![SP000095Wheel Loader Safety
Page 16
To prevent hot coolant from spurting out, shut down engine, wait
for the coolant to cool, then loosen the cap slowly to relieve the
pressure.
To prevent hot oil from spurting out, shut down engine, wait for
the oil to cool, then loosen the cap slowly to relieve the pressure.
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.
If going between movable parts is necessary, always position
and secure the work equipment so that it cannot move.
Fire Extinguisher and First Aid Kit
As a precaution if any injury or fire should occur, always do the
following.
• Be sure that fire extinguishers have been provided
and read the labels to ensure that you know now to
use them. It is recommended that an appropriately
sized (2.27 kg [5 lb] or larger) multipurpose "A/B/C"
fire extinguisher be mounted in the cab. Check and
service the fire extinguisher at regular intervals and
make sure that all work site crew members are
adequately trained in its use.
• Provide a first aid kit in the storage compartment and
keep another at the work site. Check the kit
periodically and make any additions if necessary.
• Know what to do in case of injury from fire.
• Keep emergency numbers for doctor, ambulance
service, hospital and fire department near your
telephone.
If the machine catches fire, it may lead to serious personal injury
or death. If a fire occurs during operation, escape from the
machine as follows;
• Turn the starter switch "OFF" and shut down engine.
HAOA060L
Figure 6
Figure 7
HDO1010L
Figure 8
HDO1009L](https://image.slidesharecdn.com/doosandl400wheelloaderservicerepairmanual-201223145626/85/Doosan-dl400-wheel-loader-service-repair-manual-18-320.jpg)
Doosan dl400 wheel loader service repair manual
- 1. K1010635E 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 K1010635E Serial Number 5001 and Up DL400
- 2. Table of Contents Page I 1Table of Contents Safety Wheel Loader Safety ............................................................................ SP000095 Specifications Specification for DL400......................................................................... SP000096 General Maintenance General Maintenance Procedures........................................................ SP000097 Standard Torques................................................................................. SP000098 Engine QSL9 Engine ........................................................................................ SP000204 Drive Train Transmission and Torque Converter (ZF 4WG-260-4)......................... SP000099 Transmission Error Codes (ZF) ............................................................ SP000100 Front Axle (ZF - MT-L 3105)................................................................. SP000101 Rear Axle (ZF - MT-L 3095).................................................................. SP000107 Drive Shaft............................................................................................ SP000119 Brake Service Brake ....................................................................................... SP000120 Brake Supply Valve .............................................................................. SP000121 Parking Brake ....................................................................................... SP000122 Brake Pedal Valve ................................................................................ SP000123 Accumulator.......................................................................................... SP000124 Steering Steering Unit......................................................................................... SP000125
- 3. Table of Contents Page II Flow Amplifier ....................................................................................... SP000126 Cushion Valve....................................................................................... SP000127 Emergency Steering ............................................................................. SP000128 Frame Articulation Center ................................................................................ SP000129 Counterweight....................................................................................... SP000130 Tank Oil Tank ................................................................................................ SP000131 Fuel Tank.............................................................................................. SP000132 Hydraulics Main Control Valve ............................................................................... SP000144 Load Isolation System .......................................................................... SP000149 Cooling System..................................................................................... SP000154 Pilot System.......................................................................................... SP000159 Hydraulic Schematic (DL400)............................................................... SP000168 Electrical System Air Conditioner...................................................................................... SP000172 Electrical System .................................................................................. SP000173 Electrical Schematic (DL400) ............................................................... SP000235
- 4. SP000095 Page 1 Wheel Loader Safety SP000095 WHEEL LOADER SAFETYSP000095 Wheel Loader Safety Edition 1
- 5. 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
- 6. 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
- 7. SP000095Wheel 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.
- 8. Wheel Loader Safety Page 7 SP000095 WARNING! Improper operation and maintenance of this machine can be hazardous and could result in serious injury or death. Operator and maintenance personnel should read this manual thoroughly before beginning operation or maintenance. Keep this manual in the storage compartment to the rear of the operator's seat, and have all personnel involved in working on the machine periodically read the manual. Some actions involved in operation and maintenance of the machine can cause a serious accident, if they are not done in a manner described in this manual. The procedures and precautions given in this manual apply only to intended uses of the machine. If you use your machine for any unintended uses that are not specifically prohibited, you must be sure that it is safe for any others. In no event should you or others engage in prohibited uses or actions as described in this manual. DOOSAN delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped. If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety devices and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regulations of your country, consult DOOSAN or your DOOSAN distributor before operating the machine.
- 9. SP000095Wheel Loader Safety Page 8 Learn the Signal Words Used with the Safety Alert Symbol The words "CAUTION," "WARNING," and "DANGER" used throughout this manual and on decals on the machine indicate degree of risk of hazards or unsafe practices. All three degrees of risk indicate that safety is involved. Observe precautions indicated whenever you see the Safety Alert "Triangle," no matter which signal word appears next to the "Exclamation Point" symbol. SAFETY ALERT SYMBOL Be Prepared - Get to Know All Operating and Safety Instructions. This is the Safety Alert Symbol. Wherever it appears in this manual or on safety signs on the machine you should be alert to the potential for personal injury or accidents. Always observe safety precautions and follow recommended procedures. CAUTION! This word is used on safety messages and safety labels and indicates potential of a hazardous situation that, if not avoided, could result in minor or moderate injury. It may also be used to alert against a generally unsafe practice. WARNING! This word is used on safety messages and safety labels and indicates potential of a hazardous situation that, if not avoided, could result in serious injury or death. It may also be used to alert against a highly unsafe practice. DANGER! This word is used on safety messages and safety labels and indicates an imminent hazard of a situation that, if not avoided, is very likely to cause death or extremely serious injury. It may also be used to alert against equipment that may explode or detonate if handled or treated carelessly.
- 10. Wheel Loader Safety Page 9 SP000095 Safety precautions are described in SAFETY from page -10 on. DOOSAN cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore the safety messages in this manual and on the machine may not include all possible safety precautions. If any procedures or actions not specifically recommended or allowed in this manual are used, you must be sure that you and others can do such procedures and actions safely and without damaging the machine. If you are unsure about the safety of some procedures, contact a DOOSAN distributor.
- 11. SP000095Wheel Loader Safety Page 10 GENERAL SAFETY ESSENTIALS Accessory Applications 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. Do not use bucket for lifting work, unless lift slings are used in approved configuration. LOCATION OF SAFETY LABELS Location of safety labels (decals) can vary from unit to unit. Refer to appropriate Operation and Maintenance Manual, and Parts Manual for your unit. There are several specific warning signs on this machine. The exact location of hazards and the description of the hazards are reviewed in the appropriate Operation and Maintenance Manual. Please become familiarized with all warning signs. Make sure that all of the warning signs are legible. Clean the warning signs or replace the warning signs if you cannot read the words. Replace the illustrations if the illustrations are not visible. When you clean the warning signs, use a cloth, water and soap. Do not use solvent, gasoline, or other harsh chemicals to clean the safety signs. Solvents, gasoline, or other harsh chemicals could loosen the adhesive that secures the warning sign. Loose adhesive will allow the warning sign to fall off. Replace any safety sign that is damaged, or missing. If a safety sign is attached to a part that is replaced, install a safety sign on the replacement part. UNAUTHORIZED MODIFICATIONS Any modification made without authorization or written approval from DOOSAN can create a safety hazard, for which the machine owner must be held responsible. For safety's sake, replace all OEM parts with the correct authorized or genuine DOOSAN part. For example, not taking the time to replace fasteners, bolts or nuts with the correct replacement parts could lead to a condition in which the safety of critical assemblies is dangerously compromised.
- 12. Wheel Loader Safety Page 11 SP000095 GENERAL HAZARD INFORMATION Safety Rules Only trained and authorized personnel can operate and maintain the machine. Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine. Do not operate the machine if you are not feeling well, if you are taking medication that makes you feel sleepy, if you have been drinking, or if you are suffering from emotional problems. These problems will interfere with your sense of judgement in emergencies and may cause accidents. When working with another operator or with a person on work site traffic duty, be sure that all personnel know the nature of the work and understand all hand signals that are to be used. Always observe strictly any other rules related to safety. Safety Features Be sure that all guards and covers are installed in their proper position. Have guards and covers repaired immediately if damaged. Be sure that you understand the method of use of safety features such as transmission lever neutral lock and the seat belt, and use them properly. Never remove any safety features. Always keep them in good operating condition. Failure to use safety features according to the instructions in the Operation and Maintenance Manual could result in serious bodily injury.
- 13. SP000095Wheel Loader Safety Page 12 Inside Operator's Compartment When entering the operator's compartment, always remove all mud and oil from the soles of your shoes. If you operate the accelerator and brake pedals with mud or oil stuck to your shoes, your foot may slip and this may cause a serious accident. Clean grease and dirt from pedals and controls. This contributes to safe operation. Cleaning also provides an opportunity to inspect equipment. Minor damage can be repaired or corrected before major problems result. Keep cab floor and consoles free of tools and personal items. After using the ashtray, make sure that any matches or cigarettes are properly extinguished, and be sure to close the ashtray. If the ashtray is left open, there is danger of fire. Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire. Do not leave lighters laying around the operator's compartment. If the temperature inside the operator's compartment becomes high, there is danger that the lighter may explode. Do not use cellular telephones inside the operator's compartment when driving or operating the machine. There is danger that this may lead to an unexpected accident. Never bring any dangerous objects such as flammable or explosive items into the operator's cab. To ensure safety, do not use the radio or music headphones when operating the machine. There is danger that this may lead to a serious accident. When operating the machine, do not put your hands or head out of the window. When standing up from the operator's seat, always place transmission neutral lock lever in the "LOCK" position and set pilot cutoff switch to "O" (OFF) position. If you accidentally touch the work equipment levers when they are not locked, the machine may suddenly move and cause serous injury or damage. When leaving the machine, lower the work equipment completely to the ground, set transmission neutral lock lever in the "LOCK" position, set pilot cutoff switch to "O" (OFF) position, "APPLY" parking brake, and shut down engine. Use the key to lock all the equipment. Always remove the key and take it with you.
- 14. Wheel Loader Safety Page 13 SP000095 Clothing and Personal Protective Items Contain long hair, and avoid loose clothing and jewelry. They can catch on controls or in protruding parts and cause serious injury or death. Do not wear oily clothes. They are highly flammable. Full eye protection, a hard hat, safety shoes and gloves may be required at the work site. While working on the machine, never use inadequate tools. They could break or slip, causing injury, or they may not adequately perform intended functions. HAOA020L Figure 1
- 15. SP000095Wheel Loader Safety Page 14 Breathing Masks, Ear Protection May Be Required Do not forget that some risks to your health may not be immediately apparent. Exhaust gases and noise pollution may not be visible, but these hazards can cause disabling or permanent injuries. NOTE: The equivalent continuous A-weighted sound pressure level at the workstation for this machine is given in the operation manual. Measurement is obtained on a dynamic machine following the procedures and cab conditions as described in ISO 6396. NOTE: The guaranteed sound power level emitted by the machinery for this machine is given in the operation manual. Measurement is obtained on a dynamic machine with the procedures as described in 2000/14/EC. Vibration Level Information Hands/Arms: The weighted root mean square acceleration to which the hands/arms are subjected, is less than 2.5 m/s2. Whole body: The weighted root mean square acceleration to which the whole body is subjected, is less than 0.5 m/s2 . Measurements are obtained on a representative machine, using measuring procedures as described in the following standard: ISO 2631/1. ISO 5349, and SAE J1166. Asbestos Dust Hazard Prevention Asbestos dust can be HAZARDOUS to your health if it is inhaled. Materials containing asbestos fiber can be present on work site. Breathing air that contains asbestos fiber can ultimately cause serious or fatal lung damage. To prevent lung damage from asbestos fiber, observe following precautions; • Use a respirator that is approved for use in an asbestos-laden atmosphere. • Never use compressed air for cleaning. • Use water for cleaning to keep down the dust. • Work on the machine or component with the wind at your back whenever possible. • Always observe any rules and regulations related to the work site and working environment. ARO1770L Figure 2
- 16. Wheel Loader Safety Page 15 SP000095 Mounting and Dismounting Before getting on or off the machine, if there is any oil, grease, or mud on the handrails, steps, or track shoes, wipe it off immediately. Always keep these parts clean. Repair any damage and tighten any loose bolts. Never get on or off a moving machine. In particular, never get on or off a moving machine. These actions may lead to serious injury. When getting on or off the machine, always face the machine, and maintain a three-point contact (both feet and one hand or one foot and both hands) with the handholds and steps to ensure that you support yourself securely. Never hold any control levers when getting on or off the machine. Never get up from operator's seat or leave operator's station and dismount machine if engine is running. Fuel, Oil and Hydraulic Fluid Fire Hazards Fuel, oil and antifreeze will catch fire if it is brought close to a flame. Fuel is particularly flammable and can be hazardous. Always strictly observe the following. Add fuel, oil, antifreeze and hydraulic fluid to the machine only in a well ventilated area. The machine must be parked with controls, lights and switches turned "OFF." The engine must be "OFF" and any flames, glowing embers, auxiliary heating units or spark causing equipment must be doused, turned "OFF" and/ or kept well clear of the machine. Static electricity can produce dangerous sparks at the fuel filling nozzle. In very cold, dry weather or other conditions that could produce a static discharge, keep the tip of the fuel nozzle in constant contact with the neck of the fuel filling nozzle, to provide a ground. Keep fuel and other fluid reservoir caps tight and do not start the engine until caps have been secured. Precautions When Handling Fluids at High Temperature Immediately after operations are stopped, the coolant, engine oil, and hydraulic oil are at high temperature and the radiator and hydraulic tank are still under pressure. Attempting to remove the cap, drain the oil or coolant, or replace the filters may lead to serious burns. Always wait for the temperature to go down, and follow the specified procedures when carrying out these operations. HA3O1003 Figure 3 Figure 4 HAOA050L Figure 5
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- 18. SP000095Wheel Loader Safety Page 16 To prevent hot coolant from spurting out, shut down engine, wait for the coolant to cool, then loosen the cap slowly to relieve the pressure. To prevent hot oil from spurting out, shut down engine, wait for the oil to cool, then loosen the cap slowly to relieve the pressure. 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. If going between movable parts is necessary, always position and secure the work equipment so that it cannot move. Fire Extinguisher and First Aid Kit As a precaution if any injury or fire should occur, always do the following. • Be sure that fire extinguishers have been provided and read the labels to ensure that you know now to use them. It is recommended that an appropriately sized (2.27 kg [5 lb] or larger) multipurpose "A/B/C" fire extinguisher be mounted in the cab. Check and service the fire extinguisher at regular intervals and make sure that all work site crew members are adequately trained in its use. • Provide a first aid kit in the storage compartment and keep another at the work site. Check the kit periodically and make any additions if necessary. • Know what to do in case of injury from fire. • Keep emergency numbers for doctor, ambulance service, hospital and fire department near your telephone. If the machine catches fire, it may lead to serious personal injury or death. If a fire occurs during operation, escape from the machine as follows; • Turn the starter switch "OFF" and shut down engine. HAOA060L Figure 6 Figure 7 HDO1010L Figure 8 HDO1009L
- 19. Wheel Loader Safety Page 17 SP000095 • If there is time, use the fire extinguisher to extinguish as much of the fire as possible. • Use the handrails and steps to escape from the machine. The above is the basic method for escaping from the machine, but changing the method may be necessary according to the conditions, so carry out practice drills at the work site. Protection from Falling or Flying Objects On work sites where there is danger that falling objects or flying objects may hit the operator's cab select a guard to match the operating conditions to protect the operator. Work in mines, tunnels, deep pits or on loose or wet surfaces could produce danger of falling rock, roll over or hazardous flying objects. Additional protection for operator's cab could be required in form of a FOPS/Falling Object Protective Structure and/or ROPS/Roll Over Protective Structure reinforcement system. Any reinforcement system that is installed on machine must pass safety and certification standards and carry appropriate labeling and rating information. For example, most often added type of reinforcement system, FOPS, must meet or exceed Society of Automotive Engineers standard SAE J1356, "Performance Criteria for Falling Object Guards for Wheel loaders." Never attempt to alter or modify any type of protective structure reinforcement system, by drilling holes, welding or remounting or relocating fasteners. Any serious impact or damage to system requires a complete integrity reevaluation. Reinstallation, recertification and/or replacement of system may be necessary. Install Additional Safety Equipment If Conditions Require Laminate glass protection for the front, side or rear windows may also be recommended depending upon particular site conditions. Contact your DOOSAN distributor for available safety guards and/or recommendations if there is any danger of getting hit by objects that could strike the operator's cab. Make sure that all other work site crew members are kept well away from wheel loader and safe from potential hazards. Figure 9 HAOA110L Figure 10 HAOA100L
- 20. SP000095Wheel Loader Safety Page 18 Maintain Standard Safety Equipment in Good Condition Machinery guards and body panel covers must be in place at all times. Keep well clear of rotating parts. Pinch point hazards such as cooling fan and alternator drive belts could catch hair, jewelry or oversize or very loose clothing. Safety labels must be replaced if they are damaged or become unreadable. Information on labels gives work crew members an important safety reminder. Part numbers for each decal and required mounting locations are shown on pages 1-2 through 1-4 of this section.