Part of the Doosan Repair Manuals.
The ZF power shift transmission is where most DL300-3 and DL350-3 jobs get hard, and this Doosan shop manual takes it on directly. It covers the standard ZF 4WG, the optional 5WG and the torque converter. A separate fault code table lists every hex code with its meaning, the TCU reaction and the repair steps.
The rest of the book covers the Scania DC 9 Tier 4i engine and the ZF MT-L 3085 II / 3095 II axles. It also covers the wet disk brakes, the steering with its flow amplifier and emergency circuit, and the hydraulics behind the lift arms and bucket cylinders. Both the hydraulic and electrical schematics are included.
Check which transmission and axle your machine carries before you order anything. The manual covers each variant separately, so you can match the part to the machine in front of you.
What's Inside This Doosan DL300-3, DL350-3 Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety | 5-70 | Wheel Loader Safety Precautions, Operation and Maintenance Warnings |
| Specifications | 71-90 | Component Locations, General Specifications, Engine Specification, Dimensions, Working Range and Lifting Capacity for DL300-3 and DL350-3 |
| General Maintenance | 91-128 | General Maintenance Instructions, Hydraulic System Cleanliness, Standard Torques |
| Engine | 129-360 | Scania DC 9 Engine Service, Engine Coolant Heater (Option) |
| Transmission and Torque Converter | 361-700 | ZF 4WG Standard and ZF 5WG Optional Power Shift Transmissions and Torque Converter |
| Transmission Error Codes (ZF) | 701-730 | Table of Fault Codes in Hex, Meaning, TCU Reaction and Possible Steps to Repair |
| Axles and Driveshaft | 731-806 | ZF MT-L 3085 II / 3095 II Axles, Driveshaft |
| Brake | 807-862 | Service Brake, Supply Valve, Charging Block, Parking Brake, Brake Pedal Valve, Accumulator |
| Steering | 863-946 | Power Steering System, Steering Unit, Steering Pump, Flow Amplifier, Jerk Softener, Emergency Steering |
| Frame and Tanks | 947-980 | Articulation Center, Counterweight, Oil Tank, Fuel Tank |
| Hydraulics | 981-1093 | Main Pump, Main Control Valve, 3rd Control Valve (Option), Load Isolation System, Cooling System, Pilot System, Hydraulic Schematic |
| Electrical System | 1094-1230 | Air Conditioner, Warning and Indicator Lights, Electrical Schematic |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine maker and model | SCANIA / DC 9 | p. 80 |
| Engine emission | US EPA Tier 4i (EU Stage IIIB) | p. 80 |
| Injection system | Extra high-pressure fuel injection system, XPI | p. 80 |
| Rated gross power | 202 kW (271 HP) @ 1,800 rpm (SAE J1995) | p. 80 |
| Max torque | 130 kg•m / 1,400 rpm (1,012 ft lb @ 1,400 rpm) | p. 83 |
| Fuel consumption (rated) | 159 g / ps.h | p. 83 |
| Transmission | Full Automatic Power Shift, 4 Forward, 3 Reverse (Option 5 Forward, 3 Reverse) | p. 80 |
| Travel brakes | 4 Wheel, Wet Disk | p. 80 |
| Parking brake | SAHR, Dry Disk Type | p. 80 |
| Standard bucket capacity (BOT / BOC) | 3.0 m3 (3.9 yd3) / 3.2 m3 (4.2 yd3) (DL300-3) / 3.5 m3 (4.6 yd3) / 3.7 m3 (4.8 yd3) (DL350-3) | p. 80 |
| Vehicle weight | 18,570 kg (40,940 lb) (DL300-3) / 19,920 kg (43,915 lb) (DL350-3) | p. 80 |
| Rated operating load | 6,535 kg (14,407 lb) (DL300-3) / 7,180 kg (15,829 lb) (DL350-3) | p. 80 |
| Maximum breakout force (bucket) | 169 kN (37,993 lb) | p. 80 |
Doosan DL300-3, DL350-3 Common Problems This Manual Covers
Transmission drops into neutral and runs in limp home mode
Read the hex fault code from the TCU and look it up in the ZF error code table. Each entry gives the meaning, the TCU reaction and the repair steps. For B3, which is slippage at clutch K3, the next step is a pressure check at clutch K3.
Manual Section: Transmission Error Codes (ZF) p. 724Steering feels heavy or uneven across the articulation joint
Work through the Steering chapter in order: steering pump, steering unit, flow amplifier, then the jerk softener. Each one has its own service coverage. Emergency steering is covered too, so you can test the backup circuit before the loader goes back to work.
Manual Section: Steering p. 865Lift arms and bucket cylinders slow to respond
Start with the main pump and the main control valve, then check the pilot system that feeds the loader valve. The Hydraulics chapter also covers the optional 3rd control valve, the load isolation system and cooling. A hydraulic schematic is included for tracing lines.
Manual Section: Hydraulics p. 983Frequently Asked Questions
What does ZF fault code B3 mean, and what do I check first?
B3 means the TCU has detected slippage at clutch K3. The TCU shifts to neutral and puts the machine in limp home mode. The manual's next step is a pressure check at clutch K3. The code table is valid for ZF software V 53.x to V58.0, so confirm your TCU version first. p. 724
When is the basic brake setting required?
You need it after fitting new brake lining plates or brake disks, during every repair stage, and whenever braking performance is poor. Do it with the brakes cold. The same chapter covers the supply valve, charging block, brake pedal valve, accumulator and the SAHR dry disk parking brake. p. 841
Does the manual cover both the 4WG and the optional 5WG transmission?
Yes. The transmission chapter covers the ZF 4WG standard box with 4 forward and 3 reverse gears. It also covers the optional 5WG with 5 forward and 3 reverse, plus the torque converter. ZF TCU fault codes have their own chapter, listed in hex. p. 363
The charge warning light keeps coming on. What triggers it?
The light comes on when terminal input voltage falls below 12 ±1V or rises above 33 ±0.7V. The manual puts this down to abnormal battery voltage. Use the warning and indicator light pages and the electrical schematic to trace the circuit. p. 1155
Is the DL350-3 covered in full, or just the DL300-3?
Both models are covered. The DL300-3 carries a 3.0 m3 BOT bucket and a 6,535 kg rated operating load. The DL350-3 carries a 3.5 m3 BOT bucket and a 7,180 kg rated operating load. Dimensions, working range and lifting capacity are given for each model. p. 80
