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Doosan Mega 500-V, Operation And Maintenance Manual

The Doosan Mega 500-V Operation and Maintenance Manual is a comprehensive guide indispensable for owners and operators. Discover vital information and detailed instructions to operate and maintain your Doosan Mega 500-V efficiently. Download the free manual now from manualshive.com to optimize the performance and longevity of your equipment.

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022-00029AE Operation and Maintenance Manual

   Operating Controls 2-13

GAUGES

1.

FUEL GAUGE

2.

SPEEDOMETER

3.

HOUR METER

4.

TACHOMETER

5.

COOLANT TEMPERATURE GAUGE

6.

TRANSMISSION OIL TEMPERATURE. 
GAUGE

WARNING LIGHTS

7.

PREHEAT INDICATOR LIGHT

8.

AIR CLEANER CLOGGING WARNING 
LIGHT

9.

ENGINE WARNING LIGHT

10.

ENGINE STOP LIGHT

11.

BATTERY WARNING LIGHT

12.

LEFT TURN AND HAZARD WARNING 
LIGHT

13.

HIGH BEAM INDICATOR LIGHT

14.

RIGHT TURN AND HAZARD WARNING 
LIGHT

15.

WORK LIGHT INDICATOR LIGHT

16.

BRAKE OIL PRESSURE WARNING 
LIGHT

17.

ENGINE MAINTENANCE LIGHT

18.

PARKING BRAKE INDICATOR LIGHT

19.

UNUSED LIGHT

SWITCHES

20.

HAZARD WARNING LIGHT SWITCH

21.

LOAD ISOLATION SYSTEM (LIS) 
SWITCH (OPTION)

22.

BOOM FLOAT SWITCH (OPTION)

1.

FUEL GAUGE

This gauge displays amount of fuel in tank.
"F" means the tank is "full"; "E" means the
tank is empty." If the pointer comes close
to the "E" (red zone), add fuel as soon as
possible. When the pointer comes close to
the "E” (red zone), approximately 90 liters
(24 U.S. gal.) of fuel remains.

IMPORTANT

All of the gauge and warning lights (except for the turn lights, high beam light and work light)
come "ON" for two seconds with a warning buzzer sound when the starter switch is turned to the
"I" (ON) position.

If any light fails to turn "ON" at this time, check the cause and replace.

HBOI250L

Figure 20 

Summary of Contents for Mega 500-V

Page 1: ... 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 an...

Page 2: ......

Page 3: ...hine Operation 1 24 Maintenance 1 31 Battery 1 39 Towing 1 41 Shipping and Transportation 1 42 Operating Controls 2 1 Component Locations 2 2 Control Identification 2 4 Steering Console and Pedals 2 5 Front Instrument panel 2 12 Transmission Display 2 21 Right Side Switch Panel 2 22 Various Cabin Locations 2 33 Heater and Air Conditioner Operation 2 37 Stereo 2 42 Seat Adjustment 2 46 Seat Belt 2 4...

Page 4: ...While Traveling 3 20 Allowable Water Depth 3 20 Inspection Maintenance and Adjustment 4 1 Preventive Maintenance 4 1 Table of Recommended Lubricants 4 3 Fluid Capacities 4 5 Maintenance Intervals 4 6 10 Hour Daily Service 4 8 50 Hour Weekly Service 4 18 250 Hour Monthly Service 4 25 500 Hour 3 Month Service 4 35 1 000 Hour 6 Month Service 4 37 1 500 Hour 9 Month Service 4 42 2 000 Hour Annual Serv...

Page 5: ...railer 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 Approximate Weight of Workload Materials 7 4 Index 1 1 ...

Page 6: ......

Page 7: ...nauthorized Modifications on page 1 13 4 General Hazard Information on page 1 13 5 Before Starting Engine on page 1 21 6 Machine Operation on page 1 24 7 Maintenance on page 1 31 8 Battery on page 1 39 9 Towing on page 1 41 10 Shipping and Transportation on page 1 42 DANGER Unsafe use of the wheel loader could lead to serious injury or death Operating procedures maintenance and equipment practices ...

Page 8: ...d 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 c...

Page 9: ... safety of some procedures contact a DOOSAN distributor 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 potential for personal injury or accidents Always observe safety precautions and follow recommended procedures CAUTION This word is used o...

Page 10: ...ing signs on this machine The exact location of hazards and the description of the hazards are reviewed in this section 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 ...

Page 11: ...022 00029AE Operation and Maintenance Manual Safety 1 5 Figure 1 ROPS CANOPY MACHINE WITH CABIN 1 6 8 2 4 9 5 12 10 5 9 11 2 8 3 7 3 AQO0320L ...

Page 12: ...1 6 Safety 022 00029AE Operation and Maintenance Manual Figure 2 CAB MACHINE 1 6 8 2 4 9 5 12 10 3 5 9 11 2 8 7 3 AQO0330L ...

Page 13: ...arby before operating and make sure all persons are clear of area Always make sure when leaving operator s seat to Lower bucket or other working tools to ground LOCK transmission selector in NEUTRAL 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 ...

Page 14: ... 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 Activation of any controls may enable the selected function to operate under force of gravity WARNING Before opening bonnet stop engine WARNING Explosion hazard Keep away from flame Do not weld or drill CAUTION Any raised attachment will lower to groun...

Page 15: ...ING TURN AREA 4190 1992 190 00120 6 WARNING FOR HIGH TEMPERATURE HYDRAULIC OIL 2190 2529 190 00097 IMPORTANT Refer to Shop Manual for service procedures Do not release any pilot lines until pressure within accumulator has been released DANGER Keep out of steering turn area WARNING HYDRAULIC OIL To prevent hot oil from spurting out Turn engine off Allow oil to cool Slowly loosen cap to relieve pres...

Page 16: ...ode Keep sparks and flames away from batteries Always avoid storing metals like tools or inflammable materials around or on batteries Explosion or fire can be caused by short circuiting batteries Sulfuric acid in battery is poisonous It is strong enough to burn skin eat holes in clothing and cause blindness if splashed in eyes If you spill acid on yourself 1 Flush your skin with water 2 Apply baki...

Page 17: ... MACHINE 4190 1989 190 00107 10 WARNING FOR PERFORMING MAINTENANCE ON FRONT ATTACHMENT 4190 2546 190 00105 WARNING For your safety do not stand on ladder when machine is in motion DANGER To avoid injury securely brace lift arm before disassembly of valve or piping AMO0420L AMO0430L ...

Page 18: ...11 WARNING TO USE SAFETY LOCK 4190 1993 190 00121 12 WARNING TAG 2190 2549 190 00098 WARNING Safety lock must be in LOCK position when servicing pivot area or transporting machine WARNING Don t touch when performing inspection or maintenance AMO0440L ACO1450L ...

Page 19: ...ot 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...

Page 20: ...he 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 acci...

Page 21: ...e 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 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 ge...

Page 22: ...he 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...

Page 23: ...rpose 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 ...

Page 24: ...ing 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 along with tempered glass may also be recommended depending upon particular site conditions Co...

Page 25: ...s describe in Handling of Accumulator on page 4 52 The accumulator is charged with high pressure nitrogen gas so it is extremely dangerous if it is handled in the wrong way Always observe the following precautions Do not drill or make any holes in the accumulator or expose it any flame fire or heat source Do not weld on the accumulator or try attaching anything to it When carrying out disassembly ...

Page 26: ...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 Grip the handle firmly and use the sharp point to break the glass WARNING Protect your eyes when breaking the glass Figure 14 ...

Page 27: ...ype of object in the vicinity of the boom could represent a potential hazard or cause the operator to react suddenly and cause an accident Use a spotter or signal person working near bridges phone lines work site scaffolds or other obstructions Minimum levels of insurance coverage work permits or certification physical barriers around the work site or restricted hours of operation may be mandated ...

Page 28: ...rs and check that the safety lever is in LOCKED position If any abnormalities are found in the above checks carry out repairs immediately ENGINE STARTING Walk around your machine before getting in operator s cab Look for evidence of leaking fluid loose fasteners misaligned assemblies or any other indications of possible equipment hazard All equipment covers and machinery safety guards must be in p...

Page 29: ...mmediately If the machine is used without repairing the problems it may lead to unexpected injury or failure Clear all personnel from directly around machine and from the area Clear all obstacles from the machine s path Beware of hazards Be sure that all windows are clean Secure the doors and the windows in the open position or in the shut position Adjust the rear view mirrors for best visibility ...

Page 30: ...anuals Do not let anyone operate machine unless they ve been fully and completely trained in safety and in operation of the machine SEAT BELTS SHOULD BE USED AT ALL TIMES Whenever engine is running operator should be seated at the control station with seat belt properly engaged MOVEMENT ALARMS If wheel loader is equipped with an audible travel movement alarm test alarm on a daily basis Audible ala...

Page 31: ... When traveling on rough ground travel at low speed and avoid sudden changes in direction Always keep to the permissible water depth Refer to Allowable Water Depth on page 3 20 When traveling over bridges or structures on private land check first that the bridge or structure can withstand the weight of the machine When traveling on public roads check with the local authorities and follow their ins...

Page 32: ...ACT AUTHORITIES Below ground hazards also include natural gas lines water mains tunnels and buried foundations Know what s underneath work site before starting to dig BE AWARE OF HEIGHT OBSTACLES Any type of object in vicinity of boom could represent a potential hazard or cause operator to react suddenly and cause an accident Use a spotter or signal person working near bridges phone lines work sit...

Page 33: ...r heavy rainfalls or during spring thaws STAY ALERT FOR PEOPLE MOVING THROUGH WORK AREA When loading a truck you should always know where the driver is Avoid loading over the cab of a truck even if the driver is in a safe spot Someone else could have gone inside for any number of reasons Avoid working where unseen passersby might be Slow down work cycle and use slower travel speeds in congested or...

Page 34: ... a cliff by mistake Use the machine only for its main purpose Using it for other purposes will cause failures To ensure an ample view do as follows When working in dark areas attach working lights and front lights to the machine If necessary set up lighting at the work site Stop operations when the visibility is poor such as in fog mist snow and rain Wait for the visibility to improve to a level w...

Page 35: ...nt are more likely to cause severe stress in very cold temperatures Reducing work cycle rate and work load may be necessary When the temperature rises frozen road surfaces become soft so the machine travel becomes unstable In cold weather do not touch metal surfaces with your bare hands If you touch a metal surface in extremely cold weather your skin may freeze to the metal surface PARKING MACHINE...

Page 36: ...om switch Engage all lock down security equipment that may have been installed on machine NEVER LET ANYONE RIDE ON ATTACHMENT Never let anyone ride on any work attachment such as the bucket crusher grapple or clamshell grab bucket There is a danger of the person falling and suffering serious injury IMPORTANT When hydraulic system maintenance or service work must be performed be aware that accumula...

Page 37: ... or mud in your eyes or that you may slip and injure yourself When washing the machine do the following Wear shoes with non slip soles to prevent yourself from slipping and falling on wet places Wear safety glasses and protective clothing when washing the machine with high pressure steam Take action to prevent touching high pressure water and cutting your skin or having mud fly into your eyes Do n...

Page 38: ...king fuel or fuel that is spilled onto hot surfaces or onto electrical components can cause a fire Store all fuels and all lubricants in properly marked containers and away from all unauthorized persons Store oily rags and other flammable material in a protective container Do not smoke while you refuel the machine or while you are in a refueling area Do not smoke in battery charging areas or in ar...

Page 39: ...omponents to cool before you drain the cooling system Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin Remove the hydraulic tank filter plug only after the engine has been stopped Make sure that the hydraulic tank filter plug is cool before you remove it with your bare hand Remove the hydraulic tank filter plug slowly to relieve pressu...

Page 40: ...pipes or on tubes that contain flammable fluids Do not flame cut on pipes or on tubes that contain flammable fluids Before you weld on pipes or on tubes or before you flame cut on pipes or on tubes clean the pipes or tubes thoroughly with a nonflammable solvent If heat is applied directly to rubber hoses or piping under pressure they may suddenly break so cover them with a fireproof covering Wear ...

Page 41: ...ry if there is a gust of wind CRUSHING PREVENTION AND CUTTING PREVENTION You should always have at least two people working together if the engine must be run during service One person needs to remain in the operator s seat ready to work the controls or stop the machine and shut off the engine Unless you are instructed otherwise never attempt adjustments while the machine is moving or while the en...

Page 42: ...controls When engine lube oil gearbox lubricant or other fluids require change wait for fluid temperatures to decrease to a moderate level before removing drain plugs NOTE Oil will drain more quickly and completely if it is warm Do not drain fluids at temperatures exceeding 95 C 203 F however do not allow full cool down HYDRAULIC CYLINDER SEALS REQUIRE PERIODIC REPLACEMENT Check cylinder drift rat...

Page 43: ...se your fingers Do not bend high pressure lines Do not strike high pressure lines Do not install lines tubes or hoses that are bent or damaged Make sure that all clamps guards and heat shields are installed correctly to prevent vibration rubbing against other parts and excessive heat during operation If any of the following conditions are found replace the part Damage or leakage from hose end Wear...

Page 44: ...hould have gradual bends DISPOSE OF ALL PETROLEUM BASED OILS AND FLUIDS PROPERLY Physical contact with used motor oil may pose a health risk Wipe oil from your hands promptly and wash off any remaining residue Used motor oil is an environmental contaminant and may only be disposed of at approved collection facilities To prevent pollution of the environment always do the following Never dump waste ...

Page 45: ...ng the top surface of the battery wipe it with a clean damp cloth Never use gasoline thinner or any other organic solvent or detergent Tighten the battery caps securely Explosive battery gas can be set off by sparks from incidental contact or static discharge Turn OFF all switches and engine when working on batteries Keep battery terminals tight Contact between a loose terminal and post can create...

Page 46: ...hile required battery connections are made 24 volt battery units consisting of two series connected twelve volt batteries have a cable connecting one positive terminal on one of the 12 volt batteries to a negative terminal on the other battery Booster or charger cable connections must be made between the non series connected positive terminals and between the negative terminal of the booster batte...

Page 47: ...re workers determine the signals to use and follow these signals correctly 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 It is dangerous to carry out towing on slopes so select a place where the slope is gradual If there is no ...

Page 48: ...efore making any other preparation for transport Hauling vehicle trailer and load must all be in compliance with local regulations governing intended shipping route Partial disassembly or tear down of wheel loader may be necessary to meet travel restrictions or particular conditions at job site Refer to Transportation on page 5 1 of this Operation and Maintenance Manual for information on loading ...

Page 49: ...n page 2 46 11 Seat Belt on page 2 48 12 Door Side Latch on page 2 49 13 Fuse Box Relay on page 2 50 14 Window Glass Breaking Tool on page 2 53 Each group is explained with a point location drawing or photo and a brief description of each control switch gauge or valve Indicator lights work in addition to the gauges on the instrument panel The operator should monitor machine pressure on the instrum...

Page 50: ...intenance Manual COMPONENT LOCATIONS The following figure identifies the location of major machine components 1 1 2 3 40 4 5 6 7 8 9 10 11 12 13 14 16 15 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 41 42 43 44 AQO0190L Figure 1 ...

Page 51: ...LVE 14 FRONT WHEEL COVER 15 STEERING WHEEL 16 ROPS 17 WORK LEVER 18 SEAT 19 REAR WHEEL COVER 20 PRE CLEANER 21 AIR CLEANER 22 MUFFLER 23 ENGINE 24 CAC COOLER 25 RADIATOR 26 FAN 27 GRILL 28 FUEL TANK 29 FUEL FILLER PIPE 30 ENGINE OIL LEVEL GAUGE 31 ENGINE OIL FILLER PIPE 32 REAR AXLE PIVOT 33 REAR AXLE 34 TRANSMISSION OIL FILTER 35 WHEEL CHOCK 36 TRANSMISSION 37 CENTER PIN 38 STEERING CYLINDER 39 B...

Page 52: ...Operation and Maintenance Manual CONTROL IDENTIFICATION 1 STEERING CONSOLE AND PEDALS See page 2 5 2 VARIOUS CABIN LOCATIONS See page 2 33 3 RIGHT SIDE SWITCH PANEL See page 2 22 4 SEAT ADJUSTMENT See page 2 48 4 1 2 3 AQO0020L Figure 2 ...

Page 53: ...LS 1 STARTER SWITCH 2 HORN BUTTON 3 COMBINATION SWITCH LEVER 4 ACCELERATOR PEDAL 5 STEERING TILT KNOB 6 BRAKE PEDALS 7 STEERING WHEEL 8 KICK DOWN SWITCH 9 TRANSMISSION LEVER 10 FRONT INSTRUMENT PANEL See page 2 12 11 TRANSMISSION DISPLAY See page 2 21 Figure 3 11 5 6 6 4 2 1 3 7 8 AQO0340L 10 9 ...

Page 54: ...c Control Module check their systems for a moment and the engine may not start while this is taking place Moving switch to this position will crank engine When engine starts release key and allow it to return to I ON position Do not operate the starter switch for more than 15 seconds at a time This will help prevent damage to starter Preheat position Because this machine has an automatic preheatin...

Page 55: ...ion C Window Washer Switch When the outside area of the lever is pressed it activates the washer pump and sprays fluid on the windshield Only while being pressed D Horn Button The center button on end of lever activates horn Only while being pressed E Wiper Switch Activates wipers when outside area of lever is rotated J Intermittent Mode wipes every 5 seconds 0 Stop Off I Normal Speed Mode II High...

Page 56: ... of loader and working speed of load handling system 5 STEERING TILT KNOB This knob is used to allow steering wheel to be moved to the most convenient position for the operator Loosen knob 2 Figure 10 while grabbing the steering wheel 1 Once the steering wheel is in the proper place tighten the knob CAUTION The further the pedal is pressed the more engine speed increases However do not press the p...

Page 57: ...STEERING WHEEL Rotating steering wheel controls position of front wheels and this determines direction of machine travel CAUTION When descending on an incline slow down the truck by using both the brake pedal and the engine brake Using the brake pedal too often might lead to insufficient oil pressure thus making it difficult to brake the loader IMPORTANT Do not use brake pedal as a foot rest This ...

Page 58: ...ntrol valve lever joystick 9 TRANSMISSION LEVER Transmission can be shifted into the following positions F Forward When the lever is pushed forward transmission is in FORWARD 1st 2nd 3rd and 4th are available N Neutral When the lever is returned to the center position between forward and reverse the transmission is in NEUTRAL R Reverse When the lever is pulled back transmission is in REVERSE 1st 2...

Page 59: ...ion Prevents lever from being moved out of NEUTRAL D DRIVE position Allows lever to be moved from NEUTRAL to FORWARD and REVERSE 10 FRONT INSTRUMENT PANEL See Front Instrument panel on page 2 12 11 TRANSMISSION DISPLAY See Transmission Display on page 2 21 CAUTION LOCK transmission lever When ever machine is parked LOCK transmission lever in NEUTRAL to prevent accidental machine movement Figure 16...

Page 60: ...2 12 Operating Controls 022 00029AE Operation and Maintenance Manual FRONT INSTRUMENT PANEL 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 18 19 20 21 22 AQO0360L 17 Figure 19 ...

Page 61: ...T 18 PARKING BRAKE INDICATOR LIGHT 19 UNUSED LIGHT SWITCHES 20 HAZARD WARNING LIGHT SWITCH 21 LOAD ISOLATION SYSTEM LIS SWITCH OPTION 22 BOOM FLOAT SWITCH OPTION 1 FUEL GAUGE This gauge displays amount of fuel in tank F means the tank is full E means the tank is empty If the pointer comes close to the E red zone add fuel as soon as possible When the pointer comes close to the E red zone approximat...

Page 62: ...OUR 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 This shows that the hour meter is working 4 TACHOMETER This meter displays engine speed in revolutions per minute HBOI230L Figure 21 Figure 22 10 1 HA0O2012 HBOI240L Figure 23 ...

Page 63: ...eheat function is operating Do not start engine as long as this light is ON 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 for it to cool down Do not shutdown engine If engine is shutdown heat surge may occur CAUTION When the pointer indicates H mark red zone it means the transmission is overheated Stop...

Page 64: ... ON check the engine as described under the Engine Diagnostic Switch See page 2 29 and repair the cause of the fault to prevent engine from having fatal errors NOTE The engine check light will flash between each fault code in diagnostic mode 10 ENGINE STOP LIGHT RED COLOR This light will turn ON when a fatal system error happens to the engine itself or peripherals If this light turns ON check the ...

Page 65: ...re turned ON NOTE If left and right turn indicators blink together or if they blink faster than normal a light bulb is not operating or flasher solenoid is damaged 13 HIGH BEAM INDICATOR LIGHT This light turns ON when the headlights are turned to HIGH BEAM 14 RIGHT TURN AND HAZARD WARNING LIGHT This light blinks when right turn signal is turned ON Both lights blink when warning lights are turned O...

Page 66: ... alarm also sounds 17 ENGINE MAINTENANCE LIGHT BLUE COLOR Lights up when engine maintenance or service is required If this light turns ON check the engine as described Engine Diagnostic Switch See page 2 29 and repair the cause of the fault WARNING Never operate or travel machine when this light is turned ON or when alarm is sounding Always investigate cause of the drop in brake oil pressure and r...

Page 67: ...up and flash warning others in the area At the same time the directional indicator lights on the instrument panel will turn ON to warn the operator The hazard warning lights operate independently of the starter switch O In this position this switch turns OFF hazard warning lights I In this position this switch turns ON all turn signals and they flash simultaneously NOTE Hazard warning lights will ...

Page 68: ...ded bucket NOTE LIS operates when traveling speed is over 8km h 5 MPH 22 BOOM FLOAT SWITCH OPTION Boom float allows the bucket to follow the contour of the ground working surface When pressing this switch and setting work lever to floating position lever is locked detent and boom is lowered When boom is matched to setting position lever locking is released and lever is returned to NEUTRAL position...

Page 69: ...es on page 6 6 NOTE Most codes are only two digits C Indicates that error codes have occurred and are stored D Indicates that operation must be stopped immediately to prevent damage to transmission and hazardous operating condition The gear range indicator bars will indicate which gear is selected by displaying the corresponding number of bars The forward and reverse indicator bars will be OFF whe...

Page 70: ...4 CIGAR LIGHTER 5 HEADLIGHT SWITCH 6 FRONT WORK LIGHT SWITCH 7 REAR WORK LIGHT SWITCH 8 REAR WIPER SWITCH 9 ALTERNATE TORQUE SWITCH 10 ALTERNATE LOW IDLE SWITCH 11 ROTATING BEACON SWITCH OPTION 12 CUP HOLDER 13 ENGINE DIAGNOSTIC SWITCH 14 IDLE SPEED CONTROL SWITCH 15 AUTOMATIC TRANSMISSION SWITCH 16 TRANSMISSION CUTOFF SWITCH 17 PILOT CUTOFF SWITCH 18 PARKING BRAKE SWITCH 2 3 4 5 6 7 8 9 12 13 14 ...

Page 71: ... control valve lever joystick operating pattern and description of operation 1A ERGO II PILOT CONTROL VALVE LEVER JOYSTICK OPTION Ergo II lever is a pilot control valve lever that incorporates transmission control functions It is used to reduce hand and arm movement for he otherwise complex operation of machine A Forward Neutral and Reverse Switches Button When pressing this switch machine travels...

Page 72: ...ition DISPLAY indicates NN When DISPLAY indicates N4 while N button of ERGO II is pressed start the engine When DISPLAY indicates N1 while button is pressed the machine is in the traveling ready condition When button is pressed at forward traveling while KD button is pressed machine can travel forward When button is pressed at backward traveling while KD button is pressed machine can travel backwa...

Page 73: ...ion is placed in NEUTRAL position or the switch is pressed again Log Fork Switch Function When the button is depressed and held the log forks are allowed to open and close when moving the lever from side to side See pilot control valve lever joystick movement pattern A second kick down switch Figure 49 is on the end of the transmission lever 3 HORN BUTTON TWO PLACES Pressing the left button at the...

Page 74: ...g the pilot buzzer will sound to prevent batteries discharging I In this position this switch turns ON clearance tail instrument panel and switch lights II In this position this switch turns ON clearance tail instrument panel switch and headlights IMPORTANT The cigar lighter is powered by a 24 volt circuit Never plug any 12 volt device into the cigar lighter CAUTION Do not leave clearance tail ins...

Page 75: ...HT SWITCH O In this position this switch turns OFF work lights mounted on the rear top of cab and sides of radiator I In this position this switch turns ON work lights mounted on sides of radiator II In this position this switch turns ON work lights on the rear top of cab and sides of radiator CAUTION Do not turn ON the work light when traveling on public roads CAUTION Do not turn ON the work ligh...

Page 76: ...he operator to switch between 100 throttle torque curves and about an 80 derated torque curve This improves operating fuel efficiency in loaded versus unloaded conditions O In this position torque switch is set to the OFF position and 100 torque is permitted I In this position torque switch is turned ON which limits engine torque to 80 of maximum CAUTION The washer pump can be damaged if it is act...

Page 77: ...light 12 CUP HOLDER Place to put beverages 13 ENGINE DIAGNOSTIC SWITCH If the engine warning light yellow engine stop light red or the engine maintenance light blue comes on when the engine is running it means a fault code has been recorded When this occurs the engine diagnostic switch allows the operator to view the fault codes The active fault codes can be viewed using the engine stop light Red ...

Page 78: ...ill decrease engine rpm NOTE This switch is also used to view the next or previous fault code in the diagnostic mode 15 AUTOMATIC TRANSMISSION SWITCH Automatic speed range Forward 2nd 3rd 4th Reverse 2nd 3rd O When this switch is in O MANUAL position travel mode is switched to MANUAL and allows operator to choose speeds manually I When this switch is in I AUTO position gears are AUTOMATICALLY chan...

Page 79: ...e is suitable for load handling operation When the accelerator pedal is pressed under this condition more power is concentrated on the load handling system to quicken the boom lifting speed NOTE 1 Transmission CUTOFF function dose not operate at 3rd and 4th gear for protection of transmission 2 Despite transmission CUTOFF switch the right brake pedal has braking function only 17 PILOT CUTOFF SWITC...

Page 80: ...he monitor light on the front instrument panel comes ON This brake can also be used as an emergency brake WARNING Set the parking brake switch in the I APPLIED position before leaving the loader Make sure to APPLY the parking brake switch before trying to start the loader CAUTION Do not use this parking brake to brake the loader except in an emergency otherwise it might cause premature wear or dam...

Page 81: ...g Controls 2 33 VARIOUS CABIN LOCATIONS 1 CAB LIGHT 2 STEREO 3 HEATER AND AIR CONDITIONER CONTROL PANEL 4 SPEAKERS 5 STORAGE BOX 6 WASHER TANK 7 HOT COLD REFRIGERATOR 8 ELECTRICAL BOX 9 FUSE BOX TWO 10 FUSE BOX ONE 4 5 6 7 8 1 10 9 3 2 AQO0150L Figure 68 ...

Page 82: ...NOTE If light is left on for a long time while the engine is not running the batteries will be discharged 2 STEREO For operation of stereo see Stereo on page 2 42 3 HEATER AND AIR CONDITIONER CONTROL PANEL For operation of heater and air conditioning see Heater and Air Conditioner Operation on page 2 37 4 SPEAKERS Emits sound generated by stereo HBOI400L Figure 69 HAOA951L Figure 70 HAOA771L Figur...

Page 83: ...he left of the seat Air conditioner and heating unit must be operated after starting the engine for this function Keep the cover close for proper function CAUTION The washer pump can be damaged if it is activated while there is no fluid in the tank The fluid level should be regularly checked and refilled if necessary Using soap or other solvents instead of the recommended washer fluid may damage t...

Page 84: ...nit See Fuse Box Relay on page 2 50 9 FUSE BOX TWO Fuse box two is just above the windshield washer fluid tank For a detailed explanation of fuses see Fuse Box Relay on page 2 50 10 FUSE BOX ONE The fuse box is at the rear side of right control stand For a detailed explanation of fuses see Fuse Box Relay on page 2 50 Figure 76 Figure 77 Figure 78 ...

Page 85: ...NTS 1 OPERATION PANEL 2 FRONT NOZZLE AIR CON 3 FRONT NOZZLE 4 FOOT NOZZLE 5 REAR 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 5 5 4 3 3 2 1 HBOI310L Figure 79 ...

Page 86: ...N 5 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 the panel LED s will turn ON 1 FAN AND AIR CONDITIONER SWITCH A OFF Switch Turns OFF the heater and air conditioner unit B A C Switch Turns ON the air conditioner when one of the blower switches is activated HAOA801L Figure 80 ARO0510L Fi...

Page 87: ...ERATURE CONTROL SWITCH The temperature control consists of 24 stages A LED is turned ON for every three stages Whenever pushing it it changes in stages Pushing it continuously it changes continuously A COOL Switch Lowers the temperature B WARM Switch Raises the temperature LED COLOR STATUS Green LED Air conditioner Full green maximum operation of air conditioner Red LED Heater Full red maximum ope...

Page 88: ...A Switch Draws fresh air into operator s compartment B B Switch Recirculates air within the operator s compartment Used to rapidly reduce condensation on windows MEMORY FUNCTION OF USED MODE The air conditioner panel has a memory function When the starter switch is turned OFF the settings for the panel will be stored When the machine is started the last setting will be used HBOI330L Figure 85 HBOI...

Page 89: ...irculate the refrigerant in the system NOTE The blower switch should be on LO speed NOTE In the event that the unit is being operated in a dusty environment the cleaning and replacement should be performed more frequently If filter element is damaged replace damaged filter by a new one If operating the air conditioner or heater for a long time operate the ventilation switch and when smoking vent t...

Page 90: ... button is pressed a second time power turns OFF Increase volume by rotating control clockwise When stereo is turned ON LCD display will indicate radio stations and or tape functions 2 BALANCE FADER CONTROL This control adjusts both side to side balance of stereo sound and front to back fading Rotating control counterclockwise will increase volume to the left speakers clockwise increases volume to...

Page 91: ... stereo will search out strongest stations in area These stations can then be recalled by pressing buttons 1 thru 6 Figure 89 NOTE To manually store radio station settings use band selector to select frequency band to be listened to Then use tuning control to select desired station Press and hold any preset keys for approximately 2 seconds a beep will sound when station has been set 6 TAPE EJECT B...

Page 92: ... this setting OFF 13 LCD DISPLAY PANEL A Tape Reverse Direction Indicator B Tape Forward Direction Indicator C Preset Radio Memory Channel Indicator D Radio Station Frequency E AM FM Band Indicator F Stereo Radio Signal G Dolby Noise Reduction Indicator H Metal Tape Indicator CARE OF STEREO Do not use a tape that has a longer playing time than C 90 90 minutes Avoid use of C 120 tapes because tapes...

Page 93: ...enoid valves Clean head and pinch roller periodically They continuously contact the tape If they are not kept clean stereo and tapes may be damaged Keep them clean for optimum performance If head gets dirty clean it with a soft cotton swap through cassette slot It is recommended to use a cassette deck cleaning tape for easy and efficient cleaning of head capstan and pinch roller When you turn OFF ...

Page 94: ... conditions Adjustment range is 60 mm 2 36 in for both front and rear 4 WEIGHT ADJUSTMENT KNOB Turning knob 4 Figure 97 to right makes suspension harder Turning knob to left makes suspension softer Adjust according to operator s weight by checking weight indicator dial Adjustment range is from 50 120 kg 110 265 lb 5 BACKREST ADJUSTMENT LEVER Pulling up right lever 5 Figure 97 allows seat backrest ...

Page 95: ...EST 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 7 HEADREST Headrest 7 Figure 98 can be adjusted forward backward and up down Move it by holding both sides HAOB130L Figure 98 ...

Page 96: ...adjust seat to desired position for maximum comfort and machine control then fasten seat belt Seat belts must be worn across pelvic region and adjusted snugly to lessen chance and severity of injury in event of an accident Never fasten a seat belt across abdomen Under no circumstances should operator be standing in cab when operating wheel loader Do not adjust seat position while vehicle is moving...

Page 97: ...1 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 2 To release door from side of cab push the latch lever Figure 102 down The latch lever is to the left of the operator s seat HA3O2042 Figure 101 HAOB250L Figure 102 ...

Page 98: ...f right control stand A usage diagram of fuses is shown inside of fuse box Spare fuses are under the cover 10A Qty 1 15A Qty 1 20A Qty 1 Fuse box two 2 Figure 103 is just above the windshield washer fluid tank WARNING If any fuse is blown turn OFF the starter switch and shut off the power supply Remedy the cause if needed and replace the fuse with a new one 1 2 AQO0160L Figure 103 ...

Page 99: ...are 15A 8 Air conditioning Heater 30A 9 Work Light Front Beacon Option 15A 10 Work Light Rear 15A 11 Turn Signal Light Hazard Light Indicator Light 15A 12 Stereo Cab Light Fuel Pump 15A 13 Memory Backup Pilot Buzzer 10A 14 Starter Switch 10A Fuse Box Two No Name Capacity 1 Cigar Lighter Rear Wiper 15A 2 LIS Option Detente 10A 3 Position Light Right 10A 4 Position Light Left 10A 5 ECM 10A 6 ECM 10A...

Page 100: ...e relay by the batteries at back of unit under engine compartment hood When a short circuit or an overload occurs the circuit breaker automatically cuts off current thus preventing electrical wires from burning FUSIBLE LINK A fusible link is in the battery box If electric power is not present at the I ON position of the starter switch check the fusible link first NOTE If fuse wire is burnt off rep...

Page 101: ...s 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 Grip the handle firmly and use the sharp point to break the glass WARNING Protect your eyes when breaking the glass Figure 110 ...

Page 102: ......

Page 103: ...s NEW MACHINE BREAK IN PROCEDURES All wheel loaders are inspected and adjusted before leaving the factory However it is required that the operator follow these steps during initial break in period Failure to follow these steps may result in damage to equipment or reduced performance 1 Make sure to check all fluid levels before starting and every 8 to 10 operating hours 2 Do all Daily maintenance an...

Page 104: ...Perform a machine walk around Make sure that no one is under the machine or performing any maintenance on it before starting engine 6 After starting machine Check that all operational controls and components are in proper operating condition and are functioning correctly Stop operation and correct any malfunction before continuing work ENGINE START 1 Set parking brake switch to the I ENGAGED posit...

Page 105: ...e lever joystick 5 Rotate starter key to I ON position All indicator lights should turn ON NOTE The engine has an Electronic Control Module ECM that controls the preheat system This system eliminates the need for a cold weather startup procedure Due to this system the preheat position of the starter switch is not used IMPORTANT If transmission lever is not in NEUTRAL position engine will not start...

Page 106: ...on NOTE Parking brake indicator light turns ON or OFF according to parking brake operation despite engine starting 9 Perform Hydraulic System Warm up on page 3 9 10 Check color of exhaust smoke No color or light blue Engine is running in good condition IMPORTANT If engine does not start after approximately 15 seconds of cranking release starter key Wait 5 minutes for starter motor to cool down Rep...

Page 107: ...rd or felt investigate cause NOTE If engine coolant temperature gauge shows red while running take the following action Discontinue work and allow engine to run at LOW IDLE Open engine compartment cover for good ventilation Once engine temperature gauge returns to the green zone shut down engine After engine has cooled check coolant level look for leaks clogged or dirty radiator fins radiator core...

Page 108: ...es can cause an explosion resulting in personal injury 5 Jump start vehicles on dry ground or concrete Do not jump start the machine on a steel floor because the floor is always grounded 6 When starting from another machine make sure the machines do not touch 7 Always connect the auxiliary battery positive terminal too depleted battery positive terminal first Then connect auxiliary battery negativ...

Page 109: ...arted with the other end of black cable 2 Figure 9 In the last connection to upper frame be sure to connect the cable end as far away from the machine batteries as possible DO NOT CONNECT DIRECTLY TO THE NEGATIVE BATTERY TERMINAL 4 Start the engine Disconnecting the Booster Batteries 1 Disconnect black negative cable 2 Figure 9 from the machine frame first 2 Disconnect the other end of black negat...

Page 110: ... parking brake is APPLIED 4 Set bucket on ground 5 Put pilot cutoff switch to O LOCK position This will LOCK pilot control valve lever joystick 6 Allow engine to idle for 3 5 minutes to cool down Stopping a turbocharged engine without a cool down period can seriously damage turbocharger 7 Rotate starter key to O OFF position Remove key Figure 11 O I HAOP042L Figure 12 O HBOI111L Figure 13 HAOC342L...

Page 111: ...M UP COLD WEATHER 1 Follow Steps 1 through 3 in Hydraulic System Warm up 2 Do not operate machine at full speed until system has fully warmed up 3 If working speeds continue to be slow repeat initial hydraulic warm up procedures again If repeating warm up procedures does not improve working speeds continue to operate but use extreme caution because machine function may be erratic MACHINE TRAVEL WA...

Page 112: ...ff switch to I UNLOCKED position Raise bucket to a height of 400 mm 16 in above the ground Tilt bucket completely back 3 Set pilot cutoff switch to O LOCKED position This will prevent boom and bucket from accidentally moving during travel as a result of accidentally touching pilot control valve lever joystick 4 Press brake pedal Figure 15 HBOI110L O I Figure 16 O HBOI111L Figure 17 Figure 18 ...

Page 113: ... D DRIVE position 6 Set parking brake switch to the O RELEASE position This will RELEASE the parking brake 7 Place transmission lever in desired gear Shift gears one by one Do not skip from 1st to 3rd for example 8 Shift transmission lever to FORWARD position Figure 19 O I HAOP043L Figure 20 Figure 21 ...

Page 114: ...1 Ease off throttle and apply travel brakes 2 Put transmission lever in NEUTRAL WARNING When traveling at high speed or on a steep hill do not make sharp changes in direction This could cause vehicle to overturn When traveling or changing direction always look carefully to be certain that no one is in path of vehicle Figure 22 Figure 23 Figure 24 ...

Page 115: ...witch to O LOCKED position This will lock pilot control valve lever joystick 7 Allow engine to idle for 3 5 minutes to cool down Stopping a turbocharged engine without a cool down period can seriously damage turbocharger 8 Rotate starter key to O OFF position Remove key CAUTION LOCK transmission lever When ever machine is parked LOCK transmission lever in NEUTRAL to prevent accidental machine move...

Page 116: ...ing driven down an incline BOOM RAISE KICKOUT Placing pilot control valve lever joystick in Boom Raise Detent position will lock lever joystick in raise boom position Boom will raise until trip plate 1 Figure 30 makes contact with bucket height limit switch 2 When limit switch is tripped boom will stop raising and lever joystick will automatically be returned to NEUTRAL position Trip plate can be ...

Page 117: ...position Boom will move downward until trip plate 1 Figure 32 makes contact with bucket lower limit switch 2 When limit switch is tripped boom will stop lowering and bucket lever will automatically be returned to NEUTRAL position Trip plate can be adjusted to control maximum height that boom can be lowered IMPORTANT Trip plate 1 Figure 30 must always be set to contact limit switch 2 before boom cy...

Page 118: ...er lever returns to NEUTRAL bucket will automatically position itself to be in a preselected digging position usually flat To adjust bucket to desired preselected digging position perform the following steps 1 Operate controls to place bucket on ground and in desired digging position usually flat Return bucket lever to its NEUTRAL position 2 Turn OFF engine 3 Loosen bolts 1 Figure 34 on bracket 2 ...

Page 119: ...the towed load Check if the vehicle to be towed can be braked and steered If not do not allow anyone to ride on the towed vehicle Check the tow rope or tow bar for damage and make sure it has sufficient strength for the work When necessary to descend a gradient another towing vehicle must be used in the rear to retard When towing make sure you are doing the following Start slowly A sudden start ca...

Page 120: ... be released by normal hydraulic system pressure or if the engine will not start it must be manually released before towing can take place 1 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 is released Figure 36 Figure 37 ...

Page 121: ... 1 Park vehicle on an even surface and place wheel chocks in front of and behind tires Only then release the parking brake 2 Release the screw cap 6 Figure 36 and unscrew 3 Release the lock nut 5 Figure 36 size 24 or 30 and turn the adjusting screw 4 with socket wrench size 8 or 10 clockwise until the two brake pads 1 and 2 make contact with the brake disk 4 Turn the adjusting screw 4 Figure 36 co...

Page 122: ...rtant factor to take into consideration when the loader is working in swampy areas Do not enter water whose depth exceeds the loader s minimum ground clearance height or is high enough to wet the bottom of the axle housing As a rule of thumb the allowable water depth is about 400 mm 16 in This means that the loader should not be used in a river Observe the following conditions 1 Check the water de...

Page 123: ...if machine is operating in severe atmospheric conditions Machines working in extremely hot or dusty conditions will require more frequent service checks Total hours of machine operation are determined by hour meter that is on the front instrument panel SERIAL NUMBERS There are two serial number plates attached to the body of wheel loader Please make note of these numbers and their locations These ...

Page 124: ...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 2 Clean up all fuel spills Fuel spills are hazardous especially around engine 3 Inspect all fuel lines for leakage Replace any lines fittings O rings or filters that show signs of wear or damage 4 If a test procedure requires engine to be...

Page 125: ...ELOW 0 C 32 F or HD 46 ABOVE 0 C 32 F or TERESSTIC ANTI RUST EXXON 15W40 RONEX MP 2 or RONEX MP 1 COLD TEMPS SPARTAN EP220 or EXXON GX 80W90 MOBIL MOBIL DTE 13M ALL TEMP or DTE 24 SUMMER DELVAC 1300 or SUPER 15W40 MOBIL FAW 2 or MOBIL FAW 1 COLD TEMPS MOBILUBE HD 80W90 SHELL TELLUS 32 ROTELLA T15W40 ALVANIA EP 2 SPIRAX HD 80W90 or DONAX TD TRANSMISSION PENNZOIL PENNZBELL AW 32 BELOW 0 C 32 F or AW...

Page 126: ...TAL MUTRIS EP 2 TOTAL DA80W90 Lubricant Manufacturer Transmission Gear Oil SAME AS ENGINE OIL 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 IMPORTANT Fluctuating daily or weekly extremes o...

Page 127: ...ter 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 gal Transmission 50 liters 13 U S gal Axles Front Differential 32 liters 8 5 U S gal Front Hub Reduction Gear 9 liters 2 4 U S gal Each End Rear Differential 32 liters 8 5 U S gal Rear Hub Reduction Gear 9 liters 2 4 U S gal Each End ...

Page 128: ...Welds See page 4 14 Check the Operation of All Switches See page 4 15 Check the Operation of All Exterior Lights Horn and Control Console Indicator and Monitor Lights See page 4 15 Start Engine Check Starting Ability and Observe Exhaust Color at Start up and at Normal Operating Temperature Listen for Any Abnormal Sounds See page 4 15 Check Operation of All Controls See page 4 15 Inspect Engine Fan...

Page 129: ...r Service Checks See page 4 35 Clean Exterior of Radiator Oil Cooler and Air conditioner Evaporator See page 4 35 Clean Air Conditioning Filter See page 4 35 1 000 HOUR 6 MONTH SERVICE Perform All 10 Hour Daily 50 150 250 and 500 Hour Service Checks See page 4 37 Change Radiator Coolant See page 4 37 Drain and Replace Transmission Oil and Filter See page 4 38 Clean Fuel Tank and Strainer See page ...

Page 130: ... Front Attachment Pins on page 4 18 INSPECT ALL TIRES FOR CORRECT TIRE PRESSURE AND SIGNS OF DAMAGE OR ABNORMAL WEAR 1 Inflate tires to proper operating pressure for working conditions See Tires and Wheels on page 4 57 CHECK ENGINE OIL LEVEL NOTE When checking level using a dipstick always remove and wipe it clean before making final level check 1 Check level of engine oil every day before startin...

Page 131: ... a level area 3 Place transmission lever in NEUTRAL 4 Apply parking brake 5 Allow engine to idle until engine temperature is between 82 C 180 F and 93 C 200 F 6 Remove transmission dipstick Figure 6 Wipe dipstick clean and then insert it back into transmission 7 Remove dipstick and check oil level mark Oil level must be between COLD and HOT marks Figure 7 8 To add oil remove transmission fill cap ...

Page 132: ...ssure 6 Remove bolts 2 Figure 10 cover and O ring from fill hole 7 Add oil to proper level by checking sight glass Figure 9 WARNING The hydraulic oil will be hot after normal machine operation Allow system to cool before attempting to service any of the hydraulic components The hydraulic tank is pressurized Press button in center of breather to allow the pressurized air to vent After the pressure ...

Page 133: ...ly 1 If filter assembly was removed insert assembly into the reservoir and check to make sure it is securely in place 2 Check O ring for damages and replace if necessary Check position of O ring at surface of hole 3 Place the cover on the access hole Make sure the spring retaining cup 1 Figure 12 in the lower section of the cover is lined up with the spring The filter assembly rod must be in a ver...

Page 134: ...ng proper fuel flow to engine Keep holes in fuel cap clean CHECK FOR LEAKS IN THE FUEL SYSTEM 1 Perform an inspection of engine compartment to verify that fuel system is not leaking If any is noted determine the source of leak and repair DRAIN FUEL CONDENSATION 1 Open fuel tank drain valve Figure 15 Allow any condensed water or sediment to drain out of tank Also open drains on Primary and Secondar...

Page 135: ...below freezing see Check Antifreeze Protection Levels on page 4 14 for antifreeze protection Use the table to calculate a proper mixture of anti freeze and water to provide level of protection necessary for expected temperature 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 b...

Page 136: ...tooth wear or breakage has not developed 2 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 instructions INSPECT SEAT BELT FOR PROPER OPERATION INSPECT THE STRUCTURE FOR CRACKS AND FAULTY WELDS 1 During the daily walk a...

Page 137: ...OBSERVE EXHAUST COLOR AT START UP AND AT NORMAL OPERATING TEMPERATURE LISTEN FOR ANY ABNORMAL SOUNDS CHECK OPERATION OF ALL CONTROLS 1 With engine at rated speed operate all of the controls 2 Follow cold weather hydraulic system warm up procedures 3 Note any slow operations or unusual movements Determine the cause and repair fault before operating IMPORTANT Cold weather operation requires that the...

Page 138: ...nsverse cracks are not acceptable Replace the belt if it is frayed or has pieces of material missing 2 Before installing new belts make sure all pulley grooves are clean and not worn Replace pulley if damaged or if the grooves are worn 3 All pulley support bearings shafts and brackets must be in working order 4 When replacing belts and pulleys pulley alignment must be checked with belts tensioned ...

Page 139: ...ve conditions check tension every 100 hours CHECK AIR INTAKE SYSTEM 1 Park the machine on a level surface apply the parking brake lower the attachment to the ground and stop the engine 2 Check the engine intake hose and hose bands for damage and tightness 3 If damaged wrinkled or loose replace or retighten or contact your nearest loader dealer CHECK CRANKCASE BREATHER TUBE 1 Check the crankcase br...

Page 140: ...CKS GREASE FRONT ATTACHMENT PINS 1 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 D C B F E A AQO0180L Figure 26 ...

Page 141: ...nce and Adjustment 4 19 A Bucket hinge pins 2 locations Figure 27 Lever link connecting pins 2 locations Figure 28 Bucket link connecting pins 2 locations Figure 29 B Arm lever connecting pins left right 2 locations Figure 30 Figure 27 Figure 28 Figure 29 Figure 30 ...

Page 142: ...Adjustment 022 00029AE Operation and Maintenance Manual C Bucket cylinder rod ends 2 locations Figure 31 D Lift cylinder heads left right 2 locations Figure 32 Lift cylinder rod ends 2 locations Figure 33 Figure 31 Figure 32 Figure 33 ...

Page 143: ...ection Maintenance and Adjustment 4 21 E Remote location points 1 REMOTE FITTINGS FOR BUCKET CYLINDER HEADS 50 HOUR Figure 35 and Figure 36 2 REMOTE FITTINGS FOR LOADER ARM FOOT ENDS 50 HOUR Figure 35 and Figure 37 1 1 2 2 HA503041 Figure 34 Figure 35 ...

Page 144: ...wo remote grease points 1 Figure 34 2 Loader arm foot ends 2 locations on each side of machine Greased from two remote grease points 2 Figure 34 F Grease Rear Axle Pivot Rear Axle pivot 1 Figure 38 2 locations on each side of machine Use remote grease fittings mounted on frame shown in Figure 38 Figure 36 Figure 37 1 AHO0390L Figure 38 Figure 39 ...

Page 145: ...ed on frame GREASE UPPER AND LOWER CENTER PINS 1 Center pins upper Figure 42 and lower Figure 43 Two locations on each side of machine CHANGE ENGINE OIL AND FILTER INITIAL 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 Follow procedure under 250 hour ma...

Page 146: ...st 50 hours of operation to comply with new machine break in requirements After first check water pump belt must be checked every 250 hours Follow procedure printed under 250 hour maintenance interval See page 4 29 CLEAN EXTERIOR OF RADIATOR OIL COOLER AND AIR CONDITIONER EVAPORATOR 1 Dust and dirt accumulation on fins of radiator oil cooler and additional transmission cooler greatly reduce their ...

Page 147: ... ALL 10 HOUR DAILY AND 50 HOUR SERVICE CHECKS GREASE DRIVE SHAFT CENTER BEARING 1 Grease drive shaft center bearing 1 location There is no remote fitting for this bearing REPLACE HYDRAULIC SYSTEM PILOT FILTER Replace filter element in pilot filter Perform the following steps 1 Vent hydraulic oil tank Figure 44 Figure 45 ...

Page 148: ...ver 5 Figure 46 5 Insert a new filter element 4 Figure 46 into cover 5 Install a new O ring 3 6 Screw cover 5 Figure 46 onto filter head 1 CHECK ENGINE AIR CLEANER PRE CLEANER 1 The engine is equipped with a pre cleaner Dust insects rainwater etc can be present in the air The pre cleaner collects this material and discharges it This prevents material from being drawn into air cleaner The pre clean...

Page 149: ... down into reservoir Press element down onto its base until top of element is approximately 4 mm 0 157 in below edge of reservoir 8 Install a new O ring 4 Figure 48 on cover 2 Set spring 3 into place on element 6 9 Set cover 2 Figure 48 into place over element 6 Install bolts 1 through cover 2 and tighten them 10 Tighten breather cap on reservoir WARNING The hydraulic oil will be hot after normal ...

Page 150: ...uter element of air filter assembly NOTE If indicator light on instrument panel comes ON this indicates that air cleaner needs to be serviced NOTE Replace outer element every 1500 hours of service 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 pres...

Page 151: ...quirements After first check water pump belt must be checked every 150 hours After first tension check belt must be checked every 150 hours 1 Apply 10 kg 22 lb of force to midpoint of water pump belt Figure 53 The water pump belt should deflect 10 mm 0 4 in If belt deflects more than this loosen control link and move idler pulley 2 to tighten belt tension until deflection is 10 mm 0 4 in Inspect w...

Page 152: ...auge reaches the middle of the WHITE ZONE the temperature is about 40 C 104 F 2 Replace engine oil filter The engine oil filter is a spin on type Figure 55 Remove and discard filter 3 Install new filter Apply a small amount of oil around filter gasket Screw filter on head until gasket contacts head by hand turn filter 3 4 1 turn more with filter wrench NOTE See Fluid Capacities on page 4 5 for cap...

Page 153: ...Press the button on the radiator tank cap to release any remaining pressure and remove the cap slowly Figure 56 3 Turn the coolant shutoff valve OFF 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 co...

Page 154: ...lter firmly by hand Follow the instructions supplied with the filter 8 OPEN the coolant shutoff valve and install the radiator cap 9 Run the engine and check for coolant leaks 10 Idle the engine for about five minutes to purge all air from the coolant 11 After air has been purged from the system stop the engine and check the coolant level again 12 If needed add required amount of the coolant CAUTI...

Page 155: ...n more NOTE Coat fuel filter gasket with fuel NOTE Fill fuel filter with clean fuel This will help reduce fuel system priming 6 Start engine After engine has run for a couple of minutes shutdown engine and lock for leaks If engine does not start fuel system may need priming Prime fuel system using the following procedure A Loosen plug on top of fuel filter head B Unscrew and pump the hand operated...

Page 156: ... water in the oil drain and replace the oil Oil containing water looks milky 6 Retighten the level plug 7 Check the rear axle level following the same steps CHECK PLANETARY GEAR OIL 1 Check the oil level on all four wheels 2 Move the machine on a level surface so that the oil level mark on the planetary gear housing comes to the horizontal position 3 Turn ON the parking brake switch lower the atta...

Page 157: ... water and steam to clean fins on radiator oil cooler and transmission cooler NOTE On an especially dusty job site clean fins every 50 hours On other job sites clean fins every 500 hours CLEAN AIR CONDITIONING FILTER The unit is equipped with an air filtration system which filters out dirt and dust particles from air being circulated into operator s cab The air conditioning filter is in the right ...

Page 158: ...lean it 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 If filter element is damaged replace damaged filter by a new one WARNING All service and inspection of the air conditioning system should be performed with th...

Page 159: ...9 WARNING 1 Allow the engine to cool before releasing the radiator cap Make sure to loosen the cap slowly to release any remaining pressure 2 Radiator cleaning is performed while the engine is running Take extreme caution when working on or near a running engine Make sure to lock out and tag the controls notifying personnel that service work is being performed 3 Do not remove the radiator cap unle...

Page 160: ...eeze mixture for ambient temperature Refer to coolant concentration table See page 4 14 NOTE When filling engine with coolant open vent Figure 68 on intercooler to allow air to escape Close vent when coolant is present 11 Run engine without radiator cap installed so that all air will be purged from system Fill radiator to fill neck 12 Drain and fill radiator coolant recovery tank DRAIN AND REPLACE...

Page 161: ...n filter head 10 Grease filter gasket and gasket mating surface on filter head 11 Thread filter onto filter head Tighten filter 1 2 turn after filter gasket contacts filter head Filter should be torqued to 1 6 to 2 1 kg m 11 5 to 15 ft lb 12 Fill transmission with fluid through fluid supply pipe Add fluid until fluid level reaches low mark on dipstick 13 Start engine Idle engine for two minutes 14...

Page 162: ...fuel into a suitable container 4 Remove the nuts with a 17mm wrench to remove the inspection cover Figure 75 5 Clean inside of the tank and suction stainer 6 Install the inspection cover with a new gasket Tighten the nuts Do not overtighten 7 Close the drain cock 8 Fill the fuel tank 9 Check for any leaks at cover and plug WARNING Escaping fuel flammable and harmful to skin Do not smoke while drai...

Page 163: ...Contact your nearest loader dealer or local Cummins Engine dealer for checking and adjusting the following items Engine Compression Pressure Injection Pressure Injection Timing WARNING Mixing of tobacco smoke and freon is deadly Do not smoke while servicing or recharging air conditioning system CAUTION Overfill refrigerant may cause dangerous high pressure and poor cooling action and low refrigeran...

Page 164: ...after first 250 hours of operation to comply with new machine break in requirements After that axle oil check should be done every 250 hours of operation and replacement should be done every 1500 hours Each axle contains a center differential and a planetary in each end The same oil lubricates center differential and planetaries in axle ends but oil flows very slowly between these points When chec...

Page 165: ...ntial and tighten 5 Pump oil into plug hole for level plug on center differential Add oil until oil level is even with bottom of plug hole Go to level plug holes on axle ends Add oil to these openings until oil level is even with bottom of plug hole Recheck level on center differential Add oil if necessary When oil level is satisfactory at all three level plug holes install and tighten level plugs...

Page 166: ...s a dangerous condition Never operate machine with air in brake hydraulic system A spongy feel when pressing brake pedal is a sign that air is present in brake hydraulic system To bleed air out of brake hydraulic system perform the following steps 1 Start engine and place transmission in NEUTRAL 2 Remove rubber cap from bleeder screw on wheel Place one end of a plastic hose 2 Figure 80 over bleede...

Page 167: ...ghest position Tilt bucket back as far as possible and turn OFF engine NOTE See Fluid Capacities on page 4 5 for capacity 2 Position a catch tank beneath hydraulic reservoir drain plug Open reservoir breather cap See Figure 10 on page 4 10 Remove drain plug from bottom of reservoir Figure 82 Allow all hydraulic oil to drain out CAUTION Be certain that hydraulic oil has cooled before draining it Ho...

Page 168: ... 7 from reservoir C Remove strainer 7 Figure 85 from strainer cover D Clean strainer 7 Figure 85 in a nonflammable non toxic solvent E Mount strainer 7 Figure 85 on strainer cover 9 F Insert strainer 7 Figure 85 and cover 9 into reservoir G Install and tighten bolts 8 Figure 85 that retain cover 9 6 Install reservoir drain plug Refill reservoir by pouring oil in through breather cap opening Instal...

Page 169: ...ide and outside of strainer Replace strainer if it is broken 4 Position strainer on boss portion of suction pipe 5 Fill hydraulic oil tank Check level using sight gauge on side of tank 6 Place spring on rod and assemble cover CHECK VIBRATION DAMPER 1 Park the machine on a level surface apply the parking brake lower the attachment to the ground and stop the engine 2 Check the damper on the fan end ...

Page 170: ...ll the brake accumulator with oil 3 Stop the engine 4 Turn the key to the ON position 5 Count the number of times you can depress the right hand brake pedal before the brake warning light comes on 6 If the number counted is less than five 5 there is some problem with the accumulator Contact your nearest loader dealer CHECK STEERING BRAKE DRIVE SHAFT ENGINE AND FUEL SYSTEM WARNING Pressurized Nitrog...

Page 171: ...is 2 Clean radiator and oil cooler fins to remove dirt and dust 3 Clean fuel system intake strainer and fuel filter more frequently 4 Inspect starter motor and alternator and clean as often as necessary Rocky Terrain 1 Check wheels tires rims and valve stems for damage or excessive wear 2 Inspect for loose or damaged fittings and bolts 3 On a more frequent basis inspect bucket and boom for damage ...

Page 172: ...lt in causing motor damage 3 Do not use refueling pump for other types of fuel Use only for diesel fuel Do not use refueling pump for other types of fuel which have a low flash point Do not use refueling pump for fuel contaminated with water or high humidity Moisture in pump mechanism can cause rust and can create pump failure 4 Always operate pump using the strainer installed on the inlet hose Th...

Page 173: ...itch to ON position NOTE The transfer pump rate of flow is approximately 20 liters minute Use extra care not to over fill fuel tank so that fuel does not over flow 4 Once fuel transfer is completed immediately turn switch to OFF position to stop pump 5 Lift inlet hose from fueling source and turn switch to ON position for 2 3 seconds to drain remaining fuel from hose to fuel tank 6 Replace straine...

Page 174: ... hoses until accumulator pressure has been released from the circuit To release pressure turn the starter switch to I ON position and operate pilot control valve lever and brake pedal Even though the engine is shutdown hydraulic actuated components may move while releasing pilot pressure Keep all personnel away from machine while performing this operation Set pilot cutoff switch to O OFF position ...

Page 175: ...artridge for main pump must open at 200 5 kg cm2 2 918 70 psi 3 Adjust screw on relief valve cartridge 1 Figure 95 Loosen lock nut and turn screw clockwise to raise relief pressure Turn screw counterclockwise to lower relief pressure Tighten lock nut after pressure has been adjusted Port Number Description 1 Main Pump Pressure 2 Transmission System Pressure 3 Brake Charge Pressure 4 Pilot Control ...

Page 176: ...0 kg cm2 1 707 psi PILOT CONTROL VALVE LEVER JOYSTICK ACTIVATION PRESSURE 1 Attach gauge to Port 4 Figure 94 2 Adjust relief cartridge Figure 97 on pilot parking valve Relief pressure should be set at 37 kg cm2 526 psi 3 Loosen lock nut on adjusting screw Turn adjusting screw clockwise to raise relief pressure Turn adjusting screw counterclockwise to lower relief pressure 4 Tighten lock nut after ...

Page 177: ...w clockwise to raise relief pressure Turn screw counterclockwise to lower relief pressure One turn varies 65kg cm2 4 Install plug and washer after pressure has been adjusted SERVICE BRAKE OUTLET PRESSURE 1 Attach gauge to brake pressure test Figure 100 port of front axle 2 Outlet pressure should be 60 kg cm2 853 psi PARKING BRAKE RELEASE PRESSURE 1 Attach a pressure gauge to parking brake port Fig...

Page 178: ... of fan motor 1 Figure 102 2 Adjust screw on relief valve cartridge 2 Figure 102 Pressure should be 95 kg cm2 1 350 psi 3 Loosen lock nut on adjusting screw Turn adjusting screw clockwise to raise relief pressure Turn adjusting screw counterclockwise to lower relief pressure 4 Tighten lock nut after adjustment has been made Figure 102 ...

Page 179: ...e correct pressure for front or rear tires when driving machine or when working machine Check tires for damage and embedded objects Check valve stems for damage WHEEL NUT TORQUE Tighten wheel nuts to 85 kg m 615 ft lb Tire Dimension Working Pressure Driving Pressure Remarks Front Tire Rear Tire Front Tire Rear Tire 29 5 25 22PR 3 5 kg cm2 50 psi 3 3 kg cm2 47 psi 2 8 kg cm2 40 psi 2 0 kg cm2 29 ps...

Page 180: ...Damage to the carcass exceeds 1 3 of the tire width Tire layers are separated Radial cracks reach the carcass Deformation or damage which makes the tire unsuitable for use 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 ti...

Page 181: ...always be replaced in pairs Using an old battery with a new one will shorten the life span of the new battery 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 Make sure that open flames burning objects or sparks are...

Page 182: ...0 4 84 35 7 05 51 8 30 60 12 mm x std 8 57 62 11 89 86 14 52 105 12 mm x 1 5 9 00 65 12 59 91 14 94 108 14 mm x std 13 55 98 18 95 137 23 10 167 14 mm x 1 5 14 94 108 21 02 152 24 89 180 16 mm x std 20 88 151 29 46 213 35 54 257 16 mm x 1 5 22 54 163 31 53 228 38 03 275 18 mm x std 28 90 209 40 52 293 48 41 350 18 mm x 1 5 32 50 235 45 92 332 55 04 398 20 mm x std 40 94 296 57 95 419 69 01 499 20 ...

Page 183: ...ing of light oil to all exposed cylinder rods Apply a coating of light oil to all control linkages and all control valve spools Check condition of oil coating each month and add to coating where necessary BATTERY Disconnect cables from battery or remove battery from machine If battery is removed fully charge battery and store it COOLING SYSTEM CARE If cooling system does not need antifreeze and is...

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Page 185: ...of the trailer and the machine 4 Determine the position of the ramp then slowly load the machine onto to the specified part of the trailer NOTE Have someone in clear view and in a safe position provide directions while loading 5 Lower the bucket and lock control lever using the pilot cutoff switch 6 Apply the parking brake and set the articulation stopper in the LOCKED position 7 Tape over the exh...

Page 186: ...NS FOR LIFTING To make safe lifts the following items must be evaluated by operator and work site crew Condition of ground support Wheel loader configuration and attachments Weight lifting height and lifting radius Safe rigging of load Proper handling of suspended load Taglines on opposite sides of load can be very helpful in keeping a suspended load secure if they are anchored safely to control p...

Page 187: ... or dirt in fuel system Clean system and add new fuel Air in fuel system Purge air from system Engine stop control failed Replace stop control Engine stop relay failed Replace relay Engine starts runs only at low speed or shuts down Engine oil viscosity incorrect Change oil Clogged or dirty fuel injectors Clean injectors Fuel filters plugged Replace filters Engine stop motor cable out of adjustmen...

Page 188: ...e or damaged Tighten or replace as required Temperature sensor faulty Replace sensor Engine oil pressure warning light turns ON and buzzer sounds Low engine oil level Add oil Wrong grade oil for weather conditions change oil Clogging oil filter element Change filter and oil Defective alarm switch Contact your DOOSAN dealer Oil leakage from pipe or joint Clogging suction strainer Excessive engine w...

Page 189: ...n timing Insufficient power Air cleaner element clogging Clean or replace element Fuel filer element clogging Replace fuel filter Throttle linkage adjustment wrong Check and adjust linkage Engine oil level too high Check dipstick and correct level Incorrect valve clearance Contact your DOOSAN dealer Piston ring wear Defective injectors Fuel pump failure Problem Possible Causes Remedies None of the...

Page 190: ...as required Remote control valve failed Replace control valve Wrong pilot line connection Reconnect pilot lines Oil temperature too high Debris in exterior of cooler Clean exterior of cooler Oil cooler faulty Contact your DOOSAN dealer Fan belt loose Tighten fan belting as required Actuators on one side of boom have little power or do not operate Overload relief valve is not operating properly Rep...

Page 191: ...or replace Damaged transmission or axle Repair or replace Wheel brakes not releasing Repair brakes Parking brake not releasing Repair parking brake Machine will travel but has little power Fluid pressure low in transmission clutch Repair clutch Transmission fluid low Add fluid Damage to torque converter Repair or replace Engine malfunction See Engine Troubleshooting Table Brake valve Disassemble a...

Page 192: ... joints Bent drive shaft Replace drive shaft 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 Replace slip joint Noisy Front or Rear Axle Worn or broken gears Replace gears Low oil level poor quality o...

Page 193: ... 36 Logical error at turbine speed input 37 Short circuit to battery voltage at internal speed input 38 Short circuit to ground or open circuit at internal speed input 39 Logical error at internal speed input 3A Short circuit to battery voltage at output speed input 3B Short circuit to ground or open circuit at output speed input 3C Logical error at output speed input 71 Short circuit to battery v...

Page 194: ...92 Short circuit to ground at relay reverse warning alarm 93 Open circuit at relay reverse warning alarm 94 Short circuit to battery voltage at relay starter interlock 95 Short circuit to ground at relay starter interlock 96 Open circuit at relay starter interlock 97 Short circuit to battery voltage at park brake solenoid 98 Short circuit ground at park brake solenoid 99 Open circuit at park brake...

Page 195: ...ort circuit to battery at speedometer output Not used E2 Short circuit to ground or open circuit at speedometer output Not used E3 Short circuit to battery voltage at display output Not used E4 Short circuit to ground or open circuit at display output Not used E5 Error at communication on CAN F1 General EEPROM fault F2 Configuration lost F3 Application error Error Code Number Meaning of Error Code...

Page 196: ...just pressure Steering pump failure Repair or replace Leaking steering cylinder Repair cylinder Rust on steering column bearing and spline Lubricate Tire air pressure is low Inflate to proper pressure High initial resistance to movement of steering wheel Air in load sensing line inside priority valve Bleed system to remove air Sediment blocking orifice of load sensing line inside priority valve Cl...

Page 197: ... in brake hose After bleeding brakes brakes are not fully released Damaged brake discs Replace discs Damaged brake disc return spring Replace return springs Problem Possible Causes Remedies Battery has no power and will not accept a charge Damaged battery plates Replace battery Alternator not charging properly Repair or replace alternator Bad ground Clean and tighten Loose electrical connector Cle...

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Page 199: ... 2 100 rpm Max Torque 174 kg m 1 255 ft lb 1 400 rpm Transmission Full Automatic Power Shift Full Automatic Power Shift Speeds 4 Forward 3 Reverse Brake Systems Travel Brakes 4 Wheel Wet Disk Parking Brake SAHR Dry Disc Type Performance Travel Speed 7 35 km h 4 35 21 75 MPH Steering Angle 40 Min Tire Turning Radius 6 140 mm 20 2 Safe Operating Load 8 640 kg 19 050 lb Max Breakout Force 27 000 kg 5...

Page 200: ...AE Operation and Maintenance Manual WORKING RANGE AND DIMENSIONS Figure 1 illustrates exterior machine dimensions and working range of machine when it is equipped with a standard bucket A E G I H D F C I H B a b AHO0830L Figure 1 ...

Page 201: ... 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 11 Ground Clearance G 490 mm 1 7 Dump Height to tooth H 3 080 mm 10 1 Dump Distance to Bucket Edge I 1 380 mm 4 6 Dump Height to Bucket Pivot 4 470 mm 14 8 Bucket Angle Raised a 47 Bucket Angle b Lowered at carry 48 Tire Size 29 5 25 22 PR L3 ...

Page 202: ...w describes weight of a cubic meter cubic yard of many types of workload materials APPROXIMATE WEIGHT OF WORKLOAD MATERIALS MATERIAL LOW WEIGHT OR DENSITY 1 100 KG M3 1 850 LB YD3 OR LESS MEDIUM WEIGHT OR DENSITY 1 600 KG M3 2 700 LB YD3 OR LESS HIGH WEIGHT OR DENSITY 2 000 KG M3 3 370 LB YD3 OR LESS Charcoal 401 kg m3 695 lb yd3 Coke blast furnace size 433 kg m3 729 lb yd3 Coke foundry size 449 k...

Page 203: ... m3 1 620 lb yd3 Gypsum crushed to 3 inch size 1 522 kg m3 2 565 lb yd3 Gravel DRY packed fragments 1 810 kg m3 3 051 lb yd3 Gravel WET packed fragments 1 922 kg m3 3 240 lb yd3 Limestone graded above 2 1 282 kg m3 2 160 lb yd3 Limestone graded 1 1 2 or 2 1 362 kg m3 2 295 lb yd3 Limestone crushed 1 522 kg m3 2 565 lb yd3 Limestone fine 1 602 kg m3 2 705 lb yd3 Phosphate rock 1 282 kg m3 2 160 lb ...

Page 204: ...b yd3 IMPORTANT Weights are approximations of estimated average volume and mass Exposure to rain snow or ground water settling or compaction due to overhead weight and chemical or industrial processing or changes due to thermal or chemical transformations could all increase value of weights listed in table MATERIAL LOW WEIGHT OR DENSITY 1 100 KG M3 1 850 LB YD3 OR LESS MEDIUM WEIGHT OR DENSITY 1 6...

Page 205: ...umulator 4 48 Bleeding 4 44 Brake Oil Pressure Warning Light 2 18 Pedal 2 9 Troubleshooting 6 11 Bucket Angle Indicator 3 16 Capacity 7 4 Position Switch 3 16 Teeth and Side Cutters 4 14 C Cab Light 2 34 Cigar Lighter 2 26 Circuit Breaker 2 52 Cold Weather Engine Start 3 6 Combination Switch 2 7 Component Locations 2 2 Conditions Severe Maintenance 4 49 Cooling System Antifreeze 4 14 Care 4 61 Coo...

Page 206: ...ot Filter Replace 4 25 Service Brake Outlet Pressure 4 55 Steering Pump Pressure 4 54 Suction Strainer Clean 4 47 System Pilot Filter Replace 4 25 System Warm up 3 9 System Warm up Cold Weather 3 9 Transmission System Pressure 4 54 Troubleshooting 6 3 I Idle Speed Control Switch 2 30 Indicator Lights Air Cleaner Clogging Warning Light 2 16 Battery Warning Light 2 17 Brake Oil Pressure Warning Ligh...

Page 207: ... 3 6 Engine Start 3 2 Hydraulic System Warm up 3 9 Hydraulic System Warm up Cold Weather 3 9 Inspection Before Starting Engine 3 2 Starting with Auxiliary Batteries 3 6 Steering Tilt Knob 2 8 Troubleshooting 6 10 Wheel 2 9 Stereo AM FM Band Selection 2 43 Automatic Memory AME 2 43 Automatic Selection 2 43 Balance Fader Control 2 42 Bass Treble Control 2 43 Care of Stereo 2 44 Cassette Slot 2 43 Do...

Page 208: ...21 Error Codes 6 6 Lever 2 10 Oil Drain and Replace 4 38 Oil Level Check 4 9 Oil Temperature Gauge 2 15 Travel Precautions 1 25 Travel System Troubleshooting 6 5 Troubleshooting 6 1 U Unauthorized Modifications 1 13 V Vibration Damper 4 47 Visibility 1 28 W Washer Tank 2 35 Water Pump Belt Tension 4 24 Weight of Workload Materials 7 4 Wheel Nut Torque 4 57 Window Glass Breaking Tool 1 20 2 53 Wind...

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