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1. Original InstructionsCopyright DOOSAN 2012
Serial Number 10001 and Up
Shop Manual
DL300-3 / DL350-3 Wheel Loader
950106-00431E
April 2012
DOOSAN and the DOOSAN logo are registered
trademarks of DOOSAN Corporation in the United
States and various other countries around the
world.

2. Table of Contents
Page I
1Table 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
Transmission 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
Accumulator.......................................................................................... SP002431

3. Table of Contents
Page II
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
Counterweight....................................................................................... 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

4. SP002397
Page 1
Wheel Loader Safety
SP002397
WHEEL LOADER SAFETYSP002397
Wheel Loader
Safety
Edition 1

5. SP002397
Page 3
Wheel Loader Safety
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

6. SP002397
Page 5
Wheel Loader Safety
SAFETY INSTRUCTIONS
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
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.
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

7. SP002397Wheel Loader Safety
Page 6
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.
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.
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.
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.

8. SP002397
Page 7
Wheel Loader Safety
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.

9. SP002541
Page 1
Engine
SP002541
ENGINE SP002541
Engine
Edition 1

10. SP002541Engine
Page 6
SAFETY INSTRUCTIONS
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
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.
MODEL SERIAL NUMBER RANGE
DL300-3 10001 and Up
DL350-3 10001 and Up

11. SP002541
Page 7
Engine
DC9 ENGINE
FG024302
Figure 1

12. SP002541Engine
Page 32
CYLINDER
Cylinder Head
Removal
1. 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.
2. 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.
3. Remove cooling system bleeder hose, separate the quick
release coupling at the front lifting eye.
4. Remove cable duct from the intake.
5. Remove cable ties for the cable harness from the engine
control unit.
6. Depressurize the fuel system and detach the fuel pipe
running between the accumulator and fuel manifold.
7. Detach the fuel manifold and remove bolts on the relevant
cylinder.
8. Detach the intake manifold and remove bolts on the
relevant cylinder.
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.
IMPORTANT
The fuel system components are extremely sensitive
to dirt. Clean thoroughly before dismantling and plug
all connections with lint-free rags and tape.
897
FG020250
Figure 11
IMPORTANT
All parts in the fuel injection system and valve
mechanism must be marked.
Everything must be reinstalled in the same position.

13. SP002541
Page 33
Engine
10. Remove upper rocker cover and then the rocker arm
housing, valve bridges and pushrods.
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.
12. Work on the adjacent cylinders. Remove upper rocker
cover, release the cable harness and the lower rocker
cover so it can be moved.
13. Remove relevant cylinder head. Be careful with the
adjacent rocker covers.
NOTE: Mark the cylinder heads if more than one is
being removed at the same time.
NOTE: If all cylinder heads are removed at the same
time, the turbocharger must be removed or
supported against the frame.
Installing
1. Check the liner height as described in the work description
for Checking the liner height.
2. Clean the cylinder head and cylinder block. Lubricate the
threads and below the heads of the cylinder head bolts.
3. Install a new cylinder head gasket.
4. Install the cylinder head.
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.
FG020251
Figure 12
FG020252
Figure 13

14. SP002541Engine
Page 34
5. Tighten the cylinder head as shown in the illustration and
according to specification.
Cylinder 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.
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.
7. Tighten the intake manifold and the exhaust manifold. Use
new gaskets.
8. Install the cable bracket bolt in the lower rocker cover and
install the following parts:
• Lower rocker cover.
• Pushrods.
• Valve bridge.
• Rocker arm housing.
1
2
3
4
5
6
FG020253
Figure 14
FG020254
1 2 3 4
Figure 15
1 3 5 7 9 11 13 15 17 19
2 4 6 8 10 12 14 16 18 20
FG020255
Figure 16
2
4 6 8 10 12 14 16 18 20 22 24
1 3 5 7 9 11 13 15 17 19 21 23
FG020256
Figure 17
IMPORTANT
Lubricate the valve bridge and rocker arm housing
with engine oil.

15. SP002541
Page 35
Engine
9. Install the injector, high-pressure pipe connection and
high-pressure pipe as instructed in the work description.
10. Reset adjacent cylinders.
11. Adjust the valve clearance.
12. Install the upper rocker covers.
13. Install the cooling system vent
14. 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
1. Removing Valves
A. 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.
B. Place the valves in a stand so they can be reinstalled
in the same position in the cylinder head.
2. Installing Valves
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.
A. Lubricate all parts well with engine oil before
assembly.
B. Insert the valve in the guide.
C. Install the valve springs and the valve spring collar.
D. Press together the springs in a press with tool 99 322
and install the collets. Ensure that collets are installed
in their correct positions.
WARNING
AVOID DEATH OR SERIOUS INJURY
Wear protective goggles for eye protection.
99 322
FG020258
Figure 18
FG020259
99 322
Figure 19

16. SP002541Engine
Page 36
Replacing a Valve Stem Seal
1. Remove valve according to the work description for
Removing valves.
2. Remove valve stem seal with a pair of pliers.
3. Install the valve.
4. Carefully tap a new valve stem seal into place using tool 99
323 and a hammer.
Replacing the Valve Seats
1. Remove valve seat inserts with an expanding sleeve from
the kit with puller 587 270 (1, Figure 22).
NOTE: Insert, for example, an aluminum sheet
between the cylinder head and counterhold to
protect against damage.
FG020261
Figure 20
99 323
FG020262
Figure 21
2
1
FG020266
Figure 22
WARNING
AVOID DEATH OR SERIOUS INJURY
Wear protective goggles for eye protection from flying
metal parts.

17. SP002541
Page 37
Engine
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 -80°C with dry ice or liquid air. Pressing must be
done rapidly.
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
Replacing the Valve Guides
1. Press out the valve guides using drift 99 383.
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.
99 385
99 384
FG020267
Figure 23
WARNING
AVOID DEATH OR SERIOUS INJURY
Prevent frost injuries. Be careful when handling very
cold parts and refrigerant.
99 383
FG020268
Figure 24
99 382
FG020269
Figure 25

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19. SP002541Engine
Page 38
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.
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.
Replacing the Valve Bridge Guide Pins
The cylinder head must be removed when replacing the guide
pins.
1. Remove Outlet valves and Intake valves.
FG020272
Figure 26
FG020273
Figure 27
12
FG020276
Figure 28
Reference
Number
Description
1 Outlet Valves
2 Intake Valves

20. SP002541
Page 39
Engine
2. Install shrink sleeve number 10 from tool kit 587 470.
3. Use pin extractor 587 470 to remove guide pins.
4. Press in the new guide pins using drift 99 015. Maximum
press force 15 kN.
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.
FG020277
Figure 29
FG020278
587 470
Figure 30
FG020279
Figure 31
FG020280
99 015
Figure 32

21. SP002541Engine
Page 40
Cylinder Block Generation 2 - Specifications
• 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
1. 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.
2. Zero the micrometer.
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.
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
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
FG020282
Figure 33
FG020283
Figure 34