Doosan DL200 - Page 2

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Table of Contents3
Safety13
To the Operator of a Wheel Loader13
General Safety Essentials16
Location of Safety Labels16
Unauthorized Modifications25
General Hazard Information25
Before Starting Engine34
Machine Operation38
Maintenance46
Battery56
Towing58
Shipping and Transportation59
Operating Controls61
Component Locations62
Operator's Area66
Steering Console and Pedals67
Front Instrument Panel76
Right Side Switch Panel87
2Various Cabin Locations102
Various Cabin Locations102
Heater and Air Conditioner Operation106
Stereo / CD Player (Optional)111
Seat Adjustment113
Seat Belt115
Door Side Latch116
Arm Rest117
Fuse Box/Relay/Engine Emergency Stop Switch118
Operation123
Instrument Panel Control Functions123
New Machine Break-In Procedures123
Engine Start and Stop124
Machine Travel133
Machine Shut down136
F/R (Forward/Reverse) Travel Control System (Option)138
Additional Braking139
Boom Raise Kick-Out140
Bucket Angle Indicator140
Boom Lower Kick-Out (Option)141
Adjustment of Bucket Position Switch141
Towing Machine142
If Engine Stalls While Traveling143
Allowable Water Depth144
Inspection, Maintenance and Adjustment145
Basic Preventive Maintenance145
Safety When Servicing148
Preventive Maintenance156
Table of Recommended Lubricants158
Fluid Capacities160
Lubrication and Service Chart161
Maintenance Intervals165
10 Hour / Daily Service167
Grease Front Attachment Pins (for First 100 Hours)167
Inspect All Tires for Correct Tire Pressure and Signs of Damage or Abnormal Wear167
Check Engine Oil Level167
Check Transmission Oil Level168
Check Hydraulic System Oil Level169
Check for Leaks in Hydraulic System170
Fill Fuel Tank170
Check for Leaks in Fuel System171
Drain Fuel Condensation171
Check Coolant Level171
Check Level of Windshield Washer Liquid172
Inspect the Bucket Teeth and Side Cutters for Signs of Wear172
Inspect Seat Belt for Proper Operation172
Inspect the Structure for Cracks and Faulty Welds172
Check the Operation of All Switches172
Check the Operation of All Exterior Lights, Horn and Control Console Indicator and173
Check Operation of All Controls173
Inspect Cooling Fan Blade174
Check Engine Drive Belt Wear174
Check Air Intake System175
50 Hour / Weekly Service176
Perform All Daily, 10 Hour Service Checks176
Grease Front Attachment Pins176
Grease Steering Cylinder Rod and Head Ends183
Grease Upper and Lower Center Pins183
Replace Engine Oil and Filter (after First 50 Hours)184
Replace Hydraulic Full Flow Filter (after First 50 Hours)184
Check Air Conditioner and Alternator Belt Tension (after First 50 Hours)184
Clean Exterior of Radiator, Oil Cooler and Air Conditioner Condenser185
Clean Air Conditioner Outer Filter185
250 Hour / Monthly Service186
Perform All Daily, 10 Hour and 50 Hour Service Checks186
Check Engine Air Intake Precleaner186
Drain Water from Hydraulic Oil Tank186
Turbocharger187
Check Air Conditioner and Alternator Belt Tension187
Grease Drive Shafts188
500 Hour / 3 Month Service191
1,000 Hour / 6 Month Service198
1,500 Hour / 9 Month Service206
2,000 Hour / Yearly Service208
Hour / Six Year Service214
Severe Conditions Maintenance215
Bolt Torque Chart216
Electrical System217
Engine Cooling System219
Handling of Accumulator221
Hydraulic Pressure Checks222
Long Term Storage227
Parking Brake Adjustment228
Tires229
Transportation233
Loading and Unloading233
Summary of Safety Precautions for Lifting234
Troubleshooting235
Engine235
Hydraulic System237
Travel System239
Steering240
Braking241
Electrical System241
Specification243
General Specifications243
Working Range and Dimensions245
Working Capacities249
Approximate Weight of Workload Materials249
Index253

Doosan DL200 - Page 2

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