precautions

for Lifting” on page 5-2

Figure 4

•

Use a hard hat, safety glasses, protective shoes and

gloves and an approved respirator or other protective

articles when required.

•

Do not wear loose fitting clothing or jewelry.

•

Keep service surfaces and handholds clean from oil,

dirt and ice.

Figure 5

•

Use the stepping areas provided with antislip

protection to avoid the risk of slipping. Worn, painted

over, or loose protections must be replaced.

Remember that high-pressure water jets when

washing and spilled oil can cause the protections to

loosen. Do not direct the water jet against the

protections and wipe up spilled oil.

•

Make sure that there is sufficient ventilation when

starting the engine indoors.

•

Do not exceed the maximum permissible floor load.

FG008056

•

Do not stand in front of or behind the machine while

Figure 6

the engine is running.

•

Use a ladder when changing light bulbs or carrying

out other service work high up on the machine.

•

Use a long handled window scraper and brush or a

ladder when cleaning the outside of the windows.

Inspection, Maintenance and Adjustment

OP001015

4-6

•

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). In addition the control

lever lockout and the parking brake must be applied.

•

Take care when changing oil in engine, hydraulic

system or transmission as the oil may be hot and

cause burns.

•

When emptying/draining oil or fuel, use a pump or a

hose and collect the liquids in a suitable vessel.

Spillage will damage the environment and may cause

a fire. Waste oil and other contaminating liquids must

be taken care of by a firm especially authorized to

carry out such work.

•

When operating in an area which is contaminated or

dangerous to one's health, the machine must be

especially equipped for this purpose. Special local

safety regulations apply within such areas and also

when servicing the machine.

•

Shut down engine before opening engine covers etc.

Make sure that no tools or other objects, which may

cause damage, have been forgotten in or on the

machine.

•

Check that the equipment you are using for lifting or

supporting parts of the machine, e.g. straps, slings,

ratchet blocks and ground support, can safely cope

with the strain they are exposed to and meet

applicable regulations.

•

Release the pressure in pressure vessels,

components and systems carefully and in the

prescribed way, so that the excess pressure is

released without risk.

•

When connecting hydraulic hoses, check that the

desired effect has been achieved, that is, check that

the hydraulic function operates in the expected way.

•

Hoses, pipes and quick-connect couplings may be

pressurized even if the machine is stationary and the

engine turned "OFF." Such pipes and hoses should

therefore only be disconnected by trained personnel.

•

When looking for leaks, use a piece of paper or

wood, not your hand.

Inspection, Maintenance and Adjustment

OP001015

4-7

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

material and that the active compound does not conduct electricity.

FG003902

The effectiveness grade I means that the time the extinguisher is

Figure 7

effective must not be less that eight seconds, grade II at least

eleven seconds and grade III at least fifteen seconds.

A handheld fire extinguisher ABE I (in the USA ABC type)

normally corresponds to a powder content of

4 kg (8.8 lb)

(EN-grade 13A89BC), the EN 3-1995 standard, parts 1, 2, 4 and 5.

At the slightest sign of fire, and if the situation allows, take the

following steps:

Drive the machine away from the fire sensitive area

caused by the fire.

Lower the lifting arms to the ground.

Shut down engine by turning the ignition key to the "0"

(OFF) position.

Leave the cabin.

Turn off the battery disconnect switch.

Start putting out the fire and notify the fire brigade/

department if necessary.

It is forbidden to smoke or have an open flame near a machine

when filling with fuel or when the fuel system has been opened

and in contact with the surrounding air.

Diesel fuel oil is flammable and must not be used for cleaning.

Use an approved solvent and do not inhale the fumes. Also bear

in mind that certain solvents can cause skin rashes and

constitute a fire hazard.

Flammable starting must not be used due to the use of the

electric preheating in the induction air system.

Keep the place clean where the service is to be carried out. Oil

or water makes the floor slippery and is also dangerous in

connection with electrical equipment or electrically powered

tools. Oily or greasy clothes are a serious fire hazard.

Check daily that the machine and the equipment, e.g.

underbody plates are free from dust and oil. In this way the risk

of fire is reduced and it is easier to detect faulty or loose components.

NOTE: If a high-pressure jet is used for cleaning, take great

care as the insulation of electric leads can be

damaged even at a moderately high-pressure and

temperature. Protect electrical leads in an

appropriate way.

Inspection, Maintenance and Adjustment

OP001015

4-8

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.

Fire prevention equipment which is installed on the machine

must be maintained and regarded as a complement to the

actions of the operator in case of a fire.

Check that fuel lines, hydraulic and brake hoses and electrical

cables have not been damaged by chafing or are not in danger

of being damaged because of incorrect installation or clamping.

This applies particularly to unfused cables, which are red and

marked R(B+) and routed:

•

between the batteries

•

between battery and starter motor

•

between alternator and starter motor

•

to the preheating element on the engine.

Electrical cables must not lie directly against oil or fuel lines.

The following applies for welding and grinding work:

•

A fire extinguisher must be kept near at hand.

•

The ventilation must be good when working indoors.

•

Approved respirator must be used

•

The work surface must be cleaned.

•

Do not weld or grind on components which are filled

with flammable liquids, e.g. tanks and hydraulic

pipes. Exercise care with such work in the proximity

of these places.

Working on Painted Surfaces

When welding, grinding and gas cutting, the paint finish must

first be removed from an area with a radius of at least 10 cm

(4 in) from the point where the work is to be carried out. The

reason for this is that paint when heated gives off a great

number of different substances which can cause irritation and be

very harmful to a person's health in case of long or frequent

exposure.

In addition to the health hazard, the weld will also be of an

inferior quality and strength, which in the future may cause the

weld to break. Therefore, never weld directly on a painted surface.

Inspection, Maintenance and Adjustment

OP001015

4-9

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

have to handle floor rubber.

Certain seals which have to withstand high operating

temperatures (e.g. in engines, transmissions, axles, hydraulic

motors and pumps) may be made from floor rubber, which,

when exposed to high heat (fire), forms hydrogen fluoride and

hydrofluoric acid. This acid is very corrosive and cannot be

rinsed or washed off from the skin. It causes very severe burns

which take a long time to heal.

It usually means that damaged tissue must be surgically

removed. Several hours may pass after contact with the acid,

before any symptoms appear and therefore one is not given any

immediate warning. The acid may remain on the machine parts

for several years after a fire.

If swelling, redness or a stinging feeling appears and one

suspects that the cause may be contact with heated floor rubber,

contact a medical doctor immediately. If a machine, or part of a

machine, has been exposed to fire or severe heat, it must be

handled by specially trained personnel. In all handling of

machines after a fire, thick rubber gloves and effective goggles

must be used.

The area around a part which has been very hot and which may

be made of floor rubber must be decontaminated by thorough

and ample washing with lime water (a solution or suspension of

calcium hydroxide, i.e. slaked lime in water). After the work has

been completed, gloves must be washed in lime water and then

discarded.

Inspection, Maintenance and Adjustment

OP001015

4-10

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:

•

Protect the material from heat.

•

Use protective gloves, protective goggles and an

approved respirator.

Waste Hazardous to the Environment

Painted parts or parts made of plastic or rubber which are to be

scrapped must never be burnt, but must be taken care of by an

approved refuse handling plant.

Batteries, plastic objects and anything else which is suspected

of being dangerous to the environment must be taken care of in

an environmentally safe way.

Check List After Fire

When handling a machine which has been damaged by fire

or been exposed to intense heat, the following protective

measures must under all circumstances be followed:

Use thick, gloves made of rubber and wear goggles which are

certain to protect your eyes.

Never touch burnt components with your bare hands, as there is

a risk that you may come into contact with melted polymer

materials. First wash thoroughly with plenty of lime water (a

solution or suspension of calcium hydroxide, i.e. slaked lime in

water).

As a precaution, seals (O-rings and other oil seals) should

always be handled as if they were made of floor rubber.

Treat skin, which is suspected of having come into contact with

burnt floor rubber, with Hydrofluoric Acid Burn Jelly or something

similar. Seek medical advice. Symptom may not appear until

several hours afterwards.

Discard gloves, rags etc. which are suspected of having come

into contact with burnt floor rubber.

Inspection, Maintenance and Adjustment

OP001015

4-11

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.

NOTE: Time interval between each service check may need

to be shortened if machine is operating in severe

atmospheric conditions. Machines working in

extremely hot or dusty conditions will require more

frequent service checks. Total hours of machine

operation are determined by hour meter that is on the

front instrument panel.

HAOA600L

Figure 8

Product Identification Number (P. I. N.)

Location

The PIN is stamped on the product identification plate (Figure 9)

on the right side of front frame above wheel cover.

NOTE: Please make note of these 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

Figure 9

Inspection, Maintenance and Adjustment

OP001015

4-12

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).

FG006234

Figure 11

Safety Precautions

Before performing any maintenance checks, move pilot

cutoff switch to "LOCKED" position. Place a Warning Tag

on controls so that no one begins to operate machine while

maintenance checks are being performed.

Clean up all fuel spills. Fuel spills are hazardous,

especially around engine.

Inspect all fuel lines for leakage. Replace any lines, fittings,

O-rings, or filters that show signs of wear or damage.

If a test procedure requires engine to be running, use two

people and keep all unnecessary personnel away from

machine.

Inspection, Maintenance and Adjustment

OP001015

4-13

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

HYDRAULIC OIL

ENGINE OIL

AXLE GEAR OIL

MANUFACTURER

GREASE

DOOSAN GENUINE

DSZ 46

API CI-4

NLGI No.2

LUBRICANTS

GS-CALTEX

RANDO DSZ 46

SIGMA DX-1

MULTIFAK EP #2

10W40

S-OIL TOTAL

EQUIVIS ZS 46 IV

RUBIA TIR

7400

TOTAL MULTIS EP

JID 80W90

10W40

RUBIA

POLYTRAFIC

10W40

RUBIA 8600 10W40

CHEVRON

AW 32 (BELOW 0°C)

DELO 400 15W40

DELO GREASE EP

DELO GEAR OIL

or RPM UNIV

AW 46 (ABOVE 0°C)

GEAR 80W90

TEXACO

RANDO HDZ 46

URSA SUPER

MULTIFAK ALL

MULTI-GEAR EP

PREMIUM 15W40

PURPOSE EP #2

SAE 80W90

ESSO

UNIVIS N 46

ESSOLUBE XT-5

RONEX MP

SPARTAN EP220 or

15W40

EXXON GX 80W90

MOBIL

MOBIL DTE 13M

MOBIL DELVAC

RONEX MP

LUBE SHC LS

MX 15W40

15W90 or SAE

75W90LS

SHELL

TELLUS OIL T 46

RIMULA ULTRA

ALVANIA EP #2

SPIRAY HD 85W90

10W40

or LS 90

PENNZOIL

PENNZOIL MULTI-

MULTIPURPOSE

PURPOSE 4092 or

WHITE GREASE

80W90

705 EP #2

CASTROL

PARADENE AW 32

CASTROL EPL #2

LSC SAE 90

(BELOW 0°C)

PARADENE AW 46

(ABOVE 0°C)

Inspection, Maintenance and Adjustment

OP001015

4-14

LUBRICANT

HYDRAULIC OIL

ENGINE OIL

AXLE GEAR OIL

MANUFACTURER

GREASE

IDEMITSU KOSAN

DAPHNE KOSAN

DAPHNE

APOROIL GEAR

32 WR (BELOW 0°C)

EXPONES SR #2

AE 90

DAPHNE KOSAN

46 WR (ABOVE 0°C)

DRYDEN

AP 80W90

NIPPON SEIKIYU

NISEKI SP90 or

EP90

FUCHS

RENO GEAR OIL

LSA SAE 90 or

TITAN GEAR

85W90 LS

LUBRICANT

TRANSMISSION GEAR OIL

MANUFACTURER

SAE 15W40

Same as engine oil

API CH-4 and above

Antifreeze

Recommended Concentration

Manufacturers Meeting ASTM D3306

Doosan Genuine Solution

Dexcool ELC by Chevron Texaco

50% Antifreeze - 50% Distilled Water

Alugard G48 by BASF

Others meeting or exceeding ASTM D3306

NOTE: 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.

IMPORTANT

Fluctuating daily or weekly extremes of temperature, or

operation in subzero freezing weather may make it

impractical to use straight weight lubricants. Use good

judgement in selecting lubricant types that are appropriate

for climate conditions.

Inspection, Maintenance and Adjustment

OP001015

4-15

DL06 Industrial Engines Oil Drain Intervals

by Duty Cycle (Hours)

Heavy

ACEA E5 (API CI-4)

500

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.

We don't recommend the use of CF or CG grade oils. If CF or CG oils must be used, make the oil drain

intervals half of the API CI-4 values.

Engine oil drain intervals need to be reduced by 50% when fuel sulfur content exceeds 0.5% (5000 ppm).

FLUID CAPACITIES

Component

Capacity

Engine

DL 06

27 liters

(7.1 U.S. gal.)

Oil Pan with Filter

Engine

NOTE:

The filter holds an additional 1 liter (1 qt) of oil.

40 liters

Cooling System

(10.6 U.S. gal.)

243 liters

Fuel Tank

(64 U.S. gal.)

117 liters

Hydraulic Oil Tank

(30 U.S. gal.)

30 liters

Transmission

(7.9 U.S. gal.)

15 liters

Front Differential

(4.0 U.S. gal.)

1.7 liters

Front Hub Reduction Gear

(0.4 U.S. gal.) Each end.

Axles

12.2 liters

Rear Differential

(3.2 U.S. gal.)

2.4 liters

Rear Hub Reduction Gear

(0.6 U.S. gal.) Each end.

Inspection, Maintenance and Adjustment

OP001015

4-16

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.

•

Replace old grease which may contain dirt. The

grease in the space inside the outer seal collects dirt

and prevents dirt and also water from penetrating into

the bearing.

Therefore, grease the bearing until new, clean grease is forced

out through the outer seal.

Between 10 and 15 strokes with a normal handheld grease gun

is required to grease one of the bearings for the lifting arms.

Wipe off grease fittings and grease gun before greasing, so that

dirt and sand is not introduced through the grease fittings.

Symbol key

These standard symbols are used in “Lubrication and Service

Chart” on page 4-18.

Symbol

Description

Symbol

Description

Lubrication

Fuel Filter

Transmission Oil

Air Conditioner Filter

Engine Oil

Drain Water

Engine Oil Filter

Gear Oil (Axle)

Hydraulic Oil

Brake Filter

Hydraulic Oil Return Filter

Level Check

Coolant

Hydraulic Oil Tank Breather

Air Cleaner Element

Fuel Cap Filter

Inspection, Maintenance and Adjustment

OP001015

4-17

Service Data

DL220

No.

Items To Check

Service

Qty.

Service Interval

250

500

1000

1500

2000

Front Joint Pin

Grease

F100

W10

Articulation Pin

Grease

Rear Axle Pivot

Grease

Steering Cylinder

Grease

Front Drive Shaft

Grease

Bearing

Fuel Tank

Diesel

243ℓ

Hydraulic

Hydraulic Oil Tank

117ℓ

Oil

Engine Oil

Engine Oil Pan

27ℓ

15W40

Coolant

Radiator

40ℓ

(Antifreeze)

Axle Gear

Front Axle

18.4ℓ

Oil (80W90)

Axle Gear

Rear Axle

17.0ℓ

Oil (80W90)

Engine Oil

Transmission

30ℓ

15W40

Pre

Fuel Filter

Cartridge

Main

Engine Oil Filter

Cartridge

Transmission Filter

Cartridge

Full Flow Filter

Element

Oil Suction Strainer

Strainer

Brake and Pilot Filter

Element

(Outer)

Air Cleaner

Element

(Inner)

Air Intake Precleaner

Case

Air Conditioner

Outer

Cartridge

Filter

Inner

Air Breather Filter

Element

Fuel Cap Filter

Element

V: Maintenance and Refill.

C: Cleaning.

F: First Time Exchange Only.

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.

PG: Propylene Glycol - Doosan Genuine Antifreeze Solution (Drain and replace using this interval.) See

“Engine Cooling System” on page 4-73, for further explanation.

Gray Box: Replacement On Every Interval.

NOTE: For additional service items see list of “Maintenance Intervals” on page 4-20.

Inspection, Maintenance and Adjustment

OP001015

4-19

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

Check for Leaks in Hydraulic System

4-25

Fill Fuel Tank

4-25

Check for Leaks in Fuel System

4-26

Drain Fuel Condensation

4-26

Check Coolant Level

4-26

Check Level of Windshield Washer Liquid

4-27

Inspect the Bucket Teeth and Side Cutters for Signs of Wear

4-27

Inspect Seat Belt for Proper Operation

4-27

Inspect the Structure for Cracks and Faulty Welds

4-27

Check the Operation of All Switches

4-27

Check the Operation of All Exterior Lights, Horn and Control Console Indicator and Monitor

4-28

Lights

Start Engine, Check Starting Ability, and Observe Exhaust Color at Start-up and at Normal

4-28

Operating Temperature. Listen for Any Abnormal Sounds

Check Operation of All Controls

4-28

Inspect Cooling Fan Blade

4-29

Check Engine Drive Belt Wear

4-29

Check Air Intake System

4-30

50 Hour / Weekly Service

Perform All Daily, 10 Hour Service Checks

4-31

Grease Front Attachment Pins

4-31

Grease Steering Cylinder Rod and Head Ends

4-34

Grease Upper and Lower Center Pins

4-35

Replace Engine Oil and Filter (After First 50 Hours)

4-35

Replace Hydraulic Full Flow Filter (After First 50 Hours)

4-35

Check Air Conditioner and Alternator Belt Tension (After First 50 Hours)

4-36

Clean Exterior of Radiator, Oil Cooler and Air Conditioner Condenser

4-36

Clean Air Conditioner Outer Filter

4-37

250 Hour / Monthly Service

Perform All Daily, 10 Hour and 50 Hour Service Checks

4-38

Check Engine Air Intake Precleaner

4-38

Drain Water From Hydraulic Oil Tank

4-38

Turbocharger

4-39

Check Air Conditioner and Alternator Belt Tension

4-39

Grease Drive Shafts

4-40

Inspection, Maintenance and Adjustment

OP001015

4-20

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

Replace Fuel Prefilter

4-44

Fuel Filter (Spin-On Type)

4-45

Replace Fuel Filter

4-46

Clean Exterior of Radiator, Oil Cooler and Air Conditioner Condenser

4-46

Clean Air Conditioner Inner Filter

4-47

Replace Engine Oil and Filter

4-48

Replace Air Conditioner Outer Filter

4-49

1,000 Hour / 6 Month Service

Perform All Daily, 10, 50, 250 and 500 Hour Service Checks

4-50

Air Cleaner

4-50

Replace Outer Air Cleaner Element

4-51

Drain and Replace Transmission Oil and Filter

4-52

Clean Fuel Tank and Strainer

4-53

Replace Air Conditioner Inner Filter

4-55

Check Air Conditioner Refrigerant

4-55

Check and Adjust Engine

4-56

Change Air Breather Filter

4-56

Replace Hydraulic Full Flow Filter

4-57

Change Fuel Cap Filter

4-58

1,500 Hour / 9 Month Service

Perform All Daily, 10, 50, 250 and 500 Hour Service Checks

4-60

Replace Axle Differential and Planetaries Oil

4-60

Axle Brake Disk Wear Measurement

4-61

2,000 Hour / Yearly Service

Perform All Daily, 10, 50, 250, 500 and 1,000 Hour Service Checks

4-62

Replace Inner Air Cleaner Element

4-62

Check Steering, Brake, Drive Shaft, Engine, and Fuel System

4-62

Replace Pipes and Hoses

4-62

Bleed Brakes

4-63

Replace Radiator Coolant

4-64

Replace Hydraulic Oil and Clean Oil Suction Strainer

4-65

Check Brake Accumulator

4-67

12,000 Hour / 6 Year Service

Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982

CEN)

4-68

Inspection, Maintenance and Adjustment

OP001015

4-21

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. Follow procedure printed under

the

50 hour maintenance interval

“Grease Front

Attachment Pins” on page 4-31.

Inspect All Tires for Correct Tire Pressure

and Signs of Damage or Abnormal

Wear

Inflate tires to proper operating pressure for working

conditions. See “Tires” on page 4-84

Check Engine Oil Level

NOTE: When checking level using a dipstick always remove

and wipe it clean before making final level check.

Check level of engine oil every day before starting engine.

FG006238

Figure 13

Remove engine oil dipstick (1, Figure 13). Oil level must be

between "LOW" and "FULL" marks.

NOTE: If oil is above "HIGH" mark on dipstick, some

must be drained to return oil to proper level.

To add oil, remove engine oil fill cap (2, Figure 13).

HAOC280L

Figure 14

Inspection, Maintenance and Adjustment

OP001015

4-22

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. Lower bucket to ground.

Place transmission lever in "NEUTRAL." Apply parking

brake. Shut down engine.

FG008085

Figure 15

Block tires. Once tires are blocked, start engine and have a

person remain in the cabin.

Allow engine to idle until transmission temperature is to

80°C (176°F).

Remove transmission dipstick (Figure 16). Wipe dipstick

clean and then insert it back into transmission.

Remove dipstick and check oil level mark. Oil level must be

between "LOW" and "FULL" marks.

To add oil, remove transmission fill cap (Figure 15) from

transmission oil filter pipe.

Shut down engine when done.

HAOC280L

Figure 16

Inspection, Maintenance and Adjustment

OP001015

4-23

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

released, it is safe to remove either the fill cap or service

Figure 17

covers.

Move machine to a level area and shut down engine.

Apply parking brake.

Lower bucket to ground.

Check sight gauge that is attached to hydraulic tank. Oil

level must be visible in red centered circle shown on sight

gauge (1, Figure 18).

FG008086

Figure 18

To add hydraulic oil, turn breather cap (1, Figure 19) slowly

to allow pressurized air to vent.

Remove upper cover (2, Figure 19) from hydraulic oil tank

and raise boom at max. height and replenish oil to the top

of sight gauge (Figure 18).

IMPORTANT

Do not fill above red centered circle on sight gauge.

FG008087

Overfilling can result in damage to equipment and oil

Figure 19

leaking from hydraulic tank due to expansion.

The hydraulic oil fill cover also serves as the hydraulic oil

strainer access cover. It is important to replace this cover and

the components in the proper order and alignment.

The filter (2, Figure 20), retaining rod (3) and spring (4) are

assembled as shown in Figure 20. The hole (1) in the base of

the filter fits over a circular base in the bottom of the tank. The

retaining rod (3) screws into the top of the filter (2), but the

spring (4) slides over the top of the rod. Be certain that this

spring does not fall into the tank during reassembly.

If filter assembly was removed, insert assembly into the

FG002188

tank and check to make sure it is securely in place.

Figure 20

Inspection, Maintenance and Adjustment

OP001015

4-24

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. The cover can be rotated to align the rod into a

vertical position.

Tighten mounting bolts to 4.84 kg•m (35 ft lb).

FG002189

Figure 21

Check for Leaks in Hydraulic System

Perform a daily walk-around inspection to make sure that

the hoses, piping, fittings, cylinders and hydraulic motors

are not showing any signs of leakage. If any is noted,

determine the source of the leak and repair.

Fill Fuel Tank

WARNING

Use extreme safety precautions while refueling to prevent

explosions or fire.

Immediately clean up any spilt fuel.

FG001689

At end of each work day, fill fuel tank. Add fuel through fuel

Figure 22

fill cap (Figure 22). When working at a temperature of 0°C

(32°F) or higher, use ASTM No. 2-D or its equivalent. At

temperatures below 0°C (32°F) use ASTM No. 1-D or its

equivalent.

Securely tighten cap after fueling.

NOTE: If breather holes in cap are clogged, a vacuum

may form in the tank preventing proper fuel flow

to engine. Keep holes in fuel cap clean.

FG001690

Figure 23

Inspection, Maintenance and Adjustment

OP001015

4-25

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.

NOTE: Dispose of drained fluids according to local

regulations.

FG006245

Figure 24

Check Coolant Level

NOTE: Do not mix ethylene glycol and propylene glycol

antifreeze together. If the two are mixed, the

protection level will be reduced to the level of the

ethylene glycol.

NOTE: This unit was factory filled with propylene glycol.

WARNING

FG001692

Figure 25

Never open radiator when it is hot. Scalding liquid inside a

hot radiator is under pressure. Removing cap from a hot

radiator could cause a person to be sprayed and burned

from liquid inside. Wait for radiator temperature to cool

down before removing cap.

Check sight gauge (1, Figure 26) that is attached to the

radiator. Coolant level must be visible in red centered circle

shown on gauge. To add coolant, remove fill cap (2, Figure

26) of the radiator and add coolant to proper level by

checking sight gauge (1, Figure

26). If temperature is

below freezing, see “Antifreeze Concentration Tables” on

page 4-75 for antifreeze protection. Use the table to

calculate a proper mixture of antifreeze and water to

provide level of protection necessary for expected

temperature.

FG006258

Figure 26

Inspection, Maintenance and Adjustment

OP001015

4-26

Check Level of Windshield Washer Liquid

Check fluid level in windshield washer tank, behind

operator's seat.

Open fill cap and add fluid.

NOTE: Use a washer liquid that is rated for all seasons.

The will prevent freezing during cold weather

operation.

FG001693

Figure 27

Inspect the Bucket Teeth and Side Cutters

for Signs of Wear

On a daily basis, inspect bucket teeth to make sure that

tooth wear or breakage has not developed.

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.

Figure 28

Inspect Seat Belt for Proper Operation

Inspect the Structure for Cracks and

Faulty Welds

During the daily walk-around inspection and when

greasing the machine, look for any visible damage to the

machine. Repair or replace any damaged parts before

operating machine.

Check the Operation of All Switches

Verify working condition of all switches before starting

engine.

Inspection, Maintenance and Adjustment

OP001015

4-27

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. Repair or replace if required.

Turn "ON" and inspect all exterior work lights. Replace any

monitors, burned out bulbs or cracked or broken housings

or lenses.

Start Engine, Check Starting Ability, and

Observe Exhaust Color at Start-up and

at Normal Operating Temperature.

Listen for Any Abnormal Sounds

Check Operation of All Controls

IMPORTANT

Cold weather operation requires that the operator fully

warm up the hydraulic oil before beginning machine

operation. Follow all warm up instructions listed in the

Operating Instruction section of this manual. Make sure to

cycle oil through all of the components, including all

cylinders, both travel motors and the swing motor. Cold

hydraulic oil in the lines and components needs to be

warmed before beginning full operation. If this is not done,

damage to the cylinders or hydraulic motors can occur.

With engine at rated speed, operate all of the controls.

Follow cold weather hydraulic system warm-up

procedures.

Note any slow operations or unusual movements.

Determine the cause and repair fault before operating.

Inspection, Maintenance and Adjustment

OP001015

4-28

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. Check the fan

to make sure it is securely mounted. Tighten the bolts if

necessary. Replace any fan that is damage.

Check Engine Drive Belt Wear

WARNING

Keep clear of engine fan and fan drive belts when the

engine is running. Rotating fan and belt contact can cause

injury.

WARNING

Figure 30

When checking, adjusting or replacing drive belts, care

must be taken to prevent accidental cranking of the engine.

Be sure the starter switch is in the "O" (OFF) position and

the controls are tagged.

Replace badly worn, greasy or severely cracked belts

immediately. These conditions prevent proper belt

function. Visually inspect the belt. Check the belt for

intersecting cracks. Transverse

(across the belt width)

cracks are acceptable. Longitudinal

(direction of belt

length) cracks that intersect with transverse cracks are not

acceptable. Replace the belt if it is frayed or has pieces of

material missing.

Before installing new belts, make sure all pulley grooves

are clean and not worn. Replace pulley, if damaged, or if

the grooves are worn.

All pulley support bearings, shafts, and brackets must be in

working order.

When replacing belts and pulleys, pulley alignment must

be checked with belts tensioned and brackets securely

clamped. A misalignment that can be detected by the

naked eye is detrimental to belt performance.

Inspection, Maintenance and Adjustment

OP001015

4-29

Do not force the belts into the pulley grooves by prying with

a screwdriver or pry bar. This will damage the belt side

cords which will cause the belts to turn and result in

complete destruction of the belts in operation.

Belts on new machines and replacement belts lose their

tension as they seat into the pulley grooves. Check the

tension of new belts at 20 hour intervals until tension is

stabilized and thereafter, every 250 hours. If the tension

falls below the required minimum, the belt will be able to

slip, damaging the belts and pulley grooves.

NOTE: When operating in abrasive conditions, check

tension every 100 hours.

Check Air Intake System

WARNING

Hot engine components can cause burns.

Avoid contact with hot engine components.

Park the machine on a level surface, apply the parking

brake, lower the attachment to the ground, and shut down

HAOA050L

engine.

Figure 31

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.

Do not operate engine if any leaks or defects are found

Figure 32

on air intake system.

Inspection, Maintenance and Adjustment

OP001015

4-30

F. 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.

FG008101

Figure 44

Steering cylinder head ends,

2 locations. Use remote

grease fittings mounted on frame. (1 and 2, Figure 45).

Remote Grease

Reference Number

Fittings

1 and 2,

Steering Cylinder

50 Hours

Head Ends

Drive Shaft

250 Hours

Center Bearing

FG001640

Figure 45

Inspection, Maintenance and Adjustment

OP001015

4-34

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

(After First 50 Hours)

NOTE: Replace hydraulic full flow filter after first 50 hours of

operation or rebuild and every

1,000 Hours

thereafter. Follow procedure under

1,000 hour

maintenance interval (See page 4-57).

Inspection, Maintenance and Adjustment

OP001015

4-35

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. Follow procedure printed under

250 hour

maintenance interval “Check Air Conditioner and Alternator

Belt Tension” on page 4-39.

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.

NOTE: On an especially dusty work site, clean fins

every 50 hours. On other work sites, clean fins

every 500 hours.(See page 4-45)

FG004071

Figure 48

Inspection, Maintenance and Adjustment

OP001015

4-36

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.

Remove filter (1, Figure 49) and inspect it for damage.

Use compressed air to clean filter. If element is very dirty

use a mild soap and water solution to clean it.

NOTE: Clean air-conditioning filter every 50 hours and

replace a new one every 500 hours of service.

NOTE: If water was used to clean filter be sure it is

completely dry before installation.

NOTE: In the event that the unit it being operated in a

dusty environment, the cleaning and

replacement must be performed more

frequently if filter is damaged, replace damaged

with a new one.

FG003904

Figure 49

WARNING

All service and inspection of the air-conditioning

system must be performed with the starter switch in

the "O" (OFF) position.

Inspection, Maintenance and Adjustment

OP001015

4-37

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. The precleaner

does not need periodic replacement.

Figure 50

Drain Water From Hydraulic Oil Tank

WARNING

Be certain that hydraulic oil has cooled before draining

water and sediment. Hot oil could splash and cause burns.

The hydraulic tank is pressurized. Unscrew the cap of

breather on the top of hydraulic tank to allow pressurized

air to vent. After pressure has been released, it is safe to

remove either the fill cap or service covers.

Position machine on firm, level ground. Lower boom and

position bucket on ground. Shut down engine.

Position a container under hydraulic tank drain plug. Open

tank breather cap (See Figure 19 on page 4-24). Loosen

drain valve at bottom of tank (Figure 51). Allow all water

and sediment to drain out. Tighten drain valve.

NOTE: Dispose of drained fluids according to local

regulations.

FG015616

Figure 51

Inspection, Maintenance and Adjustment

OP001015

4-38

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.

•

engine oil is changed and oil filters are replaced at

prescribed intervals.

•

the air cleaner is serviced regularly and that the

exhaust system and lubricating oil lines do not leak.

In case jarring noises can be heard, or if the turbocharger

vibrates, it must be reconditioned or replaced immediately.

Only authorized dealer workshops should carry out work on

the turbocharger.

Figure 52

Check Air Conditioner and Alternator Belt

Tension

Loosen the tension adjusting bolts of the alternator, air con.

compressor and air compressor, then take off the cooling fan.

Adjustable Link

for alternator belt

Air-con belt

Alternator belt

Adjustable link

for Air-con belt

FG006244

Figure 53

Inspection, Maintenance and Adjustment

OP001015

4-39

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

Figure 55

Replace Transmission Oil and Filter

(After First 250 Hours)

NOTE: Transmission oil and filter must be changed after first

250 hours of operation to comply with new machine

break-in requirements.

NOTE: After first change, oil and filter must be changed

every 1,000 hours. Follow procedure under 1,000

hour maintenance interval. (See page 4-52)

Replace Axle Differential and Planetaries

Oil (After First 250 Hours)

NOTE: The differential and planetaries oil must be drained

and refilled after first 250 hours of operation. There

after every 1,500 hours of operation. (See page 4-60)

Inspection, Maintenance and Adjustment

OP001015

4-40

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

km/h

x100r/min

serviced.

F/R

NOTE: When working in severely dusty conditions, the

service interval should be shortened.

FG015617

WARNING

Figure 56

Never clean or attempt to remove the air cleaner filter if

the engine is running.

This will allow dirt to be sucked into engine and cause

serious engine damage

Always turn engine "OFF" before servicing air cleaner.

Locate the air cleaner assembly.

NOTE: When it reaches every 250 hours or If indicator

light

(Figure

56) on instrument panel comes

"ON" the air cleaner must be serviced.

NOTE: Replace outer filter after cleaning 4 times or

every 1,000 hours / 6 months service.

Remove and clean rubber evacuator valve (1, Figure 58)

from bottom of air cleaner housing cover (2, Figure 58).

Inspect seal lips for wear or damage. Replace valve if

necessary.

FG001711

Figure 57

NOTE: Install evacuator valve with lips parallel to the

cover.

Remove the access cover (2, Figure 58) by loosening the

latches (3).

Remove the outer filter (4, Figure 58) from the housing. Do

not remove inner filter (5).

FG000702

Figure 58

Inspection, Maintenance and Adjustment

OP001015

4-41

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.

HAOC570L

Figure 59

Check outer filter by shinning a light through it. If small

holes or thinner parts are found on the element after

cleaning it, replace the filter.

Clean the inside of the air cleaner body and the inside of

the air cleaner cover. Do not use compressed air.

Properly install the air filter and cover.

After filter service be sure to install cover with arrows

pointing "UP."

NOTE: If after cleaning the outer filter, the air cleaner

FG000412

clogged indicator remains "ON," replace the

Figure 60

outer and inner filters. Do not clean inner filter.

Water Trap

Take care of fuel spillage by using a vessel or a plastic hose.

Drain the water trap every 250 hours.

Draining water from the fuel has to be done by hand.

A nonreturn valve in the filter head prevents the fuel from

running back to the tank. As no fuel can run back, the pressure

will remain and as a consequence no water will be drained

unless new fuel is pumped in.

FG008506

Figure 61

Proceed as follows:

•

Place the end of the hose in a vessel.

•

Loosen draining nipple (2).

•

Pump with hand pump (3) on the primary filter head

until all water has been forced out of water trap (1).

•

Tighten the draining nipple.

NOTE: Take care of waste oil and liquid in an

open

environmentally safe way!

FG000438

Figure 62

Inspection, Maintenance and Adjustment

OP001015

4-42

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. Dispose of oil.

Remove O-ring (3, Figure 64) and filter (4).

Use a nonflammable, nontoxic solvent to clean out cover

(5, Figure 64).

Insert a new filter (4, Figure 64) into cover (5). Install a new

O-ring (3).

Screw cover (5, Figure 64) onto filter head (1).

Figure 64

Inspection, Maintenance and Adjustment

OP001015

4-43

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.

Unscrew fuel filter from head assembly. Discard fuel filter.

After cleaning filter head, install new fuel filter. Screw filter

on head until gasket contacts head, turn filter 1/3 - 1/2 turn

more.

FG006241

NOTE: Coat fuel filter gasket with fuel.

Figure 65

NOTE: Fill fuel filter with clean fuel. This will help

reduce fuel system priming.

Start engine. After engine has run for a couple of minutes,

shut down engine and look for signs of leaks.

If engine does not start, fuel system may need priming.

Prime fuel system using the following procedure:

A. Loosen plug on top of fuel filter head.

B. Unscrew and pump the hand operated primer pump

near fuel injection pump. Pump primer until fuel is

present at plug hole in fuel filter head.

C. Tighten plug in fuel filter head.

D. Continue to pump primer pump until a strong

resistance is felt. Screw primer pump knob back into

housing.

E. Start engine and look for signs of leaks.

Inspection, Maintenance and Adjustment

OP001015

4-44

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

•

chassis mounted.

FG006241

Figure 66

The pressure side main fuel filter must have the following

characteristics:

•

5-micron rating

•

engine mounted

FG006240

Figure 67

Remove

Disconnect the wiring harness from the fuel heater, if equipped.

Loosen and remove the fuel filter.

Make sure the seal ring does not stick to the filter head.

Remove the ring with an O-ring pick, if necessary.

NOTE: Both fuel filters must be removed at the same time.

Install new filter. Apply a small amount of oil around filter gasket.

Screw filter on head until gasket contacts head by hand, turn

filter 3/4 - 1 turn more with filter wrench.

Figure 68

Inspection, Maintenance and Adjustment

OP001015

4-45

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.

After cleaning filter head, install new fuel filter. Screw filter

on head until gasket contacts head, and turn filter 1/2 turn

more with a filter wrench.

NOTE: Coat fuel filter gasket with fuel.

NOTE: Fill fuel filter with clean fuel. This will help

reduce fuel system priming.

FG000478

Figure 70

Clean Exterior of Radiator, Oil Cooler and

Air Conditioner Condenser

Dust and dirt accumulation on fins of radiator, oil cooler,

and additional transmission cooler greatly reduce their

cooling efficiency. Use compressed air, water and steam to

clean fins on radiator, oil cooler, and transmission cooler.

NOTE: On an especially dusty work site, clean fins

every 50 hours. On other work sites, clean fins

every 500 hours.

FG001647

Figure 71

Inspection, Maintenance and Adjustment

OP001015

4-46

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. 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.

Remove filter (2, Figure 73) and inspect it for damage.

Use compressed air to clean filter. If element is very dirty

use a mild soap and water solution to clean it.

NOTE: Clean air-conditioning filter every 500 hours and

replace with a new one every 1,000 hours of

service.

NOTE: If water was used to clean filter be sure it is

completely dry before installation.

NOTE: In the event that the unit it being operated in a

dusty environment, the cleaning and

replacement must be performed more

frequently if filter is damaged, replace damaged

with a new one.

FG003904

Figure 73

WARNING

All service and inspection of the air-conditioning

system must be performed with the starter switch in

the "O" (OFF) position.

Inspection, Maintenance and Adjustment

OP001015

4-47

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. Refer

to "DL 06 Industrial Engines Oil Drain Intervals by

Duty Cycle (Hours)" (See page 4-16).

Position a larger container under drain valve beside left

wall of fuel tank. Loosen drain valve and allow all engine oil

to drain out. Tighten drain valve.

NOTE: Oil warming is good when replacing oil. If

machine is cold, operate the engine to bring the

coolant temperature up to about 40°C (104°F).

When the needle of the coolant temperature

gauge reaches the middle of the "WHITE

ZONE," the temperature is about 40°C (104°F).

NOTE: Dispose of drained fluids according to local

FG002215

regulations.

Figure 74

Replace engine oil filter (Figure 75). Engine oil filter is a

spin-on type. Remove and discard filter.

Install new filter. Apply a small amount of oil around filter

gasket. Screw filter on head until gasket contacts head by

hand, turn filter 3/4 - 1 turn more with filter wrench.

NOTE: See

“Fluid Capacities” on page 4-16, for

capacity and

“Table of Recommended

Lubricants” on page 4-14, of this manual for

recommended oil for the operating conditions.

Fill engine with correct oil through oil fill port.

FG006237

Figure 75

Start engine and check engine oil pressure warning light.

Shut down engine. Look for signs of leaks at filter. Recheck

oil level.

Inspection, Maintenance and Adjustment

OP001015

4-48

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. Always turn engine "OFF" before servicing

air cleaner.

Engine, Air Cleaner

The degree of engine wear depends largely on the cleanliness

of the induction air. The air cleaner prevents dust and other

impurities from entering the engine. Therefore, it is very

important that the air cleaner must be checked regularly and

maintained correctly.

FG001711

Figure 77

Primary Filter, Maintenance and Replacement

When the alarm text "Clogged Air Filter" is shown or every 1,000

hours, the filter must be replaced or be cleaned. The period of

operation between filter replacements vary depending on the

working environment of the machine. In certain environments

the filter needs to be replaced more often.

•

The filter can be cleaned according to instructions

which your authorized dealer will give you. However,

after the filter has been cleaned five times or if it is

damaged, it must be replaced.

FG001712

NOTE: Make a mark on the decal at the end of the

Figure 78

secondary filter every time the primary

filter is replaced or cleaned.

•

In connection with replacing the filter, the cover for the

air cleaner should also be cleaned. It works as a container

for particles which have not been trapped in the filter.

•

Check that all hose and pipe connections from the air

cleaner to the engine induction manifold are tight.

Check tightness of hose clamps.

Inspection, Maintenance and Adjustment

OP001015

4-50

•

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.

CAUTION

Never clean the inside of air filter housing while the inner

filter is not installed.

Secondary Filter

Replace the filter every 2,000 hours or when the main filter has

been replaced three times.

The filter cannot be cleaned, but must be replaced.

The secondary filter works as a protective filter if the main filter is

damaged.

Never remove the secondary filter unless it is to be replaced.

Figure 79

Replace Outer 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. Always turn engine "OFF" before

servicing air cleaner.

Replace inner filter when outer filter is replaced.

After removing outer filter, remove wing nut and inner filter.

Clean out inside of air cleaner housing. Do not use

compressed air to blow out housing.

Install new inner filter, and secure it into position with wing

nut. Do not clean and reuse inner filter.

Install new outer filter, and secure it into position with wing nut.

Install air cleaner cover.

NOTE: Make sure that all gaskets on wing nuts and

cover are properly installed and seated.

Inspection, Maintenance and Adjustment

OP001015

4-51

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.

Start machine and drive it until transmission fluid has

warmed to 80°C (176°F). Park machine on firm, level

ground. Lower bucket to ground.

Place transmission lever in "NEUTRAL." Apply parking

brake. Shut down engine. Block tires.

NOTE: See

“Fluid Capacities” on page 4-16, for

capacity and

“Table of Recommended

Lubricants” on page 4-14, of this manual for

recommended oil for the operating conditions.

Remove drain plug. Allow all transmission fluid to drain into

a receptacle. Clean drain plug (Figure 80).

NOTE: Dispose of drained fluids according to local

regulations.

Install drain plug in transmission.

Remove inlet strainer. Use a nonflammable, nontoxic

solvent to clean strainer.

Inspect gasket on inlet strainer. Replace gasket if it is

damaged. Install inlet strainer.

FG004072

Remove breather filter. Clean breather filter and install it.

Figure 80

Rotate filter counterclockwise to remove it (Figure 81).

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).

FG002218

Figure 81

Inspection, Maintenance and Adjustment

OP001015

4-52

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. With engine idling, have second person check

transmission fluid level again. Add fluid until level reaches

high mark on dipstick.

17. Idle engine until transmission fluid temperature reaches

80°C (176°F). Check fluid level with engine idling. Level

must reach high mark on dipstick.

HAOC280L

Figure 83

NOTE: If oil level is above top high mark on dipstick,

drain oil until level is at high mark.

NOTE: If transmission cannot reach an operating

temperature of 80°C (176°F), then the oil level

must be below the high mark. Periodically check

oil level during the workday to ensure that oil

level does not rise above high mark on dipstick.

18. Check filter for leaks while engine is running.

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. Wash thoroughly with

soap and water.

NOTE: It is easier to clean the fuel tank when it is almost

empty.

Inspection, Maintenance and Adjustment

OP001015

4-53

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.

FG006245

Figure 84

Remove bolts, inspection cover and gasket (Figure 85)

from fuel tank.

Clean inside of the tank and suction stainer.

Install the inspection cover with a new gasket. Tighten the

bolts. Do not overtighten.

Close drain valve.

Fill fuel tank.

Check for any leaks at cover and plug.

FG008105

Figure 85

Inspection, Maintenance and Adjustment

OP001015

4-54

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. For filter replacement See

“Clean Air Conditioner Inner Filter” on page 4-47

NOTE: In the event that the equipment is being operated in a

dusty environment, the cleaning and replacement

must be performed more frequently.

Check Air Conditioner Refrigerant

WARNING

Mixing of tobacco smoke and freon is deadly.

Do not smoke while servicing or recharging

air-conditioning system.

Apply the parking brake and lower attachment to the

ground.

Remove the cover.

Press the "HI" flow control switch to set maximum air flow.

Set the temperature control switch fully to the cool position

and fully open the cabin doors.

Slightly accelerate the engine to about the middle speed

range (compressor speed 1500 - 1800 rpm).

Compare the flow of bubbles in the sight glass with the

drawings in the following table.

CAUTION

Overfilling refrigerant may cause dangerous

high-pressure and poor cooling action; and low

refrigerant level may cause compressor damage.

Always maintain refrigerant at normal level.

FG004075

Figure 86

Inspection, Maintenance and Adjustment

OP001015

4-55

Amount of

Appearance of the Sight Glass

Solutions

Refrigerant

Almost clear.

Normal

Any bubbles disappear if the engine

speed is increased to 1500 rpm.

High

No bubbles are seen.

Contact your local DOOSAN loader

dealer

for

inspection

and

recharging refrigerant.

Low

A flow of bubbles is visible.

Check and Adjust Engine

Contact your nearest DOOSAN loader dealer.

Contact engine manufacturer for checking and adjusting the

following items:

•

Engine Compression Pressure.

•

Injection Pressure.

•

Injection Timing.

Change Air Breather Filter

Position the machine on firm, level ground. Lower the front

attachment to the ground and shut down engine.

Lift the breather cap(2. Figure 87) slightly to release the

internal pressure.

Unscrew the bolt (1, Figure 87) and take off the breather

cap (2, Figure 87).

Change a filter cartridge (3, Figure 87) and assemble the

breather cap by tighting the bolt.

NOTE: Used filter should always be disposed of

according to local regulations.

FG013207

Figure 87

Inspection, Maintenance and Adjustment

OP001015

4-56

Doosan DL220. Operation and Maintenance Manual (2010) - page 2