Doosan dl220 wheel loader service repair manual
- 1. 950106-00118E Shop Manual Copyright 2010 Doosan DOOSAN reserves the right to improve our products in a continuing process to provide the best possible product to the market place. These improvements can be implemented at any time with no obligation to change materials on previously sold products. It is recommended that consumers periodically contact their distributors for recent documentation on purchased equipment. This documentation may include attachments and optional equipment that is not available in your machine's package. Please call your distributor for additional items that you may require. Illustrations used throughout this manual are used only as a representation of the actual piece of equipment, and may vary from the actual item. Shop Manual 950106-00118E Serial Number 5001 and Up DL220
- 2. Table of Contents Page I 1Table of Contents Safety Wheel Loader Safety ............................................................................ SP002050 Specifications Specification for DL220......................................................................... SP002051 General Maintenance General Maintenance Procedures........................................................ SP001055 Standard Torques................................................................................. SP000813 Drive Train Transmission and Torque Converter .................................................... SP001594 Transmission Error Codes (ZF) ............................................................ SP001056 Axle....................................................................................................... SP002052 Drive Shaft............................................................................................ SP001596 Brake Service Brake ....................................................................................... SP001080 Brake Supply Valve .............................................................................. SP002053 Parking Brake ....................................................................................... SP001082 Brake Pedal Valve ................................................................................ SP001083 Accumulator.......................................................................................... SP002056 Steering Steering ................................................................................................ SP002064 Cushion Valve....................................................................................... SP000328 Emergency Steering ............................................................................. SP002054
- 3. Table of Contents Page II Frame Articulation Center ................................................................................ SP002055 Counterweight....................................................................................... SP000130 Tank Oil Tank ................................................................................................ SP002057 Fuel Tank.............................................................................................. SP002065 Hydraulics Cylinders............................................................................................... SP001027 Main Pump............................................................................................ SP001212 Main Control Valve ............................................................................... SP001600 Load Isolation System .......................................................................... SP002062 Cooling System..................................................................................... SP002063 Pilot System.......................................................................................... SP002058 Hydraulic Schematic DL220 ................................................................. SP002059 Electrical System Air Conditioner...................................................................................... SP001211 Electrical System .................................................................................. SP002060 Electrical Schematic DL220.................................................................. SP002061
- 4. SP002050 Page 1 Wheel Loader Safety SP002050 WHEEL LOADER SAFETYSP002050 Wheel Loader Safety Edition 1
- 5. SP002050 Page 3 Wheel Loader Safety Table of Contents Wheel Loader Safety Safety Precautions ............................................... 5 Applicable Models ................................................ 5 To the Operator of a Wheel Loader...................... 6 General Safety Essentials .................................... 9 Location of Safety Labels ..................................... 9 Visibility Information............................................ 10 Unauthorized Modifications ................................ 12 General Hazard Information ............................... 12 Before Starting Engine ....................................... 20 Machine Operation ............................................. 24 Maintenance ....................................................... 32 Battery ................................................................ 41 Towing ................................................................ 43 Shipping and Transportation .............................. 44
- 6. SP002050 Page 5 Wheel Loader Safety SAFETY PRECAUTIONS APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. CAUTION Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that are in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. MODEL SERIAL NUMBER RANGE DL200 5001 and Up DL220 5001 and Up DL250 5001 and Up DL300 5001 and Up DL350 5001 and Up DL400 5001 and Up DL450 5001 and Up DL500 5001 and Up
- 7. SP002050Wheel Loader Safety Page 6 TO THE OPERATOR OF A WHEEL LOADER Please respect the importance of taking responsibility for your own safety, and that other people who may be affected by your actions. Safety information on the following pages is organized into the following topics. 1. “General Safety Essentials” on page 1-9. 2. “Location of Safety Labels” on page 1-9. 3. “Unauthorized Modifications” on page 1-12. 4. “General Hazard Information” on page 1-12. 5. “Before Starting Engine” on page 1-20. 6. “Machine Operation” on page 1-24. 7. “Maintenance” on page 1-32. 8. “Battery” on page 1-41. 9. “Towing” on page 1-43. 10. “Shipping and Transportation” on page 1-44. DANGER Unsafe use of the wheel loader could lead to serious injury or death. Operating procedures, maintenance and equipment practices or traveling or shipping methods that do not follow the safety guidelines on the following pages could cause serious, potentially fatal injuries or extensive damage to the machine or nearby property.
- 8. SP002050 Page 7 Wheel Loader Safety WARNING Improper operation and maintenance of this machine can be hazardous and could result in serious injury or death. Operator and maintenance personnel should read this manual thoroughly before beginning operation or maintenance. Keep this manual in the storage compartment to the rear of the operator's seat, and have all personnel involved in working on the machine periodically read the manual. Some actions involved in operation and maintenance of the machine can cause a serious accident, if they are not done in a manner described in this manual. The procedures and precautions given in this manual apply only to intended uses of the machine. If you use your machine for any unintended uses that are not specifically prohibited, you must be sure that it is safe for any others. In no event should you or others engage in prohibited uses or actions as described in this manual. DOOSAN delivers machines that comply with all applicable regulations and standards of the country to which it has been sent. If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety devices and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regulations of your country, consult DOOSAN or your DOOSAN distributor before operating the machine. SAFETY ALERT SYMBOL Be Prepared - Get to Know All Operating and Safety Instructions. This is the Safety Alert Symbol. Wherever it appears in this manual or on safety signs on the machine you should be alert to the potential for personal injury or accidents. Always observe safety precautions and follow recommended procedures.
- 9. SP002050Wheel Loader Safety Page 8 Learn the Signal Words Used with the Safety Alert Symbol The words "CAUTION", "WARNING", and "DANGER" used throughout this manual and on decals on the machine indicate degree of risk of hazards or unsafe practices. All three degrees of risk indicate that safety is involved. Observe precautions indicated whenever you see the Safety Alert "Triangle", no matter which signal word appears next to the "Exclamation Point" symbol. Safety precautions are described in SAFETY from page -9 on. DOOSAN cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore the safety messages in this manual and on the machine may not include all possible safety precautions. If any procedures or actions not specifically recommended or allowed in this manual are used, you must be sure that you and others can do such procedures and actions safely and without damaging the machine. If you are unsure about the safety of any procedures, contact a DOOSAN distributor. CAUTION This word is used on safety messages and safety labels and indicates potential of a hazardous situation that, if not avoided, could result in minor or moderate injury. It may also be used to alert against a generally unsafe practice. WARNING This word is used on safety messages and safety labels and indicates potential threat of a hazardous situation that, if not avoided, could result in serious injury or death. It may also be used to alert against highly unsafe practice. DANGER This word is used on safety messages and safety labels and indicates an imminent hazard of a situation that, if not avoided, is very likely to cause death or extremely serious injury. It may also be used to alert against equipment that may detonate or explode if handled or treated carelessly.
- 10. SP002050 Page 9 Wheel Loader Safety GENERAL SAFETY ESSENTIALS Accessory Applications This wheel loader has been designed primarily for moving earth with a bucket. For use as a grapple or for other object handling, contact DOOSAN. Lifting-work applications are permitted in approved lift configuration, to rated capacity only, with no side-loading (unless prohibited by local regulation). Do not use machine for activities for which it was not intended. Do not use bucket for lifting work, unless lift slings are used in approved configuration. LOCATION OF SAFETY LABELS Location of safety labels (decals) can vary from unit to unit. Refer to appropriate Operation and Maintenance Manual, and Parts Manual for your unit. There are several specific warning signs on this machine. The exact location of hazards and the description of the hazards are reviewed in the appropriate Operation and Maintenance Manual. Please become familiarized with all warning signs. Make sure that all the warning signs are legible. Clean the warning signs or replace the warning signs if you cannot read the words. Replace the illustrations if the illustrations are not visible. When you clean the warning signs, use a cloth, water and soap. Do not use solvent, gasoline, or other harsh chemicals to clean the safety signs. Solvents, gasoline, or other harsh chemicals could loosen the adhesive that secures the warning sign. Loose adhesive will allow the warning sign to fall off. Replace any safety sign that is damaged, or missing. If a safety sign is attached to a part that is replaced, install a safety sign on the replacement part.
- 11. SP002050Wheel Loader Safety Page 10 VISIBILITY INFORMATION A rear view camera and mirrors ensure that visibility around the machine, from the operator's seat, meets the latest ISO standards for the region or marketplace that machine is sold into. NOTE: These devices may vary from one region to another, depending upon local and regional regulations. If a machine is moved or sold into another region or marketplace, it is the owner's responsibility to make sure it complies with all regulations. Your machine may be equipped with visual aids; mirrors or cameras, but even with these aids, there still may be blind spots which cannot be seen from the operator's seat, so always be careful when operating. Adjust the visual aids for the best visibility criteria for all areas around the machine. When swinging or backing up, press button to change display mode on monitor so you can check rear and side of machine. Before moving the machine, look around the work site through mirrors and monitor to confirm that no one is around the machine. FG015658 1 1 1. Mirror Figure 1 WARNING Failure to check for and clear people from the surrounding area of a machine could result in serious injury or death. The operator should make sure that visual aids (mirrors and camera (s)) are in proper working condition. Look for any possible blind spots.
- 12. SP002050 Page 11 Wheel Loader Safety While operating or traveling in places with poor visibility, and if it is impossible to confirm the condition of the work site, or if an obstacle is in the area around the machine, there can be a danger that machine may suffer damage or operator or others may suffer serious personal injury. Inspect equipment and immediately report if there are problems with the visual aids. If machine cannot be fixed immediately, DO NOT use the machine. Contact your local DOOSAN distributor as soon as possible and ask for repairs. Guidelines • If the visibility cannot be sufficiently assured, use a flagman. The operator should pay careful attention to the signals and follow the instructions of the flagman. • Signals should only be given by one flagman. • When working in dark places, turn "ON" work lights and front lights on the machine. Set up additional lighting in the area. • Stop operations if there is poor visibility, such as fog, snow, rain, or sandstorms. • Check mirrors and rear view camera (optional) lens on machine before starting operations. Clean off any dirt and adjust view to ensure good visibility. When operating or traveling during poor visibility conditions, and especially in a large machine, strictly adhere to the above guidelines. NOTE: Refer to ISO 5006 for additional guidelines and information. It may not be possible to adjust all visual aids to see all the way around the machine. Therefore, additional precautions must be taken to ensure the safe operation of the machine. NOTE: Larger machines are more likely to have blind spots. NOTE: Refer to ISO 5006 for weight class information.
- 13. SP002050Wheel Loader Safety Page 12 UNAUTHORIZED MODIFICATIONS Any modification made without authorization or written approval from DOOSAN can create a safety hazard, for which the machine owner will be held responsible. For safety's sake, replace all OEM parts with the correct authorized or genuine DOOSAN part. For example, not taking the time to replace fasteners, bolts or nuts with the correct replacement parts could lead to a condition where the safety of critical assemblies are dangerously compromised. GENERAL HAZARD INFORMATION Safety Rules Only trained and authorized personnel can operate and maintain the machine. Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine. Do not operate the machine if you are not feeling well, if you are taking medication that makes you feel sleepy, if you have been drinking, or if you are suffering from emotional problems. These problems will interfere with your sense of judgment in emergencies and may cause accidents. When working with another operator or with a person on work site traffic duty, be sure that all personnel know the nature of the work and understand all hand signals that are to be used. Always observe strictly any other rules related to safety. Safety Features Be sure that all guards and covers are installed in their proper position. Have guards and covers repaired immediately if damaged. Be sure that you understand the method of use of safety features such as transmission lever neutral lock and the seat belt, and use them properly. Never remove any safety features. Always keep them in good operating condition. Failure to use safety features according to the instructions in the Operation and Maintenance Manual could result in serious bodily injury.
- 14. SP002050 Page 13 Wheel Loader Safety Inside Operator's Cabin When entering the operator's cabin, always remove all mud and oil from the soles of your shoes. If you operate the accelerator and brake pedals with mud or oil stuck to your shoes, your foot may slip and this may cause a serious accident. Clean grease and dirt from pedals and controls. This contributes to safe operation. Cleaning also provides an opportunity to inspect equipment. Minor damage can be repaired or corrected before major problems result. Keep cab floor and consoles free of tools and personal items. After using the ashtray, make sure that any matches or cigarettes are properly extinguished, and be sure to close the ashtray. If the ashtray is left open, there is a danger of fire. Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire. Do not leave lighters laying around the operator's cabin. If the temperature inside the operator's cabin becomes high, there is a danger that the lighter may explode. Do not use cellular telephones inside the operator's cabin when driving or operating the machine. There is a danger that this may lead to an unexpected accident. Never bring any dangerous objects such as flammable or explosive items into the operator's cabin. To ensure safety, do not use the radio or music headphones when operating the machine. There is a danger that this may lead to a serious accident. When operating the machine, do not put your hands or head out of the window. When standing up from the operator's seat, always place transmission neutral lock lever in the "LOCK" position and set pilot cutoff switch to "O" (OFF) position. If you accidentally touch the work equipment levers when they are not locked, the machine may suddenly move and cause serious injury or damage. When leaving the machine, lower the work equipment completely to the ground, set transmission neutral lock lever in the "LOCK" position, set pilot cutoff switch to "O" (OFF) position, "APPLY" parking brake, and shut down engine. Use the key to lock all the equipment. Always remove key and take it with you.
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- 16. SP002050Wheel Loader Safety Page 14 Clothing and Personal Protective Items Secure long hair, and avoid loose clothing and jewelry. These items have the tendency to catch on controls or protrude into parts and cause serious injury or death. Do not wear oily clothes. They are highly flammable. Full eye protection, a hard hat, safety shoes and gloves may be required at the work site. While working on the machine, never use inadequate tools. They could break or slip, causing injury, or they may not adequately perform intended functions. Breathing Masks, Ear Protection May Be Required Do not forget that some risks to your health may not be immediately apparent. Exhaust gases and noise pollution may not be visible, but these hazards can cause disabling or permanent injuries. NOTE: The equivalent continuous A-weighted sound pressure level at the workstation for this machine is given in the operation manual. Measurement is obtained on a dynamic machine following the procedures and cab conditions as described in ISO 6396. NOTE: The guaranteed sound power level emitted by the machinery for this machine is given in the operation manual. Measurement is obtained on a dynamic machine with the procedures as described in 2000/14/EC. Vibration Level Information Hands/Arms: The weighted root mean square acceleration to which the hands/arms are subjected, is less than 2.5 m/s2. Whole body: The weighted root mean square acceleration to which the whole body is subjected, is less than 0.5 m/s2. Measurements are obtained on a representative machine, using measuring procedures as described in the following standard: ISO 2631/1. ISO 5349, and SAE J1166. HAOA020L Figure 2
- 17. SP002050 Page 15 Wheel Loader Safety Asbestos Dust Hazard Prevention Asbestos dust can be HAZARDOUS to your health if it is inhaled. Materials containing asbestos fiber can be present on work site. Breathing air that contains asbestos fiber can ultimately cause serious or fatal lung damage. To prevent lung damage from asbestos fiber, observe following precautions: • Use a respirator that is approved for use in an asbestos-laden atmosphere. • Never use compressed air for cleaning. • Use water for cleaning to keep down the dust. • Work on the machine or component with the wind at your back whenever possible. • Always observe any regulations related to the work site and working environment. Mounting and Dismounting Before getting on or off the machine, if there is any oil, grease, or mud on the handrails, steps, or track shoes, wipe it off immediately. Always keep these parts clean. Repair any damage and tighten any loose bolts. Never get on or off a moving machine. In particular, never get on or off a moving machine. These actions may lead to serious injury. When getting on or off the machine, always face the machine, and maintain a three-point contact (both feet and one hand or one foot and both hands) with the handholds and steps to ensure that you support yourself securely. Never hold any control levers when getting on or off the machine. Never get up from operator's seat or leave operator's station and dismount machine if engine is running. ARO1770L Figure 3 HA3O1003 Figure 4
- 18. SP002050Wheel Loader Safety Page 16 Fuel, Oil and Hydraulic Fluid Fire Hazards Fuel, oil and antifreeze will catch fire if it is brought close to a flame. Fuel is particularly flammable and can be hazardous. Always strictly observe the following. Add fuel, oil, antifreeze and hydraulic fluid to the machine only in a well ventilated area. The machine must be parked with controls, lights and switches turned "OFF". The engine must be "OFF" and any flames, glowing embers, auxiliary heating units or spark causing equipment must be extinguished, turned "OFF" and/or kept well clear of the machine. Static electricity can produce dangerous sparks at the fuel filling nozzle. In very cold, dry weather or other conditions that could produce a static discharge, keep the tip of the fuel nozzle in constant contact with the neck of the fuel filling nozzle, to provide a ground. Keep fuel and other fluid reservoir caps tight and do not start the engine until caps have been secured. Precautions When Handling Fluids at High Temperature Immediately after operations are stopped, the coolant, engine oil, and hydraulic oil are at highest temperatures and the radiator and hydraulic tank are still under pressure. Attempting to remove cap, drain the oil or coolant, or replace the filters may lead to serious burns. Always wait for the temperature to go down, and follow the specified procedures when carrying out these operations. To prevent hot coolant from spurting out, shut down engine, wait for the coolant to cool, then loosen the cap slowly to relieve the pressure. To prevent hot oil from spurting out, shut down engine, wait for the oil to cool, then loosen the cap slowly to relieve the pressure. Figure 5 HAOA050L Figure 6 HAOA060L Figure 7