Doosan DL 300. Operation and Maintenance Manual (2003)

1. Cabin Light

Located in the middle of front cabin, it illuminates the cabin

for night work. Light turns on when the switch is in the "ON"

or "O" position but off in the "OFF" position. Cabin light

may be turned "ON" and "OFF" irrespective of the position

of the starter switch.

FG004192

Figure 83

2. Stereo / CD Player (Option)

For operation of stereo see “Stereo / CD Player (Optional)”

on page 2-50.

PROGRAM

AST

SOUND

AM/FM

SCAN

TUNE

FG004057

Figure 84

3. Heater and Air Conditioner Control

Panel

For operation of heater and air conditioner see “Heater and

Air Conditioner Operation” on page 2-45.

FG003955

Figure 85

Operating Controls

OP000036

2-42

4. Speakers

Emits sound generated by stereo.

HBOM350L

Figure 86

5. Storage Compartments

There are two storage compartments (1 and 2, Figure 87)

located both sides behind of the operator's seat. Keep the

operation manual and other documents in this

compartment.

FG003889

Figure 87

6. Windshield Washer Tank

Contains windshield washer fluid. It is located behind the

operator's seat. (3, Figure 87)

7. Electrical Box

Contains relays and electric components. It is located on

left side of cabin.

FG003956

Figure 88

OP000036

Operating Controls

2-43

HEATER AND AIR CONDITIONER

OPERATION

Location of Controls and Vents

FG003960

Figure 90

Reference

Description

Number

Operation Panel

Foot Nozzle

Front Nozzle (Air Conditioner)

Rear Nozzle

Front Nozzle (Defroster)

The heater and air conditioner are combined into one unit to the

right side of the operator's seat. If necessary, the operator can

control interior cabin temperature using the operation panel.

OP000036

Operating Controls

2-45

Operation Panel

FG003966

Figure 91

Reference

Description

Number

Fan and Air Conditioner Switch

Selector Switch for Wind

Direction

Blower Fan Switches

Ventilation Selector Switch

Temperature Control Switch

When a switch is selected, the LED above that switch will turn

"ON" and give an activation sound.

When the light switch is turned "ON," the panel LED's will turn

"ON."

1. Fan and Air Conditioner Switch

A. "OFF" Switch

- Turns "OFF" the heater and air

conditioner unit.

B. "A/C" Switch - Turns "ON" the air conditioner when

one of the blower switches is activated.

HAOC930L

Figure 92

Operating Controls

OP000036

2-46

2. Blower Fan Switches

These switches are used to control the speed of the blower

fan.

A. "LO" Switch - Used for low blower speed.

B. "MID" Switch - Used for intermediate blower speed.

C. "HI" Switch - Used for high blower speed.

NOTE: If you do not select a blower speed the heater

and air conditioner will not work.

HAOC940L

Figure 93

3. Temperature Control Switch

The temperature control consists of 24 stages. An LED is

turned "ON" for every three stages. Whenever pushing it, it

changes in stages. Pushing it continuously, it changes

continuously.

A. "COOL" Switch - Lowers the temperature.

B. "WARM" Switch - Raises the temperature.

LED COLOR STATUS

HAOA860I

Green LED - Air conditioner. Full green, maximum

Figure 94

operation of air conditioner.

Red LED - Heater. Full red, maximum operation of

heater.

4. Selector Switch for Wind Direction

A. Used to direct air flow to upper portion of operator's

cabin.

FG003967

Figure 95

OP000036

Operating Controls

2-47

Memory Function of Used Mode

The air conditioner panel has a memory function. When the

starter switch is turned "OFF" the settings for the panel will be

stored. When the excavator is started, the last setting will be

used.

Additional Operating Instruction

A proper interior temperature in summer is 5 - 6° C (10 - 12°F)

less than the outdoor temperature.

Operate the air conditioner from twenty - thirty minutes a week

to circulate the refrigerant in the system.

NOTE: The blower switch must be on "LO" speed.

NOTE: The filter must be cleaned out every 500 hours and

replaced with a new one every 1,000 hours.

NOTE: In the event that the unit is being operated in a dusty

environment, the cleaning and replacement must be

performed more frequently.

If operating the air conditioner or heater for a long time, operate

the ventilation switch, and when smoking, vent the air to the

outside to prevent irritation to eyes.

OP000036

Operating Controls

2-49

STEREO / CD PLAYER

(OPTIONAL)

Before operating the stereo or CD player, read operation manual

enclosed with stereo or CD player.

Stereo

PROGRAM

AST

SOUND

AM/FM

SCAN

TUNE

FG000108

Figure 99

Reference

Description

Number

Power / Volume Control

Preset Station

Sound Mode Selector

Tape Ejection

Band Selection

Fast Forward / Rewind

Tuning Up / Down

Tape Loading Slot

Scan Function / Auto Store

LCD

Operating Controls

OP000036

2-50

SEAT ADJUSTMENT

(STANDARD)

WARNING!

Whenever operator or operating condition has changed,

check to see that seating position is suitable for the

condition at hand. Always fasten your seat belt while

operating vehicle. Adjust backrest so that the operator can

fully reach and operate pedals.

HAOB110L

Figure 101

1. Adjusting Seat Forward/Backward

Lever

Holding lever (3, Figure 102), raise it, while pushing or

pulling seat to desired position. Release lever once desired

position is reached. Adjustment range is 160 mm (6.3 in).

2 and 3. Adjusting Seat's Angle and Height

Lever

HBOI350L

Figure 102

Pulling left lever (3, Figure 102) up allows rear part of seat

to be moved up or down. Pulling lever (2) up allows front

part of seat to be moved up or down. Adjust seat according

to operator's size and work conditions. Adjustment range is

60 mm (2.36 in) for both front and rear.

4. Weight Adjustment Knob

Turning knob (4, Figure 102) to right makes suspension

harder. Turning knob to left makes suspension softer.

Adjust according to operator's weight by checking weight

indicator dial. Adjustment range is from 50 - 120 kg (110 -

265 lb).

5. Backrest Adjustment Lever

Pulling up right lever (5, Figure 102) allows seat backrest

to be moved forward or backward.

Operating Controls

OP000036

2-52

6. Angle Adjustment of Armrest

Adjustment angle of left and right armrest (6, Figure 103) is

done by turning a dial in bottom of armrest. When you

adjust angle, manually raise armrest before turning dial.

7. Headrest

Headrest

(7, Figure

103) can be adjusted forward/

backward and up/down. Move it by holding both sides.

HAOB130L

Figure 103

Recommendations for Limiting Vibrations

Select the right machine, equipment and attachments for a

particular application.

Replace any damaged seat by a DOOSAN genuine part.

Keep the seat maintained and adjusted.

•

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.

OP000036

Operating Controls

2-53

SEAT ADJUSTMENT (OPTION)

WARNING!

Whenever operator or operating condition has changed,

check to see that seating position is suitable for the

condition at hand. Always fasten your seat belt while

operating vehicle. Adjust backrest so that the operator can

fully reach and operate pedals.

BSO0090L

Figure 104

1. Adjusting Seat Forward/Backward

Lever

Holding lever (1, Figure 104), raise it, while pushing or

pulling seat to desired position. Release lever once desired

position is reached. Adjustment range is 152 mm (6 in).

2. Seat Height and Firmness / Adjustment

Knob

BSO0100L

Figure 105

To raise seat or increase firmness in ride, turn key to "ON"

and push in on height/firmness adjustment knob (5, Figure

105).

To lower seat height or decrease firmness in ride, pull out

on height/firmness adjustment knob

(5, Figure

105).

Adjustment range is 76 mm (3 in).

3. Backrest Adjustment Lever

Lift backrest tilt adjustment lever (2, Figure 104) and allow

cushion to angle forward or lean backward into desired

position and release handle.

4. Lumbar Control Knob

Rotate lumbar control knob (4, Figure 104) to increase or

decrease support to lower back.

Operating Controls

OP000036

2-54

SEAT BELT

WARNING!

Seat belt is for operator's safety and should always be

worn. Before driving machine, adjust seat to desired

position for maximum comfort and machine control, then

fasten seat belt. Seat belts must be worn across pelvic

region and adjusted snugly to lessen chance and severity

of injury in event of an accident. Never fasten a seat belt

across abdomen.

Under no circumstances should operator be standing in

cabin when operating wheel loader.

Do not adjust seat position while vehicle is moving because

a loss of control may result. Stop machine, apply parking

brake, and then adjust seat.

Always, check condition of seat belt and belt bracket before

fastening it. Do not use it with twists in it. Replace belt or

bracket if damaged or worn.

Seat Belt Locking and Unlocking

Insert belt end (1, Figure 106) into buckle (2). Pull belt to check

that belt end is locked into buckle.

Adjust belt length so that it comfortably tight against operator's

pelvic region (hipbone).

HAOB140L

Figure 106

Press button (3, Figure 107) in center of buckle (2) and pull out

belt (1) to unlock.

HAOB150L

Figure 107

Operating Controls

OP000036

2-56

DOOR SIDE LATCH

Door side latches (1. LH, Figure 108) and (2. RH, Figure

109) are used to secured the doors (RH, LH) to the side of

the cabin when they are opened.

NOTE: Keep the door closed and locked when machine

is not in use.

FG003894

Figure 108

FG003895

Figure 109

The RH side door, which is emergency exit from the cabin,

can be opened in two positions.

Position 1. (ventilation position)

•

Open the window and secured it with the lock bar. (A,

Figure 110)

Position 2. (full opened position)

•

Open the window and push it to backward

FG003896

Figure 110

OP000036

Operating Controls

2-57

FUSE BOX/RELAY/ENGINE

EMERGENCY STOP SWITCH

Fuse Boxes

There are two fuse boxes inside the cabin.

Fuse boxes are on the upper side of the electric box. A usage

diagram of fuses is shown inside of fuse box. Spare fuses are

mounted on the inside of fuse box cover (10A - Qty. 1, 15A - Qty.

1, 20A - Qty. 1 and 30A - Qty. 1).

WARNING!

If any fuse is blown, turn "OFF" the starter switch and shut

off the power supply. Remedy the cause

needed and

replace the fuse with a new one.

FG003971

Figure 113

Fuse Box One

FUSE BOX (1)

FUSE BOX (2)

No.

Name

Capacity

Rear Wiper, Window Washer

10A

Parking Brake, Pilot Cut Off

10A

Rotating Beacon (Option)

10A

CCTV (Option)

10A

Spare

10A

FG003972

Figure 114

Cigar Lighter

10A

Turn Signal Light, Hazard Light,

10A

Indicate Light

Starter Switch, Hour Meter,

10A

Cabin Light

Air Conditioner, Heater

30A

Headlight

20A

Transmission

15A

Condenser Fan, Cooling Fan

15A

ECU (1)

15A

ECU (2)

15A

OP000036

Operating Controls

2-59

Fuse Box Two

No.

Name

Capacity

Gauge Panel

10A

Stop Light

10A

Auto-detent, LIS (Option)

10A

Electric Steering (Option)

10A

Emergency Steer (Option)

10A

Horn, Front Wiper

10A

Position Light (Left)

10A

Position Light (Right)

10A

Fuel Heater (Option)

30A

Work Light (Rear)

20A

Seat Suspension (Option),

Seat Heater (Option),

15A

Mirror Heater

Work Light (Front)

15A

Stereo, Clock, 12V Socket

15A

Memory Backup, Pilot Buzzer

15A

Operating Controls

OP000036

2-60

Relays

The relays are in the electrical box on the left side in the

operator's cabin. If the problem is not solved after replacing the

fuse, check the function of the relay.

FG003973

Figure 115

FG003974

Figure 116

Circuit Breaker

A circuit breaker is next to the relay by the batteries at back of

unit under engine compartment hood. When a short circuit or an

overload occurs, the circuit breaker automatically cuts off

current, thus preventing electrical wires from burning.

FG003975

Figure 117

OP000036

Operating Controls

2-61

Fusible Link

A fusible link (Figure 118) is in the battery box.

If the engine does not crank, first check that the starter switch is

turned "ON" and that no power is available (No indicator lights

will light.). Check that the "A" portion (Figure 119) of the fusible

link is not broken or burned through. Replace the fusible link if

damage and investigate cause.

FG003978

Figure 118

WARNING!

When changing the fusible link, replace the fusible link with

the same capacity part. Otherwise, a fire could break out in

the wiring harness and/or other components of the circuit.

Always use original DOOSAN parts.

HAOB100L

Figure 119

Operating Controls

OP000036

2-62

OP000037

3Operation

WARNING!

Before operating any DOOSAN Daewoo wheel loader, read

and understand "Operating Controls" section of this

manual.

INSTRUMENT PANEL CONTROL

FUNCTIONS

Monitoring System

Monitoring system uses network circuits between control system

and sensors installed at various machine system locations to

monitor selected conditions. The monitoring systems function is

to continually inform the operator of machine's condition.

Displays and gauge readouts on instrument panel provide

information such as engine speed, engine coolant temperature,

transmission oil pressure, and electrical charge status.

NEW MACHINE BREAK-IN

PROCEDURES

All DOOSAN Daewoo wheel loaders are inspected and adjusted

before leaving the factory. However, it is required that the

operator follow these steps during initial break-in period. Failure

to follow these steps may result in damage to equipment or

reduced performance.

Make sure to check all fluid levels before starting and every

8 - 10 operating hours.

Do all Daily maintenance and service checks.

For first 50 operational hours, as shown by hour meter on

control console, do not exceed 80% of maximum rated

engine speed.

At end of first

50 operational hours, drain engine oil.

Replace engine oil filter and engine oil.

OP000037

Operation

3-1

Set pilot cutoff switch to "O" (LOCK) position. This will

"LOCK" pilot control valve lever (joystick).

HBOI111L

Figure 4

Set reverse fan switch to "O" (OFF) position. This will

prevent damage to the cooling system during normal

operation.

HAAH0040

Figure 5

Rotate starter key to "I" (ON) position. All indicator lights

should turn "ON."

NOTE: If unit is equipped with and emergency steering

system. Test system before starting engine. If

system does not function properly, do not start

unit. Follow test procedure given with test

switch.

FG000084

Figure 6

Rotate starter key to "START" position. Starter motor

should crank immediately, and engine should start within a

few seconds.

FG000085

Figure 7

OP000037

Operation

3-3

After engine starts, check all indicator lights and gauges to

be certain that all engine systems

(oil pressure, oil

temperature, coolant temperature, etc.) are in normal

operating range. If any engine system is not normal, turn

starter key to "OFF" position.

Instrument Panel Light or Gauge

Indicator Reading

Fuel Gauge

Engine Coolant Temperature Gauge

WHITE RANGE

Transmission Oil Temperature Gauge

Engine Oil Pressure Warning Light

Charging Warning Light

OFF

Brake Oil Pressure Warning Light

Parking Brake Light

NOTE: Parking brake indicator light turns "ON" or

"OFF" according to parking brake operation

regardless of engine starting.

10.

Perform “Hydraulic System Warm-up” on page 3-12.

11.

Check color of exhaust smoke:

•

No color or light blue - Engine is running in good

condition.

•

Black - Incomplete combustion. Check cause.

•

White or dark blue - Engine is burning engine oil.

Check cause.

12.

Check for usual engine vibration and noises. If any are

heard or felt, investigate cause.

NOTE: If engine coolant temperature gauge shows red

while running, take the following action;

Discontinue work and allow engine to run at

"LOW IDLE." Open engine compartment cover

for good ventilation. Once engine temperature

gauge returns to the green zone, shut down

engine. After engine has cooled, check coolant

level, look for signs of leaks, clogged or dirty

radiator fins (radiator core), and fan belt tension.

OP000037

Operation

3-5

COLD WEATHER ENGINE START

Set parking brake switch to the "I" (APPLIED) position.

This will ensure that the parking brake is "APPLIED."

HA0O2019

Figure 9

Move all control levers to "NEUTRAL" position.

IMPORTANT

If transmission lever is not in "NEUTRAL" position,

engine will not start.

FG003979

Figure 10

Make sure transmission neutral lock is in the "N"

(NEUTRAL LOCK) position.

FG003980

Figure 11

Set pilot cutoff switch to "O" (LOCKED) position. This will

"LOCK" pilot control valve lever (joystick).

HBOI111L

Figure 12

Operation

OP000037

3-6

Set reverse fan switch to "O" (OFF) position. This will

prevent damage to the cooling system during normal

operation.

HAAH0040

Figure 13

Turn starter switch to the "I" (ON) position (Figure 14).

When preheat cycle is completed, the preheat indicator

light (1, Figure 15) will turn "OFF."

FG000084

Figure 14

FG004193

Figure 15

Rotate starter key to "START" position. Starter motor

should crank immediately, and engine should start within a

few seconds.

FG000085

Figure 16

OP000037

Operation

3-7

Starting with Auxiliary Batteries

WARNING!

Wear safety glasses.

Never connect negative leads to positive terminals and vice

versa.

DO NOT connect auxiliary or booster battery ground

terminal directly to battery terminal. Locate and use a

ground point on machine frame.

Depleted batteries generate hydrogen gas. Electrical sparks

around or near batteries can cause an explosion.

Figure 18

Reference

Description

Number

Auxiliary Batteries

Ground Auxiliary Batteries to

Machine Frame

Depleted Batteries

If batteries are drained during starting procedures, you can jump

start engine using auxiliary or booster batteries according to

following procedures:

Connect positive jumper cable from auxiliary batteries to

depleted batteries (Figure 18).

Connect negative jumper cable from auxiliary batteries to a

ground point on machine frame. DO NOT CONNECT

DIRECTLY TO NEGATIVE BATTERY TERMINAL.

Follow normal engine starting procedures.

After engine has started, remove negative jumper cable,

and then positive cable.

Operation

OP000037

3-10

Engine Shut Down

Move transmission lever to "NEUTRAL" position.

FG003979

Figure 19

Make sure transmission neutral lock is in the "N"

(NEUTRAL LOCK) position.

FG003980

Figure 20

Set parking brake switch to the "I" (APPLIED) position.

This will ensure that the parking brake is "APPLIED."

HA0O2019

Figure 21

Set bucket on ground.

Put pilot cutoff switch to "O" (LOCK) position. This will

"LOCK" pilot control valve lever (joystick).

Allow engine to idle for one - two minutes to cool down.

HBOI111L

Figure 22

OP000037

Operation

3-11

Rotate starter key to "O" (OFF) position. Remove key.

FG003900

Figure 23

Hydraulic System Warm-up

Correct operating temperature of hydraulic oil is 50° - 80°C

(120°

175°F). Make sure to follow procedures listed

below for hydraulic fluid warm-up.

Run engine at idle (no load) for five minutes.

Run engine for approximately five minutes at middle of

speed range, without a load.

Cycle bucket until bucket cylinder bottoms out (extended

and retracted) without a load to circulate the oil through the

system. Do this for five minutes.

NOTE: Do not allow cylinders to pass hydraulic oil over

relief valve for more than twenty seconds at a

time.

Cycle boom, and bucket about five times without a load to

circulate oil through system.

Hydraulic System Warm-up - Cold

Weather

Follow Steps 1 through 3 in "Hydraulic System Warm-up."

Do not operate machine at full speed until system has fully

warmed up.

If working speeds continue to be slow, repeat initial

hydraulic warm-up procedures again. If repeating warm-up

procedures does not improve working speeds, continue to

operate, but use extreme caution because machine

function may be erratic.

Operation

OP000037

3-12

MACHINE TRAVEL

WARNING!

If vehicle is moved while parking brake is engaged, serious

damage to parking brake disk will result.

Select a transmission gear that is appropriate for top speed

that will be traveled. Choosing a gear that is too high will

reduce acceleration and will unnecessarily heat

transmission converter oil.

Never place transmission in "NEUTRAL" when going down

a hill. Over speeding transmission can damage

transmission gears.

Never change direction of vehicle travel at high speed.

Serious damage to transmission will result.

Unlatch frame lock plate between front and rear frames

before traveling. Secure lock plate to rear frame (Figure

24).

FG001773

Figure 24

Set pilot cutoff switch to "I" (UNLOCKED) position. Raise

bucket to a height of 20 - 30 cm (8 - 12 in) above the

ground. Tilt bucket completely back.

HBOI110L

Figure 25

OP000037

Operation

3-13

Set pilot cutoff switch to "O" (LOCKED) position. This will

prevent boom and bucket from accidentally moving during

travel, as a result of accidentally touching pilot control

valve lever (joystick).

HBOI111L

Figure 26

Press brake pedal.

FG002183

Figure 27

Set transmission neutral lock is in the "D"

(DRIVE)

position.

FG003980

Figure 28

Set parking brake switch to the "O" (RELEASE) position.

This will "RELEASE" the parking brake.

HAOP043L

Figure 29

Operation

OP000037

3-14

Place transmission lever in desired gear. Shift gears one

by one. Do not skip from 1st to 3rd, for example.

Shift transmission lever to "FORWARD" position.

FG003979

Figure 30

Release the brake pedal while slowly pressing the

accelerator pedal.

WARNING!

When traveling at high speed or on a steep hill, do not

make sharp changes in direction. This could cause

vehicle to overturn.

When traveling or changing direction, always look

FG003980

carefully to be certain that no one is in path of vehicle.

Figure 31

MACHINE SHUT DOWN

Ease off throttle and apply travel brakes.

FG002183

Figure 32

OP000037

Operation

3-15

Put transmission lever in "NEUTRAL."

FG003979

Figure 33

Set transmission neutral lock is in the "N"

(NEUTRAL

LOCK) position.

CAUTION!

"LOCK" transmission lever. Whenever machine is

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

prevent accidental machine movement.

FG003980

Figure 34

Set parking brake switch to the "I" (APPLIED) position.

This will ensure that the parking brake is "APPLIED."

HA0O2019

Figure 35

Set bucket on ground.

Set pilot cutoff switch to "O" (LOCKED) position. This will

lock pilot control valve lever (joystick).

Allow engine to idle for one - two minutes to cool down.

Stopping a turbocharged engine without a cool down

period can seriously damage turbocharger.

HBOI111L

Figure 36

Operation

OP000037

3-16

Rotate starter key to "O" (OFF) position. Remove key.

FG003900

Figure 37

If machine is parked on a slope, install wheel chocks in

front of and behind vehicle wheels.

WARNING!

Always secure machine with wheel chocks when

parked on a slope. Leaving machine in gear will

provide no braking effect because transmission clutch

is hydraulically operated. When engine is turned

"OFF," there is no hydraulic pressure in transmission

and clutch is not engaged.

Figure 38

OP000037

Operation

3-17

F/R (FORWARD/REVERSE)

TRAVEL CONTROL SYSTEM

(OPTION)

An optional F/R (Forward/Reverse) travel control system can be

installed as an option on the machine. With this system installed,

the operator's light-hand can remain on the steering wheel

during operation, and not have to manually move the

transmission lever between forward and reverse.

To activate system perform the following steps:

Place transmission lever in "NEUTRAL."

NOTE: Do not move the transmission lever out of

"NEUTRAL." If the lever is moved, the system

will be deactivated.

Figure 39

Press F/R selector switch to the "I" position, and then

release. The switch will return to the "O" position, but the

system will be activated. When system is activated, the F/

R selector indicator light (Figure 41) will be turned "ON."

BSO0400L

Figure 40

F/R

BSO0032L

Figure 41

Operation

OP000037

3-18

The F/R control switch is then used to control the travel

direction of the machine.

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

In this position, the machine travels "FORWARD."

II.

In this position, the machine travels in "REVERSE."

The F/R travel control system will stay activated until one

of two things happen.

A. The transmission lever is moved out of "NEUTRAL"

into "FORWARD" or "REVERSE."

BSO0410L

Figure 42

B. The starter switch is turned "OFF."

When the system is deactivated, the F/R selector indicator

light (Figure 41) will be turned "OFF."

ADDITIONAL BRAKING

Machine hydraulic system can supply additional dynamic

braking force during travel. To accomplish this, move pilot

control valve lever (joystick) to crowd position and hold it there.

Hydraulic pump will be driven to supply output at maximum

pressure (relief pressure). Energy expended to drive pump, will

slow engine speed. Additional dynamic braking, along with

proper gear selection, can be used to slow a vehicle that is being

driven down an incline.

BOOM RAISE KICK-OUT

Placing bucket lever in "Boom Raise Detent" position will lock

bucket lever in raise boom position. Boom will raise until trip

plate (1, Figure 43) makes contact with bucket height limit switch

(2). When limit switch is tripped, boom will stop raising and

bucket lever will automatically be returned to "NEUTRAL"

position. Trip plate can be adjusted to control maximum height

that boom can be raised.

HBOI441L

Figure 43

OP000037

Operation

3-19

IMPORTANT

Trip plate (1, Figure 43) must always be set to contact limit

switch

(2) before boom cylinders reach maximum

extension. Maximum extension causes pump to force fluid

over relief valve.

To raise boom to maximum height, past preset height, hold

boom and bucket lever in "Raise" or "Hold Raise" position until

FG002238

boom has reached maximum height. Then remove your hand

Figure 44

from lever. Lever will automatically return to "NEUTRAL"

position. This prevents hydraulic pump from working against

relief valve (maximum pressure).

BUCKET ANGLE INDICATOR

Upper right side of bucket includes a bracket that indicates angle

of bottom of bucket. Top of bracket is parallel with bottom of

bucket. If bottom of bucket is not visible, top of bracket will be

visible.

FG001661

Figure 45

Operation

OP000037

3-20

BOOM LOWER KICK-OUT

(OPTION)

Placing bucket lever in "L" position will lock control lever in lower

boom position. Boom will move downward until trip plate (1,

Figure 46) makes contact with bucket lower limit switch (2).

When limit switch is tripped, boom will stop lowering and bucket

lever will automatically be returned to "NEUTRAL" position. Trip

plate can be adjusted to control maximum height that boom can

be lowered.

IMPORTANT

FG001615

Trip plate must always be set to contact limit switch before

Figure 46

boom cylinders reach maximum extension. Maximum

extension causes pump to force fluid over relief valve.

ADJUSTMENT OF BUCKET

POSITION SWITCH

When bucket lever is held in crowd detent position, after bucket

has been dumped, bucket will pivot toward crowd position. Once

full crowd position has been reached, bucket lever will

automatically return to "NEUTRAL" position. If bucket is lowered

after lever returns to "NEUTRAL," bucket will automatically

position itself to be in a preselected digging position (usually

flat). To adjust bucket to desired preselected digging position,

perform the following steps.

Operate controls to place bucket on ground and in desired

digging position (usually flat). Return bucket lever to its

FG001616

"NEUTRAL" position.

Figure 47

Shut down engine.

Loosen bolts (1, Figure 47) on bracket (2).

Position bracket (2, Figure 47) so that end of arm (3) is

aligned with center of magnetic switch (4).

Tighten bolts (4, Figure 47).

Start engine. Raise boom, dump bucket, then move bucket

lever into crowd detent position. Now lower boom and

check to see that bucket has stopped at required position.

A small readjustment of bracket (2, Figure 47) may be

necessary.

OP000037

Operation

3-21

TOWING MACHINE

When necessary to tow another vehicle, the tow rope must be

tied to the towing pin on the counterweight at the rear of vehicle.

NOTE: The loader must be used for towing only in an

emergency.

WARNING!

Do not tow machine at a speed over 10 km/h (6 MPH) and do

not tow machine farther than 10 km (6 mi). This will prevent

FG001662

damage to machine transmission that would result from

Figure 48

lack of lubrication.

WARNING!

When towing another vehicle on a public road, take

necessary measures to let other vehicles and people know

that you are towing another vehicle. Use a flag, rotating

beacon light, or hazard light.

NOTE: There are several requirements you must abide by

when towing another vehicle. Learn the regulations

and rules about towing another vehicle and observe

them.

If the loader is being towed by another vehicle and the engine

will not start, remove the front and rear drive shafts; otherwise

the transmission will rotate without being properly lubricated,

causing seizure. Before removing them, apply the parking

brakes and block the wheels securely.

If the engine can be started and the steering wheel and brakes

function normally, have someone get on the loader you are

going to tow for steering it.

Before you tow a vehicle make sure you have checked the

following:

•

Check the weights of your loader and the vehicle to

be towed and make sure you loader has sufficient

braking capacity to stop the towed load.

•

Check if the vehicle to be towed can be braked and

steered. If not, do not allow anyone to ride on the

towed vehicle.

•

Check the tow rope or tow bar for damage and make

sure it has sufficient strength for the work.

•

When necessary to descend a grade, another towing

vehicle must be used in the rear to retard.

Operation

OP000037

3-22

When towing make sure you are doing the following:

•

Start slowly. A sudden start can lead to a broken tow

rope.

•

The tow line must be along the center line of both

your loader and the vehicle to be towed.

•

If you use any other towing device, refer to the

Instruction Manual supplied with the towing device.

•

If it is difficult to tow the loader, transport it by a trailer

truck to your nearest repair shop.

•

In addition to the above measures, release the

parking brake if the engine will not start or the

hydraulic pumps are defective.

IF ENGINE STALLS WHILE

TRAVELING

BRAKE SYSTEM: The brakes can be applied approximately 9

times by pressing the brake pedal due to the oil pressure

stored in the accumulator after engine is turned "OFF" if

the engine stalls while traveling, move to an out of traffic

area and park. Do not pump the brake pedal at this time;

otherwise the brake oil pressure will be used up, thus

causing the brakes to fail.

OP000037

Operation

3-23

ALLOWABLE WATER DEPTH

The water depth is an important factor to take into consideration

when the loader is working in swampy areas. Do not enter water

whose depth exceeds the loader's minimum ground clearance

height or is high enough to wet the bottom of the axle housing.

As a rule of thumb, the allowable water depth is about 400 mm.

This means that the loader should not be used in a river.

Observe the following conditions:

Check the water depth in advance when crossing across a

river.

Use the same precautions before crossing across a

swampy area.

Do not enter rivers whose river bed is steep or has a rapid

flow.

CAUTION!

Avoid use of the loader in salt water. Salt water will

cause the development of rust which will shorten the

life of the loader.

Operation

OP000037

3-24

OP000038

5Inspection, Maintenance

and Adjustment

BASIC PREVENTIVE

MAINTENANCE

For the machine to function satisfactorily and at lowest possible

cost, a thorough maintenance program is required. This section

of the manual describes the maintenance work which the

operator can carry out. If certain operations require trained

workshop personnel and special equipment, this will be

indicated.

The intervals recommended between checks, oil changes and

lubrication apply provided that the machine is used under

normal environmental and operating conditions. See

“Lubrication and Service Chart” on page 5-20.

Arrival and Delivery Inspection

Before the machine leaves the factory, it is tested and adjusted.

The dealer must also, if the warranty is to apply, carry out

"Arrival and Delivery Inspections" according to applicable form,

which must be signed.

Delivery Instructions

Figure 1

When handing the machine over, the dealer must give the buyer

"Delivery Instructions" according to applicable form, which must

be signed, if the warranty is to apply.

OP000038

Inspection, Maintenance and Adjustment

4-1

Service Programmes

Warranty Inspection

Two Warranty Inspections must be carried out if the warranties

are to apply. The first within 100 operating hours and the second

at the latest at 1000 operating hours.

The carrying out of these inspections is a condition for the

warranty to apply.

Condition Test

A "Condition Test" is carried out at authorized dealer workshops

and provides information about the general condition of the

machine.

Inspection, Maintenance and Adjustment

OP000038

4-2

Service Points

22 1

1215

FG004068

Figure 2

Reference

Description

Number

Level Sight Gauge Hydraulic Oil

Filling Point, Engine

Breather Of Hydraulic Oil

Main Fuel Filter

Air Cleaner

Battery

Pre Cleaner

Return Oil Filter

Filling Point, Fuel

Filling Point, Coolant

Draining, Coolant

Filing Point, Washer Fluid

Pre Fuel Filter

Filling Point, Hydraulic Oil

Filling Point, Transmission

Ventilation Filters, Cabin

Draining, Hydraulic Oil

Battery

Pilot Filter

Alternator Belt

Oil Dipstick

Suction Strainer, Transmission

Oil Filter, Engine

Oil Filter, Transmission

Draining, Engine Oil

OP000038

Inspection, Maintenance and Adjustment

4-3

SAFETY WHEN SERVICING

This section deals with the safety rules which must be followed

when checking and servicing the machine. DOOSAN disclaims

all responsibility if other tools, lifting devices or working methods

are used other than those described in this publication.

Further safety rules and information and warning texts are given

within the respective section.

NOTE: Lifting with a jack must only be carried out by trained

personnel.

WARNING!

If work has to be carried out on the machine before it has

cooled down, care must be observed with regard to risk of

burns from hot liquids and hot machine parts.

Inspection, Maintenance and Adjustment

OP000038

4-4

Service Position

BEFORE beginning service work the machine must be parked

on level ground and positioned as shown below.

AFTER completing the service, all guards must be installed and

all engine covers must be closed and locked.

FG001665

Figure 3

Reference

Description

Number

The bucket/attachment must be resting on the ground.

Apply the parking brake.

Shut down engine and take out the ignition key. (Does not apply when checking oil level in

transmission).

Carefully release the pressure in pressure lines and pressure vessels to avoid risks.

Attach a black and yellow "Warning Tag" to the steering wheel.

Connect the frame joint lock.

Block the wheels in a suitable way (with, for example, wedges).

Allow the machine to cool.

OP000038

Inspection, Maintenance and Adjustment

4-5

Before Service Read

•

Read the Operator's Manual and the decals/labels

and instructions found on the machine to obtain the

required knowledge and information about the

machine.

•

To be able to carry out the service work in a correct

way, it is important that the correct tools and

equipment be used. Replace or repair broken tools

and faulty equipment.

•

When lifting the machine, the frame joint must be

locked and the machine lifted at the eyes intended for

this purpose. See “Summary of Safety Precautions

for Lifting” on page 6-2.

Figure 4

•

Use a hard hat, safety glasses, protective shoes and

gloves and an approved respirator or other protective

articles when required.

•

Do not wear loose fitting clothing or jewelry.

•

Keep service surfaces and handholds clean from oil,

dirt and ice.

Figure 5

•

Use the stepping areas provided with antislip

protection to avoid the risk of slipping. Worn, painted

over, or loose protections must be replaced.

Remember that high-pressure water jets when

washing and spilled oil can cause the protections to

loosen. Do not direct the water jet against the

protections and wipe up spilled oil.

•

Make sure that there is sufficient ventilation when

starting the engine indoors.

•

Do not exceed the maximum permissible floor load.

•

Do not stand in front of or behind the machine while

Figure 6

the engine is running.

•

Use a ladder when changing light bulbs or carrying

out other service work high up on the machine.

•

Use a long handled window scraper and brush or a

ladder when cleaning the outside of the windows.

Inspection, Maintenance and Adjustment

OP000038

4-6

•

The installation of two-way radio, lever steering or

similar equipment must be carried out by a skilled

person, as faulty installation may cause interference

with the electronic components controlling vital

machine functions.

•

When carrying out service work below raised lifting

arm system, the lifting arms must first have been

secured (lifting arm support). In addition the control

lever lockout and the parking brake must be applied.

•

Take care when changing oil in engine, hydraulic

system or transmission as the oil may be hot and

cause burns.

•

When emptying/draining oil or fuel, use a pump or a

hose and collect the liquids in a suitable vessel.

Spillage will damage the environment and may cause

a fire. Waste oil and other contaminating liquids must

be taken care of by a firm especially authorized to

carry out such work.

•

When operating in an area which is contaminated or

dangerous to one's health, the machine must be

especially equipped for this purpose. Special local

safety regulations apply within such areas and also

when servicing the machine.

•

Shut down engine before opening engine covers etc.

Make sure that no tools or other objects, which may

cause damage, have been forgotten in or on the

machine.

•

Check that the equipment you are using for lifting or

supporting parts of the machine, e.g. straps, slings,

ratchet blocks and ground support, can safely cope

with the strain they are exposed to and meet

applicable regulations.

•

Release the pressure in pressure vessels,

components and systems carefully and in the

prescribed way, so that the excess pressure is

released without risk.

•

When connecting hydraulic hoses, check that the

desired effect has been achieved, that is, check that

the hydraulic function operates in the expected way.

•

Hoses, pipes and quick-connect couplings may be

pressurized even if the machine is stationary and the

engine turned "OFF." Such pipes and hoses should

therefore only be disconnected by trained personnel.

•

When looking for leaks, use a piece of paper or

wood, not your hand.

OP000038

Inspection, Maintenance and Adjustment

4-7

Fire Prevention Measures

There is always a risk of fire. It is important that you use a fire

extinguisher that suits your machine and working environment

and that you learn how to use it. The fire extinguisher must be

placed behind the seat or externally in a lockable box.

If the machine is to be provided with a handheld fire

extinguisher, it must be of the ABE type (ABC in the USA), which

means that it is possible to extinguish fires in both solid and

liquid carbonaceous material and that the active compound does

FG003902

not conduct electricity.

Figure 7

The effectiveness grade I means that the time the extinguisher is

effective must not be less that eight seconds, grade II at least

eleven seconds and grade III at least fifteen seconds.

A handheld fire extinguisher ABE I (in the USA ABC type)

normally corresponds to a powder content of

4 kg (8.8 lb)

(EN-grade 13A89BC), the EN 3-1995 standard, parts 1, 2, 4 and

At the slightest sign of fire, and if the situation allows, take the

following steps:

Drive the machine away from the fire sensitive area

caused by the fire.

Lower the lifting arms to the ground.

Shut down engine by turning the ignition key to the "0"

(OFF) position.

Leave the cabin.

Turn off the battery disconnect switch.

Start putting out the fire and notify the fire brigade/

department if necessary.

It is forbidden to smoke or have an open flame near a machine

when filling with fuel or when the fuel system has been opened

and in contact with the surrounding air.

Diesel fuel oil is flammable and must not be used for cleaning.

Use an approved solvent and do not inhale the fumes. Also bear

in mind that certain solvents can cause skin rashes and

constitute a fire hazard.

Flammable starting must not be used due to the use of the

electric preheating in the induction air system.

Keep the place clean where the service is to be carried out. Oil

or water makes the floor slippery and is also dangerous in

connection with electrical equipment or electrically powered

tools. Oily or greasy clothes are a serious fire hazard.

Check daily that the machine and the equipment, e.g.

underbody plates are free from dust and oil. In this way the risk

of fire is reduced and it is easier to detect faulty or loose

components.

NOTE: If a high-pressure jet is used for cleaning, take great

care as the insulation of electric leads can be

Inspection, Maintenance and Adjustment

OP000038

4-8

damaged even at a moderately high-pressure and

temperature. Protect electrical leads in an

appropriate way.

Take extra care when cleaning the machine after it has been

used in a fire sensitive environment, e.g. sawmill and refuse

dumps. Reduce the risk of spontaneous combustion by installing

for example silencer guard or high capacity cyclone precleaner.

Sound absorbing material in the engine compartment must be

kept clean to minimize the fire hazard.

Fire prevention equipment which is installed on the machine

must be maintained and regarded as a complement to the

actions of the operator in case of a fire.

Check that fuel lines, hydraulic and brake hoses and electrical

cables have not been damaged by chafing or are not in danger

of being damaged because of incorrect installation or clamping.

This applies particularly to unfused cables, which are red and

marked R(B+) and routed:

•

between the batteries

•

between battery and starter motor

•

between alternator and starter motor

•

to the preheating element on the engine.

Electrical cables must not lie directly against oil or fuel lines.

The following applies for welding and grinding work:

•

A fire extinguisher must be kept near at hand.

•

The ventilation must be good when working indoors.

•

Approved respirator must be used

•

The work surface must be cleaned.

•

Do not weld or grind on components which are filled

with flammable liquids, e.g. tanks and hydraulic

pipes. Exercise care with such work in the proximity

of these places.

Working on Painted Surfaces

When welding, grinding and gas cutting, the paint finish must

first be removed from an area with a radius of at least 10 cm

(4 in) from the point where the work is to be carried out. The

reason for this is that paint when heated gives off a great

number of different substances which can cause irritation and be

very harmful to a person's health in case of long or frequent

exposure.

In addition to the health hazard, the weld will also be of an

inferior quality and strength, which in the future may cause the

weld to break. Therefore, never weld directly on a painted

surface.

OP000038

Inspection, Maintenance and Adjustment

4-9

Methods and Precautionary Measures

When Removing Paint:

Blasting

•

use respirator and eye protection

Paint remover or other chemicals

•

use a portable air extractor, respirator and protective

gloves

Grinding machine

•

use a portable air extractor, respirator and protective

gloves and eye protection

Floor Rubber

Observe extra great care when it is suspected that you may

have to handle floor rubber.

Certain seals which have to withstand high operating

temperatures (e.g. in engines, transmissions, axles, hydraulic

motors and pumps) may be made from floor rubber, which,

when exposed to high heat (fire), forms hydrogen fluoride and

hydrofluoric acid. This acid is very corrosive and cannot be

rinsed or washed off from the skin. It causes very severe burns

which take a long time to heal.

It usually means that damaged tissue must be surgically

removed. Several hours may pass after contact with the acid,

before any symptoms appear and therefore one is not given any

immediate warning. The acid may remain on the machine parts

for several years after a fire.

If swelling, redness or a stinging feeling appears and one

suspects that the cause may be contact with heated floor rubber,

contact a medical doctor immediately. If a machine, or part of a

machine, has been exposed to fire or severe heat, it must be

handled by specially trained personnel. In all handling of

machines after a fire, thick rubber gloves and effective goggles

must be used.

The area around a part which has been very hot and which may

be made of floor rubber must be decontaminated by thorough

and ample washing with lime water (a solution or suspension of

calcium hydroxide, i.e. slaked lime in water). After the work has

been completed, gloves must be washed in lime water and then

discarded.

Inspection, Maintenance and Adjustment

OP000038

4-10

Rubber and Plastics

Polymer materials when heated, can form compounds which are

dangerous to health and environment and must therefore never

be burned when scrapped. Also take care when handling

machines which have been subjected to fire or other extreme

heat.

If gas cutting or welding is to be carried out near such materials,

the following safety instructions must be followed:

•

Protect the material from heat.

•

Use protective gloves, protective goggles and an

approved respirator.

Waste Hazardous to the Environment

Painted parts or parts made of plastic or rubber which are to be

scrapped must never be burnt, but must be taken care of by an

approved refuse handling plant.

Batteries, plastic objects and anything else which is suspected

of being dangerous to the environment must be taken care of in

an environmentally safe way.

Check List After Fire

When handling a machine which has been damaged by fire

or been exposed to intense heat, the following protective

measures must under all circumstances be followed:

Use thick, gloves made of rubber and wear goggles which are

certain to protect your eyes.

Never touch burnt components with your bare hands, as there is

a risk that you may come into contact with melted polymer

materials. First wash thoroughly with plenty of lime water (a

solution or suspension of calcium hydroxide, i.e. slaked lime in

water).

As a precaution, seals (O-rings and other oil seals) should

always be handled as if they were made of floor rubber.

Treat skin, which is suspected of having come into contact with

burnt floor rubber, with Hydrofluoric Acid Burn Jelly or something

similar. Seek medical advice. Symptom may not appear until

several hours afterwards.

Discard gloves, rags etc. which are suspected of having come

into contact with burnt floor rubber.

OP000038

Inspection, Maintenance and Adjustment

4-11

PREVENTIVE MAINTENANCE

Periodic checks and replacement of oil, grease, filters, etc. must

be made at specific intervals, to keep machine in good working

condition. The following pages describe items to be checked,

lubricants to be used, and time interval between each check.

NOTE: Time interval between each service check may need

to be shortened if machine is operating in severe

atmospheric conditions. Machines working in

extremely hot or dusty conditions will require more

frequent service checks. Total hours of machine

operation are determined by hour meter that is on the

front instrument panel.

HAOA600L

Figure 8

Serial Numbers

There are two serial number plates attached to the body of

wheel loader.

Please make note of these numbers and their locations. These

will be required whenever warranty service work is requested.

Machine Serial Number

The machine serial number plate is on left side of front frame

above wheel cover (Figure 9).

FG000000

Figure 9

The number is also stamped in the rear frame on the left side

just below the cabin (Figure 10).

FG001619

Figure 10

Inspection, Maintenance and Adjustment

OP000038

4-12

Engine Serial Number

The engine name plate (identification label) is attached to rocker

cover (Figure 11). The engine serial number is stamped on the

left rear of the engine block, under exhaust manifold.

FG001620

Figure 11

Safety Precautions

Before performing any maintenance checks, move pilot

cutoff switch to "LOCKED" position. Place a Warning Tag

on controls so that no one begins to operate machine while

maintenance checks are being performed.

Clean up all fuel spills. Fuel spills are hazardous,

especially around engine.

Inspect all fuel lines for leakage. Replace any lines, fittings,

O-rings, or filters that show signs of wear or damage.

If a test procedure requires engine to be running, use two

people and keep all unnecessary personnel away from

machine.

OP000038

Inspection, Maintenance and Adjustment

4-13

TABLE OF RECOMMENDED

LUBRICANTS

IMPORTANT

Do not use lubricants other than those recommended,

without prior written approval from DOOSAN.

NOTE: Refer to the Maintenance Intervals Table for

application points.

LUBRICANT

HYDRAULIC OIL

ENGINE OIL

GEAR OIL

MANUFACTURER

GREASE

TOTAL

TOTAL EQUIVIS

TOTAL RUBIA TIR

TOTAL MULTIS EP

ZS 46 IV

7400 10W40

TOTAL

RUBIA

POLYTRAFIC

10W40

TOTAL

RUBIA

8600 10W40

GS-CALTEX

RANDO HD CZ 46

SIGMA DX-1

MULTIFAK EP #2

10W40

CHEVRON

AW 32 (BELOW

DELO 400 15W40

DELO GREASE EP

0°C)

(ABOVE

0°C)

TEXACO

RANDO HDZ 46

URSA SUPER

MULTIFAK ALL

PREMIUM 15W40

PURPOSE EP #2

ESSO

UNIVIS N 46

ESSOLUBE XT-5

RONEX MP

15W40

MOBIL

MOBIL DTE 13M

MOBIL DELVAC

RONEX MP

MOBILFLUID 424

MX 15W40

ESSO TORQUE

FLUID 56

MOBIL AGRIFLUID

424

MOBIL FLUID 426

MOBILFLUID 2040

SHELL

TELLUS OIL T 46

RIMULA ULTRA

ALVANIA EP #2

ASEOL

10W40

MULTITRAC 85W

PENNZOIL

MULTIPURPOSE

WHITE GREASE

705 EP #2

Inspection, Maintenance and Adjustment

OP000038

4-14

LUBRICANT

HYDRAULIC OIL

ENGINE OIL

GEAR OIL

MANUFACTURER

GREASE

CASTROL

PARADENE AW 32

CASTROL EPL #2

KOMATSU WBL

(BELOW 0°C)

20W40

PARADENE AW 46

(ABOVE 0°C)

IDEMITSU KOSAN

DAPHNE KOSAN

DAPHNE

32 WR (BELOW

EXPONES SR #2

0°C)

DAPHNE KOSAN

46 WR

(ABOVE

0°C)

LUBRICANT

TRANSMISSION GEAR OIL

MANUFACTURER

Same as engine oil

SAE 15W40

API CD and above

Antifreeze

Recommended Concentration

Manufacturers Meeting ASTM D3306

Dexcool ELC by Chevron Texaco

50% Antifreeze - 50% Distilled Water

Alugard G48 by BASF

Others meeting or exceeding ASTM D3306

CAUTION!

Do not mix oils from different manufacturers. DOOSAN

does not endorse specific brands but does suggest that

owners select quality oils whose suppliers provide

assurance that required standards will always be met or

exceeded.

IMPORTANT

Fluctuating daily or weekly extremes of temperature, or

operation in subzero freezing weather may make it

impractical to use straight weight lubricants. Use good

judgement in selecting lubricant types that are appropriate

for climate conditions.

OP000038

Inspection, Maintenance and Adjustment

4-15

AXLE OILS DL400, DL300, DL250

Oil Grade Mobile Fluid 424

Oil intended for axles with built-in brakes

Requirements

Property

Unit

Mobil fluid 424

Test method

Density

kg/l, @15°C

0.884

ASTM D 4052

Flash Point

°C

198

ASTM D 92

Pour Point

°C

-42

ASTM D 97

Viscosity at 40°C

ASTM D 445

mm²/s (cSt)

Viscosity at 100°C

9.3

ASTM D 445

mm²/s (cSt)

Rust Protection 24h

No rust

ASTM D 665A

API Class

GL-4

ASTM STP-512A

Brokfield Viscosity

cp (@-35C)

55,000

Viscosity Index

145

ASTM D 2270

Examples of oils which meet the requirements according to the

table on the next page.

Inspection, Maintenance and Adjustment

OP000038

4-16

Axle Oils for DL400, DL300, DL250

Examples of oils which meet the requirements according to the

table on the previous page.

Lubricant Class 05E

Viscosity grades: SAE 20W-40 / 80W-140

Oil Company

Trade Name

CASTROL INTERNATIONAL, PANGBOURNE READING/GB

KOMATSU WBL 20W40

CNH, BURR RIDGE/USA

CASE TRANSAXLE FLUID, SAE 80W-140

EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA

MOBILFLUID 2040

FUCHS PETROLUB AG, MANNHEIM/D

TITAN HYDRA ZF 20W-40

MAZIVA ZAGREB D.O.O. ZAGREB/HR

INA TRASHIDROL ZF 20W-40

OMV AG, SCHWECHAT/A

MOV AUSTROMATIC ZF SAE 20W-40

PAKELO MOTOR OIL S.R.L., SAN BONIFACIO (VR)/I

PAKELO UTTO FLUID 4D SAE 20W-40

STRUB + CO AG, REIDEN/CH

VULCOTRAC UTTO SAE 20W-40

Lubricant Class 05F

Oil Company

Trade Name

76 LUBRICANTS COMPANY, COSTA MESA/USA

76 HYDRAULIC/TRACTOR FLUID

ARAL AG, BOCHUM/D

ARAL FLUID HGS SAE 80W

AVIA MINERALOL-AG, MUNCHEN/D

AVIA HYDROFLUID DLZ

BP INTERNATIONAL, PANGBOURNE, READING/GB

BP OLEX GO 4926

BP INTERNATIONAL, PANGBOURNE, READING/GB

BP TERRAC SUPER TRANSMISSION

BP INTERNATIONAL, PANGBOURNE, READING/GB

BP TRACTRAN TF 10

BUCHER AG LANGENTHAL, LANGENTHAL/CH

MOTOREX POLYFARM 304

CASTROL INTERNATIONAL, PANGBOURNE READING/GB

CASTROL AGRI POWERTRANS 10W-30

CASTROL INTERNATIONAL, PANGBOURNE READING/GB

CASTROL AGRI TRANS PLUS 10W-30

CASTROL INTERNATIONAL, PANGBOURNE READING/GB

CASTROL KOMATSU UTTO 10W-30

CATERPILLAR MULTIPURPOSE

CATERPILLAR INC., PEORIA/USA

TRACTOR OIL (MTO) 10W-30

ENGEN PETROLEUM LTD., CAPE TOWN/ZA

ENGEN AGRIFLUID

ENI S.P.A. REFINING and MARKETING DIVISION, ROME/I

ROTRA JD/F

EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA

ESSO TORQUE FUID 56

EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA

MOBIL AGRIFLUID 424

EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA

MOBIL FLUID 424

OP000038

Inspection, Maintenance and Adjustment

4-17

Oil Company

Trade Name

EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA

MOBIL FLUID 426

FLITALIA S.P.A., VILLASTELLONE/I

AMBRA MULTI G

FUCHS PETROLUB AG, MANNHEIM/D

TITAN HYDRA J20C

GINOUVES GEORGES SA, LA FARLEDE/F

YORK 676 SAE 10W30

IGOL FRANCE SA, AMIENS/F

TICMA FLUID MU SAE 80W

JOHN DEERE, MANNHEIM/D

JOHN DEERE HY-GARD

KENDALL MOTOR OIL, COSTA MESA/USA

KENDALL HYKEN 052

KUWAIT PETROLEUM RandT B.V., EUROPOORT RT/NL

Q8 T 2000

KUWAIT PETROLEUM RandT B.V., EUROPOORT RT/NL

Q8 T 2200

OEL-BRACK AG, HUNZENSCHWIL/CH

MIDLAND TOU

OMV AG, SCHWECHAT/A

OMV AUSTROMATIC IGB SAE 10W-30

PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I

PAKELO UTTO FLUID 4D SAE 10W/30

PANOLIN AG, MADETSWIL/CH

PANOLIN JD 303

PETROGAL S.A., LISBOA/P

GALP TRALUB 807S

REPSOL LUBRICANTES, MADRID/E

AGRO ORION SAE 10W30

SHELL ASEOL AG, BERN 5/CH

ASEOL MULTITRAC 85W

SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D

WINTERSHALL HYDROFLUID N

Lubricant Class 05G

Oil Company

Trade Name

CATERPILLAR MULTIPURPOSE TRACTOR

CATERPILLAR INC., PEORIA/USA

OIL(MTO)

JOHN DEERE, MANNHEIM/D

JOHN DEERE HY-GARD

ZF FRIEDRICHSHAFEN AG, FRIEDRICHSHAFEN/D

ZF-POWERFLUID

Inspection, Maintenance and Adjustment

OP000038

4-18

DL08 Industrial Engines Oil Drain Intervals

by Duty Cycle (Hours)

Heavy

ACEA E5 (API CI-4)

500

CES 20078

NOTE:

Limit oil change interval to 250 hour maximum for oil grades if 40% of the operating time is in ambient

temperatures above 38°C (100°F) to prevent engine damage to oil degradation resulting from high oil

temperature.

We don't recommend the use of CF or CG grade oils. If CF or CG oils must be used, make the oil drain

intervals half of the API CI-4 values.

Engine oil drain intervals need to be reduced by 50% when fuel sulfur content exceeds 0.5% (5000 ppm).

FLUID CAPACITIES

Component

Capacity

Engine

DL 08

35 liters

(9.1 U.S. gal.)

Oil Pan with Filter

Engine

NOTE: The filter holds an additional 1 liter (1 qt) of oil.

50 liters

Cooling System

(13 U.S. gal.)

326 liters

Fuel Tank

(86 U.S. gal.)

190 liters

Hydraulic Oil Tank

(50 U.S. gal.)

48 liters

Transmission

(12.6 U.S. gal.)

38 liters

Front Axle

(10.0 U.S. gal.)

Axles

30 liters

Rear Axle

(7.93 U.S. gal.)

OP000038

Inspection, Maintenance and Adjustment

4-19

LUBRICATION AND SERVICE

CHART

Greasing Bearing

The service life of bushings and pivot pins can be extended

considerably, if the machine is greased regularly and in the

correct way.

The greasing of bearings has two main purposes:

•

Add grease to the bearing to reduce friction between

pin and bushing.

•

Replace old grease which may contain dirt. The

grease in the space inside the outer seal collects dirt

and prevents dirt and also water from penetrating into

the bearing.

Therefore, grease the bearing until new, clean grease is forced

out through the outer seal.

Between 10 and 15 strokes with a normal handheld grease gun

is required to grease one of the bearings for the lifting arms.

Wipe off grease fittings and grease gun before greasing, so that

dirt and sand is not introduced through the grease fittings.

Inspection, Maintenance and Adjustment

OP000038

4-20

Service Data

Service Interval

No.

Items To Check

Service

Qty.

250

500

1000

1500

2000

Front Joint Pin

Grease

F100

W10

Articulation Pin

Grease

Rear Axle Pivot

Grease

Steering Cylinder

Grease

Front Drive Shaft

Grease

Bearing

Fuel Tank

Diesel

326 L

Hydraulic

Hydraulic Oil Tank

190 L

Oil

Engine Oil

Engine Oil Pan

35 L

15W40

Coolant

Radiator

50 L

(Antifreeze)

Axle Gear

Front Axle

38 L

Oil (80W90)

Axle Gear

Rear Axle

30 L

Oil (80W90)

Engine Oil

Transmission

48 L

15W40

Pre

Fuel Filter

Cartridge

Main

Engine Oil Filter

Cartridge

Transmission

Cartridge

Filter

Full-flow Filter

Element

Oil Suction Filter

Strainer

Brake and Pilot

Element

Filter

Element

(Outer)

Air Cleaner

Element

(Inner)

Turbo Precleaner

Case

Air Conditioner

Element

Filter

V: Maintenance and Refill.

C: Cleaning.

F: First Time Exchange Only.

F100: Every 10 Hours for First 100 Hours.

W10: Every 10 Hours If Operating In Water.

EG: Ethylene Glycol - Standard Life Antifreeze (Drain and replace using this interval.) See “Engine

Cooling System” on page 4-73, for further explanation.

PG: Propylene Glycol - Extended Life Antifreeze (Drain and replace using this interval.) See “Engine

Cooling System” on page 4-73, for further explanation.

Gray Box: Replacement On Every Interval.

NOTE: For additional service items see list of “Maintenance Intervals” on page 4-24.

OP000038

Inspection, Maintenance and Adjustment

4-23

MAINTENANCE INTERVALS

SERVICE ITEM

PAGE

10 Hour / Daily Service

Grease Front Attachment Pins

5-26

Inspect All Tires for Correct Tire Pressure and Signs of Damage or Abnormal Wear

5-26

Check Engine Oil Level

5-26

Check Transmission Oil Level Sight Gauge

5-27

Check Hydraulic System Oil Level

5-28

Check for Leaks in Hydraulic System

5-29

Fill Fuel Tank

5-29

Check for Leaks in Fuel System

5-30

Drain Fuel Condensation

5-30

Water Trap

5-30

Check Coolant Level

5-31

Check Level of Windshield Washer Liquid

5-31

Inspect the Bucket Teeth and Side Cutters for Signs of Wear

5-32

Inspect Seat Belt for Proper Operation

5-32

Inspect the Structure for Cracks and Faulty Welds

5-32

Check the Operation of All Switches

5-32

Check the Operation of All Exterior Lights, Horn and Control Console Indicator and Monitor

5-32

Lights

Start Engine, Check Starting Ability, and Observe Exhaust Color at Start-up and at Normal

5-33

Operating Temperature. Listen for Any Abnormal Sounds

Check Operation of All Controls

5-33

Inspect Engine Fan Blade

5-33

Check Engine Drive Belt Wear

5-34

Check Air Intake System

5-35

50 Hour / Weekly Service

Perform All Daily Service Checks

5-36

Grease Front Attachment Pins

5-36

Grease Steering Cylinder Rod and Head Ends

5-40

Grease Upper and Lower Center Pins

5-40

Change Engine Oil and Filter

5-41

Hydraulic Full Flow Filter Replacement

5-41

Check Air Conditioner and Alternator Belt Tension

5-41

Clean Exterior of Radiator, Oil Cooler and Air Conditioner Condenser

5-41

Clean Air Conditioner Filter

5-42

250 Hour / Monthly Service

Check Engine Air Intake Precleaner

5-43

Drain Water From Hydraulic Oil Tank

5-43

Turbocharger

5-44

Air Cleaner

5-45

Check Air Conditioner and Alternator Belt Tension

5-46

Inspection, Maintenance and Adjustment

OP000038

4-24

Grease Drive Shafts

5-46

Replacement of Transmission Oil and Filter (After First 250 Hours)

5-47

500 Hour / 3 Month Service

Perform All Daily, 50 and 250 Hour Service Checks

5-48

Replace Hydraulic System Brake and Pilot Filter

5-48

Replace Prefuel Filter

5-49

Fuel Filter (Spin-On Type)

5-50

Clean Exterior of Radiator, Oil Cooler and Air Conditioner Condenser

5-51

Clean Air Conditioner Filter

5-52

Axle Differential and Planetaries Oil Replacement (After First 500 Hours)

5-52

Change Engine Oil and Filter

5-53

1,000 Hour / 6 Month Service

Perform All Daily, 50, 250 and 500 Hour Service Checks

5-54

Drain and Replace Transmission Oil and Filter

5-54

Clean Fuel Tank and Strainer

5-56

Replace Air Conditioner Filter

5-56

Check Air Conditioner Refrigerant

5-57

Check and Adjust Engine

5-58

1,500 Hour / 9 Month Service

Perform All 10, 50, 250 and 500 Hour Service Checks

5-60

Replace Outer and Inner Air Cleaner Filters

5-60

Axle Differential and Planetaries Oil Replacement

5-60

Axle Brake Disk Wear Measurement

5-62

2,000 Hour / Yearly Service

Perform All Daily, 50, 250, 500 and 1,000 Hour Service Checks

5-63

Check Steering, Brake, Drive Shaft, Engine, and Fuel System

5-63

Replace Pipes and Hoses

5-63

Bleed Brakes

5-63

Change Radiator Coolant

5-64

Drain and Replace Hydraulic Oil

5-65

Check Brake Accumulator

5-67

12,000 Hour / Six Year Service

Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 CEN)

5-68

OP000038

Inspection, Maintenance and Adjustment

4-25

10 HOUR / DAILY SERVICE

Grease Front Attachment Pins

NOTE: Fittings are greased daily, or every 10 hours, for the

first

100 hours of operation to comply with new

machine break-in requirements. After that, greasing

must be done every 50 hours. If bucket is being used

in water, grease fittings immediately after machine is

removed from water. Follow procedure printed under

the

50 hour maintenance interval

“Grease Front

Attachment Pins” on page 4-36.

Inspect All Tires for Correct Tire Pressure

and Signs of Damage or Abnormal

Wear

Inflate tires to proper operating pressure for working

conditions. See “Tires” on page 5-84..

Check Engine Oil Level

NOTE: When checking level using a dipstick always remove

and wipe it clean before making final level check.

Check level of engine oil every day before starting engine.

FG001621

Figure 13

Remove engine oil dipstick (Figure 13). Oil level must be

between "LOW" and "FULL" marks.

NOTE: If oil is above "HIGH" mark on dipstick, some

must be drained to return oil to proper level.

To add oil, remove engine oil fill cap (Figure 13).

HAOC280L

Figure 14

Inspection, Maintenance and Adjustment

OP000038

4-26

Check Transmission Oil Level Sight Gauge

Use two people to perform this operation.

Start machine and drive it until transmission fluid has

warmed to 80°C (176°F). Park machine on firm, level

ground. Lower bucket to ground.

Place transmission lever in "NEUTRAL." Apply parking

brake. Shut down engine.

Block tires. Once tires are blocked, start engine and have a

FG001622

person remain in the cabin.

Figure 15

With engine running, have second person, find

transmission oil level sight gauge

(1, Figure

16) on

transmission fill tube (2).

Oil level must be at "HOT" mark or above as shown in

(Figure 16).

NOTE: If oil level is above top end of sight gauge

(completely filling it), drain oil until level is at

"HOT" mark.

NOTE: If transmission cannot reach an operating

temperature of 80°C (176°F), then the oil level

must be visible in the sight gauge below the

"HOT" mark. Periodically check oil level during

the workday to ensure that oil level does not rise

above top end of sight gauge.

HB9O0031L

Figure 16

TRANSMISSION SIGHT GAUGE

TRANSMISSION FILL TUBE

To add oil, remove transmission fill cap (Figure 15) from

transmission oil fill pipe. Refer to “Table of Recommended

Lubricants” on page 4-14, of this manual for recommended

oil for the operating conditions.

Shut down engine when done.

HOT

COLD

HAAD4540

Figure 17

TRANSMISSION SIGHT GAUGE

OP000038

Inspection, Maintenance and Adjustment

4-27

Check Hydraulic System Oil Level

WARNING!

The hydraulic oil will be hot after normal machine operation.

Allow system to cool before attempting to service any of the

hydraulic components.

The hydraulic tank is pressurized. Turn breather cap slowly

to allow pressurized air to vent. After the pressure has been

HAOA060L

released, it is safe to remove either the fill cap or service

Figure 18

covers.

Move machine to a level area and shut down engine.

Apply parking brake.

Lower bucket to ground.

Check sight gauge that is attached to hydraulic tank. Oil

level must be visible in red centered circle shown on sight

gauge (1, Figure 19).

FG001623

Figure 19

To add hydraulic oil, turn breather cap (1, Figure 20) slowly

to allow pressurized air to vent.

Remove upper cover (2, Figure 20) from hydraulic oil tank

and raise boom at max. height and replenish oil to the top

of sight gauge (Figure 19).

IMPORTANT

Do not fill above red centered circle on sight gauge.

FG001624

Overfilling can result in damage to equipment and oil

Figure 20

leaking from hydraulic tank due to expansion.

The hydraulic oil fill cover also serves as the hydraulic oil

strainer access cover. It is important to replace this cover and

the components in the proper order and alignment.

The filter (2, Figure 21), retaining rod (3) and spring (4) are

assembled as shown in Figure 21. The hole (1) in the base of

the filter fits over a circular base in the bottom of the tank. The

retaining rod (3) screws into the top of the filter (2), but the

spring (4) slides over the top of the rod. Be certain that this

spring does not fall into the tank during reassembly.

If filter assembly was removed, insert assembly into the

FG002188

tank and check to make sure it is securely in place.

Figure 21

Inspection, Maintenance and Adjustment

OP000038

4-28

Check O-ring for damages and replace if necessary.

Check position of O-ring at surface of hole.

Place the cover on the access hole. Make sure the spring

retaining cup (1, Figure 22) in the lower section of the

cover is lined up with the spring. The filter assembly rod

must be in a vertical position and perpendicular to the base

of the tank. The cover can be rotated to align the rod into a

vertical position.

Tighten mounting bolts to 4.84 kg•m (35 ft lb).

FG002189

Figure 22

Check for Leaks in Hydraulic System

Perform a daily walk-around inspection to make sure that

the hoses, piping, fittings, cylinders and hydraulic motors

are not showing any signs of leakage. If any is noted,

determine the source of the leak and repair.

Fill Fuel Tank

WARNING!

Use extreme safety precautions while refueling to prevent

explosions or fire.

Immediately clean up any spilt fuel.

FG001689

At end of each work day, fill fuel tank. Add fuel through fuel

Figure 23

fill cap (Figure 23). When working at a temperature of 0°C

(32°F) or higher, use ASTM No. 2-D or its equivalent. At

temperatures below 0°C (32°F) use ASTM No. 1-D or its

equivalent.

Securely tighten cap after fueling.

NOTE: If breather holes in cap are clogged, a vacuum

may form in the tank preventing proper fuel flow

to engine. Keep holes in fuel cap clean.

FG001690

Figure 24

OP000038

Inspection, Maintenance and Adjustment

4-29

Check for Leaks in Fuel System

Perform an inspection of engine compartment to verify that

fuel system is not leaking. If any is noted, determine the

source of leak and repair.

Drain Fuel Condensation

Open fuel tank drain valve.

(Figure

25). Allow any

condensed water or sediment to drain out of tank.

NOTE: Dispose of drained fluids according to local

regulations.

FG002205

Figure 25

Water Trap

Take care of fuel spillage by using a vessel or a plastic hose.

Drain the water trap every 250 hours.

Draining water from the fuel has to be done by hand.

A nonreturn valve in the filter head prevents the fuel from

running back to the tank. As no fuel can run back, the pressure

will remain and as a consequence no water will be drained

unless new fuel is pumped in.

FG001691

Figure 26

Proceed as follows:

•

Place the end of the hose in a vessel.

•

Loosen draining nipple (C).

•

Pump with hand pump (A) on the primary filter head

until all water has been forced out of water trap (B).

•

Tighten the draining nipple.

NOTE: Take care of waste oil and liquid in an

open

environmentally safe way!

FG000438

Figure 27

Inspection, Maintenance and Adjustment

OP000038

4-30

Check Coolant Level

NOTE: Do not mix ethylene glycol and propylene glycol

antifreeze together. If the two are mixed, the

protection level will be reduced to the level of the

ethylene glycol.

NOTE: This unit was factory filled with propylene glycol.

WARNING!

FG001692

Figure 28

Never open radiator when it is hot. Scalding liquid inside a

hot radiator is under pressure. Removing cap from a hot

radiator could cause a person to be sprayed and burned

from liquid inside. Wait for radiator temperature to cool

down before removing cap.

Check sight gauge (1, Figure 29) that is attached to the

radiator. Coolant level must be visible in red centered circle

shown on gauge. To add coolant, remove fill cap (2, Figure

29) of the radiator and add coolant to proper level by

checking sight gauge (1, Figure 29). If temperature is

below freezing, see “Antifreeze Concentration Tables” on

page 4-74 for antifreeze protection. Use the table to

calculate a proper mixture of antifreeze and water to

provide level of protection necessary for expected

temperature.

FG003901

Figure 29

Check Level of Windshield Washer Liquid

Check fluid level in windshield washer tank, behind

operator's seat.

Open fill cap and add fluid.

NOTE: Use a washer liquid that is rated for all seasons.

The will prevent freezing during cold weather

operation.

FG001693

Figure 30

OP000038

Inspection, Maintenance and Adjustment

4-31

Inspect the Bucket Teeth and Side Cutters

for Signs of Wear

On a daily basis, inspect bucket teeth to make sure that

tooth wear or breakage has not developed.

Do not allow replaceable bucket teeth to wear down to the

point that bucket adapter is exposed. (Figure 31)

NOTE: These instructions are only for DOOSAN OEM

buckets. If you are using other manufacturers'

buckets, refer to their specific instructions.

Figure 31

Inspect Seat Belt for Proper Operation

Inspect the Structure for Cracks and

Faulty Welds

During the daily walk-around inspection and when

greasing the machine, look for any visible damage to the

machine. Repair or replace any damaged parts before

operating machine.

Check the Operation of All Switches

Verify working condition of all switches before starting

engine.

Check the Operation of All Exterior Lights,

Horn and Control Console Indicator

and Monitor Lights

Turn engine starter switch to "I" (ON) position and observe

all indicator lights.

Restore operation of any light bulbs that do not turn "ON"

at this time.

Sound the horn. Repair or replace if required.

Turn "ON" and inspect all exterior work lights. Replace any

monitors, burned out bulbs or cracked or broken housings

or lenses.

Inspection, Maintenance and Adjustment

OP000038

4-32

Start Engine, Check Starting Ability, and

Observe Exhaust Color at Start-up and

at Normal Operating Temperature.

Listen for Any Abnormal Sounds

Check Operation of All Controls

IMPORTANT

Cold weather operation requires that the operator fully

warm up the hydraulic oil before beginning machine

operation. Follow all warm up instructions listed in the

Operating Instruction section of this manual. Make sure to

cycle oil through all of the components, including all

cylinders, both travel motors and the swing motor. Cold

hydraulic oil in the lines and components needs to be

warmed before beginning full operation. If this is not done,

damage to the cylinders or hydraulic motors can occur.

With engine at rated speed, operate all of the controls.

Follow cold weather hydraulic system warm-up

procedures.

Note any slow operations or unusual movements.

Determine the cause and repair fault before operating.

Inspect Engine Fan Blade

WARNING!

Personal injury can result from a fan blade failure. Never

pull or pry on the fan. This can damage the fan blade(s) and

cause fan failure.

NOTE: Manually rotate the crankshaft by using a wrench on

the accessory drive pulley nut.

Figure 32

An inspection of the cooling fan is required daily. check for

cracks, loose rivets, bent or loose blades, and for contact

between the blade tips and the fan shroud. Check the fan

to make sure it is securely mounted. Tighten the bolts if

necessary. Replace any fan that is damage.

OP000038

Inspection, Maintenance and Adjustment

4-33

Check Engine Drive Belt Wear

WARNING!

Keep clear of engine fan and fan drive belts when the

engine is running. Rotating fan and belt contact can cause

injury.

WARNING!

Figure 33

When checking, adjusting or replacing drive belts, care

must be taken to prevent accidental cranking of the engine.

Be sure the starter switch is in the "O" (OFF) position and

the controls are tagged.

Replace badly worn, greasy or severely cracked belts

immediately. These conditions prevent proper belt

function. Visually inspect the belt. Check the belt for

intersecting cracks. Transverse

(across the belt width)

cracks are acceptable. Longitudinal

(direction of belt

length) cracks that intersect with transverse cracks are not

acceptable. Replace the belt if it is frayed or has pieces of

material missing.

Before installing new belts, make sure all pulley grooves

are clean and not worn. Replace pulley, if damaged, or if

the grooves are worn.

All pulley support bearings, shafts, and brackets must be in

working order.

When replacing belts and pulleys, pulley alignment must

be checked with belts tensioned and brackets securely

clamped. A misalignment that can be detected by the

naked eye is detrimental to belt performance.

Do not force the belts into the pulley grooves by prying with

a screwdriver or pry bar. This will damage the belt side

cords which will cause the belts to turn and result in

complete destruction of the belts in operation.

Belts on new machines and replacement belts lose their

tension as they seat into the pulley grooves. Check the

tension of new belts at 20 hour intervals until tension is

stabilized and thereafter, every 250 hours. If the tension

falls below the required minimum, the belt will be able to

slip, damaging the belts and pulley grooves.

NOTE: When operating in abrasive conditions, check

tension every 100 hours.

Inspection, Maintenance and Adjustment

OP000038

4-34

Check Air Intake System

WARNING!

Hot engine components can cause burns.

Avoid contact with hot engine components.

Park the machine on a level surface, apply the parking

brake, lower the attachment to the ground, and shut down

HAOA050L

Figure 34

engine.

Check the engine intake hose, and hose clamps for

damage and tightness.

If damaged, wrinkled or loose, replace, tighten or contact

your nearest DOOSAN loader dealer.

IMPORTANT

Severe engine damage will result from running with

unfiltered air.

Do not operate engine if any leaks or defects are found

Figure 35

on air intake system.

OP000038

Inspection, Maintenance and Adjustment

4-35

Grease Steering Cylinder Rod and Head

Ends

Steering cylinder rods, 2 locations, one on each side of

machine.

FG001707

Figure 48

Steering cylinder head ends,

2 locations. Use remote

grease fittings mounted on frame. (1 and 2, Figure 49).

Remote Grease

Reference Number

Fittings

1 and 2,

Steering Cylinder

50 Hours

Head Ends

Drive Shaft

250 Hours

Center Bearing

FG001640

Figure 49

Grease Upper and Lower Center Pins

Center pins, upper (Figure 50) and lower (Figure 51). Two

locations on right side of machine.

FG001641

Figure 50

FG001642

Figure 51

Inspection, Maintenance and Adjustment

OP000038

4-40

Change Engine Oil and Filter

NOTE: Change engine oil and filter after first 50 hours on a

new machine and every 500 hours thereafter.(See

page 5-52)

Hydraulic Full Flow Filter Replacement

NOTE: Replace hydraulic full flow filter after first 50 hours of

operation or rebuild and every

1,000 Hours

thereafter. Follow procedure under

500 hour

maintenance interval (See page 5-41)

Check Air Conditioner and Alternator Belt

Tension

Air conditioner and alternator belt tension must be checked

after first

50 hours of operation to comply with new

machine break-in requirements. After first check, air

conditioner and alternator belt must be checked every 250

hours. Follow procedure printed under

250 hour

maintenance interval “Check Air Conditioner and Alternator

Belt Tension” on page 4-46.

Clean Exterior of Radiator, Oil Cooler and

Air Conditioner Condenser

Dust and dirt accumulation on fins of radiator (1), CAC

cooler (4), oil cooler (2), and additional transmission cooler

(3), greatly reduce their cooling efficiency. Use

compressed air, water and steam to clean fins on radiator,

oil cooler, and transmission cooler.

NOTE: On an especially dusty work site, clean fins

every 50 hours. On other work sites, clean fins

every 500 hours.(See page 5-50)

FG004071

Figure 52

OP000038

Inspection, Maintenance and Adjustment

4-41

Clean Air Conditioner Filter

This unit is equipped with an air-conditioning system. There are

two filters (1 and 2, Figure 53) for air conditioner. They filter out

dirt and dust particles from air being circulated into operator's

cabin. They are located under the right side control panel.

Open access cover on the lower right side of cabin on the

outside, to gain access filter.

Remove filter (1, Figure 53) and inspect it for damage.

Use compressed air to clean filter. If element is very dirty

use a mild soap and water solution to clean it.

NOTE: Clean air-conditioning filter every 50 hours and

replace a new one every 500 hours of service.

NOTE: If water was used to clean filter be sure it is

completely dry before installation.

NOTE: In the event that the unit it being operated in a

dusty environment, the cleaning and

replacement must be performed more

frequently if filter is damaged, replace damaged

with a new one.

FG003904

Figure 53

WARNING!

All service and inspection of the air-conditioning

system must be performed with the starter switch in

the "O" (OFF) position.

Inspection, Maintenance and Adjustment

OP000038

4-42

250 HOUR / MONTHLY SERVICE

Check Engine Air Intake Precleaner

The engine is equipped with a precleaner. Dust, insects,

rainwater etc., can be present in the air. The precleaner

collects this material and discharges it. This prevents

material from being drawn into air cleaner. The precleaner

does not need periodic cleaning or replacement.

Figure 54

Drain Water From Hydraulic Oil Tank

WARNING!

Be certain that hydraulic oil has cooled before draining

water and sediment. Hot oil could splash and cause burns.

The hydraulic tank is pressurized. Unscrew the cap of

breather on the top of hydraulic tank to allow pressurized

air to vent. After pressure has been released, it is safe to

remove either the fill cap or service covers.

Position machine on firm, level ground. Lower boom and

position bucket on ground. Shut down engine.

Position a container under hydraulic tank drain plug. Open

tank breather cap (See Figure 20 on page 5-28). Loosen

drain valve at bottom of tank (Figure 55). Allow all water

and sediment to drain out. Tighten drain valve.

NOTE: Dispose of drained fluids according to local

regulations.

FG002211

Figure 55

OP000038

Inspection, Maintenance and Adjustment

4-43

Turbocharger

The turbocharger is lubricated and cooled by the engine

lubrication system.

Important for the function of the turbocharger is that:

•

lubrication and cooling is safeguarded by

- not racing the engine immediately after it has

been started.

- the engine is allowed to run at low idle for a

couple of minutes before it is turned off.

•

engine oil is changed and oil filters are replaced at

prescribed intervals.

•

the air cleaner is serviced regularly and that the

exhaust system and lubricating oil lines do not leak.

In case jarring noises can be heard, or if the turbocharger

vibrates, it must be reconditioned or replaced immediately.

Only authorized dealer workshops should carry out work on

the turbocharger.

Figure 56

Inspection, Maintenance and Adjustment

OP000038

4-44

Air Cleaner

CAUTION!

Never remove air cleaner filter while engine is running. This

will allow dirt to be sucked into engine and cause serious

engine damage. Always turn engine "OFF" before servicing

air cleaner.

Engine, Air Cleaner

The degree of engine wear depends largely on the cleanliness

of the induction air. The air cleaner prevents dust and other

impurities from entering the engine. Therefore, it is very

important that the air cleaner must be checked regularly and

maintained correctly.

Figure 57

Primary Filter, Maintenance and Replacement

When the alarm text "Clogged Air Filter" is shown or every 1,000

hours, the filter must be replaced or be cleaned. The period of

operation between filter replacements vary depending on the

working environment of the machine. In certain environments

the filter needs to be replaced more often.

•

The filter can be cleaned according to instructions

which your authorized dealer will give you. However,

after the filter has been cleaned five times or if it is

damaged, it must be replaced.

NOTE: Make a mark on the decal at the end of the

Figure 58

secondary filter every time the primary

filter is replaced or cleaned.

•

In connection with replacing the filter, the cover for

the air cleaner should also be cleaned. It works as a

container for particles which have not been trapped in

the filter.

•

Check that all hose and pipe connections from the air

cleaner to the engine induction manifold are tight.

Check tightness of hose clamps.

•

If the alarm text remains after replacing the primary

filter, also the secondary filter must be replaced. See

“9. Air Cleaner Clogged Warning Light” on page 3-20.

Do not, under any circumstances, run the engine without a filter

or with a damaged one.

OP000038

Inspection, Maintenance and Adjustment

4-45

Always have a spare filter on hand and keep the filter well

protected from dirt.

CAUTION!

Never clean the inside of air filter housing while the inner

filter is not installed.

Secondary Filter

Replace the filter every 2,000 hours or when the main filter has

been replaced three times.

The filter cannot be cleaned, but must be replaced.

The secondary filter works as a protective filter if the main filter is

damaged.

Never remove the secondary filter unless it is to be replaced.

Figure 59

Check Air Conditioner and Alternator Belt

Tension

Water pump belt

Loosen the tension adjusting bolts of the alternator, air con.

compressor and air compressor, then take off the cooling fan.

Adjustable link

for alternator belt

for Air-con belt

Air-con belt

AOO0100L

Figure 60

Grease Drive Shafts

Grease fitting for center bearing, 1 location. Use remote grease

fitting mounted on front frame (3, Figure 61).

Remote Grease

Reference Number

Fittings

1 and 2,

Steering Cylinder

50 Hours

Head Ends

Drive Shaft

FG001640

250 Hours

Center Bearing

Figure 61

Inspection, Maintenance and Adjustment

OP000038

4-46

500 HOUR / 3 MONTH SERVICE

Perform All Daily, 50 and 250 Hour Service

Checks

Replace Hydraulic System Brake and Pilot

Filter

Replace filter in pilot filter. Perform the following steps:

Vent hydraulic oil tank.

FG002208

Figure 63

Unscrew element cover (5, Figure 64). Cover is filled with

oil. Dispose of oil.

Remove O-ring (3, Figure 64) and filter (4).

Use a nonflammable, nontoxic solvent to clean out cover

(5, Figure 64).

Insert a new filter (4, Figure 64) into cover (5). Install a new

O-ring (3).

Screw cover (5, Figure 64) onto filter head (1).

Figure 64

Inspection, Maintenance and Adjustment

OP000038

4-48

Replace Prefuel Filter

WARNING!

Exchange filter after waiting for engine to cool. Be careful of

fire hazards. Do not smoke.

Locate fuel filter inside engine compartment.

Position a small container under fuel filter. Drain filter by

opening drain valve on bottom of filter.

NOTE: Dispose of drained fluids according to local

regulations.

Unscrew fuel filter from head assembly. Discard fuel filter.

After cleaning filter head, install new fuel filter. Screw filter

on head until gasket contacts head, turn filter 1/3 - 1/2 turn

more.

FG001626

NOTE: Coat fuel filter gasket with fuel.

Figure 65

NOTE: Fill fuel filter with clean fuel. This will help

reduce fuel system priming.

Start engine. After engine has run for a couple of minutes,

shut down engine and look for signs of leaks.

If engine does not start, fuel system may need priming.

Prime fuel system using the following procedure:

A. Loosen plug on top of fuel filter head.

B. Unscrew and pump the hand operated primer pump

near fuel injection pump. Pump primer until fuel is

present at plug hole in fuel filter head.

C. Tighten plug in fuel filter head.

D. Continue to pump primer pump until a strong

resistance is felt. Screw primer pump knob back into

housing.

E. Start engine and look for signs of leaks.

OP000038

Inspection, Maintenance and Adjustment

4-49

Fuel Filter (Spin-On Type)

General Information

DOOSAN Common Rail Fuel System

The Cummins Common Rail fuel system requires the use of two

fuel filters. The prefuel filter have the following characteristics:

•

water separating

•

30-micron rating

•

hand priming pump

•

chassis mounted.

FG001691

Figure 66

The pressure side main fuel filter must have the following

characteristics:

•

5-micron rating

•

engine mounted

FG004349

Figure 67

Remove

Disconnect the wiring harness from the fuel heater, if equipped.

Loosen and remove the fuel filter.

Make sure the seal ring does not stick to the filter head.

Remove the ring with an O-ring pick, if necessary.

NOTE: Both fuel filters must be removed at the same time.

Install new filter. Apply a small amount of oil around filter gasket.

Screw filter on head until gasket contacts head by hand, turn

filter 3/4 - 1 turn more with filter wrench.

Figure 68

Inspection, Maintenance and Adjustment

OP000038

4-50

Clean Exterior of Radiator, Oil Cooler and

Air Conditioner Condenser

Dust and dirt accumulation on fins of radiator, oil cooler,

and additional transmission cooler greatly reduce their

cooling efficiency. Use compressed air, water and steam to

clean fins on radiator, oil cooler, and transmission cooler.

NOTE: On an especially dusty work site, clean fins

every 50 hours. On other work sites, clean fins

every 500 hours.

FG001647

Figure 69

FG002217

Figure 70

OP000038

Inspection, Maintenance and Adjustment

4-51

Clean Air Conditioner Filter

This unit is equipped with an air-conditioning system. There are

two filters (1 and 2, Figure 71) for air conditioner. The filters out

dirt and dust particles from air being circulated into operator's

cabin. They are located under the right side control panel.

Open access cover on the lower right side of cabin on the

outside to gain access filter.

Remove filter (2, Figure 71) and inspect it for damage.

Use compressed air to clean filter. If element is very dirty

use a mild soap and water solution to clean it.

NOTE: Clean air-conditioning filter every 500 hours and

replace with a new one every 1,000 hours of

service.

NOTE: If water was used to clean filter be sure it is

completely dry before installation.

NOTE: In the event that the unit it being operated in a

dusty environment, the cleaning and

replacement must be performed more

frequently if filter is damaged, replace damaged

FG003904

with a new one.

Figure 71

WARNING!

All service and inspection of the air-conditioning

system must be performed with the starter switch in

the "O" (OFF) position.

Axle Differential and Planetaries Oil

Replacement (After First 500 Hours)

NOTE: The differential and planetaries oil must be drained

and refilled after first 500 hours of operation. There

after every 1,500 hours of operation. (See page 5-60)

Inspection, Maintenance and Adjustment

OP000038

4-52

Doosan DL 300. Operation and Maintenance Manual (2003) - page 2