Doosan DL220. Operation and Maintenance Manual (2010)

Replace Hydraulic Full Flow Filter

WARNING

The hydraulic oil will be hot after normal machine

operation. Allow system to cool before attempting to

service any of the hydraulic components.

The hydraulic tank is pressurized. Loosen hydraulic oil fill

cap slightly to allow pressurized air to vent. After pressure

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

service covers or drain water from the tank.

IMPORTANT

Make sure to clean any dirt or water from top of the

hydraulic tank, especially around fill port and filter ports.

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

operation or rebuild and every 1000 Hours thereafter.

Loosen breather cap on hydraulic tank. (See Figure 19 on

page 4-24).

Clean filter cover (2, Figure 88) and tank around cover.

Remove bolts (1, Figure 88) from cover (2).

Lift cover (2, Figure 88) and O-ring (4) off tank. A control

spring (3) sits beneath cover. Remove spring (3).

Remove valve (5, Figure 88) and filter (6) from tank.

Clean underside of cover (2, Figure 88).

Set a new element (6, Figure 88) and valve (5) down into

tank. Press element down onto its base until top of element

is approximately 4 mm (0.157") below edge of tank.

Install a new O-ring (4, Figure 88) on cover (2). Set spring

(3) into place on element (6).

Set cover (2, Figure 88) into place over element (6). Install

FG006233

bolts (1) through cover (2) and tighten them.

Figure 88

10. Tighten breather cap on tank.

Inspection, Maintenance and Adjustment

OP001015

4-57

1,500 HOUR / 9 MONTH SERVICE

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

Service Checks

Replace Axle Differential and Planetaries

Oil

NOTE: Oil in both front and rear axles must be replaced after

first

500 hours of operation to comply with new

machine break-in requirements. After that, axle oil

check must be done every 500 hours of operation

and replacement must be done every 1,500 hours.

Each axle contains a center differential, and a planetary on each

end. The same oil lubricates the center differential and

planetaries. These sections of the axle are connected, but the oil

flows very slowly between them. When checked, oil must be

checked and refilled at the level/fill plug on the differential

housing.

To drain and replace oil in an axle, perform the following steps:

Drive machine onto a level surface. Position wheels on

axle being drained so that axle end level plugs (1, Figure

95) are in the lowest position. Apply parking brake. Block

wheels.

Clean areas around drain plugs on both ends of axle.

Remove plugs.

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.

NOTE: Dispose of drained fluids according to local

Figure 95

regulations.

Clean area around level plug (1, Figure 96) and drain plug

(2) on center differential. Remove level plug and drain

plug. Allow oil to drain into a suitable container.

Install drain plug Figure

96into center differential, and

tighten.

Pump oil into level plug hole on center differential. Add oil

until oil level is even with bottom of plug hole.

Go to level plug holes on axle ends. Add oil to these

openings until oil level is even with bottom of plug hole.

Recheck level on center differential. Add oil if necessary.

When oil level is satisfactory at all three level plug holes,

Figure 96

install and tighten level plugs at all three locations.

Repeat procedure for other axle.

Inspection, Maintenance and Adjustment

OP001015

4-60

Axle Brake Disk Wear Measurement

NOTE: A wear measurement on the multidisk brake

must be made at least once a year, especially in

case of a change in braking behavior like, e.g.

•

Braking noise.

•

Braking power reduced.

•

Deceleration changed.

•

Brake fluid level changed.

•

Braking pressure changed.

Insert feeler gauge into oil level check hole to check

thickness of brake disks.

NOTE: Minimum thickness: s = 4.5mm (0.18 in)

Figure 97

Inspection, Maintenance and Adjustment

OP001015

4-61

2,000 HOUR / YEARLY SERVICE

Perform All Daily, 10, 50, 250, 500 and

1,000 Hour Service Checks

Replace Inner Air Cleaner Element

CAUTION

Never remove air cleaner element while engine is running.

This will allow dirt to be sucked into engine and cause

serious engine damage. Always turn engine "OFF" before

servicing air cleaner.

NOTE: Replace outer element after cleaning 4 times or every

1,000 hours.

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.

Check Steering, Brake, Drive Shaft,

Engine, and Fuel System

Replace Pipes and Hoses

Replace hoses that carry brake fluid to wheel brakes. Also

replace hoses that carry hydraulic fluid to steering

cylinders.

It is difficult to determine condition of many hoses. The

best way to ensure safe operation and to maintain

maximum performance is to replace hoses on a regular

basis. If any brake or steering hoses become damaged or

appear defective in any way, replace them immediately

despite time interval since their last replacement.

Inspection, Maintenance and Adjustment

OP001015

4-62

Bleed Brakes

When brake hoses or brake tubes are replaced, air can be

introduced into brake hydraulic system. Air can cause brakes to

operate intermittently, which is a dangerous condition. Never

operate machine with air in brake hydraulic system. A spongy

feel when pressing brake pedal is a sign that air is present in

brake hydraulic system.

To bleed air out of brake hydraulic system, perform the following

steps: (Figure 98)

Start engine and place transmission in "NEUTRAL."

Remove rubber cap from bleeder screw on wheel.

Place one end of a plastic hose (2) over bleeder screw (1).

Place other end of hose in a container (3) filled with brake

fluid.

Station one person in operator’s cab, and one person at

bleeder screw on wheel being bled.

Open bleeder screw (1). Then press down on brake pedal

until it rests on floor of cab. Hold pedal down on floor of

HLB3018L

cab. Close bleeder screw while pedal is being held down.

Figure 98

After bleeder screw has been closed, allow brake pedal to

return to upright position. Continue to open bleeder screw

and press down pedal as described in this step, until fluid

expelled from bleeder hose has no air bubbles present.

Securely close bleeder screw (1). Install rubber cap on

bleeder screw.

Inspection, Maintenance and Adjustment

OP001015

4-63

Replace Radiator Coolant

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. See

“Engine Cooling System” on

page 4-73, for further details.

NOTE: This unit was factory filled with propylene glycol.

WARNING

Allow the engine to cool before releasing the radiator cap.

Make sure to loosen the cap slowly to release any

remaining pressure.

Radiator cleaning is performed while the engine is running.

Take extreme caution when working on or near a running

engine. Make sure to lock out and tag the controls notifying

FG002206

personnel that service work is being performed.

Figure 99

Do not remove the radiator cap unless it is required.

Observe the coolant level in the coolant recovery tank.

CAUTION

Do not mix ethylene glycol and propylene glycol when

changing the antifreez solution. Flushing should be

performed to minimize volume of mixing between the two

columns. Mixing the two compounds may cause generation

of foreign material to damage the system.

Do not mix antifreez solutions from different manufactures.

Mixed solution may degrade the capabilities of the system.

It is recommended to use the standard product from

Doosan.

In the bitterly cold area or weather, the customer should

frequently check the performance of the coolant for

appropriateness for the weather and then determine change

cycle of the coolant.

Slowly open the radiator cap (Figure 99) to allow any

pressure to escape.

NOTE: See

“Fluid Capacities” on page 4-16 for

capacity.

Place a container under the radiator and open the drain

valve (Figure 100).

NOTE: Dispose of drained fluids according to local

regulations.

FG002225

Figure 100

Inspection, Maintenance and Adjustment

OP001015

4-64

Replace Hydraulic Oil and Clean Oil

Suction Strainer

CAUTION

Be certain that hydraulic oil has cooled before draining it.

Hot oil could splash and cause burns.

Raise boom to its highest position. Tilt bucket back as far

as possible, and shut down engine.

NOTE: See

“Fluid Capacities” on page 4-16 for

FG014461

capacity.

Figure 101

Position a catch tank beneath hydraulic tank drain plug.

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

Remove drain plug from bottom of tank. (Figure 102).

Allow all hydraulic oil to drain out.

FG015616

Figure 102

FG014462

Figure 103

FG014463

Figure 104

Inspection, Maintenance and Adjustment

OP001015

4-65

Without starting engine, operate controls to dump bucket.

(Figure 103). Then operate controls to lower boom. (Figure

104). This will drain oil out of boom and bucket cylinders.

Replace full flow hydraulic filters as described under

“Loosen breather cap on hydraulic tank. (See Figure 19 on

page 4-24).” on page 4-57.

Remove and clean pump inlet strainer (Figure 105) inside

hydraulic tank.

A. Carefully remove bolts and cover (1), from top of

hydraulic oil tank. There is a spring (2) under the

cover that will force the cover up.

B. Remove spring (2, Figure 105) and suction filter (4)

by pulling on rod (3).

C. Clean in side and outside of strainer. Replace

strainer if it is broken.

D. Position strainer on boss portion of suction pipe.

E. Fill hydraulic oil tank. Check level using sight gauge

on side of tank.

FG015633

Install tank drain plug. Refill tank by pouring oil in through

Figure 105

breather cap opening. Install and tighten breather cap.

Start engine and operate controls to raise and lower bucket

a few times. (Figure 106). Raise and lower boom a few

times. (Figure 107). Lower bucket to ground.

Check tank sight gauge. (See Figure 18 on page 4-24). Oil

level must be between upper limit and lower limit on sight

gauge. Remove breather cap and add oil if necessary.

FG014464

Figure 106

FG014465

Figure 107

Inspection, Maintenance and Adjustment

OP001015

4-66

Check Brake Accumulator

WARNING

Pressurized Nitrogen gas in brake accumulator may

explode causing serious injury or death.

Never service brake accumulator unless properly trained.

Test the brake accumulator for proper precharge of Nitrogen

gas:

Park the machine on a level surface, apply the parking

brake, lower the attachment to the ground.

Run the engine at low idle for five minutes to fill the brake

accumulator with oil.

Shut down engine.

Turn the starter switch to "ON" position.

Count the number of times you can depress the right-hand

brake pedal before the brake warning light comes on.

If the number counted is less than five (5), there is some

problem with the accumulator. Contact your nearest

DOOSAN dealer.

Inspection, Maintenance and Adjustment

OP001015

4-67

12,000 HOUR / 6 YEAR SERVICE

Hose In-service Lifetime Limit (European

Standard ISO 8331 and EN982 CEN)

European regulations state that the in-service life of any

hydraulic hose may not exceed six years. DOOSAN

recommends the following:

•

Hoses at the customer premises cannot be stored

more than 2 years before being discarded or installed

on a machine.

•

In-service lifetime of hoses fitted on a machine can

never exceed 6 years, but replace hoses described in

“Replace Pipes and Hoses” on page 4-62, every

year. Always replace hoses having exceeded the

allowed in-service lifetime irrespective of the external

appearance/wear.

•

Always store hoses in a dark place at a maximum of

65% relative humidity, between 0°C (32°F) and 35°C

(95°F) but as close as possible to 15°C (59°F) and

away from copper, manganese or tube generating

Ozone.

Inspection, Maintenance and Adjustment

OP001015

4-68

SEVERE CONDITIONS

MAINTENANCE

Operating Condition

Required Maintenance

Mud, Water, Rain

Check for loose fittings, obvious damage to machine, or any

fluid leakage.

After completing operations, clean mud, rocks, or debris from

machine. Inspect for damage, cracked welds, or loosened

parts.

Perform all daily lubrication and service.

If machine was working in salt water or other corrosive

materials, be sure to flush equipment with fresh water.

Extremely Dusty

Hot

Clean engine air filter on a more frequent basis.

Environment

Clean radiator and oil cooler fins to remove dirt and dust.

Clean fuel system intake strainer and fuel filter more

frequently.

Inspect starter motor and alternator, and clean as often as

necessary.

Rocky Terrain

Check wheels, tires, rims, and valve stems for damage or

excessive wear.

Inspect for loose or damaged fittings and bolts.

On a more frequent basis, inspect bucket and boom for

damage or excessive wear.

Install a top guard and front guard as necessary for protection

against falling rock.

Extreme Cold

Use proper grade of fuel for cold temperatures.

Use a gauge to check antifreeze to be sure that it will provide

protection for coldest temperature expected.

Use a hydrometer to check condition of batteries. In extremely

cold weather, remove batteries at night and store them in a

warm area.

Inspection, Maintenance and Adjustment

OP001015

4-69

BOLT TORQUE CHART

Tightening Torque Specifications for

Metric Bolts (For coated threads,

prelubricated assemblies)

Grade

Gr. 8.8

Gr. 10.9

Gr. 12.9

Dia.

kg•m

ft lb

kg•m

ft lb

kg•m

ft lb

5 mm x std.

0.59

4.3

0.79

5.7

1.0

7.2

6 mm x std.

1.00

7.3

1.38

1.66

8 mm x std.

2.49

3.46

4.15

8 mm x 1.0

2.76

3.87

4.56

10 mm x std.

4.84

6.92

8.30

10 mm x 1.0

4.84

7.05

8.30

12 mm x std.

8.57

11.89

14.52

105

12 mm x 1.5

9.00

12.59

14.94

108

14 mm x std.

13.55

18.95

137

23.10

167

14 mm x 1.5

14.94

108

21.02

152

24.89

180

16 mm x std.

20.88

151

29.46

213

35.54

257

16 mm x 1.5

22.54

163

31.53

228

38.03

275

18 mm x std.

28.90

209

40.52

293

48.41

350

18 mm x 1.5

32.50

235

45.92

332

55.04

398

20 mm x std.

40.94

296

57.95

419

69.01

499

20 mm x 1.5

46.05

333

64.03

463

77.03

557

22 mm x std.

54.90

397

77.86

563

93.08

673

22 mm x 1.5

61.00

441

86.02

622

105.00

759

24 mm x std.

71.00

513

100.00

723

120.00

868

24 mm x 2.0

78.00

564

109.95

795

130.00

940

27 mm x 2.0

115.06

832

160.00

1157

195.00

1410

Inspection, Maintenance and Adjustment

OP001015

4-70

ELECTRICAL SYSTEM

Check Battery Condition

WARNING

Before starting any battery service work, make sure to shut

the engine off and turn the starter switch to the "I" (OFF)

position.

The batteries create hydrogen gas. An explosion hazard

exists, particularly with a deeply discharged battery. Make

sure that open flames, burning objects or sparks are kept

away from the battery compartment.

Battery electrolyte is diluted sulfuric acid. Take extreme

caution when handling the batteries. The electrolyte can

cause severe chemical burns. If any electrolyte gets on

your clothing or skin, wash it off immediately with large

quantities of water. If the electrolyte gets into your eyes,

flush them immediately with a large quantity of water and

contact a doctor at once.

When installing a battery, wear safety glasses at all times.

When removing a battery, remove the negative (-) or ground

terminal first, and then the positive (+) terminal. This will

prevent sparks or arcing that could cause an explosion.

When installing a battery, connect the positive terminal first

and then the negative terminal. Make sure to fully tighten

the terminal clamps.

In colder weather a greater drain is placed on the batteries

when they are used for the preheat cycle and when starting

a cold engine. Battery performance decreases as the

temperature gets lower.

In extremely cold weather, remove the batteries at night

and move them to a warm location. This will help to keep

them at a higher power level.

Inspection of battery electrolyte level.

NOTE: The battery installed at the factory is a

Maintenance Free (MF) type. Electrolyte under

normal conditions should remain at its proper

level.

HJB5002L

Figure 108

Inspection, Maintenance and Adjustment

OP001015

4-71

Inspect charge condition of battery by looking at the

indicator light built into battery.

•

GREEN: Normal.

•

BLACK: Insufficient charging - check alternator.

•

TRANSPARENT: Insufficient battery electrolyte

replace with new battery.

NOTE: Colors may vary from one battery manufacturer

to another. Always refer to instructions on

battery.

The batteries should always be replaced in

pairs. Using an old battery with a new one will

shorten the life span of the new battery.

Inspection, Maintenance and Adjustment

OP001015

4-72

ENGINE COOLING SYSTEM

General

Keeping an engine's cooling system in peak operating condition,

can have many benefits to keeping a machine in good operating

condition. A properly functioning cooling system will; improve

fuel efficiency, reduce engine wear, and extend component life.

Always use distilled water in the radiator. Contaminants in tap

water neutralize the corrosion inhibitor components. If tap water

must be used, it should not exceed 300 ppm hardness, or

contain more than 100 ppm of either chloride or sulfate. Water

that has been treated with a water softener also contains salt

that will cause corrosion of components. Water from creeks and

stagnant pools usually contains dirt, minerals and/or organic

material that are deposited in the cooling system and impair

cooling efficiency. Distilled water is the best.

Engine overheating is often caused by bent or clogged radiator

fins. The spaces between the fins can be cleaned by use of air

or water under pressure. When straightening bent fins, use care

not to damage the tubes or break the bond between the fins and

the tubes.

WARNING

Pressure at air nozzle must not exceed 2.1 kg/cm² (30 psi).

Always wear goggles when using compressed air.

Do not pour cold water into radiator when engine is very hot

and water level is below the top of the tubes. Such action

could result in damage to engine cylinder heads.

Heavy duty diesel engines require a balanced mixture of water

and antifreeze. Drain and replace the mixture every year or

2,000 hours of operation, which ever comes first. This will

eliminate buildup of harmful chemicals.

Antifreeze is essential in any climate. It broadens the operating

temperature range by lowering the coolant's freezing point and

by raising its boiling point. Do not use more than 50% antifreeze

in the mixture unless additional freeze protection is required.

Never use more than 68% antifreeze under any condition.

Inspection, Maintenance and Adjustment

OP001015

4-73

Types of Antifreeze

There are two main classifications of antifreeze available on the

market today.

Ethylene Glycol - Doosan Genuine Antifreeze Solution

(for all seasons)

Propylene Glycol - Doosan Genuine Antifreeze Solution

(for all seasons)

Ethylene glycol has been on the market for many years. Its

chemical properties do not provide the improved corrosion

resistance that propylene glycol does. Ethylene glycol is also

very hazardous to the environment, people and animals.

DOOSAN recommends that ethylene glycol be replaced with

propylene glycol.

The newer propylene glycol antifreeze comes in many different

colors. Some of the colors are pink, red, orange and yellow.

There are even some that come in a blue-green color. The

blue-green color makes it very difficult to tell the difference of

what type of antifreeze is in a cooling system. The colors are

only a dye added to the clear antifreeze. Do not rely on color.

Keep careful machine records of what brand and type of

antifreeze is used in the unit. If you are unsure of what type of

antifreeze is in the system, drain and flush the system.

CAUTION

Do not mix the ethylene glycol and propylene glycol

solutions. If these two chemicals are mixed, undesirable

chemicals may be formed, which damages the equipment.

Do not mix up the solutions from different manufacturers.

Otherwise, the performance may be deteriorated. It is

recommended to use the Doosan Genuine Product

In the regions under extreme weather, the user should

determine the performance of the coolant suitable for the

weather condition and decide the replacement cycle.

Inspection, Maintenance and Adjustment

OP001015

4-74

Antifreeze Concentration Tables

Ethylene Glycol - Doosan Genuine Antifreeze Solution (for all seasons)

(2,000 Hour / Yearly)

Ambient Temperature

Cooling Water

Antifreeze

-10°C (14°F)

80%

20%

-15°C (5°F)

73%

27%

-20°C (-4°F)

67%

33%

-25°C (-13°F)

60%

40%

-30°C (-22°F)

56%

44%

-40°C (-40°F)

50%

Propylene Glycol - Doosan Genuine Antifreeze Solution (for all seasons)

(2,000 Hour / Yearly)

Ambient Temperature

Cooling Water

Antifreeze

-10°C (14°F)

78%

22%

-15°C (5°F)

71%

29%

-20°C (-4°F)

65%

35%

-25°C (-13°F)

59%

41%

-30°C (-22°F)

55%

45%

-40°C (-40°F)

48%

52%

NOTE: Mixing ratio is for reference purpose only and is not

an absolute standard.

NOTE: Replacement cycle of the Doosan Genuine Product is

2,000 hours or one year.

Inspection, Maintenance and Adjustment

OP001015

4-75

HANDLING OF ACCUMULATOR

WARNING

Even though the engine is stopped, the hydraulic

accumulators for the pilot system are still charged. Do not

disconnect any pilot system hoses until accumulator

pressure has been released from the circuit. To release

pressure, turn the starter switch to "I" (ON) position and

operate pilot control valve lever and brake pedal. Even

though the engine is shut down, hydraulic actuated

components may move while releasing pilot pressure. Keep

all personnel away from machine while performing this

operation.

•

Set pilot cutoff switch to "O" (OFF) position after

stopping engine.

•

Do not mishandle accumulator(s). They are very

dangerous because they contain high-pressure

nitrogen gas.

•

Do not punch a hole or apply heat or fire to an

accumulator.

•

Do not weld on accumulator, or try attaching

anything to it.

•

When replacing an accumulator, contact a

DOOSAN distributor or sales agency so the gas

can be properly released.

•

Wear safety goggles and protective gloves when

working on an accumulator. Hydraulic oil under

pressure can penetrate the skin and cause

serious injuries.

Release pilot accumulator pressure using the following

procedure:

Lower front attachment (bucket) to ground.

Shut down engine.

Set pilot cutoff switch on "I" (ON) position.

Turn starter switch to "I" (ON) position.

Fully move pilot control valve lever in all directions.

Repeatedly press brake until brake oil pressure warning

FG015623

light turns "ON." Press the pedal another eight to nine

Figure 109

times.

Set pilot cutoff switch on "O" (OFF) position.

Turn key to "O" (OFF) position and remove from starter

switch.

Remove accumulator by unscrewing it slowly.

Inspection, Maintenance and Adjustment

OP001015

4-76

HYDRAULIC PRESSURE

CHECKS

Hydraulic pressure for most systems can be check by using the

remote test ports shown in (Figure 110).

Reference

Description

Pressure

Number

Main Pump Pressure (TPM)

210 ± 5 kg/cm²

Brake Charge Pressure

80 kg/cm²

(TP2)

Steer Pump Pressure (TPS)

FG015619

200 ± 5 kg/cm²

at Only Steering Relief

Figure 110

Transmission Clutch

16 - 18 kg/cm²

Pressure (TM)

Control Lever Activation

Pressure (TP1) at E/G High

28 +2/-0 kg/cm²

Idle

Control Valve Pressure

Attach gauge to port (1, Figure 110).

Relief valve cartridge on control valve (Figure 111) must be

adjusted to open at 200 ± 5 kg/cm² (2,844 ± 70psi)

FG008107

Figure 111

Brake Charge Pressure

Attach gauge to port (2, Figure 110).

Adjust relief valve cartridge on brake, pilot and fan motor

supply valve (Figure 112). Relief pressure (Figure 112) for

brake charging is 80 ± 5 kg/cm²(1,138 ± 70 psi).

FG008108

Figure 112

Inspection, Maintenance and Adjustment

OP001015

4-77

Steering Pump Pressure

Attach gauge to port (3, Figure 110).

Adjust relief valve cartridge on steering valve (Figure 113).

Cartridge must be adjusted to open at 200 ± 5 kg/cm²

(2,844 ± 70 psi).

Unscrew plug and washer. Adjust screw that is beneath

plug. Turn screw clockwise to raise relief pressure. Turn

screw counter clockwise to lower relief pressure.

FG002228

Install plug and washer after pressure has been adjusted.

Figure 113

Transmission Clutch Pressure

Attach gauge to port (4, Figure 110).

It is not impossible to adjust pressure.

NOTE: Transmission clutch pressure is

kg/cm²

+28

(228

psi).

Control Lever Activation Pressure

Attach gauge to port (5, Figure 110).

Adjust relief cartridge (Figure 114) on brake and pilot and

fan motor supply valve. Relief pressure must be set at 28 -

30 kg/cm² (398 - 427 psi).

Loosen lock nut on adjusting screw. Turn adjusting screw

clockwise to raise relief pressure. Turn adjusting screw

counterclockwise to lower relief pressure.

FG008110

Tighten lock nut after adjustment has been made.

Figure 114

Service Brake Outlet Pressure

Attach gauge to brake pressure test port (1, Figure 115) of

front axle.

Outlet pressure must be 45 ± 3 kg/cm² (640 ± 3 psi).

FG008111

Figure 115

Inspection, Maintenance and Adjustment

OP001015

4-78

Fan Motor Pressure and Fan rpm

The motor intergrates a proportional pressure relief valve, the

fan speed (and thus the cooling performance) can be infinitely

controlled depending on two different simultaneous input signals

from temperature sensors.

The cooling fan controller processes the two input signals and

controls the valve coil current. The proportional relief valve has a

fail safe characteristic, this means, max. relief valve setting is

adjusted automatically if the voltage supply is interrupted (e.g.

broken wire). This results in a max. fan speed and therefore in a

max. cooling performance.

Standard

Fan Motor Pressure

100+5/-0 kg/cm²

(1,422 +70/-0 psi)

Fan rpm

1,200

FG014480

Figure 116

Reference

Description

Number

Engine

Cooling Fan

Cooling Pump

Temperature Sensor (T/M Oil)

Cooler

Temperature Sensor

(Coolant Water)

Cooling Fan Controller

Transmission

Fan Motor

Inspection, Maintenance and Adjustment

OP001015

4-80

Checking the Relief Pressure of Fan Motor

FG008112

Figure 117

Reference

Description

Number

Fan Motor

Outlet Line

Fan Guard

Relief Valve

Inlet Line

Relief Valve

Drain Line

Reversable Solenoid Valve

Maximum Fan Speed, Checking

Open the radiator grille in order to connect the pressure

gauge.

Connect the pressure gauge to the pressure port (6) on the

inlet hose

(3). Check the maximum pressure by fully

depressing the accelerator pedal and reading the pressure

gauge. Maximum fan motor pressure: 100 ±2 kg/cm² (The

fan speed is approximately 1200 rpm at this time)

Inspection, Maintenance and Adjustment

OP001015

4-81

LONG TERM STORAGE

Cleaning

Pressure wash machine. Inspect machine for any damage or

missing parts. Drive machine to check steering linkage for

damage.

Hydraulic System

Start engine and allow it to idle for a few minutes. Drive machine

around for two - three minutes. Raise and lower boom two -

three times. Crowd and dump bucket two - three times. This will

circulate hydraulic fluid through all hydraulic systems.

Lubrication

Perform all daily maintenance procedures listed in this section

(Section 4.) Grease all grease fittings in steering linkage. Apply

a coating of light oil to all exposed cylinder rods. Apply a coating

of light oil to all control linkages and all control valve spools.

Check condition of oil coating each month and add to coating

where necessary.

Battery

Disconnect cables from battery, or remove battery from

machine. If battery is removed, fully charge battery and store it.

Cooling System Care

If cooling system does not need antifreeze and is filled with

water only, add an anti-rust additive. If temperatures below

freezing are expected, add antifreeze to protect system to level

of cold expected. See antifreeze protection Table 4-1. Use a

hydrometer to check level of antifreeze protection once each

month. If desired, cooling system can be completely drained. If

system is drained, place a sign in operator's cabin to warn

operator that there is no coolant in engine.

Inspection, Maintenance and Adjustment

OP001015

4-82

PARKING BRAKE ADJUSTMENT

To adjust parking brake, perform the following steps:

Jack up machine enough to allow tires to rotate freely.

Turn “OFF” engine and place transmission lever in “NEUTRAL.”

Turn ignition switch to “ON” position. Move parking brake switch

to “UNLOCKED” position.

Front Axle Service Brakes

Checking clearance between brake pad and brake disc in the

front axle.

Locate the pinion adjusting bolt in the upper part of the

differential housing.

Remove lock bolt (2, Figure 118) and bracket (1).

Rotate the square pinion adjusting bolt (3, Figure 118) in

counter clockwise direction until it stops. At this time the

clearance of brake disk is “0”.

Rotate adjusting bolt (3, Figure 118) clockwise four turns (0.25

mm / rotation) to set the clearance to 1 mm (0.4 in).

Install lock bracket (1, Figure 118) and bolt (2).

Repeat steps 1-5 for other side.

Front Axle Parking Brake Emergency

Release

Locate parking brake release bolt on the lower section on

both sides of the housing.

Loosen lock nut (4, Figure 118) from adjusting bolt (5).

Tighten adjusting bolt (5, Figure 118) until it stops. This will

manually release the parking brake so that the drive shaft

will be free to turn.

The initial setting of adjusting bolt is 47 mm and should be

readjusted to this length and lock nut tightened after towing is

complete.

Figure 118

Rear Axle Service Brake

There are three adjusting bolts per side at 120° intervals for the

rear axle brake adjustment. All three must be adjusted for proper

operation. The adjusting procedure is same as the front brake

adjustment method and must be repeated for both sides.

Inspection, Maintenance and Adjustment

OP001015

4-83

TIRES

Inflating Tires

Recommended tire pressures should normally be followed.

Special operations may justify a different pressure. In such

cases, follow the instructions from the tire manufacturer and do

not exceed the maximum permissible pressures, (See page

4-86)

The tire pressure may have been raised before the machine was

delivered from the factory. Therefore, check and adjust the tire

pressure according to recommendations, before putting the

machine to work for the first time.

WARNING

Repair work on tires and rims must be carried out by

persons who have been especially trained for this.

The instructions stated below apply to an inflated tire where

the pressure needs to be increased. If the tire has lost all

pressure, a trained service engineer must be called in.

•

When checking the air pressure, the tire must be cold

and the machine not have a load.

•

Ask all other persons to leave the danger area (in

front of the rim).

•

Stand by the tire tread as shown in the figure. Tire

installed on a split rim may explode causing injury or

in the worst case death.

•

Use a long air hose (with a self attaching air chuck)

which allows you to stand outside the danger area.

•

Tires on stored wheels (spare wheels) must be kept

laying down on their side, and only be inflated

sufficiently to keep the rim parts in position.

Wheel Nut, Tightening Check

After having changed a tire or if the wheel has been removed

and installed for any other reason, the wheel bolts must be

check for tightness after eight hours of operation.

Tighten wheel nuts to 85 kg•m (615 ft lb).

Inspection, Maintenance and Adjustment

OP001015

4-84

Wheel Nut Torque

Tighten wheel nuts to58 - 62 kg•m (420 - 448 ft lb).

WARNING

If a wheel and tire must be removed from machine and

replaced, or if a tire must be replaced on wheel, allow this

task to be performed only by experienced service

personnel. A tire rim could be propelled off wheel and

cause serious bodily injury or death. See Figure 119.

Figure 119

Check Tire for Damage

WARNING

Improper servicing or changing tires and rims can cause

explosion resulting in serious injury or death.

Do not service or change tires and rims unless properly

trained and equipped.

Contact your nearest DOOSAN loader dealer or tire

manufacturer's local dealer for tire servicing or changing.

WARNING

An overheated tire may explode causing serious injury or

death.

If overheated tire is suspected, do not approach tire to

distance of less than 15 m (50 ft).

Stay away until tire and rim cool down.

If the following defects are found in tires, for safety reasons the

tires must be replaced with new tires.

Tread

For the replacement contact DOOSAN loader dealer or a tire

Side walls

manufacturer's local dealer.

Breakers

Carcass

•

Bead wire is broken or bent, or the tire is greatly

deformed.

•

Wear is excessive and the carcass ply (including

breaker) is exposed for more than

1/4 of the

circumference.

Beads/Bead wire

FG014479

•

Damage to the carcass exceeds 1/3 of the tire width.

Figure 120

•

Tire layers are separated.

Inspection, Maintenance and Adjustment

OP001015

4-85

•

Radial cracks reach the carcass.

•

Deformation or damage which makes the tire

unsuitable for use.

Recommended Air Pressure

Working Pressure

Driving Pressure

Tires

Remarks

Front

Rear

Front

Rear

+0.1

4.1

Bar

3.5

Bar

4.1

Bar

3.5

Bar

20.5-25-16PR

Bias Ply Tire

(Standard)

(59

psi)

(50

psi)

(59

psi)

(50

psi)

+0.1

3.5

Bar

3.0

Bar

3.5

Bar

3.0

Bar

20.5R25

Radial Ply Tire

(Optional)

(50

psi)

(43.5

psi)

(50

psi)

(43.5

psi)

The recommended tire pressures are based on the rated load

for each handling case.

In case of heavier loads, especially during loading and carrying

operations, a higher tire pressure is required. Contact the tire

manufacturer for information about which air pressure is the

correct one for the load to be handled and transported over a

particular distance.

If L5 tires are used for loading and carrying operations, due

attention must be paid to the transporting distances. Radial tires

are to be preferred for loading and carrying operation, as the

buildup of heat is less in this type of tire.

Inspection, Maintenance and Adjustment

OP001015

4-86

OP001016

5Transportation

LOADING AND UNLOADING

When transporting the machine observe the various road rules, road

transportation vehicle laws and vehicle limit ordinances, etc.

It is a good idea to obtain special platform for loading and

unloading the machine.

Park the trailer on a flat firm roadbed. Keep a fairly long

distance between the road shoulder and the machine.

Properly apply the brakes of the trailer and place wheel

chocks in front of and behind the tires to ensure that the

trailer does not move.

FG014477

Fix the ramp in line with the centers of the trailer and the

Figure 1

machine.

Determine the position of the ramp, then slowly load the

machine onto to the specified part of the trailer.

NOTE: Have someone in clear view and in a safe

position, provide directions while loading.

Lower the bucket and lock each control lever using the pilot

cutoff switch.

Apply the parking brake and set the articulation stopper in

the "LOCKED" position.

Tape over the exhaust stack outlet to prevent turbo

"Windmilling" damage.

Side

Place blocks in front of and behind the tires to prevent the

machine from moving.

To prevent the machine from moving during transportation,

fasten the machine to the trailer with chains or cables at

lower part of the rear chassis. Additional chains or cables

may be used but do not damage brake lines or cylinder rods.

FG014478

IMPORTANT

Figure 2

Brake pipe runs on axle housing.

Do not fasten axle housing.

10.

Determine the route for transporting the machine by taking

into account the width, height and weight of the machine

and the truck.

Transportation

OP001016

5-1

SUMMARY OF SAFETY

PRECAUTIONS FOR LIFTING

To make safe lifts, the following items must be evaluated by

operator and work site crew.

•

Condition of ground support.

•

Wheel loader configuration and attachments.

•

Weight, lifting height and lifting radius.

•

Safe rigging of load.

•

Proper handling of suspended load.

Tag lines on opposite sides of load can be very helpful in

keeping a suspended load secure, if they are anchored safely to_{Figure 3}

control points on ground.

Transportation

OP001016

5-2

OP000040

6Troubleshooting

ENGINE

Problem

Possible Cause

Remedy

Starter does not operate.

Blown fuse.

Replace fuse.

Low battery power.

Charge battery.

Poor terminal contact.

Clean and tighten connections.

Starter switch failed.

Replace switch.

Starter relay failed.

Replace relay.

Starter control failed.

Replace controller.

Wiring harness faulty.

Replace harness.

Battery relay failed.

Replace relay.

Starter engages, engine does

Blown fuse.

Replace fuse.

not start.

Fuel gelled in cold weather.

Replace fuel.

Fuel filters plugged.

Replace filters.

Water or dirt in fuel system.

Clean system and add new

fuel.

Air in fuel system.

Purge air from system.

Engine stop control failed.

Replace stop control.

Engine stop relay failed.

Replace relay.

Engine starts, runs only at low

Engine oil viscosity incorrect.

Change oil.

speed or shuts down.

Clogged or dirty fuel injectors.

Clean injectors.

Fuel filters plugged.

Replace filters.

Engine stop motor cable out

Readjust.

of adjustment.

Engine speed control cable

Readjust.

out of adjustment.

Engine knocks, runs unevenly

Low engine oil.

Add oil.

or surges.

Plugged air intake system.

Clean system and replace

filter.

Injection pump out of

Contact your DOOSAN dealer.

adjustment.

Plugged fuel filter.

Replace fuel filter.

Water or dirt in fuel system.

Clean system and add new

fuel.

Clogged or dirty fuel injectors.

Clean injectors.

Troubleshooting

OP000040

6-1

Problem

Possible Cause

Remedy

Engine has poor power.

Plugged air intake system.

Clean system and replace

filter.

Clogged or dirty fuel injectors.

Clean injectors.

Fuel filters plugged.

Replace filters.

Engine speed control cable

Readjust.

out of adjustment.

Injection pump out of

Contact your DOOSAN dealer.

adjustment.

Valve backlash faulty.

Adjust backlash.

Engine runs hot.

Low coolant level.

Add coolant.

Thermostat faulty.

Replace thermostat.

Radiator cap faulty.

Replace radiator cap.

Radiator core plugged.

Clean oil cooler.

Oil cooler core plugged.

Clean oil cooler.

Fan belt loose or damaged.

Tighten or replace as required.

Temperature sensor faulty.

Replace sensor.

Engine oil pressure warning

Low engine oil level.

Add oil.

light turns "ON," and buzzer

Wrong grade oil for weather

change oil.

sounds.

conditions.

Clogged oil filter.

Change filter and oil.

Defective alarm switch.

Contact your DOOSAN dealer.

Oil leakage from pipe or joint.

Clogged suction strainer.

Excessive engine wear.

Defective oil pump.

Coolant temp, warning light

Low engine coolant level.

Add coolant.

turns "ON."

Loose/slipping/broken fan belt.

Adjust or replace belt.

Clogged radiator fins.

Clean.

Scale or mineral build up

Flush or professionally clean.

inside radiator.

Defective alarm switch (gauge

Contact your DOOSAN dealer.

is in green).

Low water pump flow.

Thermostat stuck or missing.

Engine does not start when

Fuel filter clogged.

Replace fuel filter.

the starter motor is turning.

Starter motor speed too low.

Booster Battery may be used.

(Also see ELECTRICAL

Defective engine shutoff

Contact your DOOSAN dealer.

TROUBLESHOOTING.)

solenoid.

Fuel pump failure.

Incorrect fuel injection timing.

Compression pressure too low.

Defective injectors.

Troubleshooting

OP000040

6-2

Problem

Possible Cause

Remedy

Unstable (rough) idling.

Air in fuel lines.

Tighten fuel connections and

filter.

Fuel filter clogged.

Replace fuel filter.

Fuel pump failure.

Contact your DOOSAN dealer.

Incorrect fuel injection timing.

Insufficient power.

Air cleaner filter clogged.

Clean or replace element.

Fuel filer element clogged.

Replace fuel filter.

Throttle linkage adjustment

Check and adjust linkage.

wrong.

Engine oil level too high.

Check dipstick and correct

level.

Incorrect valve clearance.

Contact your DOOSAN dealer.

Piston ring wear.

Defective injectors.

Fuel pump failure.

HYDRAULIC SYSTEM

Problem

Possible Cause

Remedy

None of the controls function

Hydraulic pump failed.

Contact your DOOSAN

(loud noise from pumps).

dealer.

Low hydraulic oil level.

Add hydraulic oil as

required.

Suction line plugged or damaged.

Clean or replace as

required.

None of the controls function

Pilot pump failure.

Contact your DOOSAN

(no noise from pumps).

dealer.

Cutoff solenoid valve failed.

Replace solenoid.

Relief cartridge of pilot parking

Clean or replace as

valve stuck.

required.

Safety limit switch is ON.

Adjust limit switch

clearance.

All actuators have low power.

Low hydraulic oil level.

Add hydraulic oil as

required.

Suction filter clogged.

Clean filter.

Hydraulic pumps faulty.

Contact your DOOSAN

dealer.

Main relief pressure too low.

Contact your DOOSAN

dealer.

Hydraulic pumps cavitating.

Bleed air from hydraulic

pumps.

Troubleshooting

OP000040

6-3

Problem

Possible Cause

Remedy

Only one or two actuators

Overload relief pressure too low.

Reset pressure.

have little or no power.

Makeup check valve leaking.

Clean or replace as

required.

Control valve spool faulty.

Replace valve spool.

Dirt in valve spool.

Clean or replace as

required.

Actuator failed.

Repair or replace as

required.

Cylinder seal failed.

Repair or replace as

required.

Cylinder rod damaged.

Repair or replace as

required.

Remote control valve failed.

Replace control valve.

Wrong pilot line connection.

Reconnect pilot lines.

Oil temperature too high.

Debris in exterior of cooler.

Clean exterior of cooler.

Oil cooler faulty.

Contact your DOOSAN

dealer.

Fan belt loose.

Tighten fan belting as

required.

Actuators on one side of

Overload relief valve is not

Repair valve or replace.

boom have little power or do

operating properly.

not operate.

Damaged hydraulic hose.

Replace hose.

Loose hydraulic fittings.

Tighten fittings.

Internal damage to control valve

Replace control valve.

housing.

Control valve spool damaged.

Replace control valve.

Sediment inside control valve.

Clean and repair valve.

Check valve internal leakage.

Repair or replace valve.

Damaged cylinder or pump.

Repair or replace pump or

cylinder.

Cylinder internal leakage.

Repair or replace cylinder.

Damaged cylinder rod.

Replace rod.

Pilot valve failure.

Replace pilot valve.

Troubleshooting

OP000040

6-4

TRAVEL SYSTEM

General

Problem

Possible Cause

Remedy

Machine will not travel.

Transmission clutch pressure

Adjust pressure.

incorrect.

Transmission charge pump

Replace pump.

damaged.

Damage to transmission control

Repair wiring.

valve wiring harness.

Burned travel relay or fuse.

Replace relay or fuse.

Forward/Reverse solenoid for

Clean and repair.

transmission control valve sticking.

Damaged transmission clutch.

Repair or replace clutch.

Damaged drive shaft.

Repair or replace.

Damaged transmission or axle.

Repair or replace.

Wheel brakes not releasing.

Repair brakes.

Parking brake not releasing.

Repair parking brake.

Machine will travel but has

Fluid pressure low in transmission

Repair clutch.

little power.

clutch.

Transmission fluid low.

Add fluid.

Damage to torque converter.

Repair or replace.

Engine malfunction.

See Engine

Troubleshooting Table.

Brake valve.

Disassemble and clean.

Unusual transmission noise.

Low transmission fluid, or low

Add fluid or change fluid.

quality fluid.

Worn transmission parts.

Replace parts.

Broken gears or bearings.

Replace parts.

Transmission fails to operate.

Damaged transmission clutch

Replace disks.

disks.

Damaged wires in transmission

Repair wires.

control wire harness.

Drive shaft vibration Noisy

Bent drive shaft.

Replace drive shaft.

universal joints.

Loose universal joints.

Tighten bolts that secure

joints.

Worn or damaged universal joint.

Replace universal joint.

Loose universal joints.

Tighten bolts that secure

universal joints.

Lack of lubrication.

Lubricate universal joints.

Worn slip joint spline.

Replace slip joint.

Noisy Front or Rear Axle.

Worn or broken gears.

Replace gears.

Low oil level, poor quality oil.

Add oil, change oil.

Worn bearings.

Replace bearings.

Worn shaft spline.

Replace spline.

Troubleshooting

OP000040

6-5

STEERING

Problem

Possible Cause

Remedy

Steering Wheel is hard to turn.

Sediment blocking direction

Clean and repair.

change spool orifice, inside priority

valve.

Sediment blocking amplifying spool

Clean and repair.

orifice, inside priority valve.

Sediment blocking load sensing

Clean and repair.

line orifice, inside priority valve.

Priority valve spool sticking, inside

Clean and repair.

steering valve.

Incorrect relief valve pressure

Adjust pressure.

drop, inside priority valve.

Steering pump failure.

Repair or replace.

Leaking steering cylinder.

Repair cylinder.

Rust on steering column bearing

Lubricate.

and spline.

Tire air pressure is low.

Inflate to proper pressure.

High initial resistance to

Air in load sensing line, inside

Bleed system to remove

movement of steering wheel.

priority valve.

air.

Sediment blocking orifice of load

Clean and repair.

sensing line, inside priority valve.

Sediment in direction change

Clean and repair.

spool, inside priority valve.

Damage to control spring damping

Replace priority valve.

inside priority valve.

Steering wheel shakes.

Chattering bearing in axle end

Replace bearing.

differential.

Tire pressure not equal in left side

Equalize pressure.

and right side tires.

Troubleshooting

OP000040

6-6

BRAKING

Problem

Possible Cause

Remedy

Reduced brake action.

Low secondary pressure in brake

Repair or replace brake

valve.

Worn brake disks.

Replace brake disks.

Damaged brake disks.

Replace brake disks.

Damaged brake valve block.

Replace valve.

Air in brake hydraulics due to leak

Repair leak, bleed system.

in brake hose.

After bleeding brakes, brakes

Damaged brake disks.

Replace disks.

are not fully released.

Damaged brake disk return spring.

Replace return springs.

ELECTRICAL SYSTEM

Problem

Possible Cause

Remedy

Battery has no power and will

Damaged battery plates.

Replace battery.

not accept a charge.

Alternator not charging properly.

Repair or replace

alternator.

Bad ground.

Clean and tighten.

Loose electrical connector.

Clean and tighten.

Alternator belt loose or damaged.

Tighten or replace.

Battery will accept a charge

Internal battery short.

Replace battery.

but discharges soon after.

Wiring harness short.

Repair wire.

Troubleshooting

OP000040

6-7

OP001017

7Specification

GENERAL SPECIFICATIONS

DL220

ITEM

SPECIFICATION

Standard Bucket Capacity (BOT / BOC)

2.2 m³ (2.88 yd³) / 2.3 m³(3.01 yd³)

Vehicle Weight (STD / OPT)

12,300 kg (27,116 lb) / 12,600 kg (27,778 lb)

Engine (SAE J1995 Gross)

Emission

U.S EPA Tier3 (EU Stage IIIA)

Maker and Model

DOOSAN DL06

Type

Turbo Charged, Air to Air Intercooled Direct Injection

Injection System

Common-rail Controlled by Electronic ECM

Max. Horse Power (SAE J1995)

160 ps (118 kw) / 1800 rpm

Rated Horse Power (SAE J1995)

150 ps (110 kw) / 2200 rpm

Max. Torque

70 kg•m (686 N.m) / 1400 rpm

Transmission

Full Automatic Power -Shift

Full Automatic Power Shift

Speeds

4 Forward, 3 Reverse

Brake Systems

Service Brakes

Full Hydraulic, Separate Dual Line Wet Discs

Parking Brake

Spring Applied / Oil Released on Front Axle, Wet Disc

Performance

Travel Speed

6.9 (4.3) /12.8 (7.9) / 24.5 (15.2) / 38.5 (24) km/h (MPH)

Steering Angle

±40°

Min. Tire Turning Radius *

5,265 mm (17' 3")

(Out Tire Edge)

Safe Operating Load (BOC)

4,140 kg (9,127 lb)

Max. Breakout Force

10,360 kg (22,840 lb)

Boom Rise Time

5.3 ±0.5 s

Bucket Dump Time

1.1 ±0.4 s

Boom Down Time

3.5 ±0.4 s

Maximum Gradeability

27° (51%)

* Based on 20.5-25-16PR (L3) tire

Specification

OP001017

7-1

Doosan DL220. Operation and Maintenance Manual (2010) - page 3