Doosan Mega 500-V (TIER II). Operation and Maintenance Manual (2001)

Mega 500-V (TIER II)

Operation and Maintenance Manual

022-00029AE

Serial Number 2001 and Up

August 2001

DOOSAN reserves the right to improve our products in a continuing process to provide the best possible

product to the market place. These improvements can be implemented at any time with no obligation to

change materials on previously sold products. It is recommended that consumers periodically contact their

distributors for recent documentation on purchased equipment.

This documentation may include attachments and optional equipment that is not available in your

machine’s package. Please call your distributor for additional items that you may require.

Illustrations used throughout this manual are used only as a representation of the actual piece of

equipment, and may vary from the actual item.

022-00029AE Operation and Maintenance Manual

TABLE OF CONTENTS

Safety

1-1

To the Operator of a Wheel Loader

1-1

General Safety Essentials

1-4

Location of Safety Labels

1-4

Unauthorized Modifications

1-13

General Hazard Information

1-13

Before Starting Engine

1-21

Machine Operation

1-24

Maintenance

1-31

Battery

1-39

Towing

1-41

Shipping and Transportation

1-42

Operating Controls

2-1

Component Locations

2-2

Control Identification

2-4

Steering Console and Pedals

2-5

Front Instrument panel

2-12

Transmission Display

2-21

Right Side Switch Panel

2-22

Various Cabin Locations

2-33

Heater and Air Conditioner Operation

2-37

Stereo

2-42

Seat Adjustment

2-46

Seat Belt

2-48

Door Side Latch

2-49

Fuse Box/Relay

2-50

Window Glass Breaking Tool

2-53

Operation

3-1

022-00029AE Operation and Maintenance Manual

Table of Contents I

Instrument Panel Control Functions

3-1

New Machine Break-in Procedures

3-1

Engine Start and Stop

3-2

Machine Travel

3-9

Machine Shutdown

3-12

Additional Braking

3-14

Boom Raise Kickout

3-14

Boom Lower Kickout (Option)

3-15

Bucket Angle Indicator

3-16

Adjustment of Bucket Position Switch

3-16

Towing Machine

3-17

If Engine Stalls While Traveling

3-20

Allowable Water Depth

3-20

Inspection, Maintenance and Adjustment

4-1

Preventive Maintenance

4-1

Table of Recommended Lubricants

4-3

Fluid Capacities

4-5

Maintenance Intervals

4-6

10 Hour / Daily Service

4-8

50 Hour / Weekly Service

4-18

250 Hour / Monthly Service

4-25

500 Hour / 3 Month Service

4-35

1,000 Hour / 6 Month Service

4-37

1,500 Hour / 9 Month Service

4-42

2,000 Hour / Annual Service

4-44

Severe Conditions Maintenance

4-49

Fuel Transfer Pump

4-50

Handling of Accumulator

4-52

Check Hydraulic Pressures

4-53

Tires and Wheels

4-57

Electrical System

4-59

Bolt Torque Chart

4-60

II Table of Contents

022-00029AE Operation and Maintenance Manual

1SAFETY

TO THE OPERATOR OF A WHEEL LOADER

DANGER!

Unsafe use of the wheel loader could lead to serious injury or death. Operating procedures,

maintenance and equipment practices or traveling or shipping methods that do not follow the

safety guidelines on the following pages could cause serious, potentially fatal injuries or

extensive damage to the machine or nearby property.

Please respect the importance of taking responsibility for your own safety, and that other people who may

be affected by your actions.

Safety information on the following pages is organized into the following topics.

“General Safety Essentials” on page 1-4

“Location of Safety Labels” on page 1-4

“Unauthorized Modifications” on page 1-13

“General Hazard Information” on page 1-13

“Before Starting Engine” on page 1-21

“Machine Operation” on page 1-24

“Maintenance” on page 1-31

“Battery” on page 1-39

“Towing” on page 1-41

10.

“Shipping and Transportation” on page 1-42

022-00029AE Operation and Maintenance Manual

Safety 1-1

WARNING!

Improper operation and maintenance of this machine can be hazardous and could result in

serious injury or death.

Operator and maintenance personnel should read this manual thoroughly before beginning

operation or maintenance.

Keep this manual in the storage compartment to the rear of the operator’s seat, and have all

personnel involved in working on the machine read the manual periodically.

Some actions involved in operation and maintenance of the machine can cause a serious

accident, if they are not done in a manner described in this manual.

The procedures and precautions given in this manual apply only to intended uses of the

machine.

If you use your machine for any unintended uses that are not specifically prohibited, you must

be sure that it is safe for any others. In no event should you or others engage in prohibited uses

or actions as described in this manual.

DOOSAN delivers machines that comply with all applicable regulations and standards of the

country to which it has been shipped. If this machine has been purchased in another country or

purchased from someone in another country, it may lack certain safety devices and

specifications that are necessary for use in your country. If there is any question about whether

your product complies with the applicable standards and regulations of your country, consult

DOOSAN or your DOOSAN distributor before operating the machine.

1-2 Safety

022-00029AE Operation and Maintenance Manual

SAFETY ALERT SYMBOL

Be Prepared - Get to Know All Operating and Safety Instructions

This is the Safety Alert Symbol. Wherever it appears - in this manual or on safety signs on the

machine - you should be alert to potential for personal injury or accidents. Always observe

safety precautions and follow recommended procedures.

LEARN SIGNAL WORDS USED WITH SAFETY ALERT SYMBOL

Words "CAUTION," "WARNING," and "DANGER" used throughout this manual and on labels on machine

indicate hazards or unsafe practices. All three statements indicate that safety is involved. Observe

precautions indicated whenever you see the Safety Alert "Triangle," no matter which signal word appears

next to the "Exclamation Point" symbol.

CAUTION!

This word is used on safety messages and safety labels and indicates potential of a hazardous

situation that, if not avoided, could result in minor or moderate injury. It may also be used to

alert against a generally unsafe practice.

WARNING!

This word is used on safety messages and safety labels and indicates potential of a hazardous

situation that, if not avoided, could result in serious injury or death. It may also be used to alert

against a highly unsafe practice.

DANGER!

This word is used on safety messages and safety labels and indicates imminent hazard of a

situation that, if not avoided, is very likely to cause death or extremely serious injury. It may also

be used to alert against equipment that may explode or detonate if handled or treated carelessly.

Safety precautions are described in SAFETY from page 1-4 on.

DOOSAN cannot predict every circumstance that might involve a potential hazard in operation and

maintenance. Therefore the safety messages in this manual and on the machine may not include all

possible safety precautions. If any procedures or actions not specifically recommended or allowed in this

manual are used, you must be sure that you and others can do such procedures and actions safely and

without damaging the machine. If your unsure about the safety of some procedures, contact a DOOSAN

distributor.

022-00029AE Operation and Maintenance Manual

Safety 1-3

GENERAL SAFETY ESSENTIALS

ACCESSORY APPLICATIONS

This wheel loader has been designed primarily for moving earth with a bucket. For use as a grapple or for

other object handling, contact DOOSAN. Lifting-work applications are permitted in approved lift

configuration, to rated capacity only, with no side-loading (unless prohibited by local regulation). Do not

use machine for activities for which it was not intended. Do not use bucket for lifting work, unless lift slings

are used in approved configuration.

LOCATION OF SAFETY LABELS

There are several specific warning signs on this machine. The exact location of hazards and the

description of the hazards are reviewed in this section.

Please become familiarized with all warning signs.

Make sure that all of the warning signs are legible. Clean the warning signs or replace the warning signs if

you cannot read the words. Replace the illustrations if the illustrations are not visible. When you clean the

warning signs, use a cloth, water and soap. Do not use solvent, gasoline, or other harsh chemicals to clean

the safety signs. Solvents, gasoline, or other harsh chemicals could loosen the adhesive that secures the

warning sign. Loose adhesive will allow the warning sign to fall off.

Replace any safety sign that is damaged, or missing. If a safety sign is attached to a part that is replaced,

install a safety sign on the replacement part.

1-4 Safety

022-00029AE Operation and Maintenance Manual

WARNING FOR OPERATION, INSPECTION AND MAINTENANCE (4190-2545, 190-00092)

CAUTION!

•

Read manual and labels before

operation and maintenance.

Follow instructions and warnings

in manual and on labels on

machine.

•

Sound horn to alert people

nearby before operating, and

make sure all persons are clear

of area.

•

Always make sure when leaving

operator’s seat to:

ACO1360L

•

Lower bucket or other

working tools to ground.

•

"LOCK" transmission selector in "NEUTRAL."

•

Set park brake.

•

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

•

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

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

WARNING FOR CRUSH HAZARD (4190-2548)

DANGER!

Crushing Injury

Make sure people are clear of machine

before starting engine or moving steering

wheel.

HAOJ370L

022-00029AE Operation and Maintenance Manual

Safety 1-7

WARNINGS WHEN OPENING ENGINE HOOD (2190-2525, 190-00095)

WARNING!

Before opening bonnet, stop engine.

ACO1420L

WARNING FOR HANDLING ACCUMULATOR (2190-2528, 190-00099)

WARNING!

Explosion hazard:

•

Keep away from flame.

•

Do not weld or drill.

ACO1480L

Accumulator

The pilot control system is equipped with an accumulator. For a brief period of time after the engine has

been shut down, the accumulator will store a pressure charge that may enable hydraulic controls to be

activated. Activation of any controls may enable the selected function to operate under force of gravity.

CAUTION!

Any raised attachment will lower to ground if accumulator holds a charge.

1-8 Safety

022-00029AE Operation and Maintenance Manual

When performing maintenance on the pilot control system, the hydraulic pressure in the system must be

released as describe in “Handling of Accumulator” on page 4-52.

IMPORTANT

Refer to Shop Manual for service procedures. Do not release any pilot lines until pressure within

accumulator has been released.

KEEP OUT OF STEERING TURN AREA (4190-1992, 190-00120)

DANGER!

Keep out of steering turn area.

AMO0410L

WARNING FOR HIGH TEMPERATURE HYDRAULIC OIL (2190-2529, 190-00097)

WARNING!

HYDRAULIC OIL

To prevent hot oil from spurting out:

•

Turn engine off.

•

Allow oil to cool.

•

Slowly loosen cap to relieve

pressure before removing.

ACO1410L

022-00029AE Operation and Maintenance Manual

Safety 1-9

WARNING FOR HIGH TEMPERATURE COOLANT (2190-2531, 190-00097)

WARNING!

To prevent hot water from spurting out:

•

Turn engine "OFF."

•

Allow water to cool.

•

Slowly loosen cap to relieve

pressure before removing.

ACO1410L

WARNING FOR BATTERY MAINTENANCE (2190-2533, 190-00100)

DANGER!

•

Battery fumes can explode.

Keep sparks and flames away

from batteries.

•

Always avoid storing metals

like tools or inflammable

materials

around or on

batteries. Explosion or fire can

be caused by short circuiting

batteries.

•

Sulfuric acid in battery is

poisonous. It is strong enough

to burn skin, eat holes in

clothing, and cause blindness if

splashed in eyes.

If you spill acid on yourself:

ACO1400L

Flush your skin with water.

Apply baking soda or lime to

help neutralize acid.

Flush your eyes with water for 10-15 minutes.

Get medical attention immediately.

1-10 Safety

022-00029AE Operation and Maintenance Manual

UNAUTHORIZED MODIFICATIONS

Any modification made without authorization or written approval from DOOSAN can create a safety

hazard, for which the machine owner must be held responsible.

For safety’s sake, replace all OEM parts with the correct authorized or genuine DOOSAN part. For

example, not taking the time to replace fasteners, bolts or nuts with the correct replacement parts could

lead to a condition in which the safety of critical assemblies is dangerously compromised.

GENERAL HAZARD INFORMATION

SAFETY RULES

Only trained and authorized personnel can operate and maintain the machine.

Follow all safety rules, precautions and instructions when operating or performing maintenance on the

machine.

Do not operate the machine if you are not feeling well, if you are taking medication that makes you feel

sleepy, if you have been drinking, or if you are suffering from emotional problems. These problems will

interfere with your sense of judgement in emergencies and may cause accidents.

When working with another operator or with a person on work site traffic duty, be sure that all personnel

know the nature of the work and understand all hand signals that are to be used.

Always observe strictly any other rules related to safety.

SAFETY FEATURES

Be sure that all guards and covers are installed in their proper position. Have guards and covers repaired

immediately if damaged.

Be sure that you understand the method of use of safety features such as transmission lever neutral lock

and the seat belt, and use them properly.

Never remove any safety features. Always keep them in good operating condition.

Failure to use safety features according to the instructions in the Operation and Maintenance Manual could

result in serious bodily injury.

022-00029AE Operation and Maintenance Manual

Safety 1-13

INSIDE OPERATOR'S COMPARTMENT

When entering the operator's compartment, always remove all mud and oil from the soles of your shoes. If

you operate the accelerator and brake pedals with mud or oil stuck to your shoes, your foot may slip and

this may cause a serious accident.

Clean grease and dirt from pedals and controls. This contributes to safe operation. Cleaning also provides

an opportunity to inspect equipment. Minor damage can be repaired or corrected before major problems

result.

Keep cab floor and consoles free of tools and personal items.

Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire.

Do not leave lighters laying around the operator's compartment. If the temperature inside the operator's

compartment becomes high, there is danger that the lighter may explode.

Do not use cellular telephones inside the operator's compartment when driving or operating the machine.

There is danger that this may lead to an unexpected accident.

Never bring any dangerous objects such as flammable or explosive items into the operator's cab.

To ensure safety, do not use the radio or music headphones when operating the machine. There is danger

that this may lead to a serious accident.

When operating the machine, do not put your hands or head out of the window.

When standing up from the operator's seat, always place transmission neutral lock lever in the "LOCK"

position and set pilot cutoff switch to "O" (OFF) position. If you accidentally touch the work equipment

levers when they are not locked, the machine may suddenly move and cause serous injury or damage.

When leaving the machine, lower the work equipment completely to the ground, set transmission neutral

lock lever in the "LOCK" position, set pilot cutoff switch to "O" (OFF) position, "APPLY" parking brake, and

shut down engine. Use the key to lock all the equipment. Always remove the key and take it with you.

CLOTHING AND PERSONAL PROTECTIVE

ITEMS

Contain long hair, and avoid loose clothing and

jewelry. They can catch on controls or in

protruding parts and cause serious injury or

death.

Do not wear oily clothes. They are highly

flammable.

Full eye protection, a hard hat, safety shoes and

gloves may be required at the work site.

HAOA020L

While working on the machine, never use

Figure 3

inadequate tools. They could break or slip,

causing injury, or they may not adequately

perform intended functions.

1-14 Safety

022-00029AE Operation and Maintenance Manual

BREATHING MASKS, EAR PROTECTION MAY BE REQUIRED

Do not forget that some risks to your health may not be immediately apparent. Exhaust gases and noise

pollution may not be visible, but these hazards can cause disabling or permanent injuries.

NOTE: Sound level in closed operator’s cab is 78 dB(A). Additional information on machine sound

and vibration levels can be found in Shop Manual.

ASBESTOS DUST HAZARD PREVENTION

Asbestos dust can be HAZARDOUS to your

health if it is inhaled.

If you handle materials containing asbestos

fibers, follow these guidelines as given below:

•

Use an approved respirator.

•

Never use compressed air for

cleaning.

•

Use water for cleaning to keep down

the dust.

ARO1770L

Figure 4

•

Work on the machine or component

with the wind at your back whenever

possible.

•

Always observe any rules and

regulations related to the work site

and working environment.

MOUNTING AND DISMOUNTING

Before getting on or off the machine, if there is

any oil. grease, or mud on the handrails, steps,

or track shoes, wipe it off immediately. Always

keep these parts clean. Repair any damage and

tighten any loose bolts.

Never get on or off a moving machine. In

particular, never get on or off a moving machine.

These actions may lead to serious injury.

When getting on or off the machine, always face

the machine, and maintain a three-point contact

HA3O1003

(both feet and one hand or one foot and both

Figure 5

hands) with the handholds and steps to ensure

that you support yourself securely.

Never hold any control levers when getting on or

off the machine.

Never get up from operator’s seat or leave

operator’s station and dismount machine if

engine is running.

022-00029AE Operation and Maintenance Manual

Safety 1-15

FUEL, OIL AND HYDRAULIC FLUID FIRE

HAZARDS

Fuel, oil and antifreeze will catch fire if it is

brought close to a flame. Fuel is particularly

flammable and can be hazardous.

Always strictly observe the following.

Add fuel, oil, antifreeze and hydraulic fluid to the

machine only in a well-ventilated area. The

machine must be parked with controls, lights

and switches turned "OFF." The engine must be

"OFF" and any flames, glowing embers,

auxiliary heating units or spark-causing

equipment must be doused, turned off and/or

kept well clear of the machine.

Static electricity can produce dangerous sparks

at the fuel filling nozzle. In very cold, dry

Figure 6

weather or other conditions that could produce a

static discharge, keep the tip of the fuel nozzle

in constant contact with the neck of the fuel

filling nozzle, to provide a ground.

Keep fuel and other fluid reservoir caps tight

and do not start the engine until caps have been

secured.

PRECAUTIONS WHEN HANDLING FLUIDS

AT HIGH TEMPERATURE

Immediately after operations are stopped, the

coolant, engine oil, and hydraulic oil are at high

temperature and the radiator and hydraulic tank

are still under pressure. Attempting to remove

the cap, drain the oil or coolant, or replace the

filters may lead to serious burns. Always wait for

the temperature to go down, and follow the

specified procedures when carrying out these

operations.

HAOA050L

Figure 7

To prevent hot coolant from spurting out, stop

the engine, wait for the coolant to cool, then

loosen the cap slowly to relieve the pressure.

To prevent hot oil from spurting out, stop the

engine, wait for the oil to cool, then loosen the

cap slowly to relieve the pressure.

HAOA060L

Figure 8

1-16 Safety

022-00029AE Operation and Maintenance Manual

INJURY FROM WORK EQUIPMENT

Do not enter or put your hand, arm or any other

part of your body between movable parts, such

as between the work equipment and cylinders,

or between the machine and work equipment.

If the control levers are operated, the clearance

between the machine and the work equipment

will change and this may lead to serious

damage or personal injury.

If going between movable parts is necessary,

always position and secure the work equipment

HDO1010L

so that it cannot move.

Figure 9

FIRE EXTINGUISHER AND FIRST AID KIT

As a precaution if any injury or fire should occur,

always do the following.

•

Be sure that fire extinguishers have

been provided and read the labels to

ensure that you know now to use

them. It is recommended that an

appropriately sized (2.27 kg [5 lb] or

larger) multipurpose "A/B/C" fire

extinguisher be mounted in the cab.

Check and service the fire

HDO1009L

extinguisher at regular intervals and

Figure 10

make sure that all work site crew

members are adequately trained in

its use.

•

Provide a first aid kit in the storage compartment and keep another at the work site. Check the

kit periodically and make any additions if necessary.

•

Know what to do in case of injury from fire.

•

Keep emergency numbers for doctor, ambulance service, hospital and fire department near

your telephone.

If the machine catches fire, it may lead to serious personal injury or death. If a fire occurs during operation,

escape from the machine as follows;

•

Turn the starter switch "OFF" and stop the engine.

•

If there is time, use the fire extinguisher to extinguish as much of the fire as possible.

•

Use the handrails and steps to escape from the machine.

The above is the basic method for escaping from the machine, but changing the method may be

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

022-00029AE Operation and Maintenance Manual

Safety 1-17

PROTECTION FROM FALLING OR FLYING

OBJECTS

On work sites where there is danger that falling

objects or flying objects may hit the operator's

cab select a guard to match the operating

conditions to protect the operator.

Work in mines, tunnels, deep pits or on loose or

wet surfaces could produce danger of falling

rock, roll over or hazardous flying objects.

Additional protection for operator’s cab could be

required in form of a FOPS/Falling Object

HAOA110L

Protective Structure and/or ROPS/Roll Over

Figure 11

Protective Structure reinforcement system.

Any reinforcement system that is installed on

machine must pass safety and certification

standards and carry appropriate labeling and

rating information. For example, most often

added type of reinforcement system, FOPS,

must meet or exceed Society of Automotive

Engineers standard SAE J1356, "Performance

Criteria for Falling Object Guards for Wheel

loaders."

Never attempt to alter or modify any type of

protective structure reinforcement system, by

drilling holes, welding or remounting or

HAOA100L

relocating fasteners. Any serious impact or

Figure 12

damage to system requires a complete integrity

reevaluation. Reinstallation, recertification and/

or replacement of system may be necessary.

INSTALL ADDITIONAL SAFETY EQUIPMENT IF CONDITIONS REQUIRE

Laminate glass protection for the front, side or rear windows, along with tempered glass, may also be

recommended depending upon particular site conditions.

Contact your DOOSAN distributor for available safety guards and/or recommendations if there is any

danger of getting hit by objects that could strike the operator’s cab. Make sure that all other work site crew

members are kept well away from wheel loader and safe from potential hazards.

MAINTAIN STANDARD SAFETY EQUIPMENT IN GOOD CONDITION

Machinery guards and body panel covers must be in place at all times. Keep well clear of rotating parts.

Pinch point hazards such as cooling fan and alternator drive belts could catch hair, jewelry or oversize or

very loose clothing.

Safety labels must be replaced if they are damaged or become unreadable. Information on labels gives

work crew members an important safety reminder. Part numbers for each decal and required mounting

locations are shown on pages 1-2 through 1-4 of this section.

1-18 Safety

022-00029AE Operation and Maintenance Manual

ATTACHMENT PRECAUTIONS

Options kits are available through your dealer. Contact DOOSAN for information on available one-way

(single-acting) and two-way (double-acting) piping / valving / auxiliary control kits. Because DOOSAN

cannot anticipate, identify or test all attachments that owners may wish to install on their machines, please

contact DOOSAN for authorization and approval of attachments, and their compatibility with options kits.

ACCUMULATOR

The pilot control system is equipped with an accumulator. For a brief period of time after the engine has

been shut down, the accumulator will store a pressure charge that may enable hydraulic controls to be

activated. Activation of any controls may enable the selected function to operate under force of gravity.

When performing maintenance on the pilot control system, the hydraulic pressure in the system must be

released as describe in “Handling of Accumulator” on page 4-52.

The accumulator is charged with high-pressure nitrogen gas, so it is extremely dangerous if it is handled in

the wrong way. Always observe the following precautions;

•

Do not drill or make any holes in the accumulator or expose it any flame, fire or heat source.

•

Do not weld on the accumulator, or try attaching anything to it.

•

When carrying out disassembly or maintenance of the accumulator, or when disposing of the

accumulator, the charged gas must be properly released. Contact your DOOSAN distributor.

•

Wear safety goggles and protective gloves when working on an accumulator. Hydraulic oil

under pressure can penetrate the skin and cause serious injuries.

ENGINE VENTILATION

Engine exhaust gases can cause loss of

judgment, loss of alertness, and loss of motor

control. These gases can also cause

unconsciousness, serious injury and fatal

accidents.

Make sure of adequate ventilation before

starting engine in any enclosed area.

You should also be aware of open windows,

doors or ductwork into which exhaust may be

carried, or blown by wind, exposing others to

ARO1770L

danger.

Figure 13

022-00029AE Operation and Maintenance Manual

Safety 1-19

BEFORE STARTING ENGINE

WORK SITE PRECAUTIONS

Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous.

Check the terrain and condition of the ground at the work site, and determine the best and safest method

of operation.

Make the ground surface as hard and horizontal as possible before carrying out operations. If there is a lot

of dust and sand on the work site, spray water before starting operations.

If you need to operate on a street, protect

pedestrians and cars by designating a person

for work site traffic duty or by erecting fences

and posting "No Entry" signs around the work

site.

Erect fences, post "No Entry" signs, and take

other steps to prevent people from coming close

to or entering the work site. If people come

close to a moving machine, they may be hit or

caught by the machine, and this may lead to

serious personal injury or death.

Water lines, gas lines, phone lines and high-

Figure 15

voltage electrical lines may be buried under the

work site. Contact each utility and identify their

locations. Be careful not to damage or cut any of

these lines.

NEVER be in water that is in excess of the permissible water depth. Refer to “Allowable Water Depth” on

page 3-20.

Any type of object in the vicinity of the boom could represent a potential hazard, or cause the operator to

react suddenly and cause an accident. Use a spotter or signal person working near bridges, phone lines,

work site scaffolds, or other obstructions.

Minimum levels of insurance coverage, work permits or certification, physical barriers around the work site

or restricted hours of operation may be mandated by governing authorities. There may also be regulations,

guidelines, standards or restrictions on equipment that may have to be followed for local requirements.

There may also be regulations related to performing certain kinds of work. If there is any question about

whether your machine and work site complies with the applicable standards and regulations contact your

local authorities and agencies.

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

Avoid operating your machine to close to the edge of cliffs, overhangs, and deep ditches. The ground may

be weak in such areas. If the ground should collapse, the machine could fall or tip over and this could

result in serious injury or death.

Remember that the soil after heavy rain, blasting or after earthquakes, is weakened in these areas.

Earth laid on the ground and the soil near ditches is loose. It can collapse under the weight of vibration of

your machine and cause your machine to tip over.

Install the safety guard (ROPS/FOPS) if working in areas where there is danger of falling rocks.

022-00029AE Operation and Maintenance Manual

Safety 1-21

CHECKS BEFORE STARTING ENGINE

Every day before starting the engine for the first time, carry out the following checks. If these checks are

not carried out properly, there is danger of serious injury.

•

Completely remove all wood chips, leaves, grass, paper and other flammable materials

accumulated in the engine compartment and around the battery. They could cause a fire.

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

•

Do not leave tools or spare parts laying around in the operator's compartment. The vibration of

the machine when traveling or during operations may cause them to fall and damage or break

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

cause the work equipment to malfunction or move dangerously. This may lead to unexpected

accidents.

•

Check the coolant level, fuel level, and hydraulic tank oil level, and check for clogged air cleaner

and damage to the electrical wiring.

•

Adjust the operator's seat to a position where it is easy to operate the machine, and check the

seat belt and mounts for damage and wear.

•

Check the operation of the gauges and the angle of the mirrors, and check that the safety lever

is in "LOCKED" position.

•

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

ENGINE STARTING

•

Walk around your machine before getting in operator’s cab. Look for evidence of leaking fluid,

loose fasteners, misaligned assemblies or any other indications of possible equipment hazard.

•

All equipment covers and machinery safety guards must be in place, to protect against injury

while machine is being operated.

•

Look around work site area for potential hazards, or people or property that could be at risk

while operation is in progress.

•

NEVER start engine if there is any indication that maintenance or service work is in progress, or

if a warning tag is attached to controls in cab.

•

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

temperatures, could require a warm-up or maintenance service before start up.

•

Check gauges and monitor displays for normal operation before starting engine. Listen for

unusual noises and remain alert for other potentially hazardous conditions at start of work cycle.

•

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

operation.

•

Do not short circuit the starting motor to start the engine. This is not only dangerous, but may

also damage the machine.

•

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

•

Start and operate the machine only while seated.

1-22 Safety

022-00029AE Operation and Maintenance Manual

BEFORE OPERATING MACHINE

If checks are not carried out properly after starting the engine, it may result in a delay in discovering

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

Carry out the checks in an open area where there are no obstructions. Do not let anyone near the machine

when carrying out the checks.

•

Check the operating condition of the equipment, and the actuation of the bucket, boom, and

travel systems.

•

Check the machine for any abnormal noise, vibration, heat, smell, or abnormality with the

gauges. Check also for leakage of air, oil, and fuel.

•

If any abnormality is found, repair the problem immediately. If the machine is used without

repairing the problems, it may lead to unexpected injury or failure.

•

Clear all personnel from directly around machine and from the area.

•

Clear all obstacles from the machine's path. Beware of hazards.

•

Be sure that all windows are clean. Secure the doors and the windows in the open position or in

the shut position.

•

Adjust the rear view mirrors for best visibility close to the machine. Make sure that the horn, the

travel alarm (if equipped), and all other warning devices are working properly.

•

Fasten the seat belt securely.

•

Warm up the engine and hydraulic oil before operating machine.

•

Before moving the machine, check the position of undercarriage. The normal travel position is

with idler wheels to the front under the cab and the drive sprockets to the rear. When the

undercarriage is in the reversed position, the travel controls must be operated in opposite

directions.

022-00029AE Operation and Maintenance Manual

Safety 1-23

MACHINE OPERATION

IMPORTANT

If you need more information or have any questions or concerns about safe operating

procedures or working the wheel loader correctly in a particular application or in the specific

conditions of your individual operating environment, please

consult

your

local

DOOSAN

representative.

OPERATE WHILE SEATED AT OPERATOR’S

STATION ONLY

Never reach in through a window to work a

control. Do not try to operate wheel loader

unless you’re in command position - seated at

controls. You should stay alert and focused on

your work at all times. Do not twist out of seat if

job activity behind you (or to the side) requires

your attention.

Use a spotter or signal person if you cannot see

clearly and something is happening behind you.

HAOA151L

Replace damaged safety labels and lost or

Figure 16

damaged operator’s manuals.

Do not let anyone operate machine unless

they’ve been fully and completely trained, in

safety and in operation of the machine.

SEAT BELTS SHOULD BE USED AT ALL

TIMES

Whenever engine is running, operator should be

seated at the control station with seat belt

properly engaged.

Figure 17

MOVEMENT ALARMS

If wheel loader is equipped with an audible travel movement alarm, test alarm on a daily basis. Audible

alarm should sound as soon as travel system is engaged.

1-24 Safety

022-00029AE Operation and Maintenance Manual

TRAVEL PRECAUTIONS

When traveling, wheel loader always keeps lights on; make sure that you are in compliance with all state

and local regulations concerning warning flags and signs.

Never turn the starter switch to the "O" (OFF) position when traveling. It is dangerous if the engine stops

when the machine is traveling. It will be impossible to operate the steering unless the unit is equipped with

an emergency steering system.

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

Lower work equipment so that it is 400 mm (16 in) above ground.

Never travel over obstacles or slopes that will cause machine to tilt severely. Travel around any slope or

obstacle that causes 10 degrees tilt, or more.

Do not operate the steering suddenly. The work equipment may hit the ground and cause the machine to

lose its balance, and this may damage the machine or structures in the area.

When traveling on rough ground, travel at low speed, and avoid sudden changes in direction.

Always keep to the permissible water depth. Refer to “Allowable Water Depth” on page 3-20.

When traveling over bridges or structures on private land, check first that the bridge or structure can

withstand the weight of the machine. When traveling on public roads, check with the local authorities and

follow their instructions.

SLOPING TERRAIN REQUIRES CAUTION

Dig evenly around work site whenever possible,

trying to gradually level any existing slope. If it’s

not possible to level area or avoid working on a

slope, reducing size and cycling rate workload is

recommended.

On sloping surfaces, use caution when

positioning wheel loader before starting a work

cycle. Stay alert for instability situations to avoid

getting into them. For example, you should

always avoid working bucket over downhill side

AHO0970L

of machine when parked perpendicular to slope.

Figure 18

Avoid full extensions of bucket in a downhill

direction. Lifting bucket too high, too close to

machine, while wheel loader is turned uphill can

also be hazardous.

022-00029AE Operation and Maintenance Manual

Safety 1-25

AVOID HIGH-VOLTAGE CABLES

Serious injury or death can result from contact

or proximity to high-voltage electric lines. The

bucket does not have to make physical contact

with power lines for current to be transmitted.

Use a spotter and hand signals to stay away

from power lines not clearly visible to operator.

VOLTAGE

MINIMUM SAFE

DISTANCE

6.6 kV

3 m (9’ 10'')

Figure 19

33.0 kV

4 m (13’ 1'')

66.0 kV

5 m (16’ 5'')

154.0 kV

8 m (26’ 3'')

275.0 kV

10 m (32’ 10'')

Use these minimum distances as a guideline only. Depending upon voltage in line and atmospheric

conditions, strong current shocks can occur with boom or bucket as far away as 4 - 6 m (13 - 20 ft) from

power line. Very high voltage and rainy weather could further decrease that safety margin.

NOTE: Before starting any type of operation near power lines (either above ground or buried

cable-type) you should always contact power utility directly and work out a safety plan with

them.

BEFORE STARTING TO DIG, CONTACT AUTHORITIES

Below ground hazards also include natural gas lines, water mains, tunnels and buried foundations. Know

what’s underneath work site before starting to dig.

BE AWARE OF HEIGHT OBSTACLES

Any type of object in vicinity of boom could represent a potential hazard, or cause operator to react

suddenly and cause an accident. Use a spotter or signal person working near bridges, phone lines, work

site scaffolds, or other obstructions.

USE CARE ON LOOSE SUPPORT

Working heavy loads over loose, soft ground or uneven, broken terrain can cause dangerous side load

conditions and possible tipover and injury. Travel without a load or balanced load may also be hazardous.

If temperatures are changing, be cautious of dark and wet patches when working or traveling over frozen

ground. Stay away from ditches, overhangs and all other weak support surfaces. Halt work and install

support mats or blocking if work is required in an area of poor support.

1-26 Safety

022-00029AE Operation and Maintenance Manual

USE SOLID SUPPORT BLOCKING

Never rely on lift jacks or other inadequate

supports when work is being done. Block

wheels fore and aft to prevent any movement.

DIGGING BENEATH OVERHANGS

Digging beneath an overhang is dangerous.

Overhand could collapse on top of operator and

cause serious injury or death. Go on to another

digging area before steep overhangs are

formed. Know height and reach limits of wheel

HDO1042L

loader and plan ahead while working. Park

Figure 20

wheel loader away from overhangs before work

shutdown.

DIGGING BENEATH WHEEL LOADER

Digging beneath wheel loader is dangerous. Earth beneath could collapse. This could cause wheel loader

to tip, which could cause serious injury or death to operator. Working around deep pits, trenching or along

high walls may require support blocks, especially after heavy rainfalls or during spring thaws.

STAY ALERT FOR PEOPLE MOVING

THROUGH WORK AREA

When loading a truck you should always know

where the driver is.

Avoid loading over the cab of a truck even if the

driver is in a safe spot. Someone else could

have gone inside, for any number of reasons.

Avoid working where unseen passersby might

be.

Slow down work cycle and use slower travel

speeds in congested or populated areas. Use a

HAOA171L

commonly understood signal so that other

Figure 21

members of work crew can warn operator to

slow or halt work in an impending hazardous

situation.

BE AWARE OF AND CONFORM TO LOCAL REGULATIONS

Minimum levels of insurance coverage, work permits or certification, physical barriers around work-site or

restricted hours of operation may be mandated by governing authorities. There may also be guidelines,

standards or restrictions on equipment that may be used to perform certain kinds of work. Check and

follow all local requirements, which may also be related to below ground hazards and power lines.

022-00029AE Operation and Maintenance Manual

Safety 1-27

NEVER USE ETHER STARTING AIDS

An electric-grid type manifold heater is used for

cold starting. Glowing heater element can cause

ether or other starting fluid to detonate, causing

injury.

Figure 22

OBSERVE GENERAL SAFETY RULES

Only trained and authorized personnel, with a good knowledge and awareness of safe procedures, may be

allowed to operate or perform maintenance or service on wheel loader.

All personnel at work site should be aware of assigned individual responsibilities and tasks.

Communication and hand signals used should be understood by everyone.

Terrain and soil conditions at job site, approaching traffic, weather-related hazards and any above or below

ground obstacles or hazards should be observed and monitored by all work crew members.

TAKE TIME TO PROVIDE GOOD VISIBILITY

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

Use the machine only for its main purpose. Using it for other purposes will cause failures.

To ensure an ample view, do as follows:

•

When working in dark areas, attach working lights and front lights to the machine. If necessary,

set up lighting at the work site.

•

Stop operations when the visibility is poor, such as in fog, mist, snow, and rain. Wait for the

visibility to improve to a level which causes no problems for the operation.

•

Keep dirt and dust off of windows and off lens surfaces of work lights. Stop working if lights,

windows or mirrors need cleaning or adjustment.

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

•

When working in tunnels, on bridges, under electric wires, or when parking the machine or

carrying out other operations in places with limited height, be extremely careful not to hit the

bucket or other parts.

•

To prevent collisions, operate the machine at a safe speed when working in confined spaces,

indoors, or in crowded areas.

•

Do not pass the bucket over the heads of workers or over the operator's compartment of dump

truck.

1-28 Safety

022-00029AE Operation and Maintenance Manual

KEEP "PINCH POINT" AREAS CLEAR - USE

CAUTION IN REVERSE

Use a signal person in high traffic areas and

whenever operator’s view is not clear, such as

when traveling in reverse.

Anyone standing near wheels, or working

assemblies of the attachment, is at risk of being

caught between moving parts of machine.

Never allow anyone to ride on any part of

machine or attachment, including any part of

operator’s cab.

HAOA191L

Figure 23

OPERATE CAREFULLY ON SNOW AND ICE AND IN VERY COLD TEMPERATURES

In icy cold weather avoid sudden travel movements and stay away from even very slight slopes. Machine

could skid off to one side very easily.

Snow accumulation could hide or obscure potential hazards. Use care while operating or while using

machine to clear snow.

Warming up engine for a short period may be necessary, to avoid operating with sluggish or reduced

working capacity. Jolting shocks and impact loads caused by bumping or bottoming boom or attachment

are more likely to cause severe stress in very cold temperatures. Reducing work cycle rate and work load

may be necessary.

When the temperature rises, frozen road surfaces become soft, so the machine travel becomes unstable.

In cold weather, do not touch metal surfaces with your bare hands. If you touch a metal surface in

extremely cold weather, your skin may freeze to the metal surface.

PARKING MACHINE

Avoid making sudden stops, or parking machine wherever it happens to be at the end of the work day. Plan

ahead so that the wheel loader will be on a firm, level surface away from traffic and away from high walls,

cliff edges and any area of potential water accumulation or runoff. If parking on inclines is unavoidable,

block wheels to prevent movement. Lower bucket or other working attachment completely to ground, or to

an overnight support saddle. There should be no possibility of unintended or accidental movement.

When parking on public roads, provide fences, signs, flags, or lights, and put up any other necessary signs

to ensure that passing traffic can see the machine clearly, and park the machine so that the machine, flags,

and fences do not obstruct traffic.

022-00029AE Operation and Maintenance Manual

Safety 1-29

SHUTDOWN CONTROL FUNCTIONS

After bucket has been lowered to overnight storage position, move all switches and controls to "OFF"

position. Pull parking brake knob to "APPLIED" position. This will apply parking brake. Move pilot cutoff

switch to "LOCK" position. This will disable pilot control valve lever (joystick). Move key in starter switch to

"OFF" position, and remove key from switch.

Engage all lock-down security equipment that may have been installed on machine.

IMPORTANT

When hydraulic system maintenance or service work must be performed, be aware that

accumulators in system store fluid under pressure after system has been shutdown. To release

hydraulic pressure in accumulators, operate control with engine "OFF" until accumulator

pressure is completely dissipated.

NEVER LET ANYONE RIDE ON

ATTACHMENT

Never let anyone ride on any work attachment,

such as the bucket, crusher, grapple, or

clamshell (grab bucket). There is a danger of

the person falling and suffering serious injury.

HAAD4050

Figure 24

1-30 Safety

022-00029AE Operation and Maintenance Manual

MAINTENANCE

USE WARNING TAG DURING SERVICE

Alert others that service or maintenance is being

performed and tag operator’s cab controls - and

other machine areas if required - with a warning

notice.

Warning tags for controls are available from

WARNING

DOOSAN distributors; see Figure 25.

CLEAN BEFORE INSPECTION OR

MAINTENANCE

HAOC920L

Clean the machine before carrying out

Figure 25

inspection and maintenance. This prevents dirt

from getting into the machine and also ensures

safety during maintenance.

If inspection and maintenance are carried out when the machine is dirty, it will become more difficult to

locate the problems, and also there is danger that you may get dirt or mud in your eyes or that you may slip

and injure yourself.

When washing the machine, do the following;

•

Wear shoes with non-slip soles to prevent yourself from slipping and falling on wet places.

•

Wear safety glasses and protective clothing when washing the machine with high-pressure

steam.

•

Take action to prevent touching high-pressure water and cutting your skin or having mud fly into

your eyes.

•

Do not spray water directly on electrical components (sensors, connector) (1, Figure 26). If

water gets into the electrical system, there is danger that it will cause defective operation and

malfunction.

Figure 26

Pick up any tools or hammers that are laying in the work place, wipe up any grease or oil or any other

slippery substances, and clean the area to make it possible to carry out the operation in safety. If the work

place is left untidy, you may trip or slip and suffer injury.

022-00029AE Operation and Maintenance Manual

Safety 1-31

PROPER TOOLS

Use only tools suited to the task. Using

damaged, low qualify, faulty, or makeshift tools

could cause personal injury. There is danger

that pieces from, chisels with crushed heads, or

hammers, may get into your eyes and cause

blindness.

HDO1037L

Figure 27

USE OF LIGHTING

When checking fuel, oil, battery electrolyte, or

window washing fluid, always use lighting with

anti-explosion specifications. If such lighting

equipment is not used, there is danger of

explosion.

If work is carried out in dark places without

using lighting, it may lead to injury, so always

use proper lighting.

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

flame instead of lighting. There is danger of fire.

HDO1040L

There is also danger that the battery gas may

Figure 28

catch fire and cause and explosion.

FIRE PREVENTION AND EXPLOSION PREVENTION

All fuels, most lubricants and some coolant mixtures are flammable. Leaking fuel or fuel that is spilled onto

hot surfaces or onto electrical components can cause a fire.

Store all fuels and all lubricants in properly marked containers and away from all unauthorized persons.

Store oily rags and other flammable material in a protective container.

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

Do not smoke in battery charging areas or in areas the contain flammable material.

Clean all electrical connections and tighten all electrical connections. Check the electrical wires daily for

wires that are loose of frayed. Tighten all lose electrical wires before you operate the machine. Repair all

frayed electrical wires before you operate the machine.

Remove all flammable materials before the flammable materials accumulate on the machine.

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

contain flammable fluids. Before you weld on pipes or on tubes or before you flame cut on pipes or on

tubes, clean the pipes or tubes thoroughly with a nonflammable solvent.

1-32 Safety

022-00029AE Operation and Maintenance Manual

BURN PREVENTION

When checking the radiator coolant level, stop the engine, let the engine and radiator cool down, then

check the coolant recovery tank. If the coolant level in the coolant recovery tank is near the upper limit,

there is enough coolant in the radiator.

Loosen the radiator cap gradually to release the internal pressure before removing the radiator cap.

ARO1360L

Figure 29

If the coolant level in the coolant recovery tank is below the lower limit, add coolant.

Cooling system conditioner contains alkali. Alkali can cause personal injury. Do not allow alkali to contact

the skin, the eyes, or the mouth.

Allow cooling system components to cool before you drain the cooling system.

Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact

the skin.

Remove the hydraulic tank filter plug only after the engine has been stopped. Make sure that the hydraulic

tank filter plug is cool before you remove it with your bare hand. Remove the hydraulic tank filter plug

slowly to relieve pressure.

Relieve all pressure in the hydraulic oil system, in the fuel system, or in the cooling system before you

disconnect any lines, fittings, or related items.

Batteries give off flammable fumes that can explode.

Do not smoke while you are checking the battery electrolyte levels.

Electrolyte is an acid. Electrolyte can cause personal injury. Do not allow electrolyte to contact the skin or

the eyes.

Always wear protective glasses when you work on batteries.

022-00029AE Operation and Maintenance Manual

Safety 1-33

WELDING REPAIRS

When carrying out welding repairs, carry out the welding in a properly equipped place. The welding should

be performed by a qualified worker. During welding operations, there is the danger of, generation of gas,

fire, or electric shock, so never let an unqualified worker do welding.

The qualified welder must do the following;

•

To prevent explosion of the battery, disconnect the battery terminals and remove batteries.

•

To prevent generation of gas, remove the paint from the location of the weld.

•

If hydraulic equipment, piping or places close to them are heated, a flammable gas or mist will

be generated and there is danger of it catching fire. To avoid this, never subject these places to

heat.

•

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

tubes that contain flammable fluids. Before you weld on pipes or on tubes or before you flame

cut on pipes or on tubes, clean the pipes or tubes thoroughly with a nonflammable solvent.

•

If heat is applied directly to rubber hoses or piping under pressure, they may suddenly break so

cover them with a fireproof covering.

•

Wear protective clothing.

•

Make sure there is good ventilation.

•

Remove all flammable objects and provide a fire extinguisher.

PRECAUTIONS FOR REMOVAL,

INSTALLATION, AND STORAGE OF

ATTACHMENTS

Before starting removal and installation of

attachments, decide the team leader.

Do not allow anyone except the authorized

workers close to the machine or attachment.

Place attachments that have been removed

from the machine in a safe place so that they do

not fall. Put up a fence around the attachments

and take other measures to prevent

HDO1041L

unauthorized persons from entering.

Figure 30

1-34 Safety

022-00029AE Operation and Maintenance Manual

PRECAUTIONS WHEN WORKING ON

MACHINE

When carrying out maintenance operations on

the machine, keep the area around your feet

clean and tidy to prevent you from falling.

Always do the following;

•

Do not spill oil or grease.

•

Do not leave tools laying about.

•

Watch your step when walking.

Never jump down from the machine. When

ARO1380L

getting on or off the machine, use the steps and

Figure 31

handrails, and maintain a three-point contact

(both feet and one hand or both hands and one

foot) to support yourself securely.

If the job requires it, wear protective clothing.

To prevent injury from slipping or falling, when

working on the hood or covers, never use any

part except the inspection passage fitted with

non-slip pads.

LOCK INSPECTION COVERS

When carrying out maintenance with the inspection cover open, lock the cover securely in position with the

lock bar.

If maintenance work is carried out with the inspection cover open but not locked, there is danger that it may

suddenly close and cause injury if there is a gust of wind.

CRUSHING PREVENTION AND CUTTING PREVENTION

You should always have at least two people working together if the engine must be run during service. One

person needs to remain in the operator’s seat, ready to work the controls or stop the machine and shut off

the engine.

Unless you are instructed otherwise, never attempt adjustments while the machine is moving or while the

engine is running.

Stay clear of all rotating parts and moving parts.

Keep objects away from moving fan blades. The fan blades will throw objects and the fan blades can cut

objects.

Do not use a wire rope cable that is kinked or flayed. Wear gloves when you handle a wire rope cable.

When you strike a retainer pin, the retainer pin might fly out. The loose retainer pin can injure personnel.

Make sure that the area is clear of people when you strike a retainer pin. To avoid injury to your eyes, wear

protective glasses when you strike a retainer pin.

DO NOT RUN ENGINE IF REPAIRS OR WORK ARE BEING PERFORMED ALONE

You should always have at least two people working together if engine must be run during service. One

person needs to remain in operator’s seat, ready to work controls or stop machine and shut "OFF" engine.

022-00029AE Operation and Maintenance Manual

Safety 1-35

ALWAYS USE ADEQUATE EQUIPMENT SUPPORTS AND BLOCKING

Do not allow weight or equipment loads to remain suspended. Lower everything to ground before leaving

operator’s seat. Do not use hollow, cracked or unsteady, wobbling weight supports. Do not work under any

equipment supported solely by a lift jack.

DO NOT WORK ON HOT ENGINES OR HOT COOLING OR HYDRAULIC SYSTEMS

Wait for engine to cool off after normal operation. Park wheel loader on a firm, level surface and lower all

equipment before shutting down and switching "OFF" controls. When engine lube oil, gearbox lubricant or

other fluids require change, wait for fluid temperatures to decrease to a moderate level before removing

drain plugs.

NOTE: Oil will drain more quickly and completely if it is warm. Do not drain fluids at temperatures

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

HYDRAULIC CYLINDER SEALS REQUIRE PERIODIC REPLACEMENT

Check cylinder drift rate at regular intervals. Overhaul seal kits are available through DOOSAN.

HIGH PRESSURE HYDRAULIC LINES CAN STORE A GREAT DEAL OF ENERGY

Exposed hydraulic hoses on arm could react with explosive force if struck by a falling rock, overhead

obstacle or other job site hazard. Extra safety guards may be required. NEVER allow hoses to be hit, bent

or interfered with during operation.

1-36 Safety

022-00029AE Operation and Maintenance Manual

PRECAUTIONS WITH HIGH PRESSURE LINE, TUBES AND HOSES

When inspecting or replacing high-pressure piping or hoses, check that the pressure has been released

form the circuit. Failure to release the pressure may lead to serious injury. Always do the following;

•

Wear protective glasses and leather gloves.

•

Fluid leaks from hydraulic hoses or pressurized components can be difficult to see but

pressurized oil has enough force to pierce the skin and cause serious injury. Always use a piece

of wood or cardboard to check for suspected hydraulic leaks. Never use your hands or expose

your fingers.

•

Do not bend high pressure lines. Do not strike high pressure lines. Do not install lines, tubes or

hoses that are bent or damaged.

•

Make sure that all clamps, guards and heat shields are installed correctly to prevent vibration,

rubbing against other parts, and excessive heat during operation.

- If any of the following conditions are found, replace the part.

- Damage or leakage from hose end.

- Wear, damage, cutting of covering, or exposure of strengthening wire layer.

- Cover portion is swollen in places.

- There is twisting or crushing at movable parts of hose.

- Foreign material is embedded in the covering.

- Hose end is deformed.

HAOA420L

Figure 32

OBTAIN IMMEDIATE MEDICAL ATTENTION IF PRESSURIZED OIL PIERCES SKIN.

WARNING!

Failure to obtain prompt medical assistance could result in gangrene or other serious damage to

tissue.

022-00029AE Operation and Maintenance Manual

Safety 1-37

USE CORRECT REPLACEMENT FASTENERS TIGHTENED TO PROPER TORQUE

Refer to "General Maintenance" section of Shop Manual for information on tightening torques and

recommended assembly compounds and always use correct part.

Poor or incorrect fastener connections can dangerously weaken assemblies.

SAFETY-CRITICAL PARTS MUST BE REPLACED PERIODICALLY

Replace following fire-related components as soon as they begin to show any sign of wear, or at regular

periodic intervals, whether or not deterioration is visible:

•

Fuel system flexible hoses, the tank overflow drain hose and the fuel filler cap.

•

Hydraulic system hoses, especially the pump outlet lines and front and rear pump branch

hoses.

•

Keep mounting brackets and hose and cable routing straps tight. Hose routing should have

gradual bends.

DISPOSE OF ALL PETROLEUM-BASED OILS

AND FLUIDS PROPERLY

Physical contact with used motor oil may pose a

health risk. Wipe oil from your hands promptly

and wash off any remaining residue.

Used motor oil is an environmental contaminant

and may only be disposed of at approved

collection facilities. To prevent pollution of the

environment, always do the following;

•

Never dump waste oil in a sewer

system, rivers, etc.

HAOA470L

Figure 33

•

Always put oil drained from your

machine in containers. Never drain

oil directly onto the ground.

•

Obey appropriate laws and

regulations when disposing of

harmful materials such as oil, fuel,

solvent, filters, and batteries.

CHECK TIRE PRESSURE AND CONDITION

Maintain tire pressure but do not over inflate. Inspect tires and wheels daily. When inflating tires, follow

procedures in Maintenance Section, which include using an extension to allow you to avoid standing in

front of or over a tire. Do not change a tire unless you have both experience and proper equipment.

1-38 Safety

022-00029AE Operation and Maintenance Manual

BATTERY

BATTERY HAZARD PREVENTION

Battery electrolyte contains diluted sulfuric acid and batteries generate hydrogen gas. Hydrogen gas is

highly explosive, and mistakes in handling them can cause serious injury or fire. To prevent problems,

always do the following;

•

Do not smoke or bring any flame near the battery.

•

When working with batteries, ALWAYS wear safety glasses and rubber gloves.

•

If you spill battery electrolyte on yourself or your clothes, immediately flush the area with water.

•

If battery electrolyte gets into your eyes, flush them immediately with large quantities of water

and see a doctor at once.

•

If you accidentally drink battery electrolyte, drink a large quantity of water or milk, raw egg or

vegetable oil. Call a doctor or poison prevention center immediately.

•

When cleaning the top surface of the battery, wipe it with a clean, damp cloth. Never use

gasoline, thinner, or any other organic solvent or detergent.

•

Tighten the battery caps securely.

•

Explosive battery gas can be set off by sparks from incidental contact or static discharge. Turn

"OFF" all switches and engine when working on batteries. Keep battery terminals tight. Contact

between a loose terminal and post can create an explosive spark.

•

If the battery electrolyte is frozen, do not charge the battery or start the engine with power from

another source. There is danger that the battery may catch fire.

•

When charging the battery or starting with power from another source, let the battery electrolyte

melt and check that there is no leakage of battery electrolyte before starting the operation.

•

Always remove the battery from the machine before charging.

Figure 34

DISCONNECT BATTERIES BEFORE ELECTRICAL SERVICE OR ELECTRICAL WELDING

Remove cable to negative terminal first when disconnecting cable. Connect positive terminal cables first

when installing a battery.

022-00029AE Operation and Maintenance Manual

Safety 1-39

USE LOW HEAT PORTABLE LIGHTING

Hot surfaces on trouble lights or portable work lights can set off fuel or battery explosive gases.

BOOST STARTING OR CHARGING ENGINE

BATTERIES

If any mistake is made in the method of

connecting the booster cables, it may cause an

explosion or fire. Always do the following;

•

Turn off all electrical equipment

before connecting leads to the

battery. This includes electrical

switches on the battery charger or

boost starting equipment.

•

When boost-starting from another

HAOA310L

machine or vehicle do not allow the

Figure 35

two machines to touch. Wear safety

glasses or goggles while required

battery connections are made.

•

24 volt battery units consisting of two series-connected twelve volt batteries have a cable

connecting one positive terminal on one of the 12 volt batteries to a negative terminal on the

other battery. Booster or charger cable connections must be made between the non-series-

connected positive terminals and between the negative terminal of the booster battery and the

metal frame of the machine being boosted or charged. Refer to the procedure and illustration in

“Starting with Auxiliary Batteries” on page 3-6 of this manual.

•

Connect positive cable first when installing cables and disconnect the negative cable first when

removing them. The final cable connection, at the metal frame of the machine being charged or

boost-started, should be as far away from the batteries as possible.

1-40 Safety

022-00029AE Operation and Maintenance Manual

TOWING

PRECAUTIONS WHEN TOWING

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

it may lead to serious personal injury. Always do the following;

•

Always use the method of towing given in this Operation and Maintenance Manual. Do not use

any other method.

•

Use leather gloves when handling the wire rope.

•

When carrying out the preparation work for towing with two or more workers, determine the

signals to use and follow these signals correctly.

•

If the engine on the problem machine will not start or there is a failure in the brake system.

always contact your DOOSAN distributor.

•

Never go between the towing machine and the towed machine during the towing operation.

•

It is dangerous to carry out towing on slopes, so select a place where the slope is gradual. If

there is no place where the slope is gradual, carry out operations to reduce the angle of the

slope before starting the towing operation.

•

When towing a problem machine, always use a wire rope with a sufficient towing capacity.

•

Do not use a frayed, kinked rope or a rope with any loss of diameter.

022-00029AE Operation and Maintenance Manual

Safety 1-41

SHIPPING AND TRANSPORTATION

OBEY STATE AND LOCAL OVER-THE-ROAD REGULATIONS

Check state and local restrictions regarding weight, width and length of a load before making any other

preparation for transport.

Hauling vehicle, trailer and load must all be in compliance with local regulations governing intended

shipping route.

Partial disassembly or tear-down of wheel loader may be necessary to meet travel restrictions or particular

conditions at job site.

Refer to “Transportation” on page 5-1, of this Operation and Maintenance Manual for information on

loading and unloading.

1-42 Safety

022-00029AE Operation and Maintenance Manual

2OPERATING CONTROLS

"Operating Controls" section presented here consists of the following groups:

“Component Locations” on page 2-2

“Control Identification” on page 2-4

“Steering Console and Pedals” on page 2-5

“Front Instrument panel” on page 2-12

“Transmission Display” on page 2-21

“Right Side Switch Panel” on page 2-22

“Various Cabin Locations” on page 2-33

“Heater and Air Conditioner Operation” on page 2-37

“Stereo” on page 2-42

10.

“Seat Adjustment” on page 2-46

11.

“Seat Belt” on page 2-48

12.

“Door Side Latch” on page 2-49

13.

“Fuse Box/Relay” on page 2-50

14.

“Window Glass Breaking Tool” on page 2-53

Each group is explained with a point location drawing or photo and a brief description of each control,

switch, gauge or valve.

Indicator lights work in addition to the gauges on the instrument panel. The operator should monitor

machine pressure on the instrument panel along with indicator lights. These lights will only give the

operator an indication that there is a problem.

WARNING!

Warning lights. When any one or more of the warning lights on the control console come "ON,"

immediately stop operation and shutdown unit. Investigate and correct problem before

proceeding with operation.

022-00029AE Operation and Maintenance Manual

Operating Controls 2-1

BUCKET TOOTH

23. ENGINE

BUCKET

24. CAC COOLER

OPERATOR’S CAB

25. RADIATOR

AIR CONDITIONING CONDENSER

26. FAN

BATTERY BOX (R.H.)

27. GRILL

FAN MOTOR

28. FUEL TANK

COUNTERWEIGHT

29. FUEL FILLER PIPE

BATTERY BOX (L.H.)

30. ENGINE OIL LEVEL GAUGE

OIL TANK

31. ENGINE OIL FILLER PIPE

10.

FULL FLOW FILTER

32. REAR AXLE PIVOT

11.

TILT LEVER

33. REAR AXLE

12.

BUCKET CYLINDER

34. TRANSMISSION OIL FILTER

13.

CONTROL VALVE

35. WHEEL CHOCK

14.

FRONT WHEEL COVER

36. TRANSMISSION

15.

STEERING WHEEL

37. CENTER PIN

16.

ROPS

38. STEERING CYLINDER

17.

WORK LEVER

39. BOOM CYLINDER

18.

SEAT

40. DRIVE SHAFT

19.

REAR WHEEL COVER

41. PARKING BRAKE

20.

PRE-CLEANER

42. FRONT AXLE

21.

AIR CLEANER

43. LOADER ARM

22.

MUFFLER

44. LINK

022-00029AE Operation and Maintenance Manual

Operating Controls 2-3

STARTER SWITCH

To start or stop the engine for equipment

operation.

O. Turning the switch to this position

turns the engine "OFF" along with its

electrical system. In this position the

engine is "OFF" but the interior cab

light and fuel tank transfer pump (if

equipped) are functional. Key can be

inserted or removed at this position.

Turning the switch to this position

HAOC340L

turns the engine electrical system

Figure 4

"ON." The charge indicator light and

the oil pressure indicator light should

be "ON" at this time.

The TCU (Transmission Control Unit) and ECM (Electronic Control Module) check their systems

for a moment, and the engine may not start while this is taking place.

. Moving switch to this position will crank engine. When engine starts, release key and allow it to

return to "I" (ON) position. Do not operate the starter switch for more than 15 seconds at a time.

This will help prevent damage to starter.

WARNING!

DO NOT USE STARTING FLUIDS. The preheat system could cause the starting fluid to

explode.

. Preheat position. Because this machine has an automatic preheating function, controlled by the

ECM, this position is not used.

HORN BUTTON (TWO PLACES)

Pressing the button at the end of the

combination switch (Figure 5) or the left

button at the tip of the pilot control valve

lever

(joystick)

(Figure

6), the horn will

sound.

NOTE: Starter switch must be "ON."

AHO0890L

Figure 5

2-6 Operating Controls

022-00029AE Operation and Maintenance Manual

Figure 6

COMBINATION SWITCH LEVER

A. Left Side Directional Switch

Pushing lever forward, activates left

outside directional

lights

and

directional

indicator

light

instrument panel.

B. Right Side Directional Switch

Pulling lever back, activates right

outside directional

lights

and

directional

indicator

light

instrument panel.

AHO0920L

NOTE: When a turn is completed the

Figure 7

lever automatically returns to

"NEUTRAL" position. Should it

not, it can be manually

returned.

NOTE: Turn signals will function with starter switch in "OFF" position.

C. Window Washer Switch - When the outside area of the lever is pressed, it activates the washer

pump and sprays fluid on the windshield. (Only while being pressed.)

CAUTION!

The washer pump can be damaged if it is activated while there is no fluid in the tank.

The fluid level should be regularly checked and refilled if necessary.

Using soap or other solvents instead of the recommended washer fluid may damage

the wiper blades and the paint finish.

Only use recommended washer fluid or equivalent.

D. Horn Button - The center button on end of lever activates horn. (Only while being pressed.)

E. Wiper Switch - Activates wipers when outside area of lever is rotated.

J: Intermittent Mode - wipes every 5 seconds.

0: Stop (Off)

I: Normal Speed Mode

II: High Speed Mode

022-00029AE Operation and Maintenance Manual

Operating Controls 2-7

Push Down - Locks into position and

lights up the high beams.

G. Neutral Position - Normal low beams.

H. Pull Up

- Momentarily turns "ON"

both the low and high beams. (Lever

returns to "NEUTRAL" position when

released.)

NOTE: High and low beams will only

function with the headlight

switch in the "||" position.

HAAA4350

Figure 8

ACCELERATOR PEDAL

Controls the travel speed of loader and

working speed of load handling system.

CAUTION!

The further the pedal is pressed, the

more engine speed increases.

However, do not press the pedal

more than necessary; otherwise it

will increase fuel consumption,

cause short life on the engine, and in

Figure 9

the worst case lead to a serious

accident.

STEERING TILT KNOB

This knob is used to allow steering wheel

to be moved to the most convenient

position for the operator. Loosen knob (2,

Figure

10), while grabbing the steering

wheel (1). Once the steering wheel is in

the proper place, tighten the knob.

HBOI200L

Figure 10

2-8 Operating Controls

022-00029AE Operation and Maintenance Manual

BRAKE PEDAL (RIGHT AND LEFT

PEDALS)

Pressing brake pedal will apply the brakes

to the loader. The brake pedal modes can

be switched over from inching to no-

inching or vice-versa, by using the

transmission cutoff switch

(See page

2-31).

CAUTION!

When descending on an incline, slow

Figure 11

down the truck by using both the

brake pedal and the engine brake.

Using the brake pedal too often

might lead to insufficient oil

pressure, thus making it difficult to

brake the loader.

IMPORTANT

Do not use brake pedal as a foot rest.

This will cause brake disc to wear

faster than normal, and this could

cause brake failure.

STEERING WHEEL

Rotating steering wheel controls position

of front wheels and this determines

direction of machine travel.

Figure 12

022-00029AE Operation and Maintenance Manual

Operating Controls 2-9

KICK-DOWN SWITCH (TWO PLACES)

When transmission is in

2nd gear,

pressing this switch will shift transmission

into 1st gear. This will allow the driver to

perform a quick digging movement.

NOTE: Kick-down is "RELEASED"

when transmission is placed in

"NEUTRAL” position or the

switch is pressed again

Kick-down function range:

HAAA3670

•

Automatic: 2nd, 3rd, 4th

Figure 13

•

Manual: 2nd

A second kick-down switch (Figure 14) is

on the right button in the tip of the pilot

control valve lever (joystick).

Figure 14

TRANSMISSION LEVER

Transmission can be shifted into the

following positions:

F Forward - When the lever is pushed

forward,

transmission

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

are available.

N Neutral - When the lever is returned

to the center position, between

forward

and

reverse,

the

transmission is in "NEUTRAL."

HAAA3680

Figure 15

R Reverse - When the lever is pulled

back, transmission is in "REVERSE."

1st, 2nd and 3rd are available.

Rotating the switch shifts transmission

between 1st, 2nd, 3rd, or 4th gears.

NOTE: There is a transmission display,

on the dash, that indicates,

gears, direction of travel, error

codes and kick-down activation.

(See page 2-21)

2-10 Operating Controls

022-00029AE Operation and Maintenance Manual

A transmission neutral lever lock is in base

of transmission lever. This neutral lever

lock prevents the transmission lever from

being moved out of "NEUTRAL."

N "NEUTRAL

LOCK"

position.

Prevents lever from being moved out

of "NEUTRAL."

D "DRIVE" position. Allows lever to be

moved from "NEUTRAL" to

"FORWARD and REVERSE."

Figure 16

CAUTION!

"LOCK" transmission lever. When

ever machine is parked, "LOCK"

transmission lever in "NEUTRAL" to

prevent

accidental

machine

movement.

10. FRONT INSTRUMENT PANEL

See

“Front Instrument panel” on

page 2-12.

AQO0350L

Figure 17

11. TRANSMISSION DISPLAY

See “Transmission Display” on page 2-21.

(D)

(A)

(B)

(C)

AQO0140L

Figure 18

022-00029AE Operation and Maintenance Manual

Operating Controls 2-11

GAUGES

FUEL GAUGE

COOLANT TEMPERATURE GAUGE

SPEEDOMETER

TRANSMISSION OIL TEMPERATURE.

HOUR METER

GAUGE

TACHOMETER

WARNING LIGHTS

PREHEAT INDICATOR LIGHT

14. RIGHT TURN AND HAZARD WARNING

AIR CLEANER CLOGGING WARNING

LIGHT

15. WORK LIGHT INDICATOR LIGHT

ENGINE WARNING LIGHT

16. BRAKE OIL PRESSURE WARNING

10.

ENGINE STOP LIGHT

LIGHT

11.

BATTERY WARNING LIGHT

17. ENGINE MAINTENANCE LIGHT

12.

LEFT TURN AND HAZARD WARNING

18. PARKING BRAKE INDICATOR LIGHT

LIGHT

19. UNUSED LIGHT

13. HIGH BEAM INDICATOR LIGHT

SWITCHES

20. HAZARD WARNING LIGHT SWITCH

22. BOOM FLOAT SWITCH (OPTION)

21. LOAD ISOLATION SYSTEM (LIS)

SWITCH (OPTION)

IMPORTANT

All of the gauge and warning lights (except for the turn lights, high beam light and work light)

come "ON" for two seconds with a warning buzzer sound when the starter switch is turned to the

"I" (ON) position.

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

FUEL GAUGE

This gauge displays amount of fuel in tank.

"F" means the tank is "full"; "E" means the

tank is empty." If the pointer comes close

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

possible. When the pointer comes close to

the "E” (red zone), approximately 90 liters

(24 U.S. gal.) of fuel remains.

HBOI250L

Figure 20

022-00029AE Operation and Maintenance Manual

Operating Controls 2-13

COOLANT TEMPERATURE GAUGE

This gauge displays temperature of engine

coolant.

CAUTION!

When the pointer indicates "H" mark

(red zone), it means the engine is

overheated. Stop the operation, let

the engine run at low rpm and wait

HBOI260L

for it to cool down.

Figure 24

Do not shutdown engine. If engine is

shutdown heat surge may occur.

TRANSMISSION OIL TEMPERATURE

GAUGE

This gauge displays temperature of oil in

transmission converter and transmission

circuit.

CAUTION!

When the pointer indicates "H" mark

(red zone), it means the transmission

HBOI270L

is overheated. Stop the operation, let

the engine run at low rpm and wait

Figure 25

for transmission to cool down.

PREHEAT INDICATOR LIGHT

This light indicates that the engine preheat

function is operating. Do not start engine

as long as this light is "ON."

HAOA639L

Figure 26

022-00029AE Operation and Maintenance Manual

Operating Controls 2-15

AIR CLEANER CLOGGING WARNING

LIGHT

When this light turns "ON," dirt has built up

in the air filter and is beginning to restrict

flow of air. Clean or replace air filter

element before continuing to operate

machine. To turn indicator light "OFF," turn

starter switch "OFF" and then back "ON."

HAOA660L

Figure 27

ENGINE WARNING LIGHT (YELLOW

COLOR)

This light will turn "ON" when a non-fatal

system error occurs with the engine or its

peripherals. If this light turns "ON," check

the engine as described under the Engine

Diagnostic Switch (See page 2-29) and

repair the cause of the fault to prevent

engine from having fatal errors.

NOTE: The engine check light will flash

between each fault code in

AQO0040L

diagnostic mode.

Figure 28

10.

ENGINE STOP LIGHT (RED COLOR)

This light will turn "ON" when a fatal

system error happens to the engine itself

or peripherals.

If this light turns "ON," check the engine as

described under the Engine Diagnostic

Switch (See page 2-29) and repair the

cause of the fault.

NOTE: The engine stop light flashes

out the three-digit fault code in

the diagnostic mode.

AQO0050L

Figure 29

Fault Code 423 (example)

: Flash

: Pause

AQO0010L

Figure 30

2-16 Operating Controls

022-00029AE Operation and Maintenance Manual

11. BATTERY WARNING LIGHT

When starter switch is first turned to "ON"

position, this red light should turn "ON."

When engine is running this red light

should turn "OFF." If light remains "ON"

when engine is running, alternator is

defective.

HAOA610L

Figure 31

12. LEFT TURN AND HAZARD WARNING

LIGHT

This light blinks when left turn signal is

turned "ON." Both lights blink when

warning lights are turned "ON."

NOTE: If left and right turn indicators

blink together, or if they blink

faster than normal, a light bulb

is not operating or flasher

solenoid is damaged.

ACO0240L

Figure 32

13. HIGH BEAM INDICATOR LIGHT

This light turns "ON" when the headlights

are turned to "HIGH BEAM."

HAOD394L

Figure 33

14. RIGHT TURN AND HAZARD WARNING

LIGHT

This light blinks when right turn signal is

turned "ON." Both lights blink when

warning lights are turned "ON."

NOTE: If left and right turn indicators

blink together, or if they blink

faster than normal, a light bulb

is not operating or flasher

solenoid is damaged.

ACO0241L

Figure 34

022-00029AE Operation and Maintenance Manual

Operating Controls 2-17

15. WORK LIGHT INDICATOR LIGHT

This light should turn "ON" when the front

and/or rear work lights are activated.

Figure 35

16. BRAKE OIL PRESSURE WARNING

LIGHT

This light turns "ON" when pressure drops

in brake oil circuit. When light turns "ON,"

an alarm also sounds.

WARNING!

Never operate or travel machine

when this light is turned "ON" or

HA0O2024

when alarm is sounding. Always

investigate cause of the drop in brake

Figure 36

oil pressure, and repair problem

before operating or traveling

machine.

17. ENGINE MAINTENANCE LIGHT (BLUE

COLOR)

Lights up when engine maintenance or

service is required. If this light turns "ON,"

check the engine as described Engine

Diagnostic Switch (See page 2-29) and

repair the cause of the fault.

AQO0060L

Figure 37

2-18 Operating Controls

022-00029AE Operation and Maintenance Manual

18.

PARKING BRAKE INDICATOR LIGHT

When parking brake is "APPLIED," this

light turns "ON." If vehicle is moved while

parking brake is applied, a warning alarm

will sound.

WARNING!

If the vehicle is moved while this light

is "ON" it could cause premature

0717A

wear or damage of the brakes.

Figure 38

Always "RELEASE" parking brake

and make sure this light is "OFF"

before moving machine.

19.

UNUSED LIGHT

20.

HAZARD WARNING LIGHT SWITCH

This light is used when the equipment is

stopped due to a malfunction or when an

emergency occurs. When this switch is

pressed the directional indicator lights in

front and back of the machine light up and

flash, warning others in the area. At the

same time the directional indicator lights

on the instrument panel will turn "ON" to

warn the operator. The hazard warning

lights operate independently of the starter

switch.

HGB2013I

Figure 39

O. In this position, this switch turns

"OFF” hazard warning lights.

In this position, this switch turns "ON”

all turn signals and they flash

simultaneously.

NOTE: Hazard warning lights will

function with starter switch in

"OFF" position.

022-00029AE Operation and Maintenance Manual

Operating Controls 2-19

21.

LOAD ISOLATION SYSTEM (LIS)

SWITCH (OPTION)

O. When this switch is moved to "OFF”

position, it does not allow boom

cylinders to act as shock absorbers.

When this switch is moved to "ON”

position, it causes boom cylinders to

act as shock absorbers. This reduces

machine bouncing when machine is

traveling with a loaded bucket.

NOTE: LIS operates when traveling

HA0O2026

speed is over 8km/h (5 MPH).

Figure 40

22.

BOOM FLOAT SWITCH (OPTION)

Boom float allows the bucket to follow the

contour of the ground/working surface.

When pressing this switch and setting

work lever to floating position, lever is

locked

(detent) and boom is lowered.

When boom is matched to setting position,

lever locking is released and lever is

returned to "NEUTRAL" position and boom

lowering is stopped.

O. In this position, this switch turns

HAOA751L

"OFF" boom float.

Figure 41

In this position, this switch turns "ON"

boom float.

2-20 Operating Controls

022-00029AE Operation and Maintenance Manual

TRANSMISSION DISPLAY

A transmission display is to the left of the

steering wheel on the dash. The LCD indicates,

gears, direction of travel, error codes, and

activated kick-down.

AQO0130L

Figure 42

Figure 43, shows the transmission display in

detail.

A. Indicates travel direction and gear

selection. See Figure 44 for more detailed

information.

B. Indicates normal operation and error

codes. For a list of error codes see

“Transmission Error Codes” on page 6-6.

(D)

(A)

(B)

(C)

NOTE: Most codes are only two digits.

C. Indicates that error codes have occurred

AQO0140L

and are stored.

Figure 43

D. Indicates that operation must be stopped

immediately to prevent damage to

transmission and hazardous operating

condition.

The gear range indicator bars will indicate which

gear is selected by displaying the corresponding

FORWARD

number of bars. The forward and reverse

indicator bars will be "OFF" when the

INDICATOR

transmission is in "MANUAL MODE."

GEAR RANGE

When transmission is in "AUTOMATIC MODE,"

all the gear range indicator bars and both travel

INDICATOR BARS

direction indicators will be "ON."

REVERSE

INDICATOR

HAAA3774

Figure 44

022-00029AE Operation and Maintenance Manual

Operating Controls 2-21

RIGHT SIDE SWITCH PANEL

AQO0070L

Figure 45

PILOT CONTROL VALVE LEVER

REAR WIPER SWITCH

(JOYSTICK)

ALTERNATE TORQUE SWITCH

1A. ERGO-II PILOT CONTROL VALVE LEVER

10.

ALTERNATE LOW IDLE SWITCH

(JOYSTICK) (OPTION)

11.

ROTATING BEACON SWITCH (OPTION)

KICK-DOWN SWITCH / LOG FORK

12.

CUP HOLDER

SWITCH (OPTION)

13.

ENGINE DIAGNOSTIC SWITCH

HORN BUTTON

14.

IDLE SPEED CONTROL SWITCH

CIGAR LIGHTER

15.

AUTOMATIC TRANSMISSION SWITCH

HEADLIGHT SWITCH

16.

TRANSMISSION CUTOFF SWITCH

FRONT WORK LIGHT SWITCH

17.

PILOT CUTOFF SWITCH

REAR WORK LIGHT SWITCH

18.

PARKING BRAKE SWITCH

2-22 Operating Controls

022-00029AE Operation and Maintenance Manual

Doosan Mega 500-V (TIER II). Operation and Maintenance Manual (2001) - page 1