Doosan DL300 Wheel Loader Complete Workshop Service Repair Manual

K1010636E Shop Manual DOOSAN reserves the right to improve our products in a continuing process to provide the best possible product to the market place. These improvements can be implemented at any time with no obligation to change materials on previously sold products. It is recommended that consumers periodically contact their distributors for recent documentation on purchased equipment. This documentation may include attachments and optional equipment that is not available in your machine's package. Please call your distributor for additional items that you may require. Illustrations used throughout this manual are used only as a representation of the actual piece of equipment, and may vary from the actual item. Shop Manual K1010636E Serial Number 5001 and Up DL300

Table of Contents Page I 1 Table of Contents Safety Wheel Loader Safety ............................................................................ SP000095 Specifications Specification for DL300......................................................................... SP000104 General Maintenance General Maintenance Procedures ........................................................ SP000097 Standard Torques ................................................................................. SP000098 Drive Train Transmission and Torque Converter .................................................... SP000118 Transmission Error Codes (ZF) ............................................................ SP000100 Front Axle (ZF-MT-L 3095) ................................................................... SP000199 Rear Axle (ZF-MT-L 3085).................................................................... SP000217 Drive Shaft ............................................................................................ SP000218 Brake Service Brake ....................................................................................... SP000219 Brake Supply Valve .............................................................................. SP000220 Parking Brake ....................................................................................... SP000221 Brake Pedal Valve ................................................................................ SP000222 Accumulator .......................................................................................... SP000223 Steering Steering ................................................................................................ SP000224 Cushion Valve....................................................................................... SP000328 Emergency Steering ............................................................................. SP000225

Table of Contents Page II Frame Articulation Center ................................................................................ SP000231 Counterweight....................................................................................... SP000130 Tank Oil Tank ................................................................................................ SP000226 Fuel Tank .............................................................................................. SP000227 Hydraulics Main Control Valve ............................................................................... SP000233 Load Isolation System .......................................................................... SP000228 Cooling System..................................................................................... SP000229 Pilot System.......................................................................................... SP000230 Hydraulic Schematic (DL300) ............................................................... SP000234 Electrical System Air Conditioner ...................................................................................... SP000172 Electrical System .................................................................................. SP000268 Electrical Schematic (DL300) ............................................................... SP000272

SP000095 Page 1 Wheel Loader Safety SP000095 WHEEL LOADER SAFETYSP000095 Wheel Loader Safety Edition 1

Wheel Loader Safety SP000095 Page 2 MEMO

SP000095 Page 3 Wheel Loader Safety Table of Contents Wheel Loader Safety Safety Precautions ............................................... 5 Applicable Models ................................................ 5 To the Operator of a DOOSAN Wheel Loader ..... 6 General Safety Essentials .................................. 10 Location of Safety Labels ................................... 10 Unauthorized Modifications ................................ 10 General Hazard Information ............................... 11 Before Starting Engine ....................................... 20 Machine Operation ............................................. 25 Maintenance ....................................................... 32 Battery ................................................................ 41 Towing ................................................................ 43 Shipping and Transportation .............................. 44

Wheel Loader Safety SP000095 Page 4 MEMO

Wheel Loader Safety Page 5 SP000095 SAFETY PRECAUTIONS APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that are in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. MODEL SERIAL NUMBER RANGE DL300 5001 and Up DL400 5001 and Up

SP000095 Wheel Loader Safety Page 6 TO THE OPERATOR OF A DOOSAN WHEEL LOADER Please respect the importance of taking responsibility for your own safety, and that other people who may be affected by your actions. Safety information on the following pages is organized into the following topics. 1. “General Safety Essentials” on page 1-10. 2. “Location of Safety Labels” on page 1-10. 3. “Unauthorized Modifications” on page 1-10. 4. “General Hazard Information” on page 1-11. 5. “Before Starting Engine” on page 1-20. 6. “Machine Operation” on page 1-25. 7. “Maintenance” on page 1-32. 8. “Battery” on page 1-41. 9. “Towing” on page 1-43. 10. “Shipping and Transportation” on page 1-44. 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.

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Doosan DL300 Wheel Loader Complete Workshop Service Repair Manual

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