Doosan DL420. Operation and Maintenance Manual (2009)

15. Reverse Fan Switch

This switch causes the radiator cooling fan to rotate in

the reverse direction. The function of reversing the

direction of the radiator cooling fan is effective in

cleaning the radiator.

O. "OFF" position.

"ON" position.

Activate the switch for reverse rotation in the following

FG004188

order;

Figure 74

A. Turn the starter switch "O" (OFF) → "I" (ON) and

then turn the of the cooling fan reverse rotation

switch "O"

(OFF)

→ "I"

(ON) and start the

engine.

B. For reverse operation, the cooling fan reverse

rotation indicator light turns "ON" the same time.

C. To return to forward rotation, shut down engine,

change the position of the reverse switch "ON" →

"OFF", and start the engine again.

WARNING

Never travel or work in the reverse fan rotation

mode. This may cause damage to the cooling

system. Make sure that this switch is in the "O"

(OFF) position before starting the engine and

operating the machine.

16. Idle Speed Control Switch

The idle speed control allows the idle speed to be

adjusted 25 rpm increments by pressing the idle speed

control switch. The switch will only work from

700 to

1,200 rpm.

AQO0110L

Figure 75

Operating Controls

OP000995

2-37

17. Boom Float Switch (Optional)

Boom float allows the bucket to follow the contour of

the ground/working surface. When pressing this switch

and setting work lever to float position, the lever is

locked

(detent) and boom is lowered. When boom is

matched to setting position, the lever lock is released,

and lever is returned to "NEUTRAL" position. Boom

lowering is stopped.

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

float.

HAOA751L

Figure 77

In this position, this switch turns "ON" boom float.

18. Load Isolation System (LIS) Switch

(Optional)

This switch enables the boom cylinder to absorb shock

loading of the machine during traveling and working. It

improves dynamic stability, machine life, and

comfortability. It is most effective when traveling with

load in the bucket.

O. In this position, the LIS turned "OFF".

In this position, the LIS turned "ON" at all travel

FG004256

speeds.

Figure 78

II.

In this position, the LIS will "AUTOMATICALLY

TURN ON" if the forward travel speed exceed 6

km/h (3.7 MPH) or reverse travel speed exceed 4

km/h (2.5 MPH). LIS will automatically turn "OFF"

if the forward speed is less than

4 km/h

(2.5

MPH) or if reverse travel speed is less than

km/h (1.2 MPH).

Operating Controls

OP000995

2-38

19. Seat Heater Switch (Optional)

This switch is used to operate the seat heater. When

the switch is pressed, the seat heater starts to heat

seat.

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

heater.

In this position, this switch turns "ON" seat heater.

FG004189

Figure 79

20. Fuel Heater Switch (Optional)

This switch is used to operate the fuel heater. When

the switch is pressed, the fuel heater starts to heat

fuel. If the fuel temperature is 5°C and higher, the fuel

heater does not operate, even if switch in "I"

(ON)

position

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

heater.

In this position, this switch turns "ON" fuel heater.

FG004190

Figure 80

21. Emergency Steering Test Switch and

Automatic Test (optional)

Emergency Steering Test Switch

This switch is used to test whether the emergency

steering system is properly functioning.

The system must be tested during the start-up

procedure to ensure that the system is properly

functioning.

Test emergency steering system using the following

AJO0010L

procedure:

Figure 81

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

NOTE: Do not start engine.

B. Press emergency steering test switch and turn

steering wheel at the same time. If system is

functioning properly the unit should steer. The

emergency steering indicator light should turn

"ON".

NOTE: If unit does not steer, do not operate unit

until problem is corrected.

C. Release switch. Switch will automatically return to

"O" (OFF) position.

Operating Controls

OP000995

2-39

Automatic Test

This is a system check that tests the hydraulic oil

pressure in the emergency steering system lines. With

starter switch turn to "I"

(ON) position, an emergency

warning light on the front gauge panel will turn "ON"

for about three seconds.

WARNING

Do not press this switch continuously.

Continuously pressing switch will cause heavy

battery discharge. The emergency steering DC

motor uses high consumption of power.

22. Rotating Beacon Light Switch

(Optional)

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

beacon light.

In this position, this switch turns "ON" rotating

beacon light.

HAOA750L

Figure 82

23. Power Socket for 12 Volt

This is a power socket for only 12V DC devices.

This socket can be used for charging a cellular phone

or powering a small 12V DC electrical device.

Open the cap when using it.

12 V

NOTE: This socket is designed for small electrical

capacity devices. Do not use this socket for

large electrical capacity devices. Thus, damage

can be avoided.

HAAE1990

Figure 83

Operating Controls

OP000995

2-40

24. F/R (Forward/Reverse) Selector

Switch

O. In this position, the F/R control switch is "OFF"

In this position, the F/R control switch is activated.

When released the switch returns to the "O"

(OFF) position, but the system is still activated.

When this switch is depressed again, F/R control

switch is "OFF"

FG003977

NOTE:

1) When activating system, the transmission

lever and F/R control switch must be in

Figure 84

"NEUTRAL".

2) If the transmission lever is actuated (moved),

the gearshift functions of the F/R control switch

are deactivated, and forward/reverse travel is

again controlled by the transmission lever.

25. F/R (Forward/Reverse) Control Switch

To be able to use the forward/reverse function, the F/R

selector switch must first be depressed. When the

switch is activated, the F/R selector indicator light will

be turned "ON" in the instrument panel.

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

In this position, the machine travels "FORWARD"

II.

In this position, the machine travels "REVERSE"

NOTE: If the transmission lever is moved out of

FG015182

Figure 85

"NEUTRAL" while operating the F/R control

switch, the transmission lever will override the

switch. The F/R control switch system will

require, that the F/R selector switch to be

pressed again, with the transmission lever in

"NEUTRAL".

26. Cup Holder

Place to put beverages.

Operating Controls

OP000995

2-41

SETTING MAIN MENU

Multifunction Display Switch

By using a combination of the selector buttons, you can

review and set the contents of the display screen. Items

such as language, time, filter/oil information and AEB setting

can be checked, and if necessary, set with new information.

FG015186

Figure 86

1. Up Arrow Button

Up arrow button (

), is used to move a menu item

"Up" or to the "Left".

FG015187

Figure 87

2. Down Arrow Button

Down arrow button (

), is used to move a menu item

"Down" or to the "Right".

FG015188

Figure 88

Operating Controls

OP000995

2-42

3. Display Selector Button (ESC -

Escape)

Display selector button

(

), is used to change the

displayed information on the screen. Each time the

display selector button is pressed, the digital readout

ESC

changes.

In the normal display screen, the engine speed (rpm),

battery voltage

(volt) and odometer

(km) can be

displayed.

FG015189

Figure 89

NOTE: When this button is used for menu / exit button,

it is used to access to main menu or return to a

previous screen from each submenu.

4. Selection Button

Selection button (

), is used to set a menu or clear

the operating hour of filter/oil.

FG015190

Figure 90

Operating Controls

OP000995

2-43

Display Selection and Escaping

Display Selection

When the display button is pressed for more than three

seconds, the main menu screen is displayed.

MAIN MENU

01/04

[FRI]

11:32

1. Language

2. Set Clock

524 km

3. Filter/oil Info

< Normal Display >

< Main Menu Display >

FG015435

Figure 91

NOTE: If more than twenty seconds are spent in any menu,

without changing the screen, it will return to the

normal display screen.

Main Menu

The menu selection can be changed by pressing the "UP"

MAIN MENU

(

) or "DOWN" (

) buttons. The selected menu item will

be highlighted, and a cursor will appear by the menu item.

1. Language

When the selected menu item is highlighted, press the

2. Set Clock

"SELECT" (

) button to enter the next submenu.

3. Filter/oil Info

Language

Set Clock

FG015192

Filter

/ Oil Info

Figure 92

AEB Setting

MAIN MENU

4. AEB Setting

FG015193

Figure 93

Operating Controls

OP000995

2-44

Language

When the cursor is on "Language", press the "SELECT"

LANGUAGE

(

) button. The language submenu will appear.

The desired language can be selected by using the "UP"

(

) or "DOWN"(

) buttons.

2. English

The display can be set for the desired language.

Press the "SELECT"

(

) button to set the selected

language.

FG015194

NOTE: If more than twenty seconds are spent in the menu,

Figure 94

without changing the screen, it will return to the

normal display screen.

Set Clock

When the cursor is on "Set Clock", press the "SELECT"

SET CLOCK

(

) button. The set clock submenu will appear.

NOTE: If more than twenty seconds are spent in the menu,

02:30

without changing the screen, it will return to the

normal display screen.

2003 11/04

Setting Method

FG015195

Move the cursor to desired number by using the

Figure 95

"SELECT" (

) button. When selected the number will

flash.

Set the time by using the "UP"

(

) or "DOWN"(

)

buttons.

•

"+" (

), "-"

(

): Increase or decrease number.

•

"MOVE" (

): Confirm and move the cursor to

next number.

•

"ESC" (

): Exit to the main menu.

'00' Minute Setting

Simultaneously press the "SELECT"

(

) button and

"UP" (

) button.

If the displayed time is

30 minutes or less, the clock

will display the preceding hour.

If the displayed time is more than

30 minutes, the

clock will display the succeeding hour.

When the preceding hour is more than 23, the day will

be increased.

Operating Controls

OP000995

2-45

Menu Display Order and Icon Explanation

1. Fuel Filter → 2. Air Cleaner → 3. E/G Oil Filter → 4. Engine Oil → 5. Hydraulic Oil → 6. Coolant

Water

→ 7. Return Filter → 8. Pilot Filter → 9. Transmission Oil → 10. Transmission Oil Filter

Filter/Oil

Fuel

Air

E/G Oil

Engine

Hydraulic

Coolant

Return

Pilot

TransmissionTransmission

Name

Filter

Cleaner

Filter

Oil

Water

Filter

Oil

Oil Filter

Icon

FG015434

Figure 97

Filter / Oils Operating Hour Reset

After changing a filter or oil, reset the operating hour to zero

FILTER/OIL INFO

(Hrs: 0000). The next replacement period can than be easily

checked. The operating hours are only accumulated while

1. Fuel Filter

the engine is running.

RESET?

On the filter

/ oil information screen, press the "SELECT"

(

) button and then the reset screen will be displayed.

YES :

NO : ESC

On the reset screen, the operating hour can be changed to

zero hour (Hrs: 0000) by pressing the "SELECT" (

FG015197

If the "SELECT"

(

) button is pressed, the reset will be

Figure 98

completed. and the screen will be returned to the previous

menu.

If the "ESC"

(

) button is pressed, the screen will be

returned to the previous menu without being reset.

NOTE: If more than twenty seconds are spent in the menu,

without changing the screen, it will return to the

normal display screen.

The screen is returned to the main menu by pressing the

"ESC" (

) button.

Operating Controls

OP000995

2-47

AEB Setting

The AEB setting is for a menu that allows the AEB

AEB SETTING

(Automatic

Filling

Parameter

Adjustment)

transmission

to be done without connecting test

equipment.

Are you sure ?

A message for the present condition of AEB is

indicated in the display.

YES :

NO : ESC

AEB setting should be done every

1,000 Hours

Months to allow the transmission to operate at its best

FG015199

efficiency.

Figure 99

Procedure to Start AEB

Warm up transmission to operating temperature.

AEB SETTING

Shift transmission lever to "NEUTRAL."

Set parking brake to "APPLIED."

Processing

Set engine speed to 800 rpm

Press "YES" button for setting AEB setting.

Wait until AEB processing has finished.

After "Complete!" is displayed, turn "OFF" starter

FG015200

switch.

Figure 100

AEB SETTING

Complete !!

FG015201

Figure 101

Operating Controls

OP000995

2-48

Display During AEB-mode

Symbol

Meaning

Remarks

Transmissions stays in neutral, you

+ Kx

Kx couldn’t be calibrated, AEB finished

have to restart the TCU (starter switch

off/on)

Engine speed too low

→ raise engine

+ E

speed

Engine speed too high → lower engine

+ E

speed

Transmission oil temperature too low →

+ T

heat up transmission

Transmission oil temperature too low →

+ T

cool down transmission

Transmissions stays in neutral, you

Transmission temperature not in defined

have to restart the TCU (starter switch

range during calibration

off/on)

Operating mode not NORMAL or

Transmissions stays in neutral, you

transmission

temperature

sensor

have to restart the TCU (starter switch

defective or storing of calibrated values

off/on)

to EEPROM has failed.

Transmissions stays in neutral, you

Output speed not zero

have to restart the TCU (starter switch

off/on)

Transmissions stays in neutral, you

Shift lever not in neutral position

have to restart the TCU (starter switch

off/on)

Transmissions stays in neutral, you

Parking brake not applied

have to restart the TCU (starter switch

off/on)

NOTE:

To prevent

the transmission oil temperature from

falling down while AEB operating, keep the

transmission oil temperature about

80°C before

starting AEB. (Temperature Range: 60°C - 90°C)

Operating Controls

OP000995

2-49

1. Cabin Light

Located in the middle of front cabin, it illuminates the

cabin for night work. Light turns on when the switch is

in the "ON" or

"O" position but off in the "OFF"

position. Cabin light may be turned "ON" and "OFF"

irrespective of the position of the starter switch.

FG004192

Figure 103

2. Stereo / CD Player (Optional)

For operation of stereo see

“Stereo

/ CD Player

(Optional)” on page 2-59.

PROGRAM

AST

SOUND

AM/FM

SCAN

TUNE

FG004057

Figure 104

3. Heater and Air Conditioner Control

Panel

For operation of heater and air conditioner see “Heater

and Air Conditioner Operation” on page 2-54.

FG003955

Figure 105

Operating Controls

OP000995

2-51

4. Speakers

Emits sound generated by stereo.

HBOM350L

Figure 106

5. Storage Compartments

There are two storage compartments (1 and 2, Figure

107) located both sides behind of the operator's seat.

Keep the operation manual and other documents in this

compartment.

FG003889

Figure 107

6. Windshield Washer Tank

Contains windshield washer fluid. It is located behind of

the operator's seat. (3, Figure 107)

7. Electrical Box

Contains relays and electric component. It is located

left side of cabin.

FG003956

Figure 108

Operating Controls

OP000995

2-52

HEATER AND AIR

CONDITIONER OPERATION

Location of Controls and Vents

FG003960

Figure 110

Reference

Description

Number

Operation Panel

Foot Nozzle

Front Nozzle (Air Conditioner)

Rear Nozzle

Front Nozzle (Defroster)

The heater and air conditioner are combined into one unit to

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

operator can control interior cabin temperature using the

operation panel.

Operating Controls

OP000995

2-54

Operation Panel

FG003966

Figure 111

Reference

Description

Number

Fan and Air Conditioner Switch

Selector Switch for Wind

Direction

Blower Fan Switches

Ventilation Selector Switch

Temperature Control Switch

When a switch is selected, the LED above that switch

will turn "ON" and give an activation sound.

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

will turn "ON".

1. Fan and Air Conditioner Switch

A. "OFF" Switch

- Turns "OFF" the heater and air

conditioner unit.

B. "A/C" Switch

- Turns "ON" the air conditioner

when one of the blower switches is activated.

HAOC930L

Figure 112

Operating Controls

OP000995

2-55

2. Blower Fan Switches

These switches are used to control the speed of the

blower fan.

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

B. "MID" Switch

- Used for intermediate blower

speed.

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

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

HAOC940L

and air conditioner will not work.

Figure 113

3. Temperature Control Switch

The temperature control consists of 24 stages. An LED

is turned "ON" for every three stages. Whenever

pushing it, it changes in stages. Pushing it

continuously, it changes continuously.

A. "COOL" Switch - Lowers the temperature.

B. "WARM" Switch - Raises the temperature.

LED COLOR STATUS

HAOA860I

Green LED - Air conditioner. Full green, maximum

Figure 114

operation of air conditioner.

Red LED - Heater. Full red, maximum operation

of heater.

4. Selector Switch for Wind Direction

A. Used to direct air flow to upper portion of

operator's cabin.

FG003967

Figure 115

Operating Controls

OP000995

2-56

Memory Function of Used Mode

The air conditioner panel has a memory function. When the

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

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

be used.

Additional Operating Instruction

A proper interior temperature in summer is

5 -

6°C (10 -

12°F) less than the outdoor temperature.

Operate the air conditioner from twenty

- thirty minutes a

week to circulate the refrigerant in the system.

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

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

replaced with a new one every 1,000 hours.

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

environment, the cleaning and replacement must be

performed more frequently.

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

operate the ventilation switch, and when smoking, vent the

air to the outside to prevent irritation to eyes.

Operating Controls

OP000995

2-58

STEREO / CD PLAYER

(OPTIONAL)

Before operating the stereo or CD player, read operation

manual enclosed with stereo or CD player.

Stereo

PROGRAM

AST

SOUND

AM/FM

SCAN

TUNE

FG000108

Figure 119

Reference

Description

Number

Power / Volume Control

Preset Station

Sound Mode Selector

Tape Ejection

Band Selection

Fast Forward / Rewind

Tuning Up / Down

Tape Loading Slot

Scan Function / Auto Store

LCD

Operating Controls

OP000995

2-59

SEAT ADJUSTMENT

(STANDARD)

WARNING

Whenever operator or operating condition has changed,

check to see that seating position is suitable for the

condition at hand. Always fasten your seat belt while

operating vehicle. Adjust backrest so that the operator

can fully reach and operate pedals.

HAOB110L

Figure 121

1. Adjusting Seat Forward/Backward

Lever

Holding lever (3, Figure 122), raise it, while pushing or

pulling seat to desired position. Release lever once

desired position is reached. Adjustment range is

160 mm (6.3 in).

2 and 3. Adjusting Seat's Angle and

HBOI350L

Height Lever

Figure 122

Pulling left lever

(3, Figure 122) up allows rear part of

seat to be moved up or down. Pulling lever

(2) up

allows front part of seat to be moved up or down.

Adjust seat according to operator's size and work

conditions. Adjustment range is

60 mm (2.36 in) for

both front and rear.

4. Weight Adjustment Knob

Turning knob (4, Figure 122) to right makes suspension

harder. Turning knob to left makes suspension softer.

Adjust according to operator's weight by checking

weight indicator dial. Adjustment range is from 50 - 120

kg (110 - 265 lb).

5. Backrest Adjustment Lever

Pulling up right lever

(5, Figure

122) allows seat

backrest to be moved forward or backward.

Operating Controls

OP000995

2-61

6. Angle Adjustment of Armrest

Adjustment angle of left and right armrest

(6, Figure

123) is done by turning a dial in bottom of armrest.

When you adjust angle, manually raise armrest before

turning dial.

7. Headrest

Headrest

(7, Figure

123) can be adjusted forward/

HAOB130L

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

Figure 123

Recommendations for Limiting

Vibrations

Select the right machine, equipment and attachments

for a particular application.

Replace any damaged seat by a DOOSAN genuine

part. Keep the seat maintained and adjusted.

•

Adjust the seat and suspension for the weight

and size of the operator.

•

Inspect and maintain the suspension and

adjustment mechanisms of the seat regularly.

Check that the machine is properly maintained.

•

Tire pressure, brakes, steering, linkages, etc.

Steer, brake, accelerate, shift gears, move the

attachments and load the attachments smoothly.

Adjust the machine speed and travel path to reduce

the vibration level.

•

Slow down if it is necessary when passing rough

terrain.

•

Drive around obstacles and excessive rough

terrain conditions.

Keep the terrain on work sites where the machine is

working and traveling in good condition.

•

Remove any large rocks or obstacles.

•

Fill any ditches and holes.

•

Provide machines for and schedule time to

maintain the terrain conditions.

Travel over longer distance

(e.g. on public roads) at

adjusted (medium) speed.

•

Always adjust the speed for preventing bouncing.

Operating Controls

OP000995

2-62

SEAT ADJUSTMENT (OPTIONAL)

WARNING

Whenever operator or operating condition has changed,

check to see that seating position is suitable for the

condition at hand. Always fasten your seat belt while

operating vehicle. Adjust backrest so that the operator

can fully reach and operate pedals.

BSO0090L

Figure 124

1. Adjusting Seat Forward/Backward

Lever

Holding lever (1, Figure 124), raise it, while pushing or

pulling seat to desired position. Release lever once

desired position is reached. Adjustment range is

152 mm (6 in).

2. Seat Height and Firmness /

BSO0100L

Adjustment Knob

Figure 125

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

"ON" and push in on height/firmness adjustment knob

(5, Figure 125).

To lower seat height or decrease firmness in ride, pull

out on height/firmness adjustment knob (5, Figure 125).

Adjustment range is 76 mm (3 in).

3. Backrest Adjustment Lever

Lift backrest tilt adjustment lever

(2, Figure

124) and

allow cushion to angle forward or lean backward into

desired position and release handle.

4. Lumbar Control Knob

Rotate lumbar control knob (4, Figure 124) to increase

or decrease support to lower back.

Operating Controls

OP000995

2-63

SEAT BELT

WARNING

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

worn. Before driving machine, adjust seat to desired

position for maximum comfort and machine control,

then fasten seat belt. Seat belts must be worn across

pelvic region and adjusted snugly to lessen chance and

severity of injury in event of an accident. Never fasten a

seat belt across abdomen.

Under no circumstances should operator be standing in

cabin when operating wheel loader.

Do not adjust seat position while vehicle is moving

because a loss of control may result. Stop machine,

apply parking brake, and then adjust seat.

Always, check condition of seat belt and belt bracket

before fastening it. Do not use it with twists in it.

Replace belt or bracket if damaged or worn.

Seat Belt Locking and Unlocking

Insert belt end

(1, Figure

126) into buckle

(2). Pull belt to

check that belt end is locked into buckle.

Adjust belt length so that it comfortably tight against

operator's pelvic region (hipbone).

HAOB140L

Figure 126

Press button (3, Figure 127) in center of buckle (2) and pull

out belt (1) to unlock.

HAOB150L

Figure 127

Operating Controls

OP000995

2-65

DOOR SIDE LATCH

Door side latches

(1. LH, Figure

128) and

(2. RH,

Figure 129) are used to secured the doors (RH, LH) to

the side of the cabin when they are opened.

Keep the door closed and locked when machine is not

in use.

FG003894

Figure 128

FG003895

Figure 129

The RH side door, which is emergency exit from the

cabin, can be opened in two positions.

Position 1. (ventilation position)

•

Open the window and secured it with the lock

bar. (A, Figure 130)

Position 2. (full opened position)

•

Open the window and push it to backward

FG003896

Figure 130

Operating Controls

OP000995

2-66

FUSE BOX/RELAY

Fuse Boxes

There are two fuse boxes inside the cabin.

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

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

fuses are mounted on the inside of fuse box cover (10A -

Qty. 1, 15A - Qty. 1, 20A - Qty. 1 and 30A - Qty. 1).

WARNING

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

shut off the power supply. Remedy the cause if needed

and replace the fuse with a new one.

FG003971

Figure 133

Fuse Box One

FUSE BOX (1)

FUSE BOX (2)

No.

Name

Capacity

Rear Wiper, Window Washer

10A

Parking Brake, Pilot Cut Off

10A

Rotating Beacon (Optional)

10A

CCTV (Optional)

10A

FG003972

Spare

10A

Figure 134

Cigar Lighter

10A

Turn Signal Light, Hazard Light,

10A

Indicate Light

Starter Switch, Hour Meter,

10A

Cabin Light

Air Conditioner, Heater

30A

Headlight

20A

Transmission

15A

Condenser Fan, Cooling Fan

15A

ECU (1)

15A

ECU (2)

15A

Operating Controls

OP000995

2-68

Fuse Box Two

No.

Name

Capacity

Gauge Panel

10A

Stop Light

10A

Auto-detent, LIS (Optional)

10A

Electric Steering (Optional)

10A

Emergency Steer (Optional)

10A

Horn, Front Wiper

10A

Position Light (Left)

10A

Position Light (Right)

10A

Fuel Heater (Optional)

30A

Work Light (Rear)

20A

Seat Suspension (Optional),

Seat Heater (Optional),

15A

Mirror Heater

Work Light (Front)

15A

Stereo, Clock, 12V Socket

15A

Memory Backup, Pilot Buzzer

15A

Operating Controls

OP000995

2-69

Relays

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

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

the fuse, check the function of the relay.

FG003973

Figure 135

FG003974

Figure 136

Circuit Breaker

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

of unit under engine compartment hood. When a short

circuit

or an overload occurs, the circuit breaker

automatically cuts off current, thus preventing electrical wires

from burning.

FG003975

Figure 137

Operating Controls

OP000995

2-70

Fusible Link

A fusible link (Figure 138) is in the battery box.

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

switch is turned "ON" and that no power is available

(No

indicator lights will light.). Check that the "A" portion (Figure

139) of the fusible link is not broken or burned through.

Replace the fusible link if damage and investigate cause.

FG003978

Figure 138

WARNING

When changing the fusible link, replace the fusible link

with the same capacity part. Otherwise, a fire could

break out in the wiring harness and/or other

components of the circuit. Always use original DOOSAN

parts.

HAOB100L

Figure 139

Operating Controls

OP000995

2-71

OP000996

3Operation

WARNING

Before operating any DOOSAN wheel loader, read and

understand "Operating Controls" section of this manual.

INSTRUMENT PANEL

CONTROL FUNCTIONS

Monitoring System

Monitoring system uses network circuits between control

system and sensors installed at various machine system

locations to monitor selected conditions. The monitoring

systems function is to continually inform the operator of

machine's condition. Displays and gauge readouts on

instrument panel provide information such as engine speed,

engine coolant temperature, transmission oil pressure, and

electrical charge status.

NEW MACHINE BREAK-IN

PROCEDURES

All DOOSAN wheel loaders are inspected and adjusted

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

operator follow these steps during initial break-in period.

Failure to follow these steps may result in damage to

equipment or reduced performance.

Make sure to check all fluid levels before starting and

every 8 - 10 operating hours.

Do all Daily maintenance and service checks.

For first 50 operational hours, as shown by hour meter

on control console, do not exceed

80% of maximum

rated engine speed.

At end of first

50 operational hours, drain engine oil.

Replace engine oil filter and engine oil.

Operation

OP000996

3-1

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

"LOCK" pilot control valve lever (joystick).

HBOI111L

Figure 4

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

prevent damage to the cooling system during normal

operation.

HAAH0040

Figure 5

Rotate starter key to "I"

(ON) position. All indicator

lights should turn "ON".

NOTE: If unit is equipped with and emergency steering

system. Test system before starting engine. If

system does not function properly, do not start

unit. Follow test procedure given with test

switch.

FG000084

Figure 6

Rotate starter key to "START" position. Starter motor

should crank immediately, and engine should start

within a few seconds.

FG000085

Figure 7

Operation

OP000996

3-3

Release starter key when engine starts. Key will return

to "I"

(ON) position.

IMPORTANT

If engine does not start after approximately fifteen

seconds of cranking, release Starter Key. Wait five

minutes for starter motor to cool down. Repeat

step 7.

FG003899

Figure 8

After engine starts, check all indicator lights and

gauges to be certain that all engine systems

(oil

pressure, oil temperature, coolant temperature, etc.) are

in normal operating range. If any engine system is not

normal, turn starter key to "OFF" position.

Instrument Panel Light or Gauge

Indicator Reading

Fuel Gauge

Engine Coolant Temperature Gauge

WHITE RANGE

Transmission Oil Temperature Gauge

Engine Oil Pressure Warning Light

Charging Warning Light

OFF

Brake Oil Pressure Warning Light

Parking Brake Light

NOTE: Parking brake indicator light turns "ON" or

"OFF" according to parking brake operation

regardless of engine starting.

10.

Perform “Hydraulic System Warm-up” on page 3-10.

11.

Check color of exhaust smoke:

•

No color or light blue - Engine is running in good

condition.

•

Black - Incomplete combustion. Check cause.

•

White or dark blue - Engine is burning engine oil.

Check cause.

12.

Check for usual engine vibration and noises. If any are

heard or felt, investigate cause.

NOTE: If engine coolant temperature gauge shows red

while running, take the following action;

Discontinue work and allow engine to run at

"LOW IDLE". Open engine compartment cover

for good ventilation. Once engine temperature

gauge returns to the green zone, shut down

engine. After engine has cooled, check coolant

level, look for signs of leaks, clogged or dirty

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

Operation

OP000996

3-4

Cold Weather Engine Start

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

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

HA0O2019

Figure 9

Move all control levers to "NEUTRAL" position.

IMPORTANT

If transmission lever is not in "NEUTRAL" position,

engine will not start.

FG003979

Figure 10

Make sure transmission neutral lock is in the "N"

(NEUTRAL LOCK) position.

FG003980

Figure 11

Set pilot cutoff switch to "O"

(LOCKED) position. This

will "LOCK" pilot control valve lever (joystick).

HBOI111L

Figure 12

Operation

OP000996

3-5

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

prevent damage to the cooling system during normal

operation.

HAAH0040

Figure 13

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

When preheat cycle is completed, the preheat indicator

light

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

FG000084

Figure 14

F/R

FG015184

Figure 15

Rotate starter key to "START" position. Starter motor

should crank immediately, and engine should start

within a few seconds.

FG000085

Figure 16

Operation

OP000996

3-6

Release starter key when engine starts. Key will return

to "I"

(ON) position.

IMPORTANT

If engine does not start after approximately fifteen

seconds of cranking, release starter key. Wait five

minutes for starter motor to cool down. Repeat

step 7.

FG003899

Figure 17

After engine starts, check all indicator lights and

gauges to be certain that all engine systems

(oil

pressure, oil temperature, coolant temperature, etc.) are

in normal operating range. If any engine system is not

normal, turn starter key to "O" (OFF) position.

10. Perform

“Hydraulic System Warm-up - Cold Weather”

on page 3-10.

Operation

OP000996

3-7

Starting with Auxiliary Batteries

WARNING

Wear safety glasses.

Never connect negative leads to positive terminals and

vice versa.

DO NOT connect auxiliary or booster battery ground

terminal directly to battery terminal. Locate and use a

ground point on machine frame.

Depleted batteries generate hydrogen gas. Electrical

sparks around or near batteries can cause an explosion.

Figure 18

Reference

Description

Number

Auxiliary Batteries

Ground Auxiliary Batteries to

Machine Frame

Depleted Batteries

If batteries are drained during starting procedures, you can

jump start engine using auxiliary or booster batteries

according to following procedures:

Connect positive jumper cable from auxiliary batteries

to depleted batteries (Figure 18).

Connect negative jumper cable from auxiliary batteries

to a ground point on machine frame. DO NOT

CONNECT DIRECTLY TO NEGATIVE BATTERY

TERMINAL.

Follow normal engine starting procedures.

After engine has started, remove negative jumper

cable, and then positive cable.

Operation

OP000996

3-8

Engine Shut Down

Move transmission lever to "NEUTRAL" position.

FG003979

Figure 19

Make sure transmission neutral lock is in the "N"

(NEUTRAL LOCK) position.

FG003980

Figure 20

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

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

HA0O2019

Figure 21

Set bucket on ground.

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

"LOCK" pilot control valve lever (joystick).

Allow engine to idle for one

- two minutes to cool

down.

HBOI111L

Figure 22

Operation

OP000996

3-9

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

FG003900

Figure 23

Hydraulic System Warm-up

Correct operating temperature of hydraulic oil is

50° -

80°C (120° - 175°F). Make sure to follow procedures

listed below for hydraulic fluid warm-up.

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

Run engine for approximately five minutes at middle of

speed range, without a load.

Cycle bucket until bucket cylinder bottoms out

(extended and retracted) without a load to circulate the

oil through the system. Do this for five minutes.

NOTE: Do not allow cylinders to pass hydraulic oil over

relief valve for more than twenty seconds at a

time.

Cycle boom, and bucket about five times without a

load to circulate oil through system.

Hydraulic System Warm-up - Cold

Weather

Follow Steps

1 through

3 in "Hydraulic System

Warm-up".

Do not operate machine at full speed until system has

fully warmed up.

If working speeds continue to be slow, repeat initial

hydraulic warm-up procedures again. If repeating

warm-up procedures does not improve working speeds,

continue to operate, but use extreme caution because

machine function may be erratic.

Operation

OP000996

3-10

MACHINE TRAVEL

WARNING

If vehicle is moved while parking brake is engaged,

serious damage to parking brake disk will result.

Select a transmission gear that is appropriate for top

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

high will reduce acceleration and will unnecessarily heat

transmission converter oil.

Never place transmission in "NEUTRAL" when going

down a hill. Over speeding transmission can damage

transmission gears.

Never change direction of vehicle travel at high speed.

Serious damage to transmission will result.

Unlatch frame lock plate between front and rear frames

before traveling. Secure lock plate to rear frame (Figure

24).

FG001773

Figure 24

Set pilot cutoff switch to "I"

(UNLOCKED) position.

Raise bucket to a height of

-30 cm

12 in)

above the ground. Tilt bucket completely back.

HBOI110L

Figure 25

Operation

OP000996

3-11

Set pilot cutoff switch to "O"

(LOCKED) position. This

will prevent boom and bucket from accidentally moving

during travel, as a result of accidentally touching pilot

control valve lever (joystick).

HBOI111L

Figure 26

Press brake pedal.

FG002183

Figure 27

Set transmission neutral lock is in the "D"

(DRIVE)

position.

FG003980

Figure 28

Set parking brake switch to the "O"

(RELEASE)

position. This will "RELEASE" the parking brake.

HAOP043L

Figure 29

Operation

OP000996

3-12

Place transmission lever in desired gear. Shift gears

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

Shift transmission lever to "FORWARD" position.

FG003979

Figure 30

Release the brake pedal while slowly pressing the

accelerator pedal.

WARNING

When traveling at high speed or on a steep hill, do

not make sharp changes in direction. This could

cause vehicle to overturn.

When traveling or changing direction, always look

FG003980

carefully to be certain that no one is in path of

Figure 31

vehicle.

Operation

OP000996

3-13

MACHINE SHUT DOWN

Ease off throttle and apply travel brakes.

FG002183

Figure 32

Put transmission lever in "NEUTRAL".

FG003979

Figure 33

Set transmission neutral lock is in the "N"

(NEUTRAL

LOCK) position.

CAUTION

"LOCK" transmission lever. Whenever machine is

parked, "LOCK" transmission lever in "NEUTRAL"

to prevent accidental machine movement.

FG003980

Figure 34

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

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

HA0O2019

Figure 35

Operation

OP000996

3-14

Set bucket on ground.

Set pilot cutoff switch to "O"

(LOCKED) position. This

will lock pilot control valve lever (joystick).

Allow engine to idle for one

- two minutes to cool

down. Stopping a turbocharged engine without a cool

down period can seriously damage turbocharger.

HBOI111L

Figure 36

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

FG003900

Figure 37

If machine is parked on a slope, install wheel chocks

in front of and behind vehicle wheels.

WARNING

Always secure machine with wheel chocks when

parked on a slope. Leaving machine in gear will

provide no braking effect because transmission

clutch is hydraulically operated. When engine is

turned "OFF", there is no hydraulic pressure in

transmission and clutch is not engaged.

Figure 38

Operation

OP000996

3-15

F/R (FORWARD/REVERSE)

TRAVEL CONTROL SYSTEM

(OPTIONAL)

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

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

installed, the operator's right-hand can remain on the

steering wheel during operation, and not have to manually

move the transmission lever between forward and reverse.

To activate system perform the following steps:

Place transmission lever in "NEUTRAL".

NOTE: Do not move the transmission lever out of

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

will be deactivated.

FG005290

Figure 39

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

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

the system will be activated. When system is activated,

the F/R selector indicator light

(Figure

41) will be

turned "ON".

FG003977

Figure 40

F/R

STOP

01/04

[FRI]

11:32

524Km

km/h

x100r/min

FG015441

Figure 41

Operation

OP000996

3-16

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

travel direction of the machine.

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

In this position, the machine travels "FORWARD".

II.

In this

position, the machine travels in

"REVERSE".

The F/R travel control system will stay activated until

one of two things happen.

A. The transmission lever is moved out of

FG015182

"NEUTRAL" into "FORWARD" or "REVERSE".

Figure 42

B. The starter switch is turned "OFF".

When the system is deactivated, the F/R selector

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

ADDITIONAL BRAKING

Machine hydraulic system can supply additional dynamic

braking force during travel. To accomplish this, move pilot

control valve lever

(joystick) to crowd position and hold it

there. Hydraulic pump will be driven to supply output at

maximum pressure

(relief pressure). Energy expended to

drive pump, will slow engine speed. Additional dynamic

braking, along with proper gear selection, can be used to

slow a vehicle that is being driven down an incline.

Operation

OP000996

3-17

BOOM RAISE KICK-OUT

Placing bucket lever in "Boom Raise Detent" position will

lock bucket lever in raise boom position. Boom will raise

until trip plate

(1, Figure

43) makes contact with bucket

height limit switch

(2). When limit switch is tripped, boom

will stop raising and bucket lever will automatically be

returned to "NEUTRAL" position. Trip plate can be adjusted

to control maximum height that boom can be raised.

HBOI441L

Figure 43

IMPORTANT

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

limit switch

(2) before boom cylinders reach maximum

extension. Maximum extension causes pump to force

fluid over relief valve.

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

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

FG002238

until boom has reached maximum height. Then remove your

Figure 44

hand from lever. Lever will automatically return to

"NEUTRAL" position. This prevents hydraulic pump from

working against relief valve (maximum pressure).

BUCKET ANGLE INDICATOR

Upper right side of bucket includes a bracket that indicates

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

bottom of bucket. If bottom of bucket is not visible, top of

bracket will be visible.

FG015211

Figure 45

Operation

OP000996

3-18

BOOM LOWER KICK-OUT

(OPTIONAL)

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

lower boom position. Boom will move downward until trip

plate

(1, Figure

46) makes contact with bucket lower limit

switch

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

lowering and bucket lever will automatically be returned to

"NEUTRAL" position. Trip plate can be adjusted to control

maximum height that boom can be lowered.

IMPORTANT

FG001615

Trip plate must always be set to contact limit switch

Figure 46

before boom cylinders reach maximum extension.

Maximum extension causes pump to force fluid over

relief valve.

ADJUSTMENT OF BUCKET

POSITION SWITCH

When bucket lever is held in crowd detent position, after

bucket has been dumped, bucket will pivot toward crowd

position. Once full crowd position has been reached, bucket

lever will automatically return to "NEUTRAL" position. If

bucket is lowered after lever returns to "NEUTRAL", bucket

will automatically position itself to be in a preselected

digging position

(usually flat). To adjust bucket to desired

preselected digging position, perform the following steps.

Operate controls to place bucket on ground and in

desired digging position

(usually flat). Return bucket

FG015210

lever to its "NEUTRAL" position.

Figure 47

Shut down engine.

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

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

is aligned with center of magnetic switch (4).

Tighten bolts (1, Figure 47).

Start engine. Raise boom, dump bucket, then move

bucket lever into crowd detent position. Now lower

boom and check to see that bucket has stopped at

required position. A small readjustment of bracket

(2,

Figure 47) may be necessary.

Operation

OP000996

3-19

TOWING MACHINE

When necessary to tow another vehicle, the tow rope must

be tied to the towing pin on the counterweight at the rear of

vehicle.

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

emergency.

WARNING

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

FG001662

and do not tow machine farther than 10 km (6 mi). This

Figure 48

will prevent damage to machine transmission that would

result from lack of lubrication.

WARNING

When towing another vehicle on a public road, take

necessary measures to let other vehicles and people

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

rotating beacon light, or hazard light.

NOTE: There are several requirements you must abide by

when towing another vehicle. Learn the regulations

and rules about towing another vehicle and observe

them.

If the loader is being towed by another vehicle and the

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

otherwise the transmission will rotate without being properly

lubricated, causing seizure. Before removing them, apply the

parking brakes and block the wheels securely.

If the engine can be started and the steering wheel and

brakes function normally, have someone get on the loader

you are going to tow for steering it.

Before you tow a vehicle make sure you have checked the

following:

•

Check the weights of your loader and the vehicle

to be towed and make sure you loader has

sufficient braking capacity to stop the towed load.

•

Check if the vehicle to be towed can be braked

and steered. If not, do not allow anyone to ride

on the towed vehicle.

•

Check the tow rope or tow bar for damage and

make sure it has sufficient strength for the work.

•

When necessary to descend a grade, another

towing vehicle must be used in the rear to retard.

Operation

OP000996

3-20

When towing make sure you are doing the following:

•

Start slowly. A sudden start can lead to a broken

tow rope.

•

The tow line must be along the center line of

both your loader and the vehicle to be towed.

•

If you use any other towing device, refer to the

Instruction Manual supplied with the towing device.

•

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

trailer truck to your nearest repair shop.

•

In addition to the above measures, release the

parking brake if the engine will not start or the

hydraulic pumps are defective.

IF ENGINE STALLS WHILE

TRAVELING

BRAKE SYSTEM: The brakes can be applied approximately

9 times by pressing the brake pedal due to the oil

pressure stored in the accumulator after engine is

turned "OFF" if the engine stalls while traveling, move

to an out of traffic area and park. Do not pump the

brake pedal at this time; otherwise the brake oil

pressure will be used up, thus causing the brakes to

fail.

Operation

OP000996

3-21

ALLOWABLE WATER DEPTH

The water depth is an important factor to take into

consideration when the loader is working in swampy areas.

Do not enter water whose depth exceeds the loader's

minimum ground clearance height or is high enough to wet

the bottom of the axle housing. As a rule of thumb, the

allowable water depth is about

510 mm. This means that

the loader should not be used in a river.

Observe the following conditions:

Check the water depth in advance when crossing

across a river.

Use the same precautions before crossing across a

swampy area.

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

rapid flow.

CAUTION

Avoid use of the loader in salt water. Salt water

will cause the development of rust which will

shorten the life of the loader.

Operation

OP000996

3-22

OP000997

4Inspection, Maintenance

and Adjustment

BASIC PREVENTIVE

MAINTENANCE

For the machine to function satisfactorily and at lowest

possible cost, a thorough maintenance program is required.

This section of the manual describes the maintenance work

which the operator can carry out. If certain operations

require trained workshop personnel and special equipment,

this will be indicated.

The intervals recommended between checks, oil changes

and lubrication apply provided that the machine is used

under normal environmental and operating conditions. See

“Lubrication and Service Chart” on page 4-22.

Arrival and Delivery Inspection

Before the machine leaves the factory, it is tested and

adjusted. The dealer must also, if the warranty is to apply,

carry out "Arrival and Delivery Inspections" according to

applicable form, which must be signed.

Delivery Instructions

Figure 1

When handing the machine over, the dealer must give the

buyer "Delivery Instructions" according to applicable form,

which must be signed, if the warranty is to apply.

Inspection, Maintenance and Adjustment

OP000997

4-1

Service Programmes

Warranty Inspection

Two Warranty Inspections must be carried out if the

warranties are to apply. The first within 100 operating hours

and the second at the latest at 1000 operating hours.

The carrying out of these inspections is a condition for the

warranty to apply.

Condition Test

A "Condition Test" is carried out at authorized dealer

workshops and provides information about the general

condition of the machine.

Inspection, Maintenance and Adjustment

OP000997

4-2

Reference

Description

Number

Level Sight Gauge Hydraulic Oil

Engine Oil Filling Point

Breather Of Hydraulic Oil

Main Fuel Filter

Air Cleaner

Coolant Filter

Pre Cleaner

Battery

Fuel Filling Point

Return Oil Filter

Coolant Draining

Coolant Filling Point

Pre Fuel Filter

Washer Fluid Filling Point

Transmission Filling Point

Hydraulic Oil Filling Point

Hydraulic Oil Draining

Cabin Ventilation Filters

Pilot Filter

Battery

Engine Oil Dipstick

Alternator Belt

Engine Oil Filter

Transmission Oil Filter

Engine Oil Draining

Inspection, Maintenance and Adjustment

OP000997

4-5

SAFETY WHEN SERVICING

This section deals with the safety rules which must be

followed when checking and servicing the machine.

DOOSAN disclaims all responsibility if other tools, lifting

devices or working methods are used other than those

described in this publication.

Further safety rules and information and warning texts are

given within the respective section.

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

personnel.

WARNING

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

has cooled down, care must be observed with regard to

risk of burns from hot liquids and hot machine parts.

Inspection, Maintenance and Adjustment

OP000997

4-6

Service Position

BEFORE beginning service work the machine must be

parked on level ground and positioned as shown below.

AFTER completing the service, all guards must be installed

and all engine covers must be closed and locked.

FG015248

Figure 3

Reference

Description

Number

The attachment must be resting on the ground.

Apply the parking brake.

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

in transmission).

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

Attach a black and yellow label to the steering wheel.

Connect the frame joint lock.

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

Allow the machine to cool.

Inspection, Maintenance and Adjustment

OP000997

4-7

Before Service Read

•

Read the Operator's Manual and the decals/labels

and instructions found on the machine to obtain

the required knowledge and information about the

machine.

•

To be able to carry out the service work in a

correct way, it is important that the correct tools

and equipment be used. Replace or repair broken

tools and faulty equipment.

•

When lifting the machine, the frame joint must be

locked and the machine lifted at the eyes

intended for this purpose. See

“Summary of

Safety Precautions for Lifting” on page 5-2.

Figure 4

•

Use a hard hat, safety glasses, protective shoes

and gloves and an approved respirator or other

protective articles when required.

•

Do not wear loose fitting clothing or jewelry.

•

Keep service surfaces and handholds clean from

oil, dirt and ice.

Figure 5

•

Use the stepping areas provided with antislip

protection to avoid the risk of slipping. Worn,

painted over, or loose protections must be

replaced. Remember that high-pressure water jets

when washing and spilled oil can cause the

protections to loosen. Do not direct the water jet

against the protections and wipe up spilled oil.

•

Make sure that there is sufficient ventilation when

starting the engine indoors.

•

Do not exceed the maximum permissible floor

FG001668

load.

Figure 6

•

Do not stand in front of or behind the machine

while the engine is running.

•

Use a ladder when changing light bulbs or

carrying out other service work high up on the

machine.

Inspection, Maintenance and Adjustment

OP000997

4-8

•

Use a long handled window scraper and brush or

a ladder when cleaning the outside of the

windows.

•

The installation of two-way radio, lever steering or

similar equipment must be carried out by a skilled

person, as faulty installation may cause

interference with the electronic components

controlling vital machine functions.

•

When carrying out service work below raised

lifting arm system, the lifting arms must first have

been secured (lifting arm support). In addition the

control lever lockout and the parking brake must

be applied.

•

Take care when changing oil in engine, hydraulic

system or transmission as the oil may be hot and

cause burns.

•

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

a hose and collect the liquids in a suitable vessel.

Spillage will damage the environment and may

cause a fire. Waste oil and other contaminating

liquids must be taken care of by a firm especially

authorized to carry out such work.

•

When operating in an area which is contaminated

or dangerous to one's health, the machine must

be especially equipped for this purpose. Special

local safety regulations apply within such areas

and also when servicing the machine.

•

Shut down engine before opening engine covers

etc. Make sure that no tools or other objects,

which may cause damage, have been forgotten in

or on the machine.

•

Check that the equipment you are using for lifting

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

slings, ratchet blocks and ground support, can

safely cope with the strain they are exposed to

and meet applicable regulations.

•

Release the pressure in pressure vessels,

components and systems carefully and in the

prescribed way, so that the excess pressure is

released without risk.

•

When connecting hydraulic hoses, check that the

desired effect has been achieved, that is, check

that the hydraulic function operates in the

expected way.

•

Hoses, pipes and quick-connect couplings may be

pressurized even if the machine is stationary and

the engine turned "OFF". Such pipes and hoses

should therefore only be disconnected by trained

personnel.

•

When looking for leaks, use a piece of paper or

wood, not your hand.

Inspection, Maintenance and Adjustment

OP000997

4-9

Fire Prevention Measures

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

fire extinguisher that suits your machine and working

environment and that you learn how to use it. The fire

extinguisher must be placed behind the seat or externally in

a lockable box.

If the machine is to be provided with a handheld fire

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

which means that it is possible to extinguish fires in both

FG003902

solid and liquid carbonaceous material and that the active

compound does not conduct electricity.

Figure 7

The effectiveness grade I means that the time the

extinguisher is effective must not be less that eight seconds,

grade II at least eleven seconds and grade III at least

fifteen seconds.

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

normally corresponds to a powder content of 4 kg (8.8 lb)

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

and 5.

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

the following steps:

Drive the machine away from the fire sensitive area

caused by the fire.

Lower the lifting arms to the ground.

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

(OFF) position.

Leave the cabin.

Turn off the battery disconnect switch.

Start putting out the fire and notify the fire brigade/

department if necessary.

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

machine when filling with fuel or when the fuel system has

been opened and in contact with the surrounding air.

Diesel fuel oil is flammable and must not be used for

cleaning. Use an approved solvent and do not inhale the

fumes. Also bear in mind that certain solvents can cause

skin rashes and constitute a fire hazard.

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

electric preheating in the induction air system.

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

Oil or water makes the floor slippery and is also dangerous in

connection with electrical equipment or electrically powered

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

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

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

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

loose components.

Inspection, Maintenance and Adjustment

OP000997

4-10

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

care as the insulation of electric leads can be

damaged even at a moderately high-pressure and

temperature. Protect electrical leads in an

appropriate way.

Take extra care when cleaning the machine after it has been

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

dumps. Reduce the risk of spontaneous combustion by installing

for example silencer guard or high capacity cyclone precleaner.

Sound absorbing material in the engine compartment must

be kept clean to minimize the fire hazard.

Fire prevention equipment which is installed on the machine

must be maintained and regarded as a complement to the

actions of the operator in case of a fire.

Check that fuel lines, hydraulic and brake hoses and

electrical cables have not been damaged by chafing or are

not in danger of being damaged because of incorrect

installation or clamping. This applies particularly to unfused

cables, which are red and marked R(B+) and routed:

•

between the batteries

•

between battery and starter motor

•

between alternator and starter motor

•

to the preheating element on the engine.

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

The following applies for welding and grinding work:

•

A fire extinguisher must be kept near at hand.

•

The ventilation must be good when working indoors.

•

Approved respirator must be used

•

The work surface must be cleaned.

•

Do not weld or grind on components which are

filled with flammable liquids, e.g. tanks and

hydraulic pipes. Exercise care with such work in

the proximity of these places.

Working on Painted Surfaces

When welding, grinding and gas cutting, the paint finish

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

10 cm (4 in) from the point where the work is to be carried

out. The reason for this is that paint when heated gives off

a great number of different substances which can cause

irritation and be very harmful to a person's health in case of

long or frequent exposure.

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

inferior quality and strength, which in the future may cause

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

painted surface.

Inspection, Maintenance and Adjustment

OP000997

4-11

Methods and Precautionary Measures

When Removing Paint:

Blasting

•

use respirator and eye protection

Paint remover or other chemicals

•

use a portable air extractor, respirator and

protective gloves

Grinding machine

•

use a portable air extractor, respirator and

protective gloves and eye protection

Rubber That Contains Fluorides

Observe extra great care when it is suspected that you may

have to handle rubber that contains fluorides.

Certain seals which have to withstand high operating

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

motors and pumps) may be made from rubber that contains

fluorides, which, when exposed to high heat

(fire), forms

hydrogen fluoride and hydrofluoric acid. This acid is very

corrosive and cannot be rinsed or washed off from the skin.

It causes very severe burns which take a long time to heal.

It usually means that damaged tissue must be surgically

removed. Several hours may pass after contact with the

acid, before any symptoms appear and therefore one is not

given any immediate warning. The acid may remain on the

machine parts for several years after a fire.

If swelling, redness or a stinging feeling appears and one

suspects that cause may be contact with heated rubber that

contains fluorides, contact a medical doctor immediately. If a

machine, or part of a machine, has been exposed to fire or

severe heat, it must be handled by specially trained

personnel. In all handling of machines after a fire, thick

rubber gloves and effective goggles must be used.

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

may be made of rubber that contains fluorides must be

decontaminated by thorough and ample washing with

limewater (a solution or suspension of calcium hydroxide, i.e.

slaked lime in water). After the work has been completed,

the gloves must be washed in limewater and then discarded.

Inspection, Maintenance and Adjustment

OP000997

4-12

Rubber and Plastics

Polymer materials when heated, can form compounds which

are dangerous to health and environment and must therefore

never be burned when scrapped. Also take care when

handling machines which have been subjected to fire or

other extreme heat.

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

materials, the following safety instructions must be followed:

•

Protect the material from heat.

•

Use protective gloves, protective goggles and an

approved respirator.

Waste Hazardous to the Environment

Painted parts or parts made of plastic or rubber which are

to be scrapped must never be burnt, but must be taken

care of by an approved refuse handling plant.

Batteries, plastic objects and anything else which is

suspected of being dangerous to the environment must be

taken care of in an environmentally safe way.

Check List After Fire

When handling a machine which has been damaged by

fire or been exposed to intense heat, the following

protective measures must under all circumstances be

followed:

Use thick, gloves made of rubber and wear goggles which

are certain to protect your eyes.

Never touch burnt components with your bare hands, as

there is a risk that you may come into contact with melted

polymer materials. First wash thoroughly with plenty of lime

water

(a solution or suspension of calcium hydroxide, i.e.

slaked lime in water).

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

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

Treat skin, which is suspected of having come into contact

with burnt floor rubber, with Hydrofluoric Acid Burn Jelly or

something similar. Seek medical advice. Symptom may not

appear until several hours afterwards.

Discard gloves, rags etc. which are suspected of having

come into contact with burnt floor rubber.

Inspection, Maintenance and Adjustment

OP000997

4-13

PREVENTIVE MAINTENANCE

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

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

working condition. The following pages describe items to be

checked, lubricants to be used, and time interval between

each check.

NOTE: Time interval between each service check may need

to be shortened if machine is operating in severe

atmospheric conditions. Machines working in

extremely hot or dusty conditions will require more

frequent service checks. Total hours of machine

operation are determined by hour meter that is on the

HAOA600L

front instrument panel.

Figure 8

Serial Numbers

There are two serial number plates attached to the body of

wheel loader.

Please make note of these numbers and their locations.

These will be required whenever warranty service work is

requested.

Machine Serial Number

The machine serial number plate is on left side of front

frame above wheel cover (Figure 9).

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

side just below the cabin (Figure 10).

Doosan Infracore Co., Ltd.

7-11, Hwasu-dong, Dong-gu,

Incheon, Korea

FG012865

Figure 9

FG015391

Figure 10

Inspection, Maintenance and Adjustment

OP000997

4-14

Engine Identification

Engine Data Plate

The engine data plate provides important facts about the

engine. The engine serial number

(ESN) and control parts

list

(CPL) provide information for service and ordering parts.

The engine data plate must not be changed unless

approved.

Figure 11

Safety Precautions

Before performing any maintenance checks, move pilot

cutoff switch to "LOCKED" position. Place a Warning

Tag on controls so that no one begins to operate

machine while maintenance checks are being

performed.

Clean up all fuel spills. Fuel spills are hazardous,

especially around engine.

Inspect all fuel lines for leakage. Replace any lines,

fittings, O-rings, or filters that show signs of wear or

damage.

If a test procedure requires engine to be running, use

two people and keep all unnecessary personnel away

from machine.

Inspection, Maintenance and Adjustment

OP000997

4-15

TABLE OF RECOMMENDED

LUBRICANTS

IMPORTANT

It is highly recommend to use the Doosan Genuine

Products, or products which meet the specification

below. Using other products may damage the

equipment.

NOTE: Refer to the Maintenance Intervals Table for

application points.

LUBRICANT

HYDRAULIC OIL

ENGINE OIL

GEAR OIL

MANUFACTURER

GREASE

DOOSAN

GENUINE

DSZ 46

API CI-4

NLGI No.2

LUBRICANTS

TOTAL

TOTAL EQUIVIS

TOTAL

RUBIA

TOTAL MULTIS

ZS 46 IV

TIR 7400 10W40

EP #2

ACEA E5

(>API CH-4)

TOTAL RUBIA

POLYTRAFIC

10W40

TOTAL RUBIA

8600 10W40

CHEVRON

AW 32 (BELOW

DELO 400 15W40

DELO GREASE

0°C)

EP #2

(ABOVE

0°C)

TEXACO

RANDO HDZ 46

URSA SUPER

MULTIFAK ALL

PREMIUM 15W40

PURPOSE EP #2

ESSO

UNIVIS N 46

ESSOLUBE XT-5

RONEX MP

15W40

MOBIL

MOBIL DTE 13M

MOBIL DELVAC

MOBILUX EP #2

MOBILFLUID 424

MX 15W40

ESSO TORQUE

FLUID 56

MOBIL

AGRIFLUID 424

MOBIL

FLUID

426

MOBILFLUID

2040

SHELL

TELLUS OIL T 46

RIMULA ULTRA

ALVANIA EP #2

ASEOL

10W40

MULTITRAC 85W

Inspection, Maintenance and Adjustment

OP000997

4-16

LUBRICANT

HYDRAULIC OIL

ENGINE OIL

GEAR OIL

MANUFACTURER

GREASE

PENNZOIL

MULTIPURPOSE

WHITE GREASE

705 EP #2

CASTROL

PARADENE AW 32

CASTROL EPL #2

KOMATSU WBL

(BELOW 0°C)

20W40

PARADENE AW 46

(ABOVE 0°C)

IDEMITSU KOSAN

DAPHNE KOSAN

DAPHNE

32 WR (BELOW

EXPONES SR #2

0°C)

DAPHNE KOSAN

46 WR

(ABOVE

0°C)

LUBRICANT

TRANSMISSION GEAR OIL

MANUFACTURER

SAE 15W40

Same as engine oil

API CH-4 and above

Antifreeze

Recommended Concentration

Manufacturers Meeting ASTM D3306

Doosan Genuine Solution

Dexcool ELC by Chevron Texaco

50% Antifreeze - 50% Distilled Water

Alugard G48 by BASF

Others meeting or exceeding ASTM D3306

NOTE: Mixing ratio is for reference purpose only and is not

an absolute standard.

CAUTION

Do not mix oils from different manufacturers. DOOSAN

does not endorse specific brands but does suggest that

owners select quality oils whose suppliers provide

assurance that required standards will always be met or

exceeded.

IMPORTANT

Fluctuating daily or weekly extremes of temperature, or

operation in subzero freezing weather may make it

impractical to use straight weight lubricants. Use good

judgement in selecting lubricant types that are

appropriate for climate conditions.

Inspection, Maintenance and Adjustment

OP000997

4-17

AXLE OILS DL420, DL400,

DL300, DL250

Oil Grade Mobile Fluid 424

Oil intended for axles with built-in brakes

Requirements

Property

Unit

Mobil fluid 424

Test method

Density

kg/l,

@15°C

0.884

ASTM D 4052

Flash Point

°C

198

ASTM D 92

Pour Point

°C

-42

ASTM D 97

Viscosity at 40°C

ASTM D 445

mm²/s (cSt)

Viscosity at 100°C

9.3

ASTM D 445

mm²/s (cSt)

Rust Protection 24h

No rust

ASTM D 665A

API Class

GL-4

ASTM STP-512A

Brokfield Viscosity

cp (@-35C)

55,000

Viscosity Index

145

ASTM D 2270

Examples of oils which meet the requirements according to

the table on the next page.

Inspection, Maintenance and Adjustment

OP000997

4-18

Axle Oils for DL420, DL400, DL300,

DL250

Examples of oils which meet the requirements according to

the table on the previous page.

Lubricant Class 05E

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

Oil Company

Trade Name

CASTROL INTERNATIONAL, PANGBOURNE READING/GB

KOMATSU WBL 20W40

CNH, BURR RIDGE/USA

CASE TRANSAXLE FLUID, SAE 80W-140

EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA

MOBILFLUID 2040

FUCHS PETROLUB AG, MANNHEIM/D

TITAN HYDRA ZF 20W-40

MAZIVA ZAGREB D.O.O. ZAGREB/HR

INA TRASHIDROL ZF 20W-40

OMV AG, SCHWECHAT/A

MOV AUSTROMATIC ZF SAE 20W-40

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

PAKELO UTTO FLUID 4D SAE 20W-40

STRUB + CO AG, REIDEN/CH

VULCOTRAC UTTO SAE 20W-40

Lubricant Class 05F

Oil Company

Trade Name

76 LUBRICANTS COMPANY, COSTA MESA/USA

76 HYDRAULIC/TRACTOR FLUID

ARAL AG, BOCHUM/D

ARAL FLUID HGS SAE 80W

AVIA MINERALOL-AG, MUNCHEN/D

AVIA HYDROFLUID DLZ

BP INTERNATIONAL, PANGBOURNE, READING/GB

BP OLEX GO 4926

BP INTERNATIONAL, PANGBOURNE, READING/GB

BP TERRAC SUPER TRANSMISSION

BP INTERNATIONAL, PANGBOURNE, READING/GB

BP TRACTRAN TF 10

BUCHER AG LANGENTHAL, LANGENTHAL/CH

MOTOREX POLYFARM 304

CASTROL INTERNATIONAL, PANGBOURNE READING/GB

CASTROL AGRI POWERTRANS 10W-30

CASTROL INTERNATIONAL, PANGBOURNE READING/GB

CASTROL AGRI TRANS PLUS 10W-30

CASTROL INTERNATIONAL, PANGBOURNE READING/GB

CASTROL KOMATSU UTTO 10W-30

CATERPILLAR MULTIPURPOSE

CATERPILLAR INC., PEORIA/USA

TRACTOR OIL (MTO) 10W-30

ENGEN PETROLEUM LTD., CAPE TOWN/ZA

ENGEN AGRIFLUID

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

ROTRA JD/F

EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA

ESSO TORQUE FUID 56

Inspection, Maintenance and Adjustment

OP000997

4-19

Oil Company

Trade Name

EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA

MOBIL AGRIFLUID 424

EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA

MOBIL FLUID 424

EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA

MOBIL FLUID 426

FLITALIA S.P.A., VILLASTELLONE/I

AMBRA MULTI G

FUCHS PETROLUB AG, MANNHEIM/D

TITAN HYDRA J20C

GINOUVES GEORGES SA, LA FARLEDE/F

YORK 676 SAE 10W30

IGOL FRANCE SA, AMIENS/F

TICMA FLUID MU SAE 80W

JOHN DEERE, MANNHEIM/D

JOHN DEERE HY-GARD

KENDALL MOTOR OIL, COSTA MESA/USA

KENDALL HYKEN 052

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

Q8 T 2000

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

Q8 T 2200

OEL-BRACK AG, HUNZENSCHWIL/CH

MIDLAND TOU

OMV AG, SCHWECHAT/A

OMV AUSTROMATIC IGB SAE 10W-30

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

PAKELO UTTO FLUID 4D SAE 10W/30

PANOLIN AG, MADETSWIL/CH

PANOLIN JD 303

PETROGAL S.A., LISBOA/P

GALP TRALUB 807S

REPSOL LUBRICANTES, MADRID/E

AGRO ORION SAE 10W30

SHELL ASEOL AG, BERN 5/CH

ASEOL MULTITRAC 85W

SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D

WINTERSHALL HYDROFLUID N

Lubricant Class 05G

Oil Company

Trade Name

CATERPILLAR MULTIPURPOSE TRACTOR

CATERPILLAR INC., PEORIA/USA

OIL(MTO)

JOHN DEERE, MANNHEIM/D

JOHN DEERE HY-GARD

ZF FRIEDRICHSHAFEN AG, FRIEDRICHSHAFEN/D

ZF-POWERFLUID

Inspection, Maintenance and Adjustment

OP000997

4-20

QSM11 Industrial Engines Oil Drain

Intervals by Duty Cycle (Hours)

Severe

Heavy

Medium

> 25 (liter/h)

20 to 25 (liter/h)

< 20 (liter/h)

Fuel consumption

> 6.6 (gallon/h)

5.5 to 6.6 (gallon/h)

< 5.3 (gallon/h)

ACEA E5 (API CH-4)

250

300

500

CES 20076

ACEA E5 (API CI-4)

250

350

500

CES 20078

NOTE:

Limit oil change interval to

250 hour maximum for oil grades if 40% of the operating time is in

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

from high oil temperature.

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

oil drain intervals half of the API CH-4 values.

Engine oil drain intervals need to be reduced by

50% when fuel sulfur content exceeds

0.5%

(5000 ppm)

Valvoline Premium Blue meet CES 20076 standards. - recommended in North america

FLUID CAPACITIES

Component

Capacity

34 liters

(9 U.S. gal.)

Oil Pan with Filter

Engine

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

50 liters

Cooling System

(13 U.S. gal.)

367 liters

Fuel Tank

(97 U.S. gal.)

230 liters

Hydraulic Oil Tank

(60.8 U.S. gal.)

54 liters

Transmission

(14.2 U.S. gal.)

51 liters

Front Axle

(13.5 U.S. gal.)

Axles

42.5 liters

Rear Axle

(11.2 U.S. gal.)

Inspection, Maintenance and Adjustment

OP000997

4-21

LUBRICATION AND SERVICE

CHART

Greasing Bearing

The service life of bushings and pivot pins can be extended

considerably, if the machine is greased regularly and in the

correct way.

The greasing of bearings has two main purposes:

•

Add grease to the bearing to reduce friction

between pin and bushing.

•

Replace old grease which may contain dirt. The

grease in the space inside the outer seal collects

dirt and prevents dirt and also water from

penetrating into the bearing.

Therefore, grease the bearing until new, clean grease is

forced out through the outer seal.

Between 10 and 15 strokes with a normal handheld grease

gun is required to grease one of the bearings for the lifting

arms.

Wipe off grease fittings and grease gun before greasing,

so that dirt and sand is not introduced through the

grease fittings.

Inspection, Maintenance and Adjustment

OP000997

4-22

Service Data

Service Interval

No.

Items To Check

Service

Qty.

250

500

1000

1500

2000

4000

Front Joint Pin

Grease

F100

W10

Articulation Pin

Grease

Rear Axle Pivot

Grease

Steering Cylinder

Grease

Front Drive Shaft

Grease

Bearing

Fuel Tank

Diesel

367 L

Hydraulic

Hydraulic Oil Tank

230 L

Oil

Engine Oil

34 L

10W40

Coolant

Radiator

50 L

(Antifreeze)

Axle Gear

Front Axle

51 L

Oil (80W90)

Axle Gear

Rear Axle

42.5 L

Oil (80W90)

Engine Oil

Transmission

54 L

15W40

Fuel Filter

Cartridge

Engine Oil Filter

Cartridge

Transmission Filter

Cartridge

Full-flow Filter

Element

Oil Suction Filter

Strainer

Pilot Filter

Element

(Outer)

Air Cleaner

Element

(Inner)

Turbo Precleaner

Case

Element

Air Conditioner

(Outer)

Filter

Element

(Inner)

Engine Coolant

Cartridge

Filter

Air Breather Filter

Element

V: Maintenance and Refill.

C: Cleaning.

F: First Time Exchange Only.

F100: Every 10 Hours for First 100 Hours.

W10: Every 10 Hours If Operating In Water.

EG: Ethylene Glycol - Doosan Genuine Antifreeze Solution

(Drain and replace using this interval.)

See “Engine Cooling System” on page 4-86, for further explanation.

PG: Propylene Glycol - Doosan Genuine Antifreeze Solution (Drain and replace using this interval.)

See “Engine Cooling System” on page 4-86, for further explanation.

Gray Box: Replacement On Every Interval.

NOTE: For additional service items see list of “Maintenance Intervals” on page 4-26.

Inspection, Maintenance and Adjustment

OP000997

4-25

MAINTENANCE INTERVALS

SERVICE ITEM

PAGE

10 Hour / Daily Service

Grease Front Attachment Pins

4-28

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

4-28

Check Engine Oil Level

4-28

Check Transmission Oil Level

4-29

Check Hydraulic System Oil Level

4-30

Check for Leaks in Hydraulic System

4-31

Fill Fuel Tank

4-31

Check for Leaks in Fuel System

4-32

Drain Fuel Condensation

4-32

Check Coolant Level

4-32

Check Level of Windshield Washer Liquid

4-33

Inspect the Bucket Teeth and Side Cutters for Signs of Wear

4-33

Inspect Seat Belt for Proper Operation

4-33

Inspect the Structure for Cracks and Faulty Welds

4-33

Check the Operation of All Switches

4-33

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

4-34

Monitor Lights

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

4-34

Normal Operating Temperature. Listen for Any Abnormal Sounds

Check Operation of All Controls

4-34

Inspect Cooling Fan Blade

4-35

Water Trap

4-35

Check Engine Drive Belt Wear

4-36

Check Air Intake System

4-37

50 Hour / Weekly Service

Perform All Daily Service Checks

4-38

Grease Front Attachment Pins

4-38

Grease Steering Cylinder Rod and Head Ends

4-43

Grease Upper and Lower Center Pins

4-43

Change Engine Oil and Filter (After First 50 Hours)

4-44

Change Hydraulic Full Flow Filter (After First 50 Hours)

4-44

Check Air Conditioner and Alternator Belt Tension (After First 50 Hours)

4-44

Clean Exterior of Radiator, Oil Cooler and Air Conditioner Condenser

4-44

Clean Air Conditioner Outer Filter

4-45

250 Hour / Monthly Service

Perform All Daily and 50 Hour Service Checks

4-46

Check Engine Air Intake Precleaner

4-46

Drain Water From Hydraulic Oil Tank

4-46

Check Air Conditioner and Alternator Belt Tension

4-47

Grease Drive Shafts

4-47

Change Transmission Oil and Filter (After First 250 Hours)

4-47

Clean Outer Filter of Air Cleaner

4-48

Inspection, Maintenance and Adjustment

OP000997

4-26

500 Hour / 3 Month Service

Perform All Daily, 50 and 250 Hour Service Checks

4-50

Change Hydraulic System Brake and Pilot Filter

4-50

Supplemental Coolant Additive (SCA) and Antifreeze Concentration

4-51

Coolant Filter

4-52

Fuel Filter (Spin-On Type)

4-55

Change Fuel Prefilter

4-57

Change Fuel Filter

4-58

Turbocharger

4-59

Change Engine Oil and Filter

4-60

Clean Exterior of Radiator, Oil Cooler and Air Conditioner Condenser

4-62

Clean Air Conditioner Inner Filter

4-63

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

4-63

Change Air Conditioner Outer Filter

4-63

1,000 Hour / 6 Month Service

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

4-64

Air Cleaner

4-64

Change Outer Air Cleaner Filter

4-65

Drain and Replace Transmission Oil and filter

4-66

Clean Fuel Tank and Strainer

4-68

Change Air Conditioner Inner Filter

4-68

Check Air Conditioner Refrigerant

4-69

Check and Adjust Engine

4-70

Change Air Breather Filter

4-70

Change Hydraulic Full Flow Filter

4-71

1,500 Hour / 9 Month Service

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

4-72

Change Axle Differential and Planetaries Oil

4-72

Axle Brake Disk Wear Measurement

4-73

2,000 Hour / Yearly Service

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

4-75

Change Inner Air Cleaner Filter

4-75

Check Steering, Brake, DriveShaft, Engine, and Fuel System

4-75

Change Pipes and Hoses

4-75

Bleed Brakes

4-76

Change Radiator Coolant

4-77

Change Hydraulic Oil and Clean Oil Suction Strainer

4-79

Check Brake Accumulator

4-81

12,000 Hour / 6 Year Service

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

CEN)

4-82

Inspection, Maintenance and Adjustment

OP000997

4-27

10 HOUR / DAILY SERVICE

Grease Front Attachment Pins

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

first

100 hours of operation to comply with new

machine break-in requirements. After that, greasing

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

in water, grease fittings immediately after machine is

removed from water. Follow procedure printed under

the

50 hour maintenance interval

“Grease Front

Attachment Pins” on page 4-38.

Inspect All Tires for Correct Tire

Pressure and Signs of Damage or

Abnormal Wear

Inflate tires to proper operating pressure for working

conditions. See “Tires” on page 4-100.

Check Engine Oil Level

•

Engine Oil Fill Cap (Figure 13)

FG015204

Figure 13

•

Engine Oil Dipstick (Figure 14)

FG015212

Figure 14

Inspection, Maintenance and Adjustment

OP000997

4-28

NOTE: When checking level using a dipstick always remove

and wipe it clean before making final level check.

Check level of engine oil every day before starting

engine.

Remove engine oil dipstick (Figure 14). Oil level must

be between "LOW" and "FULL" marks.

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

must be drained to return oil to proper level.

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

HAOC280L

Figure 15

Check Transmission Oil Level

NOTE: When checking level using a dipstick always remove

and wipe it clean before making final level check.

Use two people to perform this operation.

Start engine and move machine to a level area.

Place transmission lever in "NEUTRAL".

Apply parking brake.

FG001687

Allow engine to idle until engine temperature is

between 82°C (180°F) and 93°C (200°F).

Figure 16

Remove transmission dipstick (Figure 16). Wipe dipstick

clean and then insert it back into transmission.

Remove dipstick and check oil level mark. Oil level

must be between "LOW" and "FULL" marks

(Figure

17).

To add oil, remove transmission fill cap

(Figure

16)

from transmission oil fill pipe.

Shut down engine when done.

HAOC280L

Figure 17

Inspection, Maintenance and Adjustment

OP000997

4-29

Check Hydraulic System Oil Level

WARNING

The hydraulic oil will be hot after normal machine

operation. Allow system to cool before attempting to

service any of the hydraulic components.

The hydraulic tank is pressurized. Press button in center

of breather to allow the pressurized air to vent. After the

HAOA060L

pressure has been released, it is safe to remove either

Figure 18

the fill cap or service covers

Move machine to a level area and shut down engine.

Apply parking brake.

Lower bucket to ground.

Check sight gauge that is attached to hydraulic tank.

Oil level must be visible in red centered circle shown

on sight gauge (1, Figure 19).

FG001688

Figure 19

To add hydraulic oil, turn the breather cap

(1, Figure

20) slowly to allow the pressurized air to vent.

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

tank and raise boom at max. height and replenish oil

to the top of sight gauge (Figure 19).

IMPORTANT

Do not fill above red centered circle on sight

FG002186

gauge. Overfilling can result in damage to

Figure 20

equipment and oil leaking from hydraulic tank due

to expansion.

The hydraulic oil fill cover also serves as the hydraulic oil

strainer access cover. It is important to replace this cover

and the components in the proper order and alignment.

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

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

of the filter fits over a circular base in the bottom of the

tank. The retaining rod

(3) screws into the top of the filter

(2), but the spring

(4) slides over the top of the rod. Be

certain that this spring does not fall into the tank during

reassembly.

FG002188

If filter assembly was removed, insert assembly into the

Figure 21

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

Inspection, Maintenance and Adjustment

OP000997

4-30

Check O-ring for damages and replace if necessary.

Check position of O-ring at surface of hole.

Place the cover on the access hole. Make sure the

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

of the cover is lined up with the spring. The filter

assembly rod must be in a vertical position and

perpendicular to the base of the tank. The cover can

be rotated to align the rod into a vertical position.

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

FG002189

Figure 22

Check for Leaks in Hydraulic System

Perform a daily walk-around inspection to make sure

that the hoses, piping, fittings, cylinders and hydraulic

motors are not showing any signs of leakage. If any is

noted, determine the source of the leak and repair.

Fill Fuel Tank

WARNING

Use extreme safety precautions while refueling to

prevent explosions or fire.

Immediately clean up any spilt fuel.

FG001689

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

through fuel fill cap

(Figure

23). When working at a

Figure 23

temperature of

0°C (32°F) or higher, use ASTM No.

2-D or its equivalent. At temperatures below 0°C (32°F)

use ASTM No. 1-D or its equivalent.

NOTE: See

“Fluid Capacities” on page 4-21. for

capacity.

Securely tighten cap after fueling.

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

may form in the tank preventing proper fuel flow

to engine. Keep holes in fuel cap clean.

FG001690

Figure 24

Inspection, Maintenance and Adjustment

OP000997

4-31

Check for Leaks in Fuel System

Perform an inspection of engine compartment to verify

that fuel system is not leaking. If any is noted,

determine the source of leak and repair.

Drain Fuel Condensation

Open fuel tank drain valve.

(Figure

25). Allow any

condensed water or sediment to drain out of tank.

NOTE: Dispose of drained fluids according to local

regulations.

FG002203

Figure 25

Check Coolant Level

NOTE: Do not mix ethylene glycol and propylene glycol

antifreeze together. If the two are mixed, the

protection level will be reduced to the level of the

ethylene glycol.

NOTE: This unit was factory filled with propylene glycol.

WARNING

FG001692

Figure 26

Never open radiator when it is hot. Scalding liquid

inside a hot radiator is under pressure. Removing cap

from a hot radiator could cause a person to be sprayed

and burned from liquid inside. Wait for radiator

temperature to cool down before removing cap.

Check sight gauge (1, Figure

27) that is attached to

the radiator. Coolant level must be visible in red

centered circle shown on gauge. To add coolant,

remove fill cap (2, Figure

27) of the radiator and add

coolant to proper level by checking sight gauge

(1,

Figure

27). If temperature is below freezing, see

“Antifreeze Concentration Tables” on page 4-88 for

antifreeze protection. Use the table to calculate a

proper mixture of antifreeze and water to provide level

of protection necessary for expected temperature.

FG015224

Figure 27

Inspection, Maintenance and Adjustment

OP000997

4-32

Check Level of Windshield Washer

Liquid

Check fluid level in windshield washer tank, behind

operator's seat.

Open fill cap and add fluid.

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

The will prevent freezing during cold weather

operation.

FG001693

Figure 28

Inspect the Bucket Teeth and Side

Cutters for Signs of Wear

On a daily basis, inspect bucket teeth to make sure

that tooth wear or breakage has not developed.

Do not allow replaceable bucket teeth to wear down to

the point that bucket adapter is exposed. (Figure 29)

NOTE: These instructions are only for DOOSAN OEM

buckets. If you are using other manufacturers'

FG001694

buckets, refer to their specific instructions.

Figure 29

Inspect Seat Belt for Proper Operation

Inspect the Structure for Cracks and

Faulty Welds

During the daily walk-around inspection and when

greasing the machine, look for any visible damage to

the machine. Repair or replace any damaged parts

before operating machine.

Check the Operation of All Switches

Verify working condition of all switches before starting

engine.

Inspection, Maintenance and Adjustment

OP000997

4-33

Check the Operation of All Exterior

Lights, Horn and Control Console

Indicator and Monitor Lights

Turn engine starter switch to "I"

(ON) position and

observe all indicator lights.

Restore operation of any light bulbs that do not turn

"ON" at this time.

Sound the horn. Repair or replace if required.

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

any monitors, burned out bulbs or cracked or broken

housings or lenses.

Start Engine, Check Starting Ability, and

Observe Exhaust Color at Start-up

and at Normal Operating

Temperature. Listen for Any

Abnormal Sounds

Check Operation of All Controls

IMPORTANT

Cold weather operation requires that the operator fully

warm up the hydraulic oil before beginning machine

operation. Follow all warm up instructions listed in the

Operating Instruction section of this manual. Make sure

to cycle oil through all of the components, including all

cylinders, both travel motors and the swing motor. Cold

hydraulic oil in the lines and components needs to be

warmed before beginning full operation. If this is not

done, damage to the cylinders or hydraulic motors can

occur.

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

Follow cold weather hydraulic system warm-up

procedures.

Note any slow operations or unusual movements.

Determine the cause and repair fault before operating.

Inspection, Maintenance and Adjustment

OP000997

4-34

Inspect Cooling Fan Blade

WARNING

Personal injury can result from a fan blade failure.

Never pull or pry on the fan. This can damage the fan

blade(s) and cause fan failure.

An inspection of the cooling fan is required daily. check

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

Figure 30

contact between the blade tips and the fan shroud.

Check the fan to make sure it is securely mounted.

Tighten the bolts if necessary. Replace any fan that is

damage.

Water Trap

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

hose.

Drain the water trap every 250 hours.

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

A nonreturn valve in the filter head prevents the fuel from

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

pressure will remain and as a consequence no water will be

FG001691

drained unless new fuel is pumped in.

Figure 31

Proceed as follows:

•

Place the end of the hose in a vessel.

•

Loosen draining nipple (C).

•

Pump with hand pump (A) on the primary filter

head until all water has been forced out of water

trap (B).

•

Tighten the draining nipple.

open

NOTE: Take care of waste oil and liquid in an

environmentally safe way!

FG000438

Figure 32

Inspection, Maintenance and Adjustment

OP000997

4-35

Check Engine Drive Belt Wear

WARNING

Keep clear of engine fan and fan drive belts when the

engine is running. Rotating fan and belt contact can

cause injury.

Figure 33

WARNING

When checking, adjusting or replacing drive belts, care

must be taken to prevent accidental cranking of the

engine. Be sure the starter switch is in the "OFF"

position and the controls are tagged.

Replace badly worn, greasy or severely cracked belts

immediately. These conditions prevent proper belt

function. Visually inspect the belt. Check the belt for

intersecting cracks. Transverse

(across the belt width)

cracks are acceptable. Longitudinal

(direction of belt

length) cracks that intersect with transverse cracks are

not acceptable. Replace the belt if it is frayed or has

pieces of material missing.

Before installing new belts, make sure all pulley

grooves are clean and not worn. Replace pulley, if

damaged, or if the grooves are worn.

All pulley support bearings, shafts, and brackets must

be in working order.

When replacing belts and pulleys, pulley alignment

must be checked with belts tensioned and brackets

securely clamped. A misalignment that can be detected

by the naked eye is detrimental to belt performance.

Do not force the belts into the pulley grooves by prying

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

side cords which will cause the belts to turn and result

in complete destruction of the belts in operation.

Belts on new machines and replacement belts lose

their tension as they seat into the pulley grooves.

Check the tension of new belts at

20 hour intervals

until tension is stabilized and thereafter, every

250

hours. If the tension falls below the required minimum,

the belt will be able to slip, damaging the belts and

pulley grooves.

NOTE: When operating in abrasive conditions, check

tension every 100 hours.

Inspection, Maintenance and Adjustment

OP000997

4-36

Check Air Intake System

WARNING

Hot engine components can cause burns.

Avoid contact with hot engine components

Park the machine on a level surface, apply the parking

brake, lower the attachment to the ground, and shut

HAOA050L

down engine.

Figure 34

Check the engine intake hose, and hose clamps for

damage and tightness.

If damaged, wrinkled or loose, replace, tighten or

contact your nearest DOOSAN loader dealer.

IMPORTANT

Severe engine damage will result from running with

unfiltered air.

Do not operate engine if any leaks or defects are Figure 35

found on air intake system.

Inspection, Maintenance and Adjustment

OP000997

4-37

50 HOUR / WEEKLY SERVICE

Perform All Daily Service Checks

Grease Front Attachment Pins

Following fittings are greased daily, or every 10 hours,

for first

100 hours of operation to comply with new

machine break-in requirements. After that, greasing

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

in water, grease fittings immediately after machine is

removed from water.

FG015249

Figure 36

Inspection, Maintenance and Adjustment

OP000997

4-38

Loader arm foot ends,

2 locations on each

side of machine. Greased from two remote

grease points (1, Figure 45).

FG001703

Figure 45

Bucket cylinder head, 1 point. Greased from

remote grease point (Figure 46).

FG001704

Figure 46

F. Grease rear axle pivot (1, Figure 47), 3 locations

on left side of machine. Use remote grease

fittings mounted on frame shown in Figure 48.

FG001705

Figure 47

(Pivot Cover)

(Rear Pivot)

(Front Pivot)

FG001706

Figure 48

Inspection, Maintenance and Adjustment

OP000997

4-42

Doosan DL420. Operation and Maintenance Manual (2009) - page 2