Doosan DL250. Operation and Maintenance Manual (2006)

DL250

Operation and Maintenance Manual

K1023774E

Serial Number 5001 and Up

November 2006

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.

K1023774E Operation and Maintenance Manual

Table of Contents

Safety

1-1

To the Operator of a Wheel Loader

1-1

General Safety Essentials

1-4

Location of Safety Labels

1-4

Unauthorized Modifications

1-13

General Hazard Information

1-13

Before Starting Engine

1-22

Machine Operation

1-26

Maintenance

1-34

Battery

1-45

Towing

1-47

Shipping and Transportation

1-48

Operating Controls

2-1

Component Locations

2-2

Operator's Area

2-4

Steering Console and Pedals

2-5

Front Instrument Panel

2-14

Right Side Switch Panel

2-25

Various Cabin Locations

2-41

Heater and Air Conditioner Operation

2-45

Stereo / CD Player (Optional)

2-50

Seat Adjustment

2-52

Seat Belt

2-54

Door Side Latch

2-55

Arm Rest

2-56

Fuse Box/Relay/Engine Emergency Stop Switch

2-57

Table of Contents

K1023774E

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 (Option)

3-16

Additional Braking

3-17

Boom Raise Kick-out

3-18

Bucket Angle Indicator

3-18

Boom Lower Kick-out (Option)

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

4-35

250 Hour / Monthly Service

4-41

500 Hour / 3 Month Service

4-46

1,000 Hour / 6 Month Service

4-53

1,500 Hour / 9 Month Service

4-61

2,000 Hour / Yearly Service

4-64

12,000 Hour / Six Year Service

4-70

Table of Contents

K1023774E

Severe Conditions Maintenance

4-71

Bolt Torque Chart

4-72

Electrical System

4-73

Engine Cooling System

4-75

Handling of Accumulator

4-77

Hydraulic Pressure Checks

4-78

Long Term Storage

4-83

Parking Brake Adjustment

4-84

Tires

4-86

Transportation

5-1

Loading and Unloading

5-1

Summary of Safety Precautions for Lifting

5-2

Troubleshooting

6-1

Engine

6-1

Hydraulic System

6-3

Travel System

6-5

Steering

6-6

Braking

6-7

Electrical System

6-7

Specification

7-1

General Specifications

7-1

Working Range and Dimensions

7-2

Working Capacities

7-4

Approximate Weight of Workload Materials

7-4

Index

8-1

Table of Contents

K1023774E

III

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.

The machine is designed for a maximum machine weight

(includes. equipment and attachments) of

14,500 kg

(32,077 lb) for DL250. 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

DL250 has a DOOSAN DL06 5.9 liter engine. The engine

has intercooling and is fitted with a common rail system.

The common rail system is positioned at an angle above the

pistons and are controlled via 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 via there. The Control Unit (for the machine)

receives signals from sensors on the machine and these are

passed to the Gauge Panel. The ECU controls the engine.

Power Transmission

The transmission is electrohydraulically 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 drive shafts. The axles

differentials use a LSD (Limited Slip Differential) design.

Presentation

K1023774E

I-II

Brake System

The machine is provided with a dual circuit, all hydraulic,

brake system with one circuit for each axle. Each circuit

meets the requirements for secondary brake capability.

Parking Brake

The parking brake is a dry disk brake built into the

transmission output shaft. The brake is applied by spring

force and is released hydraulically.

Steering System

The machine uses a load sensing, hydrodynamic steering

system. It has a steering arc of 40°.

Cabin

The cabin has a heating and ventilation system with

defrosting for front and rear windows. Air-conditioning is

standard. The cabin has two emergency exits, the door and

right side window.

FOPS and ROPS

The cabin is approved as a protective cabin according to

FOPS and ROPS standards. FOPS is an abbreviation of

Falling Object Protective Structure

(roof protection) and

ROPS is an abbreviation of Roll Over Protective Structure

(roll over protection).

Never carry out any unauthorized alterations to the cabin,

e.g. lowering the roof height, drilling, welding on brackets for

fire extinguisher, radio aerial or other equipment, without first

having discussed the alteration with personnel at the

DOOSAN Infracore Engineering Department. This department

will decide whether the alteration may cause the approval to

become void. It is important that all parties concerned are

aware of these regulations.

Hydraulic System

The hydraulic system use a triple vane pump which contains

three pumping sections.

The first pumping section supplies oil for the front

attachment. The second pumping section supplies oil for the

steering cyclinders. Surplus oil which is not necessary for

the steering function is directed into control valve to join the

first pump‘s oil.

Presentation

K1023774E

I-III

The third pump section is the cooling & brake & pilot pump,

used for brake & pilot line and cooling fan motor operation.

Equipment

The machine can be provided with different types of optional

equipment, depending on the requirements of different

markets. Examples of such equipment are lever steering,

Boom Suspension System (LIS), secondary steering, separate

attachment locking, automatic greasing.

CE MARKING, EMC DIRECTIVE

CE Marking

(Declaration of Conformity)

(Only applies to machines marketed within the EU/EEA.)

This machine is CE marked. This means that when

delivered the machine meets the applicable "Essential Health

and Safety Requirements," which are given in the Machinery

Safety Directive, 98/37EC.

Any person carrying out changes that affect the safety of

FG001781

the machine, is also responsible for the same.

Figure 2

As proof that the requirements are met, the machine is

supplied with an EU Declaration of Conformity, issued by

DOOSAN CE for each separate machine. This EU

declaration also covers attachments manufactured by

DOOSAN CE. The documentation is a valuable document,

which must be kept safe and retained for at least ten years.

The document should always accompany the machine when

it is sold.

If the machine is used for other purposes or with other

attachments than described in this manual, safety must at all

times and in each separate case be maintained. The person

carrying out such action is also responsible for the action

which, in some cases, may require a new CE marking and

the issue of a new EU Declaration of Conformity.

The EU EMC Directive

The electronic equipment of the machine may in some

cases cause interference to other electronic equipment, or

suffer from external electromagnetic interference, which may

constitute safety risks.

Presentation

K1023774E

I-IV

The EU EMC directive on "Electromagnetic Compatibility,"

89/336/EEC, provides a general description of what

demands can be made on the machine out of a safety point

of view, where permitted limits have been determined and

given according to international standards.

A machine or device which meets the requirements must be

CE marked. Our machines have been tested particularly for

electromagnetic interference. The CE marking of the

machine and the declaration of conformity also cover the

EMC directive.

If other electronic equipment is fitted to this machine, the

equipment must be CE marked and tested on the machine

with regard to electromagnetic interference.

COMMUNICATION EQUIPMENT

INSTALLATION

IMPORTANT

All installation of optional communication equipment

must be carried out by trained professionals and in

accordance with the DOOSAN CE instructions applicable

to the machine.

Protection Against Electromagnetic

Interference

This machine has been tested in accordance with EU

directive

89/336/EEC governing electromagnetic interference.

It is therefore very important that all nonapproved electronic

accessories, such as communication equipment, must be

tested before installation and use, since they can cause

interference to the electronic systems of the machine.

Presentation

K1023774E

I-V

PRODUCT PLATES

With the aid of the product plates, shown below, it is

possible to identify the machine and its components. The

Product Identification Number, PIN, indicates the model

designation, engine code and serial number of the machine.

The Component Identification Number, CIN, indicates the

serial number of the component. Make a note of the

identification numbers.

When ordering spare parts, and in all telephone enquiries or

correspondence the PIN and CIN must always be quoted.

1,2

FG006262

Figure 1

Reference

Description

Number

Primary Marking

The machine PIN (stamped into right side).

Product Plate

The manufacturer's name and address, machine PIN.

Additional Plate

Machine weight, engine output year of manufacture, year of delivery

for Product Plate

and position of CE mark (EU/EEA countries only).

The manufacturer's name and address, product number, machine

Cabin

model designation, max. machine weight, cabin serial number, ROPS/

FOPS number and ROPS/FOPS certificate number.

Engine

The engine type designation and number.

Front Axle

The manufacturer's name and address and front drive axle CIN.

Transmission

The manufacturer's name and address and transmission CIN.

Rear Axle

The manufacturer's name and address and rear drive axle CIN.

Presentation

K1023774E

I-VI

OP000433

1Safety

TO THE OPERATOR OF A

WHEEL LOADER

DANGER!

Improper use of wheel loader could cause serious injury

or death. Before operating wheel loader, or performing

maintenance, operator or technician must read and

understand entire Operation and Maintenance Manual.

Any operation, maintenance, traveling or shipping

methods that do not follow safety guidelines printed in

this Manual could cause serious injury or death.

Please respect the importance of taking responsibility for

your own safety, and that of other people who may be

affected by your actions.

The safety information on the following pages is organized

into the following sections:

“General Safety Essentials” on page 1-4

“Location of Safety Labels” on page 1-4

“Unauthorized Modifications” on page 1-13

“General Hazard Information” on page 1-13

“Before Starting Engine” on page 1-22

“Machine Operation” on page 1-26

“Maintenance” on page 1-34

“Battery” on page 1-45

“Towing” on page 1-47

10.

“Shipping and Transportation” on page 1-48

Safety

OP000433

1-1

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

must be alert to 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.

Safety

OP000433

1-2

Safety precautions are described in SAFETY from page 1-4

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.

Safety

OP000433

1-3

GENERAL SAFETY

ESSENTIALS

Accessory Applications

The 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

The operator should know and pay attention to the

information and warning plates/decals which are positioned

on the machine.

There are several specific warning signs on this machine.

The exact location of hazards and the description of the

hazards are reviewed in this section.

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.

Safety

OP000433

1-4

1. Warnings for Operation, Inspection

and Maintenance (4190-2545A,

190-00092)

CAUTION!

•

Read manual and labels before

operation and maintenance. Follow

instructions and warnings in manual

and on labels on machine.

•

Sound horn to alert people nearby

before operating, and make sure all

persons are clear of area.

•

Always make sure when leaving

operator's seat to:

•

Lower bucket or other working

ACO1360L

tools to ground.

•

"LOCK" transmission selector in

"NEUTRAL."

•

Set park brake.

•

Turn starter switch "OFF." Remove key from switch.

•

If hydraulic components and units are ABNORMAL, consult nearest DOOSAN dealer or

authorized service shop. Do not attempt to make an overhaul.

2. Warnings for Cooling Fan

(2190-3315, 190-00557)

WARNING!

Keep your hands away from the fan during

operation. Entanglement in the fan can cause

serious injury.

AMO0390L

Safety

OP000433

1-6

5. Warnings for Handling Accumulator

(190-00703, 190-00099)

WARNING!

Explosion hazard:

•

Keep away from flame.

•

Do not weld or drill.

ACO1480L

Accumulator

Wheel loader pilot control system is equipped with an

accumulator. Accumulator will store a pressure charge that

may enable hydraulic controls to be activated for a brief

period of time after engine has been shut down. Activation

of any controls may enable selected function to operate

under force of gravity.

CAUTION!

Any raised attachment will lower to ground if

accumulator holds a charge.

When shutting machine down, lower front attachment to

ground. After engine has been shut down, turn key to "ON"

position and move joystick controls to release pressure in

accumulator. Remove key.

IMPORTANT

Refer to Shop Manual for service procedures. Do not

release any pilot lines until pressure within accumulator

has been released.

Safety

OP000433

1-8

8. Warnings for High Temperature

Coolant (190-00692, 190-00097)

WARNING!

To prevent hot water from spurting out:

•

Turn engine "OFF."

•

Allow water to cool.

•

Slowly loosen cap to relieve

pressure before removing.

ACO1410L

9. Warnings for Battery Maintenance

(2190-2533A, 190-00100)

DANGER!

•

Battery fumes can explode. Keep

sparks and flames away from

batteries.

•

Always avoid storing metals like

tools or inflammable materials

around or on batteries. Explosion or

fire

can be caused by short

circuiting batteries.

•

Sulfuric

acid

battery

poisonous. It is strong enough to

burn skin, eat holes in clothing, and

cause blindness if splashed in eyes.

If you spill acid on yourself:

Flush your skin with water.

ACO1400L

Apply baking soda or lime to help

neutralize acid.

Flush your eyes with water for 10 -

15 minutes.

Get medical attention immediately.

Safety

OP000433

1-10

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.

Safety

OP000433

1-13

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 cabin floor and consoles free of tools and personal

items.

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 cabin.

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, lower the work equipment

completely 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.

Safety

OP000433

1-14

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 highly 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 2

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

70 dB(A).

Measurement is obtained on a dynamic machine

following the procedures and cabin conditions as

described in ISO 6396.

NOTE: The guaranteed sound power level emitted by the

machinery for this machine is 105 dB(A).

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.

Safety

OP000433

1-15

Recommendations for Limiting

Vibrations

Select the right machine, equipment and attachments

for a particular application.

Replace any damaged seat by a genuine DOOSAN

part. Keep the seat maintained and adjusted.

•

Adjust the seat and suspension for the weight and

size of the operator.

•

Inspect and maintain the suspension and

adjustment mechanisms of the seat regularly.

Check that the machine is properly maintained.

•

Tire pressure, brakes, steering, linkages, etc.

Steer, brake, accelerate, shift gears, move the

attachments and load the attachments smoothly.

Adjust the machine speed and travel path to reduce

the vibration level.

•

Slow down if it is necessary when passing rough

terrain.

•

Drive around obstacles and excessive rough

terrain conditions.

Keep the terrain on work sites where the machine is

working and traveling in good condition.

•

Remove any large rocks or obstacles.

•

Fill any ditches and holes.

•

Provide machines for and schedule time to

maintain the terrain conditions.

Travel over longer distance

(e.g. on public roads) at

adjusted (medium) speed.

•

Always adjust the speed for preventing bouncing.

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 3

•

Use water for cleaning to keep down the dust.

•

Work on the machine or component with the wind

at your back whenever possible.

Safety

OP000433

1-16

•

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 jump on or off the 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 4

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.

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

Figure 5

filling nozzle. In very cold, dry weather or other conditions

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.

Safety

OP000433

1-17

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

replace 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 6

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 7

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.

going between movable parts is necessary, always

HDO1010L

position and secure the work equipment so that it cannot

Figure 8

move.

Safety

OP000433

1-18

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 cabin. Check and service the fire

extinguisher at regular intervals and make sure

HDO1009L

that all work site crew members are adequately

Figure 9

trained in its 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 to the "O"

(OFF) position

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.

Protection from Falling or Flying Objects

On work sites where there is danger that falling objects or

flying objects may hit the operator's cabin select a guard to

match the operating conditions to protect the operator.

Working 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

cabin could be required in form of a FOPS/Falling Object

Protective Structure and/or ROPS/Roll Over Protective

Structure reinforcement system.

HAOA110L

Figure 10

Safety

OP000433

1-19

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,

remounting or relocating fasteners. Any serious impact or

damage to the system requires a complete integrity

HAOA100L

reevaluation. Reinstallation, recertification and/or replacement

Figure 11

of the system may be necessary.

Install Additional Safety Equipment If

Conditions Require

Laminate glass protection for the front, side or rear windows,

along with tempered glass, 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 cabin. 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.

Attachment Precautions

Option kits are available through your dealer. Contact

DOOSAN for information on available 3 spool control valve

and log fork piping / valving / auxiliary control kits. Because

DOOSAN cannot anticipate, identify or test all of the

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.

Safety

OP000433

1-20

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 “Handling of Accumulator” on page 4-77.

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, fatal accidents and

death.

Make sure there is adequate ventilation before starting the

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

ARO1770L

the wind, exposing others to danger.

Figure 12

Safety

OP000433

1-21

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 13

each utility and identify their locations. Be careful not to

damage or cut any of these lines.

Check the condition of the river bed, and the depth and flow

of the water before operating in water or crossing a river.

NEVER be in water that is in excess of the permissible

water depth. Refer to

“Allowable Water Depth” on

page 3-22.

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.

Safety

OP000433

1-22

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.

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 safety guard 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.

Safety

OP000433

1-23

Engine Starting

Walk around your machine before getting in the operator's

cabin. 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 the machine is being

operated.

Look around the work site area for potential hazards, people

or properly that could be at risk while operation is in

progress.

NEVER start the engine if there is any indication that

maintenance or service work is in progress, or if a warning

tag is attached to controls in the cabin.

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 the engine. Listen for unusual noises and

remain alert for other potentially hazardous conditions at the

start of the 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.

Safety

OP000433

1-24

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.

Safety

OP000433

1-25

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 14

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 Must Be Used at All Times

Whenever engine is running, operator must be seated at the

control station with seat belt properly engaged.

Figure 15

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.

Safety

OP000433

1-26

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. Refer to

“Allowable Water Depth” on page 3-22.

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

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

area or avoid working on a slope, reducing size and cycling

rate workload is recommended.

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

should always avoid working bucket over downhill side of

machine when parked perpendicular to slope. Avoid full

extensions of bucket in a downhill direction. Lifting bucket

too high, too close to machine, while wheel loader is turned

AHO0970L

uphill can also be hazardous.

Figure 16

Safety

OP000433

1-27

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")

Figure 17

33.0 kV

4 m (13' 1")

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.

Safety

OP000433

1-28

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.

Digging Beneath Overhangs

Digging beneath an overhang is dangerous. Overhang could

collapse on top of operator and cause serious injury or

HDO1042L

death. Go on to another digging area before steep

Figure 18

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.

Stay Alert for People Moving Through

Work Area

When loading a truck you should always know where the

driver is.

Avoid loading over the cabin 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 19

signal so that other members of work crew can warn

operator to slow or halt work in an impending hazardous

situation.

Safety

OP000433

1-29

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 20

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 must be aware of assigned

individual responsibilities and tasks. Communication and

hand signals used must 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 must be observed and monitored by all

work crew members.

Safety

OP000433

1-30

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.

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 cabin.

Figure 21

Safety

OP000433

1-31

Operate Carefully on Snow and Ice, In

Very Cold Temperatures

In icy cold weather avoid sudden travel movements and stay

away from even very slight slopes. The machine could skid

off to one side very easily.

Snow accumulation could hide or obscure potential hazards.

Use care while operating or while using the machine to

clear snow.

Warming up the engine for a short period may be

necessary, to avoid operating with sluggish or reduced

working capacity. The jolting shocks and impact loads

caused by bumping or bottoming the 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.

Parking Machine

Avoid making sudden stops, or parking the 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 the wheels to prevent

movement. Lower the bucket or other working attachment

completely to the ground, or to an overnight support saddle.

There must 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, and park

the machine so that the machine, flags, and fences do not

obstruct traffic.

Safety

OP000433

1-32

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 danger of the person falling and suffering serious injury.

HAAD4050

Figure 22

Safety

OP000433

1-33

MAINTENANCE

Use Warning Tag During Service

Alert others that service or maintenance is being performed

and tag operator's cabin controls - and other machine areas

if required

- with a warning notice.

Warning tags for controls are available from DOOSAN

WARNING

distributors; see Figure 23.

HAOC920L

Figure 23

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 24

•

Do not spray water directly on electrical

components (sensors, connector) (1, Figure 24). 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.

Safety

OP000433

1-34

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 25

Use of Lighting

When checking fuel, oil, battery electrolyte, or window

washing fluid, always use lighting with antiexplosion

specifications. If such lighting equipment is not used, there

is danger of an 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 26

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.

HDO1015I

Figure 27

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.

Safety

OP000433

1-35

Do not weld on pipes or on tubes that contain flammable

fluids. Do not flame cut on pipes or on tubes that contain

flammable fluids. Before you weld on pipes or on tubes or

before you flame cut on pipes or on tubes, clean the pipes

or tubes thoroughly with a nonflammable solvent.

Burn Prevention

When checking the radiator coolant level, shut down engine,

let the engine and radiator cool down, then check the

coolant recovery tank. If the coolant level in the coolant

recovery tank is near the upper limit, there is enough

coolant in the radiator.

Loosen the radiator cap gradually to release the internal

pressure before removing the radiator cap.

If the coolant level in the coolant recovery tank is below the

lower limit, add coolant.

Cooling system conditioner contains alkali. Alkali can cause

personal injury. Do not allow alkali to contact the skin, the

eyes, or the mouth.

Allow cooling system components to cool before you drain

the cooling system.

Hot oil and hot components can cause personal injury. Do

not allow hot oil or hot components to contact the skin.

Remove the hydraulic tank filter plug only after the engine

has been stopped. Make sure that the hydraulic tank filter

plug is cool before you remove it with your bare hand.

Remove the hydraulic tank filter plug slowly to relieve

pressure.

Relieve all pressure in the hydraulic oil system, in the fuel

system, or in the cooling system before you disconnect any

HAAE1980

lines, fittings, or related items.

Figure 28

Batteries give off flammable fumes that can explode.

Do not smoke while you are checking the battery electrolyte

levels.

Electrolyte is an acid. Electrolyte can cause personal injury.

Do not allow electrolyte to contact the skin or the eyes.

Always wear protective glasses when you work on batteries.

Safety

OP000433

1-36

Welding Repairs

CAUTION!

When you connect or disconnect connectors between

ECU and Engine or connector between ECU and the

machine, always disconnect the source power to protect

damage of the ECU.

If you don't observe this procedure, the ECU would be

gamaged or the engine would operate abnormally.

When carrying out welding repairs, carry out the welding in

a properly equipped place. The welding should be performed

by a qualified worker. During welding operations, there is the

danger of, generation of gas, fire, or electric shock, so never

let an unqualified worker do welding.

The qualified welder must do the following:

•

To prevent explosion of the battery, disconnect

the battery terminals and remove batteries.

•

To prevent generation of gas, remove the paint

from the location of the weld.

•

If hydraulic equipment, piping or places close to

them are heated, a flammable gas or mist will be

generated and there is danger of it catching fire.

To avoid this, never subject these places to heat.

•

Do not weld on pipes or on tubes that contain

flammable fluids. Do not flame cut on pipes or on

tubes that contain flammable fluids. Before you

weld on pipes or on tubes or before you flame

cut on pipes or on tubes, clean the pipes or

tubes thoroughly with a nonflammable solvent.

•

If heat is applied directly to rubber hoses or

piping under pressure, they may suddenly break

so cover them with a fireproof covering.

•

Wear protective clothing.

FG008124

•

Make sure there is good ventilation.

Figure 29

•

Remove all flammable objects and provide a fire

extinguisher.

Safety

OP000433

1-37

Treatment for Electrical Welding to the Body Structure

To prevent damage to ECU by electrical welding, please

observe the following procedures.:

Open the cover of the battery box.

Detach the positive and negative terminal (Figere 29, 1

and 2)of cable from the battery.

Open the side cover and detach the connector (Figure

30, 1) from the ECU that are installed at the engine.

Proceed with welding.

FG008123

Figure 30

Precautions for Removal, Installation,

and Storage of Attachments

Before starting removal and installation of attachments,

decide the team leader.

Do not allow anyone except the authorized workers close to

the machine or attachment.

Place attachments that have been removed from the

machine in a safe place so that they do not fall. Put up a

fence around the attachments and take other measures to

HDO1041L

prevent unauthorized persons from entering.

Figure 31

Precautions When Working on Machine

When carrying out maintenance operations on the machine,

keep the area around your feet clean and tidy to prevent

you from falling. Always do the following:

•

Do not spill oil or grease.

•

Do not leave tools laying about.

•

Watch your step when walking.

Never jump down from the machine. When getting on or off

ARO1380L

the machine, use the steps and handrails, and maintain a

Figure 32

three-point contact

(both feet and one hand or both hands

and one foot) to support yourself securely.

If the job requires it, wear protective clothing.

To prevent injury from slipping or falling, when working on

the hood or covers, never use any part except the

inspection passage fitted with nonslip pads.

Safety

OP000433

1-38

Lock Inspection Covers

When carrying out maintenance with the inspection cover

open, lock the cover securely in position with the lock bar.

If maintenance work is carried out with the inspection cover

open but not locked, there is danger that it may suddenly

close and cause injury if there is a gust of wind.

Crushing Prevention and Cutting

Prevention

You should always have at least two people working

together if the engine must be run during service. One

person needs to remain in the operator's seat, ready to

work the controls or stop the machine and shut off the

engine.

Unless you are instructed otherwise, never attempt

adjustments while the machine is moving or while the

engine is running.

Stay clear of all rotating parts and moving parts.

Keep objects away from moving fan blades. The fan blades

will throw objects and the fan blades can cut objects.

Do not use a wire rope cable that is kinked or flayed. Wear

gloves when you handle a wire rope cable.

When you strike a retainer pin, the retainer pin might fly out.

The loose retainer pin can injure personnel. Make sure that

the area is clear of people when you strike a retainer pin.

To avoid injury to your eyes, wear protective glasses when

you strike a retainer pin.

Do Not Run Engine If Repairs or Work

Are Being Performed Alone

You should always have at least two people working

together if engine must be run during service. One person

needs to remain in operator's seat, ready to work controls or

stop machine and shut "OFF" engine.

Always Use Adequate Equipment

Supports and Blocking

Do not allow weight or equipment loads to remain

suspended. Lower everything to ground before leaving

operator's seat. Do not use hollow, cracked or unsteady,

wobbling weight supports. Do not work under any equipment

supported solely by a lift jack.

Safety

OP000433

1-39

Do Not Work on Hot Engines or Hot

Cooling or Hydraulic Systems

Wait for engine to cool off after normal operation. Park

wheel loader on firm, level ground and lower all equipment

before shutting down and switching "OFF" controls. When

engine lube oil, gearbox lubricant or other fluids require

change, wait for fluid temperatures to decrease to a

moderate level before removing drain plugs.

NOTE: Oil will drain more quickly and completely if it is

warm. Do not drain fluids at temperatures exceeding

95°C (203°F), however do not allow full cool down.

Hydraulic Cylinder Seals Require

Periodic Replacement

Check cylinder drift rate at regular intervals. Overhaul seal

kits are available through DOOSAN.

High-pressure Hydraulic Lines Can Store

a Great Deal of Energy

Exposed hydraulic hoses on arm could react with explosive

force if struck by a falling rock, overhead obstacle or other

work site hazard. Extra safety guards may be required.

NEVER allow hoses to be hit, bent or interfered with during

operation.

Cool Down Is Required Before Radiator

or Reservoir Checks

Shut down engine and allow heat to dissipate before

performing service on engine radiator or hydraulic fluid

reservoir. Both assemblies have air vent levers at or near fill

cap for venting built-up air pressure. Release levers before

trying to take off fill caps and LOOSEN CAPS SLOWLY,

before removal.

HAOA060L

Figure 33

Safety

OP000433

1-40

Precautions with High-pressure Line,

Tubes and Hoses

When inspecting or replacing high-pressure piping or hoses,

check that the pressure has been released from the circuit.

Failure to release the pressure may lead to serious injury.

Always do the following:

•

Wear protective glasses and leather gloves.

•

Fluid leaks from hydraulic hoses or pressurized

components can be difficult to see but pressurized

oil has enough force to pierce the skin and cause

serious injury. Always use a piece of wood or

cardboard to check for suspected hydraulic leaks.

Never use your hands or expose your fingers.

•

Do not bend high-pressure lines. Do not strike

high-pressure lines. Do not install lines, tubes or

hoses that are bent or damaged.

•

Make sure that all clamps, guards and heat

shields are installed correctly to prevent vibration,

rubbing against other parts, and excessive heat

during operation.

HDO1045I

- If any of the following conditions are found,

Figure 34

replace the part.

- Damage or leakage from hose end.

- Wear, damage, cutting of covering, or

exposure of strengthening wire layer.

- Cover portion is swollen in places.

- There is twisting or crushing at movable

parts of hose.

- Foreign material is embedded in the

covering.

- Hose end is deformed.

NOTE:

Refer to “Hose In-service Lifetime Limit (European

Standard ISO 8331 and EN982 CEN)” on page 4-70,

for additional European regulations.

Obtain Immediate Medical Attention if

Pressurized Oil Pierces Skin.

WARNING!

Failure to obtain prompt medical assistance could result

in gangrene or other serious damage to tissue.

Safety

OP000433

1-41

Use Correct Replacement Fasteners

Tightened to Proper Torque

Refer to "General Maintenance" section of Shop Manual for

information on tightening torques and recommended

assembly compounds and always use correct part.

Poor or incorrect fastener connections can dangerously

weaken assemblies.

Safety Critical Parts Must Be Replaced

Periodically

Replace following fire related components as soon as they

begin to show any sign of wear, or at regular periodic

intervals, whether or not deterioration is visible:

•

Fuel system flexible hoses, the tank overflow drain

hose and the fuel fill cap.

•

Hydraulic system hoses, especially the pump

outlet lines and front and rear pump branch hoses.

•

Keep mounting brackets and hose and cable

routing straps tight. Hose routing should have

gradual bends.

Dispose of All Petroleum Based Oils

and Fluids Properly

Physical contact with used motor oil may pose a health risk.

Wipe oil from your hands promptly and wash off any

remaining residue.

Used motor oil is an environmental contaminant and may

only be disposed of at approved collection facilities. To

prevent pollution of the environment, always do the following:

•

Never dump waste oil in a sewer system, rivers, etc.

HAOA470L

•

Always put oil drained from your machine in

Figure 35

containers. Never drain oil directly onto the ground.

•

Obey appropriate laws and regulations when

disposing of harmful materials such as oil, fuel,

solvent, filters, and batteries.

Check Tire Pressure and Condition

Maintain tire pressure but do not overinflate. Inspect tires

and wheels daily. When inflating tires, follow procedures in

Maintenance Section, which include using an extension to

allow you to avoid standing in front of or over a tire. Do not

change a tire unless you have both experience and proper

equipment.

NOTE: Refer to “Recommended Air Pressure” on page 4-88

Safety

OP000433

1-42

Decreasing Risk of Injuries or Death

From Boom and Bucket

DANGER!

When operating machine or making repairs, never allow

bystanders in the operational zone or repair area.

Operation and service personnel must be careful when

working around the machine, especially around the

boom and bucket.

An unexpected fall of the front structure may cause

injuries or death.

While operating a machine, do not let people enter the

operational area. The sudden collapse of the front

structure caused from a hose failure may result in

injuries or death.

Figure 36

When stopping or parking the machine, lower the front

structure to the ground. If not, the sudden collapse of

the front structure caused from a hose failure may

result in injuries or death.

Figure 37

Safety

OP000433

1-43

When repairing or inspecting the machine, with the

front structure raised in the air, firmly support the front

structure. When installing the supporting structure,

verify that it can handle the load.

High-pressure loads between the boom structure and

support may cause the support to slip, causing the

boom to collapse, leading to injuries or death. Take the

installation location of support and supporting surface

into consideration.

A supporting structure must be used, when

disconnecting front hoses or removing any other

mechanical component related to the front structure.

High-pressure oil can be ejected from the front cylinder

to release its static pressure and force. A sudden shift

of a front structure load may cause a boom collapse

leading to injuries or death.

FG004996

Figure 38

WARNING!

Pressurized oil has enough force to pierce the skin

and cause a serious injury.

Safety

OP000433

1-44

BATTERY

Battery Hazard Prevention

Battery electrolyte contains diluted sulfuric acid and batteries

generate hydrogen gas. Hydrogen gas is highly explosive,

and mistakes in handling them can cause serious injury or

fire. To prevent problems, always do the following:

•

Do not smoke or bring any flame near the battery.

•

When working with batteries, ALWAYS wear

safety glasses and rubber gloves.

•

If you spill battery electrolyte on yourself or your

clothes, immediately flush the area with water.

•

If battery electrolyte gets into your eyes, flush

them immediately with large quantities of water

and see a doctor at once.

•

If you accidentally drink battery electrolyte, drink a

large quantity of water or milk, raw egg or

vegetable oil. Call a doctor or poison prevention

center immediately.

•

When cleaning the top surface of the battery,

wipe it with a clean, damp cloth. Never use

gasoline, thinner, or any other organic solvent or

detergent.

•

Tighten the battery caps securely.

•

Explosive battery gas can be set off by sparks

from accidental contact or static discharge. Turn

"OFF" all switches and engine when working on

batteries. Keep battery terminals tight. Contact

between a loose terminal and post can create an

Figure 39

explosive spark.

•

If the battery electrolyte is frozen, do not charge

the battery or start the engine with power from

another source. There is danger that the battery

may catch fire.

•

When charging the battery or starting with power

from another source, let the battery electrolyte

melt and check that there is no leakage of battery

electrolyte before starting the operation.

•

Always remove the battery from the machine

before charging.

Safety

OP000433

1-45

Disconnect Batteries Before Electrical

Service or Electrical Welding

Remove cable to negative terminal first when disconnecting

cable. Connect positive terminal cables first when installing a

battery.

Use Low Heat Portable Lighting

Hot surfaces on trouble lights or portable work lights can set

off fuel or battery explosive gases.

Boost Starting or Charging Engine

Batteries

If any mistake is made in the method of connecting the

booster cables, it may cause an explosion or fire. Always do

the following:

•

Turn off all electrical equipment before connecting

leads to the battery. This includes electrical

switches on the battery charger or boost starting

equipment.

HAOA310L

•

When boost starting from another machine or

Figure 40

vehicle do not allow the two machines to touch.

Wear safety glasses or goggles while required

battery connections are made.

•

24 volt battery units consisting of two series

connected twelve volt batteries have a cable

connecting one positive terminal on one of the 12

volt batteries to a negative terminal on the other

battery. Booster or charger cable connections

must be made between the nonseries connected

positive terminals and between the negative

terminal of the booster battery and the metal

frame of the machine being boosted or charged.

Refer to the procedure and illustration in “Starting

with Auxiliary Batteries” on page 3-8 of this

manual.

•

Connect positive cable first when installing cables

and disconnect the negative cable first when

removing them. The final cable connection, at the

metal frame of the machine being charged or

boost started, must be as far away from the

batteries as possible.

Safety

OP000433

1-46

TOWING

Precautions When Towing

If any mistake is made in the method of selecting or

inspecting the towing wire or in the method of towing, it may

lead to serious personal injury. Always do the following:

•

Always use the method of towing given in this

Operation and Maintenance Manual. Do not use

any other method.

•

Use leather gloves when handling the wire rope.

•

When carrying out the preparation work for towing

with two or more workers, determine the signals

to use and follow these signals correctly.

•

If the engine on the problem machine will not

start or there is a failure in the brake system.

always contact your DOOSAN distributor.

•

Never go between the towing machine and the

towed machine during the towing operation.

•

It is dangerous to carry out towing on slopes, so

select a place where the slope is gradual. If there

is no place where the slope is gradual, carry out

operations to reduce the angle of the slope before

starting the towing operation.

•

When towing a problem machine, always use a

wire rope with a sufficient towing capacity.

•

Do not use a frayed, kinked rope or a rope with

any loss of diameter.

Safety

OP000433

1-47

SHIPPING AND

TRANSPORTATION

Obey State and Local Over-the-Road

Regulations

Check state and local restrictions regarding weight, width

and length of a load before making any other preparation for

transport.

The hauling vehicle, trailer and load must all be in

compliance with local regulations governing the intended

shipping route.

Partial disassembly or teardown of wheel loader may be

necessary to meet travel restrictions or particular conditions

at the work site.

Refer to “Transportation” on page 5-1, of this Operation and

Maintenance Manual for information on loading, unloading

and towing.

Safety

OP000433

1-48

OP000434

2Operating Controls

The "Operating Controls" section presented here consists of

the following groups:

“Component Locations” on page 2-2

“Operator's Area” on page 2-4

“Steering Console and Pedals” on page 2-5

“Front Instrument Panel” on page 2-14

“Right Side Switch Panel” on page 2-25

“Various Cabin Locations” on page 2-41

“Heater and Air Conditioner Operation” on page 2-45

“Stereo / CD Player (Optional)” on page 2-50

“Seat Adjustment” on page 2-52

10.

“Seat Belt” on page 2-54

11.

“Door Side Latch” on page 2-55

12.

“Arm Rest” on page 2-56

13.

“Fuse Box/Relay/Engine Emergency Stop Switch” on

page 2-57

Each group is explained with a point location drawing or

photo and a brief description of each control, switch, gauge

or valve.

Indicator lights work besides the gauges on the instrument

panel. The operator should monitor machine pressure on the

instrument panel along with indicator lights. These lights will

only show that there is a problem.

WARNING!

Warning lights. When any one or more of the warning

lights on the control console come "ON," immediately

stop operation and shut down unit. Investigate and

correct problem before proceeding with operation.

Operating Controls

OP000434

2-1

Reference

Description

Number

Bucket Teeth

CAC Cooler

Bucket

Radiator

Rear Wheel Cover

Grille

Air Conditioner Condenser

Fan

Battery Box

Fuel Tank

Rear Light

Engine Oil Fill Cap

Counterweight

Engine Oil Filter

Fan Motor

Engine Oil Level Dipstick

Towing Pin

Rear Axle Pivot

Muffler Tail Pipe

Rear Axle

Oil Tank

Drive Shaft (Rear)

Tilt Lever

Transmission

Front Wheel Cover

Transmission Oil Filter

Bucket Cylinder

Drive Shaft (Center)

Headlight Support

Center Pin

Ladder

Steering Wheel Cylinder

Work Light

Boom Cylinder

Operator's Cabin

Drive Shaft (Front)

Air Cleaner

Parking Brake

Engine Air Intake Precleaner

Front Axle

Engine

Loader Arm

Muffler

Link

Operating Controls

OP000434

2-3

STEERING CONSOLE AND

PEDALS

FG006191

Figure 3

Reference

Description

Number

Starter Switch

Steering Wheel

Horn Button

Kick-down Switch

Combination Switch

Transmission Lever

Accelerator Pedal

Front Instrument Panel

(See page 2-14)

Steering Wheel Adjustment

Lever

Hour Meter

Brake Pedals

Hazard Warning Light Switch

Operating Controls

OP000434

2-5

Starter Switch

A three-position starter switch is used to start or shut

down engine for equipment operation.

O. Turning the switch to this position turns the

engine "OFF" along with its electrical system. In

this position the engine is "OFF" but the interior

cabin light and fuel tank transfer pump

(if

equipped) are functional.

Turning the switch to this position turns the

FG000014

engine electrical system "ON." When the switch is

Figure 4

first turned "ON" the six indicator/warning lights

across the top of the instrument panel, will light

for approximately two seconds. The battery

warning light and the engine oil pressure warning

light should remain "ON" after the other four have

turned "OFF."

NOTE: Preheat Indicator Light - The operation of

the preheat cycle depends on coolant

temperature. When the engine coolant is

cold enough, the preheat indicator light will

remain "ON" until the engine preheat cycle

is completed. The preheat cycle takes

about twenty seconds to complete, and

the indicator light will turn "OFF." When

the light turns "OFF," engage the starter.

. Moving switch to this position will crank engine.

When engine starts, release key and allow it to

return to the "I" (ON) position. Do not operate the

starter switch for more than fifteen seconds at a

time. This will help prevent damage to starter.

WARNING!

DO NOT USE STARTING FLUIDS. The preheat

system could cause the starting fluid to explode.

Starting fluids should never be used.

Operating Controls

OP000434

2-6

2. Horn Button (Two Places)

Pressing the button at the end of the combination

switch (Figure 5) or the lowest button at the tip of the

pilot control valve lever(joystick)(Figure 6) or the left (2-

lever)

/ center

(3-lever) button at the tip of the pilot

control valve lever

(finger tip, option)

(Figure

7) the

horn will sound.

NOTE: Starter switch must be "ON."

AHO0890L

Figure 5

FG003941

Figure 6

FG003935

Figure 7

Operating Controls

OP000434

2-7

Combination Switch

Left Side Directional Switch

- Pushing lever

forward, activates left outside directional lights and

directional indicator light on instrument panel.

Right Side Directional Switch - Pulling lever back,

activates right outside directional lights and

directional indicator light on instrument panel.

NOTE: When turn is completed the lever

automatically returns to the "NEUTRAL"

AHO0920L

position. Should it not, it can be manually

Figure 8

returned by hand.

NOTE: Turn signals will function with starter

switch in "OFF" position.

Window Washer Switch - When the outside area

of the lever is pressed, it activates the washer

pump and sprays fluid on the windshield.

(Only

while being pressed.)

NOTE: Do not operate the windshield washer

without any fluid. If operate without any

fluid, the washer motor may be damaged.

Check level in washer tank, and add fluid

as required.

NOTE: Using soapy water or synthetic detergent

instead of window cleaning fluid, may

damage the wiper blade or painted

surfaces. Use standard window cleaning

fluid: SSK703

Horn Button - The center button on end of lever

activates horn. (Only while being pressed.)

Wiper Switch

- Activates wipers when outside

area of lever is rotated.

J: Intermittent Mode - wipes every five seconds.

0: Stop (Off).

I: Normal Speed Mode.

II: High Speed Mode.

Push Down - Locks into position and light turns

"ON" the high beams.

Neutral Position - Normal low beams.

Pull Up

- Momentarily turns "ON" both the low

beams and high beams. (Returns to "NEUTRAL"

position when released.)

NOTE: High and low beams will only function with the

headlight switch in the "||" position.

HAAA4350

Figure 9

Operating Controls

OP000434

2-8

4. Accelerator Pedal

Controls the travel speed of loader and working speed

of load handling system.

CAUTION!

The further the pedal is pressed, the more engine

speed increases. However, do not press the pedal

more than necessary; otherwise it will increase fuel

FG006192

consumption, cause short life on the engine, and in

Figure 10

the worst case lead to a serious accident.

5. Steering Wheel Adjustment Lever

Control lever

(1, Figure 11) is used allow wheel to be

moved to the most convenient position for the operator.

Adjusting Steering Wheel Tilt

Pull lever

(1, Figure

12) upward and move wheel (2,

Figure

12) to desired position. Push lever down

(Tilt

angle is 21°).

Adjusting Steering Wheel Telescopic

FG003887

Pull lever

(1, Figure

12) upward and move wheel (2,

Figure 11

Figure

12) to desired position. Push lever down

(telescopic stroke is 80 mm)

RELEASE

LOCK

FG003888

Figure 12

Operating Controls

OP000434

2-9

6. Brake Pedal (Right and Left Pedals)

Pressing brake pedal will apply the brakes to the

loader. The brake pedal modes can be switched from

"INCHING" to "NO INCHING" or vice versa, by using

the transmission cutoff switch (See page 2-34).

CAUTION!

FG002183

When descending down an incline, slow down the

Figure 13

machine by using both the brake pedal and the

engine as a brake by shifting the transmission to a

lower gear. Using the brake pedal too often might

lead to insufficient oil pressure, thus making it

difficult to brake the loader.

IMPORTANT

Do not use brake pedal as a foot rest. This will

cause brake disk to wear faster than normal, and

this could cause brake failure.

7. Steering Wheel

Rotating steering wheel controls position of front wheels

and this determines direction of machine travel.

FG006194

Figure 14

Operating Controls

OP000434

2-10

8. Kick-down Switch (Two places)

When transmission is in 2nd gear, pressing this switch

will shift transmission into

1st gear. This will allow the

driver to perform a quick digging movement.

NOTE: Kick-down is "RELEASED" when transmission

is placed in "NEUTRAL" position or the switch is

pressed again.

Kick-down function range:

AHO0900L

•

Automatic: 2nd, 3rd, 4th.

Figure 15

•

Manual: 2nd.

A second kick-down switch(Figure 16) is on the reverse

side button in the tip of the pilot control valve lever

(joystick).

FG003936

Figure 16

FG003940

Figure 17

Operating Controls

OP000434

2-11

Transmission Lever

F Forward

- When the lever is pushed forward,

transmission is in "FORWARD." 1st, 2nd, 3rd and

4th are available.

N Neutral - When the lever is returned to the center

position, between forward and reverse, the

transmission is in "NEUTRAL."

R Reverse

- When the lever is pulled back,

transmission is in "REVERSE"

1st,

2nd and 3rd

HAAA3680

are available.

Figure 18

Rotating the switch shifts transmission between

1st,

2nd, 3rd or 4th gears.

NOTE: There is a transmission display, on the dash,

that indicates, gears, direction of travel, error

codes and kick-down activation.

(See page

2-15)

A transmission neutral lever lock is in base of

transmission lever. This neutral lever lock prevents the

transmission lever from being moved out of

"NEUTRAL."

N "NEUTRAL LOCK" position. Prevents lever from

being moved out of "NEUTRAL."

D "DRIVE" position. Allows lever to be moved from

"NEUTRAL" to "FORWARD and REVERSE."

FG006196

CAUTION!

Figure 19

"LOCK" transmission lever. Whenever machine is

parked, "LOCK" transmission lever in "NEUTRAL"

to prevent accidental machine movement.

10. Front Instrument Panel

See “Front Instrument Panel” on page 2-14.

FG006053

Figure 20

Operating Controls

OP000434

2-12

11. Hour Meter

A LCD Meter that records total time. When engine is

running, the hourglass icon blinks every four seconds.

This shows that the hour meter is working.

FG004112

Figure 21

12. Hazard Warning Light Switch

This warning light is used when the equipment is

stopped due to a malfunction or when an emergency

occurs. When this switch is pressed the directional

indicator lights in front and back of the machine light

up and flash, warning others in the area. At the same

time the directional indicator lights on the instrument

panel will turn "ON" to warn the operator. The hazard

warning lights operate independent of the starter

switch.

2665C

O. In this position, this switch turns "OFF" hazard

Figure 22

warning lights.

In this position, this switch turns "ON" all turn

signals and they flash simultaneously.

NOTE: Hazard warning lights will function with starter

switch in "OFF" position.

Operating Controls

OP000434

2-13

Gauges

Reference

Description

Number

Fuel Gauge

Engine Coolant Temperature

Gauge

Speedometer

Transmission Oil Temperature

Hour Meter

Gauge

Tachometer

Transmission Display

Warning and Indicator Lights

Reference

Description

Number

Preheat Indicator Light

F/R (Forward/Reverse) Selector

Indicator Light

Air Cleaner Clogged Warning

Light

Parking Brake Indicator Light

Battery Warning Light

Emergency Steering Indicator

Light (Option)

Left Turn and Hazard Warning

Light

Engine Warning Light

High Beam Indicator Light

Not Used

Right Turn and Hazard

Not Used

Warning Light

Mirror Heating Indicator Light

Work Light Indicator Light

Reverse Fan Indicator Light

Brake Fluid Pressure Warning

Electric Steering Select

Light

Indicator Light (Option)

IMPORTANT

All of gauge and warning lights

(except for the turn

lights, high beam light, work light and transmission

cutoff light) turn "ON" for two seconds with a warning

buzzer sound when the starter switch is turned to the

"I" (ON) position.

If any light fails to turn "ON" at this time, check the

cause and replace.

Operating Controls

OP000434

2-15

1. Fuel Gauge

This gauge displays amount of fuel in tank. "F" means

the tank is "full"; "E" means the tank is "empty." If the

pointer comes close to the "E" (red zone), add fuel as

soon as possible. When the pointer comes close to the

"E"

(red zone), approximately

21.2l

(5.6 U.S. gal.) of

fuel remains.

FG003948

Figure 24

2. Speedometer

This meter displays speed at which vehicle is traveling.

FG004182

Figure 25

3. Hour Meter

A LCD meter that records total time. When engine is

running, the hourglass icon blinks every four seconds.

This shows that the hour meter is working.

HA0O2012

Figure 26

Operating Controls

OP000434

2-16

4. Tachometer

This meter displays engine speed in revolutions per

minute.

FG004183

Figure 27

5. Engine Coolant Temperature Gauge

This gauge displays temperature of engine coolant.

CAUTION!

When the pointer indicates red zone, it means the

engine is overheated. Stop the operation, let the

engine run at low rpm and wait for it to cool down.

FG003949

Do not shut down engine. If engine is shut down

Figure 28

heat surge may occur.

6. Transmission Oil Temperature Gauge

This gauge displays temperature of oil in transmission

converter and transmission circuit.

CAUTION!

When the pointer indicates red zone, it means the

transmission is overheated. Stop the operation, let

the engine run at low rpm and wait for

FG003950

transmission to cool down.

Figure 29

Operating Controls

OP000434

2-17

7. Transmission Display

A transmission display is in the gauge panel on the

dash. The LCD indicates, gears, direction of travel,

error codes, and activated kick-down.

F/R

FG006119

Figure 30

Figure 31, shows the transmission display in detail.

A. Indicates travel direction and gear selection. See

Figure 32 for more detailed information.

B. Indicates normal operation and error codes.

NOTE: Most codes are only two digits.

C. Indicates that error codes have occurred and are

(D)

(A)

(B)

(C)

stored.

D. Indicates that operation must be stopped

immediately to prevent damage to transmission

and hazardous operating condition.

Figure 31

The gear range indicator bars will indicate which gear

is selected by displaying the corresponding number of

FORWARD

bars. The forward and reverse indicator bars will be

INDICATOR

"OFF" when the transmission is in "MANUAL MODE."

When transmission is in "AUTOMATIC MODE," all the

GEAR RANGE

gear range indicator bars and both travel direction

INDICATOR BARS

indicators will be "ON."

REVERSE

INDICATOR

HAAA3774

Figure 32

Operating Controls

OP000434

2-18

8. Preheat Indicator Light

This indicator light will turn "ON," when the engine

preheat function is operating. Do not start engine as

long as this light is "ON."

HAOA639L

Figure 33

9. Air Cleaner Clogged Warning Light

This warning light will turn "ON," when dirt has built up

in the air filter and is beginning to restrict flow of air.

Clean or replace air filter before continuing to operate

machine. To turn indicator light "OFF," turn starter

switch "OFF" and then back "ON."

HAOA660L

Figure 34

10. Battery Warning Light

When starter switch is first turned to "ON" position, this

red warning light should turn "ON." When engine is

running this red light should turn "OFF." If light remains

"ON" when engine is running, alternator is defective.

HAOA610L

Figure 35

Operating Controls

OP000434

2-19

11. Left Turn and Hazard Warning Light

This light blinks when left turn signal is turned "ON."

Both lights blink when warning lights are turned "ON."

NOTE: If left and right turn indicators blink together, or if

they blink faster than normal, a light bulb is not

operating or flasher solenoid is damaged.

FG004173

Figure 36

12. High Beam Indicator Light

This indicator light will turn "ON," when the headlights

are turned to "HIGH BEAM."

HAOD394L

Figure 37

13. Right Turn and Hazard Warning

Light

This light blinks when right turn signal is turned "ON."

Both lights blink when warning lights are turned "ON."

NOTE: If left and right turn indicators blink together, or if

they blink faster than normal, a light bulb is not

operating or flasher solenoid is damaged.

FG004174

Figure 38

Operating Controls

OP000434

2-20

14. Work Light Indicator Light

This indicator light will turn "ON," when the front and/or

rear work lights are activated.

Figure 39

15. Brake Fluid Pressure Warning Light

This warning light will turn "ON," when pressure drops

in brake fluid circuit. When light turns "ON," an alarm

also sounds.

WARNING!

Never operate or travel machine when this light is

"ON" or when alarm is sounding. Always

HA0O2024

investigate cause of the drop in brake fluid

Figure 40

pressure, and repair problem before operating or

traveling machine.

16. F/R (Forward/Reverse) Selector

Indicator Light (Option)

This indicator light will turn "ON," when the

2nd gear

function is selected.

NOTE: See

“F/R

(Forward/Reverse) Travel Control

F/R

System

(Option)” on page 3-16 for further

information.

BSO0510L

Figure 41

Operating Controls

OP000434

2-21

17. Parking Brake Indicator Light

This indicator light will turn "ON," when the parking

brake is "APPLIED." If vehicle is moved while parking

brake is applied, a warning alarm will sound.

WARNING!

If vehicle is moved while this light is turned "ON,"

it could cause premature wear or damage the

0717A

brake.

Figure 42

Always "RELEASE" parking brake and make sure

this light is "OFF" before traveling machine.

18. Emergency Steering Indicator Light

(Option)

This indicator light will turn "ON," when the emergency

steering system is activated due to a hydraulic failure.

Immediately stop any operation, stop machine, "APPLY"

parking brake, and shut down engine.

DANGER!

AJO0450L

Figure 43

Emergency steering indicator light. If this light

turns "ON" while operating machine, discontinue

operation immediately. This light indicates that

there is a serve problem with the unit.

NOTE: The light will also turn "ON" when the system is

being tested.

Operating Controls

OP000434

2-22

19. Engine Warning Light

If a defect is present in the engine system, and it is

recognized by the ECU and cause a malfunction in

operation, it can be displayed with the engine warning

light to indicate a warning to the operator. If this Light

turns "ON" or "blinking," check the engine as described

under the engine diagnostic switch (See page 2-35).

•

Light turned "ON": nonfatal system error

•

Light is "BLINKING": fatal system error

AQO0040L

NOTE: The engine warning light flashes out the two

Figure 44

digit fault code in the diagnostic mode.

Fault Code 35 (example)

: Long Light

: Short Light

FG004339

Figure 45

20. Not Used

21. Not Used

22. Mirror Heating Indicator Light

This indicator light will turn "ON," when the mirror

heater is operated.

FG004184

Figure 46

Operating Controls

OP000434

2-23

RIGHT SIDE SWITCH PANEL

< Two/Three Lever (Option) >

FG006213

Figure 49

Reference

Description

Number

Pilot Control Valve Lever

Reverse Fan Switch

(Joystick)

Engine Diagnostic Switch

Pilot Control Valve Lever

Boom Float Switch (Option)

(Two/Three Lever) (Option)

LIS Switch (Option)

Kick-down Switch

Not Used

Horn Button

Fuel Heater Switch (Option)

Cigar Lighter

Emergency Steering Test

Automatic Shift Mode Switch

Switch (Option)

Economic Mode Switch

Rotating Beacon Light Switch

Headlight Switch

(Option)

Front Work Light Switch

Power Socket for 12 Volt

Rear Work Light Switch

Cup Holder

Rear Wiper Switch

F/R (Forward/Reverse) Selector

Switch (Option)

Pilot Cutoff Switch

F/R (Forward/Reverse) Control

Parking Brake Switch

Switch (Option)

Transmission Cutoff Switch

Mirror Heating Switch

Operating Controls

OP000434

2-25

1. Pilot Control Valve Lever (Joystick)

If loader is equipped with log forks this lever controls

boom, bucket and log forks.

Used to position bucket and boom. This lever is

capable of raising or lowering boom, and crowding or

dumping bucket. When machine is being traveled, the

lever

(joystick) can be "LOCKED" out, to prevent any

movement of bucket or boom. To "LOCK" out lever

(joystick), place pilot cutoff switch in "LOCKED"

position.

BSO0530L

Figure 50

Pilot control valve lever (joystick) operating pattern and

description of operation.

Figure 51

HL.

Hold

lever

Lower Mode

Lower

HC. Hold

lever

C. Bucket Crowd

Neutral

Bucket Dump

Bucket Crowd

Raise

HR.

Hold lever in Raise

Mode

A. When the log forks control lever (6, Figure 50) is

pushed forward the log forks are allowed to open.

B. When the log forks control lever (6, Figure 50) is

pulled back the log forks are allowed to close.

This lever is capable of forward travel and reverse

travel

(2nd gear function).

Neutral Switch

When this switch is pressed,

2nd gear function

will be operated, and then 2nd gear indicator light

turns "ON."

When 2nd gear function is operated, this switch is

pressed, and then machine is neutral

Operating Controls

OP000434

2-26

Forward Switch

When this switch is pressed at forward traveling

while "KD"

(5, Figure

50) switch is pressed,

machine can travel forward. When machine is

travelled, it can convert forward and reverse travel

without pressing "KD" (5, Figure 50) switch.

Reverse Switch

When this switch is pressed at reverse traveling

while "KD"

(5, Figure

50) switch is pressed,

machine can travel reverse. When machine is

travelled, it can convert forward and reverse travel

without pressing "KD" (5, Figure 50) switch.

Horn Switch

(See page 2-29)

Kick-down Switch

(See page 2-28)

NOTE: Operating condition of 2nd gear function.

•

Start a engine.

•

Transmission lever is neutral.

•

Parking brake switch is off (release).

NOTE: Release condition of 2nd gear function.

•

When the transmission lever will be push forward

or pull reverse.

•

When the parking brake switch turns "ON."

•

When the starter switch turns "OFF."

1A.Pilot Control Valve Lever (Two/Three

Lever) (Option)

Move left control lever forward (2, Figure 52) to dump

bucket, or rearward (4, Figure 52) to roll back bucket.

Move right control lever forward (3, Figure 52) to lower

boom or rearward (5, Figure 52) to raise boom.

Float

(right lever in full forward detent position

(1,

Figure

52)): This position allows oil flow in and out

both ends of cylinders so the bucket can follow the

FG006203

contour of the ground. Manually release lever from the

Figure 52

position.

BOOM FLOAT

Return-to-Dig

(left lever in full rearward detent position

BUCKET DUMP

(6, Figure 52)):Bucket will return to set dig position.

BOOM LOWER

Boom Height Kick-out right lever in full rearward detent

BUCKET CROWD

position

(7, Figure

52)): Lever will remain in this

BOOM RAISE

position until boom is at a preset height, then will

BUCKET RETURN TO DIG

return to neutral automatically.

BOOM HEIGHT KICK-OUT

Operating Controls

OP000434

2-27

A. Kick-down Switch (Two Places)

(See page 2-11)

FG003940

Figure 53

B. Horn Switch

(Two Places)

/ Log Fork Switch

(Option)

•

Horn switch function.

•

Log fork switch function.

When the log forks control lever is pushed

forward or pulled back while this switch is

pressed, the log forks are allowed to open or

closed. (See page 2-26)

FG003935

Figure 54

2. Kick-down Switch (TWO PLACES)

Kick-down Switch Function

- When transmission is in

2nd gear, pressing this switch

(Figure

56) will shift

transmission into 1st gear. This will allow the driver to

perform a quick digging movement.

Kick-down function range:

•

Automatic: 2nd, 3rd, 4th.

•

Manual: 2nd.

FG003936

NOTE: Kick-down is "RELEASED" when transmission

Figure 55

is placed in "NEUTRAL" position or the switch is

pressed again.

A second kick-down switch (Figure 55) is on the end of

the transmission lever.

AHO0900L

Figure 56

Operating Controls

OP000434

2-28

3. Horn Button (Two Places)

Pressing the lowest button at the tip of the left pilot

control valve lever

(joystick)

(Figure

57) or the button

at the end of the combination switch

(Figure

58) will

sound the horn.

NOTE: Starter switch must be "ON."

FG003941

Figure 57

AHO0890L

Figure 58

4. Cigar Lighter

Push the lighter all the way into the socket and release

your hand. After pushing it in, it will be ejected when it

is heated. If it does not eject after a short time, pull it

out and have it serviced.

IMPORTANT

The cigar lighter is powered by a

24 volt circuit.

Never plug any 12 volt device into the cigar lighter.

HAOA780L

Figure 59

Operating Controls

OP000434

2-29

Automatic Shift Mode Switch

•

Auto 1-4 mode (Working mode)

1-4

Turn the gear selector control to gear

MAN

2-4

position 4

Set the shift mode selector to "Auto 1-4"

Selector the directional gear and accelerate

the machine.

Up and downshifts are made automatically

FG004181

between 1st - 2nd - 3rd - 4th gears forward

Figure 60

and between 2nd - 3rd in reverse.

It is unnecessary to use kick-down function

for

1st gear.

•

Auto 2-4 mode (Travel mode)

1-3 is same as Auto 1-4

Up and downshifts are made automatically

between 2nd - 3rd - 4th gears forward and

between 2nd - 3rd in reverse.

Kick-down switch must be used for shifting to

1st gear.

•

Manual mode

After starting gear shifting is done manually.

6. Economic Mode Switch

This economic mode switch allows the operator to

switch between 100% throttle torque and droop curve

and about an 80% derated torque curve and droop. In

the economy mode, fuel consumption is clearly reduced

by utilising a reduced-power characteristic map for the

engine. This is of benifit with all general loading work.

O. In this position torque switch is set to the "off"

position, and

100% torque is permitted for hard

digging or driving up sleep inclines.

FG004998

Figure 61

In this position torque switch is turn "ON", which

limits engine torque to 80% of maximum.

Operating Controls

OP000434

2-30

Doosan DL250. Operation and Maintenance Manual (2006) - page 1