PDF Operation & Maintenance Manual Daewoo Doosan DL300-5TRAV Wheel Loader - 2 MB
Get the official Operation & Maintenance Manual for the Daewoo Doosan DL300-5TRAV Wheel Loader, covering serial numbers 10001 and up.
This guide is essential for understanding the machine's controls, features, and safety systems.
It outlines the correct procedures for daily inspections and scheduled maintenance to maximize uptime.
Proper use as described in this manual will ensure the longevity and reliability of your equipment.
It's a must-have for every operator and fleet manager.
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--- Page 1 ---
01255NATRAV
September 2016
WHEEL LOADER
Operation &
Maintenance
Manual
DL300-5TRAV (NEW YORK BID-21CT)
Serial Number 10001 and Up
--- Page 3 ---
Other Signal Words
In addition to safety signal words, the following signal words are
used to indicate proper and effective use of machine.
IMPORTANT
This signal word identifies procedures which must be
followed to avoid damage to machine.
NOTE: The word "NOTE" identifies information for effective
use.
AEM SAFETY MANUAL
(NORTH AMERICA ONLY)
The AEM Safety Manual delivered with the machine gives
general safety information.
The AEM Safety Manual must be read and understood before
beginning operation or maintenance and is not intended to
replace the Operation & Maintenance Manual delivered with the
machine.
Figure 1
DL300-5TRAV Foreword
0-3
--- Page 4 ---
• A P3 type respirator/filter mask or a type FFP3 fine dust
musk, protective goggles and gloves must be used for any
work where there is a risk of exposure to dust from the
SCR catalytic converter.
• Dispose the SCR catalytic converter properly after
machining in a disposable container.
• Eating, drinking or smoking while servicing is not
permitted.
• Any dust from the SCR catalytic converter must be
removed using a vacuum cleaner with microfilter to
minimize exposure.
• Make sure that work surface is cleaned after completed
work; Vacuum first then swab.
• Make sure you clean your hands after working with SCR
catalytic converter to avoid ingestion.
• Work done on the SCR catalytic converter may generate
waste considered to be a hazardous waste subject to
applicable Code of Regulations. Before disposing of
hazardous waste, review and follow all applicable federal
and requirements.
Your Warranty Rights and Obligations
New heavy-duty off-road engines are designed, built, and
equipped to meet stringent anti-smog standards. Scania CV AB
must warrant the emission control system on your engine for the
periods of time listed below provided there has been no abuse,
neglect or improper maintenance of your engine.
Your emission control system may include parts such as the
fuel-injection system and the air induction system. Also included
may be hoses, belts, connectors and other emission-related
assemblies.
Where a warrantable condition exists, Scania CV AB will repair
your heavy-duty off-road engine at no cost to you including
diagnosis, parts and labor.
Manufacturer's Warranty Coverage
Engine
The heavy-duty off-road engines are warranted for a period of
five years, 100% parts and labor. If any emission-related part on
your engine is defective, the part will be repaired or replaced by
Scania CV AB.
Transmission
The transmissions are warranted for a period of five years,
100% parts and labor.
DL300-5TRAV Foreword
0-13
--- Page 5 ---
12. Rotating Fan (950205-03788)
WARNING
CONTACT WITH ROTATING FAN CAN CAUSE
DEATH OR SERIOUS INJURY
Keep away from fan and rotating parts. Stop engine 950205-03788
before servicing.
EX1301182
13. Hot Pressurized Fluid (950205-03781)
WARNING
HOT PRESSURIZED FLUID CAN CAUSE
SERIOUS BURNS
• Do not loosen or open cap when hot.
EX1301180
• Before opening:
1) Turn engine off.
2) Allow machine to cool.
3) Tip cap and open slowly to relieve pressure.
14. Wheel Chock (950205-01691B)
WARNING
ROLL AWAY CAN CAUSE DEATH OR SERIOUS
INJURY
• Before disengaging park brake, block wheels to 950205-01691B
prevent machine movement. WL1400815
Additional Decal
15. Electric Welding Attention (950212-02440)
IMPORTANT
Electrical welding on the frame can damage the
engine's electronic control unit (ECU).
950212-02440
EX1402396
DL300-5TRAV Safety
1-9
--- Page 6 ---
Maintenance
The machine and some attachments have components that
reach high temperatures under normal operating conditions. The
primary source of high temperatures are the engine and exhaust
system. If damaged or incorrectly maintained, the electrical
system can be a source of arcs or sparks.
Flammable debris (leaves, straw, etc.) must be removed
regularly. If flammable debris is allowed to accumulate, it can
cause a fire hazard. Clean machine often to avoid this
accumulation. Flammable debris in an engine compartment is a
potential fire hazard.
The operator's area, engine compartment and engine cooling
system must be inspected every day and cleaned. This is
necessary to prevent fire hazards and overheating.
Operation
Do not use machine where exhaust, arcs, sparks or hot
components can contact flammable material, explosive dust or
gases.
Do not operate machine near any flame.
Exhaust shields (if equipped) protect hot exhaust components
from oil spray or fuel spray in case of a break in a line, hose, or
seal. Exhaust shields must be correctly installed and maintained
properly.
Electrical
Check all electrical wiring and connections for damage daily.
Keep battery terminals clean and tight. Repair or replace any
damaged parts or wires that are loose or frayed. Clean all
electrical connections and tighten all electrical connections.
Never check battery charge by placing a metal object across
terminal posts. Use a voltmeter or a hydrometer.
Battery gas can explode and can result in death or serious
injury. Follow procedures in this manual for connecting battery
and for jump-starting. Do not jump-start or charge a frozen or
damaged battery. Keep all flames and sparks away from
batteries. Do not smoke in battery charging area.
Improper jumper cable connections can cause an explosion that
can result in death or serious injury. Refer to “Starting Engine
With CAM LOK Jumper Cable Adapter or Booster Cable” on
page 3-15 in this manual for proper procedure in this manual.
Do not charge a frozen battery. This can cause an explosion.
After market radios or other electric operated equipment in cabin
must have a fuse in the electrical circuit.
DL300-5TRAV Safety
1-19
--- Page 7 ---
Visibility Information
A rear view camera (if equipped) and mirrors provide the
operator with additional means to see the work area.
NOTE: These devices may vary from one region to another,
depending upon local and regional laws and
regulations. If a machine is moved or sold into
another region or marketplace, it is the owner's
responsibility to make sure it complies with all
applicable laws and regulations.
WARNING
AVOID DEATH OR SERIOUS INJURY
Failure to check for and clear people from the surrounding
area of a machine can result in death or serious injury. The
operator should make sure that visual aids (mirrors and
camera(s)) are in proper working condition.
Your machine may be equipped with visual aids such as mirrors
or a rear view camera. Even with these aids, there still may be
areas around the machine which cannot be seen from the
operator's seat. Always keep bystanders out of the work area.
Be careful when operating and always look in direction of travel.
Adjust visual aids for best visibility around machine.
When backing up, press camera button (if equipped) to change
display mode on display monitor so you can check rear and side
of machine.
Before moving machine, look around work site and use mirrors
and display monitor to confirm that no one is in the work area.
While operating or traveling in places with poor visibility it may
be impossible to confirm conditions of the work site. Inspect and
remove any obstacles around the machine that could be
damaged and keep other personnel and bystanders out of the
work area.
Inspect equipment and repair immediately if there are problems
with visual aids. If machine cannot be fixed immediately, DO
NOT use the machine. Contact your DOOSAN distributor and
arrange for repairs.
DL300-5TRAV Safety
1-29
--- Page 8 ---
Engine Stop
Turn engine starter switch to "O" (OFF) position and remove
engine starter switch key.
Before lowering any equipment with engine stopped, clear area
around equipment of all personnel and bystanders. This
procedure will cause high-pressure air or hydraulic pressure to
be released to lower equipment.
Do not stop engine immediately after the machine has been
operated under load. This can cause overheating and
accelerated wear of engine components.
After the machine is parked, allow engine to run for at least five
(5) minutes before stopping the engine. This allows hot areas of
engine to begin to cool gradually.
• Do not leave operator's seat when there is a raised load.
Parking Machine
Park machine on firm and level ground away from traffic and
away from high walls, drop-offs and any area of potential water
accumulation or runoff. If parking on an incline is unavoidable,
block wheels to prevent movement. Lower bucket or other
working attachment completely to ground, or to a support
saddle, to prevent unintended or accidental movement.
When parking on public roads, provide fences barricades, signs,
flags, or lights, and put up any other necessary signs to ensure
that passing traffic can see machine clearly. Park the machine
so the machine, flags, signs and fences do not obstruct traffic.
After front attachment has been lowered to an overnight storage
position and all switches and operating controls are in "OFF"
position and place the pilot cutoff switch to "O" (OFF) position.
This will disable all pilot control functions.
Always close door of operator's cabin and lock all equipment to
prevent any unauthorized person from operating the machine.
The hydraulic system remains pressurized, provided that
accumulator, is charged even when engine is not running.
Accumulator pressure should decrease in a short time
(approximately one minute). While hydraulic system maintains a
charge, hydraulic work tools and machine controls remain
functional.
Machine movement will occur if any controls are moved. This
can result in death or serious injury.
Always move hydraulic lockout control to "LOCK" position before
stopping the engine or immediately after engine stops running.
DL300-5TRAV Safety
1-39
--- Page 9 ---
Preparation for Electrical Welding on Body Structure
To prevent damage to ECU by electrical welding, observe the
following procedures:
1. Turn battery disconnect switch to "O" (OFF) position
(Figure 39).
Figure 39
2. Disconnect the connector between ECU and machine, and
the connector between ECU and engine (Figure 40).
Figure 40
3. Disconnect the negative (-) battery cables (Figure 41).
4. Proceed with welding.
5. After welding, connect the connector between ECU and
machine, and the connector between ECU and engine
(Figure 40).
6. Clean battery compartments, connect the negative (-)
battery cables (Figure 41).
7. Turn battery disconnect switch to "I" (ON) position (Figure
39).
Figure 41
DL300-5TRAV Safety
1-49
--- Page 10 ---
Poor Visibility
For good visibility, always do the following:
• When working in dark areas, attach working lights and
front lights to the machine. If necessary, set up additional
lighting at work site.
• Stop operations when visibility is poor, such as in fog, mist,
snow, and rain. Wait for visibility to improve before starting
operation.
To avoid hitting work equipment and damaging other property,
always do the following:
• When working in tunnels, on bridges, under electrical
wires, or when parking the machine or performing other
operations in places with limited height, be careful not to hit
and damage other equipment or property.
• To prevent hitting objects, operate machine at a slow
speed when working in confined spaces, indoors, or in
crowded areas.
• Do not move bucket over the top of personnel or bystander
or over operator's cabin of dump truck or other machines.
Loose or Soft Ground
Do not operate on soft ground or near edge of drop-offs,
overhangs, or deep ditches. The ground can collapse because
of the weight of the machine, causing the machine to fall or
rollover.
Check ground conditions before beginning work with the
machine. If ground is soft, reposition the machine before
operating.
The excavated material must not be dumped too close to edge.
The distance from an edge of an excavation where the
excavated material must be dumped depends on soil type and
moisture content. If loose clay is being excavated, place it at
least 5 m (16 ft) away from edge.
If excavated material is dumped too close to edge, its weight can
cause a landslide.
Thawing of frozen ground, rain, traffic, piling and blasting are
other factors which increase risk of landslide. The risk also
increases on sloping ground. If it is not possible to dig a trench
and adequately slope its sides, always install shoring
equipment.
Loose ground may easily give way under weight of the machine.
When working on loose or unstable ground, it is important not to
dig too deep and to carefully reposition the machine. Do not
panic and do not raise bucket, if ground should begin to
collapse. Lower work equipment to improve stability of machine.
Never dig under machine, if there is a potential of causing a
landslide.
DL300-5TRAV Safety
1-59
--- Page 11 ---
Sound Information
Sound Level Information: Hearing protection may be needed
when machine is operated with an open operator station for
extended periods or in a noisy environment.
Sound pressure level (LpA) at operator position
72 dB(A)
(Measurement according to ISO 6396)
Sound power level (LwA) around the machine
(Measurement according to 2000/14/EC with
103 dB(A)
applicable appendices and measuring method
according to ISO 6395)
Vibration Information
NOTE: The level of vibration is influenced by many different
parameters such as operator training, work site
organization, weather, material, environment,
machine type, machine and seat suspension system,
attachments, and condition of the machine.
Measurements are obtained on a representative machine, using
measuring procedures as described in the following standards:
ISO 2631/1, ISO 5349, and SAE J1166.
Vibration levels were given consideration according to
uncertainty (K) determined to manufacturer.
Hand/Arm Vibration Level
The vibration total value to which the hand-arm system is
subjected, is less than 2.5 m/s2.
Whole Body Vibration Level
The highest root mean square value of weighted acceleration to
which the whole body is subjected, is more than 0.5 m/s2 (less
than 1.15 m/s2).
Guidelines for Use and Working Conditions of Earth-moving
Machinery to Reduce Vibration Levels (ISO/TR 25398 Annex E)
Properly adjusting and maintaining machines, operating
machines smoothly, and maintaining the terrain conditions can
reduce whole-body vibrations. The following can help the users
of earth-moving machinery reduce whole-body vibration levels.
1. Use the right type and size of machine, equipment, and
attachments.
2. Maintain machines according to the manufacturer's
recommendations:
• Tire pressure;
• Brake and steering systems;
• Controls, hydraulic system and linkages.
DL300-5TRAV Safety
1-69
--- Page 12 ---
3. Accelerator Pedal
Controls the travel speed of loader and working speed of
load handling system.
IMPORTANT
The further the pedal is pressed, the more the engine
speed will increases. However, do not press the pedal
more than necessary otherwise, it will increase fuel WL1400126
consumption. Figure 10
4. Steering Wheel Adjustment Lever
Control lever (1, Figure 11) is used allow wheel to be Telescopic
moved to the most convenient position for the operator.
Tilt
Adjusting Steering Wheel Tilt
Push lever (1, Figure 12) downward and move wheel (2,
Figure 12) to desired position. Tilt angle is 15° to window
side, 24° to driver side. 1
Adjusting Steering Wheel Telescopic
Pull lever (1, Figure 12) upward and move wheel (2, Figure WL1400127
12) to desired position. Telescopic stroke is 85 mm. Figure 11
2
1
WL1300378
Figure 12
DL300-5TRAV Operating Controls
2-9
--- Page 13 ---
4. Hour Meter
The hour meter is used to indicate total number of
operating hours on engine. The meter will flash every 4
seconds when engine is running to indicate that it is
functioning properly.
Figure 28
DL300-5TRAV Operating Controls
2-19
--- Page 14 ---
1. Fuel Gauge
Shows remaining fuel quantity in tank.
WHITE ZONE ( ) - Indicates a normal fuel quantity.
RED ZONE ( ) - Indicates that fuel level is low.
If gauge pointer moves into red zone, fuel level symbol will
turn "ON" and be displayed on screen. Stop operation and
immediately add fuel.
Check fuel level on firm and level ground. FG019109
Figure 48
2. Engine Coolant Temperature Gauge
The colored bands indicate temperature of engine coolant.
WHITE ZONE ( ) - Indicates temperature is within
normal operating range.
RED ZONE ( ) - Indicates temperature is too high.
During operation, pointer must be in white zone.
If gauge pointer moves into red zone, engine coolant
temperature warning light will turn "ON" and engine speed
FG019110
will be automatically reduced. Allow engine to run at "LOW
IDLE" until temperature gauge registers in white zone Figure 49
again. When white zone is reached, allow engine to idle for
an additional three - five (3-5) minutes before stopping
engine. If not allowed to idle, heat surge may develop
which will damage engine. Allowing engine to idle will
dissipate heat. Check coolant level, look for a loose fan
belt, inspect for debris around radiator, etc. before
continuing to operate.
When temperature reaches normal range, engine speed
will automatically recover.
3. Transmission Oil Temperature Gauge
The colored bands indicate temperature of transmission
oil.
WHITE ZONE ( ) - Indicates temperature is within
normal operating range.
RED ZONE ( ) - Indicates temperature is too high.
During operation, pointer must be in white zone.
If gauge pointer moves into red zone, transmission oil FG019111
temperature symbol will turn "ON" and be displayed on the
in screen. Allow engine to run at "LOW IDLE" until Figure 50
temperature gauge registers in white zone again.
NOTE: See “10. Display Warning Symbols” on
page 2-33, for location of this warning symbol
and others.
DL300-5TRAV Operating Controls
2-29
--- Page 15 ---
I. Load Isolation System (LIS)
When LIS is operating, symbol is shown on lower part
of screen.
FG019136
Figure 78
J. Torque Converter Lockup
When torque converter lockup is selected, symbol is
shown on lower part of screen.
FG019137
Figure 79
K. Electric Steering
When electric steering is selected, symbol is shown
on lower part of screen.
FG004186
Figure 80
L. Reverse Fan
When reverse fan is operating, symbol is shown on
lower part of screen.
FG004185
Figure 81
DL300-5TRAV Operating Controls
2-39
--- Page 16 ---
B. Active LIS Vehicle Speed Setting
"Active LIS Vehicle Speed Setting" is used to set up a
vehicle speed for LIS function active. In "Vehicle
Setup" window, with cursor on "Active LIS Vehicle
Speed Setting" menu, press SELECTION ( ) Active LIS Vehicle Speed Setting
button to enter "Active LIS Vehicle Speed Setting" Auto Shut Off Time Setting
window.
WL1300759
Figure 108
C. Auto Shut Off Time Setting
" Auto Shut Off Time Setting" is used to set up a time
for auto shut off function. In " Vehicle Setup" window,
with cursor on " Auto Shut Off Time Setting" menu,
press SELECTION ( ) button to enter "Auto Shut Active LIS Vehicle Speed Setting
Off Time Setting" window. Auto Shut Off Time Setting
WL1300760
Figure 109
D. Auto Idle Enable/Disable State
"Auto Idle" window is used to "ENABLE" or
"DISABLE" auto idle function.
In "Vehicle Setup" window, with cursor on "Auto Idle
Enable or Disable" menu, press SELECTION ( ) Active LIS Vehicle Speed Setting
button to go to "Auto Idle Enable or Disable" window. Auto Shut Off Time Setting
Press ESC button to return to previous window.
WL1300761
Figure 110
Auto Idle Setting Procedure:
– With cursor on "Auto Idle" setting menu, press Vehicle Configuration
SELECTION ( ) button. A pop-up window
Reverse Fan Auto Period Setting
asking "Disable Auto Idle?" will appear. The
user can change setting using UP ( ) or Auto Idle Disable
Enable Auto Idle?
DOWN ( ) button and make selection with
SELECTION ( ) button. YES NO
– Auto idle disable can be changed with same
method described above. A2E S
WL1300779
– Pressing ESC button cancels change and Figure 111
removes pop-up window.
DL300-5TRAV Operating Controls
2-49
--- Page 17 ---
1. FNR Lever (Standard) 3
2 1
If machine is equipped with log forks this lever controls 5 4
boom, bucket and log forks.
B A
6
This lever is used to position bucket and boom. This lever
is capable of raising or lowering boom, and crowding or
dumping bucket. When machine is being driven,, lever
(joystick) can be "LOCKED" out, to prevent any movement
of bucket or boom. To "LOCK" out lever (joystick), place
pilot cutoff switch in "LOCKED" position.
Pilot control valve lever (joystick) operating pattern and FG019207
description of operation. Figure 136
HL. Hold
lever in
Lower
Mode
L. Lower
HC. Hold C. Bucket N. Neutral D. Bucket
lever in Crowd Dump
Bucket
Crowd
R. Raise
HR. Hold
lever in Figure 137
Raise
Mode
The buttons on this lever (Figure 136) are capable of
controlling the following functions:
1. Neutral Button
When this button is pressed, 2nd gear function will be
operational, and 2nd gear indicator light turns "ON".
When this button is pressed again, 2nd gear function
is turned "OFF", and machine is returned to
"NEUTRAL".
2. Forward Button
When this button is pressed for forward travel at
same time as "KD" (5, Figure 136) button is pressed,
machine can travel forward. When machine is driven,
it can change travel direction without pressing "KD"
(5, Figure 136) button.
3. Reverse Button
When this button is pressed for reverse travel at
same time as "KD" (5, Figure 136) button is pressed,
machine can travel in reverse. When machine is
driven, it can change travel direction without pressing
"KD" (5, Figure 136) button.
4. Horn Button
(See page 2-61)
5. Kick-down Button
(See page 2-60)
DL300-5TRAV Operating Controls
2-59
--- Page 18 ---
VARIOUS CABIN LOCATIONS
5 6
4 7
3 11
2
1
8
10
9
Figure 162
12 BSM000213
Reference Reference
Description Description
Number Number
1 Cabin Light 7 Speakers
2 Cabin Fan 8 Storage Compartments
3 Stereo/CD Player (Optional) 9 Electrical Box
Heater and Air Conditioner 10 Emergency Starter Switch
4
Control Panel 11 Rotating Beacon Light
5 Quick Coupler Switch and Key 12 Fire Extinguisher
6 Unified Antenna
DL300-5TRAV Operating Controls
2-69
--- Page 19 ---
9. Defroster Button
Used to direct airflow to front window.
FG000106
Figure 191
10. LCD Display
This display shows the current setting.
A/C OUTSIDE
AUTO MAX
FG000107
Figure 192
Memory Function
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 stored setting will
be used.
Additional Operating Instructions
A proper indoor temperature in summer is 5 - 6°C (10 - 12°F)
lower than the outdoor temperature.
Operate the air conditioner for twenty - thirty (20 - 30) minutes a
week to circulate the refrigerant in the system.
NOTE: The blower button must be on "three bars".
If operating the air conditioner or heater for a long time, operate
the air inlet selector button and, when smoking, vent the air to
the outside to prevent irritation to eyes.
DL300-5TRAV Operating Controls
2-79
--- Page 20 ---
ELECTRICAL SYSTEM MASTER
SWITCH
An electrical system master switch is located in the battery box.
This switch turns "I" (ON) and "O" (OFF) all the electrical power
for the loader.
When the switch is "OFF" it provides additional theft protection,
by not allowing the starter switch to function.
Figure 209
ENGINE BLOCK HEATER
An engine block heater is provided to warm the engine in cold
weather.
NOTE: If cold weather or temperatures are going to be cold
while the machine is parked over night, it is
recommended to plug the engine block heater in
during inactivity.
Figure 210
Figure 211
DL300-5TRAV Operating Controls
2-89
--- Page 21 ---
12. After engine has started, release key. Key will return to "I"
(ON) position (Figure 12). O I
13. Follow procedures in “Automatic Warming Up Operation”
on page 3-10.
FG019173
Figure 12
14. After warming-up the machine, check all operating indicators
to make sure that all engine systems (oil pressure, coolant,