Doosan DL 300. Operation and Maintenance Manual (2003)

Change Engine Oil and Filter

CAUTION!

Never attempt to change oil or filter on a hot engine. Hot oil

could splash and cause burns. Allow engine to cool down

before changing oil or filter.

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

new machine and every 500 hours thereafter.

Position a larger container under drain valve beside left

wall of fuel tank. Loosen drain valve and allow all engine oil

to drain out. Tighten drain valve.

NOTE: Oil warming is good when replacing oil. If

machine is cold, operate the engine to bring the

coolant temperature up to about 40°C (104°F).

When the needle of the coolant temperature

gauge reaches the middle of the "WHITE

ZONE," the temperature is about 40°C (104°F).

NOTE: Dispose of drained fluids according to local

FG002215

regulations.

Figure 72

Replace engine oil filter (Figure 73). Engine oil filter is a

spin-on type. Remove and discard filter.

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.

NOTE: See “Axle Oils DL400, DL300, DL250” on

page 5-16., for capacity and

“Table of

Recommended Lubricants” on page 4-14, of

this manual for recommended oil for the

operating conditions.

FG001646

Fill engine with correct oil through oil fill port.

Figure 73

Start engine and check engine oil pressure warning light.

Shut down engine. Look for signs of leaks at filter. Recheck

oil level.

OP000038

Inspection, Maintenance and Adjustment

4-53

1,000 HOUR / 6 MONTH SERVICE

Perform All Daily, 50, 250 and 500 Hour

Service Checks

Drain and Replace Transmission Oil and

Filter

NOTE: Transmission oil and filter must be changed after first

250 hours of operation to comply with new machine

break-in requirements. After first change, oil and filter

must be changed every 1,000 hours.

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.

NOTE: See “Axle Oils DL400, DL300, DL250” on

page 5-16., for capacity and

“Table of

Recommended Lubricants” on page 4-14, of

this manual for recommended oil for the

operating conditions.

Remove drain plug. Allow all transmission fluid to drain into

a receptacle. Clean drain plug.

NOTE: Dispose of drained fluids according to local

regulations.

Install drain plug in transmission.

Remove inlet strainer. Use a nonflammable, nontoxic

solvent to clean strainer.

Inspect gasket on inlet strainer. Replace gasket if it is

damaged. Install inlet strainer.

FG004072

Remove breather filter. Clean breather filter and install it.

Figure 74

Rotate filter counterclockwise to remove it.

10.

Clean filter head.

11.

Grease filter gasket and gasket mating surface on filter

head.

12.

Thread filter onto filter head. Tighten filter 1/2 turn after

filter gasket contacts filter head. Filter must be torque to

1.6 - 2.1 kg•m (11.5 - 15 ft lb).

FG002218

Figure 75

Inspection, Maintenance and Adjustment

OP000038

4-54

13. Fill transmission with fluid through transmission fill tube.

FG001622

Figure 76 TRANSMISSION OIL FILL CAP

14. Add fluid until fluid level is visible in lower "COLD" portion

of sight gauge (Figure 77 and Figure 78).

15. Start engine. Idle engine for two minutes. Have a person

remain in the cabin.

16. With engine idling, have second person check

transmission fluid level again. Add fluid until level reaches

"HOT" mark on sight gauge.

HB9O0031L

Figure 77

TRANSMISSION SIGHT GAUGE

TRANSMISSION FILL TUBE

17. 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.

HOT

NOTE: If transmission cannot reach an operating

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

COLD

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

HAAD4540

above top end of sight gauge.

Figure 78 TRANSMISSION SIGHT GAUGE

18. Check filter for leaks while engine is running.

OP000038

Inspection, Maintenance and Adjustment

4-55

Clean Fuel Tank and Strainer

WARNING!

Fuel is flammable and harmful to skin.

•

Do not smoke while draining moisture and

sediment from fuel tank.

•

Do not drain fuel with engine running.

•

Do not allow fuel to remain on skin for an

extended period of time. Wash thoroughly with

soap and water.

NOTE: It is easier to clean the fuel tank when it is almost

empty.

Park the machine on a level surface, apply the parking

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

engine.

Open the drain valve (Figure 79) on the bottom of the fuel

tank.

Drain the remaining fuel into a suitable container.

NOTE: Dispose of drained fluids according to local

regulations.

FG002205

Figure 79

Remove bolts, inspection cover and gasket (Figure 80)

from fuel tank.

Clean inside of the tank and suction stainer.

Install the inspection cover with a new gasket. Tighten the

bolts. Do not overtighten.

Close drain valve.

Fill fuel tank.

Check for any leaks at cover and plug.

FG002223

Figure 80

Replace Air Conditioner Filter

NOTE: This unit is equipped with an air filtration system

which filters out dirt and dust particles from air being

circulated into operator's cabin. This filter must be

cleaned out every 500 hours and replaced with a new

one every 1,000 hours. For filter replacement See

“Clean Air Conditioner Filter” on page 5-52.

NOTE: In the event that the equipment is being operated in a

dusty environment, the cleaning and replacement

must be performed more frequently.

Inspection, Maintenance and Adjustment

OP000038

4-56

Check Air Conditioner Refrigerant

WARNING!

Mixing of tobacco smoke and freon is deadly.

Do not smoke while servicing or recharging

air-conditioning system.

Apply the parking brake and lower attachment to the

ground.

Remove the cover.

Press the "HI" flow control switch to set maximum air flow.

Set the temperature control switch fully to the cool position

and fully open the cabin doors.

Slightly accelerate the engine to about the middle speed

range (compressor speed 1500 - 1800 rpm).

Compare the flow of bubbles in the sight glass with the

drawings in the following table.

CAUTION!

Overfilling refrigerant may cause dangerous

high-pressure and poor cooling action; and low

refrigerant level may cause compressor damage.

Always maintain refrigerant at normal level.

FG004075

Figure 81

Amount of

Appearance of the Sight Glass

Solutions

Refrigerant

Almost clear.

Normal

Any bubbles disappear if the engine

speed is increased to 1500 rpm.

High

No bubbles are seen.

Contact your local DOOSAN loader

dealer

for

inspection

and

recharging refrigerant.

Low

A flow of bubbles is visible.

OP000038

Inspection, Maintenance and Adjustment

4-57

Check and Adjust Engine

Contact your nearest DOOSAN loader dealer.

Contact engine manufacturer for checking and adjusting the

following items:

•

Engine Compression Pressure.

•

Injection Pressure.

•

Injection Timing.

Hydraulic Full Flow Filter Replacement

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. Loosen hydraulic oil fill

cap slightly to allow pressurized air to vent. After pressure

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

service covers or drain water from the tank.

IMPORTANT

Make sure to clean any dirt or water from top of the

hydraulic tank, especially around fill port and filter ports.

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

operation or rebuild and every 500 Hours thereafter.

Inspection, Maintenance and Adjustment

OP000038

4-58

Loosen breather cap on hydraulic tank. (See Figure 20 on

page 5-28).

Clean filter cover (2, Figure 82) and tank around cover.

Remove bolts (1, Figure 82) from cover (2).

Lift cover (2, Figure 82) and O-ring (4) off tank. A control

spring (3) sits beneath cover. Remove spring (3).

Remove valve (5, Figure 82) and filter (6) from tank.

Clean underside of cover (2, Figure 82).

Set a new element (6, Figure 82) and valve (5) down into

tank. Press element down onto its base until top of element

is approximately 4 mm (0.157") below edge of tank.

Install a new O-ring (4, Figure 82) on cover (2). Set spring

(3) into place on element (6).

Set cover (2, Figure 82) into place over element (6). Install

FG002216

bolts (1) through cover (2) and tighten them.

Figure 82

10. Tighten breather cap on tank.

OP000038

Inspection, Maintenance and Adjustment

4-59

1,500 HOUR / 9 MONTH SERVICE

Perform All 10, 50, 250 and 500 Hour

Service Checks

Replace Outer and Inner Air Cleaner

Filters

CAUTION!

Never remove air cleaner element 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.

Replace inner filter when outer filter is replaced.

After removing outer filter, remove wing nut and inner filter.

Clean out inside of air cleaner housing. Do not use

compressed air to blow out housing.

Install new inner filter, and secure it into position with wing

nut. Do not clean and reuse inner filter.

Install new outer filter, and secure it into position with wing

nut.

Install air cleaner cover.

NOTE: Make sure that all gaskets on wing nuts and

cover are properly installed and seated.

Axle Differential and Planetaries Oil

Replacement

NOTE: Oil in both front and rear axles must be replaced after

first

500 hours of operation to comply with new

machine break-in requirements. After that, axle oil

check must be done every 500 hours of operation

and replacement must be done every 1,500 hours.

Each axle contains a center differential, and a planetary on each

end. The same oil lubricates the center differential and

planetaries. These sections of the axle are connected, but the oil

flows very slowly between them. When checked, oil must be

checked and refilled at the level/fill plug on the differential

housing.

Inspection, Maintenance and Adjustment

OP000038

4-60

To drain and replace oil in an axle, perform the following steps:

Drive machine onto a level surface. Apply parking brake.

Block wheels.

Clean areas around drain plugs on both ends of axle.

Remove plugs and allow oil to drain into a suitable

container.

NOTE: See “Axle Oils DL400, DL300, DL250” on

page 5-16., for capacity and

“Table of

Recommended Lubricants” on page 4-14, of

FG002220

this manual for recommended oil for the

operating conditions.

Figure 83

NOTE: Dispose of drained fluids according to local

regulations.

NOTE: Plug Size: M24 x 1.5

Tightening Torque: 7.1 kg•m (51 ft lb)

Clean area around level plug (1, Figure 84) and drain plug

(2) on center differential. Remove level plug (1) and drain

plug (2). Allow oil to drain into a suitable container.

NOTE: Plug Size (1, Figure 84):

M36 x 1.5

Tightening Torque: 13.2 kg•m (95 ft lb)

Plug Size (2, Figure 84):

M24 x 1.5

Tightening Torque: 7.1 kg•m (51 ft lb)

FG002221

Install drain plug (2, Figure 84) into center differential, and

Figure 84

tighten. Install drain plugs on both ends of axle, and

tighten.

Pump oil into level plug hole on center differential. Add oil

until oil level is even with bottom of plug hole. Recheck

level on center differential. Add oil if necessary. When oil

level is satisfactory at the level plug hole, install and tighten

level plug.

NOTE: Allow oil time to fill planetaries.

Repeat procedure for other axle.

NOTE: Plug Size (1, Figure 85):

M36 x 1.5

Tightening Torque: 13.2 kg•m (95 ft lb)

Plug Size (2, Figure 85):

M24 x 1.5

Tightening Torque: 7.1 kg•m (51 ft lb)

FG002222

Figure 85

OP000038

Inspection, Maintenance and Adjustment

4-61

Axle Brake Disk Wear Measurement

NOTE: A wear measurement on the multidisk brake

must be made at least once a year, especially in

case of a change in braking behavior like, e.g.

•

Braking noise.

•

Braking power reduced.

•

Deceleration changed.

•

Brake fluid level changed.

•

Braking pressure changed.

A wear measurement must be made on both output sides.

Remove screw plug, actuate brake and determine

"Dimension X" according to Figure 86 and Figure 87 using

a feeler gauge. "Dimension X" corresponds with the

thickness of an inner brake disk on the piston side.

FG002219

Figure 86

NOTE: If Dimension X less than or equal to 4.0 mm

(0.16 in), the lined disks on both sides must be

replaced.

Install level plug with a new O-ring.

NOTE: Tightening Torque: = 7.1 kg•m (51 ft lb)

Figure 87

Inspection, Maintenance and Adjustment

OP000038

4-62

2,000 HOUR / YEARLY SERVICE

Perform All Daily, 50, 250, 500 and 1,000

Hour Service Checks

Check Steering, Brake, Drive Shaft,

Engine, and Fuel System

Replace Pipes and Hoses

Replace hoses that carry brake fluid to wheel brakes. Also

replace hoses that carry hydraulic fluid to steering

cylinders.

It is difficult to determine condition of many hoses. The

best way to ensure safe operation and to maintain

maximum performance is to replace hoses on a regular

basis. If any brake or steering hoses become damaged or

appear defective in any way, replace them immediately

despite time interval since their last replacement.

Bleed Brakes

When brake hoses or brake tubes are replaced, air can be

introduced into brake hydraulic system. Air can cause brakes to

operate intermittently, which is a dangerous condition. Never

operate machine with air in brake hydraulic system. A spongy

feel when pressing brake pedal is a sign that air is present in

brake hydraulic system.

To bleed air out of brake hydraulic system, perform the following

steps:

Start engine and place transmission in "NEUTRAL."

FG002224

Figure 88

OP000038

Inspection, Maintenance and Adjustment

4-63

Remove plug (Figure 89) on axle. Increase the height of

bleeder (1, Figure 89) by using special tool (4, Figure 89).

Place one end of a plastic hose (2, Figure 89) over bleeder

screw (1). Place other end of hose in a container (3) filled

with brake fluid.

NOTE: Dispose of drained fluids according to local

regulations.

Station one person in operator's cabin, and one person at

bleeder screw on axle being bled.

Open bleeder screw (1, Figure 89). Then press down on

brake pedal until it rests on floor of cabin. Hold pedal down

on floor of cabin. Close bleeder screw while pedal is being

held down. After bleeder screw has been closed, allow

brake pedal to return to upright position. Continue to open

bleeder screw and press down pedal as described in this

step, until fluid expelled from bleeder hose has no air

bubbles present.

Securely close bleeder screw (1, Figure 89). Install plug in

axle.

Perform bleeding procedure on other three locations.

Figure 89

Change Radiator Coolant

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. See

“Engine Cooling System” on

page 5-73., for further details.

NOTE: This unit was factory filled with propylene glycol.

WARNING!

Allow the engine to cool before releasing the radiator cap.

Make sure to loosen the cap slowly to release any

remaining pressure.

Radiator cleaning is performed while the engine is running.

Take extreme caution when working on or near a running

engine. Make sure to lock out and tag the controls notifying

personnel that service work is being performed.

FG002206

Figure 90

Do not remove the radiator cap unless it is required.

Observe the coolant level in the coolant recovery tank.

Inspection, Maintenance and Adjustment

OP000038

4-64

Slowly open the radiator cap (Figure 90) to allow any

pressure to escape.

NOTE: See “Axle Oils DL400, DL300, DL250” on

page 5-16. for capacity.

Place a container under the radiator and open the drain

valve (Figure 91).

NOTE: Dispose of drained fluids according to local

regulations.

FG002225

Figure 91

Drain and Replace Hydraulic Oil

CAUTION!

Be certain that hydraulic oil has cooled before draining it.

Hot oil could splash and cause burns.

Raise boom to its highest position. Tilt bucket back as far

as possible, and shut down engine.

NOTE: See “Axle Oils DL400, DL300, DL250” on

page 5-16. for capacity.

Figure 92

Position a catch tank beneath hydraulic tank drain plug.

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

Remove drain plug from bottom of tank. (Figure 93). Allow

all hydraulic oil to drain out.

FG004076

Figure 93

OP000038

Inspection, Maintenance and Adjustment

4-65

Figure 94

Figure 95

Without starting engine, operate controls to dump bucket.

(Figure 94). Then operate controls to lower boom. (Figure

95). This will drain oil out of boom and bucket cylinders.

Replace full flow hydraulic filters as described under

“Loosen breather cap on hydraulic tank. (See Figure 20 on

page 5-28).” on page 4-59.

Remove and clean pump inlet strainer (Figure 96) inside

hydraulic tank. Carefully remove bolts and cover (1, Figure

96) from top of hydraulic oil tank. There is a spring (2)

under the cover that will force the cover up.

A. Remove bolts (5, Figure 96) that retain strainer cover

(6).

B. Remove strainer cover (6, Figure 96) and strainer (4)

from tank.

C. Remove strainer (4, Figure 96) from strainer cover.

D. Clean strainer

(4, Figure

96) in a nonflammable,

nontoxic solvent.

E. Mount strainer (4, Figure 96) on strainer cover (6).

F. Insert strainer (4, Figure 96), and cover (6), into tank.

G. Install and tighten bolts

(5, Figure

96) that retain

FG004346

cover (6).

Figure 96

Install tank drain plug. Refill tank by pouring oil in through

breather cap opening. Install and tighten breather cap.

Inspection, Maintenance and Adjustment

OP000038

4-66

Start engine and operate controls to raise and lower bucket

a few times. (Figure 97). Raise and lower boom a few

times. (Figure 98). Lower bucket to ground.

Check tank sight gauge. (See Figure 19 on page 5-28). Oil

level must be between upper limit and lower limit on sight

gauge. Remove breather cap and add oil if necessary.

Figure 97

Figure 98

Check Brake Accumulator

WARNING!

Pressurized Nitrogen gas in brake accumulator may

explode causing serious injury or death.

Never service brake accumulator unless properly trained.

Test the brake accumulator for proper precharge of Nitrogen

gas:

Park the machine on a level surface, apply the parking

brake, lower the attachment to the ground.

Run the engine at low idle for five minutes to fill the brake

accumulator with oil.

Shut down engine.

Turn the starter switch to "ON" position.

Count the number of times you can depress the right-hand

brake pedal before the brake warning light comes on.

If the number counted is less than five (5), there is some

problem with the accumulator. Contact your nearest

DOOSAN dealer.

OP000038

Inspection, Maintenance and Adjustment

4-67

12,000 HOUR / SIX YEAR

SERVICE

Hose In-service Lifetime Limit (European

Standard ISO 8331 and EN982 CEN)

European regulations state that the in-service life of any

hydraulic hose may not exceed six years. DOOSAN

recommends the following:

•

Hoses at the customer premises cannot be stored

more than 2 years before being discarded or installed

on a machine.

•

In-service lifetime of hoses fitted on a machine can

never exceed 6 years, but replace hoses described in

“Replace Pipes and Hoses” on page 4-63, every

year. Always replace hoses having exceeded the

allowed in-service lifetime irrespective of the external

appearance/wear.

•

Always store hoses in a dark place at a maximum of

65% relative humidity, between 0°C (32°F) and 35°C

(95°F) but as close as possible to 15°C (59°F) and

away from copper, manganese or tube generating

Ozone.

Inspection, Maintenance and Adjustment

OP000038

4-68

SEVERE CONDITIONS

MAINTENANCE

Operating Condition

Required Maintenance

Mud, Water, Rain

Check for loose fittings, obvious damage to machine, or any

fluid leakage.

After completing operations, clean mud, rocks, or debris from

machine. Inspect for damage, cracked welds, or loosened

parts.

Perform all daily lubrication and service.

If machine was working in salt water or other corrosive

materials, be sure to flush equipment with fresh water.

Extremely Dusty

Hot

Clean engine air filter on a more frequent basis.

Environment

Clean radiator and oil cooler fins to remove dirt and dust.

Clean fuel system intake strainer and fuel filter more

frequently.

Inspect starter motor and alternator, and clean as often as

necessary.

Rocky Terrain

Check wheels, tires, rims, and valve stems for damage or

excessive wear.

Inspect for loose or damaged fittings and bolts.

On a more frequent basis, inspect bucket and boom for

damage or excessive wear.

Install a top guard and front guard as necessary for protection

against falling rock.

Extreme Cold

Use proper grade of fuel for cold temperatures.

Use a gauge to check antifreeze to be sure that it will provide

protection for coldest temperature expected.

Use a hydrometer to check condition of batteries. In extremely

cold weather, remove batteries at night and store them in a

warm area.

OP000038

Inspection, Maintenance and Adjustment

4-69

BOLT TORQUE CHART

Tightening Torque Specifications for

Metric Bolts (For coated threads,

prelubricated assemblies)

Grade

Gr. 8.8

Gr. 10.9

Gr. 12.9

Dia.

kg•m

ft lb

kg•m

ft lb

kg•m

ft lb

5 mm x std.

0.59

4.3

0.79

5.7

1.0

7.2

6 mm x std.

1.00

7.3

1.38

1.66

8 mm x std.

2.49

3.46

4.15

8 mm x 1.0

2.76

3.87

4.56

10 mm x std.

4.84

6.92

8.30

10 mm x 1.0

4.84

7.05

8.30

12 mm x std.

8.57

11.89

14.52

105

12 mm x 1.5

9.00

12.59

14.94

108

14 mm x std.

13.55

18.95

137

23.10

167

14 mm x 1.5

14.94

108

21.02

152

24.89

180

16 mm x std.

20.88

151

29.46

213

35.54

257

16 mm x 1.5

22.54

163

31.53

228

38.03

275

18 mm x std.

28.90

209

40.52

293

48.41

350

18 mm x 1.5

32.50

235

45.92

332

55.04

398

20 mm x std.

40.94

296

57.95

419

69.01

499

20 mm x 1.5

46.05

333

64.03

463

77.03

557

22 mm x std.

54.90

397

77.86

563

93.08

673

22 mm x 1.5

61.00

441

86.02

622

105.00

759

24 mm x std.

71.00

513

100.00

723

120.00

868

24 mm x 2.0

78.00

564

109.95

795

130.00

940

27 mm x 2.0

115.06

832

160.00

1157

195.00

1410

Inspection, Maintenance and Adjustment

OP000038

4-70

ELECTRICAL SYSTEM

Check Battery Condition

WARNING!

Before starting any battery service work, make sure to shut

the engine off and turn the starter switch to the "I" (OFF)

position.

The batteries create hydrogen gas. An explosion hazard

exists, particularly with a deeply discharged battery. Make

sure that open flames, burning objects or sparks are kept

away from the battery compartment.

Battery electrolyte is diluted sulfuric acid. Take extreme

caution when handling the batteries. The electrolyte can

cause severe chemical burns. If any electrolyte gets on your

clothing or skin, wash it off immediately with large

quantities of water. If the electrolyte gets into your eyes,

flush them immediately with a large quantity of water and

contact a doctor at once.

When installing a battery, wear safety glasses at all times.

When removing a battery, remove the negative (-) or ground

terminal first, and then the positive (+) terminal. This will

prevent sparks or arcing that could cause an explosion.

When installing a battery, connect the positive terminal first

and then the negative terminal. Make sure to fully tighten

the terminal clamps.

In colder weather a greater drain is placed on the batteries

when they are used for the preheat cycle and when starting

a cold engine. Battery performance decreases as the

temperature gets lower.

In extremely cold weather, remove the batteries at night

and move them to a warm location. This will help to keep

them at a higher power level.

Inspection of battery electrolyte level.

NOTE: The battery installed at the factory is a

Maintenance Free (MF) type. Electrolyte under

normal conditions should remain at its proper

level.

HJB5002L

Figure 99

OP000038

Inspection, Maintenance and Adjustment

4-71

Inspect charge condition of battery by looking at the

indicator light built into battery.

•

GREEN: Normal.

•

BLACK: Insufficient charging - check alternator.

•

TRANSPARENT: Insufficient battery electrolyte

replace with new battery.

NOTE: Colors may vary from one battery manufacturer

to another. Always refer to instructions on

battery.

The batteries should always be replaced in

pairs. Using an old battery with a new one will

shorten the life span of the new battery.

Inspection, Maintenance and Adjustment

OP000038

4-72

ENGINE COOLING SYSTEM

General

Keeping an engine's cooling system in peak operating condition,

can have many benefits to keeping a machine in good operating

condition. A properly functioning cooling system will; improve

fuel efficiency, reduce engine wear, and extend component life.

Always use distilled water in the radiator. Contaminants in tap

water neutralize the corrosion inhibitor components. If tap water

must be used, it should not exceed 300 ppm hardness, or

contain more than 100 ppm of either chloride or sulfate. Water

that has been treated with a water softener also contains salt

that will cause corrosion of components. Water from creeks and

stagnant pools usually contains dirt, minerals and/or organic

material that are deposited in the cooling system and impair

cooling efficiency. Distilled water is the best.

Engine overheating is often caused by bent or clogged radiator

fins. The spaces between the fins can be cleaned by use of air

or water under pressure. When straightening bent fins, use care

not to damage the tubes or break the bond between the fins and

the tubes.

WARNING!

Pressure at air nozzle must not exceed 2.1 kg/cm² (30 psi).

Always wear goggles when using compressed air.

Do not pour cold water into radiator when engine is very hot

and water level is below the top of the tubes. Such action

could result in damage to engine cylinder heads.

Heavy duty diesel engines require a balanced mixture of water

and antifreeze. Drain and replace the mixture every year or

2,000 hours of operation, which ever comes first. This will

eliminate buildup of harmful chemicals.

Antifreeze is essential in any climate. It broadens the operating

temperature range by lowering the coolant's freezing point and

by raising its boiling point. Do not use more than 50% antifreeze

in the mixture unless additional freeze protection is required.

Never use more than 68% antifreeze under any condition.

OP000038

Inspection, Maintenance and Adjustment

4-73

Types of Antifreeze

There are two main classifications of antifreeze available on the

market today.

Ethylene Glycol - Standard Life Antifreeze

Propylene Glycol - Extended Life Antifreeze

Ethylene glycol (standard life antifreeze) has been on the market

for many years. Its chemical properties do not provide the

improved corrosion resistance that propylene glycol (extended

life antifreeze) does. Ethylene glycol is also very hazardous to

the environment, people and animals. DOOSAN recommends

that ethylene glycol be replaced with propylene glycol.

The newer propylene glycol antifreeze comes in many different

colors. Some of the colors are pink, red, orange and yellow.

There are even some that come in a blue-green color. The

blue-green color makes it very difficult to tell the difference of

what type of antifreeze is in a cooling system. The colors are

only a dye added to the clear antifreeze. Do not rely on color.

Keep careful machine records of what brand and type of

antifreeze is used in the unit. If you are unsure of what type of

antifreeze is in the system, drain and flush the system.

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.

Antifreeze Concentration Tables

Ethylene Glycol - Standard Life Antifreeze

(1,000 Hour / 6 Months)

Ambient Temperature

Cooling Water

Antifreeze

-10°C (14°F)

80%

20%

-15°C (5°F)

73%

27%

-20°C (-4°F)

67%

33%

-25°C (-13°F)

60%

40%

-30°C (-22°F)

56%

44%

-40°C (-40°F)

50%

Propylene Glycol - Extended Life Antifreeze

(2,000 Hour / Yearly)

Ambient Temperature

Cooling Water

Antifreeze

-10°C (14°F)

78%

22%

-15°C (5°F)

71%

29%

-20°C (-4°F)

65%

35%

-25°C (-13°F)

59%

41%

-30°C (-22°F)

55%

45%

-40°C (-40°F)

48%

52%

Inspection, Maintenance and Adjustment

OP000038

4-74

HANDLING OF ACCUMULATOR

WARNING!

Even though the engine is stopped, the hydraulic

accumulators for the pilot system are still charged. Do not

disconnect any pilot system hoses until accumulator

pressure has been released from the circuit. To release

pressure, turn the starter switch to "I" (ON) position and

operate pilot control valve lever and brake pedal. Even

though the engine is shut down, hydraulic actuated

components may move while releasing pilot pressure. Keep

all personnel away from machine while performing this

operation.

•

Set pilot cutoff switch to "O" (OFF) position after

stopping engine.

•

Do not mishandle accumulator(s). They are very

dangerous because they contain high-pressure

nitrogen gas.

•

Do not punch a hole or apply heat or fire to an

accumulator.

•

Do not weld on accumulator, or try attaching

anything to it.

•

When replacing an accumulator, contact a

DOOSAN distributor or sales agency so the gas

can be properly released.

•

Wear safety goggles and protective gloves when

working on an accumulator. Hydraulic oil under

pressure can penetrate the skin and cause

serious injuries.

Release pilot accumulator pressure using the following

procedure:

Lower front attachment (bucket) to ground.

Shut down engine.

Set pilot cutoff switch on "I" (ON) position.

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

Fully move pilot control valve lever in all directions.

Repeatedly press brake until brake oil pressure warning

FG001743

light turns "ON." Press the pedal another eight to nine

Figure 100

times.

Set pilot cutoff switch on "O" (OFF) position.

Turn key to "O" (OFF) position and remove from starter

switch.

Remove accumulator by unscrewing it slowly.

OP000038

Inspection, Maintenance and Adjustment

4-75

HYDRAULIC PRESSURE

CHECKS

Hydraulic pressure for most systems can be check by using the

remote test ports shown in (Figure 101).

Reference

Description

Pressure

Number

Main Pump Pressure (TPM)

220 ±5 kg/cm²

Brake Charge Pressure

120 kg/cm²

(TP2)

Steer Pump Pressure (TPS)

FG001653

220 ±5 kg/cm²

at Only Steering Relief

Figure 101

Transmission Clutch

16 - 18 kg/cm²

Pressure (TM)

Control Lever Activation

Pressure (TP1) at E/G High

30 +2/-0 kg/cm²

Idle

Control Valve Pressure

Attach gauge to port (1, Figure 101).

Relief valve cartridge on control valve (Figure 102) must be

adjusted to open at 220 ±5 kg/cm² (3,135 ±70psi)

FG004350

Figure 102

Brake Charge Pressure

Attach gauge to port (2, Figure 101).

Adjust relief valve cartridge on brake, pilot and fan motor

supply valve (Figure 103). Relief pressure (Figure 103) for

brake charging is 120 ±5 kg/cm²(1,707 ±70 psi).

FG005115

Figure 103

Inspection, Maintenance and Adjustment

OP000038

4-76

Steering Pump Pressure

Attach gauge to port (3, Figure 101).

Adjust relief valve cartridge on steering valve (Figure 104).

Cartridge must be adjusted to open at 220 ±5 kg/cm²

(3,135 ±70 psi).

FG002228

Figure 104

Remove plug and washer (Figure 105). Adjust screw that

is beneath plug. Turn screw clockwise to raise relief

pressure. Turn screw counterclockwise to lower relief

pressure.

Install plug and washer after pressure has been adjusted.

FG002229

Figure 105

Transmission Clutch Pressure

Attach gauge to port (4, Figure 101).

It is not impossible to adjust pressure.

NOTE: Transmission clutch pressure is

kg/cm²

+28

(228

psi).

Control Lever Activation Pressure

Attach gauge to port (5, Figure 101).

Adjust relief cartridge (Figure 106) on brake and pilot and

fan motor supply valve. Relief pressure must be set at 30 -

32 kg/cm² (427 - 456 psi).

Loosen lock nut on adjusting screw. Turn adjusting screw

clockwise to raise relief pressure. Turn adjusting screw

counterclockwise to lower relief pressure.

FG002227

Tighten lock nut after adjustment has been made.

Figure 106

OP000038

Inspection, Maintenance and Adjustment

4-77

Fan Motor Pressure and Fan rpm

The motor intergrates a proportional pressure relief valve, the

fan speed (and thus the cooling performance) can be infinitely

controlled depending on two different simultaneous input signals

from temperature sensors.

The cooling fan controller processes the two input signals and

controls the valve coil current. The proportional relief valve has a

fail safe characteristic, this means, max. relief valve setting is

adjusted automatically if the voltage supply is interrupted (e.g.

broken wire). This results in a max. fan speed and therefore in a

max. cooling performance.

Standard

Fan Motor Pressure

140+5/-0 kg/cm²

(2,030 +70/-0 psi)

Fan rpm

1,200

FG001746

Figure 109

Reference

Description

Number

Engine

Cooling Fan

Brake and Pilot Pump

Temperature Sensor (T/M Oil)

Cooler

Temperature Sensor

(Coolant Water)

Cooling Fan Controller

Transmission

Fan Motor

OP000038

Inspection, Maintenance and Adjustment

4-79

Checking the Relief Pressure of Fan Motor

FG001747

Figure 110

Reference

Description

Number

Fan Motor

Outlet Line

Fan Guard

Relief Valve

Inlet Line

Proportional Relief Valve

Drain Line

Reversable Solenoid Valve

Maximum Fan Speed, Checking

Open the radiator grille in order to connect the pressure

gauge.

Connect the pressure gauge to the pressure port (6) on the

inlet hose

(3). Check the maximum pressure by fully

depressing the accelerator pedal and reading the pressure

gauge. Maximum fan motor pressure: 140 ±2 kg/cm² (The

fan speed is approximately 1200 rpm at this time)

Inspection, Maintenance and Adjustment

OP000038

4-80

LONG TERM STORAGE

Cleaning

Pressure wash machine. Inspect machine for any damage or

missing parts. Drive machine to check steering linkage for

damage.

Hydraulic System

Start engine and allow it to idle for a few minutes. Drive machine

around for two - three minutes. Raise and lower boom two -

three times. Crowd and dump bucket two - three times. This will

circulate hydraulic fluid through all hydraulic systems.

Lubrication

Perform all daily maintenance procedures listed in this section

(Section 4.) Grease all grease fittings in steering linkage. Apply

a coating of light oil to all exposed cylinder rods. Apply a coating

of light oil to all control linkages and all control valve spools.

Check condition of oil coating each month and add to coating

where necessary.

Battery

Disconnect cables from battery, or remove battery from

machine. If battery is removed, fully charge battery and store it.

Cooling System Care

If cooling system does not need antifreeze and is filled with

water only, add an anti-rust additive. If temperatures below

freezing are expected, add antifreeze to protect system to level

of cold expected. See antifreeze protection Table 4-1. Use a

hydrometer to check level of antifreeze protection once each

month. If desired, cooling system can be completely drained. If

system is drained, place a sign in operator's cabin to warn

operator that there is no coolant in engine.

OP000038

Inspection, Maintenance and Adjustment

4-81

Release the screw cap (6, Figure 111) and unscrew.

Release the lock nut (5, Figure 111) and turn the adjusting

screw (4) counterclockwise until the brake disk is free.

Install lock nut

(5, Figure 111) and screw cap (6) and

tighten both as far as possible. This will protect the parking

brake assembly from dirt.

NOTE: Now, the vehicle does not have any brake

function. The vehicle must be secured against

moving away with proper means. Before putting

FG002232

the vehicle into operation again, the brake has

to be adjusted according to adjusting

Figure 113

regulations.

Adjusting regulations

During this adjusting process, the parking brake must be

released, i.e. the bank of cup springs (3, Figure 111) must be

completely pretensioned.

Park vehicle on an even surface and place wheel chocks in

front of and behind tires. Only then release the parking

brake.

Release the screw cap (6, Figure 111) and unscrew.

Release the lock nut (5, Figure 111) (size 24 or 30) and

turn the adjusting screw (4) with socket wrench (size 8 or

10) clockwise until the two brake pads (1) and (2) make

contact with the brake disk.

Turn the adjusting screw (4, Figure 111) counterclockwise

and set the clearance specified in the following table.

Type

Adjusting Screw

Clearance (mm)

Revolutions

min.

0.5

1/4

Small

M 16 (size 8)

Rated clearance

1.0

1/2

max

1.5

3/4

min.

1.0

2/5

Large

M 20 (size 10)

Rated clearance

2.0

4/5

max

3.0

1 1/5

Hold the adjusting screw (4, Figure 111) in position with the

hexagonal socket wrench and lock with the lock nut (5).

Mount the screw cap (6, Figure 111) and tighten as far as

possible manually.

Actuate the brake valve several times and check the

braking efficiency of the parking brake on slope.

OP000038

Inspection, Maintenance and Adjustment

4-83

TIRES

Inflating Tires

Recommended tire pressures should normally be followed.

Special operations may justify a different pressure. In such

cases, follow the instructions from the tire manufacturer and do

not exceed the maximum permissible pressures, (See page

5-86)

The tire pressure may have been raised before the machine was

delivered from the factory. Therefore, check and adjust the tire

pressure according to recommendations, before putting the

machine to work for the first time.

WARNING!

Repair work on tires and rims must be carried out by

persons who have been especially trained for this.

The instructions stated below apply to an inflated tire where

the pressure needs to be increased. If the tire has lost all

pressure, a trained service engineer must be called in.

•

When checking the air pressure, the tire must be cold

and the machine not have a load.

•

Ask all other persons to leave the danger area (in

front of the rim).

•

Stand by the tire tread as shown in the figure. Tire

installed on a split rim may explode causing injury or

in the worst case death.

•

Use a long air hose (with a self attaching air chuck)

which allows you to stand outside the danger area.

•

Tires on stored wheels (spare wheels) must be kept

laying down on their side, and only be inflated

sufficiently to keep the rim parts in position.

Wheel Nut, Tightening Check

After having changed a tire or if the wheel has been removed

and installed for any other reason, the wheel bolts must be

check for tightness after eight hours of operation.

Tighten wheel nuts to 85 kg•m (615 ft lb).

Inspection, Maintenance and Adjustment

OP000038

4-84

Wheel Nut Torque

Tighten wheel nuts to 85 kg•m (615 ft lb).

WARNING!

If a wheel and tire must be removed from machine and

replaced, or if a tire must be replaced on wheel, allow this

task to be performed only by experienced service

personnel. A tire rim could be propelled off wheel and

cause serious bodily injury or death. See Figure 114.

Figure 114

Check Tire for Damage

WARNING!

Improper servicing or changing tires and rims can cause

explosion resulting in serious injury or death.

Do not service or change tires and rims unless properly

trained and equipped.

Contact your nearest DOOSAN loader dealer or tire

manufacturer's local dealer for tire servicing or changing.

WARNING!

An overheated tire may explode causing serious injury or

death.

If overheated tire is suspected, do not approach tire to

distance of less than 15 m (50 ft).

Stay away until tire and rim cool down.

If the following defects are found in tires, for safety reasons the

tires must be replaced with new tires.

For the replacement contact DOOSAN loader dealer or a tire

manufacturer's local dealer.

•

Bead wire is broken or bent, or the tire is greatly

deformed.

•

Wear is excessive and the carcass ply (including

breaker) is exposed for more than

1/4 of the

circumference.

•

Damage to the carcass exceeds 1/3 of the tire width.

Figure 115

•

Tire layers are separated.

OP000038

Inspection, Maintenance and Adjustment

4-85

•

Radial cracks reach the carcass.

•

Deformation or damage which makes the tire

unsuitable for use.

Recommended Air Pressure

Material handling loading work

Material handling Loading/

DL300

10 km/h (6.2 MPH)

Carrying 25 km/h (15.5 MPH)

Tires

Front

Rear

Front

Rear

HanKook L3

kPa

325

200

325

200

23.5 x 25 x 16 PR

psi

Kumho L3

kPa

325

200

325

200

23.5 x 25 x 16 PR

psi

Michelin L5

kPa

325

200

325

200

23.5R25 x LDD2AT

psi

Bridgestone L3

kPa

375

200

375

200

23.5R25 VMT

psi

Triangle L3

kPa

325

200

325

200

23.5 x 25 x 16PR

psi

Bridgestone L5

kPa

400

250

400

250

23.5R25 VSDL

psi

The recommended tire pressures are based on the rated load

for each handling case.

In case of heavier loads, especially during loading and carrying

operations, a higher tire pressure is required. Contact the tire

manufacturer for information about which air pressure is the

correct one for the load to be handled and transported over a

particular distance.

If L5 tires are used for loading and carrying operations, due

attention must be paid to the transporting distances. Radial tires

are to be preferred for loading and carrying operation, as the

buildup of heat is less in this type of tire.

Inspection, Maintenance and Adjustment

OP000038

4-86

OP000039

5Transportation

LOADING AND UNLOADING

When transporting the machine observe the various road rules,

road transportation vehicle laws and vehicle limit ordinances,

etc.

It is a good idea to obtain special platform for loading and

unloading the machine.

Park the trailer on a flat firm roadbed. Keep a fairly long

distance between the road shoulder and the machine.

Properly apply the brakes of the trailer and place wheel

chocks in front of and behind the tires to ensure that the

trailer does not move.

Figure 1

Fix the ramp in line with the centers of the trailer and the

machine.

Determine the position of the ramp, then slowly load the

machine onto to the specified part of the trailer.

NOTE: Have someone in clear view and in a safe

position, provide directions while loading.

Lower the bucket and lock each control lever using the pilot

cutoff switch.

Apply the parking brake and set the articulation stopper in

the "LOCKED" position.

Tape over the exhaust stack outlet to prevent turbo

"Windmilling" damage.

Place blocks in front of and behind the tires to prevent the

machine from moving.

Fasten the machine to the trailer with chains or cables at

lower part of the rear chassis. Additional chains or cables

may be used but do not damage brake lines or cylinder

rods.

IMPORTANT

Figure 2

Brake pipe runs on axle housing.

Do not fasten axle housing.

OP000039

Transportation

5-1

10. Determine the route for transporting the machine by taking

into account the width, height and weight of the machine

and the truck.

SUMMARY OF SAFETY

PRECAUTIONS FOR LIFTING

To make safe lifts, the following items must be evaluated by

operator and work site crew.

•

Condition of ground support.

•

Wheel loader configuration and attachments.

•

Weight, lifting height and lifting radius.

•

Safe rigging of load.

•

Proper handling of suspended load.

Tag lines on opposite sides of load can be very helpful in

keeping a suspended load secure, if they are anchored safely to

Figure 3

control points on ground.

Transportation

OP000039

5-2

OP000040

6Troubleshooting

ENGINE

Problem

Possible Cause

Remedy

Starter does not operate.

Blown fuse.

Replace fuse.

Low battery power.

Charge battery.

Poor terminal contact.

Clean and tighten connections.

Starter switch failed.

Replace switch.

Starter relay failed.

Replace relay.

Starter control failed.

Replace controller.

Wiring harness faulty.

Replace harness.

Battery relay failed.

Replace relay.

Starter engages, engine does

Blown fuse.

Replace fuse.

not start.

Fuel gelled in cold weather.

Replace fuel.

Fuel filters plugged.

Replace filters.

Water or dirt in fuel system.

Clean system and add new fuel.

Air in fuel system.

Purge air from system.

Engine stop control failed.

Replace stop control.

Engine stop relay failed.

Replace relay.

Engine starts, runs only at low

Engine oil viscosity incorrect.

Change oil.

speed or shuts down.

Clogged or dirty fuel injectors.

Clean injectors.

Fuel filters plugged.

Replace filters.

Engine stop motor cable out of

Readjust.

adjustment.

Engine speed control cable out

Readjust.

of adjustment.

Engine knocks, runs unevenly or

Low engine oil.

Add oil.

surges.

Plugged air intake system.

Clean system and replace filter.

Injection pump out of

Contact your DOOSAN dealer.

adjustment.

Plugged fuel filter.

Replace fuel filter.

Water or dirt in fuel system.

Clean system and add new fuel.

Clogged or dirty fuel injectors.

Clean injectors.

OP000040

Troubleshooting

6-1

Problem

Possible Cause

Remedy

Engine has poor power.

Plugged air intake system.

Clean system and replace filter.

Clogged or dirty fuel injectors.

Clean injectors.

Fuel filters plugged.

Replace filters.

Engine speed control cable out

Readjust.

of adjustment.

Injection pump out of

Contact your DOOSAN dealer.

adjustment.

Valve backlash faulty.

Adjust backlash.

Engine runs hot.

Low coolant level.

Add coolant.

Thermostat faulty.

Replace thermostat.

Radiator cap faulty.

Replace radiator cap.

Radiator core plugged.

Clean oil cooler.

Oil cooler core plugged.

Clean oil cooler.

Fan belt loose or damaged.

Tighten or replace as required.

Temperature sensor faulty.

Replace sensor.

Engine oil pressure warning light

Low engine oil level.

Add oil.

turns "ON," and buzzer sounds.

Wrong grade oil for weather

change oil.

conditions.

Clogged oil filter.

Change filter and oil.

Defective alarm switch.

Contact your DOOSAN dealer.

Oil leakage from pipe or joint.

Clogged suction strainer.

Excessive engine wear.

Defective oil pump.

Coolant temp, warning light

Low engine coolant level.

Add coolant.

turns "ON."

Loose/slipping/broken fan belt.

Adjust or replace belt.

Clogged radiator fins.

Clean.

Scale or mineral build up inside

Flush or professionally clean.

radiator.

Defective alarm switch (gauge is

Contact your DOOSAN dealer.

in green).

Low water pump flow.

Thermostat stuck or missing.

Engine does not start when the

Fuel filter clogged.

Replace fuel filter.

starter motor is turning. (Also

Starter motor speed too low.

Booster Battery may be used.

see ELECTRICAL

Defective engine shutoff

Contact your DOOSAN dealer.

TROUBLESHOOTING.)

solenoid.

Fuel pump failure.

Incorrect fuel injection timing.

Compression pressure too low.

Defective injectors.

Troubleshooting

OP000040

6-2

Problem

Possible Cause

Remedy

Unstable (rough) idling.

Air in fuel lines.

Tighten fuel connections and

filter.

Fuel filter clogged.

Replace fuel filter.

Fuel pump failure.

Contact your DOOSAN dealer.

Incorrect fuel injection timing.

Insufficient power.

Air cleaner filter clogged.

Clean or replace element.

Fuel filer element clogged.

Replace fuel filter.

Throttle linkage adjustment

Check and adjust linkage.

wrong.

Engine oil level too high.

Check dipstick and correct level.

Incorrect valve clearance.

Contact your DOOSAN dealer.

Piston ring wear.

Defective injectors.

Fuel pump failure.

HYDRAULIC SYSTEM

Problem

Possible Cause

Remedy

None of the controls function

Hydraulic pump failed.

Contact your DOOSAN

(loud noise from pumps).

dealer.

Low hydraulic oil level.

Add hydraulic oil as

required.

Suction line plugged or damaged.

Clean or replace as

required.

None of the controls function (no

Pilot pump failure.

Contact your DOOSAN

noise from pumps).

dealer.

Cutoff solenoid valve failed.

Replace solenoid.

Relief cartridge of pilot parking valve

Clean or replace as

stuck.

required.

Safety limit switch is ON.

Adjust limit switch

clearance.

All actuators have low power.

Low hydraulic oil level.

Add hydraulic oil as

required.

Suction filter clogged.

Clean filter.

Hydraulic pumps faulty.

Contact your DOOSAN

dealer.

Main relief pressure too low.

Contact your DOOSAN

dealer.

Hydraulic pumps cavitating.

Bleed air from hydraulic

pumps.

OP000040

Troubleshooting

6-3

Problem

Possible Cause

Remedy

Only one or two actuators have

Overload relief pressure too low.

Reset pressure.

little or no power.

Makeup check valve leaking.

Clean or replace as

required.

Control valve spool faulty.

Replace valve spool.

Dirt in valve spool.

Clean or replace as

required.

Actuator failed.

Repair or replace as

required.

Cylinder seal failed.

Repair or replace as

required.

Cylinder rod damaged.

Repair or replace as

required.

Remote control valve failed.

Replace control valve.

Wrong pilot line connection.

Reconnect pilot lines.

Oil temperature too high.

Debris in exterior of cooler.

Clean exterior of cooler.

Oil cooler faulty.

Contact your DOOSAN

dealer.

Fan belt loose.

Tighten fan belting as

required.

Actuators on one side of boom

Overload relief valve is not operating

Repair valve or replace.

have little power or do not

properly.

operate.

Damaged hydraulic hose.

Replace hose.

Loose hydraulic fittings.

Tighten fittings.

Internal damage to control valve

Replace control valve.

housing.

Control valve spool damaged.

Replace control valve.

Sediment inside control valve.

Clean and repair valve.

Check valve internal leakage.

Repair or replace valve.

Damaged cylinder or pump.

Repair or replace pump or

cylinder.

Cylinder internal leakage.

Repair or replace cylinder.

Damaged cylinder rod.

Replace rod.

Pilot valve failure.

Replace pilot valve.

Troubleshooting

OP000040

6-4

TRAVEL SYSTEM

General

Problem

Possible Cause

Remedy

Machine will not travel.

Transmission clutch pressure

Adjust pressure.

incorrect.

Transmission charge pump

Replace pump.

damaged.

Damage to transmission control

Repair wiring.

valve wiring harness.

Burned travel relay or fuse.

Replace relay or fuse.

Forward/Reverse solenoid for

Clean and repair.

transmission control valve sticking.

Damaged transmission clutch.

Repair or replace clutch.

Damaged drive shaft.

Repair or replace.

Damaged transmission or axle.

Repair or replace.

Wheel brakes not releasing.

Repair brakes.

Parking brake not releasing.

Repair parking brake.

Machine will travel but has little

Fluid pressure low in transmission

Repair clutch.

power.

clutch.

Transmission fluid low.

Add fluid.

Damage to torque converter.

Repair or replace.

Engine malfunction.

See Engine Troubleshooting

Table.

Brake valve.

Disassemble and clean.

Unusual transmission noise.

Low transmission fluid, or low quality

Add fluid or change fluid.

fluid.

Worn transmission parts.

Replace parts.

Broken gears or bearings.

Replace parts.

Transmission fails to operate.

Damaged transmission clutch disks.

Replace disks.

Damaged wires in transmission

Repair wires.

control wire harness.

Drive shaft vibration Noisy

Bent drive shaft.

Replace drive shaft.

universal joints.

Loose universal joints.

Tighten bolts that secure

joints.

Worn or damaged universal joint.

Replace universal joint.

Loose universal joints.

Tighten bolts that secure

universal joints.

Lack of lubrication.

Lubricate universal joints.

Worn slip joint spline.

Replace slip joint.

Noisy Front or Rear Axle.

Worn or broken gears.

Replace gears.

Low oil level, poor quality oil.

Add oil, change oil.

Worn bearings.

Replace bearings.

Worn shaft spline.

Replace spline.

OP000040

Troubleshooting

6-5

STEERING

Problem

Possible Cause

Remedy

Steering Wheel is hard to turn.

Sediment blocking direction change

Clean and repair.

spool orifice, inside priority valve.

Sediment blocking amplifying spool

Clean and repair.

orifice, inside priority valve.

Sediment blocking load sensing line

Clean and repair.

orifice, inside priority valve.

Priority valve spool sticking, inside

Clean and repair.

steering valve.

Incorrect relief valve pressure drop,

Adjust pressure.

inside priority valve.

Steering pump failure.

Repair or replace.

Leaking steering cylinder.

Repair cylinder.

Rust on steering column bearing

Lubricate.

and spline.

Tire air pressure is low.

Inflate to proper pressure.

High initial resistance to

Air in load sensing line, inside

Bleed system to remove air.

movement of steering wheel.

priority valve.

Sediment blocking orifice of load

Clean and repair.

sensing line, inside priority valve.

Sediment in direction change spool,

Clean and repair.

inside priority valve.

Damage to control spring damping

Replace priority valve.

inside priority valve.

Steering wheel shakes.

Chattering bearing in axle end

Replace bearing.

differential.

Tire pressure not equal in left side

Equalize pressure.

and right side tires.

Troubleshooting

OP000040

6-6

BRAKING

Problem

Possible Cause

Remedy

Reduced brake action.

Low secondary pressure in brake

Repair or replace brake

valve.

Worn brake disks.

Replace brake disks.

Damaged brake disks.

Replace brake disks.

Damaged brake valve block.

Replace valve.

Air in brake hydraulics due to leak in

Repair leak, bleed system.

brake hose.

After bleeding brakes, brakes

Damaged brake disks.

Replace disks.

are not fully released.

Damaged brake disk return spring.

Replace return springs.

ELECTRICAL SYSTEM

Problem

Possible Cause

Remedy

Battery has no power and will

Damaged battery plates.

Replace battery.

not accept a charge.

Alternator not charging properly.

Repair or replace alternator.

Bad ground.

Clean and tighten.

Loose electrical connector.

Clean and tighten.

Alternator belt loose or damaged.

Tighten or replace.

Battery will accept a charge but

Internal battery short.

Replace battery.

discharges soon after.

Wiring harness short.

Repair wire.

OP000040

Troubleshooting

6-7

OP000041

8Specification

GENERAL SPECIFICATIONS

DL300

Item

Specification

Serial Number

5001 and Up

Standard Bucket Capacity

3.0 m³ (3.9 yd³)

Vehicle Weight

17,300 kg (38,139 lb)

Engine

Type

DL08

Aspiration

Air to Air After Cooled

Displacement

7.64 liter (466 in³)

Rated Power

220 ps (209 hp) @ 2,000 RPM

(SAE J 1995, Gross)

Max. Torque

105 kg•m (666 ft lb) @ 1,300 RPM

(SAE J 1995, Gross)

Emission

TierT ฌ

Transmission

Full Automatic Power -Shift

Full Automatic Power Shift

Speeds

4 Forward, 3 Reverse

Brake Systems

Travel Brakes

4 Wheel, Wet Disk

Parking Brake

Dry Disk Type

Performance

Travel Speed

6.5 (4.0) / 12 (7.4) / 22.5 (13.9) / 34.0 (21) km/h (MPH)

Steering Angle

±40°

Turning Radius

5,780 mm (19')

(Out tire edge)

Safe Operating Load

5,400 kg (11,905lb)

Max. Breakout Force

18,200 kg (40,124lb)

OP000041

Specification

7-1

Doosan DL 300. Operation and Maintenance Manual (2003) - page 3