Page 1 Serial Number 2001 and Up August 2001 DOOSAN reserves the right to improve our products in a continuing process to provide the best possible product to the market place. These improvements can be implemented at any time with no obligation to change materials on previously sold products.
Page 3: Table Of Contents
TABLE OF CONTENTS Safety ....................1-1 To the Operator of a Wheel Loader ............. 1-1 General Safety Essentials ................1-4 Location of Safety Labels ................1-4 Unauthorized Modiﬁcations ............... 1-13 General Hazard Information ..............1-13 Before Starting Engine ................1-21 Machine Operation ..................1-24 Maintenance....................
Page 4 Instrument Panel Control Functions ............3-1 New Machine Break-in Procedures.............3-1 Engine Start and Stop..................3-2 Machine Travel....................3-9 Machine Shutdown..................3-12 Additional Braking ..................3-14 Boom Raise Kickout ..................3-14 Boom Lower Kickout (Option) ..............3-15 Bucket Angle Indicator ................3-16 Adjustment of Bucket Position Switch ............3-16 Towing Machine..................
Page 5 Long Term Storage ..................4-61 Transportation ..................5-1 Loading Machine on a Trailer..............5-1 Summary of Safety Precautions for Lifting ..........5-2 Troubleshooting................. 6-1 Engine ......................6-1 Hydraulic System ..................6-3 Travel System .....................6-5 Steering ..................... 6-10 Braking ...................... 6-11 Electrical System..................6-11 Specifications..................7-1 General Specifications ................7-1 Working Range and Dimensions..............7-2 Working Capacities ..................7-4...
Page 7: Safety
SAFETY TO THE OPERATOR OF A WHEEL LOADER DANGER! Unsafe use of the wheel loader could lead to serious injury or death. Operating procedures, maintenance and equipment practices or traveling or shipping methods that do not follow the safety guidelines on the following pages could cause serious, potentially fatal injuries or extensive damage to the machine or nearby property.
Page 8 In no event should you or others engage in prohibited uses or actions as described in this manual. DOOSAN delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped. If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety devices and specifications that are necessary for use in your country.
Page 9 If any procedures or actions not specifically recommended or allowed in this manual are used, you must be sure that you and others can do such procedures and actions safely and without damaging the machine. If your unsure about the safety of some procedures, contact a DOOSAN distributor.
Page 10: General Safety Essentials
This wheel loader has been designed primarily for moving earth with a bucket. For use as a grapple or for other object handling, contact DOOSAN. Lifting-work applications are permitted in approved lift configuration, to rated capacity only, with no side-loading (unless prohibited by local regulation). Do not use machine for activities for which it was not intended.
Page 11 AQO0320L Figure 1 ROPS CANOPY MACHINE WITH CABIN 022-00029AE Operation and Maintenance Manual Safety 1-5...
Page 12 AQO0330L Figure 2 CAB MACHINE 1-6 Safety 022-00029AE Operation and Maintenance Manual...
Page 13 Set park brake. • Turn starter switch "OFF." Remove key from switch. If hydraulic components and units are ABNORMAL, consult nearest DOOSAN dealer • or authorized service shop. Do not attempt to make an overhaul. WARNING FOR CRUSH HAZARD (4190-2548)
Page 14 WARNINGS WHEN OPENING ENGINE HOOD (2190-2525, 190-00095) WARNING! Before opening bonnet, stop engine. ACO1420L WARNING FOR HANDLING ACCUMULATOR (2190-2528, 190-00099) WARNING! Explosion hazard: • Keep away from flame. • Do not weld or drill. ACO1480L Accumulator The pilot control system is equipped with an accumulator. For a brief period of time after the engine has been shut down, the accumulator will store a pressure charge that may enable hydraulic controls to be activated.
Page 15 When performing maintenance on the pilot control system, the hydraulic pressure in the system must be released as describe in “Handling of Accumulator” on page 4-52. IMPORTANT Refer to Shop Manual for service procedures. Do not release any pilot lines until pressure within accumulator has been released.
Page 16 WARNING FOR HIGH TEMPERATURE COOLANT (2190-2531, 190-00097) WARNING! To prevent hot water from spurting out: • Turn engine "OFF." • Allow water to cool. • Slowly loosen cap to relieve pressure before removing. ACO1410L WARNING FOR BATTERY MAINTENANCE (2190-2533, 190-00100) DANGER! •...
Page 17 WARNING FOR RIDING ON MACHINE (4190-1989, 190-00107) WARNING! For your safety, do not stand on ladder when machine is in motion. AMO0420L 10. WARNING FOR PERFORMING MAINTENANCE ON FRONT ATTACHMENT (4190-2546, 190-00105) DANGER! To avoid injury, securely brace lift arm before disassembly of valve or piping.
Page 18 WARNING TO USE SAFETY LOCK (4190-1993, 190-00121) WARNING! Safety lock must be in "LOCK" position when servicing pivot area or transporting machine. AMO0440L 12. WARNING TAG (2190-2549, 190-00098) WARNING! Don’t touch when performing inspection or maintenance. ACO1450L 1-12 Safety 022-00029AE Operation and Maintenance Manual...
Page 19: Unauthorized Modifications
For safety’s sake, replace all OEM parts with the correct authorized or genuine DOOSAN part. For example, not taking the time to replace fasteners, bolts or nuts with the correct replacement parts could lead to a condition in which the safety of critical assemblies is dangerously compromised.
Page 20 INSIDE OPERATOR'S COMPARTMENT When entering the operator's compartment, always remove all mud and oil from the soles of your shoes. If you operate the accelerator and brake pedals with mud or oil stuck to your shoes, your foot may slip and this may cause a serious accident.
Page 21 BREATHING MASKS, EAR PROTECTION MAY BE REQUIRED Do not forget that some risks to your health may not be immediately apparent. Exhaust gases and noise pollution may not be visible, but these hazards can cause disabling or permanent injuries. NOTE: Sound level in closed operator’s cab is 78 dB(A).
Page 22 FUEL, OIL AND HYDRAULIC FLUID FIRE HAZARDS Fuel, oil and antifreeze will catch fire if it is brought close to a flame. Fuel is particularly flammable and can be hazardous. Always strictly observe the following. Add fuel, oil, antifreeze and hydraulic fluid to the machine only in a well-ventilated area.
Page 23 INJURY FROM WORK EQUIPMENT Do not enter or put your hand, arm or any other part of your body between movable parts, such as between the work equipment and cylinders, or between the machine and work equipment. If the control levers are operated, the clearance between the machine and the work equipment will change and this may lead to serious damage or personal injury.
Page 24 Contact your DOOSAN distributor for available safety guards and/or recommendations if there is any danger of getting hit by objects that could strike the operator’s cab. Make sure that all other work site crew members are kept well away from wheel loader and safe from potential hazards.
Page 25 ATTACHMENT PRECAUTIONS Options kits are available through your dealer. Contact DOOSAN for information on available one-way (single-acting) and two-way (double-acting) piping / valving / auxiliary control kits. Because DOOSAN cannot anticipate, identify or test all attachments that owners may wish to install on their machines, please contact DOOSAN for authorization and approval of attachments, and their compatibility with options kits.
Page 26 EMERGENCY EXIT This loader is equipped with a glass breaking tool. It is in the lower right side of the cab just rear of the door. This tool can be used in case of an emergency situation which requires the breaking of glass to exit from the operator’s cabin.
Page 27: Before Starting Engine
BEFORE STARTING ENGINE WORK SITE PRECAUTIONS Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous. Check the terrain and condition of the ground at the work site, and determine the best and safest method of operation.
Page 28 CHECKS BEFORE STARTING ENGINE Every day before starting the engine for the first time, carry out the following checks. If these checks are not carried out properly, there is danger of serious injury. • Completely remove all wood chips, leaves, grass, paper and other flammable materials accumulated in the engine compartment and around the battery.
Page 29 BEFORE OPERATING MACHINE If checks are not carried out properly after starting the engine, it may result in a delay in discovering abnormalities in the machine, and this may lead to personal injury or damage to the machine. Carry out the checks in an open area where there are no obstructions. Do not let anyone near the machine when carrying out the checks.
Page 30: Machine Operation
If you need more information or have any questions or concerns about safe operating procedures or working the wheel loader correctly in a particular application or in the specific conditions of your individual operating environment, please consult your local DOOSAN representative.
Page 31 TRAVEL PRECAUTIONS When traveling, wheel loader always keeps lights on; make sure that you are in compliance with all state and local regulations concerning warning flags and signs. Never turn the starter switch to the "O" (OFF) position when traveling. It is dangerous if the engine stops when the machine is traveling.
Page 32 AVOID HIGH-VOLTAGE CABLES Serious injury or death can result from contact or proximity to high-voltage electric lines. The bucket does not have to make physical contact with power lines for current to be transmitted. Use a spotter and hand signals to stay away from power lines not clearly visible to operator.
Page 33 USE SOLID SUPPORT BLOCKING Never rely on lift jacks or other inadequate supports when work is being done. Block wheels fore and aft to prevent any movement. DIGGING BENEATH OVERHANGS Digging beneath an overhang is dangerous. Overhand could collapse on top of operator and cause serious injury or death.
Page 34 NEVER USE ETHER STARTING AIDS An electric-grid type manifold heater is used for cold starting. Glowing heater element can cause ether or other starting fluid to detonate, causing injury. Figure 22 OBSERVE GENERAL SAFETY RULES Only trained and authorized personnel, with a good knowledge and awareness of safe procedures, may be allowed to operate or perform maintenance or service on wheel loader.
Page 35 KEEP "PINCH POINT" AREAS CLEAR - USE CAUTION IN REVERSE Use a signal person in high traffic areas and whenever operator’s view is not clear, such as when traveling in reverse. Anyone standing near wheels, or working assemblies of the attachment, is at risk of being caught between moving parts of machine.
Page 36 SHUTDOWN CONTROL FUNCTIONS After bucket has been lowered to overnight storage position, move all switches and controls to "OFF" position. Pull parking brake knob to "APPLIED" position. This will apply parking brake. Move pilot cutoff switch to "LOCK" position. This will disable pilot control valve lever (joystick). Move key in starter switch to "OFF"...
Page 37: Maintenance
Alert others that service or maintenance is being performed and tag operator’s cab controls - and other machine areas if required - with a warning notice. WARNING Warning tags for controls are available from DOOSAN distributors; see Figure 25. CLEAN BEFORE INSPECTION OR MAINTENANCE HAOC920L Clean machine...
Page 38 PROPER TOOLS Use only tools suited to the task. Using damaged, low qualify, faulty, or makeshift tools could cause personal injury. There is danger that pieces from, chisels with crushed heads, or hammers, may get into your eyes and cause blindness.
Page 39 BURN PREVENTION When checking the radiator coolant level, stop the engine, let the engine and radiator cool down, then check the coolant recovery tank. If the coolant level in the coolant recovery tank is near the upper limit, there is enough coolant in the radiator. Loosen the radiator cap gradually to release the internal pressure before removing the radiator cap.
Page 40 WELDING REPAIRS When carrying out welding repairs, carry out the welding in a properly equipped place. The welding should be performed by a qualified worker. During welding operations, there is the danger of, generation of gas, fire, or electric shock, so never let an unqualified worker do welding. The qualified welder must do the following;...
Page 41 PRECAUTIONS WHEN WORKING ON MACHINE When carrying out maintenance operations on the machine, keep the area around your feet clean and tidy to prevent you from falling. Always do the following; • Do not spill oil or grease. • Do not leave tools laying about. •...
Page 42 95°C (203°F), however do not allow full cool-down. HYDRAULIC CYLINDER SEALS REQUIRE PERIODIC REPLACEMENT Check cylinder drift rate at regular intervals. Overhaul seal kits are available through DOOSAN. HIGH PRESSURE HYDRAULIC LINES CAN STORE A GREAT DEAL OF ENERGY Exposed hydraulic hoses on arm could react with explosive force if struck by a falling rock, overhead obstacle or other job site hazard.
Page 43 PRECAUTIONS WITH HIGH PRESSURE LINE, TUBES AND HOSES When inspecting or replacing high-pressure piping or hoses, check that the pressure has been released form the circuit. Failure to release the pressure may lead to serious injury. Always do the following; •...
Page 44 USE CORRECT REPLACEMENT FASTENERS TIGHTENED TO PROPER TORQUE Refer to "General Maintenance" section of Shop Manual for information on tightening torques and recommended assembly compounds and always use correct part. Poor or incorrect fastener connections can dangerously weaken assemblies. SAFETY-CRITICAL PARTS MUST BE REPLACED PERIODICALLY Replace following fire-related components as soon as they begin to show any sign of wear, or at regular periodic intervals, whether or not deterioration is visible: •...
Page 45: Battery
BATTERY BATTERY HAZARD PREVENTION Battery electrolyte contains diluted sulfuric acid and batteries generate hydrogen gas. Hydrogen gas is highly explosive, and mistakes in handling them can cause serious injury or fire. To prevent problems, always do the following; • Do not smoke or bring any flame near the battery. •...
Page 46 USE LOW HEAT PORTABLE LIGHTING Hot surfaces on trouble lights or portable work lights can set off fuel or battery explosive gases. BOOST STARTING OR CHARGING ENGINE BATTERIES If any mistake is made in the method of connecting the booster cables, it may cause an explosion or fire.
Page 47: Towing
• If the engine on the problem machine will not start or there is a failure in the brake system. always contact your DOOSAN distributor. • Never go between the towing machine and the towed machine during the towing operation.
Page 48: Shipping And Transportation
SHIPPING AND TRANSPORTATION OBEY STATE AND LOCAL OVER-THE-ROAD REGULATIONS Check state and local restrictions regarding weight, width and length of a load before making any other preparation for transport. Hauling vehicle, trailer and load must all be in compliance with local regulations governing intended shipping route.
Page 49 2OPERATING CONTROLS "Operating Controls" section presented here consists of the following groups: “Component Locations” on page 2-2 “Control Identification” on page 2-4 “Steering Console and Pedals” on page 2-5 “Front Instrument panel” on page 2-12 “Transmission Display” on page 2-21 “Right Side Switch Panel”...
Page 50: Component Locations
COMPONENT LOCATIONS The following figure identifies the location of major machine components. 24 25 AQO0190L Figure 1 2-2 Operating Controls 022-00029AE Operation and Maintenance Manual...
Page 51 BUCKET TOOTH 23. ENGINE BUCKET 24. CAC COOLER OPERATOR’S CAB 25. RADIATOR AIR CONDITIONING CONDENSER 26. FAN BATTERY BOX (R.H.) 27. GRILL FAN MOTOR 28. FUEL TANK COUNTERWEIGHT 29. FUEL FILLER PIPE BATTERY BOX (L.H.) 30. ENGINE OIL LEVEL GAUGE OIL TANK 31.
Page 52: Control Identification
CONTROL IDENTIFICATION AQO0020L Figure 2 STEERING CONSOLE AND PEDALS (See RIGHT SIDE SWITCH PANEL (See page page 2-5) 2-22) VARIOUS CABIN LOCATIONS (See page SEAT ADJUSTMENT (See page 2-48) 2-33) 2-4 Operating Controls 022-00029AE Operation and Maintenance Manual...
Page 53: Steering Console And Pedals
STEERING CONSOLE AND PEDALS AQO0340L Figure 3 STARTER SWITCH KICK-DOWN SWITCH HORN BUTTON TRANSMISSION LEVER COMBINATION SWITCH LEVER 10. FRONT INSTRUMENT PANEL (See page ACCELERATOR PEDAL 2-12) STEERING TILT KNOB TRANSMISSION DISPLAY (See page BRAKE PEDALS 2-21) STEERING WHEEL 022-00029AE Operation and Maintenance Manual Operating Controls 2-5...
Page 54 STARTER SWITCH To start or stop the engine for equipment operation. Turning the switch to this position turns the engine "OFF" along with its electrical system. In this position the engine is "OFF" but the interior cab light and fuel tank transfer pump (if equipped) are functional.
Page 55 Figure 6 COMBINATION SWITCH LEVER Left Side Directional Switch Pushing lever forward, activates left outside directional lights directional indicator light instrument panel. Right Side Directional Switch - Pulling lever back, activates right outside directional lights directional indicator light instrument panel. AHO0920L NOTE: When a turn is completed the...
Page 56 Push Down - Locks into position and lights up the high beams. Neutral Position - Normal low beams. Pull Up - Momentarily turns "ON" both the low and high beams. (Lever returns to "NEUTRAL" position when released.) NOTE: High and low beams will only function with headlight...
Page 57 BRAKE PEDAL (RIGHT AND LEFT PEDALS) Pressing brake pedal will apply the brakes to the loader. The brake pedal modes can be switched over from inching to no- inching or vice-versa, by using the transmission cutoff switch (See page 2-31). CAUTION! Figure 11 When descending on an incline, slow...
Page 58 KICK-DOWN SWITCH (TWO PLACES) When transmission is in 2nd gear, pressing this switch will shift transmission into 1st gear. This will allow the driver to perform a quick digging movement. NOTE: Kick-down "RELEASED" when transmission is placed in "NEUTRAL” position or the switch is pressed again Kick-down function range: HAAA3670...
Page 59 A transmission neutral lever lock is in base of transmission lever. This neutral lever lock prevents the transmission lever from being moved out of "NEUTRAL." "NEUTRAL LOCK" position. Prevents lever from being moved out of "NEUTRAL." "DRIVE" position. Allows lever to be moved from "NEUTRAL"...
Page 60: Front Instrument Panel
FRONT INSTRUMENT PANEL AQO0360L Figure 19 2-12 Operating Controls 022-00029AE Operation and Maintenance Manual...
Page 61 GAUGES FUEL GAUGE COOLANT TEMPERATURE GAUGE SPEEDOMETER TRANSMISSION OIL TEMPERATURE. HOUR METER GAUGE TACHOMETER WARNING LIGHTS PREHEAT INDICATOR LIGHT 14. RIGHT TURN AND HAZARD WARNING AIR CLEANER CLOGGING WARNING LIGHT LIGHT 15. WORK LIGHT INDICATOR LIGHT ENGINE WARNING LIGHT 16. BRAKE OIL PRESSURE WARNING 10.
Page 62 SPEEDOMETER This meter displays speed at which vehicle is traveling. HBOI230L Figure 21 HOUR METER A LCD meter that records total time that starter switch is turned "ON" up to 99,999.9 hours. When engine is running, the hourglass icon blinks every four seconds.
Page 63 COOLANT TEMPERATURE GAUGE This gauge displays temperature of engine coolant. CAUTION! When the pointer indicates "H" mark (red zone), it means the engine is overheated. Stop the operation, let the engine run at low rpm and wait HBOI260L for it to cool down. Figure 24 Do not shutdown engine.
Page 64 AIR CLEANER CLOGGING WARNING LIGHT When this light turns "ON," dirt has built up in the air filter and is beginning to restrict flow of air. Clean or replace air filter element before continuing to operate machine. To turn indicator light "OFF," turn starter switch "OFF"...
Page 65 BATTERY WARNING LIGHT When starter switch is first turned to "ON" position, this red light should turn "ON." When engine is running this red light should turn "OFF." If light remains "ON" when engine is running, alternator is defective. HAOA610L Figure 31 12.
Page 66 15. WORK LIGHT INDICATOR LIGHT This light should turn "ON" when the front and/or rear work lights are activated. Figure 35 16. BRAKE OIL PRESSURE WARNING LIGHT This light turns "ON" when pressure drops in brake oil circuit. When light turns "ON," an alarm also sounds.
Page 67 18. PARKING BRAKE INDICATOR LIGHT When parking brake is "APPLIED," this light turns "ON." If vehicle is moved while parking brake is applied, a warning alarm will sound. WARNING! If the vehicle is moved while this light is "ON" it could cause premature 0717A wear or damage of the brakes.
Page 68 21. LOAD ISOLATION SYSTEM (LIS) SWITCH (OPTION) When this switch is moved to "OFF” position, it does not allow boom cylinders to act as shock absorbers. When this switch is moved to "ON” position, it causes boom cylinders to act as shock absorbers. This reduces machine bouncing when machine is traveling with a loaded bucket.
Page 69: Transmission Display
TRANSMISSION DISPLAY A transmission display is to the left of the steering wheel on the dash. The LCD indicates, gears, direction of travel, error codes, and activated kick-down. AQO0130L Figure 42 Figure 43, shows the transmission display in detail. Indicates travel direction gear...
Page 70: Right Side Switch Panel
RIGHT SIDE SWITCH PANEL AQO0070L Figure 45 PILOT CONTROL VALVE LEVER REAR WIPER SWITCH (JOYSTICK) ALTERNATE TORQUE SWITCH 1A. ERGO-II PILOT CONTROL VALVE LEVER 10. ALTERNATE LOW IDLE SWITCH (JOYSTICK) (OPTION) ROTATING BEACON SWITCH (OPTION) KICK-DOWN SWITCH / LOG FORK 12.
Page 71 PILOT CONTROL VALVE LEVER (JOYSTICK) Used to position bucket and boom. This lever is capable of raising or lowering boom, and crowding or dumping bucket. When machine is being traveled, the lever (joystick) can be "LOCKED" out, to prevent any movement of bucket or boom. To "LOCK"...
Page 72 Traveling Speed Changing Switches. The transmission has 4 speeds in forward and 3 speeds in reverse. Button − When pressing this "+" switch, machine speed increase. Button − When pressing this "-" switch, machine speed decrease. Kick-down Switch. "KD" Button − When pressing this switch that is in the rear side, kick- HAAD3761 down function is selected.
Page 73 KICK-DOWN SWITCH (TWO PLACES) / LOG FORK SWITCH (OPTION) Kick-down Switch Function When transmission is in 2nd gear, pressing this switch (Figure 50) will shift transmission into 1st gear. This will allow the driver to perform a quick digging movement. Kick-down function range: •...
Page 74 AHO0890L Figure 52 CIGAR LIGHTER Push in cigar lighter. It will remain in, until it is hot. When hot, it will pop back. It is now ready for use. IMPORTANT The cigar lighter is powered by a 24 volt circuit. Never plug any 12 volt device into the cigar lighter.
Page 75 FRONT WORK LIGHT SWITCH In this position, this switch turns "OFF" work lights mounted on the front top of cab. In this position, this switch turns "ON" work lights mounted on the front top of cab. CAUTION! HAOQ071L Do not turn "ON" the work light when Figure 55 traveling on public roads.
Page 76 REAR WIPER SWITCH In this position, this switch turns "OFF" windshield wiper mounted on rear windshield of operator’s cab. In this position, windshield washer fluid sprays onto the rear windshield while running the rear wiper. When released, the switch returns to the "O"...
Page 77 10. ALTERNATE IDLE SPEED SWITCH The alternate low idle switch allows operator to select an alternate idle speed (about 1,200 rpm). This feature is activated whenever the normally open alternate low idle switch is closed and 0 volts are detected by the ECM on the alternate low idle signal line.
Page 78 14. IDLE SPEED CONTROL SWITCH The idle speed control allows the idle speed to be adjusted in 25 rpm increments by pressing the idle speed control switch. The switch will only work from 800 to 900 rpm. Pressing the "I" position of the switch will increase (+) engine rpm.
Page 79 16. TRANSMISSION CUTOFF SWITCH This switch changes over the modes of the brake pedal, inching and no-inching. In this position, the "NO INCHING" mode is selected. In the "NO INCHING" mode, the power transmission line still connected when the brake pedal is pressed, thus, making it easier to start off on an incline.
Page 80 18. PARKING BRAKE SWITCH In this position, the parking brake is "RELEASED" and the monitor light on the front instrument panel turns "OFF." In this position, the parking brake is "APPLIED" and the monitor light on the front instrument panel comes "ON."...
Page 81: Various Cabin Locations
VARIOUS CABIN LOCATIONS AQO0150L Figure 68 CAB LIGHT WASHER TANK STEREO HOT/COLD REFRIGERATOR HEATER AND AIR CONDITIONER ELECTRICAL BOX CONTROL PANEL FUSE BOX TWO SPEAKERS 10. FUSE BOX ONE STORAGE BOX 022-00029AE Operation and Maintenance Manual Operating Controls 2-33...
Page 82 CAB LIGHT A light is on the front of the ceiling. Turn the light "ON" and "OFF" by pressing its switch. The light will work despite starter switch position. NOTE: If light is left on for a long time while the engine is not running, the batteries will be discharged.
Page 83 STORAGE BOX There is a storage box (1, Figure 73) behind the seat. Keep the operation maintenance manual and other documents in this compartment. HBOI431L Figure 73 WASHER TANK Contains windshield washer fluid. CAUTION! The washer pump can be damaged if it is activated while there is no fluid in the tank.
Page 84 ELECTRIC BOX Under the seat are two pullout trays that contain relays for unit. See “Fuse Box/ Relay” on page 2-50. Figure 76 FUSE BOX TWO Fuse box two is just above the windshield washer fluid tank. detailed explanation of fuses see “Fuse Box/Relay” on page 2-50.
Page 85: Heater And Air Conditioner Operation
HEATER AND AIR CONDITIONER OPERATION LOCATION OF CONTROLS AND VENTS HBOI310L Figure 79 OPERATION PANEL FOOT NOZZLE FRONT NOZZLE (AIR-CON) REAR NOZZLE FRONT NOZZLE The heater and air-conditioner are combined into one unit to the rear of the operator’s seat. If necessary, the operator can control inner temperature using the operation of panel installed in the right control stand.
Page 86 OPERATION PANEL HAOA801L Figure 80 FAN AND AIR-CONDITIONER SWITCH SELECTION SWITCH FOR WIND BLOWER FAN SWITCHES DIRECTION TEMPERATURE CONTROL SWITCH VENTILATION SELECTION SWITCH When a switch is selected, the LED above that switch will turn "ON" and give an activation sound. When the light switch is turned "ON,"...
Page 87 BLOWER FAN SWITCHES These switches are used to control the speed of the blower fan. "LO" Switch - Used for low blower speed. "MID" Switch - Used for intermediate blower speed. "HI" Switch - Used for high blower speed. NOTE: If you do not select a blower ARO0520L speed...
Page 88 Used to direct air flow to lower portion of operator’s cab. HBOI330L Figure 85 Used to direct air flow for defrosting front window of operator’s cab. HBOI340L Figure 86 VENTILATION SELECTION SWITCH "A" Switch - Draws fresh air into operator’s compartment. "B"...
Page 89 ADDITIONAL OPERATING INSTRUCTION A proper indoor temperature in summer is 5 - 6° C (41 - 43° F) less than the outdoor temperature. Operate the air conditioner from 20 - 30 minutes a week to circulate the refrigerant in the system. NOTE: The blower switch should be on "LO"...
Page 90: Stereo
STEREO Figure 88 ON-OFF / VOLUME CONTROL KNOB CASSETTE SLOT BALANCE / FADER CONTROL 8. & 9. PLAY DIRECTION BUTTON BASS/TREBLE CONTROL 10. AUTOMATIC SELECTION AM/FM BAND SELECTION DOLBY B SELECTION AUTOMATIC MEMORY (AME) 12. METAL SELECTION TAPE EJECT BUTTON 13.
Page 91 BASS/TREBLE CONTROL This control adjust bass and treble tone levels. To adjust treble tone level rotate control counterclockwise to decrease treble and clockwise to increase treble. To adjust bass tone level press on control and it will pop out. Rotate control counterclockwise to decrease bass and clockwise to increase bass.
Page 92 DOLBY B SELECTION If the tape being listened to has been recorded with Dolby B, press preset selector button 1 to turn Dolby B control on. Dolby symbol will appear on display. Press this control a second time to turn Dolby B control "OFF."...
Page 93 Do not store cassette tapes in the following places or under the following conditions. Damage to tape and stereo may result. • Direct sunlight. • Humid place. • Dusty place. • Around heater or heater vents which discharge heat. • Around speakers and other magnet devices that generate a strong HLB2014L...
Page 94: Seat Adjustment
SEAT ADJUSTMENT WARNING! Whenever operator or operating condition has changed, check to see that seating position is suitable for the condition at hand. Always fasten your seat belt while operating vehicle. Adjust backrest so that the operator can fully reach and operate pedals.
Page 95 ANGLE ADJUSTMENT OF ARMREST Adjustment angle of left and right armrest (6, Figure 98) is done by turning a dial in bottom of armrest. When you adjust angle, manually raise armrest before turning dial. HEADREST Headrest (7, Figure 98) can be adjusted forward/backward and up/down.
Page 96: Seat Belt
SEAT BELT WARNING! Seat belt is for operator's safety and should be worn at all times. Before driving machine, adjust seat to desired position for maximum comfort and machine control, then fasten seat belt. Seat belts must be worn across pelvic region and adjusted snugly to lessen chance and severity of injury in event of an accident.
Page 97: Door Side Latch
DOOR SIDE LATCH The door side latch (1, Figure 101) is used to secured the door to the side of the cab when it is opened (Only cabin machine). NOTE: Keep the door closed and locked when machine is not in use.
Page 98: Fuse Box/Relay
FUSE BOX/RELAY FUSE BOXES There are two fuse boxes inside the cab. Fuse box one (1, Figure 103) is in the rear side of right control stand. A usage diagram of fuses is shown inside of fuse box. Spare fuses are under the cover (10A - Qty.
Page 99 Fuse Box One Name Capacity Gauge Panel Transmission Front Wipers, Horn Parking Brake, Pilot Cutoff, Log Fork (Option) Stop Light, Headlight HBOI380L Figure 104 FUSE BOX ONE Condenser Fan Engine Derating Spare Air-conditioning, Heater Work Light (Front), Beacon (Option) Work Light (Rear) Turn Signal Light, Hazard Light, Indicator Light Stereo, Cab Light,...
Page 100 RELAY The relays are in the electrical box under the seat. If the problem is not solved after replacing the fuse, check the function of the relay. APO0210L Figure 106 Figure 107 CIRCUIT BREAKER A circuit breaker is next to the relay by the batteries back unit...
Page 101: Window Glass Breaking Tool
WINDOW GLASS BREAKING TOOL This loader is equipped with a glass breaking tool. It is in the lower right side of the cab just rear of the door. This tool can be used in case of an emergency situation which requires the breaking of glass to exit from the operator’s cabin.
Page 103: Operation
OPERATION WARNING! Before operating any wheel loader, read and understand "Operating Controls" section of this manual. INSTRUMENT PANEL CONTROL FUNCTIONS MONITORING SYSTEM Monitoring system uses network circuits between control system and sensors installed at various machine system locations to monitor selected conditions. This monitoring systems function is to continually inform operator of machine’s condition.
Page 104: Engine Start And Stop
ENGINE START AND STOP INSPECTION BEFORE STARTING ENGINE WARNING! If a flammable materials such as leaves, paper, etc. are allowed to accumulate on high temperature components, such as the engine muffler and turbo, a fire may occur. Fuel, lubricant and hydraulic oil leaks, may cause a fire. If there is anything wrong, perform the appropriate corrective action.
Page 105 Move all control levers to "NEUTRAL" position. IMPORTANT transmission lever "NEUTRAL" position, engine will not start. Figure 2 Make sure transmission neutral lock is in the "N" (NEUTRAL LOCK) position. Figure 3 Set pilot cutoff switch to "O" (LOCK) position. This will "LOCK" pilot control valve lever (joystick).
Page 106 Rotate starter key to "START" position. Starter motor should crank immediately, and engine should start within a few seconds. HAOB350L Figure 6 Release starter key when engine starts. Key will return to "I" (ON) position. IMPORTANT engine does start after approximately seconds cranking, release starter key.
Page 107 • Black - Incomplete combustion. Check cause. • White or dark blue - Engine is burning engine oil. Check cause. 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."...
Page 108 STARTING WITH AUXILIARY BATTERIES WARNING! An explosive gas is produced while batteries are in use or being charged. Keep flames or sparks away from the battery area. Charge batteries in a well-ventilated area. HAOA440L Always wear eye protection when Figure 8 starting a machine with jumper cables.
Page 109 Connecting the Booster Batteries Stop the engine of the machine on which booster batteries are mounted. Connect one end of red cable (1, Figure 9) to the positive (+) terminal of the machine batteries, and the other end to the positive (+) terminal of the booster batteries.
Page 110 Make sure transmission neutral lock is in the "N" (NEUTRAL LOCK) position. Figure 11 Set parking brake switch to the "I" (APPLIED) position. This will ensure that the parking brake is "APPLIED." HAOP042L Figure 12 Set bucket on ground. Put pilot cutoff switch to "O" (LOCK) position.
Page 111: Machine Travel
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 5 minutes. Run engine for approximately 5 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.
Page 112 Unlatch frame lock plate between front and rear frames before traveling. Secure lock plate to rear frame (Figure 15). Figure 15 Set pilot cutoff switch to "I" (UNLOCKED) position. Raise bucket to a height of 400 mm (16 in) above the ground. Tilt bucket completely back.
Page 113 Set transmission neutral lock is in the "D" (DRIVE) position. Figure 19 Set parking brake switch to the "O" (RELEASE) position. This will "RELEASE" the parking brake. HAOP043L Figure 20 Place transmission lever in desired gear. Shift gears one by one. Do not skip from 1st to 3rd, for example.
Page 114: Machine Shutdown
Release the brake pedal while slowly pressing the accelerator pedal. WARNING! When traveling at high speed or on a steep hill, make sharp changes in direction. This could cause vehicle to overturn. When traveling changing direction, always look carefully to be Figure 22 certain that no one is in path of vehicle.
Page 115 Set transmission neutral lock is in the "N" (NEUTRAL LOCK) position. CAUTION! "LOCK" transmission lever. When ever machine is parked, "LOCK" transmission lever in "NEUTRAL" to prevent accidental machine movement. Figure 25 Set parking brake switch to the "I" (APPLIED) position. This will ensure that the parking brake is "APPLIED."...
Page 116: Additional Braking
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 braking effect because transmission clutch is hydraulically operated.
Page 117: Boom Lower Kickout (Option)
IMPORTANT Trip plate (1, Figure 30) must always be set to contact limit switch (2) before boom cylinders reach maximum extension. Maximum extension causes pump to force fluid over relief valve. To raise boom to maximum height, past preset height, hold pilot control valve lever (joystick) in "RAISE"...
Page 118: Bucket Angle Indicator
BUCKET ANGLE INDICATOR Upper right side of bucket includes a bracket that indicates angle of bottom of bucket. Top of bracket is parallel with bottom of bucket. If bottom of bucket is not visible, top of bracket will be visible. ADJUSTMENT OF Figure 33 BUCKET POSITION...
Page 119: Towing Machine
TOWING MACHINE When necessary to tow another vehicle, the tow rope must be tied to the towing pin on the counterweight at the rear of vehicle. NOTE: The loader must be used for towing only in an emergency. WARNING! Do not tow machine at a speed over 10 kph (6 MPH) and do not tow machine farther than 10 Km (6 miles).
Page 120 EMERGENCY RELEASE OF THE PARKING BRAKE Figure 36 If the parking brake cannot be released by normal hydraulic system pressure, or if the engine will not start, it must be manually released before towing can take place. Before releasing parking brake make sure that wheels have wheel chocks placed in front of and behind them, to prevent machine from moving when parking brake...
Page 121 Release the screw cap (6, Figure 36) and unscrew. Release the lock nut (5, Figure 36) and turn the adjusting screw (4) counter- clockwise until the brake disc is free. Install lock nut (5, Figure 36) and screw cap (6) and tighten both as far as possible. This will protect...
Page 122: If Engine Stalls While Traveling
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.
Page 123: Preventive Maintenance
4INSPECTION, MAINTENANCE AND ADJUSTMENT PREVENTIVE MAINTENANCE Periodic checks and replacement of oil, grease, filters, etc. must be made at specific intervals, to keep machine in good working condition. The following pages describe items to be checked, lubricants to be used, and time interval between each check. NOTE: Time interval between each service check may need to be shortened if machine is operating in severe atmospheric conditions.
Page 124 Engine Serial Number The engine name plate (identification label) is on the fuel pump side of the engine, on the rocker housing (Figure 3). Figure 3 SAFETY PRECAUTIONS 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.
Page 125: Table Of Recommended Lubricants
TABLE OF RECOMMENDED LUBRICANTS IMPORTANT Do not use lubricants other than those recommended, without prior written approval from DOOSAN. NOTE: Refer to Maintenance Intervals Table for application points. LUBRICANT LUBRICANT HYDRAULIC OIL ENGINE OIL* AXLE GEAR OIL MANUFACTURER GREASE CALTEX...
Page 126 SAE 15W40 (API CD AND ABOVE) CAUTION! Do not mix oils from different manufacturers. DOOSAN does not endorse specific brands but does suggest that owners select quality oils whose suppliers provide assurance that required standards will always be met or exceeded.
Page 127: Fluid Capacities
FLUID CAPACITIES Component Capacity Engine Oil Pan with Filter 34 liters (9 U.S. gal.) NOTE: The filter holds an additional 1 liter (1 qt) of oil. Cooling System 60 liters (16 U.S. gal.) Fuel Tank 480 liters (127 U.S. gal.) Hydraulic Oil Tank 280 liters (74 U.S.
Page 128: Maintenance Intervals
MAINTENANCE INTERVALS 10 HOUR / DAILY SERVICE • Grease Front Attachment Pins (See page • Inspect Seat Belt for Proper Operation (See 4-8)* page 4-14) • Inspect All Tires for Correct Tire Pressure • Inspect the Structure for Cracks and Faulty and Signs of Damage or Abnormal Wear Welds (See page 4-14) (See page 4-8)
Page 129 250 HOUR / MONTHLY SERVICE • Perform All 10 Hour / Daily and 50 hour • Check Water Pump Belt Tension (See page Service Checks (See page 4-25) 4-29) • Grease Drive Shaft Center Bearing (See • Change Engine Oil and Filter (See page page 4-25) 4-30) •...
Page 130: 10 Hour / Daily Service
10 HOUR / DAILY SERVICE GREASE FRONT ATTACHMENT PINS NOTE: Fittings are greased daily, or every 10 hours, for the first 100 hours of operation to comply with new machine break-in requirements. After that, greasing should be done every 50 hours.
Page 131 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.
Page 132 CHECK HYDRAULIC SYSTEM OIL LEVEL WARNING! The hydraulic oil will be hot after normal machine operation. Allow system to cool before attempting to service any of the hydraulic components. The hydraulic tank is pressurized. Press button in center of breather to allow the HAOA060L pressurized air to vent.
Page 133 The hydraulic oil filler cover also serves as the hydraulic oil strainer access cover. It is important to replace this cover and the components in the proper order and alignment. The filter element (2, Figure 11), retaining rod (2) and spring (4) are assembled as shown in Figure 11.
Page 134 REFILL FUEL WARNING! Use extreme safety precautions while refueling to prevent explosions or fire. Immediately clean up any spilt fuel. At end of each work day, fill fuel tank. Add fuel through fuel filler pipe (Figure 13). When working at a temperature of 0°C Figure 13 (32°F) or higher, use ASTM No.
Page 135 CHECK COOLANT LEVEL WARNING! Never open radiator when it is hot. Scalding liquid inside a hot radiator is under pressure. Removing cap from a hot radiator could cause a person to be sprayed and burned from liquid inside. Wait for radiator temperature to cool down before removing cap. Figure 18 Figure 17 Remove fill cap from radiator (Figure 18).
Page 136 Do not allow replaceable bucket teeth to wear down to the point that bucket adapter is exposed. (Figure 20) NOTE: These instructions are only for DOOSAN OEM buckets. If you are using other manufacturers’ buckets, refer to their specific Figure 20 instructions.
Page 137 CHECK THE OPERATION OF ALL SWITCHES Verify working condition of all switches before starting engine. CHECK THE OPERATION OF ALL EXTERIOR LIGHTS, HORN AND CONTROL CONSOLE INDICATOR AND MONITOR LIGHTS Turn engine starter switch to the "ON" position and observe all indicator lights. Restore operation of any light bulbs that do not turn "ON"...
Page 138 INSPECT ENGINE FAN BLADE WARNING! Personal injury can result from a fan blade failure. Never pull or pry on the fan. This can damage the fan blade(s) and cause fan failure. NOTE: Manually rotate the crankshaft by using a wrench on the accessory drive pulley nut.
Page 139 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.
Page 140: 50 Hour / Weekly Service
50 HOUR / WEEKLY SERVICE PERFORM ALL 10 HOUR / 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 should be done every 50 hours. If bucket is being used in water, grease fittings immediately after machine is removed from water.
Page 141 Bucket hinge pins, 2 locations (Figure 27). Figure 27 Lever link connecting pins, locations (Figure 28). Figure 28 Bucket link connecting pins, locations (Figure 29). Figure 29 Arm lever connecting pins (left, right), 2 locations. (Figure 30) Figure 30 022-00029AE Operation and Maintenance Manual Inspection, Maintenance and Adjustment 4-19...
Page 142 Bucket cylinder rod ends, 2 locations. (Figure 31) Figure 31 Lift cylinder heads (left, right), 2 locations (Figure 32). Figure 32 Lift cylinder rod ends, 2 locations. (Figure 33) Figure 33 4-20 Inspection, Maintenance and Adjustment 022-00029AE Operation and Maintenance Manual...
Page 143 Remote location points HA503041 Figure 34 REMOTE FITTINGS FOR BUCKET REMOTE FITTINGS FOR LOADER ARM CYLINDER HEADS (50 HOUR) (Figure 35 FOOT ENDS (50 HOUR) (Figure 35 and and Figure 36) Figure 37) Figure 35 022-00029AE Operation and Maintenance Manual Inspection, Maintenance and Adjustment 4-21...
Page 144 Bucket cylinder heads (left, right), 2 points. Greased from two remote grease points (1, Figure 34). Figure 36 Loader foot ends, locations on each side of machine. Greased from two remote grease points (2, Figure 34). Figure 37 Grease Rear Axle Pivot Rear Axle pivot (1, Figure 38), 2 locations on each side of machine.
Page 145 GREASE STEERING CYLINDER ROD AND BASE ENDS Steering cylinder rods, 2 locations, one on each side of machine. Figure 40 Steering cylinder head ends, 2 locations. Use remote grease fittings mounted on frame. Figure 41 GREASE UPPER AND LOWER CENTER PINS Center pins, upper (Figure 42) and lower (Figure 43).
Page 146 HYDRAULIC FULL FLOW FILTER REPLACEMENT (INITIAL) NOTE: Replace hydraulic full flow filter after first 50 hours of operation and every 250 Hours thereafter. Follow procedure under 250 hour maintenance interval (See page 4-27) CHECK WATER PUMP BELT TENSION - ALTERNATOR, AND AIR CONDITIONER BELT (INITIAL) NOTE: Water pump belt tension must be checked after first 50 hours of operation to comply with new machine break-in requirements.
Page 147: 250 Hour / Monthly Service
250 HOUR / MONTHLY SERVICE PERFORM ALL 10 HOUR / DAILY AND 50 HOUR SERVICE CHECKS GREASE DRIVE SHAFT CENTER BEARING Grease drive shaft center bearing, 1 location. There is no remote fitting for this bearing. Figure 44 REPLACE HYDRAULIC SYSTEM PILOT FILTER Replace filter element in pilot filter.
Page 148 Unscrew element cover (5, Figure 46). Cover is filled with oil. Dispose of oil. Remove O-ring (3, Figure 46) and filter element (4). Use a non flammable, non-toxic solvent to clean out cover (5, Figure 46). Insert a new filter element (4, Figure 46) into cover (5).
Page 149 HYDRAULIC FULL FLOW FILTER REPLACEMENT WARNING! The hydraulic oil will be hot after normal machine operation. Allow system to cool before attempting to service any of the hydraulic components. The hydraulic tank is pressurized. Loosen hydraulic oil fill cap slightly to allow pressurized air to vent.
Page 150 DRAIN WATER FROM HYDRAULIC OIL TANK WARNING! Be certain that hydraulic oil has cooled before draining water and sediment. Hot oil could splash and cause burns. The hydraulic tank is pressurized. Press button in center of breather to allow pressurized air to vent.
Page 151 Clean outer filter by blowing compressed air from inside of filter towards the outside. Do not use more than 205 kPa (30 psi) air pressure. Clean the inside of air filter housing and inside of air filter housing cover. CAUTION! Never clean the inside of air filter HAOC570L housing while the inner element is...
Page 152 CHANGE ENGINE OIL AND FILTER NOTE: Engine oil and filter must be changed after first 50 hours of operation to comply with new machine break-in requirements. After first change, oil and filter should be changed every 250 hours. CAUTION! Never attempt to change oil or filter on a hot engine. Hot oil could splash and cause burns. Allow engine to cool down before changing oil or filter.
Page 153 REPLACE DCA4 COOLANT FILTER CARTRIDGE CAUTION! Pressurized radiator tank. Spray of hot coolant can cause burn. Stop engine and allow radiator and coolant to cool completely, then open cap slowly to relieve pressure. CAUTION! Hot coolant and engine components can cause burn. Avoid contact with coolant or engine components.
Page 154 Remove and properly dispose of the coolant filter. Clean the filter head gasket surface. Apply a light film of clean engine oil to the gasket surface of a new DCA4 coolant filter cartridge. Figure 58 Install the filter firmly by hand. Follow the instructions supplied with the filter.
Page 155 REPLACE FUEL FILTER WARNING! Exchange filter after waiting for engine to cool. Be careful of fire hazards. Do not smoke. Locate fuel filter inside engine compartment. Position a small container under fuel filter. Drain filter by opening drain valve on bottom of filter.
Page 156 Tighten plug in fuel filter head. Continue to pump primer pump until a strong resistance is felt. Screw primer pump knob back into housing. Start engine and lock for signs of leaks. AXLE DIFFERENTIAL AND PLANETARIES OIL REPLACEMENT (INITIAL) NOTE: The differential and planetaries oil should be drained and refilled after first 250 hours of operation.
Page 157: 500 Hour / 3 Month Service
500 HOUR / 3 MONTH SERVICE PERFORM ALL 10 HOUR / DAILY, 50, 150, AND 250 HOUR SERVICE CHECKS CLEAN EXTERIOR OF RADIATOR, OIL COOLER AND AIR-CONDITIONER EVAPORATOR Dust and dirt accumulation on fins of radiator, cooler, additional transmission cooler greatly reduce their cooling efficiency.
Page 158 Remove filter element and inspect it for damage. Use compressed air to clean filter element. If element is very dirty use a mild soap and water solution to clean it. Figure 67 NOTE: If water was used to clean filter element be sure it is completely dry before installation. NOTE: In the event that the unit is being operated in a dusty environment, the cleaning and replacement should be performed more frequently.
Page 159: 1,000 Hour / 6 Month Service
1,000 HOUR / 6 MONTH SERVICE PERFORM ALL 10 HOUR / DAILY, 50, 150, 250, AND 500 HOUR SERVICE CHECKS CHANGE RADIATOR COOLANT WARNING! Allow the engine to cool before releasing the radiator cap. Make sure to loosen the cap slowly to release any remaining pressure.
Page 160 Open heater shutoff valve (Figure 70) to allow coolant to drain from heater core. Install drain plug, and close vent and drain valve after coolant has completely drained from system. Fill cooling system with a flushing solution. NOTE: When filling engine with flushing solution open vent...
Page 161 Remove drain plug. Allow all transmission fluid to drain into a receptacle. Properly dispose of drained fluid. Clean drain plug. Install drain plug in transmission. Remove inlet strainer. nonflammable, non-toxic solvent to clean strainer. Inspect gasket on inlet strainer. Replace gasket if it is damaged.
Page 162 CLEAN FUEL TANK AND STRAINER WARNING! Escaping fuel flammable and harmful to skin. • Do not smoke while draining moisture and sediment from tank. • Do not drain with engine running. • Do not allow fuel to remain on skin for an extended period of time.Wash thoroughly with soap and water.
Page 163 CHECK AIR CONDITION REFRIGERANT WARNING! Mixing of tobacco smoke and freon is deadly. Do not smoke while servicing or recharging air conditioning system. Apply the parking brake and lower the attachment to the ground. Remove the cover. Press the "HI" ﬂow control switch to set maximum air ﬂow. Set the temp.
Page 164: 1,500 Hour / 9 Month Service
1,500 HOUR / 9 MONTH SERVICE PERFORM ALL 10, 50, 150, 250, AND 500 HOUR SERVICE CHECKS REPLACE OUTER AND INNER AIR CLEANER ELEMENTS CAUTION! Never remove air cleaner element while engine is running. This will allow dirt to be sucked into engine and cause serious engine damage.
Page 165 Clean area around level plug (1, Figure drain plug center differential. Remove level plug (1) and drain plug (2). Allow oil to drain into a container. Install drain plug (2, Figure 77) into center differential, and tighten. Pump oil into plug hole for level plug on center differential.
Page 166: 2,000 Hour / Annual Service
2,000 HOUR / ANNUAL SERVICE PERFORM ALL 10 HOUR / DAILY, 50, 150, 250, 500 AND 1000 HOUR SERVICE CHECKS REPLACE HOSES Replace hoses that carry brake fluid to wheel brakes. Also replace hoses that carry hydraulic fluid to steering cylinders. It is difficult to determine condition of many hoses.
Page 167 Securely close bleeder screw (1, Figure 80). Install rubber cap on bleeder screw. Perform bleeding procedure on other three wheels. DRAIN AND REPLACE HYDRAULIC OIL CAUTION! Be certain that hydraulic oil has cooled before draining it. Hot oil could splash and cause burns. Raise boom to its highest position.
Page 168 Without starting engine, operate controls to dump bucket. (Figure 83). Then operate controls to lower boom. (Figure 84). This will drain oil out of boom and bucket cylinders. Replace full flow hydraulic filters as described under “Loosen breather cap on hydraulic reservoir. (See Figure 10 on page 4-10).”...
Page 169 CLEAN HYDRAULIC OIL SUCTION STRAINER Carefully remove bolts and cover (1, Figure 88) from top of hydraulic oil tank. There is a spring (2) under the cover that will force the cover up. Remove spring (2, Figure 88) and strainer (4), by pulling on rod (3).
Page 170 CHECK BRAKE ACCUMULATOR Test the brake accumulator for proper precharge of Nitrogen gas WARNING! Pressurized Nitrogen gas in brake accumulator may explode causing serious injury or death. Never service brake accumulator unless trained properly. Park the machine on a level surface, apply the parking brake and lower the attachment to the ground. Run the engine at low idle for ﬁve minutes to ﬁll the brake accumulator with oil.
Page 171: Severe Conditions Maintenance
SEVERE CONDITIONS MAINTENANCE OPERATING CONDITION REQUIRED MAINTENANCE Mud, Water, Rain Check for loose fittings, obvious damage to machine, or any fluid leakage. After completing operations, clean mud, rocks, or debris from machine. Inspect for damage, cracked welds, or loosened parts. Perform all daily lubrication and service.
Page 172: Fuel Transfer Pump
FUEL TRANSFER PUMP WARNING! Do not dry operate fuel pump for more than 15 seconds. • Cooling and lubrication of pump is achieved by fuel passing through the pump. If the pump is dry operated, the heat generated by the moving parts will cause damage to the pump rotors, vanes and seals.
Page 173 HAOP401L Figure 90 Remove strainer cap (4, Figure 90) from inlet hose. NOTE: Keep strainer cap in a safe location to reseal strainer after refueling is complete. Insert inlet hose (5, Figure 90) into refueling tank. Turn fuel pump switch to “ON” position. NOTE: The transfer pump rate of flow is approximately 20 liters /...
Page 174: Handling Of Accumulator
DO NOT punch a hole or apply heat or fire to an accumulator. • DO NOT weld on accumulator, or try attaching anything to it. When replacing an accumulator, contact a DOOSAN distributor or sales agency so the • gas can be properly released.
Page 175: Check Hydraulic Pressures
CHECK HYDRAULIC PRESSURES Hydraulic pressures for most systems can be check by using the remote test ports shown in Figure 93. Port Number Description Main Pump Pressure Transmission System Pressure Brake Charge Pressure HAOP341S Pilot Control Valve Lever Figure 93 (Joystick) Activation Pressure MAIN PUMP PRESSURE...
Page 176 TRANSMISSION SYSTEM PRESSURE Attach gauge to (Port 2, Figure 93) Pressure 16-18 kg/cm (228-256 psi) BRAKE CHARGE PRESSURE Attach gauge to (Port 3, Figure 93). Relief pressure for unloading is 140 kg/ (1,991 psi). Relief pressure for loading is 120 kg/cm (1,707 psi).
Page 177 Adjust relief valve cartridge on amplifier (Figure 99). Cartridge must be adjusted to open at 185 ±5 kg/cm (2,630 ±70 psi). Unscrew remove plug and washer. Adjust screw that is beneath plug. Turn screw clockwise to raise relief pressure. Turn screw counterclockwise to lower relief pressure.
Page 178 FAN MOTOR PRESSURE Attach gauge to inlet port of fan motor (1,Figure 102). Adjust screw on relief valve cartridge (2,Figure 102). Pressure should be 95 kg/ (1,350 psi). Loosen lock nut on adjusting screw. Turn adjusting screw clockwise to raise relief pressure.
Page 179: Tires And Wheels
TIRES AND WHEELS Properly inflated tire (2, Figure 103) is an important factor in determining tire performance and tire life. A tire that is under-inflated (1, Figure 103) does not properly support machine, and will wear out quickly. Over-inflated tires (3, Figure 103) have poor traction and puncture easily.
Page 180 CHECK TIRE FOR DAMAGE WARNING! Improper servicing or changing tires and rims can cause explosion resulting in serious injury or death. Do not service or change tires and rims unless properly trained and equipped. Contact your nearest loader dealer or tire manufacturer’s local dealer for tire servicing or changing.
Page 181: Electrical System
ELECTRICAL SYSTEM CHECK BATTERY CONDITION WARNING! Before starting any battery service work, make sure to shut the engine off and turn the starter key to the "OFF" position. The batteries create hydrogen gas. An explosion hazard exists, particularly with a deeply discharged battery.
Page 182: Bolt Torque Chart
BOLT TORQUE CHART Tightening Torque Specifications for Metric Bolts (For coated threads, pre-lubricated assemblies) Grade Gr. 8.8 Gr. 10.9 Gr. 12.9 Dia. Kg•m ft lb Kg•m ft lb Kg•m ft lb 5 mm x std 0.59 0.79 6 mm x std 1.00 1.38 1.66...
Page 183: Long Term Storage
LONG TERM STORAGE CLEANING Pressure wash machine. Inspect machine for any damage or missing parts. Drive machine to check steering linkage for damage. HYDRAULIC SYSTEM Start engine and allow it to idle for a few minutes. Drive machine around for 2 - 3 minutes. Raise and lower boom 2 - 3 times.
Page 185: Transportation
5TRANSPORTATION LOADING MACHINE ON A TRAILER When transporting the machine observe the various road rules, road transportation vehicle laws and vehicle limit ordinances, etc. It is a good idea to obtain special platform for loading and unloading the machine. Park the trailer on a flat firm roadbed. Keep a fairly long distance between the road shoulder and the machine.
Page 186: Summary Of Safety Precautions For Lifting
10. Determine the route for transporting the machine by taking into account the width, height and weight of the machine and the truck. SUMMARY OF SAFETY PRECAUTIONS FOR LIFTING To make safe lifts, the following items must be evaluated by operator and work site crew. •...
Page 187: Troubleshooting
Low engine oil Refill surges Plugged air intake system Clean system and replace filter Contact your DOOSAN dealer Injection pump out of adjustment Plugged fuel filter Replace fuel filter Water or dirt in fuel system Clean system and add new fuel...
Page 188 Clogged or dirty fuel injectors Clean injectors Fuel filters plugged Replace filters Engine speed control cable out Readjust of adjustment Contact your DOOSAN dealer Injection pump out of adjustment Valve backlash faulty Adjust backlash Engine runs hot Low coolant level Add coolant...
Page 189: Hydraulic System
(Also ELECTRICAL TROUBLESHOOTING) Defective engine shut solenoid Fuel pump failure Contact your DOOSAN dealer Incorrect fuel injection timing Compression pressure too low Defective injectors Unstable (rough) idling Air in fuel lines Tighten fuel connections and filter Fuel filter element clogging...
Page 190 All actuators have low power Low hydraulic oil level Add hydraulic oil as required Suction filter clogged Clean filter Contact your DOOSAN dealer Hydraulic pumps faulty Contact your DOOSAN dealer Main relief pressure too low Hydraulic pumps cavitating Bleed air from hydraulic pumps...
Page 191: Travel System
TRAVEL SYSTEM GENERAL Problem Possible Causes Remedies Machine will not travel Transmission clutch pressure Adjust pressure incorrect Transmission charge pump Replace pump damaged Damage to transmission control Repair wiring valve wiring harness Burned travel relay or fuse Replace relay or fuse Forward/Reverse solenoid for Clean and repair transmission...
Page 192 Problem Possible Causes Remedies Drive shaft vibration Noisy Bent drive shaft Replace drive shaft universal joints Loose universal joints Tighten bolts that secure joints Worn or damaged universal joint Replace universal joint Loose universal joints Tighten bolts that secure universal joints Lack of lubrication Lubricate universal joints Worn slip joint spline...
Page 193 Error Code Meaning of Error Code Remarks Number Short circuit to ground or open circuit at clutch cutoff input. Short circuit to battery voltage at load sensor input. Not used. Short circuit to ground or open circuit at load sensor input. Not used.
Page 194 Error Code Meaning of Error Code Remarks Number Open circuit at converter clutch. Not used Short circuit battery voltage at clutch K4. Short circuit to ground at clutch K4. Open circuit at clutch K4. Short circuit to battery voltage at clutch KV. Short circuit to ground at clutch KV.
Page 195 Error Code Meaning of Error Code Remarks Number Low power at battery. High power at battery. Error at switch 1 for valve power supply. Error at switch 2 for valve power supply. Short circuit to battery at speedometer output. Not used. Short circuit to ground or open circuit at speedometer output.
Page 196: Steering
STEERING Problem Possible Causes Remedies Steering Wheel is hard to turn Sediment blocking direction Clean and repair change spool orifice, inside priority valve Sediment blocking amplifying Clean and repair spool orifice, inside priority valve Sediment blocking load sensing Clean and repair line orifice, inside priority valve Priority valve spool sticking, Clean and repair...
Page 197: Braking
BRAKING Problem Possible Causes Remedies Reduced brake action Low secondary pressure in Repair or replace brake valve brake valve Worn brake discs Replace brake discs Damaged brake discs Replace brake discs Damaged brake valve block Replace valve Air in brake hydraulics due Repair leak, bleed system to leak in brake hose After bleeding brakes, brakes...
Page 199: Specifications
7SPECIFICATIONS GENERAL SPECIFICATIONS MEGA 500-V (TIER II) Item Specification Standard Bucket Capacity 4.8 m (6.28 yd Vehicle Weight [W/ROPS CANOPY] 28,800 kg (63,490 lb) [29,600 kg (65,260 lb)] Engine Type Cummins QSM11 w/Electronic Governor Horsepower 340 ps (335 hp) @ 2,100 rpm Max.
Page 200: Working Range And Dimensions
WORKING RANGE AND DIMENSIONS Figure 1, illustrates exterior machine dimensions and working range of machine when it is equipped with a standard bucket. AHO0830L Figure 1 7-2 Specifications 022-00029AE Operation and Maintenance Manual...
Page 201 Category Dimension Overall Length (A) 9,320 mm (30’ 7'') Overall Width, without bucket (B) 3,190 mm (10’ 6'') Overall Height (C) 3,780 mm (12’ 5'') Bucket Width (D) 3,480 mm (11’ 5'') Wheel Base (E) 3,600 mm (11’ 10'') Tread (F) 2,420 mm (7’...
Page 202: Working Capacities
WORKING CAPACITIES BUCKET CAPACITY Standard toothed bucket has a capacity of 4.8 m (6.28 yd ). An optional bucket equipped with a cutting edge and no teeth has a capacity of 5.0 m (6.54 yd TIPPING LOAD Static Tipping Load with bucket in Over Front position is 22,000 kg (48,500 lb). With bucket in Fully Turned position, Static Tipping Load is 19,000 kg (41,890 lb).
Page 203 LOW WEIGHT OR MEDIUM WEIGHT OR HIGH WEIGHT OR DENSITY DENSITY DENSITY MATERIAL 1,100 KG/M 1,600 KG/M 2,000 KG/M (1,850 LB/YD ), OR (2,700 LB/YD ), OR (3,370 LB/YD ), OR LESS LESS LESS Cement, Portland, DRY 1,506 kg/m --------------------- --------------------- granular (2,583 lb/yd...
Page 204 LOW WEIGHT OR MEDIUM WEIGHT OR HIGH WEIGHT OR DENSITY DENSITY DENSITY MATERIAL 1,100 KG/M 1,600 KG/M 2,000 KG/M (1,850 LB/YD ), OR (2,700 LB/YD ), OR (3,370 LB/YD ), OR LESS LESS LESS Salt 929 kg/m --------------------- --------------------- (1,566 lb/yd Snow, light density 529 kg/m ---------------------...
Page 205: Index
8INDEX Numerics 4-37 2-34 1,000 Hour / 6 Month Service Cab Light 4-42 2-26 1,500 Hour / 9 Month Service Cigar Lighter 2-52 10 Hour / Daily Service Circuit Breaker 4-44 2,000 Hour / Annually Service Cold Weather Engine Start 4-25 250 Hour Service Combination Switch...
Page 206 Fuel System System Warm-up 4-12 Condensation - Draining System Warm-up – Cold Weather 4-33 4-54 Filter - Replace Transmission System Pressure 2-13 Gauge Troubleshooting 4-12 Refill 4-40 Tank - Cleaning 4-50 Transfer Pump 2-30 Idle Speed Control Switch 2-50 Fuse Boxes Indicator Lights 2-52 Fusible Link...
Page 207 Starter Switch Start-up New Machine Break-in Procedures Cold Weather Engine Start Engine Start Hydraulic System Warm-up 1-24, 3-1 Operation Hydraulic System Warm-up – Cold Weather 4-42 Outer Air Cleaner Element Inspection Before Starting Engine Starting with Auxiliary Batteries Parking Brake Steering 3-19 Adjustment...
Page 208 2-29 Rotating Beacon Switch Troubleshooting Starter Switch Troubleshooting Steering Tilt Knob 2-31 Transmission Cutoff Switch 2-10 Transmission Lever 1-13 Unauthorized Modifications 2-14 Tachometer 4-47 Vibration Damper Tipping Load 1-28 Visibility 4-58 Tire Damage 4-57 Tires and Wheels 3-17 Towing the Machine 2-35 Washer Tank Transmission...

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Doosan Mega 500-V Operation And Maintenance Manual

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