Doosan DL300 Wheel Loader Workshop Repair Service Manual PDF with Electrical Wiring Diagrams - MDSDL300OPES.zip

This is a full repair and service manual for the Doosan DL300 Wheel Loader, complete with electrical wiring diagrams, plus the technical data needed to maintain, troubleshoot, fix, and service the machine the way professional technicians do.

The Doosan DL300 Wheel Loader workshop service and repair manual contains:

* Numbered table of contents easy to use so that you can find the information you need fast.

* Detailed sub-steps expand on repair procedure information

* Numbered instructions guide you through every repair procedure step by step.

* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.

* Notes, cautions and warnings throughout each chapter pinpoint critical information.

* Bold figure number help you quickly match illustrations with instructions.

* Detailed illustrations, drawings and photos guide you through every procedure.

* Enlarged inset helps you identify and examine parts in detail.

Total Pages: 1,021

File Format: PDF (bookmarked, Searchable, Printable, high quality)

Language: English

Doosan DL300 Wheel Loader Shop Manual.pdf

K1010636E; Serial Number 5001 and Up

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

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

...

CENDL3000001.......2

DL300 Electrical Wiring Diagram.......3

K1010630E - DL300 Operation and Maintenance Manual.......4

맨앞1-6.pdf.......0

맨앞.......0

Presentation.......10

Presentation.......10

Intended Use.......11

Engine.......11

Electrical System.......11

Power Transmission.......11

Brake System.......12

Parking Brake.......12

Steering System.......12

Cabin.......12

FOPS and ROPS.......12

Hydraulic System.......12

Equipment.......12

CE Marking, EMC Directive.......13

CE Marking.......13

The EU EMC Directive.......13

Communication Equipment Installation.......14

Protection Against Electromagnetic Interference.......14

Product Plates.......15

01-omK1010630E-48.pdf.......0

Safety.......16

To the Operator of a DOOSAN Daewoo Wheel Loader.......16

Learn Signal Words Used With Safety Alert Symbol.......17

General Safety Essentials.......19

Accessory Applications.......19

Location of Safety Labels.......19

1. Warnings for Operation, Inspection and Maintenance (41902545A, 19000092).......21

2. Warnings for Cooling Fan (21903315, 19000557).......21

3. Warnings When Opening Engine Hood (21903315, 19000095).......22

4. Warnings for Using Wheel Block (41902547A, 19000207).......22

5. Warnings for Handling Accumulator (19000703, 19000099).......23

Accumulator.......23

6. Keep Out of Steering Turn Area (41901992A, 19000120).......24

7. Warnings for High Temperature Hydraulic Oil (19000691, 19000097).......24

8. Warnings for High Temperature Coolant (19000692, 19000097).......25

9. Warnings for Battery Maintenance (19000537, 19000100).......25

10. Warnings for Performing Maintenance On Front Attachment (41902546A, 19000105).......26

11. Warnings to Use Safety Lock (41901993, 19000121).......26

12. Warning Tag (19000695, 19000098).......27

Unauthorized Modifications.......28

General Hazard Information.......28

Safety Rules.......28

Safety Features.......28

Inside Operator's Compartment.......29

Clothing and Personal Protective Items.......30

Breathing Masks, Ear Protection May Be Required.......30

Vibration Level Information.......30

Recommendations for Limiting Vibrations.......30

Asbestos Dust Hazard Prevention.......31

Mounting and Dismounting.......32

Fuel, Oil and Hydraulic Fluid Fire Hazards.......32

Precautions When Handling Fluids at High Temperature.......33

Injury from Work Equipment.......33

Fire Extinguisher and First Aid Kit.......34

Protection from Falling or Flying Objects.......34

Install Additional Safety Equipment If Conditions Require.......35

Maintain Standard Safety Equipment in Good Condition.......35

Attachment Precautions.......35

Accumulator.......36

Engine Ventilation.......36

Before Starting Engine.......37

Work Site Precautions.......37

Checks Before Starting Engine.......38

Engine Starting.......38

Before Operating Machine.......39

Machine Operation.......41

Operate While Seated at Operator's Station Only.......41

Seat Belts Must Be Used at All Times.......41

Movement Alarms.......41

Travel Precautions.......42

Sloping Terrain Requires Caution.......42

Avoid High Voltage Cables.......43

Before Starting to Dig, Contact Authorities.......43

Be Aware of Height Obstacles.......43

Use Care on Loose Support.......44

Use Solid Support Blocking.......44

Digging Beneath Overhangs.......44

Digging Beneath Wheel Loader.......44

Stay Alert for People Moving Through Work Area.......44

Be Aware of and Conform to Local Regulations.......45

Never Use Ether Starting Aids.......45

Observe General Safety Rules.......45

Take Time to Provide Good Visibility.......46

Keep "Pinch Point" Areas Clear Use Caution in Reverse.......46

Operate Carefully on Snow and Ice, In Very Cold Temperatures.......47

Parking Machine.......47

Shutdown Control Functions.......48

Never Let Anyone Ride on Attachment.......48

Maintenance.......49

Use Warning Tag During Service.......49

Clean Before Inspection or Maintenance.......49

Proper Tools.......50

Use of Lighting.......50

Fire Prevention and Explosion Prevention.......50

Burn Prevention.......51

Welding Repairs.......51

Precautions for Removal, Installation, and Storage of Attachments.......52

Precautions When Working on Machine.......52

Lock Inspection Covers.......53

Crushing Prevention and Cutting Prevention.......53

Do Not Run Engine If Repairs or Work Are Being Performed Alone.......53

Always Use Adequate Equipment Supports and Blocking.......53

Do Not Work on Hot Engines or Hot Cooling or Hydraulic Systems.......54

Hydraulic Cylinder Seals Require Periodic Replacement.......54

Highpressure Hydraulic Lines Can Store a Great Deal of Energy.......54

Cool Down Is Required Before Radiator or Reservoir Checks.......54

Precautions with Highpressure Line, Tubes and Hoses.......55

Obtain Immediate Medical Attention if Pressurized Oil Pierces Skin........56

Use Correct Replacement Fasteners Tightened to Proper Torque.......56

Safety Critical Parts Must Be Replaced Periodically.......56

Dispose of All Petroleum Based Oils and Fluids Properly.......57

Check Tire Pressure and Condition.......57

Decreasing Risk of Injuries or Death From Boom and Bucket.......58

Battery.......60

Battery Hazard Prevention.......60

Disconnect Batteries Before Electrical Service or Electrical Welding.......61

Use Low Heat Portable Lighting.......61

Boost Starting or Charging Engine Batteries.......61

Towing.......62

Precautions When Towing.......62

Shipping and Transportation.......63

Obey State and Local OvertheRoad Regulations.......63

02-omK1010630E-64.pdf.......0

OP000036.......64

Operating Controls.......64

1. “Component Locations” on page 22.......64

2. “Operator's Area” on page 24.......64

3. “Steering Console and Pedals” on page 25.......64

4. “Gauges” on page 216.......64

5. “Gauges” on page 216.......64

6. “Right Side Switch Panel” on page 226.......64

7. “Various Cabin Locations” on page 241.......64

8. “Heater and Air Conditioner Operation” on page 245.......64

9. “Stereo / CD Player (Optional)” on page 250.......64

10. “Seat Adjustment (Standard)” on page 252.......64

11. “Seat Adjustment (Option)” on page 254.......64

12. “Seat Belt” on page 256.......64

13. “Door Side Latch” on page 257.......64

14. “Fuse Box/Relay/Engine Emergency Stop Switch” on page 259.......64

Component Locations.......65

Figure 1.......65

1.......66

Bucket Teeth.......66

2.......66

Bucket.......66

3.......66

Air Conditioner Condenser.......66

4.......66

Rear Wheel Cover.......66

5.......66

Battery Box.......66

6.......66

Rear Light.......66

7.......66

Counterweight.......66

8.......66

Fan Motor.......66

9.......66

Towing Pin.......66

10.......66

Muffler Tail Pipe.......66

11.......66

Oil Tank.......66

12.......66

Tilt Lever.......66

13.......66

Front Wheel Cover.......66

14.......66

Bucket Cylinder.......66

15.......66

Headlight Support.......66

16.......66

Ladder.......66

17.......66

Work Light.......66

18.......66

Operator's Cabin.......66

19.......66

Air Cleaner.......66

20.......66

Engine Air Intake Precleaner.......66

21.......66

Engine.......66

22.......66

Muffler.......66

23.......66

CAC Cooler.......66

24.......66

Radiator.......66

25.......66

Grille.......66

26.......66

Fan.......66

27.......66

Fuel Tank.......66

28.......66

Engine Oil Fill Cap.......66

29.......66

Engine Oil Filter.......66

30.......66

Engine Oil Level Dipstick.......66

31.......66

32.......66

Rear Axle.......66

33.......66

Drive Shaft (Rear).......66

34.......66

Transmission.......66

35.......66

Transmission Oil Filter.......66

36.......66

Drive Shaft (Center).......66

37.......66

Center Pin.......66

38.......66

Steering Wheel Cylinder.......66

39.......66

Boom Cylinder.......66

40.......66

Drive Shaft (Front).......66

41.......66

Parking Brake.......66

42.......66

Front Axle.......66

43.......66

Loader Arm.......66

44.......66

Link.......66

Operator's Area.......67

Figure 2.......67

Steering Console and Pedals.......68

Figure 3.......68

Figure 4.......69

1. Starter Switch.......69

A threeposition starter switch is used to start or shut down engine for equipment operation........69

O. Turning the switch to this position turns the engine "OFF" along with its electrical system. In this position the engine is "OFF" but the interior cabin light and fuel tank transfer pump (if equipped) are functional........69

I. Turning the switch to this position turns the engine electrical system "ON." When the switch is first turned "ON" the six indicator/warning lights across the top of the instrument panel, will light for approximately two seconds. The batter.........69

NOTE: Preheat Indicator Light The operation of the preheat cycle depends on coolant temperature. When the engine coolant is cold enough, the preheat indicator light will remain "ON" until the engine preheat cycle is completed. The preheat cyc.........69

. Moving switch to this position will crank engine. When engine starts, release key and allow it to return to the "I" (ON) position. Do not operate the starter switch for more than fifteen seconds at a time. This will help prevent damage to starter........69