Doosan DL300-5 and DL350-5 Wheel Loader Service Repair Manual Instant Download

1
Shop Manual
DL300-5/DL350-5
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.
950106-01256E April 2014
Original Instructions
Copyright DOOSAN 2014
2
Table of Contents
1 Safety
1 Wheel Loader Safety
2 Specifications
1 Specifications
3 General Maintenance
1 General Maintenance Instructions
2 Standard Torques
4 Engine
1 Engine
5 Drivetrain

1. Transmission and Torque Converter (4WG)
2. Transmission and Torque Converter (5WG) (Option)

1. Front Axle
2. Rear Axle
3. Driveshaft

6 Steering
1 Power Steering System

1. Steering Unit
2. Steering Pump
3. Flow Amplifier
4. Jerk Softener Accumulator

7 Brake
1 Service Brake

• Brake Pilot Supply Valve
• Charging Block
• Parking Brake
• Brake Pedal Valve
• Accumulator
• Brake Filter
• Table of Contents
• Page I

3
8 Cooling System
1 Cooling System

1. Fan Brake Pump
2. Fan Motor
3. Fan Control Valve

9 Hydraulic System
1 Main Pump

1. Main Control Valve
2. Pilot System
3. Hydraulic System
4. Hydraulic System Troubleshooting

10 Frame
1 Articulation Center

1. Cabin
2. Counterweight
3. Oil Tank
4. Fuel Tank
5. Cylinders

11 Electrical System
1 Electrical System
2 Air Conditioner
12 Options
1 Emergency Steering

1. Load Isolation System
2. Auto Grease System

13 Schematic
1 Hydraulic Schematic/Electrical Schematic
Table of Contents Page II
4
https//www.ebooklibonline.com Hello dear
friend! Thank you very much for reading. Enter
the link into your browser. The full manual is
available for immediate download. https//www.eb
ooklibonline.com
5
Wheel Loader
Safety
Edition 1
Wheel Loader Safety 1-1-1
DL300-5/DL350-5
6
Table of Contents Wheel Loader Safety Safety
Instructions .....................................
.....1-1-5 Safety Messages .......................
.....................1-1-5 General................
...........................................1-1-7 O
peration..........................................
............1-1-18 Maintenance ...................
..............................1-1-31 Transportatio
n ..............................................1-
1-46 Environment and Circumstances................
..1-1-48
Wheel Loader Safety 1-1-3
DL300-5/DL350-5
7
SAFETY INSTRUCTIONS WARNING
AVOID DEATH OR SERIOUS INJURY Instructions are
necessary before operating or servicing machine.
Read and understand the Operation 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.
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.
Wheel Loader Safety 1-1-5
DL300-5/DL350-5
8
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. 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.

1. Turn battery disconnect switch to "ON" position.
2. Close battery compartment door.

DL300-5/DL350-5
Wheel Loader Safety 1-1-6
9
Engine
10
SAFETY INSTRUCTIONS WARNING
AVOID DEATH OR SERIOUS INJURY Instructions are
necessary before operating or servicing machine.
Read and understand the Operation 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.
Engine 4-1-7
DL300-5/DL350-5
11
OVERVIEW
FRONT
WL1400224
Figure 1
DL300-5/DL350-5
Engine 4-1-8
12

• Mounting the Engine in a Universal Stand
• Preparations before commencing work
• Remove engine from the machine.

2
3
4
1
FG020231
Figure 3
Reference Number Description
1 Engine Control Unit
2 Fuel Filter
Reference Number Description
3 High-pressure Pump and Feed Pump
4 Starter Motor
1. Mount the engine in the universal stand.
Reference Number Description
1 Bolt M10 x 30 (8 off)
2 Nut M16 (4 off)
3 Bolt M16 x 50 (4 off)
2
3 99 331
1
FG020232
Figure 4
Engine 4-1-19
DL300-5/DL350-5
13
ENGINE IDENTIFICATION Engine Data Plate
Reference Number Description
A Smoke Value
B Engine Type
C Engine Serial Number
A
B
C
FG020225
Figure 5
Figure 6
Reference Number Description
1 Warning! Only for Lifting Engines
2 Warning! Draining the Fuel Housing. Warning! High Fuel Pressure
3 Engine Power
4 Important! Warranty Registration
5 Valve Clearance
6 Assistance
7 Information on Emissions
2
3
1
4
5
7
6 Figure 7
DL300-5/DL350-5
Engine 4-1-20
14
ENGINE SPECIFICATION
Items Items Specification
Engine Type 4-Cycle Water Cooled, Waste Gate Turbocharge, Air to Air Intercooled Direct Injection
Engine Emission US EPA Tier 4 Final (EU Stage IV)
Engine Model DC 9
Engine Injection System Extra High-pressure Fuel Injection System
Engine Rated Net Power 202 kW (271 HP) _at_ 1,800 rpm (SAE J1995)
Valve Clearance Intake Valve 0.45 mm
Valve Clearance Exhaust valve 0.70 mm
Number of Cylinders and Configuration Number of Cylinders and Configuration 5, Straight
Rotating Direction (from Flywheel) Rotating Direction (from Flywheel) Counterclockwise
Oil Pressure Normal with the Engine at Operating Temperature, Operating Speed 3.1 - 6.1 kg/cm2 (3 - 6 bar, 43.5 - 87 psi)
Oil Pressure Min. Permitted at Idling Speed 0.71 kg/cm2 (0.7 bar, 10.2 psi)
Crankcase Pressure with Closed Crankcase Ventilation -5.4 - 2.0 bar
Using Lubrication Oil ACEA-E5 or E7 (for Fuel with Ultra Low Sulfur Content)
Oil Filter Paper Filter
Interval Between Oil Changes 500 h
Working Principle 4 Stoke Engine
Cylinder Diameter 130 mm
Piston Stroke 140 mm
Displacement 9,300 cc
Compression Ratio 171
Number of Teeth on the Flywheel 158
Low Idle Speed 600 - 750 rpm
Max. Full Load Speed 2,100 rpm
Weight, without Coolant and Oil 1,035 kg
Cooling System Volume, Excluding Radiator 16,000 cc
Cooling System Coolant Temperature 90 - 95C
Cooling System Number of Thermostats 1
Cooling System Thermostat, Opening Temperature 80C
Electrical System Type 1-pin, 24V, DC
Electrical System Starter Motor (Standard Equipment) 1-pin, 24V, 6 kW
Electrical System Alternator (Standard Equipment) 1-pin, 28V, 100 A
Engine 4-1-21
DL300-5/DL350-5
15
Tightening Torques for Engines
IMPORTANT
Tightening torques for threaded joints in
engines. If the tightening torque is not
available in the table for each engine, refer to
the special and normal tightening torques tables.
Engine Assembly Engine Assembly Engine Assembly Engine Assembly Engine Assembly Engine Assembly
Cylinder Block Cylinder Block Cylinder Block Cylinder Block Cylinder Block Cylinder Block
Piston cooling nozzle 23 Nm Piston cooling nozzle 23 Nm Piston cooling nozzle 23 Nm Piston cooling nozzle 23 Nm Piston cooling nozzle 23 Nm Piston cooling nozzle 23 Nm
Main Bearing Cap Main Bearing Cap Main Bearing Cap Main Bearing Cap Main Bearing Cap Main Bearing Cap
NOTE The screws can only be reused 3 times. Mark the NOTE The screws can only be reused 3 times. Mark the
screws each time before installing. screws each time before installing. 1 2 3 4

EX1301810
Torx screw (M19) 110 Nm 90 Torx screw (M19) 110 Nm 90
Hexagon screw (M19) 110 Nm 90 Hexagon screw (M19) 110 Nm 90
EX1301811 EX1301811 EX1301811 EX1301811
Connecting Rod Cap Connecting Rod Cap Connecting Rod Cap Connecting Rod Cap Connecting Rod Cap Connecting Rod Cap
NOTE The screws can only be reused 3 times. Mark the
screws each time before installing. 1 2 3 4

EX1301810
DL300-5/DL350-5
Engine 4-1-30
16
Torx screw 50 Nm 90 Check torque 170 Nm EX1302070 EX1302070 EX1302070 EX1302070 EX1302070 EX1302070 EX1302070 EX1302070
Flywheel Housing Flywheel Housing Flywheel Housing Flywheel Housing Flywheel Housing Flywheel Housing Flywheel Housing Flywheel Housing Flywheel Housing
Lead-in union 40 Nm 6
Cylinder Head and Valve Package Cylinder Head and Valve Package Cylinder Head and Valve Package Cylinder Head and Valve Package Cylinder Head and Valve Package Cylinder Head and Valve Package Cylinder Head and Valve Package Cylinder Head and Valve Package Cylinder Head and Valve Package
Cylinder Head Cylinder Head Cylinder Head Cylinder Head Cylinder Head Cylinder Head Cylinder Head Cylinder Head Cylinder Head
NOTE The screws can only be reused 3 times. Mark the
screws each time before fitting. 1 2 3 4

EX1301810
Cylinder head bolt, tightened in four stages 3 6 1 2 5 4 FG020253
First stage 60 Nm 3 6 1 2 5 4 FG020253
Second stage 150 Nm 3 6 1 2 5 4 FG020253
Third stage 250 Nm 3 6 1 2 5 4 FG020253
Fourth stage 90 3 6 1 2 5 4 FG020253
Engine 4-1-31
DL300-5/DL350-5
17
Rocker Cover Rocker Cover
Rocker cover, upper 18 Nm Rocker cover, lower 18 Nm
Rocker cover, upper 18 Nm Rocker cover, lower 18 Nm
Valve Mechanism Valve Mechanism
Adjusting screw nut on rocker arm 35 Nm
Adjusting screw nut on rocker arm 35 Nm
DL300-5/DL350-5
Engine 4-1-32
18
Screw for rocker arm shaft bearing retainer 90 Nm 60
Roller Tappet Shaft Roller Tappet Shaft
Banjo screw for roller tappet shaft (engines produced earlier) 33 Nm Slotted screw for roller tappet shaft (engines produced later) 40 Nm
Banjo screw for roller tappet shaft (engines produced earlier) 33 Nm Slotted screw for roller tappet shaft (engines produced later) 40 Nm
Banjo screw for roller tappet shaft (engines produced earlier) 33 Nm Slotted screw for roller tappet shaft (engines produced later) 40 Nm
Engine 4-1-33
DL300-5/DL350-5
19
Crank Mechanism Crank Mechanism
Flywheel Flywheel
M18 flange screw 180 Nm 120
Torsion Damper Torsion Damper
Torsion damper hub 90 Nm 30 Torsion damper hub 90 Nm 30
Timing Gear Timing Gear
Intermediate gear 50 Nm 60 Camshaft gear 20 Nm 40 EX1301830
Lubrication System Lubrication System
Oil sump Cylinder block, 8.8 screw 26 Nm Cylinder block, 10.9 screw 32 Nm Against cylinder block, 8.8 screw with spacer 26 Nm
Oil Sump, Plastic Oil Sump, Plastic
Oil sump, spring screw 20 Nm Oil sump, spring screw 20 Nm
DL300-5/DL350-5
Engine 4-1-34
20
Suggest If the above button click is invalid.
Please download this document first, and then
click the above link to download the complete
manual. Thank you so much for reading
21
Oil Plug Oil Plug
Thread insert for oil plug 320 Nm Magnetic oil plug, oiled seal 80 Nm
Thread insert for oil plug 320 Nm Magnetic oil plug, oiled seal 80 Nm
Magnetic oil plug, dry seal 115 Nm
Oil plug for filler connection in oil sump 60 Nm Oil pump, 10.9 screw 32 Nm Oil pump, 8.8 screw 26 Nm Hose connection for cooling system 85 Nm Oil fill pipe, retaining screw 20 Nm Oil plug for filler connection in oil sump 60 Nm Oil pump, 10.9 screw 32 Nm Oil pump, 8.8 screw 26 Nm Hose connection for cooling system 85 Nm Oil fill pipe, retaining screw 20 Nm
Oil Filter Oil Filter
Element type filter, cover 25 Nm Oil filter unit without loose filter Hand tighten
Engine 4-1-35
DL300-5/DL350-5
22
Oil Cooler Oil Cooler
Oil cooler core 26 Nm
Centrifugal Oil Cleaner Centrifugal Oil Cleaner
Nut for outer cover 15 Nm
Oil Mist Separator Oil Mist Separator
Nut (M18 x 1.5) 35 5 Nm Nut (M18 x 1.5) 35 5 Nm
Exhaust System Exhaust System
Exhaust Manifold Exhaust Manifold
Cylinder head hexagon screw 40 Nm 60 Cylinder head Torx screw 60 Nm 60 Turbocharger 50 Nm Cylinder head hexagon screw 40 Nm 60 Cylinder head Torx screw 60 Nm 60 Turbocharger 50 Nm
Exhaust pipe from Turbocharger Exhaust pipe from Turbocharger
Turbocharger (V-clamp) 20 Nm EX1301840
Turbocharger Oil Pipe Turbocharger Oil Pipe
Turbocharger lubrication pipe 40 1.2 Nm (3 ) Nut for turbocharger lubrication pipe 35 5 Nm Turbocharger lubrication pipe 40 1.2 Nm (3 ) Nut for turbocharger lubrication pipe 35 5 Nm
Turbocharger Coolant Pipe Turbocharger Coolant Pipe
Water inlet, turbocharger 40 Nm Water inlet, variable geometry turbocharger electric motor 10 Nm Water inlet, turbocharger 40 Nm Water inlet, variable geometry turbocharger electric motor 10 Nm
DL300-5/DL350-5
Engine 4-1-36
23
https//www.ebooklibonline.com Hello dear
friend! Thank you very much for reading. Enter
the link into your browser. The full manual is
available for immediate download. https//www.eb
ooklibonline.com