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Doosan Mega 500-V (TIER II). Operation and Maintenance Manual (2001) - page 2

1.

PILOT CONTROL VALVE LEVER

(JOYSTICK)

Used to position bucket and boom. This

lever is capable of raising or lowering

boom, and crowding or dumping bucket.

When machine is being traveled, the lever

(joystick) can be "LOCKED" out, to prevent

any movement of bucket or boom. To

"LOCK" out lever

(joystick), place pilot

cutoff switch in "LOCKED" position.

NOTE: If loader is equipped with log

forks the bucket dump circuit is

used to control the angle of the

forks and grasping action.

Figure 46

Pilot control valve lever (joystick) operating

pattern and description of operation.

HL.

Hold lever

in

Lower Mode

L.

Lower

HC. Hold lever in

C. Bucket Crowd

/

N.

Neutral

D.

Bucket Dump

/

Bucket Crowd /

Close Log Fork

Open Log Fork

Close Log Fork

R.

Raise

HR.

Hold lever

in

Raise Mode

1A.

ERGO-II PILOT CONTROL VALVE

LEVER (JOYSTICK) (OPTION)

Ergo-II lever is a pilot control valve lever

that incorporates transmission control

functions. It is used to reduce hand and

arm movement for he otherwise complex

operation of machine.

A. Forward, Neutral and Reverse

Switches.

"↑" Button

− When pressing this

switch, machine

travels

"FORWARD."

"N" Button

− When pressing this

switch,

machine

is

in

AJO0591L

"NEUTRAL."

Figure 47

"↓" Button

− When pressing this

switch,

machine

travels

"REVERSE."

022-00029AE Operation and Maintenance Manual

Operating Controls 2-23

B. Traveling Speed Changing Switches.

The transmission has 4 speeds in

N

forward and 3 speeds in reverse.

"+"

Button − When pressing this

switch, machine speed increase.

"-"

Button − When pressing this

switch, machine speed decrease.

+

C. Kick-down Switch.

"KD" Button

− When pressing this

switch that is in the rear side, kick-

HAAD3761

down function is selected.

Figure 48

Ergo-II lever switch usage:

•

When Rotating the starter switch to "I" (ON) position, DISPLAY indicates "NN."

•

When DISPLAY indicates "N4" while "N" button of ERGO-II is pressed, start the engine.

•

When DISPLAY indicates "N1" while "-" button is pressed, the machine is in the traveling ready

condition.

•

When "↑" button is pressed at forward traveling while "KD" button is pressed, machine can travel

forward.

•

When "↓" button is pressed at backward traveling while "KD" button is pressed, machine can

travel backward.

•

When machine is travelled, it can convert forward and backward travel without pressing "KD"

button.

NOTE: Travel can be possible while "KD" button is pressed at NEUTRAL condition.

•

"+" Button − Increase speed.

•

"-" Button − Decrease speed.

•

Kick-down switch: "KD" Button.

2-24 Operating Controls

022-00029AE Operation and Maintenance Manual

2.

KICK-DOWN SWITCH (TWO PLACES) /

LOG FORK SWITCH (OPTION)

Kick-down Switch Function

- When

transmission is in 2nd gear, pressing this

switch (Figure 50) will shift transmission

into 1st gear. This will allow the driver to

perform a quick digging movement.

Kick-down function range:

•

Automatic: 2nd, 3rd, 4th

•

Manual: 2nd

NOTE: Kick-down is "RELEASED"

Figure 49

when transmission is placed in

"NEUTRAL” position or the

switch is pressed again

Log Fork Switch Function

- When the

button is depressed and held the log forks

are allowed to open and close when

moving the lever from side to side. See

pilot

control valve lever

(joystick)

movement pattern.

A second kick-down switch (Figure 49) is

on the end of the transmission lever.

HAAA3670

Figure 50

3.

HORN BUTTON (TWO PLACES)

Pressing the left button at the tip of the

pilot control valve lever (joystick) (Figure

51) or the button at the end of the

combination switch (Figure 52) will sound

the horn.

NOTE: Starter switch must be "ON."

Figure 51

022-00029AE Operation and Maintenance Manual

Operating Controls 2-25

AHO0890L

Figure 52

4.

CIGAR LIGHTER

Push in cigar lighter. It will remain in, until it

is hot. When hot, it will pop back. It is now

ready for use.

IMPORTANT

The cigar lighter is powered by a 24

volt circuit. Never plug any 12 volt

device into the cigar lighter.

HAOA780L

Figure 53

5.

HEADLIGHT SWITCH

O. In this position, this switch turns

"OFF" clearances, tail, instrument

panel, pendant light of switches and

head lights.

O

NOTE: If the switch is not this position

I

with the engine not running, the

II

pilot buzzer will sound to

prevent batteries discharging.

I.

In this position, this switch turns "ON"

clearance, tail, instrument panel and

AQO0080L

switch lights.

Figure 54

II.

In this position, this switch turns "ON"

clearance, tail, instrument panel,

switch and headlights.

CAUTION!

Do not leave clearance, tail,

instrument panel or headlights "ON"

when the engine is not running.

Leaving lights "ON" with the engine

shutdown will discharge batteries.

2-26 Operating Controls

022-00029AE Operation and Maintenance Manual

6.

FRONT WORK LIGHT SWITCH

O. In this position, this switch turns

"OFF" work lights mounted on the

front top of cab.

I.

In this position, this switch turns "ON"

O

work lights mounted on the front top

of cab.

I

CAUTION!

HAOQ071L

Do not turn "ON" the work light when

Figure 55

traveling on public roads.

7.

REAR WORK LIGHT SWITCH

O. In this position, this switch turns

"OFF" work lights mounted on the

rear top of cab, and sides of radiator.

O

I.

In this position, this switch turns "ON"

work lights mounted on sides of

I

radiator.

II

II.

In this position, this switch turns "ON"

work lights on the rear top of cab and

sides of radiator.

AHO0850L

Figure 56

CAUTION!

Do not turn "ON" the work light when

traveling on public roads.

022-00029AE Operation and Maintenance Manual

Operating Controls 2-27

8.

REAR WIPER SWITCH

O. In this position, this switch turns

"OFF" windshield wiper mounted on

rear windshield of operator’s cab.

I.

In this position, windshield washer

fluid sprays onto the rear windshield

O

O

while running the rear wiper. When

released, the switch returns to the

I

II

"O" position.

II.

In this position, this switch turns "ON"

windshield wiper mounted on rear

APO0200L

windshield of operator’s cab.

Figure 57

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.

9.

ALTERNATE TORQUE SWITCH

(ECONOMIC MODE)

This alternate torque switch allows the

operator to switch between 100% throttle

torque curves and about an 80% derated

O

torque curve. This improves operating fuel

efficiency in loaded versus unloaded

I

conditions.

O. In this position torque switch is set to

the "OFF" position, and 100% torque

is permitted.

AQO0090L

I.

In this position, torque switch is

Figure 58

turned "ON," which limits engine

torque to 80% of maximum.

2-28 Operating Controls

022-00029AE Operation and Maintenance Manual

10.

ALTERNATE IDLE SPEED SWITCH

The alternate low idle switch allows

operator to select an alternate idle speed

(about 1,200 rpm).

O

This feature is activated whenever the

normally open alternate low idle switch is

closed and 0 volts are detected by the

I

ECM on the alternate low idle signal line.

This is convenient to use when operator

wants to decrease warm-up time in the

winter.

AQO0100L

Figure 59

O. "OFF" position.

I.

"ON" position.

11.

ROTATING BEACON SWITCH (OPTION)

O. "OFF" position.

I.

When this switch is moved to "ON"

position, it activates the warning light.

O

12.

CUP HOLDER

I

Place to put beverages.

HAOA750L

Figure 60

13.

ENGINE DIAGNOSTIC SWITCH

If the engine warning light (yellow), engine

stop light (red), or the engine maintenance

light (blue), comes on when the engine is

running, it means a fault code has been

O

recorded. When this occurs, the engine

diagnostic switch allows the operator to

view the fault codes.

I

The active fault codes can be viewed using

the engine stop light (Red) as described

below.

AQO0120L

A. The engine must be shut off (not

Figure 61

running).

B. The starter switch must be in the

"ON" position.

C. The engine diagnostic switch must

be in the "I" position.

If a fault code is displayed, contact your

authorized dealer for repair.

To know the fault code information, refer to

the engine control system of shop manual.

022-00029AE Operation and Maintenance Manual

Operating Controls 2-29

14.

IDLE SPEED CONTROL SWITCH

The idle speed control allows the idle

speed to be adjusted in 25 rpm increments

by pressing the idle speed control switch.

The switch will only work from 800 to 900

rpm.

O

O

Pressing the "I" position of the switch will

increase (+) engine rpm.

I

II

Pressing the "II" position of the switch will

decrease (-) engine rpm.

AQO0110L

NOTE: This switch is also used to view

Figure 62

the next or previous fault code

in the diagnostic mode.

15.

AUTOMATIC TRANSMISSION SWITCH

Automatic speed range:

•

Forward - 2nd, 3rd, 4th.

•

Reverse - 2nd, 3rd.

O

O. When this switch is in "O" (MANUAL)

position, travel mode is switched to

"MANUAL" and allows operator to

I

choose speeds manually.

I.

When this switch is in "I"

(AUTO)

position,

gears

are

HLB20071L

"AUTOMATICALLY" changed to the

Figure 63

appropriate speed up to the limit set

by the transmission lever and

according to travel load and engine

rpm.

2-30 Operating Controls

022-00029AE Operation and Maintenance Manual

16. TRANSMISSION CUTOFF SWITCH

This switch changes over the modes of the

brake pedal, inching and no-inching.

O. In this position, the "NO INCHING"

mode is selected.

O

In the "NO INCHING" mode, the

power transmission line is still

I

connected when the brake pedal is

pressed, thus, making it easier to

start off on an incline. This mode is

also suitable for traveling, because

HA3O2018

both engine braking and the service

Figure 64

brake can be used in descending

grades.

I.

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

In this mode, the transmission is put in "NEUTRAL" by pressing the brake pedal. This mode is

suitable for load handling operation. When the accelerator pedal is pressed under this condition,

more power is concentrated on the load handling system, to quicken the boom lifting speed.

NOTE:

1) Transmission "CUTOFF" function dose not operate at 3rd and 4th gear for protection of

transmission.

2) Despite transmission "CUTOFF" switch, the right brake pedal has braking function only.

WARNING!

When pressing brake pedal while traveling or working on a slope, set this switch to "O" for

engine brake.

17. PILOT CUTOFF SWITCH

O. In this position the operator cannot

operate the pilot control valve lever

(joystick).

I.

In this position the operator can fully

O

control the movement of the pilot

control valve lever (joystick).

I

CAUTION!

HBOI110L

When driving or parking, the pilot

Figure 65

cutoff switch should be changed to

"O" position.

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Operating Controls 2-31

18. PARKING BRAKE SWITCH

O. In this position, the parking brake is

"RELEASED" and the monitor light

on the front instrument panel turns

"OFF."

O

I.

In this position, the parking brake is

"APPLIED" and the monitor light on

I

the front instrument panel comes

"ON." This brake can also be used as

an emergency brake.

HAOP042L

Figure 66

WARNING!

Set the parking brake switch in the

"I" (APPLIED) position before leaving

the loader. Make sure to "APPLY" the

parking brake switch before trying to

start the loader.

CAUTION!

Do not use this parking brake to

brake the loader, except in an

emergency; otherwise, it might cause

premature wear or damage of the

brake.

AQO0171L

Figure 67

2-32 Operating Controls

022-00029AE Operation and Maintenance Manual

VARIOUS CABIN LOCATIONS

3

4

2

5

1

10

6

9

7

8

AQO0150L

Figure 68

1.

CAB LIGHT

6.

WASHER TANK

2.

STEREO

7.

HOT/COLD REFRIGERATOR

3.

HEATER AND AIR CONDITIONER

8.

ELECTRICAL BOX

CONTROL PANEL

9.

FUSE BOX TWO

4.

SPEAKERS

10.

FUSE BOX ONE

5.

STORAGE BOX

022-00029AE Operation and Maintenance Manual

Operating Controls 2-33

1.

CAB LIGHT

A light is on the front of the ceiling. Turn

the light "ON" and "OFF" by pressing its

switch. The light will work despite starter

switch position.

NOTE: If light is left on for a long time

while the engine is not running,

the batteries will be discharged.

HBOI400L

Figure 69

2.

STEREO

For operation of stereo see “Stereo” on

page 2-42.

HAOA951L

Figure 70

3.

HEATER AND AIR CONDITIONER

CONTROL PANEL

For operation of heater and air

conditioning see

“Heater and Air

Conditioner Operation” on page 2-37.

HAOA771L

Figure 71

4.

SPEAKERS

Emits sound generated by stereo.

HBOM350L

Figure 72

2-34 Operating Controls

022-00029AE Operation and Maintenance Manual

5.

STORAGE BOX

There is a storage box

(1, Figure

73)

behind the seat. Keep the operation

1

maintenance manual and other documents

in this compartment.

HBOI431L

Figure 73

6.

WASHER TANK

Contains windshield washer fluid.

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.

HBOM680I

Using soap or other solvents instead

Figure 74

of the recommended washer fluid

may damage the wiper blades and

the paint finish.

Only use recommended washer fluid

or equivalent.

7.

HOT/COLD REFRIGERATOR

There is a hot/cold refrigerator (1, Figure

75) behind and to the left of the seat. Air

conditioner and heating unit must be

operated after starting the engine for this

function. Keep the cover close for proper

function.

1

HBOI432L

Figure 75

022-00029AE Operation and Maintenance Manual

Operating Controls 2-35

8.

ELECTRIC BOX

Under the seat are two pullout trays that

contain relays for unit. See

“Fuse Box/

Relay” on page 2-50.

Figure 76

9.

FUSE BOX TWO

Fuse box two is just above the windshield

washer fluid tank. For a detailed

explanation of fuses see “Fuse Box/Relay”

on page 2-50.

Figure 77

10. FUSE BOX ONE

The fuse box is at the rear side of right

control stand. For a detailed explanation of

fuses see “Fuse Box/Relay” on page 2-50.

Figure 78

2-36 Operating Controls

022-00029AE Operation and Maintenance Manual

HEATER AND AIR CONDITIONER OPERATION

LOCATION OF CONTROLS AND VENTS

1

5

3

5

3

4

2

HBOI310L

Figure 79

1.

OPERATION PANEL

4.

FOOT NOZZLE

2.

FRONT NOZZLE (AIR-CON)

5.

REAR NOZZLE

3.

FRONT NOZZLE

The heater and air-conditioner are combined into one unit to the rear of the operator’s seat. If necessary,

the operator can control inner temperature using the operation of panel installed in the right control stand.

022-00029AE Operation and Maintenance Manual

Operating Controls 2-37

OPERATION PANEL

HAOA801L

Figure 80

1.

FAN AND AIR-CONDITIONER SWITCH

4.

SELECTION SWITCH FOR WIND

2.

BLOWER FAN SWITCHES

DIRECTION

3.

TEMPERATURE CONTROL SWITCH

5.

VENTILATION SELECTION SWITCH

When a switch is selected, the LED above that switch will turn "ON" and give an activation sound.

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

1.

FAN AND AIR CONDITIONER SWITCH

A. "OFF" Switch

- Turns "OFF" the

heater and air conditioner unit.

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

conditioner when one of the blower

switches is activated.

ARO0510L

Figure 81

2-38 Operating Controls

022-00029AE Operation and Maintenance Manual

2.

BLOWER FAN SWITCHES

These switches are used to control the

speed of the blower fan.

A. "LO" Switch - Used for low blower

speed.

B. "MID" Switch - Used for intermediate

blower speed.

C. "HI" Switch - Used for high blower

speed.

NOTE: If you do not select a blower

ARO0520L

speed the heater and air

Figure 82

conditioner will not work.

3.

TEMPERATURE CONTROL SWITCH

The temperature control consists of

24

stages. A LED is turned "ON" for every

three stages. Whenever pushing it, it

changes in stages. Pushing it continuously,

it changes continuously.

A. "COOL" Switch

-

Lowers the

temperature.

B. "WARM" Switch

-

Raises the

temperature.

ARO0530L

LED COLOR STATUS

Figure 83

Green LED - Air conditioner. Full

green, maximum operation of

air-conditioner.

Red LED

- Heater. Full red,

maximum operation of heater.

4.

SELECTION SWITCH FOR WIND

DIRECTION

A. Used to direct air flow to upper

portion of operator’s cab.

HBOI320L

Figure 84

022-00029AE Operation and Maintenance Manual

Operating Controls 2-39

B. Used to direct air flow to lower

portion of operator’s cab.

HBOI330L

Figure 85

C. Used to direct air flow for defrosting

front window of operator’s cab.

HBOI340L

Figure 86

5.

VENTILATION SELECTION SWITCH

A. "A" Switch

- Draws fresh air into

A

B

operator’s compartment.

B. "B" Switch - Recirculates air within

the operator’s compartment. Used to

rapidly reduce condensation on

windows.

ARO0560L

Figure 87

MEMORY FUNCTION OF USED MODE

The air conditioner panel has a memory function. When the starter switch is turned "OFF" the settings for

the panel will be stored. When the machine is started, the last setting will be used.

2-40 Operating Controls

022-00029AE Operation and Maintenance Manual

STEREO

Figure 88

1.

ON-OFF / VOLUME CONTROL KNOB

7.

CASSETTE SLOT

2.

BALANCE / FADER CONTROL

8. & 9. PLAY DIRECTION BUTTON

3.

BASS/TREBLE CONTROL

10. AUTOMATIC SELECTION

4.

AM/FM BAND SELECTION

11. DOLBY B SELECTION

5.

AUTOMATIC MEMORY (AME)

12. METAL SELECTION

6.

TAPE EJECT BUTTON

13. LCD DISPLAY PANEL

1.

ON-OFF / VOLUME CONTROL KNOB

When this button is pressed, stereo will be turned "ON."

When this button is pressed a second time, power turns "OFF."

Increase volume by rotating control clockwise.

When stereo is turned "ON," LCD display will indicate radio stations and/or tape functions.

2.

BALANCE / FADER CONTROL

This control adjusts both side to side balance of stereo sound and front to back fading.

Rotating control counterclockwise will increase volume to the left speakers, clockwise increases

volume to the right speakers.

Press on control and it will pop out; you can now adjust the fader (front/rear) balance.

Rotating control counterclockwise increases volume to the rear speakers, clockwise increases

volume to the front speakers.

2-42 Operating Controls

022-00029AE Operation and Maintenance Manual

3.

BASS/TREBLE CONTROL

This control adjust bass and treble tone levels.

To adjust treble tone level rotate control counterclockwise to decrease treble and clockwise to

increase treble.

To adjust bass tone level press on control and it will pop out. Rotate control counterclockwise to

decrease bass and clockwise to increase bass.

4.

AM/FM BAND SELECTION

This button sets radio to either AM-1, AM-2, FM-1 or FM-2 frequency bands. Each frequency bands

will enable the stereo to store 6 preset radio station frequencies. Each time the button is pressed the

stereo will move to the next band.

5.

AUTOMATIC MEMORY (AME)

This function automatically finds the six

strongest radio signals in the frequency

selected and stores them in memory.

Select band (AM-1, AM-2, FM-1, FM-2).

Press and hold AME button for

approximately two seconds and stereo will

search out strongest stations in area.

These stations can then be recalled by

pressing buttons (1 thru 6, Figure 89).

NOTE: To manually store radio station

HAOC990L

settings, use band selector to

Figure 89

select frequency band to be

listened to. Then use tuning

control to select desired station.

Press and hold any preset keys

for approximately 2 seconds; a

beep will sound when station

has been set.

6.

TAPE EJECT BUTTON

Eject tape from cassette deck by pressing this button. Stereo returns to tuner mode.

7.

CASSETTE SLOT

Press "ON/OFF" switch for power. Insert a tape with exposed tape facing right. The tape will start to

play. "TAPE" is displayed on LCD display.

8. & 9. PLAY DIRECTION BUTTON

Pressing this control button to either right or left will fast forward or rewind tape. The button will lock

into this position. To stop action, press opposite side button and tape will return to normal play mode.

Pressing both control buttons at the same time will reverse direction of tape.

10. AUTOMATIC SELECTION

Press this control to change channels manually to either higher or lower frequencies.

022-00029AE Operation and Maintenance Manual

Operating Controls 2-43

11. DOLBY B SELECTION

If the tape being listened to has been recorded with Dolby B, press preset selector button 1 to turn

Dolby B control on. Dolby symbol will appear on display. Press this control a second time to turn

Dolby B control "OFF."

12. METAL SELECTION

If tape being listened to is either a metal or chromium type of tape, press preset selector button 2 to

select "MTL" setting. "MTL" will appear on display. Press this control a second time to turn this setting

"OFF."

13. LCD DISPLAY PANEL

A. Tape Reverse Direction Indicator

H

A

B. Tape Forward Direction Indicator

G

B

F

C. Preset Radio Memory Channel

Indicator

D. Radio Station Frequency

C

E. AM/FM Band Indicator

E

D

F.

Stereo Radio Signal

G. Dolby Noise Reduction Indicator

HAOA960L

Figure 90

H. Metal Tape Indicator

CARE OF STEREO

Do not use a tape that has a longer playing time

than C-90 (90 minutes). Avoid use of C-120

tapes because tapes are made of a thinner

material that may break and get tangled inside

stereo.

Figure 91

Make sure tapes are wound tight. If you use a

loose tape, it may cause a problem in a deck. If

they are loose, use a pencil or similar device to

wind up slack.

Do not use poor quality tapes.

Figure 92

2-44 Operating Controls

022-00029AE Operation and Maintenance Manual

Do not store cassette tapes in the following

places or under the following conditions.

Damage to tape and stereo may result.

•

Direct sunlight.

•

Humid place.

•

Dusty place.

•

Around heater or heater vents which

discharge heat.

•

Around speakers and other magnet

devices that generate a strong

HLB2014L

magnetic field (solenoid valves).

Figure 93

Clean head and pinch roller periodically. They

continuously contact the tape. If they are not

kept clean, stereo and tapes may be damaged.

Keep them clean for optimum performance.

Figure 94

If head gets dirty, clean it with a soft cotton swap

through cassette slot.

It is recommended to use a cassette deck

cleaning tape for easy and efficient cleaning of

head, capstan and pinch roller.

When you turn "OFF" power, be sure to take out

cassette tape by pressing eject button.

When not using a cassette tape, keep it stored

in a plastic case.

Figure 95

022-00029AE Operation and Maintenance Manual

Operating Controls 2-45

SEAT ADJUSTMENT

WARNING!

Whenever operator or operating condition

has changed, check to see that seating

position is suitable for the condition at

hand. Always fasten your seat belt while

operating vehicle. Adjust backrest so that

the operator can fully reach and operate

pedals.

HAOB110L

Figure 96

1.

ADJUSTING SEAT FORWARD/

BACKWARD LEVER

Holding lever (3, Figure 97), raise it up,

while pushing or pulling seat to desired

position. Release lever once desired

position is reached. Adjustment range is

4

5

160 mm (6.3 in).

1

2 & 3.ADJUSTING SEAT'S ANGLE AND

HEIGHT LEVER

3

2

Pulling left lever (3, Figure 97) up allows

HBOI350L

rear part of seat to be moved up or down.

Figure 97

Pulling lever (2) up allows front part of seat

to be moved up or down. Adjust seat

according to operator’s size and work

conditions. Adjustment range is

60 mm

(2.36 in) for both front and rear.

4.

WEIGHT ADJUSTMENT KNOB

Turning knob (4, Figure 97) to right makes suspension harder. Turning knob to left makes suspension

softer. Adjust according to operator’s weight by checking weight indicator dial. Adjustment range is

from 50 - 120 kg (110 - 265 lb).

5.

BACKREST ADJUSTMENT LEVER

Pulling up right lever (5, Figure 97) allows seat backrest to be moved forward or backward.

2-46 Operating Controls

022-00029AE Operation and Maintenance Manual

6.

ANGLE ADJUSTMENT OF ARMREST

Adjustment angle of left and right armrest

(6, Figure 98) is done by turning a dial in

bottom of armrest. When you adjust angle,

manually raise armrest before turning dial.

7.

HEADREST

Headrest (7, Figure 98) can be adjusted

forward/backward and up/down. Move it

by holding both sides.

HAOB130L

Figure 98

022-00029AE Operation and Maintenance Manual

Operating Controls 2-47

SEAT BELT

WARNING!

Seat belt is for operator's safety and should be worn at all times. Before driving machine, adjust

seat to desired position for maximum comfort and machine control, then fasten seat belt. Seat

belts must be worn across pelvic region and adjusted snugly to lessen chance and severity of

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

Under no circumstances should operator be standing in cab when operating wheel loader.

Do not adjust seat position while vehicle is moving because a loss of control may result. Stop

machine, apply parking brake, and then adjust seat.

Always, check condition of seat belt and belt bracket before fastening it. Do not use it with twists

in it. Replace belt or bracket if damaged or worn.

SEAT BELT LOCKING AND UNLOCKING

Insert belt end (1, Figure 99) into buckle (2). Pull

belt to check that belt end is locked into buckle.

Adjust belt length so that it is comfortably tight

against operator’s pelvic region (hipbone).

HAOB140L

Figure 99

Press button (3, Figure 100) in center of buckle

(2) and pull out belt (1) to unlock.

HAOB150L

Figure 100

2-48 Operating Controls

022-00029AE Operation and Maintenance Manual

DOOR SIDE LATCH

1.

The door side latch (1, Figure 101) is used

to secured the door to the side of the cab

when it is opened (Only cabin machine).

NOTE: Keep the door closed and

locked when machine is not in

use.

HA3O2042

Figure 101

2.

To release door from side of cab, push the

latch lever (Figure 102) down. The latch

lever is to the left of the operator’s seat.

HAOB250L

Figure 102

022-00029AE Operation and Maintenance Manual

Operating Controls 2-49

FUSE BOX/RELAY

FUSE BOXES

There are two fuse boxes inside the cab.

Fuse box one (1, Figure 103) is in the rear side

of right control stand. A usage diagram of fuses

is shown inside of fuse box. Spare fuses are

under the cover (10A - Qty. 1, 15A - Qty. 1, 20A

- Qty. 1).

2

Fuse box two (2, Figure 103) is just above the

1

windshield washer fluid tank.

WARNING!

If any fuse is blown, turn "OFF" the starter

switch and shut off the power supply.

Remedy the cause if needed and replace

AQO0160L

the fuse with a new one.

Figure 103

2-50 Operating Controls

022-00029AE Operation and Maintenance Manual

Fuse Box One

No.

Name

Capacity

1

Gauge Panel

15A

2

Transmission

15A

3

Front Wipers, Horn

15A

4

Parking Brake, Pilot

15A

Cutoff, Log Fork (Option)

5

Stop Light, Headlight

20A

HBOI380L

Figure 104 FUSE BOX ONE

6

Condenser Fan

15A

Engine Derating

7

Spare

15A

8

Air-conditioning, Heater

30A

9

Work Light (Front),

15A

Beacon (Option)

10

Work Light (Rear)

15A

11

Turn Signal Light, Hazard

15A

Light, Indicator Light

12

Stereo, Cab Light,

15A

Fuel Pump

13

Memory Backup,

10A

Pilot Buzzer

14

Starter Switch

10A

Fuse Box Two

No.

Name

Capacity

1

3

1

Cigar Lighter, Rear Wiper

15A

2

4

2

LIS (Option), Detente

10A

3

Position Light (Right)

10A

5

6

4

Position Light (Left)

10A

5

ECM

10A

HAAA3740

6

ECM

10A

Figure 105 FUSE BOX TWO

022-00029AE Operation and Maintenance Manual

Operating Controls 2-51

RELAY

The relays are in the electrical box under the

seat. If the problem is not solved after replacing

the fuse, check the function of the relay.

APO0210L

Figure 106

Figure 107

CIRCUIT BREAKER

A circuit breaker is next to the relay by the

batteries at back of unit under engine

compartment hood. When a short circuit or an

overload

occurs,

the

circuit

breaker

automatically cuts-off current, thus preventing

electrical wires from burning.

Figure 108

FUSIBLE LINK

A fusible link is in the battery box. If electric

power is not present at the "I" (ON) position of

the starter switch, check the fusible link first.

NOTE: If fuse wire is burnt off, replace

link.

Figure 109

2-52 Operating Controls

022-00029AE Operation and Maintenance Manual

WINDOW GLASS

BREAKING TOOL

This loader is equipped with a glass breaking

tool. It is in the lower right side of the cab just

rear of the door. This tool can be used in case of

an emergency situation which requires the

breaking of glass to exit from the operator’s

cabin. Grip the handle firmly and use the sharp

point to break the glass.

Figure 110

WARNING!

Protect your eyes when breaking the

glass.

022-00029AE Operation and Maintenance Manual

Operating Controls 2-53

3OPERATION

WARNING!

Before operating any wheel loader, read and understand "Operating Controls" section of this

manual.

INSTRUMENT PANEL CONTROL FUNCTIONS

MONITORING SYSTEM

Monitoring system uses network circuits between control system and sensors installed at various machine

system locations to monitor selected conditions. This monitoring systems function is to continually inform

operator of machine’s condition. Displays and gauge readouts on instrument panel provide information

such as engine speed, engine coolant temperature, transmission oil pressure, and electrical charge status.

NEW MACHINE BREAK-IN PROCEDURES

All wheel loaders are inspected and adjusted before leaving the factory. However, it is required that the

operator follow these steps during initial break-in period. Failure to follow these steps may result in damage

to equipment or reduced performance.

1.

Make sure to check all fluid levels before starting and every 8 to 10 operating hours.

2.

Do all Daily maintenance and service checks.

3.

For first 50 operational hours, as shown by Hour Meter on control console, do not exceed 80% of

maximum rated engine speed.

4.

At end of first 50 operational hours, drain engine oil. Replace engine oil filter and engine oil.

022-00029AE Operation and Maintenance Manual

Operation 3-1

ENGINE START AND STOP

INSPECTION BEFORE STARTING ENGINE

WARNING!

If a flammable materials such as leaves, paper, etc. are allowed to accumulate on high

temperature components, such as the engine muffler and turbo, a fire may occur. Fuel, lubricant

and hydraulic oil leaks, may cause a fire. If there is anything wrong, perform the appropriate

corrective action.

Before starting engine, inspect the following items;

1.

Electric system - Check for damaged electric cables, and loose or missing connectors.

2.

Fuel system - Drain water and sediment from fuel tank and water separator.

3.

Hydraulic system - Check for hydraulic oil leaks, damaged tubing and hoses, and interference points

of components.

4.

Lubrication - Perform all daily and periodic maintenance services. Perform services according to

reading shown on hour meter.

5.

Safety - Perform a machine walk-around. Make sure that no one is under the machine or performing

any maintenance on it, before starting engine.

6.

After starting machine - Check that all operational controls and components, are in proper operating

condition, and are functioning correctly. Stop operation and correct any malfunction before continuing

work.

ENGINE START

1.

Set parking brake switch to the "I"

(ENGAGED) position. This will ensure that

the parking brake is "APPLIED."

O

I

HAOP042L

Figure 1

3-2 Operation

022-00029AE Operation and Maintenance Manual

2.

Move all control levers to "NEUTRAL"

position.

IMPORTANT

If transmission lever is not in

"NEUTRAL" position, engine will not

start.

Figure 2

3.

Make sure transmission neutral lock is in

the "N" (NEUTRAL LOCK) position.

Figure 3

4.

Set pilot cutoff switch to "O"

(LOCK)

position. This will "LOCK" pilot control

valve lever (joystick).

O

HBOI111L

Figure 4

5.

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

indicator lights should turn "ON."

NOTE: The engine has an Electronic

Control Module

(ECM) that

controls the preheat system.

This system eliminates the

need for a cold weather startup

procedure. Due to this system

the preheat position of the

starter switch is not used.

HAOB320L

Figure 5

022-00029AE Operation and Maintenance Manual

Operation 3-3

6.

Rotate starter key to "START" position.

Starter motor should crank immediately,

and engine should start within a few

seconds.

HAOB350L

Figure 6

7.

Release starter key when engine starts.

Key will return to "I" (ON) position.

IMPORTANT

If

engine does not start after

approximately

15

seconds of

cranking, release starter key. Wait 5

minutes for starter motor to cool

down. Repeat step 6.

HAOB360L

Figure 7

8.

After engine starts, check all indicator lights and gauges to be certain that all engine systems (oil

pressure, oil temperature, coolant temperature, etc.) are in normal operating range. If any engine

system is not normal, turn starter key to "OFF" position.

Instrument Panel Light or Gauge

Indicator Reading

Fuel gauge

Engine coolant temperature gauge

White Range

Transmission oil temperature gauge

Engine oil pressure warning light

Charging warning light

Off

Brake oil pressure warning light

Parking brake light

On

NOTE: Parking brake indicator light turns "ON" or "OFF" according to parking brake operation

despite engine starting.

9.

Perform “Hydraulic System Warm-up” on page 3-9.

10. Check color of exhaust smoke

•

No color or light blue - Engine is running in good condition.

3-4 Operation

022-00029AE Operation and Maintenance Manual

STARTING WITH AUXILIARY BATTERIES

WARNING!

1.

An explosive gas is produced while

batteries are in use or being charged.

Keep flames or sparks away from the

battery area.

2.

Charge batteries in a well-ventilated

area.

HAOA440L

3.

Always wear eye protection when

Figure 8

starting a machine with jumper

cables.

4.

Improper jump starting procedures

can cause an explosion resulting in

personal injury.

5.

Jump start vehicles on dry ground or

concrete. Do not jump start the

machine on a steel floor, because the

floor is always grounded.

6.

When starting from another machine,

make sure the machines do not

touch.

7.

Always connect the auxiliary battery

positive

(+) terminal too depleted

battery positive

(+) terminal first.

Then connect

auxiliary battery

negative (-) terminal to the frame of

the depleted battery machine

second.

8.

Connect positive cable first when

installing cables and disconnect the

negative cable first when removing.

IMPORTANT

The machine has a 24V (-) negative ground electrical system. Use the same capacity 24V booster

batteries when jump starting engine.

If the batteries are drained during starting procedures, jump start engine using auxiliary or booster

batteries according to the following procedure;

3-6 Operation

022-00029AE Operation and Maintenance Manual

Connecting the Booster Batteries

1

1.

Stop the engine of the machine on which

RED

booster batteries are mounted.

2.

Connect one end of red cable (1, Figure 9)

to the positive (+) terminal of the machine

batteries, and the other end to the positive

(+) terminal of the booster batteries.

3.

Connect one end of black cable (2, Figure

3

4

BLACK

9) to the negative

(-) terminal of the

booster batteries, and then make ground

2

5

connection to the upper frame of the

ARO0440L

machine to be started with the other end of

Figure 9

black (-) cable (2, Figure 9). In the last

connection to upper frame, be sure to

connect the cable end as far away from

the machine batteries as possible. DO

NOT CONNECT DIRECTLY TO THE

NEGATIVE BATTERY TERMINAL.

4.

Start the engine

Disconnecting the Booster Batteries

1.

Disconnect black negative

(-) cable

(2,

Figure 9) from the machine frame first.

2.

Disconnect the other end of black negative

(-) cable

(1, Figure

9) from the booster

batteries.

3.

Disconnect red positive

(+) cable

(1,

Figure 9) from the booster batteries.

4.

Disconnect red positive

(+) cable

(1,

Figure 9) from the machine batteries.

ENGINE STOP

1.

Move transmission lever to "NEUTRAL"

position.

Figure 10

022-00029AE Operation and Maintenance Manual

Operation 3-7

2.

Make sure transmission neutral lock is in

the "N" (NEUTRAL LOCK) position.

Figure 11

3.

Set parking brake switch to the "I"

(APPLIED) position. This will ensure that

the parking brake is "APPLIED."

O

I

HAOP042L

Figure 12

4.

Set bucket on ground.

5.

Put pilot cutoff switch to "O"

(LOCK)

position. This will "LOCK" pilot control

valve lever (joystick).

O

6.

Allow engine to idle for 3 - 5 minutes to

cool down. Stopping a turbocharged

engine without a cool down period can

seriously damage turbocharger.

HBOI111L

Figure 13

7.

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

Remove key.

HAOC342L

Figure 14

3-8 Operation

022-00029AE Operation and Maintenance Manual

1.

Unlatch frame lock plate between front and

rear frames before traveling. Secure lock

plate to rear frame (Figure 15).

Figure 15

2.

Set pilot cutoff switch to "I" (UNLOCKED)

position. Raise bucket to a height of 400

mm (16 in) above the ground. Tilt bucket

completely back.

O

I

HBOI110L

Figure 16

3.

Set pilot cutoff switch to "O" (LOCKED)

position. This will prevent boom and bucket

from accidentally moving during travel, as

a result of accidentally touching pilot

control valve lever (joystick).

O

HBOI111L

Figure 17

4.

Press brake pedal.

Figure 18

3-10 Operation

022-00029AE Operation and Maintenance Manual

5.

Set transmission neutral lock is in the "D"

(DRIVE) position.

Figure 19

6.

Set parking brake switch to the "O"

(RELEASE) position. This will "RELEASE"

the parking brake.

O

I

HAOP043L

Figure 20

7.

Place transmission lever in desired gear.

Shift gears one by one. Do not skip from

1st to 3rd, for example.

8.

Shift transmission lever to "FORWARD"

position.

Figure 21

022-00029AE Operation and Maintenance Manual

Operation 3-11

9.

Release the brake pedal while slowly

pressing the accelerator pedal.

WARNING!

When traveling at high speed or on a

steep hill, do not make sharp

changes in direction. This could

cause vehicle to overturn.

When traveling or changing

direction, always look carefully to be

certain that no one is in path of

Figure 22

vehicle.

MACHINE SHUTDOWN

1.

Ease off throttle and apply travel brakes.

Figure 23

2.

Put transmission lever in "NEUTRAL."

Figure 24

3-12 Operation

022-00029AE Operation and Maintenance Manual

3.

Set transmission neutral lock is in the "N"

(NEUTRAL LOCK) position.

CAUTION!

"LOCK" transmission lever. When

ever machine is parked, "LOCK"

transmission lever in "NEUTRAL" to

prevent

accidental

machine

movement.

Figure 25

4.

Set parking brake switch to the "I"

(APPLIED) position. This will ensure that

the parking brake is "APPLIED."

O

I

HAOP042L

Figure 26

5.

Set bucket on ground.

6.

Select pilot cutoff switch to "O" (LOCKED)

position. This will lock pilot control valve

lever (joystick).

O

7.

Allow engine to idle for 3 - 5 minutes to

cool down. Stopping a turbocharged

engine without a cool down period can

seriously damage turbocharger.

HBOI111L

Figure 27

8.

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

Remove key.

HAOC342L

Figure 28

022-00029AE Operation and Maintenance Manual

Operation 3-13

9.

If machine is parked on a slope, install

wheel chocks in front of and behind vehicle

wheels.

WARNING!

Always secure machine with wheel

chocks when parked on a slope.

Leaving machine in gear will provide

no braking

effect

because

transmission clutch is hydraulically

operated. When engine is turned

Figure 29

"OFF," there is no hydraulic pressure

in transmission and clutch is not

engaged.

ADDITIONAL BRAKING

Machine hydraulic system can supply additional braking force during travel. To accomplish this, move pilot

control valve lever (joystick) to crowd position and hold it there. Hydraulic pump will be driven to supply

output at maximum pressure (relief pressure). Energy expended to drive pump, will slow engine speed.

Additional braking, along with proper gear selection, can be used to slow a vehicle that is being driven

down an incline.

BOOM RAISE KICKOUT

Placing pilot control valve lever

(joystick) in

"Boom Raise Detent" position will lock lever

2

(joystick) in raise boom position. Boom will raise

until trip plate (1, Figure 30) makes contact with

bucket height limit switch (2). When limit switch

3

is tripped, boom will stop raising and lever

(joystick) will automatically be returned to

"NEUTRAL" position. Trip plate can be adjusted

to control maximum height that boom can be

raised.

1

HBOI441L

Figure 30

3-14 Operation

022-00029AE Operation and Maintenance Manual

IMPORTANT

Trip plate (1, Figure 30) must always be set

to contact limit switch (2) before boom

cylinders reach maximum extension.

Maximum extension causes pump to force

fluid over relief valve.

To raise boom to maximum height, past preset

height, hold pilot control valve lever (joystick) in

"RAISE" or "HOLD RAISE" position until boom

has reached maximum height. Then remove

Figure 31

your hand from lever. Lever will automatically

return to "NEUTRAL" position. This prevents

hydraulic pump from working against relief valve

(maximum pressure).

BOOM LOWER KICKOUT (OPTION)

Placing bucket lever in

“L” position will lock

control lever in lower boom position. Boom will

move downward until trip plate (1, Figure 32)

makes contact with bucket lower limit switch (2).

When limit switch is tripped, boom will stop

lowering and bucket lever will automatically be

returned to “NEUTRAL” position. Trip plate can

be adjusted to control maximum height that

boom can be lowered.

IMPORTANT

Trip plate must always be set to contact

limit switch before boom cylinders reach

Figure 32

maximum extension. Maximum extension

causes pump to force fluid over relief

valve.

022-00029AE Operation and Maintenance Manual

Operation 3-15

BUCKET ANGLE

INDICATOR

Upper right side of bucket includes a bracket

that indicates angle of bottom of bucket. Top of

bracket is parallel with bottom of bucket. If

bottom of bucket is not visible, top of bracket will

be visible.

ADJUSTMENT OF

Figure 33

BUCKET POSITION

SWITCH

When bucket lever is held in crowd detent

position, after bucket has been dumped, bucket

will pivot toward crowd position. Once full crowd

position has been reached, bucket lever will

automatically return to “NEUTRAL” position. If

bucket is lowered after lever returns to

“NEUTRAL,” bucket will automatically position

itself to be in a preselected digging position

(usually flat). To adjust bucket to desired

preselected digging position, perform the

following steps.

1.

Operate controls to place bucket on

ground and in desired digging position

Figure 34

(usually flat). Return bucket lever to its

“NEUTRAL” position.

2.

Turn “OFF” engine.

3.

Loosen bolts (1, Figure 34) on bracket (2).

4.

Position bracket (2, Figure 34) so that end of arm (3) is aligned with center of magnetic switch (4).

5.

Tighten bolts (4, Figure 34).

6.

Start engine. Raise boom, dump bucket, then move bucket lever into crowd detent position. Now

lower boom and check to see that bucket has stopped at required position. A small readjustment of

bracket (2, Figure 34) may be necessary.

3-16 Operation

022-00029AE Operation and Maintenance Manual

TOWING MACHINE

When necessary to tow another vehicle, the tow

rope must be tied to the towing pin on the

counterweight at the rear of vehicle.

NOTE: The loader must be used for

towing only in an emergency.

WARNING!

Do not tow machine at a speed over 10

kph (6 MPH) and do not tow machine

farther than

10 Km (6 miles). This will

prevent damage to machine transmission

Figure 35

that would result from lack of lubrication.

WARNING!

When towing another vehicle on a public road, take necessary measures to let other vehicles

and people know that you are towing another vehicle. Use a flag, rotating light, or hazard light.

NOTE: There are several requirements you must abide by when towing another vehicle. Learn the

regulations and rules about towing another vehicle and observe them.

If the loader is being towed by another vehicle and the engine will not start, remove the front and rear drive

shafts; otherwise the transmission will rotate without being properly lubricated, causing seizure. Before

removing them, apply the parking brakes and block the wheels securely.

If the engine can be started and the steering wheel and brakes function normally, have someone get on the

loader you are going to tow for steering it.

Before you tow a vehicle make sure you have checked the following:

•

Check the weights of your loader and the vehicle to be towed and make sure you loader has

sufficient braking capacity to stop the towed load.

•

Check if the vehicle to be towed can be braked and steered. If not, do not allow anyone to ride

on the towed vehicle.

•

Check the tow rope or tow bar for damage and make sure it has sufficient strength for the work.

•

When necessary to descend a gradient, another towing vehicle must be used in the rear to

retard.

When towing make sure you are doing the following:

•

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

•

The tow line must be in line with the centerline of both your loader and the vehicle to be towed.

•

If you use any other towing device, refer to the Instruction Manual supplied with the towing

device.

•

If it is difficult to tow the loader, transport it by a trailer truck to your nearest repair shop.

•

In addition to the above measures, release the parking brake if the engine will not start or the

hydraulic pumps are defective.

022-00029AE Operation and Maintenance Manual

Operation 3-17

EMERGENCY RELEASE OF THE PARKING BRAKE

Figure 36

If the parking brake cannot be released by normal hydraulic system pressure, or if the engine will not start,

it must be manually released before towing can take place.

1.

Before releasing parking brake make sure

that wheels have wheel chocks placed in

front of and behind them, to prevent

machine from moving when parking brake

is released.

Figure 37

3-18 Operation

022-00029AE Operation and Maintenance Manual

2.

Release the screw cap (6, Figure 36) and

unscrew.

3.

Release the lock nut (5, Figure 36) and

turn the adjusting screw

(4) counter-

clockwise until the brake disc is free.

4.

Install lock nut (5, Figure 36) 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

Figure 38

moving away with proper

means. Before putting the

vehicle into operation again, the

brake has to be adjusted

according

to

adjusting

regulations.

ADJUSTING REGULATIONS

During this adjusting process, the parking brake must be released, i.e. the bank of cup springs (3, Figure

36) must be completely pre-tensioned.

1.

Park vehicle on an even surface and place wheel chocks in front of and behind tires. Only then

release the parking brake.

2.

Release the screw cap (6, Figure 36) and unscrew.

3.

Release the lock nut (5, Figure 36) (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.

4.

Turn the adjusting screw (4, Figure 36) counter-clockwise 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

5.

Hold the adjusting screw (4, Figure 36) in position with the hexagonal socket wrench and lock with

the lock nut (5).

6.

Mount the screw cap (6, Figure 36) and tighten as far as possible manually.

7.

Actuate the brake valve several times and check the braking efficiency of the parking brake on slope.

022-00029AE Operation and Maintenance Manual

Operation 3-19

IF ENGINE STALLS WHILE TRAVELING

BRAKE SYSTEM: The brakes can be applied approximately 9 times by pressing the brake pedal due to the

oil pressure stored in the accumulator after engine is turned "OFF" If the engine stalls while traveling,

move to an out of traffic area and park. Do not pump the brake pedal at this time; otherwise the brake

oil pressure will be used up, thus causing the brakes to fail.

ALLOWABLE WATER DEPTH

The water depth is an important factor to take into consideration when the loader is working in swampy

areas. Do not enter water whose depth exceeds the loader's minimum ground clearance height or is high

enough to wet the bottom of the axle housing. As a rule of thumb, the allowable water depth is about 400

mm (16 in). This means that the loader should not be used in a river.

Observe the following conditions:

1.

Check the water depth in advance when crossing across a river.

2.

Use the same precautions before crossing across a swampy area.

3.

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

CAUTION!

Avoid use of the loader in salt water. Salt water will cause the development of rust which will

shorten the life of the loader.

3-20 Operation

022-00029AE Operation and Maintenance Manual

4INSPECTION, MAINTENANCE AND

ADJUSTMENT

PREVENTIVE MAINTENANCE

Periodic checks and replacement of oil, grease, filters, etc. must be made at specific intervals, to keep

machine in good working condition. The following pages describe items to be checked, lubricants to be

used, and time interval between each check.

NOTE: Time interval between each service check may need to be shortened if machine is

operating in severe atmospheric conditions. Machines working in extremely hot or dusty

conditions will require more frequent service checks. Total hours of machine operation are

determined by hour meter that is on the front instrument panel.

SERIAL NUMBERS

There are two serial number plates attached to

the body of wheel loader.

Please make note of these numbers and their

locations. These will be required whenever

warranty service work is requested.

Main Serial Number

Main serial number plate is on left side of front

frame above fender (Figure 1).

Figure 1

The number is also stamped in the rear frame

on the left side just below the cab (Figure 2).

Figure 2

022-00029AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-1

Engine Serial Number

The engine name plate (identification label) is

on the fuel pump side of the engine, on the

rocker housing (Figure 3).

Figure 3

SAFETY PRECAUTIONS

1.

Before performing any maintenance checks, move pilot cutoff switch to "LOCKED" position. Place a

Warning Tag on controls so that no one begins to operate machine while maintenance checks are

being performed.

2.

Clean up all fuel spills. Fuel spills are hazardous, especially around engine.

3.

Inspect all fuel lines for leakage. Replace any lines, fittings, O-rings, or filters that show signs of wear

or damage.

4.

If a test procedure requires engine to be running, use two people and keep all unnecessary

personnel away from machine.

4-2 Inspection, Maintenance and Adjustment

022-00029AE Operation and Maintenance Manual

TABLE OF RECOMMENDED LUBRICANTS

IMPORTANT

Do not use lubricants other than those recommended, without prior written approval from

DOOSAN.

NOTE: Refer to Maintenance Intervals Table for application points.

LUBRICANT

LUBRICANT

HYDRAULIC OIL

ENGINE OIL*

AXLE GEAR OIL

MANUFACTURER

GREASE

CALTEX

CALTEX HD32

CALTEX RPM or

MULTIFAC EP

MULTIPURPOSE

EP90

DELO 300

EXXON/ESSO

NUTO (ANTI-

EXXON 15W40

RONEX MP #2 or

SPARTAN EP220

WEAR)

or

RONEX MP #1

HD 32 (BELOW

(COLD TEMPS)

EXXON GX

0°C (32°F)) or

80W90

HD 46 (ABOVE

0°C (32°F)) or

TERESSTIC

(ANTI-RUST)

MOBIL

MOBIL

DELVAC 1300 or

MOBIL FAW #2

MOBILUBE HD

or

80W90

DTE 13M (ALL-

SUPER 15W40

TEMP) or

MOBIL FAW #1

(COLD TEMPS)

DTE 24

(SUMMER)

SHELL

TELLUS 32

ROTELLA

ALVANIA EP #2

SPIRAX HD

80W90 or

T15W40

DONAX TD

(TRANSMISSION)

PENNZOIL

PENNZBELL

LONGLIFE

PENNZOIL 705

PENZOIL

EP #2

MULTIPUPOSE

AW 32 (BELOW

SAE15W40

4092 or

0°C (32°F)) or

80W90

AW 46 (ABOVE

0°C (32°F))

DRYDEN

PARADENE

DIESELALL

EP #2 (RED)

AP80W90

PLUS 15W40

AW 32 (BELOW

0°C (32°F)) or

AW 46 (ABOVE

0°C (32°F))

* Engine oil must meet ACEA-E2, ACEA-E3 or API-CH-4 EQUIVALENT and be SAE 15W40 or 10W40.

022-00029AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-3

LUBRICANT

LUBRICANT

HYDRAULIC OIL

ENGINE OIL*

AXLE GEAR OIL

MANUFACTURER

GREASE

CHEVRON

AW MV 32

DELO 400

DELO GREASE

DELO GEAR OIL

(BELOW 0°C

15W40

EP-2

or

(32°F)) or

RPM UNIV GEAR

AW MV 46

80W90

(ABOVE 0°C

(32°F))

TEXACO

RANDO

URSA SUPER

STAR PLEX 2

MULTIGEAR

PLUS 15W40 or

EPSAE 80W90

HD32 (BELOW

STAR PLEX

0°C (32°F)) or

URSA PREMIUM

PREMIUM

TDX 15W40

HD46 (ABOVE

0°C (32°F))

IDEMITSU

DAPHNE KOSAN

APOROIL

DAPHNE

APOROIL GEAR

KOSAN

46WR

MOTIRE S300

CORRONE #2

HE 90

NIPPON SEIKIYU

SUPER

LIPANOC

NISEKI SP90 or

HIGHLAND S26

GREASE

EP90

or 32

TOTAL

TOTAL EQUIVIS

TOTAL

TOTAL MUTRIS

TOTAL DA80W90

ZS46

EP #2

* Engine oil must meet ACEA-E2, ACEA-E3 or API-CH-4 EQUIVALENT and be SAE 15W40 or 10W40.

Lubricant Manufacturer

Transmission Gear Oil

SAME AS ENGINE OIL

SAE 15W40 (API CD AND ABOVE)

CAUTION!

Do not mix oils from different manufacturers. DOOSAN does not endorse specific brands but

does suggest that owners select quality oils whose suppliers provide assurance that required

standards will always be met or exceeded.

IMPORTANT

Fluctuating daily or weekly extremes of temperature, or operation in sub-zero freezing weather

may make it impractical to use straight weight lubricants. Use good judgement in selecting

lubricant types that are appropriate for climate conditions.

4-4 Inspection, Maintenance and Adjustment

022-00029AE Operation and Maintenance Manual

FLUID CAPACITIES

Component

Capacity

Engine

Oil Pan with Filter

34 liters

(9 U.S. gal.)

NOTE: The filter holds an additional 1

liter (1 qt) of oil.

Cooling System

60 liters

(16 U.S. gal.)

Fuel Tank

480 liters

(127 U.S. gal.)

Hydraulic Oil Tank

280 liters

(74 U.S. gal.)

Transmission

50 liters

(13 U.S. gal.)

Axles

Front Differential

32 liters

(8.5 U.S. gal.)

Front Hub Reduction Gear

9 liters

(2.4 U.S. gal.) Each End.

Rear Differential

32 liters

(8.5 U.S. gal.)

Rear Hub Reduction Gear

9 liters

(2.4 U.S. gal.) Each End.

022-00029AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-5

10 HOUR / DAILY SERVICE

GREASE FRONT ATTACHMENT PINS

NOTE: Fittings are greased daily, or every 10 hours, for the first 100 hours of operation to comply

with new machine break-in requirements. After that, greasing should be done every 50

hours. If bucket is being used in water, grease fittings immediately after machine is

removed from water. Follow procedure printed under the 50 hour maintenance interval

“Grease Front Attachment Pins” on page 4-18.

INSPECT ALL TIRES FOR CORRECT TIRE PRESSURE AND SIGNS OF DAMAGE OR ABNORMAL

WEAR

1.

Inflate tires to proper operating pressure for working conditions. See

“Tires and Wheels” on

page 4-57.

CHECK ENGINE OIL LEVEL

NOTE: When checking level using a dipstick always remove and wipe it clean before making final

level check.

1.

Check level of engine oil every day before

starting engine.

2.

Remove engine oil dipstick. (Figure 4). Oil

level must be between "LOW" and "FULL"

marks.

NOTE: If oil is above "HIGH" mark on

dipstick, some must be drained

to return oil to proper level.

Figure 4 ENGINE OIL DIPSTICK

3.

To add oil, remove engine oil fill cap

(Figure 5).

Figure 5 ENGINE OIL FILL CAP

4-8 Inspection, Maintenance and Adjustment

022-00029AE Operation and Maintenance Manual

CHECK TRANSMISSION OIL LEVEL

NOTE: When checking level using a

dipstick always remove and

wipe it clean before making

final level check.

1.

Use two people to perform this operation.

2.

Start engine and move machine to a level

area.

3.

Place transmission lever in "NEUTRAL."

4.

Apply parking brake.

Figure 6

5.

Allow engine to idle until engine

temperature is between 82°C (180°F) and

93°C (200°F).

6.

Remove transmission dipstick (Figure 6).

Wipe dipstick clean and then insert it back

into transmission.

7.

Remove dipstick and check oil level mark.

Oil level must be between “COLD” and

H

“HOT” marks (Figure 7).

8.

To add oil, remove transmission fill cap

(Figure 6) from transmission oil filler pipe.

C

9.

Shutdown engine when done.

HAOC281L

Figure 7

022-00029AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-9

CHECK HYDRAULIC SYSTEM OIL LEVEL

WARNING!

The hydraulic oil will be hot after normal

machine operation. Allow system to cool

before attempting to service any of the

hydraulic components.

The hydraulic tank is pressurized. Press

button in center of breather to allow the

HAOA060L

pressurized air to vent. After the pressure

Figure 8

has been released, it is safe to remove

either the fill cap or service covers.

1.

Move machine to a level area and

shutdown engine.

2.

Apply parking brake.

3.

Lower bucket to ground.

4.

Check sight gauge that is attached to

hydraulic reservoir. Oil level must be

between upper limit (1, Figure 9) and lower

limit (2) shown on gauge.

Figure 9

5.

To add hydraulic oil, first press down on

pressure relief button

(1, Figure

10) to

release system pressure.

6.

Remove bolts (2, Figure 10), cover and O-

ring from fill hole.

7.

Add oil to proper level by checking sight

glass (Figure 9).

IMPORTANT

Do not fill above "H" mark on sight

Figure 10

gauge. Overfilling can result in

damage to equipment and oil leaking

from hydraulic tank due to

expansion.

4-10 Inspection, Maintenance and Adjustment

022-00029AE Operation and Maintenance Manual

The hydraulic oil filler cover also serves as the

hydraulic oil strainer access cover. It is important

to replace this cover and the components in the

proper order and alignment.

The filter element (2, Figure 11), retaining rod

(2) and spring (4) are assembled as shown in

Figure 11. The hole (1) in the base of the filter

element fits over a circular base in the bottom of

the reservoir. The retaining rod (3) screws into

the top of the filter element (2), but the spring (4)

slides over the top of the rod. Be certain that this

spring does not fall into the tank during

reassembly.

Figure 11

1.

If filter assembly was removed, insert

assembly into the reservoir and check to

make sure it is securely in place.

2.

Check O-ring for damages and replace if

necessary. Check position of O-ring at

surface of hole.

3.

Place the cover on the access hole. Make

sure the spring retaining cup (1, Figure 12)

in the lower section of the cover is lined up

with the spring. The filter assembly rod

must be in a vertical position and

perpendicular to the base of the reservoir.

The cover can be rotated to align the rod

into a vertical position.

4.

Tighten mounting bolts to 4.84 kg•m (35 ft

lb).

Figure 12

CHECK FOR LEAKS IN THE HYDRAULIC SYSTEM

1.

Perform a daily walk-around inspection to make sure that the hoses, piping, fittings, cylinders and

hydraulic motors are not showing any signs of leakage. If any is noted, determine the source of the

leak and repair.

022-00029AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-11

REFILL FUEL

WARNING!

Use extreme safety precautions while

refueling to prevent explosions or fire.

Immediately clean up any spilt fuel.

1.

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

fuel through fuel filler pipe

(Figure

13).

When working at a temperature of 0°C

Figure 13

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

equivalent. At temperatures below

0°C

(32°F) use ASTM No. 1-D or its equivalent.

NOTE: See

“Fluid Capacities” on

page 4-5 for capacity.

2.

Securely tighten cap after fueling.

NOTE: If breather holes in cap are

clogged, a vacuum may form in

the tank preventing proper fuel

flow to engine. Keep holes in

fuel cap clean.

CHECK FOR LEAKS IN THE FUEL SYSTEM

1.

Perform an inspection of engine

compartment to verify that fuel system is

not leaking. If any is noted, determine the

source of leak and repair.

HAOC510L

Figure 14

DRAIN FUEL CONDENSATION

Figure 15

Figure 16

1.

Open fuel tank drain valve. (Figure 15). Allow any condensed water or sediment to drain out of tank.

Also open drains on Primary and Secondary fuel filters and drain out any water or sediment. (Figure

16). Catch drained material in a container. Properly dispose of drained material.

4-12 Inspection, Maintenance and Adjustment

022-00029AE Operation and Maintenance Manual

CHECK COOLANT LEVEL

WARNING!

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

Removing cap from a hot radiator could cause a person to be sprayed and burned from liquid

inside. Wait for radiator temperature to cool down before removing cap.

Figure 18

Figure 17

1.

Remove fill cap from radiator (Figure 18). Check level of coolant inside radiator. If low, add coolant to

fill radiator to a point that is 10 - 20 mm (1/2 - 3/4") below top of overflow pipe. If temperature is below

freezing, see “Check Antifreeze Protection Levels” on page 4-14 for antifreeze protection. Use the

table to calculate a proper mixture of anti-freeze and water to provide level of protection necessary

for expected temperature.

022-00029AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-13

CHECK ANTIFREEZE PROTECTION LEVELS

AMBIENT TEMPERATURE

COOLING WATER

ANTIFREEZE

-10°C (15°F)

80%

20%

-15°C (5°F)

73%

27%

-20°C (-5°F)

67%

33%

-25°C (-15°F)

60%

40%

-30°C (-20°F)

56%

44%

-40°C (-30°F)

50%

50%

CHECK LEVEL OF WINDOW WASHER FLUID

1.

Check fluid level in windshield washer

tank, in the storage box of the rear of the

seat.

2.

Open fill cap and add fluid.

NOTE: Use a washer liquid that is

rated for all seasons. This will

prevent freezing during cold

weather operation.

Figure 19

INSPECT THE BUCKET TEETH AND SIDE

CUTTERS FOR SIGNS OF WEAR

1.

On a daily basis, inspect bucket teeth to

make sure that tooth wear or breakage has

not developed.

2.

Do not allow replaceable bucket teeth to

wear down to the point that bucket adapter

is exposed. (Figure 20)

NOTE: These instructions are only for

DOOSAN OEM buckets. If you

are using other manufacturers’

buckets, refer to their specific

Figure 20

instructions.

INSPECT SEAT BELT FOR PROPER OPERATION

INSPECT THE STRUCTURE FOR CRACKS AND FAULTY WELDS

1.

During the daily walk-around inspection and when greasing the machine, look for any visible damage

to the machine. Repair or replace any damaged parts before operating machine.

4-14 Inspection, Maintenance and Adjustment

022-00029AE Operation and Maintenance Manual

INSPECT ENGINE FAN BLADE

WARNING!

Personal injury can result from a fan blade

failure. Never pull or pry on the fan. This

can damage the fan blade(s) and cause

fan failure.

NOTE: Manually rotate the crankshaft

by using a wrench on the

accessory drive pulley nut.

Figure 21

1.

An inspection of the cooling fan is required

daily. check for cracks, loose rivets, bent or

loose blades, and for contact between the

blade tips and the fan shroud. Check the

fan to make sure it is securely mounted.

Tighten the bolts if necessary. Replace

any fan that is damage.

CHECK ENGINE DRIVE BELT WEAR

WARNING!

Keep clear of engine fan and fan drive

belts when the engine is running. Rotating

fan and belt contact can cause injury.

WARNING!

Figure 22

When checking, adjusting or replacing

drive belts, care must be taken to prevent

accidental cranking of the engine. Be sure

the starter switch is in the "OFF" position

and the controls are tagged.

1.

Replace badly worn, greasy or severely cracked belts immediately. These conditions prevent proper

belt function. Visually inspect the belt. Check the belt for intersecting cracks. Transverse (across the

belt width) cracks are acceptable. Longitudinal (direction of belt length) cracks that intersect with

transverse cracks are not acceptable. Replace the belt if it is frayed or has pieces of material missing.

2.

Before installing new belts, make sure all pulley grooves are clean and not worn. Replace pulley, if

damaged, or if the grooves are worn.

3.

All pulley support bearings, shafts, and brackets must be in working order.

4.

When replacing belts and pulleys, pulley alignment must be checked with belts tensioned and

brackets securely clamped. A misalignment that can be detected by the naked eye is detrimental to

belt performance.

4-16 Inspection, Maintenance and Adjustment

022-00029AE Operation and Maintenance Manual

5.

Do not force the belts into the pulley grooves by prying with a screwdriver or pry bar. This will damage

the belt side cords which will cause the belts to turn and result in complete destruction of the belts in

operation.

6.

Belts on new machines and replacement belts lose their tension as they seat into the pulley grooves.

Check the tension of new belts at 20 hour intervals until tension is stabilized and thereafter, every 250

hours. If the tension falls below the required minimum, the belt slips damaging the belts and pulley

grooves.

NOTE: When operating in abrasive conditions, check tension every 100 hours.

CHECK AIR INTAKE SYSTEM

CAUTION!

Hot engine components can cause burns.

Avoid contact with hot engine

components

1.

Park the machine on a level surface, apply

the parking brake, lower the attachment to

HAOA050L

the ground, and stop the engine.

Figure 23

2.

Check the engine intake hose, and hose

bands for damage and tightness.

3.

If damaged, wrinkled or loose, replace or

retighten or contact your nearest loader

dealer.

IMPORTANT

Severe engine damage will result

from running with unfiltered air.

Do not operate engine if any leaks or

defects are found on air intake

Figure 24

system.

CHECK CRANKCASE BREATHER TUBE

1.

Check the crankcase breather tube daily

during cold weather operations for ice

buildup, which could obstruct the tube.

NOTE: If ice buildup is present, remove

the breather tube and clear the

obstruction.

Figure 25

022-00029AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-17

50 HOUR / WEEKLY SERVICE

PERFORM ALL 10 HOUR / DAILY SERVICE CHECKS

GREASE FRONT ATTACHMENT PINS

1.

Following fittings are greased daily, or every 10 hours, for first 100 hours of operation to comply with

new machine break-in requirements. After that, greasing should be done every 50 hours. If bucket is

being used in water, grease fittings immediately after machine is removed from water.

D

C

B

E

F

AQO0180L

Figure 26

4-18 Inspection, Maintenance and Adjustment

022-00029AE Operation and Maintenance Manual

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