Doosan DL200, DL200TC. Operation and Maintenance Manual (2006)

B. Bucket lever connecting pins,

2 locations. Lever

link connecting pins,

2 locations. Bucket cylinder

rod ends, 2 locations. (Figure 47)

FG008097

Figure 47

C. Bucket cylinder heads,

2 locations. Arm lever

connecting pins, 2 locations. Lever link connecting

pins, 2 locations. (Figure 43)

Link foot pins, 2 locations.

FG008098

Figure 48

D. Lift cylinder heads

(left, right),

2 locations. Lift

cylinder rod ends, 2 locations. (Figure 49)

FG008099

Figure 49

E. Remote location points.

Remote fittings for loader arm foot end

(50

HOUR),

(Figure 50).

FG008100

Figure 50

Inspection, Maintenance and Adjustment

OP000509

4-37

Grease Steering Cylinder Rod and Head

Ends

Steering cylinder rods, 2 locations, one on each side of

machine.

FG008101

Figure 53

Steering cylinder head ends,

2 locations. Use remote

grease fittings mounted on frame. (1 and 2, Figure 54).

Remote Grease

Reference Number

Fittings

1 and 2,

Steering Cylinder

50 Hours

Head Ends

Drive Shaft

250 Hours

Center Bearing

FG001640

Figure 54

Grease Upper and Lower Center Pins

Center pins, upper

(Figure

55) and lower (Figure

56).

Two locations on right side of machine.

FG001641

Figure 55

Inspection, Maintenance and Adjustment

OP000509

4-39

FG001642

Figure 56

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 4-52)

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 4-61).

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 4-43.

Inspection, Maintenance and Adjustment

OP000509

4-40

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 4-49)

FG004071

Figure 57

Clean Air Conditioner Outer Filter

This unit is equipped with an air-conditioning system. There

are two filters (1 and 2, Figure 58) 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 58) 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 58

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

OP000509

4-41

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 59

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 20 on page 4-25).

Loosen drain valve at bottom of tank (Figure 60). Allow

all water and sediment to drain out. Tighten drain

valve.

NOTE: Dispose of drained fluids according to local

regulations.

FG008102

Figure 60

Inspection, Maintenance and Adjustment

OP000509

4-42

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 61

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 62

Inspection, Maintenance and Adjustment

OP000509

4-43

Grease Drive Shafts

Grease fitting for center bearing,

1 location. Use remote

grease fitting mounted on front frame (3, Figure 63).

Remote Grease

Reference Number

Fittings

1 and 2,

Steering Cylinder

50 Hours

Head Ends

Drive Shaft

FG001640

250 Hours

Center Bearing

Figure 63

FG002212

Figure 64

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 4-56)

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 4-62)

Inspection, Maintenance and Adjustment

OP000509

4-44

Clean Outer Filter of Air Cleaner

NOTE: Clean outer filter every 250 hours / monthly service.

NOTE: If air cleaner clogged warning light (Figure 65) on

instrument panel comes "ON" the air cleaner must be

serviced.

F/R

NOTE: When working in severely dusty conditions, the

service interval should be shortened.

FG008103

WARNING!

Figure 65

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

65) 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

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

67). Inspect seal lips for wear or damage. Replace

valve if necessary.

Figure 66

NOTE: Install evacuator valve with lips parallel to the

cover.

Remove the access cover (2, Figure 67) by loosening

the latches (3).

Remove the outer filter (4, Figure 67) from the housing.

Do not remove inner filter (5).

FG000702

Figure 67

Inspection, Maintenance and Adjustment

OP000509

4-45

Clean the outer filter

(4, Figure

67) by blowing

compressed air from the inside of the filter towards the

outside. Do not use more than

205 kPa (30 psi) air

pressure.

WARNING!

If using compressed an to clean the filter, make

sure that proper eye protection is worn.

HAOC570L

Figure 68

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 69

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

FG008506

drained unless new fuel is pumped in.

Figure 70

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.

open

NOTE: Take care of waste oil and liquid in an

environmentally safe way!

FG000438

Figure 71

Inspection, Maintenance and Adjustment

OP000509

4-46

500 HOUR / 3 MONTH SERVICE

Perform All Daily, 10, 50 and 250 Hour

Service Checks

Replace Hydraulic System Brake and

Pilot Filter

Replace filter in pilot filter. Perform the following steps:

Vent hydraulic oil tank.

FG008104

Figure 72

Unscrew element cover (5, Figure 73). Cover is filled

with oil. Dispose of oil.

Remove O-ring (3, Figure 73) and filter (4).

Use a nonflammable, nontoxic solvent to clean out

cover (5, Figure 73).

Insert a new filter (4, Figure 73) into cover (5). Install a

new O-ring (3).

Screw cover (5, Figure 73) onto filter head (1).

Figure 73

Inspection, Maintenance and Adjustment

OP000509

4-47

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

FG006241

1/2 turn more.

Figure 74

NOTE: Coat fuel filter gasket with fuel.

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

OP000509

4-48

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 75

The pressure side main fuel filter must have the following

characteristics:

•

5-micron rating

•

engine mounted

FG006240

Figure 76

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.

Figure 77

Screw filter on head until gasket contacts head by hand,

turn filter

3/4 - 1 turn more with filter wrench.

Inspection, Maintenance and Adjustment

OP000509

4-49

Replace Fuel Filter

WARNING!

Exchange filter after waiting for engine to cool. Be

careful of fire hazards. Do not smoke.

Locate fuel filter inside engine compartment.

Position a small container under fuel filter.

FG006240

Figure 78

Unscrew fuel filter from head assembly. Discard fuel

filter.

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

FG000478

reduce fuel system priming.

Figure 79

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

FG001647

every 500 hours.

Figure 80

Inspection, Maintenance and Adjustment

OP000509

4-50

FG002217

Figure 81

Clean Air Conditioner Inner Filter

This unit is equipped with an air-conditioning system. There

are two filters

(1 and 2, Figure 82) for air conditioner. The

filters out dirt and dust particles from air being circulated

into operator's cabin. They are located under the right side

control panel.

Open access cover on the lower right side of cabin on

the outside to gain access filter.

Remove filter (2, Figure 82) 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

FG003904

with a new one.

Figure 82

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

OP000509

4-51

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 83

Replace engine oil filter (Figure 84). 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.

FG006237

Fill engine with correct oil through oil fill port.

Figure 84

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

OP000509

4-52

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.

Figure 86

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.

Figure 87

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

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.

Inspection, Maintenance and Adjustment

OP000509

4-54

•

Check that all hose and pipe connections from the

air cleaner to the engine induction manifold are

tight. Check tightness of hose clamps.

•

If the alarm text remains after replacing the

primary filter, also the secondary filter must be

replaced. See

“9. Air Cleaner Clogged Warning

Light” on page 2-21

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 88

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.

Open the side access cover at the rear of the cabin.

Remove the evacuator valve

(1, Figure

89) and air

FG000425

cleaner cover (2, Figure 89).

Figure 89

NOTE: Inspect evacuator valve seal lips for wear or

damage. Replace valve if necessary. Install

evacuator valve with lips parallel to the cover.

Inspection, Maintenance and Adjustment

OP000509

4-55

Remove outer filter (4, Figure 89) from the air cleaner

housing.

Clean the air cleaner cover and the inside of the air

cleaner housing. Do not use compressed air to blow

out housing.

Install new outer filter.

Install air cleaner cover and evacuator valve.

NOTE: Make sure that all gaskets on wing nuts and

cover are properly installed and seated.

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 90).

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

Figure 90

it.

Inspection, Maintenance and Adjustment

OP000509

4-56

Rotate filter counterclockwise to remove it (Figure 91).

10. Clean filter head.

11. Grease filter gasket and gasket mating surface on filter

head.

12. Thread filter onto filter head. Tighten filter 1/2 turn after

filter gasket contacts filter head. Filter must be torque

to 1.6 - 2.1 kg•m (11.5 - 15 ft lb).

FG002218

Figure 91

13. Fill transmission with fluid through transmission fill tube

(Figure 92).

FG008085

Figure 92

14. Add fluid until fluid level reaches low mark on dipstick

(Figure 92).

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 93

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.

Inspection, Maintenance and Adjustment

OP000509

4-57

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.

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 94) 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 94

Remove bolts, inspection cover and gasket (Figure 95)

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 95

Inspection, Maintenance and Adjustment

OP000509

4-58

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 4-51

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 96

Inspection, Maintenance and Adjustment

OP000509

4-59

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.

Inspection, Maintenance and Adjustment

OP000509

4-60

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 20

on page 4-25).

Clean filter cover (2, Figure 97) and tank around cover.

Remove bolts (1, Figure 97) from cover (2).

Lift cover

(2, Figure

97) and O-ring

(4) off tank. A

control spring

(3) sits beneath cover. Remove spring

(3).

Remove valve (5, Figure 97) and filter (6) from tank.

Clean underside of cover (2, Figure 97).

Set a new element (6, Figure 97) 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

97) on cover

(2). Set

spring (3) into place on element (6).

FG006233

Figure 97

Set cover

(2, Figure

97) into place over element

(6).

Install bolts

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

10. Tighten breather cap on tank.

Inspection, Maintenance and Adjustment

OP000509

4-61

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

98) 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.

Figure 98

NOTE: Dispose of drained fluids according to local

regulations.

Clean area around level plug (1, Figure 99) 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

99into 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.

Figure 99

Inspection, Maintenance and Adjustment

OP000509

4-62

Go to level plug holes

(1, Figure

100) 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, install and

tighten level plugs at all three locations.

Repeat procedure for other axle.

FG002222

Figure 100

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 101

Inspection, Maintenance and Adjustment

OP000509

4-63

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

Inspection, Maintenance and Adjustment

OP000509

4-64

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.

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 102)

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

HLB3018L

floor of cab. Close bleeder screw while pedal is being

Figure 102

held down. 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

OP000509

4-65

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 4-75, 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

FG002206

controls notifying personnel that service work is being

performed.

Figure 103

Do not remove the radiator cap unless it is required.

Observe the coolant level in the coolant recovery tank.

Slowly open the radiator cap (Figure 103) 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 104).

NOTE: Dispose of drained fluids according to local

regulations.

FG002225

Figure 104

Inspection, Maintenance and Adjustment

OP000509

4-66

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

capacity.

Figure 105

Position a catch tank beneath hydraulic tank drain plug.

Open tank breather cap.

(See Figure

20 on page 4-

25). Remove drain plug from bottom of tank.

(Figure

106). Allow all hydraulic oil to drain out.

FG008102

Figure 106

Figure 107

Inspection, Maintenance and Adjustment

OP000509

4-67

Figure 108

Without starting engine, operate controls to dump

bucket.

(Figure

107). Then operate controls to lower

boom. (Figure 108). This will drain oil out of boom and

bucket cylinders.

Replace full flow hydraulic filters as described under

“Loosen breather cap on hydraulic tank. (See Figure 20

on page 4-25).” on page 4-61.

Remove and clean pump inlet strainer

(Figure

109)

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

109) 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.

Install tank drain plug. Refill tank by pouring oil in

through breather cap opening. Install and tighten

FG006228

breather cap.

Figure 109

Start engine and operate controls to raise and lower

bucket a few times.

(Figure

110). Raise and lower

boom a few times.

(Figure

111). Lower bucket to

ground.

Check tank sight gauge. (See Figure 19 on page 4-25).

Oil level must be between upper limit and lower limit

on sight gauge. Remove breather cap and add oil if

necessary.

Figure 110

Inspection, Maintenance and Adjustment

OP000509

4-68

Figure 111

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

OP000509

4-69

12,000 HOUR / SIX YEAR

SERVICE

Hose In-service Lifetime Limit (European

Standard ISO 8331 and EN982 CEN)

European regulations state that the in-service life of any

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 4-65, 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

OP000509

4-70

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

OP000509

4-71

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

mm x

1.0

2.76

3.87

4.56

mm x std.

4.84

6.92

8.30

mm x

1.0

4.84

7.05

8.30

mm x std.

8.57

11.89

14.52

105

mm x

1.5

9.00

12.59

14.94

108

mm x std.

13.55

18.95

137

23.10

167

mm x

1.5

14.94

108

21.02

152

24.89

180

mm x std.

20.88

151

29.46

213

35.54

257

mm x

1.5

22.54

163

31.53

228

38.03

275

mm x std.

28.90

209

40.52

293

48.41

350

mm x

1.5

32.50

235

45.92

332

55.04

398

mm x std.

40.94

296

57.95

419

69.01

499

mm x

1.5

46.05

333

64.03

463

77.03

557

mm x std.

54.90

397

77.86

563

93.08

673

mm x

1.5

61.00

441

86.02

622

105.00

759

mm x std.

71.00

513

100.00

723

120.00

868

mm x

2.0

78.00

564

109.95

795

130.00

940

mm x

2.0

115.06

832

160.00

1157

195.00

1410

Inspection, Maintenance and Adjustment

OP000509

4-72

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 112

Inspection, Maintenance and Adjustment

OP000509

4-73

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

OP000509

4-74

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

OP000509

4-75

Types of Antifreeze

There are two main classifications of antifreeze available on

the market today.

Ethylene Glycol - Standard Life Antifreeze

Propylene Glycol - Extended Life Antifreeze

Ethylene glycol

(standard life antifreeze) has been on the

market for many years. Its chemical properties do not

provide the improved corrosion resistance that propylene

glycol (extended life antifreeze) does. Ethylene glycol is also

very hazardous to the environment, people and animals.

DOOSAN recommends that ethylene glycol be replaced with

propylene glycol.

The newer propylene glycol antifreeze comes in many

different colors. 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.

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.

Antifreeze Concentration Tables

Ethylene Glycol - Standard Life Antifreeze

(1,000 Hour / 6 Months)

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 - Extended Life Antifreeze

(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%

Inspection, Maintenance and Adjustment

OP000509

4-76

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

FG008106

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

Figure 113

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

OP000509

4-77

HYDRAULIC PRESSURE

CHECKS

Hydraulic pressure for most systems can be check by using

the remote test ports shown in (Figure 114).

Reference

Description

Pressure

Number

Main Pump Pressure

200 ±5 kg/cm²

(TPM)

Brake Charge Pressure

80 kg/cm²

(TP2)

FG001653

Steer Pump Pressure

Figure 114

(TPS) at Only Steering

200 ±5 kg/cm²

Relief

Transmission Clutch

16 - 18 kg/cm²

Pressure (TM)

Control Lever Activation

28 +2/-0 kg/

Pressure (TP1) at E/G

cm²

High Idle

Control Valve Pressure

Attach gauge to port (1, Figure 114).

Relief valve cartridge on control valve

(Figure

115)

must be adjusted to open at

200 ±5 kg/cm²

(2,844 ±70psi)

FG008107

Figure 115

Brake Charge Pressure

Attach gauge to port (2, Figure 114).

Adjust relief valve cartridge on brake, pilot and fan

motor supply valve

(Figure

116). Relief pressure

(Figure

116) for brake charging is

80 ±5 kg/cm²

(1,138 ±70 psi).

FG008108

Figure 116

Inspection, Maintenance and Adjustment

OP000509

4-78

Steering Pump Pressure

Attach gauge to port (3, Figure 114).

Adjust relief valve cartridge on steering valve

(Figure

117). Cartridge must be adjusted to open at

200 ±5

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

Figure 117

adjusted.

Transmission Clutch Pressure

Attach gauge to port (4, Figure 114).

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 114).

Adjust relief cartridge

(Figure

118) 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 118

Service Brake Outlet Pressure

Attach gauge to brake pressure test port

(1, Figure

119) of front axle.

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

FG008111

Figure 119

Inspection, Maintenance and Adjustment

OP000509

4-79

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

FG001746

Figure 120

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

OP000509

4-81

Checking the Relief Pressure of Fan

Motor

FG008112

Figure 121

Reference

Description

Number

Fan Motor

Outlet Line

Fan Guard

Relief Valve

Inlet Line

Proportional Relief Valve

Drain Line

Reversable Solenoid Valve

Maximum Fan Speed, Checking

Open the radiator grille in order to connect the

pressure gauge.

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

OP000509

4-82

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

OP000509

4-83

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 122) and bracket (1).

Rotate the square pinion adjusting bolt (3, Figure 122)

in counter clockwise direction until it stops. At this time

the clearance of brake disk is “0”.

Rotate adjusting bolt

(3, Figure

122) clockwise four turns

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

Install lock bracket (1, Figure 122) 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 122) from adjusting bolt (5).

Tighten adjusting bolt (5, Figure 122) 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 122

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

OP000509

4-84

TIRES

Inflating Tires

Recommended tire pressures should normally be followed.

Special operations may justify a different pressure. In such

cases, follow the instructions from the tire manufacturer and

do not exceed the maximum permissible pressures,

(See

page 4-87)

The tire pressure may have been raised before the machine

was delivered from the factory. 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 58 - 62 kg•m (420 - 448 ft lb).

Inspection, Maintenance and Adjustment

OP000509

4-85

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 123.

Figure 123

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.

For the replacement contact DOOSAN loader dealer or a

tire manufacturer's local dealer.

•

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.

•

Damage to the carcass exceeds

1/3 of the tire

Figure 124

width.

Inspection, Maintenance and Adjustment

OP000509

4-86

•

Tire layers are separated.

•

Radial cracks reach the carcass.

•

Deformation or damage which makes the tire

unsuitable for use.

Recommended Air Pressure

Working Pressure

Driving Pressure

Tires

Remarks

Front

Rear

Front

Rear

+0.1

4.2

Bar

3.5

Bar

4.2

Bar

3.5

Bar

20.5-25-16PR

Bias Ply Tire

(Standard)

(60

psi)

(50

psi)

(60

psi)

(50

psi)

+0.1

3.5

Bar

3.0

Bar

3.5

Bar

3.0

Bar

20.5R25

Radial Ply Tire

(Option)

(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

OP000509

4-87

OP000039

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.

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.

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

machine from moving.

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.

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

OP000039

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

OP000039

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

OP000510

7Specification

GENERAL SPECIFICATIONS

DL200

ITEM

SPECIFICATION

Standard Bucket Capacity (BOT / BOC)

1.9 m³ (2.5 yd³) / 2.0 m³(2.62 yd³)

Vehicle Weight (STD / OPT)

11,300 kg (24,912 lb) / 11,645 kg (25,673 lb)

Engine (SAE J1995 Gross)

Emission

U.S EPA Tier3 (EU Stage IIIA)

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

160 ps (118 kw) / 1800 rpm

Rated Horse Power

145 ps (107 kw) / 2100 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

6.6 (4.1) /12.1 (7.5) / 22.6 (14) / 35 (21.7) km/h (MPH)

Steering Angle

±40°

Min. Tire Turning Radius *

5,210 mm (17' 1")

(Out Tire Edge)

Safe Operating Load

3,420 kg (7,540 lb)

Max. Breakout Force

10,500 kg (23,149 lb)

Boom Rise Time

5.8 ±0.5Sec.

Bucket Dump Time

1.1 ±0.4 Sec.

Boom Down Time

4.1 ±0.4 Sec.

Maximum Gradeability

30° (58%)

Specification

OP000510

7-1

DL200TC

ITEM

SPECIFICATION

Standard Bucket Capacity (BOT / BOC)

1.9 m³ (2.5 yd³) / 2.0 m³(2.62 yd³)

Vehicle Weight (STD / OPT)

11,300 kg (24,912 lb) / 11,580 kg (25,530 lb)

Engine (SAE J1995 Gross)

Emission

U.S EPA Tier3 (EU Stage IIIA)

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

160 ps (118 kw) / 1800 rpm

Rated Horse Power

145 ps (107 kw) / 2100 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

6.6 (4.1) /12.1 (7.5) / 22.6 (14) / 35 (21.7) km/h (MPH)

Steering Angle

±40°

Min. Tire Turning Radius *

5,210 mm (17' 1")

(Out Tire Edge)

Safe Operating Load

3,420 kg (7,540 lb)

Max. Breakout Force

10,500 kg (23,149 lb)

Boom Rise Time

5.8 ±0.5Sec.

Bucket Dump Time

1.2 ±0.4 Sec.

Boom Down Time

4.1 ±0.4 Sec.

Maximum Gradeability

30° (58%)

* Based on 20.5R25 tire

Specification

OP000510

7-2

Doosan DL200, DL200TC. Operation and Maintenance Manual (2006) - page 3