Doosan DL420. Operation and Maintenance Manual (2009)

DL420

Operation and Maintenance Manual

950106-00008E

Serial Number 5001 and Up

September 2009

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.

950106-00008E Operation and Maintenance Manual

Intended Use

The machine is intended to be used under normal conditions

for the applications described in the Operator's Manual. If it

is used for other purposes or in potentially dangerous

environments, for example explosive atmosphere or areas

with dust containing asbestos, etc., special safety regulations

must be followed and the machine must be equipped for

such use. Contact the manufacturer/dealer for further

information.

The machine is designed for a maximum machine weight

(includes equipment and attachments) of

22,300 kg

(49,163 lb) for DL420. If the maximum weight is exceeded,

no warranties on the part of the manufacturer will apply.

However, always pay attention to national regulations for

traveling on public roads.

Engine

DL420 has a Cummins QSM11 10.8 liter engine. The engine

has intercooling and is fitted with common rail system. The

common rail system is positioned at an angle above the

pistons and are controlled via the camshaft and a electronic

control module (ECM).

The cylinder head covers all cylinders.

The engine has four valves per cylinder.

The accelerator position is transferred electrically from

accelerator pedal.

Electrical System

The machine has three control units. The Gauge Panel for

the instrumentation is integrated with the display unit,

warning lights and instruments and provides the operator

with information via there. The Control Unit (for the machine)

receives signals from sensors on the machine and these are

passed to the Gauge Panel. The E-ECU controls the engine.

Power Transmission

The transmission is electrohydraulically controlled, where all

gears are in constant mesh. The gear ranges are achieved

by applying different combinations of clutches. Between the

engine and transmission gears there is a hydraulic torque

converter, which controls the output torque. The front and

rear axles have planetary gears in the wheel hubs and this

reduces the strain on the respective drive shafts. The axles

differentials use a LSD (Limited Slip Differential) design.

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950106-00008E

I-II

Brake System

The machine is provided with a dual circuit, all hydraulic,

brake system with one circuit for each axle. Each circuit

meets the requirements for secondary brake capability.

Parking Brake

The parking brake is a dry disk brake built into the

transmission output shaft. The brake is applied by spring

force and is released hydraulically.

Steering System

The machine uses a load sensing, hydrodynamic steering

system. It has a steering arc of 40°.

Cabin

The cabin has a heating and ventilation system with

defrosting for front and rear windows. Air-conditioning is

standard. The cabin has two emergency exits, the door and

right side window.

FOPS and ROPS

The cabin is approved as a protective cabin according to

FOPS and ROPS standards. FOPS is an abbreviation of

Falling Object Protective Structure

(roof protection) and

ROPS is an abbreviation of Roll Over Protective Structure

(roll over protection).

Never carry out any unauthorized alterations to the cabin,

e.g. lowering the roof height, drilling, welding on brackets for

fire extinguisher, radio aerial or other equipment, without first

having discussed the alteration with personnel at the

DOOSAN Infracore Engineering Department. This department

will decide whether the alteration may cause the approval to

become void. It is important that all parties concerned are

aware of these regulations.

Hydraulic System

The hydraulic system is load sensing with pumps in

common for steering systems and the working hydraulics.

However, the brake and steering systems are prioritized by

one of the pumps.

Presentation

950106-00008E

I-III

Equipment

The machine can be provided with different types of optional

equipment, depending on the requirements of different

markets. Examples of such equipment are lever steering,

Boom Suspension System

(LIS), secondary steering,

separate attachment locking, automatic greasing.

CE MARKING, EMC DIRECTIVE

CE Marking

(Declaration of Conformity)

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

This machine is CE marked. This means that when

delivered the machine meets the applicable "Essential Health

and Safety Requirements," which are given in the Machinery

Safety Directive, 98/37EC.

Any person carrying out changes that affect the safety of

FG001781

the machine, is also responsible for the same.

Figure 2

As proof that the requirements are met, the machine is

supplied with an EU Declaration of Conformity, issued by

DOOSAN CE for each separate machine. This EU

declaration also covers attachments manufactured by

DOOSAN CE. The documentation is a valuable document,

which must be kept safe and retained for at least ten years.

The document should always accompany the machine when

it is sold.

If the machine is used for other purposes or with other

attachments than described in this manual, safety must at all

times and in each separate case be maintained. The person

carrying out such action is also responsible for the action

which, in some cases, may require a new CE marking and

the issue of a new EU Declaration of Conformity.

The EU EMC Directive

The electronic equipment of the machine may in some

cases cause interference to other electronic equipment, or

suffer from external electromagnetic interference, which may

constitute safety risks.

The EU EMC directive on "Electromagnetic Compatibility,"

89/336/EEC, provides a general description of what

demands can be made on the machine out of a safety point

of view, where permitted limits have been determined and

given according to international standards.

A machine or device which meets the requirements must be

CE marked. Our machines have been tested particularly for

Presentation

950106-00008E

I-IV

electromagnetic interference. The CE marking of the

machine and the declaration of conformity also cover the

EMC directive.

If other electronic equipment is fitted to this machine, the

equipment must be CE marked and tested on the machine

with regard to electromagnetic interference.

COMMUNICATION EQUIPMENT

INSTALLATION

IMPORTANT

All installation of optional communication equipment

must be carried out by trained professionals and in

accordance with the DOOSAN CE instructions applicable

to the machine.

Protection Against Electromagnetic

Interference

This machine has been tested in accordance with EU

directive

89/336/EEC governing electromagnetic interference.

It is therefore very important that all nonapproved electronic

accessories, such as communication equipment, must be

tested before installation and use, since they can cause

interference to the electronic systems of the machine.

Presentation

950106-00008E

I-V

When ordering spare parts, and in all telephone enquiries or

correspondence the PIN and CIN must always be quoted.

FG015225

Figure 3

Reference

Description

Number

Primary Marking

The machine PIN (stamped into right side).

Product Plate

The manufacturer's name and address, machine PIN.

Additional Plate

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

for Product Plate

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

Engine

The engine type designation and number.

Front Axle

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

Transmission

The manufacturer's name and address and transmission CIN.

Rear Axle

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

Presentation

950106-00008E

I-VII

TABLE OF CONTENTS

Presentation

I-I

Presentation

I-I

CE Marking, EMC Directive

I-IV

Communication Equipment Installation

I-V

Product Plates

I-VI

Safety

1-1

To the Operator of a DOOSAN Wheel Loader

1-1

General Safety Essentials

1-5

Location of Safety Labels

1-5

Unauthorized Modifications

1-14

General Hazard Information

1-14

Before Starting Engine

1-23

Machine Operation

1-27

Maintenance

1-35

Battery

1-47

Towing

1-49

Shipping and Transportation

1-50

Operating Controls

2-1

Component Locations

2-2

Operator's Area

2-4

Steering Console and Pedals

2-5

Front Instrument Panel

2-16

Right Side Switch Panel

2-27

Setting Main Menu

2-42

Various Cabin Locations

2-50

Heater and Air Conditioner Operation

2-54

Table of Contents

950106-00008E

Stereo / CD Player (Optional)

2-59

Seat Adjustment (Standard)

2-61

Seat Adjustment (Optional)

2-63

Seat Belt

2-65

Door side latch

2-66

Arm Rest

2-67

Fuse Box/Relay

2-68

Operation

3-1

Instrument Panel Control Functions

3-1

New Machine Break-in Procedures

3-1

Engine Start and Stop

3-2

Machine Travel

3-11

Machine Shut Down

3-14

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

3-16

Additional Braking

3-17

Boom Raise Kick-out

3-18

Bucket Angle Indicator

3-18

Boom Lower Kick-out (Optional)

3-19

Adjustment of Bucket Position Switch

3-19

Towing Machine

3-20

If Engine Stalls While Traveling

3-21

Allowable Water Depth

3-22

Inspection, Maintenance and Adjustment

4-1

Basic Preventive Maintenance

4-1

Safety When Servicing

4-6

Preventive Maintenance

4-14

Table of Recommended Lubricants

4-16

Axle Oils DL420, DL400, DL300, DL250

4-18

Fluid Capacities

4-21

Lubrication and Service Chart

4-22

Maintenance Intervals

4-26

Table of Contents

950106-00008E

10 Hour / Daily Service

4-28

50 Hour / Weekly Service

4-38

250 Hour / Monthly Service

4-46

500 Hour / 3 Month Service

4-50

1,000 Hour / 6 Month Service

4-64

1,500 Hour / 9 Month Service

4-72

2,000 Hour / Yearly Service

4-75

12,000 Hour / 6 Year Service

4-82

Bolt Torque Chart

4-83

Electrical System

4-84

Engine Cooling System

4-86

Handling of Accumulator

4-89

Hydraulic Pressure Checks

4-91

Long Term Storage

4-96

Parking Brake Adjustment

4-97

Severe Conditions Maintenance

4-99

Tires

4-100

Transmission Recalibration

4-104

Transportation

5-1

Loading and Unloading

5-1

Summary of Safety Precautions for Lifting

5-2

Troubleshooting

6-1

Braking

6-1

Electrical System

6-1

Engine

6-2

Hydraulic System

6-4

Steering

6-6

Travel System

6-8

Specification

7-1

General Specifications

7-1

Table of Contents

950106-00008E

III

OP000994

1Safety

TO THE OPERATOR OF A

DOOSAN WHEEL LOADER

DANGER

Improper use of wheel loader could cause serious injury

or death. Before operating wheel loader, or performing

maintenance, operator or technician must read and

understand entire Operation and Maintenance Manual.

Any operation, maintenance, traveling or shipping

methods that do not follow safety guidelines printed in

this Manual could cause serious injury or death.

Please respect the importance of taking responsibility for

your own safety, and that of other people who may be

affected by your actions.

The safety information on the following pages is organized

into the following sections:

“General Safety Essentials” on page 1-5

“Location of Safety Labels” on page 1-5

“Unauthorized Modifications” on page 1-14

“General Hazard Information” on page 1-14

“Before Starting Engine” on page 1-23

“Machine Operation” on page 1-27

“Maintenance” on page 1-35

“Battery” on page 1-47

“Towing” on page 1-49

10.

“Shipping and Transportation” on page 1-50

Safety

OP000994

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.

Safety

OP000994

1-2

SAFETY ALERT SYMBOL

Be Prepared - Get to Know All Operating and Safety

Instructions

This is the Safety Alert Symbol. Wherever it appears - in

this manual or on safety signs on the machine - you

must be alert to potential for personal injury or

accidents. Always observe safety precautions and follow

recommended procedures.

Learn Signal Words Used With Safety

Alert Symbol

The words "CAUTION", "WARNING", and "DANGER" used

throughout this manual and on decals on the machine

indicate degree of risk of hazards or unsafe practices. All

three degrees of risk indicate that safety is involved.

Observe precautions indicated whenever you see the Safety

Alert "Triangle", no matter which signal word appears next to

the "Exclamation Point" symbol.

CAUTION

This word is used on safety messages and safety labels

and indicates potential of a hazardous situation that, if

not avoided, could result in minor or moderate injury. It

may also be used to alert against a generally unsafe

practice.

WARNING

This word is used on safety messages and safety labels

and indicates potential of a hazardous situation that, if

not avoided, could result in serious injury or death. It

may also be used to alert against a highly unsafe

practice.

DANGER

This word is used on safety messages and safety labels

and indicates an imminent hazard of a situation that, if

not avoided, is very likely to cause death or extremely

serious injury. It may also be used to alert against

equipment that may explode or detonate if handled or

treated carelessly.

Safety

OP000994

1-3

Safety precautions are described in SAFETY from page 1-5

on.

DOOSAN cannot predict every circumstance that might

involve a potential hazard in operation and maintenance.

Therefore the safety messages in this manual and on the

machine may not include all possible safety precautions. If

any procedures or actions not specifically recommended or

allowed in this manual are used, you must be sure that you

and others can do such procedures and actions safely and

without damaging the machine. If you are unsure about the

safety of some procedures, contact a DOOSAN distributor.

Safety

OP000994

1-4

GENERAL SAFETY

ESSENTIALS

ACCESSORY APPLICATIONS

The wheel loader has been designed primarily for moving

earth with a bucket. For use as a grapple or for other object

handling, contact DOOSAN. Lifting-work applications are

permitted in approved lift configuration, to rated capacity

only, with no side-loading

(unless prohibited by local

regulation). Do not use machine for activities for which it

was not intended. Do not use bucket for lifting work, unless

lift slings are used in approved configuration.

LOCATION OF SAFETY

LABELS

The operator should know and pay attention to the

information and warning plates/decals which are positioned

on the machine.

There are several specific warning signs on this machine.

The exact location of hazards and the description of the

hazards are reviewed in this section.

Please become familiarized with all warning signs.

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

the warning signs or replace the warning signs if you cannot

read the words. Replace the illustrations if the illustrations

are not visible. When you clean the warning signs, use a

cloth, water and soap. Do not use solvent, gasoline, or other

harsh chemicals to clean the safety signs. Solvents,

gasoline, or other harsh chemicals could loosen the

adhesive that secures the warning sign. Loose adhesive will

allow the warning sign to fall off.

Replace any safety sign that is damaged, or missing. If a

safety sign is attached to a part that is replaced, install a

safety sign on the replacement part.

Safety

OP000994

1-5

1. Warnings for Operation, Inspection

and Maintenance (4190-2545A,

190-00092)

WARNING

•

AVOID DEATH OR SERIOUS INJURY-

READ AND UNDERSTAND THE

INSTRUCTIONS AND WARNINGS IN

THE OPERATION AND MAINTENANCE

MANUALS prior to operating this

machine.

•

Sound the horn to alert the people

nearby before operating, and sure all

persons are clear of area.

•

Always make sure when leaving

operator's seat to:

ACO1360L

•

Lower bucket or other working

tools to the ground.

•

LOCK transmission selector in neutral.

•

Set park brake.

•

Turn key switch OFF. Remove key from switch.

•

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

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

2. Warnings for Cooling Fan

(2190-3315, 190-00557)

WARNING

Keep your hands away from the fan during

operation. Entanglement in the fan can cause

serious injury.

AMO0390L

Safety

OP000994

1-7

5. Warnings for Handling Accumulator

(190-00703, 190-00099)

WARNING

Explosion hazard:

•

Keep away from flame.

•

Do not weld on or drill into the accumulator.

ACO1480L

Accumulator

Wheel loader pilot control system is equipped with an

accumulator. Accumulator will store a pressure charge that

may enable hydraulic controls to be activated for a brief

period of time after engine has been shut down. Activation

of any controls may enable selected function to operate

under force of gravity.

CAUTION

Any raised attachment will lower to ground if

accumulator holds a charge.

When shutting machine down, lower front attachment to

ground. After engine has been shut down, turn key to "ON"

position and move joystick controls to release pressure in

accumulator. Remove key.

IMPORTANT

Refer to Shop Manual for service procedures. Do not

release any pilot lines until pressure within accumulator

has been released.

Safety

OP000994

1-9

6. Keep Out of Steering Turn Area

(4190-1992A, 190-00120)

DANGER

Severe injury and death from crushing could

occure in articulated area when machine

turns.

Make sure people are clear of machine before

starting engine or moving steering wheel.

Lock safety bar during servicing or

transporting machine.

AMO0410L

7. Warnings for High Temperature

Hydraulic Oil (190-00691A, 190-00097)

WARNING

HYDRAULIC OIL CAN CAUSE INJURY OR

BLINDNESS.

To prevent hot oil from spurting out:

•

Turn engine off

•

Allow oil to cool

•

Lift cap to relieve pressure.

ACO1410L

Safety

OP000994

1-10

8. Warnings for High Temperature

Coolant (190-00692, 190-00097)

WARNING

HOT COOLANT CAN CAUSE INJURY OR

BLINDNESS.

Never loosen or open radiator cap when

coolant is hot and under pressure.

To open cap, stop engine, wait until radiator

is cool. Then loosen cap slowly to relieve the

pressure.

ACO1410L

9. Warnings for Battery Maintenance

(2190-2533A, 190-00100)

DANGER

•

Battery fumes can explode. Keep

sparks and flames away from

batteries.

•

Always avoid storing metals like

tools or flammable materials around

or on the batteries. Explosion or fire

can be caused by short circuiting

batteries.

•

Sulfuric

acid

battery

poisonous. It is strong enough burn

skin, eat holes in clothing, and

cause blindness if splashed in eyes.

If you spill acid on yourself:

Flush your skin with water.

ACO1400L

Apply baking soda or lime to help

neutralize the acid.

Flush your eyes with water for 10 -

15 minutes.

Get medical attention immediately.

Safety

OP000994

1-11

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.

Safety

OP000994

1-14

Inside Operator's Compartment

When entering the operator's compartment, always remove

all mud and oil from the soles of your shoes. If you operate

the accelerator and brake pedals with mud or oil stuck to

your shoes, your foot may slip and this may cause a

serious accident.

Clean grease and dirt from pedals and controls. This

contributes to safe operation. Cleaning also provides an

opportunity to inspect equipment. Minor damage can be

repaired or corrected before major problems result.

Keep cabin floor and consoles free of tools and personal

items.

Do not stick suction pads to the window glass. Suction pads

act as a lens and may cause fire.

Do not leave lighters laying around the operator's

compartment. If the temperature inside the operator's

compartment becomes high, there is danger that the lighter

may explode.

Do not use cellular telephones inside the operator's

compartment when driving or operating the machine. There

is danger that this may lead to an unexpected accident.

Never bring any dangerous objects such as flammable or

explosive items into the operator's cabin.

To ensure safety, do not use the radio or music

headphones when operating the machine. There is danger

that this may lead to a serious accident.

When operating the machine, do not put your hands or

head out of the window.

When standing up from the operator's seat, always place

transmission neutral lock lever in the "LOCK" position and

set pilot cutoff switch to "O"

(OFF) position. If you

accidentally touch the work equipment levers when they are

not locked, the machine may suddenly move and cause

serous injury or damage.

When leaving the machine, lower the work equipment

completely to the ground, set transmission neutral lock lever

in the "LOCK" position, set pilot cutoff switch to "O"

(OFF)

position, "APPLY" parking brake, and shut down engine. Use

the key to lock all the equipment. Always remove the key

and take it with you.

Safety

OP000994

1-15

Clothing and Personal Protective Items

Contain long hair, and avoid loose clothing and jewelry.

They can catch on controls or in protruding parts and cause

serious injury or death.

Do not wear oily clothes. They are highly flammable.

Full eye protection, a hard hat, safety shoes and gloves

may be required at the work site.

While working on the machine, never use inadequate tools.

They could break or slip, causing injury, or they may not

HAOA020L

adequately perform intended functions.

Figure 2

Breathing Masks, Ear Protection May Be

Required

Do not forget that some risks to your health may not be

immediately apparent. Exhaust gases and noise pollution

may not be visible, but these hazards can cause disabling

or permanent injuries.

NOTE: The equivalent continuous A-weighted sound

pressure level at the workstation for this machine is

72 dB(A).

Measurement is obtained on a dynamic machine

following the procedures and cabin conditions as

described in ISO 6396.

NOTE: The guaranteed sound power level emitted by the

machinery for this machine is 106 dB(A).

Measurement is obtained on a dynamic machine with

the procedures as described in 2000/14/EC.

Vibration Level Information

Hands/Arms: The weighted root mean square acceleration to

which the hands/arms are subjected, is less than 2.5 m/s².

Whole body: The weighted root mean square acceleration to

which the whole body is subjected, is less than 0.5 m/s².

Measurements are obtained on a representative machine,

using measuring procedures as described in the following

standard: ISO 2631/1. ISO 5349, and SAE J1166.

Recommendations for Limiting

Vibrations

Select the right machine, equipment and attachments

for a particular application.

Replace any damaged seat by a genuine DOOSAN

part. Keep the seat maintained and adjusted.

Safety

OP000994

1-16

•

Adjust the seat and suspension for the weight and

size of the operator.

•

Inspect and maintain the suspension and

adjustment mechanisms of the seat regularly.

Check that the machine is properly maintained.

•

Tire pressure, brakes, steering, linkages, etc.

Steer, brake, accelerate, shift gears, move the

attachments and load the attachments smoothly.

Adjust the machine speed and travel path to reduce

the vibration level.

•

Slow down if it is necessary when passing rough

terrain.

•

Drive around obstacles and excessive rough

terrain conditions.

Keep the terrain on work sites where the machine is

working and traveling in good condition.

•

Remove any large rocks or obstacles.

•

Fill any ditches and holes.

•

Provide machines for and schedule time to

maintain the terrain conditions.

Travel over longer distance

(e.g. on public roads) at

adjusted (medium) speed.

•

Always adjust the speed for preventing bouncing.

Asbestos Dust Hazard Prevention

Asbestos dust can be HAZARDOUS to your health if it is

inhaled. Materials containing asbestos fiber can be present

on work site. Breathing air that contains asbestos fiber can

ultimately cause serious or fatal lung damage. To prevent

lung damage from asbestos fiber, observe following

precautions:

•

Use a respirator that is approved for use in an

asbestos-laden atmosphere.

ARO1770L

•

Never use compressed air for cleaning.

Figure 3

•

Use water for cleaning to keep down the dust.

•

Work on the machine or component with the wind

at your back whenever possible.

•

Always observe any rules and regulations related

to the work site and working environment.

Safety

OP000994

1-17

Mounting and Dismounting

Before getting on or off the machine, if there is any oil.

grease, or mud on the handrails, steps, or track shoes, wipe

it off immediately. Always keep these parts clean. Repair

any damage and tighten any loose bolts.

Never jump on or off the machine. In particular, never get

on or off a moving machine. These actions may lead to

serious injury.

When getting on or off the machine, always face the

HA3O1003

machine, and maintain a three-point contact (both feet and

one hand or one foot and both hands) with the handholds

Figure 4

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.

Fuel, Oil and Hydraulic Fluid Fire

Hazards

Fuel, oil and antifreeze will catch fire if it is brought close to

a flame. Fuel is particularly flammable and can be

hazardous.

Always strictly observe the following.

Add fuel, oil, antifreeze and hydraulic fluid to the machine

only in a well ventilated area. The machine must be parked

with controls, lights and switches turned "OFF". The engine

must be "OFF" and any flames, glowing embers, auxiliary

heating units or spark causing equipment must be doused,

turned "OFF" and/or kept well clear of the machine.

Static electricity can produce dangerous sparks at the fuel

filling nozzle. In very cold, dry weather or other conditions

Figure 5

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.

Safety

OP000994

1-18

Precautions When Handling Fluids at

High Temperature

Immediately after operations are stopped, the coolant,

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

radiator and hydraulic tank are still under pressure.

Attempting to remove the cap, drain the oil or coolant, or

replace the filters may lead to serious burns. Always wait for

the temperature to go down, and follow the specified

procedures when carrying out these operations.

HAOA050L

Figure 6

To prevent hot coolant from spurting out, shut down engine,

wait for the coolant to cool, then loosen the cap slowly to

relieve the pressure.

To prevent hot oil from spurting out, shut down engine, wait

for the oil to cool, then loosen the cap slowly to relieve the

pressure.

HAOA060L

Figure 7

Injury from Work Equipment

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

your body between movable parts, such as between the

work equipment and cylinders, or between the machine and

work equipment.

If the control levers are operated, the clearance between the

machine and the work equipment will change and this may

lead to serious damage or personal injury.

going between movable parts is necessary, always

HDO1010L

position and secure the work equipment so that it cannot

Figure 8

move.

Safety

OP000994

1-19

Fire Extinguisher and First Aid Kit

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

the following.

•

Be sure that fire extinguishers have been provided

and read the labels to ensure that you know now

to use them. It is recommended that an

appropriately sized

(2.27 kg

[5 lb] or larger)

multipurpose "A/B/C" fire extinguisher be mounted

in the cabin. Check and service the fire

extinguisher at regular intervals and make sure

HDO1009L

that all work site crew members are adequately

Figure 9

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 to the "O"

(OFF) position

and shut down engine.

•

If there is time, use the fire extinguisher to

extinguish as much of the fire as possible.

•

Use the handrails and steps to escape from the

machine.

The above is the basic method for escaping from the

machine, but changing the method may be necessary

according to the conditions, so carry out practice drills at the

work site.

Protection from Falling or Flying Objects

On work sites where there is danger that falling objects or

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

match the operating conditions to protect the operator.

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

surfaces could produce danger of falling rock, roll over or

hazardous flying objects. Additional protection for operator's

cabin could be required in form of a FOPS/Falling Object

Protective Structure and/or ROPS/Roll Over Protective

Structure reinforcement system.

HAOA110L

Figure 10

Safety

OP000994

1-20

Any reinforcement system that is installed on machine must

pass safety and certification standards and carry appropriate

labeling and rating information. For example, most often

added type of reinforcement system, FOPS, must meet or

exceed Society of Automotive Engineers standard SAE

J1356, "Performance Criteria for Falling Object Guards for

Wheel loaders".

Never attempt to alter or modify any type of protective

structure reinforcement system, by drilling holes, welding,

remounting or relocating fasteners. Any serious impact or

damage to the system requires a complete integrity

HAOA100L

reevaluation. Reinstallation, recertification and/or replacement

Figure 11

of the 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 cabin. Make sure

that all other work site crew members are kept well away

from wheel loader and safe from potential hazards.

Maintain Standard Safety Equipment in

Good Condition

Machinery guards and body panel covers must be in place

at all times. Keep well clear of rotating parts. Pinch point

hazards such as cooling fan and alternator drive belts could

catch hair, jewelry or oversize or very loose clothing.

Safety labels must be replaced if they are damaged or

become unreadable. Information on labels gives work crew

members an important safety reminder. Part numbers for

each decal and required mounting locations are shown on

pages 1-2 through 1-4 of this section.

Attachment Precautions

Option kits are available through your dealer. Contact

DOOSAN for information on available one-way (single-acting)

and two-way

(double-acting) piping

/ valving

/ auxiliary

control kits. Because DOOSAN cannot anticipate, identify or

test all of the attachments that owners may wish to install

on their machines, please contact DOOSAN for authorization

and approval of attachments, and their compatibility with

options kits.

Safety

OP000994

1-21

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 4-89.

The accumulator is charged with high-pressure nitrogen gas,

so it is extremely dangerous if it is handled in the wrong

way. Always observe the following precautions:

•

Do not drill or make any holes in the accumulator

or expose it any flame, fire or heat source.

•

Do not weld on the accumulator, or try attaching

anything to it.

•

When carrying out disassembly or maintenance of

the accumulator, or when disposing of the

accumulator, the charged gas must be properly

released. Contact your DOOSAN distributor.

•

Wear safety goggles and protective gloves when

working on an accumulator. Hydraulic oil under

pressure can penetrate the skin and cause

serious injuries.

Engine Ventilation

Engine exhaust gases can cause loss of judgment, loss of

alertness, and loss of motor control. These gases can also

cause unconsciousness, serious injury, fatal accidents and

death.

Make sure there is adequate ventilation before starting the

engine in any enclosed area.

You should also be aware of open windows, doors or

ductwork into which exhaust may be carried, or blown by

ARO1770L

the wind, exposing others to danger.

Figure 12

Safety

OP000994

1-22

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.

DANGER

No Entry

Water lines, gas lines, phone lines and high voltage

FG015427

electrical lines may be buried under the work site. Contact

Figure 13

each utility and identify their locations. Be careful not to

damage or cut any of these lines.

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

of the water before operating in water or crossing a river.

NEVER be in water that is in excess of the permissible

water depth. Refer to

“Allowable Water Depth” on

page 3-22.

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

Safety

OP000994

1-23

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 if working in areas where there is

danger of falling rocks.

Checks Before Starting Engine

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

out the following checks. If these checks are not carried out

properly, there is danger of serious injury.

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

other flammable materials accumulated in the engine

compartment and around the battery. They could cause a

fire. Remove any dirt from the window glass, mirrors,

handrails, and steps.

Do not leave tools or spare parts laying around in the

operator's compartment. The vibration of the machine when

traveling or during operations may cause them to fall and

damage or break the control levers or switches. They may

also get caught in the gap of the control levers and cause

the work equipment to malfunction or move dangerously.

This may lead to unexpected accidents.

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

level, and check for clogged air cleaner and damage to the

electrical wiring.

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

operate the machine, and check the seat belt and mounts

for damage and wear.

Check the operation of the gauges and the angle of the

mirrors, and check that the safety lever is in "LOCKED"

position.

If any abnormalities are found in the above checks, carry

out repairs immediately.

Engine Starting

Walk around your machine before getting in the operator's

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

misaligned assemblies or any other indications of possible

equipment hazard.

All equipment covers and machinery safety guards must be

in place, to protect against injury while the machine is being

operated.

Safety

OP000994

1-24

Look around the work site area for potential hazards, people

or properly that could be at risk while operation is in

progress.

NEVER start the engine if there is any indication that

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

tag is attached to controls in the cabin.

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

operated in extremely cold temperatures, could require a

warm-up or maintenance service before start-up.

Check gauges and monitor displays for normal operation

before starting the engine. Listen for unusual noises and

remain alert for other potentially hazardous conditions at the

start of the work cycle.

Check tire inflation and check tires for damage or uneven

wear. Perform maintenance before operation.

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

This is not only dangerous, but may also damage the

machine.

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

Start and operate the machine only while seated.

Before Operating Machine

If checks are not carried out properly after starting the

engine, it may result in a delay in discovering abnormalities

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

damage to the machine.

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

obstructions. Do not let anyone near the machine when

carrying out the checks.

•

Check the operating condition of the equipment,

and the actuation of the bucket, boom, and travel

systems.

•

Check the machine for any abnormal noise,

vibration, heat, smell, or abnormality with the

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

fuel.

•

If any abnormality is found, repair the problem

immediately. If the machine is used without

repairing the problems, it may lead to unexpected

injury or failure.

•

Clear all personnel from directly around machine

and from the area.

•

Clear all obstacles from the machine's path.

Beware of hazards.

•

Be sure that all windows are clean. Secure the

doors and the windows in the open position or in

the shut position.

Safety

OP000994

1-25

•

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 cabin and the

drive sprockets to the rear. When the

undercarriage is in the reversed position, the

travel controls must be operated in opposite

directions.

Safety

OP000994

1-26

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.

Replace damaged safety labels and lost or damaged

operator's manuals.

HAOA151L

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

Figure 14

and completely trained, in safety and in operation of the

machine.

Seat Belts Must Be Used at All Times

Whenever engine is running, operator must be seated at the

control station with seat belt properly engaged.

Figure 15

Movement Alarms

If wheel loader is equipped with an audible travel movement

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

sound as soon as travel system is engaged.

Safety

OP000994

1-27

Travel Precautions

When traveling, wheel loader always keeps lights on; make

sure that you are in compliance with all state and local

regulations concerning warning flags and signs.

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

traveling. It is dangerous if the engine stops when the

machine is traveling. It will be impossible to operate the

steering unless the unit is equipped with an emergency

steering system.

Pilot control valve lever

(joystick) should not be operated

while traveling.

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

ground.

Never travel over obstacles or slopes that will cause

machine to tilt severely. Travel around any slope or obstacle

that causes 10° tilt, or more.

Do not operate the steering suddenly. The work equipment

may hit the ground and cause the machine to lose its

balance, and this may damage the machine or structures in

the area.

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

avoid sudden changes in direction.

Always keep to the permissible water depth. Refer to

“Allowable Water Depth” on page 3-22.

When traveling over bridges or structures on private land,

check first that the bridge or structure can withstand the

weight of the machine. When traveling on public roads,

check with the local authorities and follow their instructions.

Sloping Terrain Requires Caution

Dig evenly around work site whenever possible, trying to

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

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

rate workload is recommended.

On sloping surfaces, use caution when positioning wheel

loader before starting a work cycle. Stay alert for unstable

situations to avoid getting into them. For example, you

should always avoid working bucket over downhill side of

machine when parked perpendicular to slope. Avoid full

extensions of bucket in a downhill direction. Lifting bucket

too high, too close to machine, while wheel loader is turned

AHO0970L

uphill can also be hazardous.

Figure 16

Safety

OP000994

1-28

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 17

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.

Safety

OP000994

1-29

Use Care on Loose Support

Working heavy loads over loose, soft ground or uneven,

broken terrain can cause dangerous side load conditions

and possible tipover and injury. Travel without a load or

balanced load may also be hazardous.

If temperatures are changing, be cautious of dark and wet

patches when working or traveling over frozen ground. Stay

away from ditches, overhangs and all other weak support

surfaces. Halt work and install support mats or blocking if

work is required in an area of poor support.

Use Solid Support Blocking

Never rely on lift jacks or other inadequate supports when

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

any movement.

Digging Beneath Overhangs

Digging beneath an overhang is dangerous. Overhang could

collapse on top of operator and cause serious injury or

HDO1042L

death. Go on to another digging area before steep

Figure 18

overhangs are formed. Know height and reach limits of

wheel loader and plan ahead while working. Park wheel

loader away from overhangs before work shut down.

Digging Beneath Wheel Loader

Digging beneath wheel loader is dangerous. Earth beneath

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

could cause serious injury or death to operator. Working

around deep pits, trenching or along high walls may require

support blocks, especially after heavy rainfalls or during

spring thaws.

Stay Alert for People Moving Through

Work Area

When loading a truck you should always know where the

driver is.

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

in a safe spot. Someone else could have gone inside, for

any number of reasons. Avoid working where unseen

passersby might be.

Slow down work cycle and use slower travel speeds in

HAOA171L

congested or populated areas. Use a commonly understood

Figure 19

signal so that other members of work crew can warn

operator to slow or halt work in an impending hazardous

situation.

Safety

OP000994

1-30

Be Aware of and Conform to Local

Regulations

Minimum levels of insurance coverage, work permits or

certification, physical barriers around work site or restricted

hours of operation may be mandated by governing

authorities. There may also be guidelines, standards or

restrictions on equipment that may be used to perform

certain kinds of work. Check and follow all local

requirements, which may also be related to below ground

hazards and power lines.

Never Use Ether Starting Aids

An electric grid type manifold heater is used for cold

starting. Glowing heater element can cause ether or other

starting fluid to detonate, causing injury.

Figure 20

Observe General Safety Rules

Only trained and authorized personnel, with a good

knowledge and awareness of safe procedures, may be

allowed to operate or perform maintenance or service on

wheel loader.

All personnel at work site must be aware of assigned

individual responsibilities and tasks. Communication and

hand signals used must be understood by everyone.

Terrain and soil conditions at work site, approaching traffic,

weather related hazards and any above or below ground

obstacles or hazards must be observed and monitored by all

work crew members.

Safety

OP000994

1-31

Take Time to Provide Good Visibility

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

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

other purposes will cause failures.

To ensure an ample view, do as follows:

•

When working in dark areas, attach working lights

and front lights to the machine. If necessary, set

up lighting at the work site.

•

Stop operations when the visibility is poor, such

as in fog, mist, snow, and rain. Wait for the

visibility to improve to a level which causes no

problems for the operation.

•

Keep dirt and dust off of windows and off lens

surfaces of work lights. Stop working if lights,

windows or mirrors need cleaning or adjustment.

To avoid hitting the work equipment, always do the

following:

•

When working in tunnels, on bridges, under

electric wires, or when parking the machine or

carrying out other operations in places with limited

height, be extremely careful not to hit the bucket

or other parts.

•

To prevent collisions, operate the machine at a

safe speed when working in confined spaces,

indoors, or in crowded areas.

•

Do not pass the bucket over the heads of workers

or over the operator's compartment of dump truck.

Keep "Pinch Point" Areas Clear - Use

Caution in Reverse

Use a signal person in high traffic areas and whenever

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

reverse.

Anyone standing near wheels, or working assemblies of the

attachment, is at risk of being caught between moving parts

of machine.

Never allow anyone to ride on any part of machine or

HAOA191L

attachment, including any part of operator's cabin.

Figure 21

Safety

OP000994

1-32

Operate Carefully on Snow and Ice, In

Very Cold Temperatures

In icy cold weather avoid sudden travel movements and stay

away from even very slight slopes. The machine could skid

off to one side very easily.

Snow accumulation could hide or obscure potential hazards.

Use care while operating or while using the machine to

clear snow.

Warming up the engine for a short period may be

necessary, to avoid operating with sluggish or reduced

working capacity. The jolting shocks and impact loads

caused by bumping or bottoming the boom or attachment

are more likely to cause severe stress in very cold

temperatures. Reducing work cycle rate and work load may

be necessary.

When the temperature rises, frozen road surfaces become

soft, so the machine travel becomes unstable.

In cold weather, do not touch metal surfaces with your bare

hands. If you touch a metal surface in extremely cold

weather, your skin may freeze to the metal surface.

Parking Machine

Avoid making sudden stops, or parking the machine

wherever it happens to be at the end of the work day. Plan

ahead so that the wheel loader will be on firm, level ground

away from traffic and away from high walls, cliff edges and

any area of potential water accumulation or runoff. If parking

on inclines is unavoidable, block the wheels to prevent

movement. Lower the bucket or other working attachment

completely to the ground, or to an overnight support saddle.

There must be no possibility of unintended or accidental

movement.

When parking on public roads, provide fences, signs, flags,

or lights, and put up any other necessary signs to ensure

that passing traffic can see the machine clearly, and park

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

obstruct traffic.

Safety

OP000994

1-33

Shutdown Control Functions

After bucket has been lowered to overnight storage position,

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

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

parking brake. Move pilot cutoff switch to "LOCK" position.

This will disable pilot control valve lever (joystick). Move key

in starter switch to "OFF" position, and remove key from

switch.

Engage all lock-down security equipment that may have

been installed on machine.

IMPORTANT

When hydraulic system maintenance or service work

must be performed, be aware that accumulators in

system store fluid under pressure after system has been

shut down. To release hydraulic pressure in

accumulators, operate control with engine "OFF" until

accumulator pressure is completely dissipated.

Never Let Anyone Ride on Attachment

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

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

a danger of the person falling and suffering serious injury.

HAAD4050

Figure 22

Safety

OP000994

1-34

MAINTENANCE

Use Warning Tag During Service

Alert others that service or maintenance is being performed

WARNING

and tag operator's cabin controls - and other machine areas

if required - with a warning notice.

DO NOT OPERATE

Warning tags for controls are available from DOOSAN

distributors; see Figure 23.

when performing inspection

or maintenance

190-00695A

FG012195

Figure 23

Clean Before Inspection or Maintenance

Clean the machine before carrying out inspection and

maintenance. This prevents dirt from getting into the

machine and also ensures safety during maintenance.

If inspection and maintenance are carried out when the

machine is dirty, it will become more difficult to locate the

problems, and also there is danger that you may get dirt or

mud in your eyes or that you may slip and injure yourself.

When washing the machine, do the following:

•

Wear shoes with nonslip soles to prevent yourself

from slipping and falling on wet places.

•

Wear safety glasses and protective clothing when

washing the machine with high-pressure steam.

•

Take action to prevent touching high-pressure

water and cutting your skin or having mud fly into

your eyes.

ARO1330L

Figure 24

•

Do not spray water directly on electrical

components (sensors, connector) (1, Figure 24). If

water gets into the electrical system, there is

danger that it will cause defective operation and

malfunction.

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

place, wipe up any grease or oil or any other slippery

substances, and clean the area to make it possible to carry

out the operation in safety. If the work place is left untidy,

you may trip or slip and suffer injury.

Safety

OP000994

1-35

Proper Tools

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

qualify, faulty, or makeshift tools could cause personal injury.

There is danger that pieces from, chisels with crushed

heads, or hammers, may get into your eyes and cause

blindness.

HDO1037L

Figure 25

Use of Lighting

When checking fuel, oil, battery electrolyte, or window

washing fluid, always use lighting with antiexplosion

specifications. If such lighting equipment is not used, there

is danger of an explosion.

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

may lead to injury, so always use proper lighting.

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

instead of lighting. There is danger of fire. There is also

HDO1040L

danger that the battery gas may catch fire and cause and

Figure 26

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.

HDO1015I

Figure 27

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 they accumulate on

the machine.

Do not weld on pipes or on tubes that contain flammable

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

Safety

OP000994

1-36

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.

Burn Prevention

When checking the radiator coolant level, shut down engine,

let the engine and radiator cool down, then check the

coolant recovery tank. If the coolant level in the coolant

recovery tank is near the upper limit, there is enough

coolant in the radiator.

Loosen the radiator cap gradually to release the internal

pressure before removing the radiator cap.

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

lower limit, add coolant.

Cooling system conditioner contains alkali. Alkali can cause

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

eyes, or the mouth.

Allow cooling system components to cool before you drain

the cooling system.

Hot oil and hot components can cause personal injury. Do

not allow hot oil or hot components to contact the skin.

Remove the hydraulic tank filter plug only after the engine

has been stopped. Make sure that the hydraulic tank filter

plug is cool before you remove it with your bare hand.

Remove the hydraulic tank filter plug slowly to relieve

pressure.

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

system, or in the cooling system before you disconnect any

HAAE1980

lines, fittings, or related items.

Figure 28

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.

Welding Repairs

When carrying out welding repairs, carry out the welding in

a properly equipped place. The welding must be performed

by a qualified worker. During welding operations, there is the

danger of, generation of gas, fire, or electric shock, so never

let an unqualified worker do welding.

The qualified welder must do the following:

•

To prevent explosion of the battery, disconnect

the battery terminals and remove batteries.

Safety

OP000994

1-37

•

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

HDO1041L

prevent unauthorized persons from entering.

Figure 29

Precautions When Working on Machine

When carrying out maintenance operations on the machine,

keep the area around your feet clean and tidy to prevent

you from falling. Always do the following:

•

Do not spill oil or grease.

•

Do not leave tools laying about.

•

Watch your step when walking.

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

ARO1380L

the machine, use the steps and handrails, and maintain a

Figure 30

three-point contact

(both feet and one hand or both hands

and one foot) to support yourself securely.

If the job requires it, wear protective clothing.

Safety

OP000994

1-38

To prevent injury from slipping or falling, when working on

the hood or covers, never use any part except the

inspection passage fitted with nonslip pads.

Lock Inspection Covers

When carrying out maintenance with the inspection cover

open, lock the cover securely in position with the lock bar.

If maintenance work is carried out with the inspection cover

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

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

Crushing Prevention and Cutting

Prevention

You should always have at least two people working

together if the engine must be run during service. One

person needs to remain in the operator's seat, ready to

work the controls or stop the machine and shut off the

engine.

Unless you are instructed otherwise, never attempt

adjustments while the machine is moving or while the

engine is running.

Stay clear of all rotating parts and moving parts.

Keep objects away from moving fan blades. The fan blades

will throw objects and the fan blades can cut objects.

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

gloves when you handle a wire rope cable.

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

The loose retainer pin can injure personnel. Make sure that

the area is clear of people when you strike a retainer pin.

To avoid injury to your eyes, wear protective glasses when

you strike a retainer pin.

Do Not Run Engine If Repairs or Work

Are Being Performed Alone

You should always have at least two people working

together if engine must be run during service. One person

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

stop machine and shut "OFF" engine.

Always Use Adequate Equipment

Supports and Blocking

Do not allow weight or equipment loads to remain

suspended. Lower everything to ground before leaving

operator's seat. Do not use hollow, cracked or unsteady,

Safety

OP000994

1-39

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 firm, level ground and lower all equipment

before shutting down and switching "OFF" controls. When

engine lube oil, gearbox lubricant or other fluids require

change, wait for fluid temperatures to decrease to a

moderate level before removing drain plugs.

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

warm. Do not drain fluids at temperatures exceeding

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

Safety

OP000994

1-40

Hydraulic Cylinder Seals Require

Periodic Replacement

Check cylinder drift rate at regular intervals. Overhaul seal

kits are available through DOOSAN.

High-pressure Hydraulic Lines Can Store

a Great Deal of Energy

Exposed hydraulic hoses on arm could react with explosive

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

work site hazard. Extra safety guards may be required.

NEVER allow hoses to be hit, bent or interfered with during

operation.

Cool Down Is Required Before Radiator

or Reservoir Checks

Shut down engine and allow heat to dissipate before

performing service on engine radiator or hydraulic fluid

reservoir. Both assemblies have air vent levers at or near fill

cap for venting built-up air pressure. Release levers before

trying to take off fill caps and LOOSEN CAPS SLOWLY,

before removal.

HAOA060L

Figure 31

Safety

OP000994

1-41

Precautions with High-pressure Line,

Tubes and Hoses

When inspecting or replacing high-pressure piping or hoses,

check that the pressure has been released from the circuit.

Failure to release the pressure may lead to serious injury.

Always do the following:

•

Wear protective glasses and leather gloves.

•

Fluid leaks from hydraulic hoses or pressurized

components can be difficult to see but pressurized

oil has enough force to pierce the skin and cause

serious injury. Always use a piece of wood or

cardboard to check for suspected hydraulic leaks.

Never use your hands or expose your fingers.

•

Do not bend high-pressure lines. Do not strike

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

hoses that are bent or damaged.

•

Make sure that all clamps, guards and heat

shields are installed correctly to prevent vibration,

rubbing against other parts, and excessive heat

during operation.

HDO1045I

- If any of the following conditions are found,

Figure 32

replace the part.

- Damage or leakage from hose end.

- Wear, damage, cutting of covering, or

exposure of strengthening wire layer.

- Cover portion is swollen in places.

- There is twisting or crushing at movable

parts of hose.

- Foreign material is embedded in the

covering.

- Hose end is deformed.

NOTE: Refer to

“Hose In-service Lifetime Limit

(European

Standard

ISO 8331

and

EN982 CEN)”

on page 4-82, for additional

European regulations.

Safety

OP000994

1-42

Obtain Immediate Medical Attention if

Pressurized Oil Pierces Skin.

WARNING

Failure to obtain prompt medical assistance could result

in gangrene or other serious damage to tissue.

Use Correct Replacement Fasteners

Tightened to Proper Torque

Refer to "General Maintenance" section of Shop Manual for

information on tightening torques and recommended

assembly compounds and always use correct part.

Poor or incorrect fastener connections can dangerously

weaken assemblies.

Safety Critical Parts Must Be Replaced

Periodically

Replace following fire related components as soon as they

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

intervals, whether or not deterioration is visible:

•

Fuel system flexible hoses, the tank overflow drain

hose and the fuel fill cap.

•

Hydraulic system hoses, especially the pump

outlet lines and front and rear pump branch

hoses.

•

Keep mounting brackets and hose and cable

routing straps tight. Hose routing should have

gradual bends.

Safety

OP000994

1-43

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:

HAOA470L

•

Never dump waste oil in a sewer system, rivers,

Figure 33

etc.

•

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 overinflate. Inspect tires

and wheels daily. When inflating tires, follow procedures in

Maintenance Section, which include using an extension to

allow you to avoid standing in front of or over a tire. Do not

change a tire unless you have both experience and proper

equipment.

NOTE: Refer to

“Recommended Air Pressure” on

page 4-103

Safety

OP000994

1-44

Decreasing Risk of Injuries or Death

From Boom and Bucket

DANGER

When operating machine or making repairs, never allow

bystanders in the operational zone or repair area.

Operation and service personnel must be careful when

working around the machine, especially around the

boom and bucket.

An unexpected fall of the front structure may cause

injuries or death.

While operating a machine, do not let people enter the

operational area. The sudden collapse of the front

structure caused from a hose failure may result in

injuries or death.

Figure 34

When stopping or parking the machine, lower the front

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

the front structure caused from a hose failure may

result in injuries or death.

Figure 35

Safety

OP000994

1-45

When repairing or inspecting the machine, with the

front structure raised in the air, firmly support the front

structure. When installing the supporting structure,

verify that it can handle the load.

High-pressure loads between the boom structure and

support may cause the support to slip, causing the

boom to collapse, leading to injuries or death. Take the

installation location of support and supporting surface

into consideration.

A supporting structure must be used, when

disconnecting front hoses or removing any other

mechanical component related to the front structure.

High-pressure oil can be ejected from the front cylinder

to release its static pressure and force. A sudden shift

of a front structure load may cause a boom collapse

leading to injuries or death.

FG004996

Figure 36

WARNING

Pressurized oil has enough force to pierce the skin

and cause a serious injury.

Safety

OP000994

1-46

BATTERY

Battery Hazard Prevention

Battery electrolyte contains diluted sulfuric acid and batteries

generate hydrogen gas. Hydrogen gas is highly explosive,

and mistakes in handling them can cause serious injury or

fire. To prevent problems, always do the following:

•

Do not smoke or bring any flame near the battery.

•

When working with batteries, ALWAYS wear

safety glasses and rubber gloves.

•

If you spill battery electrolyte on yourself or your

clothes, immediately flush the area with water.

•

If battery electrolyte gets into your eyes, flush

them immediately with large quantities of water

and see a doctor at once.

•

If you accidentally drink battery electrolyte, drink a

large quantity of water or milk, raw egg or

vegetable oil. Call a doctor or poison prevention

center immediately.

•

When cleaning the top surface of the battery,

wipe it with a clean, damp cloth. Never use

gasoline, thinner, or any other organic solvent or

detergent.

•

Tighten the battery caps securely.

•

Explosive battery gas can be set off by sparks

from accidental contact or static discharge. Turn

"OFF" all switches and engine when working on

batteries. Keep battery terminals tight. Contact

between a loose terminal and post can create an

Figure 37

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.

Safety

OP000994

1-47

Disconnect Batteries Before Electrical

Service or Electrical Welding

Remove cable to negative terminal first when disconnecting

cable. Connect positive terminal cables first when installing a

battery.

Use Low Heat Portable Lighting

Hot surfaces on trouble lights or portable work lights can set

off fuel or battery explosive gases.

Boost Starting or Charging Engine

Batteries

If any mistake is made in the method of connecting the

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

the following:

•

Turn off all electrical equipment before connecting

leads to the battery. This includes electrical

switches on the battery charger or boost starting

equipment.

HAOA310L

•

When boost starting from another machine or

Figure 38

vehicle do not allow the 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 nonseries connected

positive terminals and between the negative

terminal of the booster battery and the metal

frame of the machine being boosted or charged.

Refer to the procedure and illustration in “Starting

with Auxiliary Batteries” on page 3-8 of this

manual.

•

Connect positive cable first when installing cables

and disconnect the negative cable first when

removing them. The final cable connection, at the

metal frame of the machine being charged or

boost started, must be as far away from the

batteries as possible.

Safety

OP000994

1-48

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.

Safety

OP000994

1-49

SHIPPING AND

TRANSPORTATION

Obey State and Local Over-the-Road

Regulations

Check state and local restrictions regarding weight, width

and length of a load before making any other preparation for

transport.

The hauling vehicle, trailer and load must all be in

compliance with local regulations governing the intended

shipping route.

Partial disassembly or teardown of wheel loader may be

necessary to meet travel restrictions or particular conditions

at the work site.

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

Maintenance Manual for information on loading, unloading

and towing.

Safety

OP000994

1-50

OP000995

2Operating Controls

The "Operating Controls" section presented here consists of

the following groups:

“Component Locations” on page 2-2

“Operator's Area” on page 2-4

“Steering Console and Pedals” on page 2-5

“Front Instrument Panel” on page 2-16

“Right Side Switch Panel” on page 2-27

“Setting Main Menu” on page 2-42

“Various Cabin Locations” on page 2-50

“Heater and Air Conditioner Operation” on page 2-54

“Stereo / CD Player (Optional)” on page 2-59

10.

“Seat Adjustment (Standard)” on page 2-61

11.

“Seat Adjustment (Optional)” on page 2-63

12.

“Seat Belt” on page 2-65

13.

“Door side latch” on page 2-66

14.

“Arm Rest” on page 2-67

15.

“Fuse Box/Relay” on page 2-68

Each group is explained with a point location drawing or

photo and a brief description of each control, switch, gauge

or valve.

Indicator lights work besides the gauges on the instrument

panel. The operator should monitor machine pressure on the

instrument panel along with indicator lights. These lights will

only show that there is a problem.

WARNING

Warning lights. When any one or more of the warning

lights on the control console come "ON", immediately

stop operation and shut down unit. Investigate and

correct problem before proceeding with operation.

Operating Controls

OP000995

2-1

Reference

Description

Number

Bucket Teeth

Operator's Cabin

Bucket

Air Cleaner

Air Conditioner Condenser

Engine Air Intake Precleaner

Rear Wheel Cover

Engine

Battery Box

Muffler

Rear Light

CAC Cooler

Counterweight

Radiator

Fan Motor

Grille

Fre-fuel Filter

Fan

Muffler Tail Pipe

Fuel Tank

Oil Tank

Fuel Filter

Tilt Lever

Rear Axle

Front Wheel Cover

Boom Cylinder

Bucket Cylinder

Link

Headlight Support

Front Axle

Ladder

Loader Arm

Work Light

Operating Controls

OP000995

2-3

STEERING CONSOLE AND

PEDALS

FG015174

Figure 3

Reference

Description

Number

Starter Switch

Kick-down Switch

Horn Button

Transmission Lever

Combination Switch

Front Instrument Panel

(See page 2-16)

Accelerator Pedal

Hour Meter

Steering Wheel Adjustment

Lever

Automatic Shift Mode Switch

Brake Pedals

Hazard Warning Light Switch

Steering Wheel

Multifunction Display Switch

Operating Controls

OP000995

2-5

Starter Switch

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

down engine for equipment operation.

O. Turning the switch to this position turns the

engine "OFF" along with its electrical system. In

this position the engine is "OFF" but the interior

cabin light and fuel tank transfer pump

(if

equipped) are functional.

Turning the switch to this position turns the

FG000014

engine electrical system "ON". When the switch is

Figure 4

first turned "ON" the six indicator/warning lights

across the top of the instrument panel, will light

for approximately two seconds. The battery

warning light and the engine oil pressure warning

light should remain "ON" after the other four have

turned "OFF".

NOTE: Preheat Indicator Light - The operation of

the preheat cycle depends on coolant

temperature. When the engine coolant is

cold enough, the preheat indicator light will

remain "ON" until the engine preheat cycle

is completed. When preheat cycle

completes, the indicator light will turn

"OFF". When the light turns "OFF",

engage the starter.

. Moving switch to this position will crank engine.

When engine starts, release key and allow it to

return to the "I" (ON) position. Do not operate the

starter switch for more than fifteen seconds at a

time. This will help prevent damage to starter.

WARNING

DO NOT USE STARTING FLUIDS. The preheat

system could cause the starting fluid to explode.

Starting fluids should never be used.

Operating Controls

OP000995

2-6

Combination Switch

Left Side Directional Switch

- Pushing lever

forward, activates left outside directional lights and

directional indicator light on instrument panel.

Right Side Directional Switch - Pulling lever back,

activates right outside directional lights and

directional indicator light on instrument panel.

NOTE: When turn is completed the lever

automatically returns to the "NEUTRAL"

AHO0920L

position. Should it not, it can be manually

Figure 8

returned by hand.

NOTE: Turn signals will function with starter

switch in "OFF" position.

Window Washer Switch - When the outside area

of the lever is pressed, it activates the washer

pump and sprays fluid on the windshield.

(Only

while being pressed.)

NOTE: Do not operate the windshield washer

without any fluid. If operate without any

fluid, the washer motor may be damaged.

Check level in washer tank, and add fluid

as required.

NOTE: Using soapy water or synthetic detergent

instead of window cleaning fluid, may

damage the wiper blade or painted

surfaces. Use standard window cleaning

fluid: SSK703

Horn Button - The center button on end of lever

activates horn. (Only while being pressed.)

Wiper Switch

- Activates wipers when outside

area of lever is rotated.

J: Intermittent Mode - wipes every five seconds.

0: Stop (Off).

I: Normal Speed Mode.

II: High Speed Mode.

Neutral Position - Normal low beams.

Pull Up

1st Step

- Momentarily turns "ON" both

the low beams and high beams. (Lever returns to

"NEUTRAL"

position when released.)

Pull Up

2nd Step - The high beams turn "ON."

(Lever returns to "NEUTRAL" position when

released.) To turn "OFF" lights, pull lever up to

2nd step again.

NOTE: High and low beams will only function with the

FG015170

headlight switch in the "||" position.

Figure 9

Operating Controls

OP000995

2-8

4. 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

FG003937

consumption, cause short life on the engine, and in

Figure 10

the worst case lead to a serious accident.

5. Steering Wheel Adjustment Lever

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

moved to the most convenient position for the operator.

Adjusting Steering Wheel Tilt

Pull lever

(1, Figure

12) upward and move wheel (2,

Figure

12) to desired position. Push lever down

(Tilt

angle is 21°).

Adjusting Steering Wheel Telescopic

FG003887

Pull lever

(1, Figure

12) upward and move wheel (2,

Figure 11

Figure

12) to desired position. Push lever down

(telescopic stroke is 80 mm)

RELEASE

LOCK

FG003888

Figure 12

Operating Controls

OP000995

2-9

6. Brake Pedal (Right and Left Pedals)

Pressing brake pedal will apply the brakes to the

loader. The brake pedal modes can be switched from

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

the transmission cutoff switch (See page 2-36).

CAUTION

FG002183

When descending down an incline, slow down the

Figure 13

machine by using both the brake pedal and the

engine as a brake by shifting the transmission to a

lower gear. Using the brake pedal too often might

lead to insufficient oil pressure, thus making it

difficult to brake the loader.

IMPORTANT

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

cause brake disk to wear faster than normal, and

this could cause brake failure.

7. Steering Wheel

Rotating steering wheel controls position of front wheels

and this determines direction of machine travel.

FG003939

Figure 14

8. Kick-down Switch (Two places)

When transmission is in 2nd gear, pressing this switch

will shift transmission into

1st gear. This will allow the

driver to perform a quick digging movement.

NOTE: Kick-down is "RELEASED" when transmission

is placed in "NEUTRAL" position or the switch is

pressed again.

Kick-down function range:

AHO0900L

•

Automatic: 2nd, 3rd, 4th.

Figure 15

•

Manual: 2nd.

Operating Controls

OP000995

2-10

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

button in the tip of the pilot control valve lever

(joystick)

(Right one of two levers).

FG003940

Figure 16

FG003936

Figure 17

9. Transmission Lever

F Forward

- When the lever is pushed forward,

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

4th are available.

N Neutral - When the lever is returned to the center

position, between forward and reverse, the

transmission is in "NEUTRAL".

R Reverse

- When the lever is pulled back,

transmission is in "REVERSE"

1st,

2nd and 3rd

HAAA3680

are available.

Figure 18

Rotating the switch shifts transmission between

1st,

2nd, 3rd or 4th gears.

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

that indicates, gears, direction of travel, error

codes and kick-down activation.

(See page

2-17)

Operating Controls

OP000995

2-11

A transmission neutral lever lock is in base of

transmission lever. This neutral lever lock prevents the

transmission lever from being moved out of

"NEUTRAL".

N "NEUTRAL LOCK" position. Prevents lever from

being moved out of "NEUTRAL".

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

"NEUTRAL" to "FORWARD and REVERSE".

FG003943

CAUTION

Figure 19

"LOCK" transmission lever. Whenever machine is

parked, "LOCK" transmission lever in "NEUTRAL"

to prevent accidental machine movement.

10. Front Instrument Panel

See “Front Instrument Panel” on page 2-16.

F/R

01/04

[FRI]

11:32

STOP

524Km

km/h

x100r/min

FG015438

Figure 20

11. Hour Meter

A LCD Meter that records total time. When engine is

running, the hourglass icon blinks every four seconds.

This shows that the hour meter is working.

FG004112

Figure 21

Operating Controls

OP000995

2-12

12. Automatic Shift Mode Switch

•

Auto 1-4 mode (Working mode)

1-4

Turn the gear selector control to gear

MAN

2-4

position 4

Set the shift mode selector to "Auto 1-4"

Selector the directional gear and accelerate

the machine.

Up and downshifts are made automatically

FG004181

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

Figure 22

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

It is unnecessary to use kick-down function

for

1st gear.

•

Auto 2-4 mode (Travel mode)

1-3 is same as Auto 1-4

Up and downshifts are made automatically

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

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

Kick-down switch must be used for shifting to

1st gear.

•

Manual mode

After starting gear shifting is done manually.

13. Hazard Warning Light Switch

This warning light is used when the equipment is

stopped due to a malfunction or when an emergency

occurs. When this switch is pressed the directional

indicator lights in front and back of the machine light

up and flash, warning others in the area. At the same

time the directional indicator lights on the instrument

panel will turn "ON" to warn the operator. The hazard

warning lights operate independent of the starter

switch.

2665C

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

Figure 23

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.

Operating Controls

OP000995

2-13

Gauges

Reference

Description

Number

Fuel Gauge

Engine Coolant Temperature

Gauge

Speedometer

Transmission Oil Temperature

Hour Meter

Gauge

Tachometer

Multifunction Display

Warning and Indicator Lights

Reference

Description

Number

Preheat Indicator Light

Parking Brake Indicator Light

Air Cleaner Clogged Warning

Emergency Steering Indicator

Light

Light (Optional)

Battery Warning Light

Engine Warning Light

Left Turn and Hazard Warning

Engine Stop Light

Light

Engine Oil Pressure Warning

High Beam Indicator Light

Light

Right Turn and Hazard

Engine Coolant Temperature

Warning Light

Work Light Indicator Light

Reverse Fan Indicator Light

Brake Fluid Pressure Warning

Electric Steering Select

Light

Indicator Light (Optional)

F/R (Forward/Reverse) Selector

Water In Fuel Warning

Indicator Light

IMPORTANT

All of gauge and warning lights

(except for the turn

lights, high beam light, work light and transmission

cutoff light) turn "ON" for two seconds with a warning

buzzer sound when the starter switch is turned to the

"I" (ON) position.

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

cause and replace.

Operating Controls

OP000995

2-17

1. Fuel Gauge

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

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

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

soon as possible. When the pointer comes close to the

"E"

(red zone), approximately

90 L (23 U.S. gal.) of

fuel remains.

FG003948

Figure 26

2. Speedometer

This meter displays speed at which vehicle is traveling.

FG004182

Figure 27

3. Hour Meter

A LCD meter that records total time. When engine is

running, the hourglass icon blinks every four seconds.

This shows that the hour meter is working.

HA0O2012

Figure 28

Operating Controls

OP000995

2-18

4. Tachometer

This meter displays engine speed in revolutions per

minute.

FG004183

Figure 29

5. Engine Coolant Temperature Gauge

This gauge displays temperature of engine coolant.

CAUTION

When the pointer indicates red zone, it means the

engine is overheated. Stop the operation, let the

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

FG003949

Do not shut down engine. If engine is shut down

heat surge may occur.

Figure 30

6. Transmission Oil Temperature Gauge

This gauge displays temperature of oil in transmission

converter and transmission circuit.

CAUTION

When the pointer indicates red zone, it means the

transmission is overheated. Stop the operation, let

the engine run at low rpm and wait for

FG003950

transmission to cool down.

Figure 31

Operating Controls

OP000995

2-19

7. Multifunction Display

A multifunction display is in the gauge panel on the

dash. The LCD indicates, gears, direction of travel,

F/R

01/04

[FRI]

11:32

STOP

error codes and activated kick-down.

524Km

km/h

x100r/min

FG015439

Figure 32

A digital clock, shows the current time. Refer to

the

“Setting Main Menu” on page 2-42 for time

setting.

01/04

[FRI]

11:32

Indicates shift mode. "M" is displayed for manual

mode, "A1" is displayed for auto 1-4, and "A2" is

displayed for auto 2-4.

524 km

Indicates travel direction and gear selection. First

number displays gear range, alphabet displays

travel direction. (See Figure 34 for more details.)

C D

FG015179

Indicates gear range of transmission lever.

Figure 33

The engine rpm is normally displayed at the

bottom of the screen when the starter switch is

first turned "ON." Each time the display selector

button is pressed, the digital readout changes in

* Current actual gear

the following sequence; engine speed

(rpm)

→

battery voltage (Volt) → odd meter (km).

xF - x : Gear range

- F(R) : Travel direction

FG015436

Figure 34

Operating Controls

OP000995

2-20

8. Preheat Indicator Light

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

preheat function is operating. Do not start engine as

long as this light is "ON".

HAOA639L

Figure 35

9. Air Cleaner Clogged Warning Light

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

in the air filter and is beginning to restrict flow of air.

Clean or replace air filter before continuing to operate

machine. To turn indicator light "OFF", turn starter

switch "OFF" and then back "ON".

HAOA660L

Figure 36

10. Battery Warning Light

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

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

running this red light should turn "OFF". If light remains

"ON" when engine is running, alternator is defective.

HAOA610L

Figure 37

Operating Controls

OP000995

2-21

11. Left Turn and Hazard Warning Light

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

Both lights blink when warning lights are turned "ON".

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

they blink faster than normal, a light bulb is not

operating or flasher solenoid is damaged.

FG004173

Figure 38

12. High Beam Indicator Light

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

are turned to "HIGH BEAM".

HAOD394L

Figure 39

13. Right Turn and Hazard Warning

Light

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

Both lights blink when warning lights are turned "ON".

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

they blink faster than normal, a light bulb is not

operating or flasher solenoid is damaged.

FG004174

Figure 40

Operating Controls

OP000995

2-22

14. Work Light Indicator Light

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

rear work lights are activated.

Figure 41

15. Brake Fluid Pressure Warning Light

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

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

also sounds.

WARNING

Never operate or travel machine when this light is

"ON" or when alarm is sounding. Always

HA0O2024

investigate cause of the drop in brake fluid

Figure 42

pressure, and repair problem before operating or

traveling machine.

16. F/R (Forward/Reverse) Selector

Indicator Light (Optional)

This indicator light will turn "ON", when the

2nd gear

function is selected.

NOTE: See

“F/R

(Forward/Reverse) Travel Control

F/R

System (Optional)” on page 3-16 for further

information.

BSO0510L

Figure 43

Operating Controls

OP000995

2-23

17. Parking Brake Indicator Light

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

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

brake is applied, a warning alarm will sound.

WARNING

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

it could cause premature wear or damage the

0717A

brake.

Figure 44

Always "RELEASE" parking brake and make sure

this light is "OFF" before traveling machine.

18. Emergency Steering Indicator Light

(Optional)

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

steering system is activated due to a hydraulic failure.

Immediately stop any operation, stop machine, "APPLY"

parking brake, and shut down engine.

DANGER

AJO0450L

Figure 45

Emergency steering indicator light. If this light

turns "ON" while operating machine, discontinue

operation immediately. This light indicates that

there is a serve problem with the unit.

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

being tested.

19. Engine Warning Light (Yellow Color)

This light will turn "ON" when a nonfatal system error

occurs with the engine or its peripherals. If this light

turns "ON", check the engine as described under the

engine diagnostic switch 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 diagnostic mode.

AQO0040L

Figure 46

Operating Controls

OP000995

2-24

20. Engine Stop Light (Red Color) (Not

Used)

21. Engine Oil Pressure Warning Light

This indicator light will turn "ON" when the engine

starter switch is turned "ON", and should go "OFF"

after the engine starts. For example, if the engine oil

pressure becomes too low, the light will turn "ON" and

a warning buzzer will sound. If this happens, shut the

engine down immediately and determine the cause of

the problem. If you continue to work when this light is

"ON", it will result in serious engine damage.

HAOA620L

Figure 47

CAUTION

If you continue to work when this light is "ON", it

will result in serious engine damage.

22. Engine Coolant Temperature Warning

Light

If engine coolant overheats, this light will turn "ON", an

alarm will sound, and the engine speed will be

automatically reduced, until coolant temperature drops.

Do not turn engine "OFF" because this will cause

coolant temperature to rise and may cause engine to

siege due to heat surge.

NOTE: Check the engine coolant temperature gauge. If

HAOD350L

the gauge pointer moves into the red zone, the

Figure 48

engine coolant temperature warning light will

turn "ON", a warning buzzer will sound, and the

engine speed will be automatically reduced.

Allow the engine to run at low idle speed until

the temperature gauge registers in the blue

zone again. When the blue zone is reached,

allow the engine to idle for an additional three -

five minutes before shutting down the engine. If

not allowed to idle, heat surge may develop

which will damage the engine. Allowing the

engine to idle will dissipate heat. Check the

coolant level, look for a loose fan belt, inspect

for debris around radiator, and so on.

When the temperature reaches the normal

range, the engine speed will automatically

recover.

Operating Controls

OP000995

2-25

23. Cooling Fan Reverse Rotation

Indicator Light

This indicator light will turn "ON", when the cooling fan

rotates in the reverse direction.

FG004185

Figure 49

24. Electric Steering Select Indicator

Light

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

steering system is selected.

FG004186

Figure 50

25. Water In Fuel Warning

This symbol indicates when the water is full in the fuel

prefilter

When this symbol appears drain the water from the

fuel prefilter as soon as possible.

FG013744

Figure 51

Operating Controls

OP000995

2-26

RIGHT SIDE SWITCH PANEL

1, 1A

FG015390

Figure 52

Reference

Description

Number

Pilot Control Valve Lever

Reverse Fan Switch

(Two Lever)

Idle Speed Control Speed

Pilot Control Valve Lever

Boom Float Switch (Optional)

(Joystick) (Optional)

LIS Switch (Optional)

Kick-down Switch

Seat Heater Switch (Optional)

Horn Button

Fuel Heater Switch (Optional)

Cigar Lighter

Emergency Steering Test

Economic Mode Switch

Switch (Optional)

Alternative Idle Switch

Rotating Beacon Light Switch

Headlight Switch

(Optional)

Front Work Light Switch

Power Socket for 12 Volt

Rear Work Light Switch

F/R (Forward/Reverse) Selector

Switch (Optional)

Rear Wiper Switch

F/R (Forward/Reverse) Control

Pilot Cutoff Switch

Switch (Optional)

Parking Brake Switch

Cup Holder

Transmission Cutoff Switch

Mirror Heating Switch

Operating Controls

OP000995

2-27

1. Pilot Control Valve Lever (Two

Lever)

Move left control lever forward (2, Figure 53) to dump

bucket, or rearward (4, Figure 53) to roll back bucket.

Move right control lever forward (3, Figure 53) to lower

boom or rearward (5, Figure 53) to raise boom.

Float

(right lever in full forward detent position

(1,

Figure

53)): This position allows oil flow in and out

both ends of cylinders so the bucket can follow the

FG003952

contour of the ground. Manually release lever from the

Figure 53

position.

BOOM FLOAT

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

BUCKET DUMP

(6, Figure 53)):Bucket will return to set dig position.

BOOM LOWER

Boom Height Kick-out right lever in full rearward detent

BUCKET CROWD

position

(7, Figure

53)): Lever will remain in this

BOOM RAISE

position until boom is at a preset height, then will

BUCKET RETURN TO DIG

return to neutral automatically.

BOOM HEIGHT KICK-OUT

A. Kick-down Switch (Two Places)

(See page 2-10)

FG003940

Figure 54

B. Horn Switch

(Two Places)

/ Log Fork Switch

(Optional)

•

Horn switch function.

•

Log fork switch function.

When the log forks control lever is pushed

forward or pulled back while this switch is

pressed, the log forks are allowed to open or

closed. (See page 2-29)

FG003935

Figure 55

Operating Controls

OP000995

2-28

1A. Pilot Control Valve Lever (Joystick)

(Optional)

If loader is equipped with log forks this lever controls

boom, bucket and log forks.

Used to position bucket and boom. This lever is

capable of raising or lowering boom, and crowding or

dumping bucket. When machine is being traveled, the

lever

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

movement of bucket or boom. To "LOCK" out lever

BSO0530L

(joystick), place pilot cutoff switch in "LOCKED"

Figure 56

position.

Pilot control valve lever (joystick) operating pattern and

description of operation.

Figure 57

HL.

Hold lever

Lower Mode

Lower

HC. Hold lever in

C. Bucket Crowd

Neutral

Bucket Dump

Bucket Crowd

Raise

HR.

Hold lever

Raise Mode

A. When the log forks control lever (6, Figure 56) is

pushed forward the log forks are allowed to open.

B. When the log forks control lever (6, Figure 56) is

pulled back the log forks are allowed to close.

This lever is capable of forward travel and reverse

travel (2nd gear function).

Neutral Switch

When this switch is pressed,

2nd gear function

will be operated, and then 2nd gear indicator light

turns "ON".

When 2nd gear function is operated, this switch is

pressed, and then machine is neutral.

Operating Controls

OP000995

2-29

Forward Switch

When this switch is pressed at forward traveling

while "KD"

(5, Figure

56) switch is pressed,

machine can travel forward. When machine is

travelled, it can convert forward and reverse travel

without pressing "KD" (5, Figure 56) switch.

Reverse Switch

When this switch is pressed at reverse traveling

while "KD"

(5, Figure

56) switch is pressed,

machine can travel reverse. When machine is

travelled, it can convert forward and reverse travel

without pressing "KD" (5, Figure 56) switch.

Horn Switch

(See page 2-31)

Kick-down Switch

(See page 2-30)

NOTE: Operating condition of 2nd gear function.

•

Start a engine.

•

Transmission lever is neutral.

•

Parking brake switch is off (release).

NOTE: Release condition of 2nd gear function.

•

When the transmission lever will be push forward

or pull reverse.

•

When the parking brake switch turns "ON".

•

When the starter switch turns "OFF".

2. Kick-down Switch (Two Places)

Kick-down Switch Function

- When transmission is in

2nd gear, pressing this switch

(Figure

59) will shift

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

perform a quick digging movement.

Kick-down function range:

•

Automatic: 2nd, 3rd, 4th.

•

Manual: 2nd.

FG003936

NOTE: Kick-down is "RELEASED" when transmission

Figure 58

is placed in "NEUTRAL" position or the switch is

pressed again.

Operating Controls

OP000995

2-30

4. Cigar Lighter

Push the lighter all the way into the socket and release

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

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

out and have it serviced.

IMPORTANT

The cigar lighter is powered by a

24 volt circuit.

Never plug any 12 volt device into the cigar lighter.

HAOA780L

Figure 62

5. Economic Mode Switch

This economic mode switch allows the operator to

switch between 100% throttle torque and droop curve

and about an 80% derated torque curve and droop. In

the economy mode, fuel consumption is clearly reduced

by utilising a reduced-power characteristic map for the

engine. This is of benifit with all general loading work.

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

position, and

100% torque is permitted for hard

digging or driving up sleep inclines.

FG004998

Figure 63

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

limits engine torque to 80% of maximum.

6. Alternative Idle Switch

The alternate low idle switch allows operator to select

an alternate idle speed. This feature is activated

whenever the normally open alternate low idle switch is

closed and

0 volts are detected by the ECM on the

alternate low idle signal line. This is convenient to use

when operator wants to decrease warm-up time in the

winter and improve machine acceleration.

O. "OFF" position.

AQO0100L

"ON" position.

Figure 64

Operating Controls

OP000995

2-32

7. Headlight Switch

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

tail, instrument panel, switch and headlights.

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

engine not running, the pilot buzzer will

sound to warn the operator that the

batteries are being discharged.

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

tail, instrument panel and switch lights.

FG003976

II.

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

Figure 65

tail, instrument panel, and headlights.

CAUTION

Do not leave clearance, tail, instrument panel or

headlights "ON" when the engine is not running.

Leaving lights "ON" with the engine shut down will

discharge batteries.

8. Front Work Light Switch

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

mounted on the front top of cabin.

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

mounted on the front top of cabin.

CAUTION

HAOQ071L

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

Figure 66

public roads.

Operating Controls

OP000995

2-33

9. Rear Work Light Switch

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

mounted on the rear top of cabin and the sides of

radiator.

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

mounted on the sides of radiator.

II.

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

mounted on the rear top of cabin and the top of

the sides of radiator.

AHO0850L

Figure 67

CAUTION

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

public roads.

10. Rear Wiper Switch

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

wiper mounted on rear windshield of operator's

cabin.

In this position, windshield washer fluid sprays

onto the rear windshield while running the rear

wiper. When released, the switch returns to the

"O" (OFF) position.

II.

In this position, this switch turns "ON" windshield

HAOD421L

wiper mounted on rear windshield of operator's

Figure 68

cabin.

CAUTION

The washer pump can be damaged if it is activated

while there is no fluid in the tank.

The fluid level must be checked regularly and

refilled as necessary.

Using soap or other solvents instead of the

recommended washer may damage the wiper

blades and the paint finish. Only use the

recommended washer fluid or equivalent.

Operating Controls

OP000995

2-34

11. Pilot Cutoff Switch

O. In this position the operator cannot operate the

pilot control valve lever (joystick).

In this position the operator can fully control the

movement of the pilot control valve lever

(joystick).

CAUTION

HBOI110L

Figure 69

When driving or parking, the pilot cutoff switch

must be changed to "O" (OFF) position.

12. Parking Brake switch

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

and the indicator light on the front instrument

panel turns "OFF".

In this position, the parking brake is "APPLIED"

and the indicator light on the front instrument

panel comes "ON". This brake can also be used

as an emergency brake.

HA0O2019

Figure 70

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

F/R

STOP

01/04

[FRI]

11:32

Do not use the parking brake to stop the loader,

524Km

except in an emergency; otherwise, it might cause

premature wear or damage of the brake.

km/h

x100r/min

FG015440

Figure 71

Operating Controls

OP000995

2-35

13. Transmission Cutoff Switch

This switch changes the mode of the brake pedal from

"INCHING" to "NO INCHING".

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

selected.

In the "NO INCHING" mode, the power

transmission line is still connected when the brake

pedal is pressed, thus, making it easier to start off

on an incline. This mode is also suitable for

HA3O2018

traveling, because both dynamic engine braking

Figure 72

and the service brake can be used when

descending grades.

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

In this mode, the transmission is put in

"NEUTRAL" by pressing the left brake pedal. This

mode is suitable for a load handling operation.

When the accelerator pedal is pressed in this

setting, more power is concentrated on the load

handling system, to quicken the boom lifting

speed.

NOTE:

1) Transmission "CUTOFF" function dose not

operate at 3rd and 4th gear for protection of

transmission.

2) Despite transmission "CUTOFF" switch, the

right brake pedal has braking function only.

WARNING

When pressing brake pedal while traveling or

working on a slope, set this switch to "O" for

dynamic engine braking.

14. Mirror Heating Switch

This switch is used to operate a heater installed in the

mirror. Press the switch and the mirror heater will

remove frost and ice from mirror.

O. "OFF" position.

"ON" position.

FG004187

Figure 73

Operating Controls

OP000995

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Doosan DL420. Operation and Maintenance Manual (2009) - page 1