PDF Operation & Maintenance Manual Daewoo Doosan DL200 Wheel Loader - 2 MB
Maximize the performance and lifespan of your Daewoo Doosan DL200 or DL200TC Wheel Loader with this official manual.
It details all operational procedures, safety warnings, and the complete schedule of maintenance tasks.
Following the manufacturer's recommendations is the best way to prevent unexpected failures and costly repairs.
This guide is essential for both operators and service personnel.
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K1024537EE
July 2014
WHEEL LOADER
Operation &
Maintenance
Manual
DL200 / DL200TC
Serial Number 5001 and Up
--- Page 3 ---
Other Signal Words
In addition to safety signal words, the following signal words are
used to indicate proper and effective use of machine.
IMPORTANT
This signal word identifies procedures which must be
followed to avoid damage to machine.
The word "NOTE" identifies information for effective use.
DL200/DL200TC Safety
1-3
--- Page 4 ---
19. Lift/Tie down (950205-03815)
Identifies lift point and tie down point location.
950205-03815
EX1301201
20. Diesel (K1016409)
IMPORTANT
• Only use diesel fuel.
K1016409
WL1400818
21. Unlock (950205-01487)
950205-01487
WL1400819
DL200/DL200TC Safety
1-13
--- Page 5 ---
Attachment Precautions
Option kits are available through your dealer. Contact DOOSAN
for information on available one-way (single-acting) and two-way
(double-acting) piping / valving / auxiliary control kits. Because
DOOSAN cannot anticipate, identify or test all the attachments
that owners may wish to install on their machines, please
contact DOOSAN for authorization and approval of attachments,
and their compatibility with optional kits.
Accumulator
The pilot control system is equipped with an accumulator. For a
brief period of time after the engine has been shut down, the
accumulator will store a pressure charge that may enable
hydraulic controls to be activated. Activation of any controls may
enable the selected function to operate under force of gravity.
When performing maintenance on the pilot control system, the
hydraulic pressure in the system must be released as described
in “Handling of Accumulator” on page 4-87.
The accumulator is charged with high-pressure nitrogen gas, so
it is extremely dangerous if it is handled in the wrong way.
Always observe the following precautions:
• Do not drill or make any holes in the accumulator or
expose it to any flames, fire or heat source.
• Do not weld on the accumulator, or try attaching anything
to it.
• When carrying out disassembly or maintenance of the
accumulator, or when disposing of the accumulator, the
charged gas must be properly released. Contact your
DOOSAN distributor.
• Wear safety goggles and protective gloves when working
on an accumulator. Hydraulic oil under pressure can
penetrate the skin and cause serious injuries.
Engine Ventilation
Engine exhaust gases can cause loss of judgment, loss of
alertness, and loss of motor control. These gases can also
cause unconsciousness, serious injury, fatal accidents and
death.
Make sure there is adequate ventilation before starting the
engine in any enclosed area.
You should also be aware of open windows, doors or ductwork
where exhaust may be carried, or blown by the wind, exposing
ARO1770L
others to danger.
Figure 14
DL200/DL200TC Safety
1-23
--- Page 6 ---
Operate Carefully on Snow and Ice, In Very
Cold Temperatures
In icy cold weather avoid sudden travel movements and stay
away from even very slight slopes. The machine could skid off to
one side very easily.
Snow accumulation could hide or obscure potential hazards.
Use care while operating or while using the machine to clear
snow.
Warming up the engine for a short period may be necessary, to
avoid operating with sluggish or reduced working capacity. The
jolting shocks and impact loads caused by bumping or
bottoming the boom or attachment are more likely to cause
severe stress in very cold temperatures. Reducing work cycle
rate and workload may be necessary.
When the temperature rises, frozen road surfaces become soft,
and machine travel becomes unstable.
In cold weather, do not touch metal surfaces with your bare
hands. If you touch a metal surface in extremely cold weather,
your skin may freeze to the metal surface.
Parking Machine
Avoid making sudden stops, or parking the machine wherever it
happens to be at the end of the workday. Plan so the wheel
loader will be on firm and level ground away from traffic and
away from high walls, cliff edges and any area of potential water
accumulation or runoff. If parking on inclines is unavoidable,
block the wheels to prevent movement. Lower the bucket or
other working attachment completely to the ground, or to an
overnight support saddle. There must be no possibility of
unintended or accidental movement.
When parking on public roads, provide fences, signs, flags, or
lights, and put up any other necessary signs to ensure that
passing traffic can see the machine clearly. Park the machine so
the machine, flags, and fences do not obstruct traffic.
DL200/DL200TC Safety
1-33
--- Page 7 ---
Dispose of All Petroleum Based Oils and
Fluids Properly X
Physical contact with used motor oil may pose a health risk.
Wipe oil from your hands promptly and wash off any remaining
residue.
Used motor oil is an environmental contaminant and may only
be disposed of at approved collection facilities. To prevent
pollution of the environment, always do the following:
• Never dump waste oil in a sewer system, rivers, etc. HAOA470L
• Always put oil drained from your machine in containers. Figure 35
Never drain oil directly onto the ground.
• Obey appropriate laws and regulations when disposing of
harmful materials such as oil, fuel, solvent, filters, and
batteries.
Check Tire Pressure and Condition
Maintain tire pressure but do not overinflate. Inspect tires and
wheels daily. When inflating tires, follow procedures in
Maintenance Section, which include using an extension to allow
you to avoid standing in front of or over a tire. Do not change a
tire unless you have both experience and proper equipment.
NOTE: Refer to “Recommended Air Pressure” on page 4-96
Decreasing Risk of Injuries or Death From
Boom and Bucket
DANGER
AVOID DEATH
When operating machine or making repairs, never allow
bystanders in the operational zone or repair area. Operation
and service personnel must be careful when working
around the machine, especially around the boom and
bucket.
An unexpected fall of the front structure can cause injuries
or death.
DL200/DL200TC Safety
1-43
--- Page 8 ---
Reference Reference
Description Description
Number Number
1 Bucket Teeth 25 Grille
2 Bucket 26 Fan
3 Air Conditioner Condenser 27 Fuel Tank
4 Rear Wheel Cover 28 Engine Oil Fill Cap
5 Battery Box 29 Engine Oil Filter
6 Rear Light 30 Engine Oil Level Dipstick
7 Counterweight 31 Rear Axle Pivot
8 Fan Motor 32 Rear Axle
9 Towing Pin 33 Drive Shaft (Rear)
10 Muffler Tail Pipe 34 Transmission
11 Oil Tank 35 Transmission Oil Filter
12 Lever 36 Drive Shaft (Center)
13 Front Wheel Cover 37 Center Pin
14 Tilt Cylinder 38 Steering Wheel Cylinder
15 Headlight Support 39 Lift Cylinder
16 Ladder 40 Drive Shaft (Front)
17 Work Light 41 Parking Brake
18 Operator's Cabin 42 Front Axle
19 Air Cleaner 43 Loader Arm
20 Engine Air Intake Precleaner 44 Link
21 Engine 45 Link
22 Muffler 46 Lever
23 CAC Cooler 47 Quick Coupler (Optional)
24 Radiator
DL200/DX200TC Operating Controls
2-5
--- Page 9 ---
12. Hazard Warning Light Switch 1
This warning light is used when the equipment is stopped
because of a malfunction or when an emergency occurs.
When this switch is pressed the directional indicator lights O
in front and back of the machine light up and flash, warning
others in the area. At the same time the directional
indicator lights on the instrument panel will turn "ON" to
I
warn the operator. The hazard warning lights operate
independent of the starter switch.
O. In this position, this switch turns "OFF" hazard 2665C
warning lights. Figure 23
I. In this position, this switch turns "ON" all turn signals
and they flash simultaneously.
NOTE: Hazard warning lights will function with starter
switch in "OFF" position.
DL200/DX200TC Operating Controls
2-15
--- Page 10 ---
Fault Code 423 (example)
: Flash : Pause
AQO0010L
Figure 47
21. Engine Coolant Temperature Warning
Symbol
If engine coolant overheats, this symbol appears on the
screen an alarm will sound, and the engine speed will be
automatically reduced, until coolant temperature drops. Do
not turn engine "OFF" because this will cause coolant
temperature to rise and can cause engine to seize up
because of heat surge.
NOTE: Check the engine coolant temperature gauge. If
the gauge pointer moves into the red zone, the HAOD350L
engine coolant temperature warning light will Figure 48
turn "ON", a warning buzzer will sound, and the
engine speed will be automatically reduced.
Allow the engine to run at "LOW IDLE" until
temperature gauge registers in the white zone
again. When the white zone is reached, allow
the engine to idle for an additional three - five
minutes before stopping the engine. If not
allowed to idle, heat surge may develop which
will damage the engine. Allowing the engine to
idle will dissipate heat. Check the coolant level,
look for a loose fan belt, inspect for debris
around radiator, etc.
When the temperature reaches the normal
range, the engine speed will automatically
recover.
DL200/DX200TC Operating Controls
2-25
--- Page 11 ---
CAUTION
AVOID INJURY
The washer pump can be damaged if it is activated
while there is no fluid in the tank.
The fluid level must be checked regularly and refilled
as necessary.
Using soap or other solvents instead of the
recommended washer can damage the wiper blades
and the paint finish. Only use the recommended
washer fluid or equivalent.
11. Pilot Cutoff Switch
O. In this position the operator cannot operate the pilot
control valve lever (joystick).
I. In this position the operator can fully control the O
movement of the pilot control valve lever (joystick).
I
CAUTION
HBOI110L
AVOID INJURY
Figure 71
When driving or parking, the pilot cutoff switch must
be changed to "O" (OFF) position.
12. Parking Brake switch
This switch is used to park the machine.
O. In this position, parking brake is "RELEASED" and
the monitor light on the front display monitor turns
O
P
"OFF".
I. In this position, parking brake is "APPLIED" and the I
monitor light on the front display monitor turns "ON".
NOTE: If parking brake is released, the engine can not
be started. To start the engine, engage parking
HA0O2019
brake first.
Figure 72
NOTE: When starting the engine parking brake is
engaged automatically.
To release parking brake, turn parking brake
switch "ON" then "OFF" once more although
parking brake may look not to be engaged
DL200/DX200TC Operating Controls
2-35
--- Page 12 ---
8. Fuse Box
The fuse box is on the upper side of electric box. For a
detailed explanation of fuses see “Fuse Box/Relay/Engine
Emergency Stop Switch” on page 2-57.
FG003959
Figure 94
DL200/DX200TC Operating Controls
2-45
--- Page 13 ---
DOOR SIDE LATCH
1. Door side latches (1. LH, Figure 111) and (2. RH, Figure
112) are used to secured the doors (RH, LH) to the side of
the cabin when they are opened.
NOTE: Keep the door closed and locked when machine
is not in use.
1
FG003894
Figure 111
2
FG003895
Figure 112
2. The RH side door, which is emergency exit from the cabin,
can be opened in two positions.
Position 1. (ventilation position) A
• Open the window and secured it with the lock bar. (A,
Figure 113)
Position 2. (full opened position)
• Open the window and push it to backward
FG003896
Figure 113
3. To release doors from both sides of the cabin. Pull the
handles (Figure 114) in the direction of arrows. The
handles are located on both sides of the operator's seat.
FG003897
Figure 114
DL200/DX200TC Operating Controls
2-55
--- Page 14 ---
4. Set pilot cutoff switch to "O" (LOCK) position. This will
"LOCK" pilot control valve lever (joystick).
O
I
HBOI111L
Figure 4
5. Set reverse fan switch to "O" (OFF) position. This will
prevent damage to the cooling system during normal
operation.
O
I
HAAH0040
Figure 5
6. Rotate starter key to "I" (ON) position. All indicator lights
should turn "ON".
O I
NOTE: If unit is equipped with and emergency steering
system. Test system before starting engine. If
system does not function properly, do not start
unit. Follow test procedure given with test
switch.
FG000084
Figure 6
7. Rotate starter key to "START" position. Starter motor
should crank immediately, and engine should start within a
few seconds.
O I
FG000085
Figure 7
DL200/DX200TC Operation
3-3
--- Page 16 ---
7. Place transmission lever in desired gear. Shift gears one
by one. Do not skip from 1st to 3rd, for example.
8. Shift transmission lever to "FORWARD" position.
FG003979
Figure 30
9. Release the brake pedal while slowly pressing the
accelerator pedal.
WARNING
AVOID DEATH OR SERIOUS INJURY
When traveling at high speed or on a steep hill, do not
make sharp changes in direction. This could cause
vehicle to overturn. FG003980
When traveling or changing direction, always look Figure 31
carefully to be certain that no one is in path of vehicle.
DL200/DX200TC Operation
3-13
--- Page 17 ---
5. Always keep the fuel tank fully filled after completion of the
operation. Always drain water from the fuel tank before and
after the operation. In addition, check the water separator,
and drain it if required. The fuel filter, if frozen, may
interrupt the flow of fuel. Periodically remove water from
the fuel tank, drain water from the filter, and replace the
filter upon regular basis. To prevent fuel from being
clogged due to formation of wax in fuel, make sure that
wax formation point of fuel is lower than atmospheric
temperature.
WARNING
AVOID DEATH OR SERIOUS INJURY
Explosion of the fuel tank may cause serious injury or
death. Never attempt to directly heat the fuel tank with
open fire.
6. Lubricate entire machine according to Periodic Service
Table and Chart Section 4, in this manual, or lubrication
chart on machine.
7. Start engine and allow it to reach normal operating
temperature before operating.
• If mud and ice collects and freezes on any of moving
parts while machine is idle, apply heat to thaw frozen
material before attempting to operate machine.
• Operate hydraulic units with care until they have
reached a temperature which enable them to operate
normally.
• Check all machine controls and functions to be sure
they are operating correctly.
8. At an oil temperature in the shifting circuit < -12°C, the
transmission must be warmed-up for some minutes (about
5 min).
This must be carried out in neutral with an increased
engine speed (about 1,500 min).
Until this oil temperature is reached, the electronics
remains in neutral, and the symbol of the cold start phase
will be indicated on ZF-display.
Indication on the display: **
After the indication on the ZF-display is extinguished, the
full driving program can be utilized out of "NEUTRAL".
9. An extra outer air filter must be kept in operator's cabin to
replace filter that could become iced and cause restricted
airflow to engine.
10. Clean off all mud, snow and ice to prevent freezing. Cover
machine with a tarp if possible and keep ends of tarp from
freezing to ground.
DL200/DX200TC Operation
3-23
--- Page 18 ---
• The installation of two-way radio, lever steering or similar
equipment must be carried out by a skilled person, as
faulty installation can cause interference with the electronic
components controlling vital machine functions.
• When carrying out service work below raised lifting arm
system, the lifting arms must first have been secured
(lifting arm support). In addition the control lever lockout
and the parking brake must be applied.
• Take care when changing oil in engine, hydraulic system
or transmission as the oil may be hot and cause burns.
• When emptying/draining oil or fuel, use a pump or a hose
and collect the liquids in a suitable vessel. Spillage will
damage the environment and can cause a fire. Waste oil
and other contaminating liquids must be taken care of by a
firm especially authorized to carry out such work.
• When operating in an area which is contaminated or
dangerous to one's health, the machine must be especially
equipped for this purpose. Special local safety regulations
apply within such areas and also when servicing the
machine.
• Stop engine before opening engine covers etc. Make sure
that no tools or other objects, which can cause damage,
have been forgotten in or on the machine.
• Check that the equipment you are using for lifting or
supporting parts of the machine, e.g. straps, slings, ratchet
blocks and ground support, can safely cope with the strain
they are exposed to and meet applicable regulations.
• Release the pressure in pressure vessels, components
and systems carefully and in the prescribed way, so that
the excess pressure is released without risk.
• When connecting hydraulic hoses, check that the desired
effect has been achieved, that is, check that the hydraulic
function operates in the expected way.
• Hoses, pipes and quick-connect couplings may be
pressurized even if the machine is stationary and the
engine turned "OFF". Such pipes and hoses should
therefore only be disconnected by trained personnel.
• When looking for leaks, use a piece of paper or wood, not
your hand.
DL200/DL200TC Inspection, Maintenance and Adjustment
4-7
--- Page 19 ---
• Vehicles which are prone to high levels of ingested water in
the axle, or water as a result of condensation, should not
use extended drain intervals.
• Severe applications* - 85W140 or 80W140 lubricants that
meet the requirements of API GL-5 or MIL-PRF-2105E.
Before using a synthetic lubricant in severe applications,
the customer must check with the lubricant supplier on the
issue of high-pressure lubricant applications.
• Vehicle warm-up procedure should be utilized when
machine is at temperatures lower than oil operating range.
• Friction modifiers for Posi-torq (limited slip) differentials
can be used to minimize operational noise or in liquid-
cooled brakes to reduce brake noise. 2% to 5% by weight
is recommended.
DANGER
AVOID DEATH
After the additives are placed into the oil, verify
service brake and parking brake performance after a
few hours of work. Also verify brake noise has been
eliminated. If brake performance is insufficient or
noise is still occurring, flush with washing oil, refill
with new oil, and check again.
• It is important to consult the applicable axle Service
Manual as it may have unique lubrication requirements not
outlined in this bulletin.
DL200/DL200TC Inspection, Maintenance and Adjustment
4-17
--- Page 20 ---
Check Transmission Oil Level
NOTE: When checking level using a dipstick always remove
and wipe it clean before making final level check.
1. Use two people to perform this operation.
2. Start machine and drive it until transmission fluid has
warmed to 80°C (176°F). Park machine on firm and level
ground. Lower bucket or work tool to ground.
3. Place transmission lever in "NEUTRAL". Apply parking
brake. Stop engine. FG008085
Figure 16
4. Block tires. Once tires are blocked, start engine and have a
person remain in the cabin.
5. Allow engine to idle until transmission temperature is to
80°C (176°F).
6. Remove transmission dipstick (Figure 17). Wipe dipstick
clean and then insert it back into transmission.
7. Remove dipstick and check oil level mark. Oil level must be
between "LOW" and "FULL" marks.
8. To add oil, remove transmission fill cap (Figure 16) from
transmission oil filter pipe.
9. Stop engine when done.
HAOC280L
Figure 17
Check Hydraulic System Oil Level
WARNING
AVOID DEATH OR SERIOUS INJURY
The hydraulic oil will be hot after normal machine
operation. Allow system to cool before attempting to
service any of the hydraulic components.
HAOA060L
The hydraulic tank is pressurized. Turn breather cap slowly
Figure 18
to allow pressurized air to vent. After the pressure has been
released, it is safe to remove either the fill cap or service
covers.
DL200/DL200TC Inspection, Maintenance and Adjustment
4-27
--- Page 21 ---
C. Bucket cylinder rod end, 1 location. (Figure 39).
FG006252
Figure 39
D. Lift cylinder heads (left, right), 2 locations (Figure 40).
FG006253
Figure 40
Lift cylinder rod ends, 2 locations. (Figure 41).
FG006254
Figure 41
E. Remote location points.
Remote fittings for bucket cylinder head (50 HOUR),
(1, Figure 42).
Remote fittings for loader arm foot end (50 HOUR),
(2, Figure 42).
1
2
FG006255
Figure42
DL200/DL200TC Inspection, Maintenance and Adjustment
4-37
--- Page 22 ---
9. Stop engine. Remove key.
If the machine moved during the test, contact your dealer for a
brake inspection. Make any necessary repairs before the
machine is returned to operation.
Parking Brake Test
Refer to the Operation & Maintenance Manual, "Operating
Controls" section for more information.
1. Start the engine.
2. Attach the heaviest approved attachment. If using a
bucket, fill the bucket with material. DO NOT exceed the
rated operating load of the wheel loader.
3. Move the machine to an area with a dry, hard surface with
a slope equivalent to the maximum authorized slope on the
work site where the machine will be operated.
WARNING
AVOID DEATH OR SERIOUS INJURY
• Keep the heavy end of the machine uphill.
• Do not travel on slopes greater than 30 degrees.
• Do not exceed Rated Operating Capacity (ROC).
• Check for adequate traction.
4. Drive the wheel loader up the incline with the heavy end of
the machine facing uphill. (Figure 64)
WL1400681
Figure 64
5. Apply the service brake. (Figure 65)
WL1400677
Figure 65
DL200/DL200TC Inspection, Maintenance and Adjustment
4-47
--- Page 23 ---
Clean Air Conditioner Inner Filter
This unit is equipped with an air-conditioning system. There are
two filters (1 and 2, Figure 91) 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.
1. Open access cover on the lower right side of cabin on the
outside to gain access filter.
2. Remove filter (2, Figure 91) and inspect it for damage.
3. Use compressed air to clean filter. If element is very dirty
use a mild soap and water solution to clean it.
NOTE: Clean air-conditioning filter every 500 hours and
replace with a new one every 1,000 hours of service.
NOTE: If water was used to clean filter be sure it is
completely dry before installation.
NOTE: In the event that the unit it being operated in a dusty
environment, the cleaning and replacement
must be performed more frequently if filter is
damaged, replace damaged with a new one.
1 2
FG003904
WARNING Figure 91
AVOID DEATH OR SERIOUS INJURY
All service and inspection of the air-conditioning