Doosan DL300-3 and DL350-3 Wheel Loader Service Repair Manual Instant Download

1
Shop Manual
DL300-3 / DL350-3 Wheel Loader
Serial Number 10001 and Up
DOOSAN and the DOOSAN logo are registered
trademarks of DOOSAN Corporation in the United
States and various other countries around the
world.
950106-00431E April 2012
Original Instructions
Copyright DOOSAN 2012
2
Table of Contents
Safety Wheel Loader Safety .......................
..................................................
... SP002397 Specifications Specification for
DL300-3 / DL350-3.................................
.................... SP002473 General
Maintenance General Maintenance
Instructions......................................
.................. SP002454 Standard
Torques...........................................
......................................
SP002404 Engine Engine...........................
..................................................
...................... SP002541 Engine Coolant
Heater (Option) ..................................
......................... SP002328 Drivetrain Tra
nsmission and Torque Converter (ZF 4WG)
................................... SP002519
Transmission and Torque Converter (ZF 5WG)
(Option) ..................... SP002520
Transmission Error Codes (ZF) ....................
........................................
SP002423 Axle (ZF - MT-L 3085 II / 3095 II)
..................................................
....... SP002474 Driveshaft......................
..................................................
...................... SP002424 Brake Service
Brake ............................................
...........................................
SP002475 Supply Valve.............................
..................................................
.......... SP002427 Charging Block
..................................................
...................................
SP002428 Parking Brake ...........................
..................................................
.......... SP002476 Brake Pedal Valve
..................................................
.............................. SP002477 Accumulato
r.................................................
......................................... SP002431
Table of Contents Page I
3
Steering Power Steering System ...................
..................................................
... SP002478 Steering Unit .......................
..................................................
................ SP002479 Steering
Pump..............................................
........................................
SP002480 Flow Amplifier ..........................
..................................................
........... SP002481 Jerk Softener and
Accumulator ......................................
...................... SP002482 Emergency
Steering .........................................
....................................
SP002483 Frame Articulation Center
..................................................
.............................. SP002467 Counterwei
ght...............................................
........................................
SP002437 Tank Oil Tank ..........................
..................................................
.................... SP002484 Fuel
Tank..............................................
................................................
SP002485 Hydraulics Main Pump....................
..................................................
...................... SP002486 Main Control
Valve ............................................
................................... SP002441 3rd
Control Valve (Option)............................
........................................
SP002442 Load Isolation System ...................
..................................................
..... SP002487 Cooling System.....................
..................................................
.............. SP002488 Pilot System..............
..................................................
.......................... SP002445 Hydraulic
Schematic DL300-3 / DL350-3 ......................
....................... SP002489 Electrical
System Air Conditioner............................
..................................................
........ SP002447 Electrical System
..................................................
................................ SP002575
Electrical Schematic DL300-3 / DL350-3 / DL420-3
/ DL450-3 ............ SP002449
Table of Contents Page II
4
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Wheel Loader
Safety
SP002397
Edition 1
SP002397 Page 1
Wheel Loader Safety
6
Table of Contents Wheel Loader Safety Safety
Instructions .....................................
........... 5 Applicable Models
................................................
5 Safety Messages ................................
.................. 6 General......................
...........................................
6 Transportation .................................
................... 16 Operation..................
..........................................
18 Maintenance ...................................
.................... 36 Environment and
Circumstances........................ 51
SP002397 Page 3
Wheel Loader Safety
7
SAFETY INSTRUCTIONS WARNING
AVOID DEATH OR SERIOUS INJURY Instructions are
necessary before operating or servicing machine.
Read and understand the Operation and
Maintenance Manual and signs (decals) on machine.
Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing.
Check for correct function after adjustments
repairs or service. Untrained operators and
failure to follow instructions can cause death
or serious injury.
APPLICABLE MODELS The contents of this section
apply to the following models and serial number
ranges.
MODEL SERIAL NUMBER RANGE
DL200-3 10001 and Up
DL220-3 10001 and Up
DL250-3 10001 and Up
DL300-3 10001 and Up
DL350-3 10001 and Up
DL420-3 10001 and Up
DL450-3 10001 and Up
DL550-3 10001 and Up
SP002397 Page 5
Wheel Loader Safety
8
SAFETY MESSAGES Safety messages and safety decals
included in this manual and on the machine
provide instructions how to operate, service and
maintain the machine. Safety messages and safety
decals indicate potential hazards and describe
safety precautions required to avoid hazards.
Operator and maintenance personnel should read
and understand these safety messages and decals
before beginning operation or maintenance.
SAFETY ALERT SYMBOL
Be Prepared - Get to Know All Operating and
Safety Instructions. This is a Safety Alert
Symbol. Wherever it appears in this manual or on
safety decals on the machine, you must be alert
to the potential for personal injury or
accidents. Always observe safety precautions and
follow recommended procedures. Signal
Words The signal words "DANGER", "WARNING",
"CAUTION" are used throughout safety messages
and safety decals in this manual or on the
machine. They indicate an existence of, and the
relative seriousness of a hazard. All three
indicate that a safety risk is involved. Observe
the precautions indicated whenever a Safety
Alert Symbol is present, no matter which signal
word appears next to it.
DANGER
DANGER - This signal word is used on safety
messages and safety labels and indicates an
imminently hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING
WARNING - This signal word is used on safety
messages and safety labels and indicates a
potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION
CAUTION - This signal word is used on safety
messages and safety labels and indicates a
potentially hazardous situation which, if not
avoided, could result in minor or moderate
injury.
SP002397
Wheel Loader Safety Page 6
9
SAFETY DECALS Location of safety labels (decals)
can vary from unit to unit. Refer to appropriate
Operation and Maintenance Manual, and parts
manual for your unit. Always replace damaged or
faded decals.
GENERAL
Safe Operation is Operator's Responsibility Only
trained and authorized personnel should operate
and maintain the machine. Follow all safety
rules, regulations and instructions when
operating or performing maintenance on machine.

• Do not operate machine if you are under the
  influence of drugs or alcohol. An operator who is
  taking prescription drugs must get medical
  advice to determine if he or she can safely
  operate the machine.
• When working with other personnel on a work site,
  be sure that all personnel know the nature of
  work and understand all hand signals that are to
  be used.
• Be sure that all guards and shields are installed
  in their proper location. Have guards and
  shields repaired or replaced immediately if
  damaged.
• Be sure that you understand the use and
  maintenance of all safety features such as pilot
  cutoff switch and seat belt. Use them at all
  times.
• Never remove, modify or disable any safety
  features. Always keep them in good operating
  condition.
• Always check for and know the location of
  underground and overhead utility lines before
  working.
• Failure to use and maintain safety features
  according to instructions in this manual, Safety
  Manual and Shop Manual can result in death or
  serious injury.

Know Your Machine Know how to operate your
machine. Know the purpose of all controls,
gauges, signals, indicators and monitor displays.
Know the rated load capacity, speed range,
braking and steering characteristics, turning
radius and operating clearances. Keep in mind
that rain, snow, ice, loose gravel, soft ground,
slopes etc., can change operating capabilities
of your machine.
SP002397 Page 7
Wheel Loader Safety
10
Engine
SP002541
Edition 1
SP002541 Page 1
Engine
11
SAFETY INSTRUCTIONS
WARNING
AVOID DEATH OR SERIOUS INJURY Instructions are necessary before operating or servicing machine. Read and understand the Operation and Maintenance Manual and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments repairs or service. Untrained operators and failure to follow instructions can cause death or serious injury.
APPLICABLE MODELS The contents of this section
apply to the following models and serial number
ranges.
MODEL SERIAL NUMBER RANGE
DL300-3 10001 and Up
DL350-3 10001 and Up

SP002541
Engine Page 6
12
DC9 ENGINE
FG024302
Figure 1
SP002541 Page 7
Engine
13
CYLINDER Cylinder Head

• Removal
• If the engine has EGR
• Remove water-cooled EGR cooler as instructed in
  the work description for Removing the
  water-cooled EGR cooler.
• Remove brackets for the water-cooled EGR cooler.
• Remove bolts for the exhaust manifold on the
  relevant cylinder and slacken the bolts on the
  adjacent cylinders so the relevant part of the
  exhaust manifold comes loose.
• Remove cooling system bleeder hose, separate the
  quick release coupling at the front lifting eye.
• Remove cable duct from the intake.
• Remove cable ties for the cable harness from the
  engine control unit.

IMPORTANT
The fuel system components are extremely sensitive to dirt. Clean thoroughly before dismantling and plug all connections with lint-free rags and tape.

1. Depressurize the fuel system and detach the fuel
   pipe running between the accumulator and fuel
   manifold.
2. Detach the fuel manifold and remove bolts on the
   relevant cylinder.
3. Detach the intake manifold and remove bolts on
   the relevant cylinder.

7 9 8
IMPORTANT
All parts in the fuel injection system and valve mechanism must be marked. Everything must be reinstalled in the same position.
FG020250
Figure 11
9. Remove injectors as instructed in the work
description for Removing the injectors. Also
remove high-pressure pipes and connection on the
cylinder head at the back viewed from the coolant
pump.
SP002541
Engine Page 32
14
IMPORTANT
If work is done on the 6th cylinder of an engine with an EGR system, the EGR valve control cylinder must be detached at the damper and removed.
10. Remove upper rocker cover and then the rocker
arm housing, valve bridges and pushrods.
FG020251
Figure 12 11. Pull the cable harness out of the
lower rocker cover and remove it.
NOTE
Take care when pulling the cable harness out of
the rocker cover the cable terminals can be
damaged which can cause the nut securing the
cable harness to the injector to come loose.

1. Work on the adjacent cylinders. Remove upper
   rocker cover, release the cable harness and the
   lower rocker cover so it can be moved.
2. Remove relevant cylinder head. Be careful with
   the adjacent rocker covers.

FG020252
Figure 13
NOTE
Mark the cylinder heads if more than one is
being removed at the same time. If all cylinder
heads are removed at the same time, the
turbocharger must be removed or supported
against the frame.
NOTE

• Installing
• Check the liner height as described in the work
  description for Checking the liner height.
• Clean the cylinder head and cylinder block.
  Lubricate the threads and below the heads of the
  cylinder head bolts.
• Install a new cylinder head gasket.
• Install the cylinder head.

SP002541 Page 33
Engine
15
5. Tighten the cylinder head as shown in the
illustration and according to specification. Cyli
nder head bolts can only be reused three times.
Make a mark with a center punch on the head of
the bolt. If any of the bolts already has three
marks, it must be replaced.
1
5
3
4
6
2
FG020253
Figure 14
1
2
3
4
FG020254
Figure 15 6. Tighten the intake manifold. Use a
new gasket. Tighten the bolts in the order 1-20
or 1-24 as illustrated. Tighten the bolts in the
same order again. 2 4 6 8 10 12 14 16 18 20
1
3 5
7 9 11 13 15 17 19
FG020255

• Figure 16
• Tighten the intake manifold and the exhaust
  manifold. Use new gaskets.
• Install the cable bracket bolt in the lower
  rocker cover and install the following parts

2

• Lower rocker cover.
• Pushrods.
• Valve bridge.
• Rocker arm housing.

4 6 8 10 12 14 16 18 20 22 24
1 3 5 7 9 11 13 15 17 19 21 23
FG020256
IMPORTANT Figure 17
Lubricate the valve bridge and rocker arm housing with engine oil.

SP002541
Engine Page 34
16

• Install the injector, high-pressure pipe
  connection and high-pressure pipe as instructed
  in the work description.
• Reset adjacent cylinders.
• Adjust the valve clearance.
• Install the upper rocker covers.
• Install the cooling system vent
• If the engine has an EGR system
• Install the brackets for the water-cooled EGR
  cooler.
• Install the water-cooled EGR cooler as described
  in the work description for Installing the
  water-cooled EGR cooler.
• Removing and Installing Valves

WARNING
AVOID DEATH OR SERIOUS INJURY Wear protective goggles for eye protection.
1. Removing Valves

1. Remove split collets, valve spring collars,
   springs and valves. Press down the spring using
   tool 99 322 in a press so the collets can be
   removed.
2. Place the valves in a stand so they can be
   reinstalled in the same position in the cylinder
   head.

99 322
FG020258
Figure 18
2. Installing Valves
99 322
NOTE
There are different versions of the combination
valve valve spring collar split collet. Parts
from the different versions must not be mixed
on the same valve.

• Lubricate all parts well with engine oil before
  assembly.
• Insert the valve in the guide. C.
• D.

Install the valve springs and the valve spring
collar. Press together the springs in a press
with tool 99 322 and install the collets. Ensure
that collets are installed in their correct
positions.
FG020259
Figure 19
SP002541 Page 35
Engine
17

• Replacing a Valve Stem Seal
• Remove valve according to the work description
  for Removing valves.
• Remove valve stem seal with a pair of pliers.
• Install the valve.

FG020261
Figure 20 4. Carefully tap a new valve stem seal
into place using tool 99 323 and a hammer.
99 323
FG020262
Figure 21
Replacing the Valve Seats
1. Remove valve seat inserts with an expanding
sleeve from the kit with puller 587 270 (1,
Figure 22).
1
NOTE
Insert, for example, an aluminum sheet between
the cylinder head and counterhold to protect
against damage.
2
WARNING
AVOID DEATH OR SERIOUS INJURY Wear protective goggles for eye protection from flying metal parts.
FG020266
Figure 22
SP002541
Engine Page 36
18
2. Press in new valve seat inserts. Use drift 99
384 (2, Figure 22) and shank 99 385. Cool the
drift and valve seat insert to about -80C with
dry ice or liquid air. Pressing must be done
rapidly.
99 385
99 384
WARNING
AVOID DEATH OR SERIOUS INJURY Prevent frost injuries. Be careful when handling very cold parts and refrigerant.
FG020267
Figure 23 Oversize valve seat inserts can be
installed if the valve seat insert position has
been damaged. The position is then machined using
tool 587 277 according to the work description
for Machining a valve seat position. Adjust Repl
acing the Valve Guides 1. Press out the valve
guides using drift 99 383.
99 383
FG020268
Figure 24
2. Press in the new valve guides using drift 99
382. Press the guide down as far as the drift
allows, i.e. until it contacts the spring seat
in the cylinder head.
99 382
FG020269
Figure 25
SP002541 Page 37
Engine
19
Replacing the XPI Injector Sleeves The cylinder
head must be removed when replacing the unit
injector sleeve. The valves do not need removing.
The illustrations show the cylinder head with
valves removed to demonstrate clearly the work
described. NOTE Guide and pilot tap on
extension piece 99 397.

FG020272
Figure 26

1. Thread the lower part of the sleeve using the
   pilot tap and guide from tool kit 99 574.
2. Knock out the pilot tap and sleeve from
   underneath. Use a 100 mm long metal rod of
   diameter 9 mm.
3. Degrease and check the contact surfaces of the
   sleeve and cylinder head. Smooth off any burrs
   and irregularities that may score the sleeve.
4. Degrease the new injector sleeve and apply a thin
   film of sealant 561 200 on the sleeve and
   cylinder head contact surfaces.
5. Press in the sleeve using the drift and guide
   from tool kit 99 574.

FG020273
Figure 27
Replacing the Valve Bridge Guide Pins The
cylinder head must be removed when replacing the
guide pins. 1. Remove Outlet valves and Intake
valves.
1
2
Reference Number Description
1 Outlet Valves
2 Intake Valves
FG020276
Figure 28
SP002541
Engine Page 38
20
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2. Install shrink sleeve number 10 from tool kit
587 470.
FG020277
Figure 29
3. Use pin extractor 587 470 to remove guide pins.
587 470
FG020278
Figure 30
FG020279
Figure 31 4. Press in the new guide pins using
drift 99 015. Maximum press force 15 kN.
99 015
NOTE
Check before pressing in that tool is not
deformed. Check after pressing in that valve
bridge slides easily on the guide pin.
5. Install all the parts in the cylinder head.
FG020280
Figure 32
SP002541 Page 39
Engine
22
Cylinder Block Generation 2 - Specifications
Intake Valve Intake Valve
Oversize valve seat, outer diameter 46.254 - 46.265 mm
Valve seat position, outer diameter 46.200 - 46.216 mm
Valve seat position, deep 11.25 - 11.35 mm
Exhaust valve seat Exhaust valve seat
Oversize valve seat, outer diameter 44.281 - 44.292 mm
Valve seat position, outer diameter 44.200 - 44.216 mm
Valve seat position, deep 11.25 - 11.35 mm

• Remove cylinder head according to the work
  description for Removing the cylinder head.
• Remove inlet and exhaust valves according to the
  work description for Removing the valves.

• Machining the Valve Seat Position
• Check that contact surface on the cylinder head
  is level and clean. Also check that magnetic
  stand on the valve seat cutter is clean. Clean
  the valve guides.
• Zero the micrometer.

FG020282
Figure 33 3. Assemble the micrometer with a
suitable spindle on the valve seat cutter and
adjust the cutter. It is very important that tip
of the cutter is in the center of the micrometer
spindle.
FG020283
Figure 34
SP002541
Engine Page 40
23
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