Daewoo Doosan DL220-3 WAYN (NEW YORK BID-21CL) Operation & Maintenance Manual – PDF DOWNLOAD
DESCRIPTION:
Daewoo Doosan DL220-3 WAYN (NEW YORK BID-21CL) Operation & Maintenance Manual – PDF DOWNLOAD
DL220-3 WAYN (NEW YORK BID-21CL)
Serial Number 10001 and Up
Serial Number 10001 and Up
950106-00988NAWAYN
December 2013
December 2013
Power Transmission:
- The transmission is electro hydraulically controlled, where all gears are in constant mesh.
- The gear ranges are achieved by applying different combinations of clutches.
- Between the engine and transmission gears there is a hydraulic torque converter, which controls the output torque.
- The front and rear axles have planetary gears in the wheel hubs and this reduces the stress on the respective driveshafts.
- The axle’s differentials use a LSD (Limited Slip Differential) design or DHL (Differential Hydraulic Lock) design (optional).
Brake System:
- The machine is provided with a dual circuit, all hydraulic, brake system with one circuit for each axle.
- Each circuit meets the requirements for secondary brake capability.
Parking Brake:
- The parking brake is a dry disk brake built into the transmission output shaft.
- The brake is applied by spring force and is released hydraulically.
Power Steering System:
- The machine uses a load sensing, hydraulic power steering system.
- It has a steering arc of 40°.
Cabin:
- The cabin has a heating and ventilation system with defrosting for front and rear windows.
- Air-conditioning is standard. The cabin has two emergency exits, the door and right side window.
FOPS and ROPS:
- The cabin is approved as a protective cabin according to FOPS and ROPS standards.
- FOPS is an abbreviation of Falling Object Protective Structure (overhead protection) and ROPS is an abbreviation of Rollover Protective Structure (rollover protection) for a seat belted operator.
- Never perform any unauthorized alterations to the cabin, e.g. lowering the roof height, drilling, welding on brackets for fire extinguisher, radio aerial or other equipment, without Doosan approval.
Hydraulic System:
- The hydraulic system is load sensing with piston pumps.
- Working and steering system is composed of integrated hydraulic line using priority valve.
- However, brake, pilot and fan systems are controlled by one piston pump.
Equipment (Optional):
- The machine can be provided with different types of optional equipment, depending on the requirements of different markets.
- Examples of such equipment are lever steering, Boom Suspension System (LIS), secondary steering, separate attachment locking, automatic greasing.
TABLE OF CONTENTS:
Daewoo Doosan DL220-3 WAYN (NEW YORK BID-21CL) Operation & Maintenance Manual – PDF DOWNLOAD
Foreword…………………………………………………………………………..1-I
CE Marking, EMC Directive …………………………………………………….. 1-III
Communication Equipment Installation………………………………………1-IV
Product Plates…………………………………………………………………………1-V
Safety Messages ……………………………………………………………………1-VI
AEM Safety Manual
(North America Only) ……………………………………………………………..1-VII
Federal Emission Control Systems………………………………………….1-VIII
Safety ………………………………………………………………………………1-1
Safety Decals…………………………………………………………………………. 1-2
General ……………………………………………………………………………….. 1-19
Transportation ………………………………………………………………………. 1-30
Operation …………………………………………………………………………….. 1-32
Maintenance ………………………………………………………………………… 1-50
Environment and Circumstances …………………………………………….. 1-66
Operating Controls …………………………………………………………..2-1
Component Locations……………………………………………………………… 2-2
Operator’s Area………………………………………………………………………. 2-4
Steering Console and Pedals …………………………………………………… 2-5
Gauges ……………………………………………………………………………….. 2-15
Quick Coupler Key Switch………………………………………………………. 2-18
Front Instrument Panel…………………………………………………………… 2-19
Multifunction Gauge and Graphic Information Display………………… 2-24
Right Side Switch Panel…………………………………………………………. 2-53
Various Cabin Locations ………………………………………………………… 2-64
Heater and Air Conditioner Operation………………………………………. 2-71
CE Marking, EMC Directive …………………………………………………….. 1-III
Communication Equipment Installation………………………………………1-IV
Product Plates…………………………………………………………………………1-V
Safety Messages ……………………………………………………………………1-VI
AEM Safety Manual
(North America Only) ……………………………………………………………..1-VII
Federal Emission Control Systems………………………………………….1-VIII
Safety ………………………………………………………………………………1-1
Safety Decals…………………………………………………………………………. 1-2
General ……………………………………………………………………………….. 1-19
Transportation ………………………………………………………………………. 1-30
Operation …………………………………………………………………………….. 1-32
Maintenance ………………………………………………………………………… 1-50
Environment and Circumstances …………………………………………….. 1-66
Operating Controls …………………………………………………………..2-1
Component Locations……………………………………………………………… 2-2
Operator’s Area………………………………………………………………………. 2-4
Steering Console and Pedals …………………………………………………… 2-5
Gauges ……………………………………………………………………………….. 2-15
Quick Coupler Key Switch………………………………………………………. 2-18
Front Instrument Panel…………………………………………………………… 2-19
Multifunction Gauge and Graphic Information Display………………… 2-24
Right Side Switch Panel…………………………………………………………. 2-53
Various Cabin Locations ………………………………………………………… 2-64
Heater and Air Conditioner Operation………………………………………. 2-71
Stereo/CD Player (Optional) …………………………………………………… 2-77
Seat Adjustment Mechanical Suspension (Standard)………………… 2-78
Seat Belt ……………………………………………………………………………… 2-81
Door Side Latch ……………………………………………………………………. 2-82
Arm Rest……………………………………………………………………………… 2-83
Fuse Box/Relay…………………………………………………………………….. 2-84
Electrical System Master Switch……………………………………………… 2-86
Engine Block Heater ……………………………………………………………… 2-87
Operation…………………………………………………………………………3-1
To Operate a New Wheel Loader………………………………………………. 3-1
Starting and Stopping Engine …………………………………………………… 3-2
Machine Travel ……………………………………………………………………… 3-23
If Engine Stalls While Traveling……………………………………………….. 3-25
Working in Water…………………………………………………………………… 3-26
Towing…………………………………………………………………………………. 3-27
Machine Shut Down………………………………………………………………. 3-34
Operation of Attachment ………………………………………………………… 3-36
Boom Raise Kick-out …………………………………………………………….. 3-36
Bucket Angle Indicator …………………………………………………………… 3-37
Adjustment of Bucket Position Switch………………………………………. 3-38
Operation Under Abnormal Conditions…………………………………….. 3-39
Long Term Storage ……………………………………………………………….. 3-44
Inspection, Maintenance and Adjustment………………………….4-1
Maintenance Information …………………………………………………………. 4-1
Machine Setup Position for Maintenance……………………………………. 4-5
Maintenance Handling Access………………………………………………….. 4-7
Handling Oil, Fuel, Coolant …………………………………………………….. 4-10
Electrical System Maintenance……………………………………………….. 4-13
Recommend Fuel, Coolant, and Lubricant ……………………………….. 4-15
Preventive Maintenance…………………………………………………………. 4-22
Table of Recommended Lubricants …………………………………………. 4-24
Fluid Capacities ……………………………………………………………………. 4-28
Lubrication and Service Chart ………………………………………………… 4-29
Maintenance Intervals……………………………………………………………. 4-34
10 Hour / Daily Service ………………………………………………………….. 4-36
50 Hour / Weekly Service ………………………………………………………. 4-44
250 Hour / Monthly Service ……………………………………………………. 4-51
500 Hour / 3 Month Service ……………………………………………………. 4-57
1,000 Hour / 6 Month Service …………………………………………………. 4-62
1,500 Hour / 9 Month Service …………………………………………………. 4-70
2,000 Hour / Yearly Service ……………………………………………………. 4-72
4,500 Hour / Biennial Service …………………………………………………. 4-80
12,000 Hour / 6 Year Service………………………………………………….. 4-81
Standard Bolt Torque Chart ……………………………………………………. 4-82
Electrical System ………………………………………………………………….. 4-83
Engine Cooling System………………………………………………………….. 4-84
Handling of Accumulator………………………………………………………… 4-87
Hydraulic Pressure Checks…………………………………………………….. 4-89
Long Term Storage ……………………………………………………………….. 4-93
Parking Brake Adjustment………………………………………………………. 4-94
Severe Conditions Maintenance ……………………………………………… 4-97
Tires ……………………………………………………………………………………. 4-98
Transportation………………………………………………………………….5-1
Transporting Machine ……………………………………………………………… 5-1
Troubleshooting……………………………………………………………….6-1
Braking………………………………………………………………………………….. 6-1
Electrical System ……………………………………………………………………. 6-2
Engine…………………………………………………………………………………… 6-2
Turbocharger………………………………………………………………………….. 6-6
Hydraulic System ……………………………………………………………………. 6-7
Steering ………………………………………………………………………………… 6-8
Travel System…………………………………………………………………………. 6-9
Specification ……………………………………………………………………7-1
General Specifications …………………………………………………………….. 7-1
Working Range and Dimensions ………………………………………………. 7-2
Working Capacities …………………………………………………………………. 7-4
Approximate Weight of Workload Materials ………………………………… 7-4
Index ……………………………………………………………………………….8-1
Seat Adjustment Mechanical Suspension (Standard)………………… 2-78
Seat Belt ……………………………………………………………………………… 2-81
Door Side Latch ……………………………………………………………………. 2-82
Arm Rest……………………………………………………………………………… 2-83
Fuse Box/Relay…………………………………………………………………….. 2-84
Electrical System Master Switch……………………………………………… 2-86
Engine Block Heater ……………………………………………………………… 2-87
Operation…………………………………………………………………………3-1
To Operate a New Wheel Loader………………………………………………. 3-1
Starting and Stopping Engine …………………………………………………… 3-2
Machine Travel ……………………………………………………………………… 3-23
If Engine Stalls While Traveling……………………………………………….. 3-25
Working in Water…………………………………………………………………… 3-26
Towing…………………………………………………………………………………. 3-27
Machine Shut Down………………………………………………………………. 3-34
Operation of Attachment ………………………………………………………… 3-36
Boom Raise Kick-out …………………………………………………………….. 3-36
Bucket Angle Indicator …………………………………………………………… 3-37
Adjustment of Bucket Position Switch………………………………………. 3-38
Operation Under Abnormal Conditions…………………………………….. 3-39
Long Term Storage ……………………………………………………………….. 3-44
Inspection, Maintenance and Adjustment………………………….4-1
Maintenance Information …………………………………………………………. 4-1
Machine Setup Position for Maintenance……………………………………. 4-5
Maintenance Handling Access………………………………………………….. 4-7
Handling Oil, Fuel, Coolant …………………………………………………….. 4-10
Electrical System Maintenance……………………………………………….. 4-13
Recommend Fuel, Coolant, and Lubricant ……………………………….. 4-15
Preventive Maintenance…………………………………………………………. 4-22
Table of Recommended Lubricants …………………………………………. 4-24
Fluid Capacities ……………………………………………………………………. 4-28
Lubrication and Service Chart ………………………………………………… 4-29
Maintenance Intervals……………………………………………………………. 4-34
10 Hour / Daily Service ………………………………………………………….. 4-36
50 Hour / Weekly Service ………………………………………………………. 4-44
250 Hour / Monthly Service ……………………………………………………. 4-51
500 Hour / 3 Month Service ……………………………………………………. 4-57
1,000 Hour / 6 Month Service …………………………………………………. 4-62
1,500 Hour / 9 Month Service …………………………………………………. 4-70
2,000 Hour / Yearly Service ……………………………………………………. 4-72
4,500 Hour / Biennial Service …………………………………………………. 4-80
12,000 Hour / 6 Year Service………………………………………………….. 4-81
Standard Bolt Torque Chart ……………………………………………………. 4-82
Electrical System ………………………………………………………………….. 4-83
Engine Cooling System………………………………………………………….. 4-84
Handling of Accumulator………………………………………………………… 4-87
Hydraulic Pressure Checks…………………………………………………….. 4-89
Long Term Storage ……………………………………………………………….. 4-93
Parking Brake Adjustment………………………………………………………. 4-94
Severe Conditions Maintenance ……………………………………………… 4-97
Tires ……………………………………………………………………………………. 4-98
Transportation………………………………………………………………….5-1
Transporting Machine ……………………………………………………………… 5-1
Troubleshooting……………………………………………………………….6-1
Braking………………………………………………………………………………….. 6-1
Electrical System ……………………………………………………………………. 6-2
Engine…………………………………………………………………………………… 6-2
Turbocharger………………………………………………………………………….. 6-6
Hydraulic System ……………………………………………………………………. 6-7
Steering ………………………………………………………………………………… 6-8
Travel System…………………………………………………………………………. 6-9
Specification ……………………………………………………………………7-1
General Specifications …………………………………………………………….. 7-1
Working Range and Dimensions ………………………………………………. 7-2
Working Capacities …………………………………………………………………. 7-4
Approximate Weight of Workload Materials ………………………………… 7-4
Index ……………………………………………………………………………….8-1
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