DL250

DL250TC
Shop Manual
K1023773CE
Serial Number 5001 and Up

DOOSAN reserves the right to improve our products in a continuing process to provide the best
possible product to the market place. These improvements can be implemented at any time with no
obligation to change materials on previously sold products. It is recommended that consumers
periodically contact their distributors for recent documentation on purchased equipment.
This documentation may include attachments and optional equipment that is not available in your
machine's package. Please call your distributor for additional items that you may require.
Illustrations used throughout this manual are used only as a representation of the actual piece of
equipment, and may vary from the actual item.

K1023773CE Shop Manual

Copyright 2011 Doosan
Find manuals at https://best-manuals.com
 Pub.No. K1023773CE
Serial Number 5001 and Up
DL250 DL250TC
Product Label

Instructions

Trim Out The Label Along

The Lines And Insert Into
Pocket On The Binder Spine

Pub. No. K1023773CE

Find manuals at https://best-manuals.com
Find manuals at https://best-manuals.com
 1Table of Contents
Safety
Wheel Loader Safety........................................................................... SP000865

Specifications
Specification for DL250/DL250TC....................................................... SP001562

General Maintenance
General Maintenance Procedures ...................................................... SP000097
Standard Torques ................................................................................ SP000813

Drive Train
Transmission and Torque Converter.................................................. SP000867
Transmission Error Codes (ZF).......................................................... SP001056
Front Axle (ZF-MT-L 3085)................................................................. SP000868
Rear Axle (ZF-MT-L 3075 ll).............................................................. SP002273
Drive Shaft ........................................................................................... SP000870

Brake
Service Brake....................................................................................... SP001359
Brake Supply Valve............................................................................. SP001360
Parking Brake ...................................................................................... SP000873
Brake Pedal Valve............................................................................... SP000874
Accumulator.......................................................................................... SP000875

Steering
Steering ................................................................................................ SP002293
Cushion Valve...................................................................................... SP000328
Emergency Steering ............................................................................ SP002294

Table of Contents
Page I

Find manuals at https://best-manuals.com

Frame
Articulation Center ............................................................................... SP000878
Counterweight....................................................................................... SP000130

Tank
Oil Tank................................................................................................ SP000879
Fuel Tank ............................................................................................. SP001362

Hydraulics
Cylinders............................................................................................... SP001027
Main Pump........................................................................................... SP001035
Main Control Valve.............................................................................. SP000881
Load Isolation System......................................................................... SP000882
Cooling System.................................................................................... SP001374
Pilot System ......................................................................................... SP000884
Hydraulic Schematic (DL250) ............................................................. SP002295

Electrical System
Air Conditioner ..................................................................................... SP000172
Electrical System ................................................................................. SP000924
Electrical Schematic (DL250).............................................................. SP000925

Table of Contents
Page II

Find manuals at https://best-manuals.com

 1Safety

Find manuals at https://best-manuals.com

Find manuals at https://best-manuals.com
 SP000865
WHEEL LOADER SAFETYSP000865

Wheel Loader
Safety

Edition 1

Wheel Loader Safety SP000865

Page 1

Find manuals at https://best-manuals.com

 MEMO

Wheel Loader Safety SP000865

Page 2

Find manuals at https://best-manuals.com

 Table of Contents

Wheel Loader Safety

Safety Precautions............................................... 5
Applicable Models................................................ 5
To the Operator of a Wheel Loader ................. 6
General Safety Essentials................................. 10
Location of Safety Labels................................. 10
Unauthorized Modifications ............................... 11
General Hazard Information.............................. 11
Before Starting Engine ...................................... 19
Machine Operation ............................................ 23
Maintenance ....................................................... 31
Battery ................................................................ 40
Towing ................................................................ 42
Shipping and Transportation ............................. 43

Wheel Loader Safety SP000865

Page 3
 MEMO

Wheel Loader Safety SP000865

Page 4
SAFETY PRECAUTIONS

CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.

APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.

MODEL SERIAL NUMBER RANGE

DL200 5001 and Up
DL250 5001 and Up
DL300 5001 and Up
DL400 5001 and Up
DL500 5001 and Up

Wheel Loader Safety SP000865

Page 5
TO THE OPERATOR OF A
WHEEL LOADER

DANGER
Unsafe use of the wheel loader could lead to serious
injury or death. Operating procedures, maintenance and
equipment practices or traveling or shipping methods
that do not follow the safety guidelines on the following
pages could cause serious, potentially fatal injuries or
extensive damage to the machine or nearby property.

Please respect the importance of taking responsibility for

your own safety, and that other people who may be affected
by your actions.
Safety information on the following pages is organized into
the following topics.
1. “General Safety Essentials” on page 1-10.
2. “Location of Safety Labels” on page 1-10.
3. “Unauthorized Modifications” on page 1-11.
4. “General Hazard Information” on page 1-11.
5. “Before Starting Engine” on page 1-19.
6. “Machine Operation” on page 1-23.
7. “Maintenance” on page 1-31.
8. “Battery” on page 1-40.
9. “Towing” on page 1-42.
10. “Shipping and Transportation” on page 1-43.

Wheel Loader Safety SP000865

Page 6
 WARNING
Improper operation and maintenance of this machine
can be hazardous and could result in serious injury or
death.
Operator and maintenance personnel should read this
manual thoroughly before beginning operation or
maintenance.
Keep this manual in the storage compartment to the
rear of the operator's seat, and have all personnel
involved in working on the machine periodically read the
manual.
Some actions involved in operation and maintenance of
the machine can cause a serious accident, if they are
not done in a manner described in this manual.
The procedures and precautions given in this manual
apply only to intended uses of the machine.
If you use your machine for any unintended uses that
are not specifically prohibited, you must be sure that it
is safe for any others. In no event should you or others
engage in prohibited uses or actions as described in
this manual.
DOOSAN delivers machines that comply with all
applicable regulations and standards of the country to
which it has been shipped. If this machine has been
purchased in another country or purchased from
someone in another country, it may lack certain safety
devices and specifications that are necessary for use in
your country. If there is any question about whether
your product complies with the applicable standards and
regulations of your country, consult DOOSAN or your
DOOSAN distributor before operating the machine.

Wheel Loader Safety SP000865

Page 7
 SAFETY ALERT SYMBOL
Be Prepared - Get to Know All Operating and Safety
Instructions.
This is the Safety Alert Symbol. Wherever it appears in
this manual or on safety signs on the machine you
should be alert to the potential for personal injury or
accidents. Always observe safety precautions and follow
recommended procedures.

Learn Signal Words Used with Safety

Alert Symbol
The words "CAUTION," "WARNING," and "DANGER" used
throughout this manual and on decals on the machine
indicate degree of risk of hazards or unsafe practices. All
three degrees of risk indicate that safety is involved.
Observe precautions indicated whenever you see the Safety
Alert "Triangle," no matter which signal word appears next to
the "Exclamation Point" symbol.

CAUTION
This word is used on safety messages and safety labels
and indicates potential of a hazardous situation that, if
not avoided, could result in minor or moderate injury. It
may also be used to alert against a generally unsafe
practice.

WARNING
This word is used on safety messages and safety labels
and indicates potential of a hazardous situation that, if
not avoided, could result in serious injury or death. It
may also be used to alert against a highly unsafe
practice.

DANGER
This word is used on safety messages and safety labels
and indicates an imminent hazard of a situation that, if
not avoided, is very likely to cause death or extremely
serious injury. It may also be used to alert against
equipment that may explode or detonate if handled or
treated carelessly.

Wheel Loader Safety SP000865

Page 8
Safety precautions are described in SAFETY from page -10
on.
DOOSAN cannot predict every circumstance that might
involve a potential hazard in operation and maintenance.
Therefore the safety messages in this manual and on the
machine may not include all possible safety precautions. If
any procedures or actions not specifically recommended or
allowed in this manual are used, you must be sure that you
and others can do such procedures and actions safely and
without damaging the machine. If you are unsure about the
safety of some procedures, contact a DOOSAN distributor.

Wheel Loader Safety SP000865

Page 9
GENERAL SAFETY
ESSENTIALS

Accessory Applications
This wheel loader has been designed primarily for moving
earth with a bucket. For use as a grapple or for other object
handling, contact DOOSAN. Lifting-work applications are
permitted in approved lift configuration, to rated capacity
only, with no side-loading (unless prohibited by local
regulation). Do not use machine for activities for which it
was not intended. Do not use bucket for lifting work, unless
lift slings are used in approved configuration.

LOCATION OF SAFETY LABELS

Location of safety labels (decals) can vary from unit to unit.
Refer to appropriate Operation and Maintenance Manual,
and Parts Manual for your unit.
There are several specific warning signs on this machine.
The exact location of hazards and the description of the
hazards are reviewed in the appropriate Operation and
Maintenance Manual.
Please become familiarized with all warning signs.
Make sure that all of the warning signs are legible. Clean
the warning signs or replace the warning signs if you cannot
read the words. Replace the illustrations if the illustrations
are not visible. When you clean the warning signs, use a
cloth, water and soap. Do not use solvent, gasoline, or other
harsh chemicals to clean the safety signs. Solvents,
gasoline, or other harsh chemicals could loosen the
adhesive that secures the warning sign. Loose adhesive will
allow the warning sign to fall off.
Replace any safety sign that is damaged, or missing. If a
safety sign is attached to a part that is replaced, install a
safety sign on the replacement part.

Wheel Loader Safety SP000865

Page 10
UNAUTHORIZED
MODIFICATIONS
Any modification made without authorization or written
approval from DOOSAN can create a safety hazard, for
which the machine owner must be held responsible.
For safety's sake, replace all OEM parts with the correct
authorized or genuine DOOSAN part. For example, not
taking the time to replace fasteners, bolts or nuts with the
correct replacement parts could lead to a condition in which
the safety of critical assemblies is dangerously compromised.

GENERAL HAZARD
INFORMATION

Safety Rules
Only trained and authorized personnel can operate and
maintain the machine.
Follow all safety rules, precautions and instructions when
operating or performing maintenance on the machine.
Do not operate the machine if you are not feeling well, if
you are taking medication that makes you feel sleepy, if you
have been drinking, or if you are suffering from emotional
problems. These problems will interfere with your sense of
judgement in emergencies and may cause accidents.
When working with another operator or with a person on
work site traffic duty, be sure that all personnel know the
nature of the work and understand all hand signals that are
to be used.
Always observe strictly any other rules related to safety.

Safety Features
Be sure that all guards and covers are installed in their
proper position. Have guards and covers repaired
immediately if damaged.
Be sure that you understand the method of use of safety
features such as transmission lever neutral lock and the
seat belt, and use them properly.
Never remove any safety features. Always keep them in
good operating condition.
Failure to use safety features according to the instructions in
the Operation and Maintenance Manual could result in
serious bodily injury.

Wheel Loader Safety SP000865

Page 11
Inside Operator's Compartment
When entering the operator's compartment, always remove
all mud and oil from the soles of your shoes. If you operate
the accelerator and brake pedals with mud or oil stuck to
your shoes, your foot may slip and this may cause a
serious accident.
Clean grease and dirt from pedals and controls. This
contributes to safe operation. Cleaning also provides an
opportunity to inspect equipment. Minor damage can be
repaired or corrected before major problems result.
Keep cab floor and consoles free of tools and personal
items.
After using the ashtray, make sure that any matches or
cigarettes are properly extinguished, and be sure to close
the ashtray. If the ashtray is left open, there is danger of
fire.
Do not stick suction pads to the window glass. Suction pads
act as a lens and may cause fire.
Do not leave lighters laying around the operator's
compartment. If the temperature inside the operator's
compartment becomes high, there is danger that the lighter
may explode.
Do not use cellular telephones inside the operator's
compartment when driving or operating the machine. There
is danger that this may lead to an unexpected accident.
Never bring any dangerous objects such as flammable or
explosive items into the operator's cab.
To ensure safety, do not use the radio or music
headphones when operating the machine. There is danger
that this may lead to a serious accident.
When operating the machine, do not put your hands or
head out of the window.
When standing up from the operator's seat, always place
transmission neutral lock lever in the "LOCK" position and
set pilot cutoff switch to "O" (OFF) position. If you
accidentally touch the work equipment levers when they are
not locked, the machine may suddenly move and cause
serous injury or damage.
When leaving the machine, completely lower the work
equipment to the ground, set transmission neutral lock lever
in the "LOCK" position, set pilot cutoff switch to "O" (OFF)
position, "APPLY" parking brake, and shut down engine. Use
the key to lock all the equipment. Always remove the key
and take it with you.

Wheel Loader Safety SP000865

Page 12
Clothing and Personal Protective Items
Contain long hair, and avoid loose clothing and jewelry.
They can catch on controls or in protruding parts and cause
serious injury or death.
Do not wear oily clothes. They are flammable.
Full eye protection, a hard hat, safety shoes and gloves
may be required at the work site.
While working on the machine, never use inadequate tools.
They could break or slip, causing injury, or they may not HAOA020L
adequately perform intended functions. Figure 1

Breathing Masks, Ear Protection May Be

Required
Do not forget that some risks to your health may not be
immediately apparent. Exhaust gases and noise pollution
may not be visible, but these hazards can cause disabling
or permanent injuries.
NOTE: The equivalent continuous A-weighted sound
pressure level at the workstation for this machine is
given in the operation manual.
Measurement is obtained on a dynamic
machine following the procedures and cab
conditions as described in ISO 6396.
NOTE: The guaranteed sound power level emitted by the
machinery for this machine is given in the operation
manual.
Measurement is obtained on a dynamic
machine with the procedures as described in
2000/14/EC.

Vibration Level Information

Hands/Arms: The weighted root mean square acceleration to
which the hands/arms are subjected, is less than 2.5 m/s2.
Whole body: The weighted root mean square acceleration to
which the whole body is subjected, is less than 0.5 m/s2.
Measurements are obtained on a representative machine,
using measuring procedures as described in the following
standard: ISO 2631/1. ISO 5349, and SAE J1166.

Wheel Loader Safety SP000865

Page 13
Asbestos Dust Hazard Prevention
Asbestos dust can be HAZARDOUS to your health if it is
inhaled. Materials containing asbestos fiber can be present
on work site. Breathing air that contains asbestos fiber can
ultimately cause serious or fatal lung damage. To prevent
lung damage from asbestos fiber, observe following
precautions;
• Use a respirator that is approved for use in an
asbestos-laden atmosphere.
ARO1770L
• Never use compressed air for cleaning.
Figure 2
• Use water for cleaning to keep down the dust.
• Work on the machine or component with the wind
at your back whenever possible.
• Always observe any rules and regulations related
to the work site and working environment.

Mounting and Dismounting

Before getting on or off the machine, if there is any oil,
grease, or mud on the handrails, steps, or track shoes, wipe
it off immediately. Always keep these parts clean. Repair
any damage and tighten any loose bolts.
Never get on or off a moving machine. In particular, never
get on or off a moving machine. These actions may lead to
serious injury.
When getting on or off the machine, always face the
HA3O1003
machine, and maintain a three-point contact (both feet and
Figure 3
one hand or one foot and both hands) with the handholds
and steps to ensure that you support yourself securely.
Never hold any control levers when getting on or off the
machine.
Never get up from operator's seat or leave operator's station
and dismount machine if engine is running.

Wheel Loader Safety SP000865

Page 14
Fuel, Oil and Hydraulic Fluid Fire
Hazards
Fuel, oil and antifreeze will catch fire if it is brought close to
a flame. Fuel is particularly flammable and can be
hazardous.
Always strictly observe the following.
Add fuel, oil, antifreeze and hydraulic fluid to the machine
only in a well ventilated area. The machine must be parked
with controls, lights and switches turned "OFF." The engine
must be "OFF" and any flames, glowing embers, auxiliary
heating units or spark causing equipment must be doused,
turned "OFF" and/or kept well clear of the machine.
Static electricity can produce dangerous sparks at the fuel
filling nozzle. In very cold, dry weather or other conditions Figure 4
that could produce a static discharge, keep the tip of the
fuel nozzle in constant contact with the neck of the fuel
filling nozzle, to provide a ground.
Keep fuel and other fluid reservoir caps tight and do not
start the engine until caps have been secured.

Precautions When Handling Fluids at

High Temperature
Immediately after operations are stopped, the coolant,
engine oil, and hydraulic oil are at high temperature and the
radiator and hydraulic tank are still under pressure.
Attempting to remove the cap, drain the oil or coolant, or
replacing the filters may lead to serious burns. Always wait
for the temperature to go down, and follow the specified
procedures when carrying out these operations.
HAOA050L
Figure 5

To prevent hot coolant from spurting out, shut down engine,

wait for the coolant to cool, then loosen the cap slowly to
relieve the pressure.
To prevent hot oil from spurting out, shut down engine, wait
for the oil to cool, then loosen the cap slowly to relieve the
pressure.

HAOA060L
Figure 6

Wheel Loader Safety SP000865

Page 15
Injury from Work Equipment
Do not enter or put your hand, arm or any other part of
your body between movable parts, such as between the
work equipment and cylinders, or between the machine and
work equipment.
If the control levers are operated, the clearance between the
machine and the work equipment will change and this may
lead to serious damage or personal injury.
If going between movable parts is necessary, always
HDO1010L
position and secure the work equipment so that it cannot
Figure 7
move.

Fire Extinguisher and First Aid Kit

As a precaution if any injury or fire should occur, always do
the following.
• Be sure that fire extinguishers have been provided
and read the labels to ensure that you know now
to use them. It is recommended that an
appropriately sized (2.27 kg [5 lb] or larger)
multipurpose "A/B/C" fire extinguisher be mounted
in the cab. Check and service the fire extinguisher
at regular intervals and make sure that all work HDO1009L
site crew members are adequately trained in its Figure 8
use.
• Provide a first aid kit in the storage compartment
and keep another at the work site. Check the kit
periodically and make any additions if necessary.
• Know what to do in case of injury from fire.
• Keep emergency numbers for doctor, ambulance
service, hospital and fire department near your
telephone.
If the machine catches fire, it may lead to serious personal
injury or death. If a fire occurs during operation, escape
from the machine as follows;
• Turn the starter switch "OFF" and shut down
engine.
• If there is time, use the fire extinguisher to
extinguish as much of the fire as possible.
• Use the handrails and steps to escape from the
machine.
The above is the basic method for escaping from the
machine, but changing the method may be necessary
according to the conditions, so carry out practice drills at the
work site.

Wheel Loader Safety SP000865

Page 16
Protection from Falling or Flying Objects
On work sites where there is danger that falling objects or
flying objects may hit the operator's cab select a guard to
match the operating conditions to protect the operator.
Work in mines, tunnels, deep pits or on loose or wet
surfaces could produce danger of falling rock, roll over or
hazardous flying objects. Additional protection for operator's
cab could be required in form of a FOPS/Falling Object
Protective Structure and/or ROPS/Roll Over Protective
Structure reinforcement system. HAOA110L
Figure 9

Any reinforcement system that is installed on machine must

pass safety and certification standards and carry appropriate
labeling and rating information. For example, most often
added type of reinforcement system, FOPS, must meet or
exceed Society of Automotive Engineers standard SAE
J1356, "Performance Criteria for Falling Object Guards for
Wheel loaders."
Never attempt to alter or modify any type of protective
structure reinforcement system, by drilling holes, welding or
remounting or relocating fasteners. Any serious impact or
damage to system requires a complete integrity reevaluation. HAOA100L
Reinstallation, recertification and/or replacement of system Figure 10
may be necessary.

Install Additional Safety Equipment If

Conditions Require
Laminate glass protection for the front, side or rear windows
may also be recommended depending upon particular site
conditions.
Contact your DOOSAN distributor for available safety guards
and/or recommendations if there is any danger of getting hit
by objects that could strike the operator's cab. Make sure
that all other work site crew members are kept well away
from wheel loader and safe from potential hazards.

Maintain Standard Safety Equipment in

Good Condition
Machinery guards and body panel covers must be in place
at all times. Keep well clear of rotating parts. Pinch point
hazards such as cooling fan and alternator drive belts could
catch hair, jewelry or oversize or very loose clothing.
Safety labels must be replaced if they are damaged or
become unreadable. Information on labels gives work crew
members an important safety reminder. Part numbers for
each decal and required mounting locations are shown on
pages 1-2 through 1-4 of this section.

Wheel Loader Safety SP000865

Page 17
Attachment Precautions
Options kits are available through your dealer. Contact
DOOSAN for information on available one-way (single-acting)
and two-way (double-acting) piping / valving / auxiliary
control kits. Because DOOSAN cannot anticipate, identify or
test all attachments that owners may wish to install on their
machines, please contact DOOSAN for authorization and
approval of attachments, and their compatibility with options
kits.

Accumulator
The pilot control system is equipped with an accumulator.
For a brief period of time after the engine has been shut
down, the accumulator will store a pressure charge that may
enable hydraulic controls to be activated. Activation of any
controls may enable the selected function to operate under
force of gravity.
When performing maintenance on the pilot control system,
the hydraulic pressure in the system must be released as
describe in Operation and Maintenance Manual.
The accumulator is charged with high-pressure nitrogen gas,
so it is extremely dangerous if it is handled in the wrong
way. Always observe the following precautions;
• Do not drill or make any holes in the accumulator
or expose it any flame, fire or heat source.
• Do not weld on the accumulator, or try attaching
anything to it.
• When carrying out disassembly or maintenance of
the accumulator, or when disposing of the
accumulator, the charged gas must be properly
released. Contact your DOOSAN distributor.
• Wear safety goggles and protective gloves when
working on an accumulator. Hydraulic oil under
pressure can penetrate the skin and cause
serious injuries.

Engine Ventilation
Engine exhaust gases can cause loss of judgment, loss of
alertness, and loss of motor control. These gases can also
cause unconsciousness, serious injury and fatal accidents.
Make sure of adequate ventilation before starting engine in
any enclosed area.
You should also be aware of open windows, doors or
ductwork into which exhaust may be carried, or blown by
wind, exposing others to danger.
ARO1770L
Figure 11

Wheel Loader Safety SP000865

Page 18
BEFORE STARTING ENGINE

Work Site Precautions

Before starting operations, thoroughly check the area for any
unusual conditions that could be dangerous.
Check the terrain and condition of the ground at the work
site, and determine the best and safest method of operation.
Make the ground surface as hard and horizontal as possible
before carrying out operations. If there is a lot of dust and
sand on the work site, spray water before starting
operations.
If you need to operate on a street, protect pedestrians and
cars by designating a person for work site traffic duty or by
erecting fences and posting "No Entry" signs around the
work site.
Erect fences, post "No Entry" signs, and take other steps to
prevent people from coming close to or entering the work
site. If people come close to a moving machine, they may
be hit or caught by the machine, and this may lead to
serious personal injury or death.
Water lines, gas lines, phone lines and high voltage
electrical lines may be buried under the work site. Contact
Figure 12
each utility and identify their locations. Be careful not to
damage or cut any of these lines.
NEVER be in water that is in excess of the permissible
water depth. Refer to "Operation Manual."
Any type of object in the vicinity of the boom could
represent a potential hazard, or cause the operator to react
suddenly and cause an accident. Use a spotter or signal
person working near bridges, phone lines, work site
scaffolds, or other obstructions.
Minimum levels of insurance coverage, work permits or
certification, physical barriers around the work site or
restricted hours of operation may be mandated by governing
authorities. There may also be regulations, guidelines,
standards or restrictions on equipment that may have to be
followed for local requirements. There may also be
regulations related to performing certain kinds of work. If
there is any question about whether your machine and work
site complies with the applicable standards and regulations
contact your local authorities and agencies.
Avoid entering soft ground. It will be difficult for the machine
to escape.
Avoid operating your machine to close to the edge of cliffs,
overhangs, and deep ditches. The ground may be weak in
such areas. If the ground should collapse, the machine
could fall or tip over and this could result in serious injury or
death.

Wheel Loader Safety SP000865

Page 19
Remember that the soil after heavy rain, blasting or after
earthquakes, is weakened in these areas.
Earth laid on the ground and the soil near ditches is loose.
It can collapse under the weight of vibration of your machine
and cause your machine to tip over.
Install the head guard (FOPS) if working in areas where
there is danger of falling rocks.

Checks Before Starting Engine

Every day before starting the engine for the first time, carry
out the following checks. If these checks are not carried out
properly, there is danger of serious injury.
• Completely remove all wood chips, leaves, grass,
paper and other flammable materials accumulated
in the engine compartment and around the
battery. They could cause a fire. Remove any dirt
from the window glass, mirrors, handrails, and
steps.
• Do not leave tools or spare parts laying around in
the operator's compartment. The vibration of the
machine when traveling or during operations may
cause them to fall and damage or break the
control levers or switches. They may also get
caught in the gap of the control levers and cause
the work equipment to malfunction or move
dangerously. This may lead to unexpected
accidents.
• Check the coolant level, fuel level, and hydraulic
tank oil level, and check for clogged air cleaner
and damage to the electrical wiring.
• Adjust the operator's seat to a position where it is
easy to operate the machine, and check the seat
belt and mounts for damage and wear.
• Check the operation of the gauges and the angle
of the mirrors, and check that the safety lever is
in "LOCKED" position.
• If any abnormalities are found in the above
checks, carry out repairs immediately.

Wheel Loader Safety SP000865

Page 20
Engine Starting
• Walk around your machine before getting in
operator's cab. Look for evidence of leaking fluid,
loose fasteners, misaligned assemblies or any
other indications of possible equipment hazard.
• All equipment covers and machinery safety guards
must be in place, to protect against injury while
machine is being operated.
• Look around work site area for potential hazards,
or people or property that could be at risk while
operation is in progress.
• NEVER start engine if there is any indication that
maintenance or service work is in progress, or if a
warning tag is attached to controls in cab.
• A machine that has not been used recently, or is
being operated in extremely cold temperatures,
could require a warm-up or maintenance service
before start up.
• Check gauges and monitor displays for normal
operation before starting engine. Listen for
unusual noises and remain alert for other
potentially hazardous conditions at start of work
cycle.
• Check tire inflation and check tires for damage or
uneven wear. Perform maintenance before
operation.
• Do not short circuit the starting motor to start the
engine. This is not only dangerous, but may also
damage the machine.
• When starting the engine, sound the horn as an
alert.
• Start and operate the machine only while seated.

Wheel Loader Safety SP000865

Page 21
Before Operating Machine
If checks are not carried out properly after starting the
engine, it may result in a delay in discovering abnormalities
in the machine, and this may lead to personal injury or
damage to the machine.
Carry out the checks in an open area where there are no
obstructions. Do not let anyone near the machine when
carrying out the checks.
• Check the operating condition of the equipment,
and the actuation of the bucket, boom, and travel
systems.
• Check the machine for any abnormal noise,
vibration, heat, smell, or abnormality with the
gauges. Check also for leakage of air, oil, and
fuel.
• If any abnormality is found, repair the problem
immediately. If the machine is used without
repairing the problems, it may lead to unexpected
injury or failure.
• Clear all personnel from directly around machine
and from the area.
• Clear all obstacles from the machine's path.
Beware of hazards.
• Be sure that all windows are clean. Secure the
doors and the windows in the open position or in
the shut position.
• Adjust the rear view mirrors for best visibility close
to the machine. Make sure that the horn, the
travel alarm (if equipped), and all other warning
devices are working properly.
• Fasten the seat belt securely.
• Warm up the engine and hydraulic oil before
operating machine.
• Before moving the machine, check the position of
undercarriage. The normal travel position is with
idler wheels to the front under the cab and the
drive sprockets to the rear. When the
undercarriage is in the reversed position, the
travel controls must be operated in opposite
directions.

Wheel Loader Safety SP000865

Page 22
MACHINE OPERATION

IMPORTANT
If you need more information or have any questions or
concerns about safe operating procedures or working
the wheel loader correctly in a particular application or
in the specific conditions of your individual operating
environment, please consult your local DOOSAN
representative.

Operate While Seated at Operator's

Station ONLY
Never reach in through a window to work a control. Do not
try to operate wheel loader unless you're in command
position - seated at controls. You should stay alert and
focused on your work at all times. Do not twist out of seat
if job activity behind you (or to the side) requires your
attention.
Use a spotter or signal person if you cannot see clearly and
HAOA151L
something is happening behind you.
Figure 13
Replace damaged safety labels and lost or damaged
operator's manuals.
Do not let anyone operate machine unless they've been fully
and completely trained, in safety and in operation of the
machine.

Seat Belts Should Be Used at All Times

Whenever engine is running, operator should be seated at
the control station with seat belt properly engaged.

Figure 14

Movement Alarms
If wheel loader is equipped with an audible travel movement
alarm, test alarm on a daily basis. Audible alarm should
sound as soon as travel system is engaged.

Wheel Loader Safety SP000865

Page 23
Travel Precautions
When traveling, wheel loader always keeps lights on; make
sure that you are in compliance with all state and local
regulations concerning warning flags and signs.
Never turn the starter switch to the "O" (OFF) position when
traveling. It is dangerous if the engine stops when the
machine is traveling. It will be impossible to operate the
steering unless the unit is equipped with an emergency
steering system.
Pilot control valve lever (joystick) should not be operated
while traveling.
Lower work equipment so that it is 400 mm (16 in) above
ground.
Never travel over obstacles or slopes that will cause
machine to tilt severely. Travel around any slope or obstacle
that causes 10° tilt, or more.
Do not operate the steering suddenly. The work equipment
may hit the ground and cause the machine to lose its
balance, and this may damage the machine or structures in
the area.
When traveling on rough ground, travel at low speed, and
avoid sudden changes in direction.
Always keep to the permissible water depth.
When traveling over bridges or structures on private land,
check first that the bridge or structure can withstand the
weight of the machine. When traveling on public roads,
check with the local authorities and follow their instructions.

Sloping Terrain Requires Caution

Dig evenly around work site whenever possible, trying to TURBO-II

gradually level any existing slope. If it's not possible to level

area or avoid working on a slope, reducing size and cycling )
m(16''
rate workload is recommended. 400 m
TURBO-II

On sloping surfaces, use caution when positioning wheel

loader before starting a work cycle. Stay alert for unstable
situations to avoid getting into them. For example, you
400 m
should always avoid working bucket over downhill side of m(16
'')
machine when parked perpendicular to slope. Avoid full AHO0970L
extensions of bucket in a downhill direction. Lifting bucket Figure 15
too high, too close to machine, while wheel loader is turned
uphill can also be hazardous.

Wheel Loader Safety SP000865

Page 24
Avoid High Voltage Cables
Serious injury or death can result from contact or proximity
to high voltage electric lines. The bucket does not have to
make physical contact with power lines for current to be
transmitted.
Use a spotter and hand signals to stay away from power
lines not clearly visible to operator.

Voltage Minimum Safe Distance

6.6 kV 3 m (9' 10")
33.0 kV 4 m (13' 1") Figure 16
66.0 kV 5 m (16' 5")
154.0 kV 8 m (26' 3")
275.0 kV 10 m (32' 10")

Use these minimum distances as a guideline only.

Depending upon voltage in line and atmospheric conditions,
strong current shocks can occur with boom or bucket as far
away as 4 - 6 m (13 - 20 ft) from power line. Very high
voltage and rainy weather could further decrease that safety
margin.
NOTE: Before starting any type of operation near power lines
(either above ground or buried cable type) you should
always contact power utility directly and work out a
safety plan with them.

Before Starting to Dig, Contact

Authorities
Below ground hazards also include natural gas lines, water
mains, tunnels and buried foundations. Know what's
underneath work site before starting to dig.

Be Aware of Height Obstacles

Any type of object in vicinity of boom could represent a
potential hazard, or cause operator to react suddenly and
cause an accident. Use a spotter or signal person working
near bridges, phone lines, work site scaffolds, or other
obstructions.

Wheel Loader Safety SP000865

Page 25
Use Care on Loose Support
Working heavy loads over loose, soft ground or uneven,
broken terrain can cause dangerous side load conditions
and possible tipover and injury. Travel without a load or
balanced load may also be hazardous.
If temperatures are changing, be cautious of dark and wet
patches when working or traveling over frozen ground. Stay
away from ditches, overhangs and all other weak support
surfaces. Halt work and install support mats or blocking if
work is required in an area of poor support.

Use Solid Support Blocking

Never rely on lift jacks or other inadequate supports when
work is being done. Block wheels fore and aft to prevent
any movement.

HDO1042L
Figure 17

Digging Beneath Overhangs

Digging beneath an overhang is dangerous. Overhang could
collapse on top of operator and cause serious injury or
death. Go on to another digging area before steep
overhangs are formed. Know height and reach limits of
wheel loader and plan ahead while working. Park wheel
loader away from overhangs before work shut down.

Digging Beneath Wheel Loader

Digging beneath wheel loader is dangerous. Earth beneath
could collapse. This could cause wheel loader to tip, which
could cause serious injury or death to operator. Working
around deep pits, trenching or along high walls may require
support blocks, especially after heavy rainfalls or during
spring thaws.

Wheel Loader Safety SP000865

Page 26
Stay Alert for People Moving Through
Work Area
When loading a truck you should always know where the
driver is.
Avoid loading over the cab of a truck even if the driver is in
a safe spot. Someone else could have gone inside, for any
number of reasons. Avoid working where unseen passersby
might be.
Slow down work cycle and use slower travel speeds in HAOA171L
congested or populated areas. Use a commonly understood Figure 18
signal so that other members of work crew can warn
operator to slow or halt work in an impending hazardous
situation.

Be Aware of and Conform to Local

Regulations
Minimum levels of insurance coverage, work permits or
certification, physical barriers around work site or restricted
hours of operation may be mandated by governing
authorities. There may also be guidelines, standards or
restrictions on equipment that may be used to perform
certain kinds of work. Check and follow all local
requirements, which may also be related to below ground
hazards and power lines.

Never Use Ether Starting Aids

An electric grid type manifold heater is used for cold
starting. Glowing heater element can cause ether or other
starting fluid to detonate, causing injury.

Figure 19

Wheel Loader Safety SP000865

Page 27
Observe General Safety Rules
Only trained and authorized personnel, with a good
knowledge and awareness of safe procedures, may be
allowed to operate or perform maintenance or service on
wheel loader.
All personnel at work site should be aware of assigned
individual responsibilities and tasks. Communication and
hand signals used should be understood by everyone.
Terrain and soil conditions at work site, approaching traffic,
weather related hazards and any above or below ground
obstacles or hazards should be observed and monitored by
all work crew members.

Take Time to Provide Good Visibility

Be careful not to go close to the edge of a cliff by mistake.
Use the machine only for its main purpose. Using it for
other purposes will cause failures.
To ensure an ample view, do as follows:
• When working in dark areas, attach working lights
and front lights to the machine. If necessary, set
up lighting at the work site.
• Stop operations when the visibility is poor, such
as in fog, mist, snow, and rain. Wait for the
visibility to improve to a level which causes no
problems for the operation.
• Keep dirt and dust off of windows and off lens
surfaces of work lights. Stop working if lights,
windows or mirrors need cleaning or adjustment.
To avoid hitting the work equipment, always do the following;
• When working in tunnels, on bridges, under
electric wires, or when parking the machine or
carrying out other operations in places with limited
height, be extremely careful not to hit the bucket
or other parts.
• To prevent collisions, operate the machine at a
safe speed when working in confined spaces,
indoors, or in crowded areas.
• Do not pass the bucket over the heads of workers
or over the operator's compartment of dump truck.

Wheel Loader Safety SP000865

Page 28
Keep "Pinch Point" Areas Clear - Use
Caution in Reverse
Use a signal person in high traffic areas and whenever
operator's view is not clear, such as when traveling in
reverse.
Anyone standing near wheels, or working assemblies of the
attachment, is at risk of being caught between moving parts
of machine.
Never allow anyone to ride on any part of machine or HAOA191L
attachment, including any part of operator's cab. Figure 20

Operate Carefully on Snow and Ice and

in Very Cold Temperatures
In icy cold weather avoid sudden travel movements and stay
away from even very slight slopes. Machine could skid off to
one side very easily.
Snow accumulation could hide or obscure potential hazards.
Use care while operating or while using machine to clear
snow.
Warming up engine for a short period may be necessary, to
avoid operating with sluggish or reduced working capacity.
Jolting shocks and impact loads caused by bumping or
bottoming boom or attachment are more likely to cause
severe stress in very cold temperatures. Reducing work
cycle rate and work load may be necessary.
When the temperature rises, frozen road surfaces become
soft, so the machine travel becomes unstable.
In cold weather, do not touch metal surfaces with your bare
hands. If you touch a metal surface in extremely cold
weather, your skin may freeze to the metal surface.

Wheel Loader Safety SP000865

Page 29
Parking Machine
Avoid making sudden stops, or parking machine wherever it
happens to be at the end of the work day. Plan ahead so
that the wheel loader will be on firm, level ground away
from traffic and away from high walls, cliff edges and any
area of potential water accumulation or runoff. If parking on
inclines is unavoidable, block wheels to prevent movement.
Lower bucket or other working attachment completely to
ground, or to an overnight support saddle. There should be
no possibility of unintended or accidental movement.
When parking on public roads, provide fences, signs, flags,
or lights, and put up any other necessary signs to ensure
that passing traffic can see the machine clearly. Park the
machine so that the machine, flags, and fences do not
obstruct traffic.

Shutdown Control Functions

After bucket has been lowered to overnight storage position,
move all switches and controls to "OFF" position. Pull
parking brake knob to "APPLIED" position. This will apply
parking brake. Move pilot cutoff switch to "LOCK" position.
This will disable pilot control valve lever (joystick). Move key
in starter switch to "OFF" position, and remove key from
switch.
Engage all lock-down security equipment that may have
been installed on machine.

IMPORTANT
When hydraulic system maintenance or service work
must be performed, be aware that accumulators in
system store fluid under pressure after system has been
shut down. To release hydraulic pressure in
accumulators, operate control with engine "OFF" until
accumulator pressure is completely dissipated.

Never Let Anyone Ride on Attachment

Never let anyone ride on any work attachment, such as the
bucket, crusher, grapple, or clamshell (grab bucket). There is
a potential danger of the person falling and suffering serious
injury.

HAAD4050
Figure 21

Wheel Loader Safety SP000865

Page 30
MAINTENANCE

Use Warning Tag During Service

Alert others that service or maintenance is being performed WARNING
and tag operator's cab controls - and other machine areas if
required - with a warning notice.
DO NOT OPERATE
Warning tags for controls are available from DOOSAN
distributors; see Figure 22. when performing inspection
or maintenance
190-00695A

FG012195
Figure 22

Clean Before Inspection or Maintenance

Clean the machine before carrying out inspection and
maintenance. This prevents dirt from getting into the
machine and also ensures safety during maintenance.
If inspection and maintenance are carried out when the
machine is dirty, it will become more difficult to locate the
problems, and also there is danger that you may get dirt or
mud in your eyes or that you may slip and injure yourself.
When washing the machine, do the following;
• Wear shoes with nonslip soles to prevent yourself
from slipping and falling on wet places.
• Wear safety glasses and protective clothing when
washing the machine with high-pressure steam.
• Take action to prevent touching high-pressure
water and cutting your skin or having mud fly into
your eyes. ARO1330L
Figure 23
• Do not spray water directly on electrical
components (sensors, connector) (1, Figure 23). If
water gets into the electrical system, there is
danger that it will cause defective operation and
malfunction.
Pick up any tools or hammers that are laying in the work
place. Wipe up any grease or oil or any other slippery
substances, and clean the area to make it possible to carry
out the operation in safety. If the work place is left untidy,
you may trip or slip and suffer injury.

Wheel Loader Safety SP000865

Page 31
Proper Tools
Use only tools suited to the task. Using damaged, low
qualify, faulty, or makeshift tools could cause personal injury.
There is danger that pieces from, chisels with crushed
heads, or hammers, may get into your eyes and cause
blindness.

HDO1037L
Figure 24

Use of Lighting
When checking fuel, oil, battery electrolyte, or window
washing fluid, always use lighting with anti-explosion
specifications. If such lighting equipment is not used, there
is danger of explosion.
If work is carried out in dark places without using lighting, it
may lead to injury, so always use proper lighting.
Even if the place is dark, never use a lighter or flame
instead of lighting. There is danger of fire. There is also
HDO1040L
danger that the battery gas may catch fire and cause and
Figure 25
explosion.

Fire Prevention and Explosion

Prevention
All fuels, most lubricants and some coolant mixtures are
flammable. Leaking fuel or fuel that is spilled onto hot
surfaces or onto electrical components can cause a fire.
Store all fuels and all lubricants in properly marked
containers and away from all unauthorized persons.
Store oily rags and other flammable material in a protective
container.
Do not smoke while you refuel the machine or while you are
in a refueling area.
Do not smoke in battery charging areas or in areas the
contain flammable material.
Clean all electrical connections and tighten all electrical
connections. Check the electrical wires daily for wires that
are loose of frayed. Tighten all lose electrical wires before
you operate the machine. Repair all frayed electrical wires
before you operate the machine.
Remove all flammable materials before they accumulate on
the machine.

Wheel Loader Safety SP000865

Page 32
This as a preview PDF file from best-manuals.com

Download full PDF manual at best-manuals.com