Daewoo Doosan DL400 Wheel Loader Operation & Maintenance Manual K1010629CE – PDF DOWNLOAD

Description

Daewoo Doosan DL400 Wheel Loader Operation & Maintenance Manual K1010629CE – PDF DOWNLOAD

DESCRIPTION:

Daewoo Doosan DL400 Wheel Loader Operation & Maintenance Manual K1010629CE – PDF DOWNLOAD

Intended Use:

• The machine is intended to be used under normal conditions for the applications described in the Operator’s Manual.
• If it is used for other purposes or in potentially dangerous environments, for example explosive atmosphere or areas with dust containing asbestos, etc., special safety regulations must be followed and the machine must be equipped for such use.
• Contact the manufacturer/dealer for further information. T
• he machine is designed for a maximum machine weight (includes equipment and attachments) of 22,500 kg (49,603 l b) for DL400.
• If the maximum weight is exceeded, no warranties on the part of the manufacturer will apply. However, always pay attention to national regulations for traveling on public roads.

Engine:

• DL400 has a Cummins QSL9 8.9 liter engine. The engine has intercooling and is fitted with common rail system.
• The common rail system is positioned at an angle above the pistons and are controlled by way of the camshaft and a electronic control module (ECM). The cylinder head covers all cylinders.
• The engine has four valves per cylinder. The accelerator position is transferred electrically from accelerator pedal.

Electrical System:

• The machine has three control units.
• The Gauge Panel for the instrumentation is integrated with the display unit, warning lights and instruments and provides the operator with information by way of there.
• The Control Unit (for the machine) receives signals from sensors on the machine and these are passed to the Gauge Panel. The E-ECU controls the engine.

Power Transmission:

• The transmission is electro hydraulically controlled, where all gears are in constant mesh.
• The gear ranges are achieved by applying different combinations of clutches.
• Between the engine and transmission gears there is a hydraulic torque converter, which controls the output torque.
• The front and rear axles have planetary gears in the wheel hubs and this reduces the strain on the respective driveshafts.
• The axles differentials use a LSD (Limited Slip Differential) design.

TABLE OF CONTENTS:

Daewoo Doosan DL400 Wheel Loader Operation & Maintenance Manual K1010629CE – PDF DOWNLOAD

Preface………………………………………………………………………………I-I
Presentation…………………………………………………………………………….. I-I
CE Marking, EMC Directive ………………………………………………………I-IV
Communication Equipment Installation………………………………………..I-V
Product Plates…………………………………………………………………………I-VI
Safety………………………………………………………………………………1-1
To the Operator of a DOOSAN Wheel Loader …………………………….. 1-1
General Safety Essentials………………………………………………………… 1-5
Location of Safety Labels…………………………………………………………. 1-5
Unauthorized Modifications…………………………………………………….. 1-14
General Hazard Information……………………………………………………. 1-14
Before Starting Engine…………………………………………………………… 1-23
Machine Operation………………………………………………………………… 1-26
Maintenance ………………………………………………………………………… 1-34
Battery ………………………………………………………………………………… 1-46
Towing…………………………………………………………………………………. 1-48
Shipping and Transportation …………………………………………………… 1-49
Operating Controls …………………………………………………………..2-1
Component Locations ……………………………………………………………… 2-2
Operator’s Area………………………………………………………………………. 2-4
Steering Console and Pedals …………………………………………………… 2-5
Front Instrument Panel…………………………………………………………… 2-15
Right Side Switch Panel…………………………………………………………. 2-26
Various Cabin Locations ………………………………………………………… 2-41
Heater and Air Conditioner Operation………………………………………. 2-45
Stereo / CD Player (Optional) …………………………………………………. 2-50
Seat Adjustment (Standard)……………………………………………………. 2-52
Seat Adjustment (Optional)…………………………………………………….. 2-54
Seat Belt ……………………………………………………………………………… 2-56
Door Side Latch ……………………………………………………………………. 2-57
Arm Rest ……………………………………………………………………………… 2-58
Fuse Box/Relay…………………………………………………………………….. 2-59
Operation…………………………………………………………………………3-1
Instrument Panel Control Functions…………………………………………… 3-1
New Machine Break-in Procedures …………………………………………… 3-1
Engine Start and Stop……………………………………………………………… 3-2
Machine Travel ……………………………………………………………………… 3-11
Machine Shut Down………………………………………………………………. 3-14
F/R (Forward/Reverse) Travel Control System (Optional)……………. 3-16
Additional Braking …………………………………………………………………. 3-17
Boom Raise Kick-out……………………………………………………………… 3-18
Bucket Angle Indicator …………………………………………………………… 3-18
Boom Lower Kick-out (Optional) ……………………………………………… 3-19
Adjustment of Bucket Position Switch………………………………………. 3-19
Towing Machine ……………………………………………………………………. 3-20
If Engine Stalls While Traveling……………………………………………….. 3-21
Allowable Water Depth…………………………………………………………… 3-22
Inspection, Maintenance and Adjustment………………………….4-1
Basic Preventive Maintenance………………………………………………….. 4-1
Safety When Servicing…………………………………………………………….. 4-4
Preventive Maintenance…………………………………………………………. 4-12
Table of Recommended Lubricants …………………………………………. 4-14
Axle Oils DL400, DL300, DL250……………………………………………… 4-16
Fluid Capacities ……………………………………………………………………. 4-19
Lubrication and Service Chart ………………………………………………… 4-20
Maintenance Intervals……………………………………………………………. 4-24
10 Hour / Daily Service ………………………………………………………….. 4-26
50 Hour / Weekly Service ………………………………………………………. 4-36
250 Hour / Monthly Service ……………………………………………………. 4-44
500 Hour / 6 Month Service ……………………………………………………. 4-47
1,000 Hour / 6 Month Service …………………………………………………. 4-61
1,500 Hour / 9 Month Service …………………………………………………. 4-68
2,000 Hour / Yearly Service ……………………………………………………. 4-71
12,000 Hour / Six Year Service……………………………………………….. 4-78
Bolt Torque Chart ………………………………………………………………….. 4-79
Electrical System ………………………………………………………………….. 4-80
Engine Cooling System………………………………………………………….. 4-82
Handling of Accumulator………………………………………………………… 4-86
Hydraulic Pressure Checks…………………………………………………….. 4-87
Long Term Storage ……………………………………………………………….. 4-93
Parking Brake Adjustment………………………………………………………. 4-94
Severe Conditions Maintenance ……………………………………………… 4-96
Tires ……………………………………………………………………………………. 4-97
Transmission Recalibration …………………………………………………… 4-101
Transportation………………………………………………………………….5-1
Loading and Unloading……………………………………………………………. 5-1
Summary of Safety Precautions for Lifting………………………………….. 5-2
Troubleshooting……………………………………………………………….6-1
Braking………………………………………………………………………………….. 6-1
Electrical System ……………………………………………………………………. 6-1
Engine…………………………………………………………………………………… 6-2
Hydraulic System……………………………………………………………………. 6-4
Steering ………………………………………………………………………………… 6-6
Travel System…………………………………………………………………………. 6-7
Specification ……………………………………………………………………7-1
General Specifications …………………………………………………………….. 7-1
Working Range and Dimensions ………………………………………………. 7-4
Working Capacities …………………………………………………………………. 7-6
Approximate Weight of Workload Materials ………………………………… 7-6
Index ……………………………………………………………………………….8-1
Publication Request for Proposed Revision…………………….10-1

DAEWOO DOOSAN DL400 WHEEL LOADER OPERATION & MAINTENANCE MANUAL K1010629CE – PDF DOWNLOAD:

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