Doosan DL 300. Operation and Maintenance Manual (2003)

DL 300

Operation and Maintenance Manual

K1010630E

Serial Number 5001 and Up

August 2005

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.

K1010630E Operation and Maintance Manual

Table of Contents

Presentation

I-I

Presentation

I-I

CE Marking, EMC Directive

I-IV

Communication Equipment Installation

I-V

Product Plates

I-VI

Safety

1-1

To the Operator of a DOOSAN Daewoo Wheel Loader

1-1

General Safety Essentials

1-4

Location of Safety Labels

1-4

Unauthorized Modifications

1-13

General Hazard Information

1-13

Before Starting Engine

1-22

Machine Operation

1-26

Maintenance

1-34

Battery

1-45

Towing

1-47

Shipping and Transportation

1-48

Operating Controls

2-1

Component Locations

2-2

Operator's Area

2-4

Steering Console and Pedals

2-5

Front Instrument Panel

2-15

Right Side Switch Panel

2-26

Various Cabin Locations

2-41

Heater and Air Conditioner Operation

2-45

K1010630E

Table of Contents

Stereo / CD Player (Optional)

2-50

Seat Adjustment (Standard)

2-52

Seat Adjustment (Option)

2-54

Seat Belt

2-56

Door Side Latch

2-57

Arm Rest

2-58

Fuse Box/Relay/Engine Emergency Stop Switch

2-59

Operation

3-1

Instrument Panel Control Functions

3-1

New Machine Break-in Procedures

3-1

Engine Start and Stop

3-2

Machine Travel

3-13

Machine Shut Down

3-15

F/R (Forward/Reverse) Travel Control System (Option)

3-18

Additional Braking

3-19

Boom Raise Kick-out

3-19

Bucket Angle Indicator

3-20

Boom Lower Kick-out (Option)

3-21

Adjustment of Bucket Position Switch

3-21

Towing Machine

3-22

If Engine Stalls While Traveling

3-23

Allowable Water Depth

3-24

Inspection, Maintenance and Adjustment

4-1

Basic Preventive Maintenance

4-1

Safety When Servicing

4-4

Preventive Maintenance

4-12

Table of Recommended Lubricants

4-14

Axle Oils DL400, DL300, DL250

4-16

Fluid Capacities

4-19

Lubrication and Service Chart

4-20

Maintenance Intervals

4-24

K1010630E

Table of Contents

10 Hour / Daily Service

4-26

50 Hour / Weekly Service

4-36

250 Hour / Monthly Service

4-43

500 Hour / 3 Month Service

4-48

1,000 Hour / 6 Month Service

4-54

1,500 Hour / 9 Month Service

4-60

2,000 Hour / Yearly Service

4-63

12,000 Hour / Six Year Service

4-68

Severe Conditions Maintenance

4-69

Bolt Torque Chart

4-70

Electrical System

4-71

Engine Cooling System

4-73

Handling of Accumulator

4-75

Hydraulic Pressure Checks

4-76

Long Term Storage

4-81

Parking Brake Adjustment

4-82

Tires

4-84

Transportation

5-1

Loading and Unloading

5-1

Summary of Safety Precautions for Lifting

5-2

Troubleshooting

6-1

Engine

6-1

Hydraulic System

6-3

Travel System

6-5

Steering

6-6

Braking

6-7

Electrical System

6-7

Specification

7-1

General Specifications

7-1

Working Range and Dimensions

7-3

K1010630E

Table of Contents

III

Intended Use

The machine is intended to be used under normal conditions for

the applications described in the Operator's Manual. If it is used

for other purposes or in potentially dangerous environments, for

example explosive atmosphere or areas with dust containing

asbestos, etc., special safety regulations must be followed and

the machine must be equipped for such use. Contact the

manufacturer/dealer for further information.

The machine is designed for a maximum machine weight

(includes. equipment and attachments) of 17,300 kg (38,139 lb)

for DL300. If the maximum weight is exceeded, no warranties on

the part of the manufacturer will apply. However, always pay

attention to national regulations for traveling on public roads.

Engine

DL300 has a DOOSAN DL08 7.64 liter engine. The engine has

intercooling and is fitted with a common rail system. The

common rail system is positioned at an angle above the pistons

and are controlled via the camshaft and a electronic control

module (ECM).

The cylinder head covers all cylinders.

The engine has four valves per cylinder.

The accelerator position is transferred electrically from

accelerator pedal.

Electrical System

The machine has three control units. The Gauge Panel for the

instrumentation is integrated with the display unit, warning lights

and instruments and provides the operator with information via

there. The Control Unit (for the machine) receives signals from

sensors on the machine and these are passed to the Gauge

Panel. The ECU controls the engine.

Power Transmission

The transmission is electrohydraulically 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 strain on

the respective drive shafts. The axles differentials use a LSD

(Limited Slip Differential) design.

Presentation

K1010630E

I-II

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.

Steering System

The machine uses a load sensing, hydrodynamic 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

(roof protection) and ROPS is an

abbreviation of Roll Over Protective Structure

(roll over

protection).

Never carry out 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 first having

discussed the alteration with personnel at the DOOSAN

Infracore Engineering Department. This department will decide

whether the alteration may cause the approval to become void. It

is important that all parties concerned are aware of these

regulations.

Hydraulic System

The hydraulic system is load sensing with pumps in common for

steering systems and the working hydraulics. However, the

brake and steering systems are prioritized by one of the pumps.

Equipment

The machine can be provided with different types of optional

equipment, depending on the requirements of different markets.

K1010630E

Presentation

I-III

Examples of such equipment are lever steering, Boom

Suspension System

(LIS), secondary steering, separate

attachment locking, automatic greasing.

CE MARKING, EMC DIRECTIVE

CE Marking

(Declaration of Conformity)

(Only applies to machines marketed within the EU/EEA.)

This machine is CE marked. This means that when delivered the

machine meets the applicable "Essential Health and Safety

Requirements," which are given in the Machinery Safety

Directive, 98/37EC.

Any person carrying out changes that affect the safety of the

FG001781

machine, is also responsible for the same.

Figure 2

As proof that the requirements are met, the machine is supplied

with an EU Declaration of Conformity, issued by DOOSAN CE

for each separate machine. This EU declaration also covers

attachments manufactured by DOOSAN CE. The documentation

is a valuable document, which must be kept safe and retained for

at least ten years. The document should always accompany the

machine when it is sold.

If the machine is used for other purposes or with other

attachments than described in this manual, safety must at all

times and in each separate case be maintained. The person

carrying out such action is also responsible for the action which,

in some cases, may require a new CE marking and the issue of

a new EU Declaration of Conformity.

The EU EMC Directive

The electronic equipment of the machine may in some cases

cause interference to other electronic equipment, or suffer from

external electromagnetic interference, which may constitute

safety risks.

The EU EMC directive on "Electromagnetic Compatibility," 89/

336/EEC, provides a general description of what demands can

be made on the machine out of a safety point of view, where

permitted limits have been determined and given according to

international standards.

A machine or device which meets the requirements must be CE

marked. Our machines have been tested particularly for

electromagnetic interference. The CE marking of the machine

and the declaration of conformity also cover the EMC directive.

Presentation

K1010630E

I-IV

If other electronic equipment is fitted to this machine, the

equipment must be CE marked and tested on the machine with

regard to electromagnetic interference.

COMMUNICATION EQUIPMENT

INSTALLATION

IMPORTANT

All installation of optional communication equipment must

be carried out by trained professionals and in accordance

with the DOOSAN CE instructions applicable to the

machine.

Protection Against Electromagnetic

Interference

This machine has been tested in accordance with EU directive

89/336/EEC governing electromagnetic interference. It is

therefore very important that all nonapproved electronic

accessories, such as communication equipment, must be tested

before installation and use, since they can cause interference to

the electronic systems of the machine.

K1010630E

Presentation

I-V

PRODUCT PLATES

With the aid of the product plates, shown below, it is possible to

identify the machine and its components. The Product

Identification Number, PIN, indicates the model designation,

engine code and serial number of the machine. The Component

Identification Number, CIN, indicates the serial number of the

component. Make a note of the identification numbers.

When ordering spare parts, and in all telephone enquiries or

correspondence the PIN and CIN must always be quoted.

1, 2

FG004336

Figure 1

Reference

Description

Number

Primary Marking

The machine PIN (stamped into right side).

Product Plate

The manufacturer's name and address, machine PIN.

Additional Plate for

Machine weight, engine output year of manufacture, year of delivery and

Product Plate

position of CE mark (EU/EEA countries only).

The manufacturer's name and address, product number, machine model

Cabin

designation, max. machine weight, cabin serial number, ROPS/FOPS

number and ROPS/FOPS certificate number.

Engine

The engine type designation and number.

Front Axle

The manufacturer's name and address and front drive axle CIN.

Transmission

The manufacturer's name and address and transmission CIN.

Rear Axle

The manufacturer's name and address and rear drive axle CIN.

Presentation

K1010630E

I-VI

OP000035

2Safety

TO THE OPERATOR OF A

DOOSAN DAEWOO WHEEL

LOADER

DANGER!

Improper use of wheel loader could cause serious injury or

death. Before operating wheel loader, or performing

maintenance, operator or technician must read and

understand entire Operation and Maintenance Manual.

Any operation, maintenance, traveling or shipping methods

that do not follow safety guidelines printed in this Manual

could cause serious injury or death.

Please respect the importance of taking responsibility for your

own safety, and that of other people who may be affected by

your actions.

The safety information on the following pages is organized into

the following sections:

“General Safety Essentials” on page 1-4

“Location of Safety Labels” on page 1-4

“Unauthorized Modifications” on page 1-13

“General Hazard Information” on page 1-13

“Before Starting Engine” on page 1-22

“Machine Operation” on page 1-26

“Maintenance” on page 1-34

“Battery” on page 1-45

“Towing” on page 1-47

10.

“Shipping and Transportation” on page 1-48

OP000035

Safety

1-1

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 must

be alert to potential for personal injury or accidents. Always

observe safety precautions and follow recommended

procedures.

Learn Signal Words Used With 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.

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 of a hazardous situation that, if not

avoided, could result in serious injury or death. It may also

be used to alert against a 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 explode or detonate if handled or treated carelessly.

Safety

OP000035

1-2

Safety precautions are described in SAFETY from page 2-4 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 some procedures,

contact a DOOSAN distributor.

OP000035

Safety

1-3

GENERAL SAFETY ESSENTIALS

Accessory Applications

The 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

The operator should know and pay attention to the information

and warning plates/decals which are positioned on the machine.

There are several specific warning signs on this machine. The

exact location of hazards and the description of the hazards are

reviewed in this section.

Please become familiarized with all warning signs.

Make sure that all of 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.

Safety

OP000035

1-4

1. Warnings for Operation, Inspection

and Maintenance (4190-2545A,

190-00092)

CAUTION!

•

Read manual and labels before

operation and maintenance. Follow

instructions and warnings in manual

and on labels on machine.

•

Sound horn to alert people nearby

before operating, and make sure all

persons are clear of area.

•

Always make sure when leaving

operator's seat to:

•

Lower bucket or other working

ACO1360L

tools to ground.

•

"LOCK" transmission selector in

"NEUTRAL."

•

Set park brake.

•

Turn starter switch "OFF." Remove key from switch.

•

If hydraulic components and units are ABNORMAL, consult nearest DOOSAN dealer or

authorized service shop. Do not attempt to make an overhaul.

2. Warnings for Cooling Fan (2190-3315,

190-00557)

WARNING!

Keep your hands away from the fan during

operation. Entanglement in the fan can cause

serious injury.

AMO0390L

Safety

OP000035

1-6

5. Warnings for Handling Accumulator

(190-00703, 190-00099)

WARNING!

Explosion hazard:

•

Keep away from flame.

•

Do not weld or drill.

ACO1480L

Accumulator

Wheel loader pilot control system is equipped with an

accumulator. Accumulator will store a pressure charge that may

enable hydraulic controls to be activated for a brief period of

time after engine has been shut down. Activation of any controls

may enable selected function to operate under force of gravity.

CAUTION!

Any raised attachment will lower to ground if accumulator

holds a charge.

When shutting machine down, lower front attachment to ground.

After engine has been shut down, turn key to "ON" position and

move joystick controls to release pressure in accumulator.

Remove key.

IMPORTANT

Refer to Shop Manual for service procedures. Do not

release any pilot lines until pressure within accumulator

has been released.

Safety

OP000035

1-8

8. Warnings for High Temperature

Coolant (190-00692, 190-00097)

WARNING!

To prevent hot water from spurting out:

•

Turn engine "OFF."

•

Allow water to cool.

•

Slowly loosen cap to relieve pressure

before removing.

ACO1410L

9. Warnings for Battery Maintenance

(190-00537, 190-00100)

DANGER!

•

Battery fumes can explode. Keep

sparks and flames away from

batteries.

•

Always avoid storing metals like tools

or inflammable materials around or on

batteries. Explosion or fire can be

caused by short circuiting batteries.

•

Sulfuric acid in battery is poisonous. It

is strong enough to burn skin, eat

holes in clothing, and cause blindness

if splashed in eyes.

If you spill acid on yourself:

Flush your skin with water.

Apply baking soda or lime to help

ACO1400L

neutralize acid.

Flush your eyes with water for 10 - 15

minutes.

Get medical attention immediately.

Safety

OP000035

1-10

UNAUTHORIZED

MODIFICATIONS

Any modification made without authorization or written approval

from DOOSAN can create a safety hazard, for which the

machine owner must 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 in which the safety

of critical assemblies is 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 judgement 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.

OP000035

Safety

1-13

Inside Operator's Compartment

When entering the operator's compartment, 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 cabin floor and consoles free of tools and personal items.

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 compartment.

If the temperature inside the operator's compartment becomes

high, there is danger that the lighter may explode.

Do not use cellular telephones inside the operator's

compartment when driving or operating the machine. There is

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 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 serous 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 the key and take it with

you.

Safety

OP000035

1-14

Clothing and Personal Protective Items

Contain long hair, and avoid loose clothing and jewelry. They

can catch on controls or in protruding 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

HAOA020L

adequately perform intended functions.

Figure 2

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

71 dB(A).

Measurement is obtained on a dynamic machine

following the procedures and cabin conditions as

described in ISO 6396.

NOTE: The guaranteed sound power level emitted by the

machinery for this machine is 70 dB(A).

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.

Recommendations for Limiting Vibrations

Select the right machine, equipment and attachments for a

particular application.

Replace any damaged seat by a genuine DOOSAN part.

Keep the seat maintained and adjusted.

OP000035

Safety

1-15

•

Adjust the seat and suspension for the weight and

size of the operator.

•

Inspect and maintain the suspension and adjustment

mechanisms of the seat regularly.

Check that the machine is properly maintained.

•

Tire pressure, brakes, steering, linkages, etc.

Steer, brake, accelerate, shift gears, move the

attachments and load the attachments smoothly.

Adjust the machine speed and travel path to reduce the

vibration level.

•

Slow down if it is necessary when passing rough

terrain.

•

Drive around obstacles and excessive rough terrain

conditions.

Keep the terrain on work sites where the machine is

working and traveling in good condition.

•

Remove any large rocks or obstacles.

•

Fill any ditches and holes.

•

Provide machines for and schedule time to maintain

the terrain conditions.

Travel over longer distance

(e.g. on public roads) at

adjusted (medium) speed.

•

Always adjust the speed for preventing bouncing.

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.

ARO1770L

•

Use water for cleaning to keep down the dust.

Figure 3

•

Work on the machine or component with the wind at

your back whenever possible.

•

Always observe any rules and regulations related to

the work site and working environment.

Safety

OP000035

1-16

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 jump on or off the 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

HA3O1003

one foot and both hands) with the handholds and steps to

ensure that you support yourself securely.

Figure 4

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.

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 doused, 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

Figure 5

provide a ground.

Keep fuel and other fluid reservoir caps tight and do not start the

engine until caps have been secured.

OP000035

Safety

1-17

Precautions When Handling Fluids at High

Temperature

Immediately after operations are stopped, the coolant, engine

oil, and hydraulic oil are at high temperature and the radiator

and hydraulic tank are still under pressure. Attempting to

remove the 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.

HAOA050L

Figure 6

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.

HAOA060L

Figure 7

Injury from Work Equipment

Do not enter or put your hand, arm or any other part of your body

between movable parts, such as between the work equipment

and cylinders, or between the machine and work equipment.

If the control levers are operated, the clearance between the

machine and the work equipment will change and this may lead

to serious damage or personal injury.

If going between movable parts is necessary, always position

and secure the work equipment so that it cannot move.

HDO1010L

Figure 8

Safety

OP000035

1-18

Fire Extinguisher and First Aid Kit

As a precaution if any injury or fire should occur, always do the

following.

•

Be sure that fire extinguishers have been provided

and read the labels to ensure that you know now to

use them. It is recommended that an appropriately

sized (2.27 kg [5 lb] or larger) multipurpose "A/B/C"

fire extinguisher be mounted in the cabin. Check and

service the fire extinguisher at regular intervals and

make sure that all work site crew members are

HDO1009L

adequately trained in its use.

Figure 9

•

Provide a first aid kit in the storage compartment and

keep another at the work site. Check the kit

periodically and make any additions if necessary.

•

Know what to do in case of injury from fire.

•

Keep emergency numbers for doctor, ambulance

service, hospital and fire department near your

telephone.

If the machine catches fire, it may lead to serious personal injury

or death. If a fire occurs during operation, escape from the

machine as follows:

•

Turn the starter switch to the "O" (OFF) position and

shut down engine.

•

If there is time, use the fire extinguisher to extinguish

as much of the fire as possible.

•

Use the handrails and steps to escape from the

machine.

The above is the basic method for escaping from the machine,

but changing the method may be necessary according to the

conditions, so carry out practice drills at the work site.

Protection from Falling or Flying Objects

On work sites where there is danger that falling objects or flying

objects may hit the operator's cabin select a guard to match the

operating conditions to protect the operator.

Working in mines, tunnels, deep pits or on loose or wet surfaces

could produce danger of falling rock, roll over or hazardous

flying objects. Additional protection for operator's cabin could be

required in form of a FOPS/Falling Object Protective Structure

and/or ROPS/Roll Over Protective Structure reinforcement

system.

HAOA110L

Figure 10

OP000035

Safety

1-19

Any reinforcement system that is installed on machine must

pass safety and certification standards and carry appropriate

labeling and rating information. For example, most often added

type of reinforcement system, FOPS, must meet or exceed

Society of Automotive Engineers standard SAE J1356,

"Performance Criteria for Falling Object Guards for Wheel

loaders."

Never attempt to alter or modify any type of protective structure

reinforcement system, by drilling holes, welding, remounting or

relocating fasteners. Any serious impact or damage to the

system requires a complete integrity reevaluation.

HAOA100L

Reinstallation, recertification and/or replacement of the system

Figure 11

may be necessary.

Install Additional Safety Equipment If

Conditions Require

Laminate glass protection for the front, side or rear windows,

along with tempered glass, may also be recommended

depending upon particular site conditions.

Contact your DOOSAN distributor for available safety guards

and/or recommendations if there is any danger of getting hit by

objects that could strike the operator's cabin. Make sure that all

other work site crew members are kept well away from wheel

loader and safe from potential hazards.

Maintain Standard Safety Equipment in

Good Condition

Machinery guards and body panel covers must be in place at all

times. Keep well clear of rotating parts. Pinch point hazards

such as cooling fan and alternator drive belts could catch hair,

jewelry or oversize or very loose clothing.

Safety labels must be replaced if they are damaged or become

unreadable. Information on labels gives work crew members an

important safety reminder. Part numbers for each decal and

required mounting locations are shown on pages 1-2 through

1-4 of this section.

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 of the

attachments that owners may wish to install on their machines,

please contact DOOSAN for authorization and approval of

attachments, and their compatibility with options kits.

Safety

OP000035

1-20

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 describe

in “Handling of Accumulator” on page 4-75.

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 any flame, 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

into which exhaust may be carried, or blown by the wind,

ARO1770L

exposing others to danger.

Figure 12

OP000035

Safety

1-21

BEFORE STARTING ENGINE

Work Site Precautions

Before starting operations, thoroughly check the area for any

unusual conditions that could be dangerous.

Check the terrain and condition of the ground at the work site,

and determine the best and safest method of operation.

Make the ground surface as hard and horizontal as possible

before carrying out operations. If there is a lot of dust and sand

on the work site, spray water before starting operations.

If you need to operate on a street, protect pedestrians and cars

by designating a person for work site traffic duty or by erecting

fences and posting "No Entry" signs around the work site.

Erect fences, post "No Entry" signs, and take other steps to

prevent people from coming close to or entering the work site. If

people come close to a moving machine, they may be hit or

caught by the machine, and this may lead to serious personal

injury or death.

Water lines, gas lines, phone lines and high voltage electrical

lines may be buried under the work site. Contact each utility and

identify their locations. Be careful not to damage or cut any of

Figure 13

these lines.

Check the condition of the river bed, and the depth and flow of

the water before operating in water or crossing a river. NEVER

be in water that is in excess of the permissible water depth.

Refer to “Allowable Water Depth” on page 3-24.

Any type of object in the vicinity of the boom could represent a

potential hazard, or cause the operator to react suddenly and

cause an accident. Use a spotter or signal person working near

bridges, phone lines, work site scaffolds, or other obstructions.

Minimum levels of insurance coverage, work permits or

certification, physical barriers around the work site or restricted

hours of operation may be mandated by governing authorities.

There may also be regulations, guidelines, standards or

restrictions on equipment that may have to be followed for local

requirements. There may also be regulations related to

performing certain kinds of work. If there is any question about

whether your machine and work site complies with the

applicable standards and regulations contact your local

authorities and agencies.

Avoid entering soft ground. It will be difficult for the machine to

escape.

Avoid operating your machine to close to the edge of cliffs,

overhangs, and deep ditches. The ground may be weak in such

areas. If the ground should collapse, the machine could fall or tip

over and this could result in serious injury or death.

Remember that the soil after heavy rain, blasting or after

earthquakes, is weakened in these areas.

Safety

OP000035

1-22

Earth laid on the ground and the soil near ditches is loose. It can

collapse under the weight of vibration of your machine and

cause your machine to tip over.

Install the safety guard if working in areas where there is danger

of falling rocks.

Checks Before Starting Engine

Every day before starting the engine for the first time, carry out

the following checks. If these checks are not carried out

properly, there is danger of serious injury.

Completely remove all wood chips, leaves, grass, paper and

other flammable materials accumulated in the engine

compartment and around the battery. They could cause a fire.

Remove any dirt from the window glass, mirrors, handrails, and

steps.

Do not leave tools or spare parts laying around in the operator's

compartment. The vibration of the machine when traveling or

during operations may cause them to fall and damage or break

the control levers or switches. They may also get caught in the

gap of the control levers and cause the work equipment to

malfunction or move dangerously. This may lead to unexpected

accidents.

Check the coolant level, fuel level, and hydraulic tank oil level,

and check for clogged air cleaner and damage to the electrical

wiring.

Adjust the operator's seat to a position where it is easy to

operate the machine, and check the seat belt and mounts for

damage and wear.

Check the operation of the gauges and the angle of the mirrors,

and check that the safety lever is in "LOCKED" position.

If any abnormalities are found in the above checks, carry out

repairs immediately.

Engine Starting

Walk around your machine before getting in the operator's

cabin. Look for evidence of leaking fluid, loose fasteners,

misaligned assemblies or any other indications of possible

equipment hazard.

All equipment covers and machinery safety guards must be in

place, to protect against injury while the machine is being

operated.

Look around the work site area for potential hazards, people or

properly that could be at risk while operation is in progress.

NEVER start the engine if there is any indication that

maintenance or service work is in progress, or if a warning tag is

attached to controls in the cabin.

OP000035

Safety

1-23

A machine that has not been used recently, or is being operated

in extremely cold temperatures, could require a warm-up or

maintenance service before start-up.

Check gauges and monitor displays for normal operation before

starting the engine. Listen for unusual noises and remain alert

for other potentially hazardous conditions at the start of the work

cycle.

Check tire inflation and check tires for damage or uneven wear.

Perform maintenance before operation.

Do not short circuit the starting motor to start the engine. This is

not only dangerous, but may also damage the machine.

When starting the engine, sound the horn as an alert.

Start and operate the machine only while seated.

Before Operating Machine

If checks are not carried out properly after starting the engine, it

may result in a delay in discovering abnormalities in the

machine, and this may lead to personal injury or damage to the

machine.

Carry out the checks in an open area where there are no

obstructions. Do not let anyone near the machine when carrying

out the checks.

•

Check the operating condition of the equipment, and

the actuation of the bucket, boom, and travel

systems.

•

Check the machine for any abnormal noise, vibration,

heat, smell, or abnormality with the gauges. Check

also for leakage of air, oil, and fuel.

•

If any abnormality is found, repair the problem

immediately. If the machine is used without repairing

the problems, it may lead to unexpected injury or

failure.

•

Clear all personnel from directly around machine and

from the area.

•

Clear all obstacles from the machine's path. Beware

of hazards.

•

Be sure that all windows are clean. Secure the doors

and the windows in the open position or in the shut

position.

•

Adjust the rear view mirrors for best visibility close to

the machine. Make sure that the horn, the travel

alarm (if equipped), and all other warning devices are

working properly.

•

Fasten the seat belt securely.

•

Warm up the engine and hydraulic oil before

operating machine.

Safety

OP000035

1-24

MACHINE OPERATION

IMPORTANT

If you need more information or have any questions or

concerns about safe operating procedures or working the

wheel loader correctly in a particular application or in the

specific conditions of your individual operating

environment, please consult your local DOOSAN

representative.

Operate While Seated at Operator's Station

Only

Never reach in through a window to work a control. Do not try to

operate wheel loader unless you're in command position

seated at controls. You should stay alert and focused on your

work at all times. Do not twist out of seat if job activity behind

you (or to the side) requires your attention.

Use a spotter or signal person if you cannot see clearly and

something is happening behind you.

HAOA151L

Replace damaged safety labels and lost or damaged operator's

Figure 14

manuals.

Do not let anyone operate machine unless they've been fully

and completely trained, in safety and in operation of the

machine.

Seat Belts Must Be Used at All Times

Whenever engine is running, operator must be seated at the

control station with seat belt properly engaged.

Figure 15

Movement Alarms

If wheel loader is equipped with an audible travel movement

alarm, test alarm on a daily basis. Audible alarm should sound

as soon as travel system is engaged.

Safety

OP000035

1-26

Travel Precautions

When traveling, wheel loader always keeps lights on; make sure

that you are in compliance with all state and local regulations

concerning warning flags and signs.

Never turn the starter switch to the "O" (OFF) position when

traveling. It is dangerous if the engine stops when the machine

is traveling. It will be impossible to operate the steering unless

the unit is equipped with an emergency steering system.

Pilot control valve lever (joystick) should not be operated while

traveling.

Lower work equipment so that it is

400 mm (16 in) above

ground.

Never travel over obstacles or slopes that will cause machine to

tilt severely. Travel around any slope or obstacle that causes 10°

tilt, or more.

Do not operate the steering suddenly. The work equipment may

hit the ground and cause the machine to lose its balance, and

this may damage the machine or structures in the area.

When traveling on rough ground, travel at low speed, and avoid

sudden changes in direction.

Always keep to the permissible water depth. Refer to “Allowable

Water Depth” on page 3-24.

When traveling over bridges or structures on private land, check

first that the bridge or structure can withstand the weight of the

machine. When traveling on public roads, check with the local

authorities and follow their instructions.

Sloping Terrain Requires Caution

Dig evenly around work site whenever possible, trying to

gradually level any existing slope. If it's not possible to level area

or avoid working on a slope, reducing size and cycling rate

workload is recommended.

On sloping surfaces, use caution when positioning wheel loader

before starting a work cycle. Stay alert for unstable situations to

avoid getting into them. For example, you should always avoid

working bucket over downhill side of machine when parked

perpendicular to slope. Avoid full extensions of bucket in a

downhill direction. Lifting bucket too high, too close to machine,

while wheel loader is turned uphill can also be hazardous.

AHO0970L

Figure 16

OP000035

Safety

1-27

Avoid High Voltage Cables

Serious injury or death can result from contact or proximity to

high voltage electric lines. The bucket does not have to make

physical contact with power lines for current to be transmitted.

Use a spotter and hand signals to stay away from power lines

not clearly visible to operator.

Voltage

Minimum Safe Distance

6.6 kV

3 m (9' 10")

33.0 kV

4 m (13' 1")

Figure 17

66.0 kV

5 m (16' 5")

154.0 kV

8 m (26' 3")

275.0 kV

10 m (32' 10")

Use these minimum distances as a guideline only. Depending

upon voltage in line and atmospheric conditions, strong current

shocks can occur with boom or bucket as far away as 4 - 6 m

(13 - 20 ft) from power line. Very high voltage and rainy weather

could further decrease that safety margin.

NOTE: Before starting any type of operation near power lines

(either above ground or buried cable type) you should

always contact power utility directly and work out a

safety plan with them.

Before Starting to Dig, Contact Authorities

Below ground hazards also include natural gas lines, water

mains, tunnels and buried foundations. Know what's underneath

work site before starting to dig.

Be Aware of Height Obstacles

Any type of object in vicinity of boom could represent a potential

hazard, or cause operator to react suddenly and cause an

accident. Use a spotter or signal person working near bridges,

phone lines, work site scaffolds, or other obstructions.

Safety

OP000035

1-28

Use Care on Loose Support

Working heavy loads over loose, soft ground or uneven, broken

terrain can cause dangerous side load conditions and possible

tipover and injury. Travel without a load or balanced load may

also be hazardous.

If temperatures are changing, be cautious of dark and wet

patches when working or traveling over frozen ground. Stay

away from ditches, overhangs and all other weak support

surfaces. Halt work and install support mats or blocking if work is

required in an area of poor support.

Use Solid Support Blocking

Never rely on lift jacks or other inadequate supports when work

is being done. Block wheels fore and aft to prevent any

movement.

Digging Beneath Overhangs

Digging beneath an overhang is dangerous. Overhang could

collapse on top of operator and cause serious injury or death.

HDO1042L

Go on to another digging area before steep overhangs are

Figure 18

formed. Know height and reach limits of wheel loader and plan

ahead while working. Park wheel loader away from overhangs

before work shut down.

Digging Beneath Wheel Loader

Digging beneath wheel loader is dangerous. Earth beneath

could collapse. This could cause wheel loader to tip, which could

cause serious injury or death to operator. Working around deep

pits, trenching or along high walls may require support blocks,

especially after heavy rainfalls or during spring thaws.

Stay Alert for People Moving Through

Work Area

When loading a truck you should always know where the driver

is.

Avoid loading over the cabin of a truck even if the driver is in a

safe spot. Someone else could have gone inside, for any

number of reasons. Avoid working where unseen passersby

might be.

Slow down work cycle and use slower travel speeds in

HAOA171L

congested or populated areas. Use a commonly understood

Figure 19

signal so that other members of work crew can warn operator to

slow or halt work in an impending hazardous situation.

OP000035

Safety

1-29

Be Aware of and Conform to Local

Regulations

Minimum levels of insurance coverage, work permits or

certification, physical barriers around work site or restricted

hours of operation may be mandated by governing authorities.

There may also be guidelines, standards or restrictions on

equipment that may be used to perform certain kinds of work.

Check and follow all local requirements, which may also be

related to below ground hazards and power lines.

Never Use Ether Starting Aids

An electric grid type manifold heater is used for cold starting.

Glowing heater element can cause ether or other starting fluid to

detonate, causing injury.

Figure 20

Observe General Safety Rules

Only trained and authorized personnel, with a good knowledge

and awareness of safe procedures, may be allowed to operate

or perform maintenance or service on wheel loader.

All personnel at work site must be aware of assigned individual

responsibilities and tasks. Communication and hand signals

used must be understood by everyone.

Terrain and soil conditions at work site, approaching traffic,

weather related hazards and any above or below ground

obstacles or hazards must be observed and monitored by all

work crew members.

Safety

OP000035

1-30

Take Time to Provide Good Visibility

Be careful not to go close to the edge of a cliff by mistake.

Use the machine only for its main purpose. Using it for other

purposes will cause failures.

To ensure an ample view, do as follows:

•

When working in dark areas, attach working lights

and front lights to the machine. If necessary, set up

lighting at the work site.

•

Stop operations when the visibility is poor, such as in

fog, mist, snow, and rain. Wait for the visibility to

improve to a level which causes no problems for the

operation.

•

Keep dirt and dust off of windows and off lens

surfaces of work lights. Stop working if lights,

windows or mirrors need cleaning or adjustment.

To avoid hitting the work equipment, always do the following:

•

When working in tunnels, on bridges, under electric

wires, or when parking the machine or carrying out

other operations in places with limited height, be

extremely careful not to hit the bucket or other parts.

•

To prevent collisions, operate the machine at a safe

speed when working in confined spaces, indoors, or

in crowded areas.

•

Do not pass the bucket over the heads of workers or

over the operator's compartment of dump truck.

Keep "Pinch Point" Areas Clear - Use

Caution in Reverse

Use a signal person in high traffic areas and whenever

operator's view is not clear, such as when traveling in reverse.

Anyone standing near wheels, or working assemblies of the

attachment, is at risk of being caught between moving parts of

machine.

Never allow anyone to ride on any part of machine or

attachment, including any part of operator's cabin.

HAOA191L

Figure 21

OP000035

Safety

1-31

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 work load may be necessary.

When the temperature rises, frozen road surfaces become soft,

so the 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 work day. Plan ahead so that the

wheel loader will be on firm, 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, and park the

machine so that the machine, flags, and fences do not obstruct

traffic.

Safety

OP000035

1-32

Shutdown Control Functions

After bucket has been lowered to overnight storage position,

move all switches and controls to "OFF" position. Pull parking

brake knob to "APPLIED" position. This will apply parking brake.

Move pilot cutoff switch to "LOCK" position. This will disable pilot

control valve lever (joystick). Move key in starter switch to "OFF"

position, and remove key from switch.

Engage all lock-down security equipment that may have been

installed on machine.

IMPORTANT

When hydraulic system maintenance or service work must

be performed, be aware that accumulators in system store

fluid under pressure after system has been shut down. To

release hydraulic pressure in accumulators, operate control

with engine "OFF" until accumulator pressure is completely

dissipated.

Never Let Anyone Ride on Attachment

Never let anyone ride on any work attachment, such as the

bucket, crusher, grapple, or clamshell (grab bucket). There is a

danger of the person falling and suffering serious injury.

HAAD4050

Figure 22

OP000035

Safety

1-33

MAINTENANCE

Use Warning Tag During Service

Alert others that service or maintenance is being performed and

tag operator's cabin controls

- and other machine areas if

required - with a warning notice.

Warning tags for controls are available from DOOSAN

WARNING

distributors; see Figure 23.

HAOC920L

Figure 23

Clean Before Inspection or Maintenance

Clean the machine before carrying out inspection and

maintenance. This prevents dirt from getting into the machine

and also ensures safety during maintenance.

If inspection and maintenance are carried out when the machine

is dirty, it will become more difficult to locate the problems, and

also there is danger that you may get dirt or mud in your eyes or

that you may slip and injure yourself.

When washing the machine, do the following:

•

Wear shoes with nonslip soles to prevent yourself

from slipping and falling on wet places.

•

Wear safety glasses and protective clothing when

washing the machine with high-pressure steam.

•

Take action to prevent touching high-pressure water

and cutting your skin or having mud fly into your

eyes.

ARO1330L

Figure 24

•

Do not spray water directly on electrical components

(sensors, connector) (1, Figure 24). If water gets into

the electrical system, there is danger that it will cause

defective operation and malfunction.

Pick up any tools or hammers that are laying in the work place,

wipe up any grease or oil or any other slippery substances, and

clean the area to make it possible to carry out the operation in

safety. If the work place is left untidy, you may trip or slip and

suffer injury.

Safety

OP000035

1-34

Proper Tools

Use only tools suited to the task. Using damaged, low qualify,

faulty, or makeshift tools could cause personal injury. There is

danger that pieces from, chisels with crushed heads, or

hammers, may get into your eyes and cause blindness.

HDO1037L

Figure 25

Use of Lighting

When checking fuel, oil, battery electrolyte, or window washing

fluid, always use lighting with antiexplosion specifications. If

such lighting equipment is not used, there is danger of an

explosion.

If work is carried out in dark places without using lighting, it may

lead to injury, so always use proper lighting.

Even if the place is dark, never use a lighter or flame instead of

lighting. There is danger of fire. There is also danger that the

HDO1040L

battery gas may catch fire and cause and explosion.

Figure 26

Fire Prevention and Explosion Prevention

All fuels, most lubricants and some coolant mixtures are

flammable. Leaking fuel or fuel that is spilled onto hot surfaces

or onto electrical components can cause a fire.

Store all fuels and all lubricants in properly marked containers

and away from all unauthorized persons.

Store oily rags and other flammable material in a protective

container.

Do not smoke while you refuel the machine or while you are in a

HDO1015I

refueling area.

Figure 27

Do not smoke in battery charging areas or in areas the contain

flammable material.

Clean all electrical connections and tighten all electrical

connections. Check the electrical wires daily for wires that are

loose of frayed. Tighten all lose electrical wires before you

operate the machine. Repair all frayed electrical wires before

you operate the machine.

Remove all flammable materials before they accumulate on the

machine.

Do not weld on pipes or on tubes that contain flammable fluids.

Do not flame cut on pipes or on tubes that contain flammable

fluids. Before you weld on pipes or on tubes or before you flame

OP000035

Safety

1-35

cut on pipes or on tubes, clean the pipes or tubes thoroughly

with a nonflammable solvent.

Burn Prevention

When checking the radiator coolant level, shut down engine, let

the engine and radiator cool down, then check the coolant

recovery tank. If the coolant level in the coolant recovery tank is

near the upper limit, there is enough coolant in the radiator.

Loosen the radiator cap gradually to release the internal

pressure before removing the radiator cap.

If the coolant level in the coolant recovery tank is below the

lower limit, add coolant.

Cooling system conditioner contains alkali. Alkali can cause

personal injury. Do not allow alkali to contact the skin, the eyes,

or the mouth.

Allow cooling system components to cool before you drain the

cooling system.

Hot oil and hot components can cause personal injury. Do not

allow hot oil or hot components to contact the skin.

Remove the hydraulic tank filter plug only after the engine has

been stopped. Make sure that the hydraulic tank filter plug is

cool before you remove it with your bare hand. Remove the

hydraulic tank filter plug slowly to relieve pressure.

Relieve all pressure in the hydraulic oil system, in the fuel

system, or in the cooling system before you disconnect any

lines, fittings, or related items.

HAAE1980

Batteries give off flammable fumes that can explode.

Figure 28

Do not smoke while you are checking the battery electrolyte

levels.

Electrolyte is an acid. Electrolyte can cause personal injury. Do

not allow electrolyte to contact the skin or the eyes.

Always wear protective glasses when you work on batteries.

Welding Repairs

When carrying out welding repairs, carry out the welding in a

properly equipped place. The welding must be performed by a

qualified worker. During welding operations, there is the danger

of, generation of gas, fire, or electric shock, so never let an

unqualified worker do welding.

The qualified welder must do the following:

•

To prevent explosion of the battery, disconnect the

battery terminals and remove batteries.

•

To prevent generation of gas, remove the paint from

the location of the weld.

Safety

OP000035

1-36

•

If hydraulic equipment, piping or places close to them

are heated, a flammable gas or mist will be generated

and there is danger of it catching fire. To avoid this,

never subject these places to heat.

•

Do not weld on pipes or on tubes that contain

flammable fluids. Do not flame cut on pipes or on

tubes that contain flammable fluids. Before you weld

on pipes or on tubes or before you flame cut on pipes

or on tubes, clean the pipes or tubes thoroughly with

a nonflammable solvent.

•

If heat is applied directly to rubber hoses or piping

under pressure, they may suddenly break so cover

them with a fireproof covering.

•

Wear protective clothing.

•

Make sure there is good ventilation.

•

Remove all flammable objects and provide a fire

extinguisher.

Precautions for Removal, Installation, and

Storage of Attachments

Before starting removal and installation of attachments, decide

the team leader.

Do not allow anyone except the authorized workers close to the

machine or attachment.

Place attachments that have been removed from the machine in

a safe place so that they do not fall. Put up a fence around the

attachments and take other measures to prevent unauthorized

HDO1041L

persons from entering.

Figure 29

Precautions When Working on Machine

When carrying out maintenance operations on the machine,

keep the area around your feet clean and tidy to prevent you

from falling. Always do the following:

•

Do not spill oil or grease.

•

Do not leave tools laying about.

•

Watch your step when walking.

Never jump down from the machine. When getting on or off the

ARO1380L

machine, use the steps and handrails, and maintain a

Figure 30

three-point contact (both feet and one hand or both hands and

one foot) to support yourself securely.

If the job requires it, wear protective clothing.

To prevent injury from slipping or falling, when working on the

hood or covers, never use any part except the inspection

passage fitted with nonslip pads.

OP000035

Safety

1-37

Lock Inspection Covers

When carrying out maintenance with the inspection cover open,

lock the cover securely in position with the lock bar.

If maintenance work is carried out with the inspection cover

open but not locked, there is danger that it may suddenly close

and cause injury if there is a gust of wind.

Crushing Prevention and Cutting

Prevention

You should always have at least two people working together if

the engine must be run during service. One person needs to

remain in the operator's seat, ready to work the controls or stop

the machine and shut off the engine.

Unless you are instructed otherwise, never attempt adjustments

while the machine is moving or while the engine is running.

Stay clear of all rotating parts and moving parts.

Keep objects away from moving fan blades. The fan blades will

throw objects and the fan blades can cut objects.

Do not use a wire rope cable that is kinked or flayed. Wear

gloves when you handle a wire rope cable.

When you strike a retainer pin, the retainer pin might fly out. The

loose retainer pin can injure personnel. Make sure that the area

is clear of people when you strike a retainer pin. To avoid injury

to your eyes, wear protective glasses when you strike a retainer

pin.

Do Not Run Engine If Repairs or Work Are

Being Performed Alone

You should always have at least two people working together if

engine must be run during service. One person needs to remain

in operator's seat, ready to work controls or stop machine and

shut "OFF" engine.

Always Use Adequate Equipment

Supports and Blocking

Do not allow weight or equipment loads to remain suspended.

Lower everything to ground before leaving operator's seat. Do

not use hollow, cracked or unsteady, wobbling weight supports.

Do not work under any equipment supported solely by a lift jack.

Safety

OP000035

1-38

Do Not Work on Hot Engines or Hot

Cooling or Hydraulic Systems

Wait for engine to cool off after normal operation. Park wheel

loader on firm, level ground and lower all equipment before

shutting down and switching "OFF" controls. When engine lube

oil, gearbox lubricant or other fluids require change, wait for fluid

temperatures to decrease to a moderate level before removing

drain plugs.

NOTE: Oil will drain more quickly and completely if it is

warm. Do not drain fluids at temperatures exceeding

95°C (203°F), however do not allow full cool down.

Hydraulic Cylinder Seals Require Periodic

Replacement

Check cylinder drift rate at regular intervals. Overhaul seal kits

are available through DOOSAN.

High-pressure Hydraulic Lines Can Store a

Great Deal of Energy

Exposed hydraulic hoses on arm could react with explosive

force if struck by a falling rock, overhead obstacle or other work

site hazard. Extra safety guards may be required. NEVER allow

hoses to be hit, bent or interfered with during operation.

Cool Down Is Required Before Radiator or

Reservoir Checks

Shut down engine and allow heat to dissipate before performing

service on engine radiator or hydraulic fluid reservoir. Both

assemblies have air vent levers at or near fill cap for venting

built-up air pressure. Release levers before trying to take off fill

caps and LOOSEN CAPS SLOWLY, before removal.

HAOA060L

Figure 31

OP000035

Safety

1-39

Precautions with High-pressure Line,

Tubes and Hoses

When inspecting or replacing high-pressure piping or hoses,

check that the pressure has been released from the circuit.

Failure to release the pressure may lead to serious injury.

Always do the following:

•

Wear protective glasses and leather gloves.

•

Fluid leaks from hydraulic hoses or pressurized

components can be difficult to see but pressurized oil

has enough force to pierce the skin and cause

serious injury. Always use a piece of wood or

cardboard to check for suspected hydraulic leaks.

Never use your hands or expose your fingers.

•

Do not bend high-pressure lines. Do not strike

high-pressure lines. Do not install lines, tubes or

hoses that are bent or damaged.

•

Make sure that all clamps, guards and heat shields

are installed correctly to prevent vibration, rubbing

against other parts, and excessive heat during

operation.

HDO1045I

- If any of the following conditions are found,

Figure 32

replace the part.

- Damage or leakage from hose end.

- Wear, damage, cutting of covering, or exposure

of strengthening wire layer.

- Cover portion is swollen in places.

- There is twisting or crushing at movable parts of

hose.

- Foreign material is embedded in the covering.

- Hose end is deformed.

NOTE:

Refer to “Hose In-service Lifetime Limit (European

Standard ISO 8331 and EN982 CEN)” on page 4-68,

for additional European regulations.

Safety

OP000035

1-40

Obtain Immediate Medical Attention if

Pressurized Oil Pierces Skin.

WARNING!

Failure to obtain prompt medical assistance could result in

gangrene or other serious damage to tissue.

Use Correct Replacement Fasteners

Tightened to Proper Torque

Refer to "General Maintenance" section of Shop Manual for

information on tightening torques and recommended assembly

compounds and always use correct part.

Poor or incorrect fastener connections can dangerously weaken

assemblies.

Safety Critical Parts Must Be Replaced

Periodically

Replace following fire related components as soon as they begin

to show any sign of wear, or at regular periodic intervals,

whether or not deterioration is visible:

•

Fuel system flexible hoses, the tank overflow drain

hose and the fuel fill cap.

•

Hydraulic system hoses, especially the pump outlet

lines and front and rear pump branch hoses.

•

Keep mounting brackets and hose and cable routing

straps tight. Hose routing should have gradual bends.

OP000035

Safety

1-41

Dispose of All Petroleum Based Oils and

Fluids Properly

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

Figure 33

containers. 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 See

“Recommended Air Pressure” on

page 4-86.

Safety

OP000035

1-42

Decreasing Risk of Injuries or Death From

Boom and Bucket

DANGER!

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 may cause injuries

or death.

While operating a machine, do not let people enter the

operational area. The sudden collapse of the front

structure caused from a hose failure may result in injuries

or death.

Figure 34

When stopping or parking the machine, lower the front

structure to the ground. If not, the sudden collapse of the

front structure caused from a hose failure may result in

injuries or death.

Figure 35

OP000035

Safety

1-43

When repairing or inspecting the machine, with the front

structure raised in the air, firmly support the front structure.

When installing the supporting structure, verify that it can

handle the load.

High-pressure loads between the boom structure and

support may cause the support to slip, causing the boom to

collapse, leading to injuries or death. Take the installation

location of support and supporting surface into

consideration.

A supporting structure must be used, when disconnecting

front hoses or removing any other mechanical component

related to the front structure. High-pressure oil can be

ejected from the front cylinder to release its static pressure

and force. A sudden shift of a front structure load may

cause a boom collapse leading to injuries or death.

FG004996

Figure 36

WARNING!

Pressurized oil has enough force to pierce the skin

and cause a serious injury.

Safety

OP000035

1-44

BATTERY

Battery Hazard Prevention

Battery electrolyte contains diluted sulfuric acid and batteries

generate hydrogen gas. Hydrogen gas is highly explosive, and

mistakes in handling them can cause serious injury or fire. To

prevent problems, always do the following:

•

Do not smoke or bring any flame near the battery.

•

When working with batteries, ALWAYS wear safety

glasses and rubber gloves.

•

If you spill battery electrolyte on yourself or your

clothes, immediately flush the area with water.

•

If battery electrolyte gets into your eyes, flush them

immediately with large quantities of water and see a

doctor at once.

•

If you accidentally drink battery electrolyte, drink a

large quantity of water or milk, raw egg or vegetable

oil. Call a doctor or poison prevention center

immediately.

•

When cleaning the top surface of the battery, wipe it

with a clean, damp cloth. Never use gasoline, thinner,

or any other organic solvent or detergent.

•

Tighten the battery caps securely.

•

Explosive battery gas can be set off by sparks from

accidental contact or static discharge. Turn "OFF" all

switches and engine when working on batteries.

Keep battery terminals tight. Contact between a loose

terminal and post can create an explosive spark.

Figure 37

•

If the battery electrolyte is frozen, do not charge the

battery or start the engine with power from another

source. There is danger that the battery may catch

fire.

•

When charging the battery or starting with power

from another source, let the battery electrolyte melt

and check that there is no leakage of battery

electrolyte before starting the operation.

•

Always remove the battery from the machine before

charging.

OP000035

Safety

1-45

Disconnect Batteries Before Electrical

Service or Electrical Welding

Remove cable to negative terminal first when disconnecting

cable. Connect positive terminal cables first when installing a

battery.

Use Low Heat Portable Lighting

Hot surfaces on trouble lights or portable work lights can set off

fuel or battery explosive gases.

Boost Starting or Charging Engine

Batteries

If any mistake is made in the method of connecting the booster

cables, it may cause an explosion or fire. Always do the

following:

•

Turn off all electrical equipment before connecting

leads to the battery. This includes electrical switches

on the battery charger or boost starting equipment.

•

When boost starting from another machine or vehicle

HAOA310L

do not allow the two machines to touch. Wear safety

Figure 38

glasses or goggles while required battery

connections are made.

•

24 volt battery units consisting of two series

connected twelve volt batteries have a cable

connecting one positive terminal on one of the 12 volt

batteries to a negative terminal on the other battery.

Booster or charger cable connections must be made

between the nonseries connected positive terminals

and between the negative terminal of the booster

battery and the metal frame of the machine being

boosted or charged. Refer to the procedure and

illustration in

“Starting with Auxiliary Batteries” on

page 3-10 of this manual.

•

Connect positive cable first when installing cables

and disconnect the negative cable first when

removing them. The final cable connection, at the

metal frame of the machine being charged or boost

started, must be as far away from the batteries as

possible.

Safety

OP000035

1-46

TOWING

Precautions When Towing

If any mistake is made in the method of selecting or inspecting

the towing wire or in the method of towing, it may lead to serious

personal injury. Always do the following:

•

Always use the method of towing given in this

Operation and Maintenance Manual. Do not use any

other method.

•

Use leather gloves when handling the wire rope.

•

When carrying out the preparation work for towing

with two or more workers, determine the signals to

use and follow these signals correctly.

•

If the engine on the problem machine will not start or

there is a failure in the brake system. always contact

your DOOSAN distributor.

•

Never go between the towing machine and the towed

machine during the towing operation.

•

It is dangerous to carry out towing on slopes, so

select a place where the slope is gradual. If there is

no place where the slope is gradual, carry out

operations to reduce the angle of the slope before

starting the towing operation.

•

When towing a problem machine, always use a wire

rope with a sufficient towing capacity.

•

Do not use a frayed, kinked rope or a rope with any

loss of diameter.

OP000035

Safety

1-47

SHIPPING AND

TRANSPORTATION

Obey State and Local Over-the-Road

Regulations

Check state and local restrictions regarding weight, width and

length of a load before making any other preparation for

transport.

The hauling vehicle, trailer and load must all be in compliance

with local regulations governing the intended shipping route.

Partial disassembly or teardown of wheel loader may be

necessary to meet travel restrictions or particular conditions at

the work site.

Refer to “Transportation” on page 5-1, of this Operation and

Maintenance Manual for information on loading, unloading and

towing.

Safety

OP000035

1-48

OP000036

3Operating Controls

The "Operating Controls" section presented here consists of the

following groups:

“Component Locations” on page 2-2

“Operator's Area” on page 2-4

“Steering Console and Pedals” on page 2-5

“Gauges” on page 2-16

“Right Side Switch Panel” on page 2-26

“Various Cabin Locations” on page 2-41

“Heater and Air Conditioner Operation” on page 2-45

“Stereo / CD Player (Optional)” on page 2-50

10.

“Seat Adjustment (Standard)” on page 2-52

11.

“Seat Adjustment (Option)” on page 2-54

12.

“Seat Belt” on page 2-56

13.

“Door Side Latch” on page 2-57

14.

“Fuse Box/Relay/Engine Emergency Stop Switch” on

page 2-59

Each group is explained with a point location drawing or photo

and a brief description of each control, switch, gauge or valve.

Indicator lights work besides the gauges on the instrument

panel. The operator should monitor machine pressure on the

instrument panel along with indicator lights. These lights will only

show that there is a problem.

WARNING!

Warning lights. When any one or more of the warning lights

on the control console come "ON," immediately stop

operation and shut down unit. Investigate and correct

problem before proceeding with operation.

OP000036

Operating Controls

2-1

Reference

Description

Number

Bucket Teeth

CAC Cooler

Bucket

Radiator

Air Conditioner Condenser

Grille

Rear Wheel Cover

Fan

Battery Box

Fuel Tank

Rear Light

Engine Oil Fill Cap

Counterweight

Engine Oil Filter

Fan Motor

Engine Oil Level Dipstick

Towing Pin

Rear Axle Pivot

Muffler Tail Pipe

Rear Axle

Oil Tank

Drive Shaft (Rear)

Tilt Lever

Transmission

Front Wheel Cover

Transmission Oil Filter

Bucket Cylinder

Drive Shaft (Center)

Headlight Support

Center Pin

Ladder

Steering Wheel Cylinder

Work Light

Boom Cylinder

Operator's Cabin

Drive Shaft (Front)

Air Cleaner

Parking Brake

Engine Air Intake Precleaner

Front Axle

Engine

Loader Arm

Muffler

Link

OP000036

Operating Controls

2-3

Starter Switch

A three-position starter switch is used to start or shut down

engine for equipment operation.

O. Turning the switch to this position turns the engine

"OFF" along with its electrical system. In this position

the engine is "OFF" but the interior cabin light and

fuel tank transfer pump (if equipped) are functional.

Turning the switch to this position turns the engine

electrical system "ON." When the switch is first turned

FG000014

"ON" the six indicator/warning lights across the top of

Figure 4

the instrument panel, will light for approximately two

seconds. The battery warning light and the engine oil

pressure warning light should remain "ON" after the

other four have turned "OFF."

NOTE: Preheat Indicator Light - The operation of

the preheat cycle depends on coolant

temperature. When the engine coolant is

cold enough, the preheat indicator light will

remain "ON" until the engine preheat cycle

is completed. The preheat cycle takes

about twenty seconds to complete, and

the indicator light will turn "OFF." When the

light turns "OFF," engage the starter.

. Moving switch to this position will crank engine. When

engine starts, release key and allow it to return to the

"I" (ON) position. Do not operate the starter switch for

more than fifteen seconds at a time. This will help

prevent damage to starter.

WARNING!

DO NOT USE STARTING FLUIDS. The preheat system

could cause the starting fluid to explode. Starting

fluids should never be used.

Operating Controls

OP000036

2-6

Combination Switch

Left Side Directional Switch - Pushing lever forward,

activates left outside directional lights and directional

indicator light on instrument panel.

Right Side Directional Switch - Pulling lever back,

activates right outside directional lights and

directional indicator light on instrument panel.

NOTE: When turn is completed the lever

automatically returns to the "NEUTRAL"

AHO0920L

position. Should it not, it can be manually

Figure 8

returned by hand.

NOTE: Turn signals will function with starter

switch in "OFF" position.

Window Washer Switch - When the outside area of

the lever is pressed, it activates the washer pump

and sprays fluid on the windshield. (Only while being

pressed.)

NOTE: Do not operate the windshield washer

without any fluid. If operate without any

fluid, the washer motor may be damaged.

Check level in washer tank, and add fluid

as required.

NOTE: Using soapy water or synthetic detergent

instead of window cleaning fluid, may

damage the wiper blade or painted

surfaces. Use standard window cleaning

fluid: SSK703

Horn Button - The center button on end of lever

activates horn. (Only while being pressed.)

Wiper Switch - Activates wipers when outside area of

lever is rotated.

J: Intermittent Mode - wipes every five seconds.

0: Stop (Off).

I: Normal Speed Mode.

II: High Speed Mode.

Push Down - Locks into position and light turns "ON"

the high beams.

Neutral Position - Normal low beams.

Pull Up - Momentarily turns "ON" both the low beams

and high beams. (Returns to "NEUTRAL" position

when released.)

NOTE: High and low beams will only function with the

headlight switch in the "||" position.

HAAA4350

Figure 9

Operating Controls

OP000036

2-8

5. Steering Wheel Adjustment Lever

Control lever (1, Figure 11) is used allow wheel to be

moved to the most convenient position for the operator.

Adjusting Steering Wheel Tilt

Pull lever (1, Figure 12) upward and move wheel (2, Figure

12) to desired position. Push lever down (Tilt angle is 21°).

Adjusting Steering Wheel Telescopic

Pull lever (1, Figure 12) upward and move wheel (2, Figure

FG003887

12) to desired position. Push lever down (telescopic stroke

Figure 11

is 80 mm)

RELEASE

LOCK

FG003888

Figure 12

6. Brake Pedal (Right and Left Pedals)

Pressing brake pedal will apply the brakes to the loader.

The brake pedal modes can be switched from "INCHING"

to "NO INCHING" or vice versa, by using the transmission

cutoff switch (See page 3-35).

CAUTION!

FG002183

When descending down an incline, slow down the

machine by using both the brake pedal and the engine Figure 13

as a brake by shifting the transmission to a lower gear.

Using the brake pedal too often might lead to

insufficient oil pressure, thus making it difficult to

brake the loader.

IMPORTANT

Do not use brake pedal as a foot rest. This will cause

brake disk to wear faster than normal, and this could

cause brake failure.

Operating Controls

OP000036

2-10

7. Steering Wheel

Rotating steering wheel controls position of front wheels

and this determines direction of machine travel.

FG003939

Figure 14

8. Kick-down Switch (Two places)

When transmission is in 2nd gear, pressing this switch will

shift transmission into 1st gear. This will allow the driver to

perform a quick digging movement.

NOTE: Kick-down is "RELEASED" when transmission

is placed in "NEUTRAL" position or the switch is

pressed again.

Kick-down function range:

•

Automatic: 2nd, 3rd, 4th.

AHO0900L

Figure 15

•

Manual: 2nd.

A second kick-down switch (Figure 16) is on the right

button in the tip of the pilot control valve lever (joystick)

(Right one of two levers).

FG003940

Figure 16

FG003936

Figure 17

OP000036

Operating Controls

2-11

Transmission Lever

F Forward

- When the lever is pushed forward,

transmission is in "FORWARD." 1st, 2nd, 3rd and 4th

are available.

N Neutral - When the lever is returned to the center

position, between forward and reverse, the

transmission is in "NEUTRAL."

R Reverse

- When the lever is pulled back,

transmission is in "REVERSE" 1st, 2nd and 3rd are

HAAA3680

available.

Figure 18

Rotating the switch shifts transmission between 1st, 2nd,

3rd or 4th gears.

NOTE: There is a transmission display, on the dash,

that indicates, gears, direction of travel, error

codes and kick-down activation.

(See page

3-16)

A transmission neutral lever lock is in base of transmission

lever. This neutral lever lock prevents the transmission

lever from being moved out of "NEUTRAL."

N "NEUTRAL LOCK" position. Prevents lever from

being moved out of "NEUTRAL."

D "DRIVE" position. Allows lever to be moved from

"NEUTRAL" to "FORWARD and REVERSE."

FG003943

CAUTION!

Figure 19

"LOCK" transmission lever. Whenever machine is

parked, "LOCK" transmission lever in "NEUTRAL" to

prevent accidental machine movement.

Operating Controls

OP000036

2-12

12. Automatic Shift Mode Switch

•

1-4; Auto 1-4 mode (Working mode)

1-4

Turn the gear selector control to gear position 4

MAN

2-4

Set the shift mode selector to "Auto

1 ê

Selector the directional gear and accelerate the

machine.

Up and downshifts are made automatically

FG004181

between 1st - 2nd - 3rd - 4th gears forward and

Figure 22

between 2nd - 3rd - 4th in reverse.

It is unnecessary to use kick-down function for

1st gear.

•

Auto 2-4 mode (Travel mode)

1-3 is same as Auto 1-4

Up and downshifts are made automatically

between 2nd - 3rd - 4th gears forward and

between 2nd - 3rd - 4th in reverse.

Kick-down switch must be used for shifting to

1st gear.

•

Manual mode

After starting gear shifting is done manually.

13. Hazard Warning Light Switch

This warning light is used when the equipment is stopped

due to a malfunction or when an emergency occurs. When

this switch is pressed the directional indicator lights 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 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

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.

Operating Controls

OP000036

2-14

Gauges

Reference

Description

Number

Fuel Gauge

Transmission Oil Temperature

Gauge

Speedometer

Transmission Display

Hour Meter

Tachometer

Engine Coolant Temperature

Gauge

Warning and Indicator Lights

Reference

Description

Number

Preheat Indicator Light

F/R (Forward/Reverse) Selector

Indicator Light

Air Cleaner Clogged Warning

Light

Parking Brake Indicator Light

Battery Warning Light

Emergency Steering Indicator

Light (Option)

Left Turn and Hazard Warning

Light

Engine Warning Light

High Beam Indicator Light

Not Used

Right Turn and Hazard Warning

Not Used

Light

Mirror Heating Indicator Light

Work Light Indicator Light

Reverse Fan Indicator Light

Brake Fluid Pressure Warning

Electric Steering Select Indicator

Light

Light (Option)

IMPORTANT

All of gauge and warning lights (except for the turn lights,

high beam light, work light and transmission cutoff light)

turn "ON" for two seconds with a warning buzzer sound

when the starter switch is turned to the "I" (ON) position.

If any light fails to turn "ON" at this time, check the cause

and replace.

Operating Controls

OP000036

2-16

1. Fuel Gauge

This gauge displays amount of fuel in tank. "F" means the

tank is "full"; "E" means the tank is "empty." If the pointer

comes close to the "E" (red zone), add fuel as soon as

possible. When the pointer comes close to the "E" (red

zone), approximately 21.2l (5.6 U.S. gal.) of fuel remains.

FG003948

Figure 25

2. Speedometer

This meter displays speed at which vehicle is traveling.

FG004182

Figure 26

3. Hour Meter

A LCD meter that records total time. When engine is

running, the hourglass icon blinks every four seconds. This

shows that the hour meter is working.

HA0O2012

Figure 27

OP000036

Operating Controls

2-17

4. Tachometer

This meter displays engine speed in revolutions per

minute.

FG004183

Figure 28

5. Engine Coolant Temperature Gauge

This gauge displays temperature of engine coolant.

CAUTION!

When the pointer indicates red zone, it means the

engine is overheated. Stop the operation, let the

engine run at low rpm and wait for it to cool down.

FG003949

Do not shut down engine. If engine is shut down heat

Figure 29

surge may occur.

6. Transmission Oil Temperature Gauge

This gauge displays temperature of oil in transmission

converter and transmission circuit.

CAUTION!

When the pointer indicates red zone, it means the

transmission is overheated. Stop the operation, let the

engine run at low rpm and wait for transmission to

FG003950

cool down.

Figure 30

Operating Controls

OP000036

2-18

7. Transmission Display

A transmission display is in the gauge panel on the dash.

The LCD indicates, gears, direction of travel, error codes,

and activated kick-down.

FG003946

Figure 31

Figure 32, shows the transmission display in detail.

A. Indicates travel direction and gear selection. See

Figure 33 for more detailed information.

B. Indicates normal operation and error codes.

NOTE: Most codes are only two digits.

C. Indicates that error codes have occurred and are

(D)

(A)

(B)

(C)

stored.

D. Indicates that operation must be stopped immediately

to prevent damage to transmission and hazardous

HAAA3770

operating condition.

Figure 32

The gear range indicator bars will indicate which gear is

selected by displaying the corresponding number of bars.

FORWARD

The forward and reverse indicator bars will be "OFF" when

INDICATOR

the transmission is in "MANUAL MODE."

When transmission is in "AUTOMATIC MODE," all the

GEAR RANGE

gear range indicator bars and both travel direction

INDICATOR BARS

indicators will be "ON."

REVERSE

INDICATOR

HAAA3774

Figure 33

OP000036

Operating Controls

2-19

8. Preheat Indicator Light

This indicator light will turn "ON," when the engine preheat

function is operating. Do not start engine as long as this

light is "ON."

HAOA639L

Figure 34

9. Air Cleaner Clogged Warning Light

This warning light will turn "ON," when dirt has built up in

the air filter and is beginning to restrict flow of air. Clean or

replace air filter before continuing to operate machine. To

turn indicator light "OFF," turn starter switch "OFF" and

then back "ON."

HAOA660L

Figure 35

10. Battery Warning Light

When starter switch is first turned to "ON" position, this red

warning light should turn "ON." When engine is running

this red light should turn "OFF." If light remains "ON" when

engine is running, alternator is defective.

HAOA610L

Figure 36

Operating Controls

OP000036

2-20

11. Left Turn and Hazard Warning Light

This light blinks when left turn signal is turned "ON." Both

lights blink when warning lights are turned "ON."

NOTE: If left and right turn indicators blink together, or if

they blink faster than normal, a light bulb is not

operating or flasher solenoid is damaged.

FG004173

Figure 37

12. High Beam Indicator Light

This indicator light will turn "ON," when the headlights are

turned to "HIGH BEAM."

HAOD394L

Figure 38

13. Right Turn and Hazard Warning Light

This light blinks when right turn signal is turned "ON." Both

lights blink when warning lights are turned "ON."

NOTE: If left and right turn indicators blink together, or if

they blink faster than normal, a light bulb is not

operating or flasher solenoid is damaged.

FG004174

Figure 39

OP000036

Operating Controls

2-21

14. Work Light Indicator Light

This indicator light will turn "ON," when the front and/or

rear work lights are activated.

Figure 40

15. Brake Fluid Pressure Warning Light

This warning light will turn "ON," when pressure drops in

brake fluid circuit. When light turns "ON," an alarm also

sounds.

WARNING!

Never operate or travel machine when this light is

"ON" or when alarm is sounding. Always investigate

HA0O2024

cause of the drop in brake fluid pressure, and repair

Figure 41

problem before operating or traveling machine.

16. F/R (Forward/Reverse) Selector

Indicator Light (Option)

This indicator light will turn "ON," when the

2nd gear

function is selected.

NOTE: See

“F/R

(Forward/Reverse) Travel Control

F/R

System

(Option)” on page 3-18 for further

information.

BSO0510L

Figure 42

Operating Controls

OP000036

2-22

17. Parking Brake Indicator Light

This indicator light will turn "ON," when the parking brake is

"APPLIED." If vehicle is moved while parking brake is

applied, a warning alarm will sound.

WARNING!

If vehicle is moved while this light is turned "ON," it

could cause premature wear or damage the brake.

0717A

Figure 43

Always "RELEASE" parking brake and make sure this

light is "OFF" before traveling machine.

18. Emergency Steering Indicator Light

(Option)

This indicator light will turn "ON," when the emergency

steering system is activated due to a hydraulic failure.

Immediately stop any operation, stop machine, "APPLY"

parking brake, and shut down engine.

DANGER!

AJO0450L

Figure 44

Emergency steering indicator light. If this light turns

"ON" while operating machine, discontinue operation

immediately. This light indicates that there is a serve

problem with the unit.

NOTE: The light will also turn "ON" when the system is

being tested.

OP000036

Operating Controls

2-23

19. Engine Warning Light

If a defect is present in the engine system, and it is

recognized by the ECU and cause a malfunction in

operation, it can be displayed with the engine warning light

to indicate a warning to the operator. If this Light turns

"ON" or "blinking," check the engine as described under

the engine diagnostic switch (See page 3-36).

•

Light turned "ON": nonfatal system error

•

Light is "BLINKING": fatal system error

AQO0040L

NOTE: The engine warning light flashes out the two

Figure 45

digit fault code in the diagnostic mode.

Fault Code 35 (example)

: Long Light

: Short Light

FG004339

Figure 46

20. Not Used

21. Not Used

22. Mirror Heater Indicator Light

This indicator light will turn "ON," when the mirror heater is

operated.

FG004184

Figure 47

Operating Controls

OP000036

2-24

RIGHT SIDE SWITCH PANEL

FG003951

Figure 50

Reference

Description

Number

Pilot Control Valve Lever

Reverse Fan Switch

(Two Lever)

Engine Diagnostic Switch

Pilot Control Valve Lever

Not Used

(Joystick) (Option)

Boom Float Switch (Option)

Kick-down Switch

LIS Switch (Option)

Horn Button

Seat Heater Switch (Option)

Cigar Lighter

Fuel Heater Switch (Option)

Economic Mode Switch

Emergency Steering Test Switch

Not Used

(Option)

Headlight Switch

Rotating Beacon Light Switch

Front Work Light Switch

(Option)

Rear Work Light Switch

Power Socket for 12 Volt

Rear Wiper Switch

F/R (Forward/Reverse) Selector

Switch (Option)

Pilot Cutoff Switch

F/R (Forward/Reverse) Control

Parking Brake Switch

Switch (Option)

Transmission Cutoff Switch

Cup Holder

Mirror Heating Switch

Operating Controls

OP000036

2-26

1. Pilot Control Valve Lever (Two Lever)

(Option)

Move left control lever forward (2, Figure 51) to dump

bucket, or rearward (4, Figure 51) to roll back bucket.

Move right control lever forward (3, Figure 51) to lower

boom or rearward (5, Figure 51) to raise boom.

Float (right lever in full forward detent position (1, Figure

51)): This position allows oil flow in and out both ends of

cylinders so the bucket can follow the contour of the

FG003952

ground. Manually release lever from the position.

Figure 51

Return-to-Dig (left lever in full rearward detent position (6,

BOOM FLOAT

Figure 51)):Bucket will return to set dig position.

BUCKET DUMP

Boom Height Kick-out right lever in full rearward detent

BOOM LOWER

position (7, Figure 51)): Lever will remain in this position

BUCKET CROWD

until boom is at a preset height, then will return to neutral

BOOM RAISE

automatically.

BUCKET RETURN TO DIG

BOOM HEIGHT KICK-OUT

A. Kick-down Switch (Two Places)

(See page 3-11)

FG003940

Figure 52

B. Horn Switch (Two Places) / Log Fork Switch (Option)

•

Horn switch function.

•

Log fork switch function.

When the log forks control lever is pushed forward or

pulled back while this switch is pressed, the log forks

are allowed to open or closed. (See page 3-28)

FG003935

Figure 53

OP000036

Operating Controls

2-27

1A. Pilot Control Valve Lever (Joystick)

(Option)

If loader is equipped with log forks this lever controls boom,

bucket and log forks.

Used to position bucket and boom. This lever is capable of

raising or lowering boom, and crowding or dumping bucket.

When machine is being traveled, the lever (joystick) can be

"LOCKED" out, to prevent any movement of bucket or

boom. To "LOCK" out lever (joystick), place pilot cutoff

BSO0530L

switch in "LOCKED" position.

Figure 54

Pilot control valve lever (joystick) operating pattern and

description of operation.

Figure 55

HL. Hold lever in

Lower Mode

L. Lower

HC. Hold lever in

C. Bucket Crowd

N. Neutral

Bucket Dump

Bucket Crowd

R. Raise

HR. Hold lever in Raise

Mode

A. When the log forks control lever (6, Figure 54) is

pushed forward the log forks are allowed to open.

B. When the log forks control lever (6, Figure 54) is

pulled back the log forks are allowed to close.

This lever is capable of forward travel and reverse travel

(2nd gear function).

Neutral Switch

When this switch is pressed, 2nd gear function will be

operated, and then 2nd gear indicator light turns

"ON."

When 2nd gear function is operated, this switch is

pressed, and then machine is neutral.

Operating Controls

OP000036

2-28

Forward Switch

When this switch is pressed at forward traveling while

"KD" (5, Figure 54) switch is pressed, machine can

travel forward. When machine is travelled, it can

convert forward and reverse travel without pressing

"KD" (5, Figure 54) switch.

Reverse Switch

When this switch is pressed at reverse traveling while

"KD" (5, Figure 54) switch is pressed, machine can

travel reverse. When machine is travelled, it can

convert forward and reverse travel without pressing

"KD" (5, Figure 54) switch.

Horn Switch

(See page 3-30)

Kick-down Switch

(See page 3-29)

NOTE: Operating condition of 2nd gear function.

•

Start a engine.

•

Transmission lever is neutral.

•

Parking brake switch is off (release).

NOTE: Release condition of 2nd gear function.

•

When the transmission lever will be push forward or

pull reverse.

•

When the parking brake switch turns "ON."

•

When the starter switch turns "OFF."

2. Kick-down Switch (TWO PLACES)

Kick-down Switch Function - When transmission is in 2nd

gear, pressing this switch (Figure 57) will shift transmission

into 1st gear. This will allow the driver to perform a quick

digging movement.

Kick-down function range:

•

Automatic: 2nd, 3rd, 4th.

•

Manual: 2nd.

FG003936

NOTE: Kick-down is "RELEASED" when transmission

Figure 56

is placed in "NEUTRAL" position or the switch is

pressed again.

OP000036

Operating Controls

2-29

4. Cigar Lighter

Push the lighter all the way into the socket and release

your hand. After pushing it in, it will be ejected when it is

heated. If it does not eject after a short time, pull it out and

have it serviced.

IMPORTANT

The cigar lighter is powered by a 24 volt circuit. Never

plug any 12 volt device into the cigar lighter.

HAOA780L

Figure 60

5. Economic Mode Switch

This economic mode switch allows the operator to switch

between 100% throttle torque and droop curve and about

an 80% derated torque curve and droop. In the economy

mode, fuel consumption is clearly reduced by utilising a

reduced-power characteristic map for the engine. This is of

benifit with all general loading work.

O. In this position torque switch is set to the "off"

position, and

100% torque is permitted for hard

digging or driving up sleep inclines.

FG004998

Figure 61

In this position torque switch is turn "ON", which limits

engine torque to 80% of maximum.

6. Not Used

OP000036

Operating Controls

2-31

7. Headlight Switch

O. In this position, this switch turns "OFF" clearance, tail,

instrument panel, switch and headlights.

NOTE: If the switch is not in this position with the

engine not running, the pilot buzzer will

sound to warn the operator that the

batteries are being discharged.

In this position, this switch turns "ON" clearance, tail,

instrument panel and switch lights.

FG003976

II.

In this position, this switch turns "ON" clearance, tail,

Figure 62

instrument panel, and headlights.

CAUTION!

Do not leave clearance, tail, instrument panel or

headlights "ON" when the engine is not running.

Leaving lights "ON" with the engine shut down will

discharge batteries.

8. Front Work Light Switch

O. In this position, this switch turns "OFF" work lights

mounted on the front top of cabin.

In this position, this switch turns "ON" work lights

mounted on the front top of cabin.

CAUTION!

HAOQ071L

Do not turn "ON" the work light when traveling on

Figure 63

public roads.

Operating Controls

OP000036

2-32

9. Rear Work Light Switch

O. In this position, this switch turns "OFF" work lights

mounted on the rear top of cabin and the sides of

radiator.

In this position, this switch turns "ON" work lights

mounted on the sides of radiator.

II.

In this position, this switch turns "ON" work lights

mounted on the rear top of cabin and the top of the

sides of radiator.

AHO0850L

Figure 64

CAUTION!

Do not turn "ON" the work light when traveling on

public roads.

10. Rear Wiper Switch

O. In this position, this switch turns "OFF" windshield

wiper mounted on rear windshield of operator's cabin.

In this position, windshield washer fluid sprays onto

the rear windshield while running the rear wiper.

When released, the switch returns to the "O" (OFF)

position.

II.

In this position, this switch turns "ON" windshield

wiper mounted on rear windshield of operator's cabin.

HAOD421L

Figure 65

CAUTION!

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 may damage the wiper blades

and the paint finish. Only use the recommended

washer fluid or equivalent.

OP000036

Operating Controls

2-33

11. Pilot Cutoff Switch

O. In this position the operator cannot operate the pilot

control valve lever (joystick).

In this position the operator can fully control the

movement of the pilot control valve lever (joystick).

CAUTION!

HBOI110L

When driving or parking, the pilot cutoff switch must

Figure 66

be changed to "O" (OFF) position.

12. Parking Brake switch

O. In this position, the parking brake is "RELEASED"

and the indicator light on the front instrument panel

turns "OFF."

In this position, the parking brake is "APPLIED" and

the indicator light on the front instrument panel

comes "ON." This brake can also be used as an

emergency brake.

HA0O2019

Figure 67

WARNING!

Set the parking brake switch in the "I" (APPLIED)

position before leaving the loader. Make sure to

"APPLY" the parking brake switch before trying to

start the loader.

CAUTION!

Do not use the parking brake to stop the loader, except

in an emergency; otherwise, it might cause premature

wear or damage of the brake.

FG003953

Figure 68

Operating Controls

OP000036

2-34

13. Transmission Cutoff Switch

This switch changes the mode of the brake pedal from

"INCHING" to "NO INCHING."

O. In this position, the "NO INCHING" mode is selected.

In the "NO INCHING" mode, the power transmission

line is still connected when the brake pedal is

pressed, thus, making it easier to start off on an

incline. This mode is also suitable for traveling,

because both dynamic engine braking and the

HA3O2018

service brake can be used when descending grades.

Figure 69

In this position, the "INCHING" mode is selected.

In this mode, the transmission is put in "NEUTRAL"

by pressing the left brake pedal. This mode is

suitable for a load handling operation. When the

accelerator pedal is pressed in this setting, more

power is concentrated on the load handling system,

to quicken the boom lifting speed.

NOTE:

1) Transmission "CUTOFF" function dose not

operate at 3rd and 4th gear for protection of

transmission.

2) Despite transmission "CUTOFF" switch, the

right brake pedal has braking function only.

WARNING!

When pressing brake pedal while traveling or working

on a slope, set this switch to "O" for dynamic engine

braking.

14. Mirror Heating Switch

This switch is used to operate a heater installed in the

mirror. Press the switch and the mirror heater will remove

frost and ice from mirror.

O. "OFF" position.

"ON" position.

FG004187

Figure 70

OP000036

Operating Controls

2-35

15. Reverse Fan Switch

This switch causes the radiator cooling fan to rotate in the

reverse direction. The function of reversing the direction of

the radiator cooling fan is effective in cleaning the radiator.

O. "OFF" position.

"ON" position.

Activate the switch for reverse rotation in the following

order;

FG004188

A. Turn the starter switch "O" (OFF) → "I" (ON) and then

Figure 71

turn the of the cooling fan reverse rotation switch "O"

(OFF) → "I" (ON) and start the engine.

B. For reverse operation, the cooling fan reverse

rotation indicator light turns "ON" the same time.

C. To return to forward rotation, shut down engine,

change the position of the reverse switch "ON" →

"OFF," and start the engine again.

WARNING!

Never travel or work in the reverse fan rotation mode.

This may cause damage to the cooling system. Make

sure that this switch is in the "O" (OFF) position before

starting the engine and operating the machine.

16. Engine Diagnostic Switch

If the engine warning light turns "ON" or "blinks," when the

engine is running, it means a fault code has been

recorded. When this occurs, the engine diagnostic switch

allows the operator to view the fault codes. The active fault

code is started after this switch turns "ON" "OFF," if during

the output of the fault code this switch turns "ON" "OFF"

again, the output of the current fault code is interrupted and

the next fault code is displayed. Each depression of the

diagnostic switch causes the output of a fault code. If a

AQO0120L

fault code is displayed, contact your authorized dealer for

Figure 72

repair. To know the fault code information, refer to the

engine control system of shop manual.

Operating Controls

OP000036

2-36

17. Not Used

18. Boom Float Switch (Option)

Boom float allows the bucket to follow the contour of the

ground/working surface. When pressing this switch and

setting work lever to float position, the lever is locked

(detent) and boom is lowered. When boom is matched to

setting position, the lever lock is released, and lever is

returned to "NEUTRAL" position. Boom lowering is

stopped.

O. In this position, this switch turns "OFF" boom float.

HAOA751L

In this position, this switch turns "ON" boom float.

Figure 73

19. Load Isolation System (LIS) Switch

(Option)

This switch enables the boom cylinder to absorb shock

loading of the machine during traveling and working. It

improves dynamic stability, machine life, and

comfortability. It is most effective when traveling with load

in the bucket.

O. In this position, the LIS turned "OFF."

In this position, the LIS turned "ON" at all travel

FG004256

speeds.

Figure 74

II.

In this position, the LIS will "AUTOMATICALLY

TURN ON" if the forward travel speed exceed 6 km/h

(3.7 MPH) or reverse travel speed exceed 4 km/h

(2.5 MPH). LIS will automatically turn "OFF" if the

forward speed is less than 4 km/h (2.5 MPH) or if

reverse travel speed is less than 2 km/h (1.2 MPH).

20. Seat Heater Switch (Option)

This switch is used to operate the seat heater. When the

switch is pressed, the seat heater starts to heat seat.

O. In this position, this switch turns "OFF" seat heater.

In this position, this switch turns "ON" seat heater.

FG004189

Figure 75

OP000036

Operating Controls

2-37

21. Fuel Heater Switch (Option)

This switch is used to operate the fuel heater. When the

switch is pressed, the fuel heater starts to heat fuel. If the

fuel temperature is 5°C and higher, the fuel heater does

not operate, even if switch in "I " (ON) position

O. In this position, this switch turns "OFF" fuel heater.

In this position, this switch turns "ON" fuel heater.

FG004190

Figure 76

22. Emergency Steering Test Switch and

Automatic Test (option)

Emergency Steering Test Switch

This switch is used to test whether the emergency steering

system is properly functioning.

The system must be tested during the start-up procedure

to ensure that the system is properly functioning.

Test emergency steering system using the following

AJO0010L

procedure:

Figure 77

A. Turn starter switch to "I" (ON) position.

NOTE: Do not start engine.

B. Press emergency steering test switch and turn

steering wheel at the same time. If system is

functioning properly the unit should steer. The

emergency steering indicator light should turn "ON."

NOTE: If unit does not steer, do not operate unit

until problem is corrected.

C. Release switch. Switch will automatically return to

"O" (OFF) position.

Automatic Test

This is a system check that tests the hydraulic oil pressure

in the emergency steering system lines. With starter switch

turn to "I" (ON) position, an emergency warning light on the

front gauge panel will turn "ON" for about three seconds.

WARNING!

Do not press this switch continuously. Continuously

pressing switch will cause heavy battery discharge.

The emergency steering DC motor has a high

consumption of power.

Operating Controls

OP000036

2-38

23. Rotating Beacon Light Switch (Option)

O. In this position, this switch turns "OFF" rotating

beacon light.

In this position, this switch turns "ON" rotating beacon

light.

HAOA750L

Figure 78

24. Power Socket for 12 Volt

This is a power socket for only 12V DC devices.

This socket can be used for charging a cellular phone or

powering a small 12V DC electrical device.

Open the cap when using it.

12 V

NOTE: This socket is designed for small electrical

capacity devices. Do not use this socket for

large electrical capacity devices. Thus, damage

can be avoided.

HAAE1990

Figure 79

25. F/R (Forward/Reverse) Selector Switch

O. In this position, the F/R control switch is "OFF"

In this position, the F/R control switch is activated.

When released the switch returns to the "O" (OFF)

position, but the system is still activated. When this

switch is depressed again, F/R control switch is

"OFF"

NOTE:

1) When activating system, the transmission

lever and F/R control switch must be in

FG003977

"NEUTRAL."

Figure 80

2) If the transmission lever is actuated (moved),

the gearshift functions of the F/R control switch

are deactivated, and forward/reverse travel is

again controlled by the transmission lever.

OP000036

Operating Controls

2-39

26. F/R (Forward/Reverse) Control Switch

To be able to use the forward/reverse function, the F/R

selector switch must first be depressed. When the switch is

activated, the F/R selector indicator light will be turned

"ON" in the instrument panel.

O. In this position, the machine is in "NEUTRAL"

In this position, the machine travels "FORWARD"

II.

In this position, the machine travels "REVERSE"

BSO0410L

NOTE: If the transmission lever is moved out of

Figure 81

"NEUTRAL" while operating the F/R control

switch, the transmission lever will override the

switch. The F/R control switch system will

require, that the F/R selector switch to be

pressed again, with the transmission lever in

"NEUTRAL."

27. Cup Holder

Place to put beverages.

Operating Controls

OP000036

2-40

Doosan DL 300. Operation and Maintenance Manual (2003) - page 1