Doosan DL250-3 Shop Manual
Shop Manual
DL250-3 Wheel Loader
Serial Number 10001 and Up
DOOSAN and the DOOSAN logo are registered
trademarks of DOOSAN Corporation in the United
States and various other countries around the
world.
950106-00985E
July 2012
Original Instructions Copyright DOOSAN 2012
1Table of Contents
Safety
Wheel Loader Safety ............................................................................ SP002397
Specifications
Specification for DL250-3 ..................................................................... SP002778
General Maintenance
General Maintenance Instructions........................................................ SP002454
Standard Torques................................................................................. SP002404
Drivetrain
Transmission and Torque Converter (ZF 4WG-190)............................ SP002779
Transmission Error Codes (ZF) ............................................................ SP002423
Axle (ZF-MT-L 3085 II) ......................................................................... SP002780
Driveshaft.............................................................................................. SP002663
Brake
Service Brake ....................................................................................... SP002781
Brake Supply Valve .............................................................................. SP002427
Charging Block ..................................................................................... SP002428
Parking Brake ....................................................................................... SP002429
Brake Pedal Valve ................................................................................ SP002430
Accumulator.......................................................................................... SP002782
Steering
Power Steering System ........................................................................ SP002599
Priority Valve......................................................................................... SP002600
Emergency Steering............................................................................. SP002601
Table of Contents
Page I
Frame
Articulation Center ................................................................................ SP002783
Counterweight....................................................................................... SP002784
Tank
Oil Tank ................................................................................................ SP002664
Fuel Tank.............................................................................................. SP002785
Hydraulics
Main Pump............................................................................................ SP002440
Main Control Valve ............................................................................... SP002786
Load Isolation System .......................................................................... SP002787
Cooling System..................................................................................... SP002788
Pilot System.......................................................................................... SP002445
Hydraulic Schematic DL250-3 .............................................................. SP002789
Electrical System
Air Conditioner...................................................................................... SP002447
Electrical System .................................................................................. SP002662
Electrical Schematic DL200-3 / DL220-3 / DL250-3............................. SP002666
Table of Contents
Page II
1Safety
SP002397
WHEEL LOADER SAFETYSP002397
Wheel Loader
Safety
Edition 3
Wheel Loader Safety
SP002397
Page 1
MEMO
Wheel Loader Safety
Page 2
SP002397
Table of Contents
Wheel Loader Safety
Safety Instructions ................................................ 5
Applicable Models ................................................ 5
Safety Messages .................................................. 6
Safety Decals ....................................................... 7
General................................................................. 8
Transportation .................................................... 19
Operation............................................................ 21
Maintenance ....................................................... 39
Environment and Circumstances........................ 54
Wheel Loader Safety
SP002397
Page 3
MEMO
Wheel Loader Safety
Page 4
SP002397
SAFETY INSTRUCTIONS
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation and
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
MODEL SERIAL NUMBER RANGE
DL200-3 10001 and Up
DL220-3 10001 and Up
DL250-3 10001 and Up
Wheel Loader Safety
SP002397
Page 5
SAFETY MESSAGES
Safety messages and safety decals included in this manual and
on the machine provide instructions how to operate, service and
maintain the machine. Safety messages and safety decals
indicate potential hazards and describe safety precautions
required to avoid hazards. Operator and maintenance personnel
should read and understand these safety messages and decals
before beginning operation or maintenance.
SAFETY ALERT SYMBOL
Be Prepared - Get to Know All Operating and Safety
Instructions.
This is a Safety Alert Symbol. Wherever it appears in this
manual or on safety decals on the machine, you must be
alert to the potential for personal injury or accidents.
Always observe safety precautions and follow
recommended procedures.
Signal Words
The signal words "DANGER", "WARNING", "CAUTION" are
used throughout safety messages and safety decals in this
manual or on the machine. They indicate an existence of, and
the relative seriousness of a hazard. All three indicate that a
safety risk is involved. Observe the precautions indicated
whenever a Safety Alert Symbol is present, no matter which
signal word appears next to it.
DANGER
DANGER - This signal word is used on safety messages and
safety labels and indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
WARNING
WARNING - This signal word is used on safety messages and
safety labels and indicates a potentially hazardous situation
which, if not avoided, could result in death or serious injury.
CAUTION
CAUTION - This signal word is used on safety messages
and safety labels and indicates a potentially hazardous
situation which, if not avoided, could result in minor or
moderate injury.
Page 6
SP002397Wheel Loader Safety
Other Signal Words
In addition to safety signal words, the following signal words are
used to indicate proper and effective use of machine.
IMPORTANT
This signal word identifies procedures which must be
followed to avoid damage to machine.
NOTE: The word "NOTE" identifies information for effective
use.
SAFETY DECALS
Location of safety labels (decals) can vary from unit to unit.
Refer to appropriate Operation and Maintenance Manual, and
parts manual for your unit.
Always replace damaged or faded decals.
Wheel Loader Safety
SP002397
Page 7
GENERAL
Safe Operation is Operator's Responsibility
Only trained and authorized personnel should operate and
maintain the machine.
Follow all safety rules, regulations and instructions when
operating or performing maintenance on machine.
• Do not operate machine if you are under the
influence of drugs or alcohol. An operator who is
taking prescription drugs must get medical advice to
determine if he or she can safely operate the
machine.
• When working with other personnel on a work site, be
sure that all personnel know the nature of work and
understand all hand signals that are to be used.
• Be sure that all guards and shields are installed in
their proper location. Have guards and shields
repaired or replaced immediately if damaged.
• Be sure that you understand the use and
maintenance of all safety features such as pilot cutoff
switch and seat belt. Use them always.
• Never remove, modify or disable any safety features.
Always keep them in good operating condition.
• Always check for and know the location of
underground and overhead utility lines before working.
• Failure to use and maintain safety features according
to instructions in this manual, Safety Manual and
Shop Manual can result in death or serious injury.
Know Your Machine
Know how to operate your machine. Know the purpose of all
controls, gauges, signals, indicators and monitor displays. Know
the rated load capacity, speed range, braking and steering
characteristics, turning radius and operating clearances. Keep in
mind that rain, snow, ice, loose gravel, soft ground, slopes etc.,
can change operating capabilities of your machine.
Proper Work Tools and Attachments
Only use work tools and attachments that are recommended by
DOOSAN for use on DOOSAN machines. When installing and
using optional attachments, read instruction manual for
attachment, and general information related to attachments in
this manual. Because DOOSAN cannot anticipate, identify or
test all attachments that owners may want to install on their
machines, contact DOOSAN for written authorization and
approval of attachments, and their compatibility with optional
kits.
Page 8
SP002397Wheel Loader Safety
Attachments and attachment control systems that are
compatible with the machine are required for safe and reliable
machine operation. Do not exceed maximum operating weight
(machine weight plus attachment) that is listed on ROPS
certification plate.
Make sure that all guards and shields are in place on machine
and on work tool. Depending on type or
equipment, there is a potential that work
interfere with the cabin or other parts of
unfamiliar work equipment, check if there
interference, and operate with caution.
While you are performing any maintenance, testing, or
adjustments to attachments, stay clear of the following areas:
cutting edges, pinch points, and crushing surfaces.
Never use attachment as a work platform or manlift.
Contact your DOOSAN distributor about auxiliary hydraulic kits
for attachments installation. If you are in doubt about the
compatibility of a particular attachment with the machine, consult
your DOOSAN distributor.
combination of work
equipment could
machine. Before using
is any potential of
Pressurized Fluids
Pressurized air or fluids can cause debris and/or fluids to be
blown out. This could result in death or serious injury.
Immediately after operations are stopped, coolant, engine oil,
and hydraulic oil are at their highest temperatures and the
radiator and hydraulic tank are still under pressure. Always wait
for temperature to cool down. Follow specified procedures when
attempting to remove caps, drain oil or coolant, or replacing
filters. Always wait for temperature to cool down, and follow
specified procedures when performing these operations. Failure
to do so can result in death or serious injury.
When pressurized air and/or pressurized water is used for
cleaning, wear protective clothing, protective shoes, and eye
protection. Eye protection includes goggles or a protective face
shield.
Pressure can be trapped in a hydraulic system and must be
relieved before maintenance is started.
Releasing trapped pressure can cause sudden machine
movement or attachment movement. Use caution if you
disconnect hydraulic lines or fittings.
High-pressure oil that is released can cause a hose to whip or oil
to spray. Fluid penetration can result in death or serious injury. If
fluid enters skin or eyes, get immediate medical attention from a
physician familiar with this injury.
FG018457
Figure 1
Obey all local laws and regulations for disposal of liquids.
To prevent hot coolant from spraying out, stop engine and wait
for coolant to cool. Using gloves, slowly loosen cap to relieve
pressure.
Wheel Loader Safety
SP002397
Page 9
Flying or Falling Objects
On work sites where there is a potential hazard that flying or
falling objects can come in contact with operator's cabin, select
and use a guard to match operating conditions for additional
operator protection.
Working in mines, tunnels, deep pits, and loose or wet surfaces,
can produce hazard of falling rocks or flying objects. Additional
protection for operator's cabin may be required such as a Falling
Object Protective Structure (FOPS) or window guards. Contact
your DOOSAN distributor for information on available protective
guards.
To prevent personnel from being struck by flying objects, keep
personnel out of work area.
HAOA110L
Figure 2
Personal Protective Equipment (PPE)
Do not wear loose clothing and accessories. Secure long hair.
These items can snag on controls or on other parts of equipment.
Do not wear oily clothes. They are highly flammable.
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. Breathing masks and/or ear protection may be required.
Wear a hard hat, safety shoes, safety goggles, mask, leather
gloves, earplugs and other protective equipment, as required.
While working on machine, never use inadequate tools. They
could break or slip, or they may not adequately perform intended
functions.
Correction of Machine Problems
If any machine problems are found during operation and
maintenance (noise, vibration, smell, incorrect gauges, smoke,
oil leakage, etc.), or if any abnormal warming alerts are
displayed on display monitor, stop the machine immediately and
take the necessary corrective actions. Do not operate the
machine until problem has been corrected.
HAOA100L
Figure 3
HAOA020L
Figure 4
Page 10
SP002397Wheel Loader Safety
Crushing and Cutting
Keep objects away from moving fan blades. Fan blades can
throw and cut objects.
Do not use a wire rope that is kinked or frayed, or a wire rope
with any loss of diameter. Wear leather gloves when handling a
wire rope.
When striking a loose retainer pin, it can fly out and can cause a
serious injury. Make sure that area is clear of personnel when
striking a retainer pin. To avoid injury to your eyes, wear safety
goggles when striking a retainer pin.
Do not put your hand, arm or any other part of your body
between movable parts. If going between movable parts is
necessary, always position and secure work equipment so it
cannot move. Properly support equipment before performing
any work or maintenance under raised equipment.
If control levers are operated, clearance between machine and
work equipment will change and this may lead to serious
damage or can result in death or serious injury. Stay clear of
areas that may have a sudden change in clearance with
machine movement or equipment movement. Stay clear of all
rotating and moving parts. Unless instructed, never attempt
adjustments while machine is moving or while engine is running.
Do not depend on hydraulic cylinders to support raised
equipment. Equipment can fall if a control is moved, or if a
hydraulic line breaks, is loosened or disconnected.
If it is necessary to remove guards to perform maintenance,
always install guards after maintenance is completed.
Always have at least two people working together if the engine
must be running during service. One person needs to remain in
the operator's seat, ready to work the controls to stop the
machine or stop engine, if necessary.
HDO1010L
Figure 5
Wheel Loader Safety
SP002397
Page 11
Hot Coolant and Oils - Burn Prevention
Do not touch any part of an operating engine. Immediately after
operations are stopped, coolant, engine oil, and hydraulic oil are
at their highest temperatures. The radiator and hydraulic tank
are still under pressure. Always wait for temperature to cool
down. Attempting to remove caps, drain oil or coolant, or
replacing filters may lead to serious burns, if done when hot.
Relieve all pressure in air system, hydraulic oil system,
lubrication system, fuel system, and cooling system, before any
lines, fittings or related items are disconnected.
To prevent hot oil or coolant from spraying out, stop engine and
wait for oil and coolant to cool. Using gloves, slowly loosen cap
to relieve pressure.
FG019095
Figure 6
FG019096
Figure 7
Fire and Explosion Prevention
All fuels, most lubricants and some coolant mixtures are
flammable and can cause a fire resulting in death or serious
injury, and property damage. Flammable fluids that are leaking
or spilled onto hot surfaces or onto electrical components can
cause fire.
Inspect for and remove all flammable materials such as spilled
fuel and oil, and debris from machine. Do not allow any
flammable materials to accumulate on machine.
Always observe the following:
• Add fuel, oil, antifreeze and hydraulic fluid to machine
only in a well ventilated area. Machine must be
parked with controls, lights and switches turned
"OFF." Engine must be "OFF" and any flames,
glowing embers, auxiliary heating units or spark
causing equipment must be extinguished, or turned
"OFF" and kept well clear of machine.
• Dust that is generated from repairing or grinding
nonmetallic hoods or nonmetallic fenders can be
toxic, flammable and explosive. Repair these
components in a well ventilated area away from
flames or sparks and wear a dust mask when
grinding painted parts.
HDO1015I
Figure 8
FG018458
Figure 9
Page 12
SP002397Wheel Loader Safety
Maintenance
The machine and some attachments have components that
reach high temperatures under normal operating conditions. The
primary source of high temperatures are the engine and exhaust
system. If damaged or incorrectly maintained, the electrical
system can be a source of arcs or sparks.
Flammable debris (leaves, straw, etc.) must be removed
regularly. If flammable debris is allowed to accumulate, it can
cause a fire hazard. Clean machine often to avoid this
accumulation. Flammable debris in an engine compartment is a
potential fire hazard.
The operator's area, engine compartment and engine cooling
system must be inspected every day and cleaned. This is
necessary to prevent fire hazards and overheating.
Operation
Do not use machine where exhaust, arcs, sparks or hot
components can contact flammable material, explosive dust or
gases.
Do not operate machine near any flame.
Exhaust shields (if equipped) protect hot exhaust
from oil spray or fuel spray in case of a break in
components
a line, hose, or
seal. Exhaust shields must be correctly installed and maintained
properly.
Electrical
Check all electrical wiring and connections for damage daily.
Keep battery terminals clean and tight. Repair or replace any
damaged parts or wires that are loose or frayed. Clean all
electrical connections and tighten all electrical connections.
Never check battery charge by placing a metal object across
terminal posts. Use a voltmeter or a hydrometer.
Battery gas can explode and can result in death or serious
injury. Follow procedures in this manual for connecting battery
and for jump-starting. Do not jump-start or charge a frozen or
damaged battery. Keep all flames and sparks away from
batteries. Do not smoke in battery charging area.
Improper jumper cable connections can cause an explosion that
can result in death or serious injury. Refer to Operation and
Maintenance Manual for proper procedure in this manual.
Do not charge a frozen battery. This can cause an explosion.
After market radios or other electric operated equipment in cabin
must have a fuse in the electrical circuit.
Wheel Loader Safety
SP002397
Page 13
Hydraulic System
Check hydraulic tubes, hoses and fittings for damage, wear or
for leaks. Hydraulic lines and hoses must be properly routed and
have adequate support and secure clamps. Leaks can cause
fires. Never use a flame or bare skin to check for leaks.
Tighten or replace any parts that show leakage.
Check that all hose and tube clamps, guards, and cushions are
securely attached. If they are loose, they can vibrate during
operation and rub against other parts. This can cause damage
to hoses and cause high-pressure oil to spray on hot surfaces,
causing a fire and death or serious injury.
Always clean fluid spills. Do not use gasoline or diesel fuel for
cleaning parts. Use commercial nonflammable solvents.
X
X
HDO1045I
Figure 10
Fueling
Use caution when you are refueling a machine.
Fuel is flammable and can catch fire if it is brought close to a
flame.
Stop engine and let it cool before adding fuel. Do not smoke
while you are refueling a machine. Do not refuel a machine near
flames or sparks. Fill fuel tank outdoors.
Keep fuel and other fluid reservoir caps tight and do not start
engine until caps have been secured.
Store fuels and lubricants in properly marked containers away
from unauthorized personnel. Store oily rags and any flammable
materials in protective containers.
Static electricity can produce dangerous sparks at fuel filling
nozzle. In very cold, dry weather or other conditions that could
produce a static discharge, keep tip of fuel nozzle in constant
contact with neck of fuel filling nozzle, to provide a ground and
prevent sparks.
Always place plastic fuel containers on the ground before filling.
ARO1050S
Figure 11
Page 14
SP002397Wheel Loader Safety
Never Use Ether Starting Aids
Do not use ether or starting fluids on any engine that has glow
plugs, or an electric grid type manifold heater. These starting
aids can cause an explosion and result in death or serious
injury.
Use procedures in this manual for connecting battery and for
jump-starting.
Welding and Grinding
Always clean machine and attachment, disconnect battery
switch, and disconnect wiring from electronic controllers before
welding. Cover rubber hoses, battery and all other flammable
parts. Keep a fire extinguisher near machine when welding.
Toxic dust or gas can be produced when grinding or welding
painted parts. Grinding or welding painted parts must be done in
a well ventilated area. Wear a dust mask when grinding painted
parts.
FG018458
Figure 12
Dust generated from repairing nonmetallic parts such as hoods,
fenders or covers can be flammable or explosive.
Repair such components in a well ventilated area away from
flames or sparks.
Do not weld on lines or on tanks that contain flammable fluids.
Do not flame cut lines or tanks that contain flammable fluid.
Clean any such lines or tanks thoroughly with a nonflammable
solvent before welding or flame cutting.
If a Fire Occurs
If a fire occurs:
• Do not attempt to move machine or continue
operations.
• Turn starter switch to "O" (OFF) position to stop
engine.
• Use handrails and steps to get off machine.
• Immediately call for help or fire station.
• When using a fire extinguisher, always aim
extinguisher at base of fire.
• If an optional fire extinguishing system is in place, be
familiar with its operating procedures.
FG018459
Figure 13
NOTE: Depending on job conditions, other
Wheel Loader Safety
procedures could be necessary if a fire
occurs.
SP002397
Page 15
Fire Extinguisher and First-Aid Kit
(Emergency Medical Kit)
To be prepared in the event of a fire:
• Be sure that fire extinguishers have been provided
and read labels to ensure that you know how 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 cabin. Check and service
fire extinguisher at regular intervals and make sure
that all work site crew members are adequately
trained in its use.
• Inspect fire extinguisher and service fire extinguisher
regularly.
• Follow instructions on extinguisher instruction plate.
• Keep a first aid kit in storage compartment (Figure
15) and keep another kit at work site. Check kit
periodically and keep it properly supplied.
• Keep emergency numbers for doctor, ambulance
service, hospital and fire department readily
available.
HDO1009L
Figure 14
Electrical System and Electrical Shock
Never short across starter terminals or across batteries.
Shorting could damage electrical system and engine neutral
start system.
When engine is running or immediately after it has stopped, high
voltage is generated at injector terminal and inside engine
controller, so there is a potential for an electrical shock. Never
touch injector terminal or inside of engine controller.
NOTE:If it is necessary to touch injector terminal or inside
engine controller, contact your DOOSAN distributor.
FG026170
Figure 15
Page 16
SP002397Wheel Loader Safety
Rollover Protective Structure (ROPS)
The operator's cabin is a ROPS certified structure for protecting
the seat belted operator. It absorbs the impact energy of a
rollover impact. Do not allow machine weight (mass) to exceed
certified value on certification plate. If weight is exceeded, the
ROPS structure will not be able to fulfill its safety function.
Do not increase machine weight beyond certified value by
modifying machine or by installing attachments on machine. If
weight limit of protective equipment is exceeded, protective
equipment will not be able to protect operator, and this can
result in death or serious injury. Always observe the following:
• This machine is equipped with a protective structure.
Do not remove protective structure and perform
operations without it.
• Never modify the operator's cabin by welding,
grinding, drilling holes or adding attachments unless
instructed by DOOSAN in writing. Changes to the
cabin can cause loss of operator protection from
rollover and falling objects, and result in death or
serious injury.
• When protective structure is damaged or deformed
by falling objects or by rolling over, its strength will be
reduced and it will not be able to adequately protect
the operator. Contact your DOOSAN distributor if you
have any questions about the ROPS. Never repair a
damaged ROPS cabin.
• Always wear your seat belt when operating machine.
ROPS Certification
This DOOSAN machine has an operator's cabin that meets
ROPS requirements. The seat belt must be worn for rollover
protection.
The ROPS certification plate (Figure 16) is found on the back of
the cabin on most models. It may vary slightly in its location on
some models.
Check the ROPS cabin, mounting, and hardware for damage.
Never modify the ROPS cabin. Replace the cabin and hardware
if damaged. See your DOOSAN distributor for parts.
ROPS - Rollover Protective Structure complies with
ISO 3471:2008.
WARNING
AVOID DEATH OR SERIOUS INJURY
Never modify the operator cabin by welding, grinding,
drilling holes or adding attachments unless instructed in
writing by DOOSAN. Changes to the cabin can cause loss
of operator protection from rollover and falling objects, and
can result in death or serious injury.
FG020110
Figure 16
Wheel Loader Safety
SP002397
Page 17
Emergency Exit from Operator's Station
If the primary exit is blocked, the window on the right side may
be used as an alternate exit. Open the window and exit the
machine through the window.
Door Catch
FG022692
Figure 17
Page 18
SP002397Wheel Loader Safety
TRANSPORTATION
Obey State and Local Over-the-Road Laws
and Regulations
Check federal, state and local laws and regulations regarding
weight, width and length of a load before making preparations
for transporting on public roads or highways.
The hauling vehicle, trailer and load must be in compliance with
applicable regulations for the shipping route.
Partial disassembly of the machine may be necessary to meet
travel restrictions or particular conditions at work site. See Shop
Manual for information on partial disassembly.
Refer to Operation and Maintenance Manual for information on
loading, unloading and towing.
The machine can be disassembled into parts for transporting.
Contact your DOOSAN distributor for assistance with
disassembly.
Loading and Unloading
To prevent machine tipping or rollover when loading or
unloading machine, always do the following:
• Perform loading and unloading only on firm and level
ground. Maintain a safe distance from edge of road or
drop-off.
• Never use work equipment to load or unload
machine. The machine may fall or tip over.
• Always use loading ramps of adequate strength and
capacity. Be sure that ramps are wide, and long
enough to provide a safe loading slope. Take steps to
prevent ramps from moving out of position or coming off.
• Clean ramp surfaces so they are free of grease, oil,
ice and loose materials. Remove dirt from machine
tires. On a rainy day, be careful since ramp surfaces
can be slippery.
• Turn auto idle switch "OFF."
• Run engine at low speed and travel slowly.
• When on ramps, do not operate any control lever
except for shift lever.
• Never correct your steering on ramps. If necessary,
drive off ramps, correct machine direction, then drive
back onto ramps.
• For machines equipped with a cabin, always lock
door after loading machine to prevent door from
suddenly opening during transportation.
Wheel Loader Safety
SP002397
Page 19
Transporting Machine
When transporting machine on a trailer or truck, do the following:
• The weight, transportation height, and overall length
of machine may change depending on work
equipment attached to it. Always check the machine
dimensions and work equipment's dimensions before
transporting.
• When passing over bridges or structures on private
land, check that structure is strong enough to support
weight of machine. Before traveling on public roads,
check with appropriate authorities and follow their
instructions.
Page 20
SP002397Wheel Loader Safety
OPERATION
Always make sure that the machine is properly maintained.
Before Engine Starting
Machine Condition
Every day before starting engine for first time, perform the
following checks and repair machine before operating, as
necessary. If these checks are not properly done death or
serious injury could result.
• Check coolant, fuel, and hydraulic tank oil levels, and
check for clogged air cleaner and damage to
electrical wiring.
• Check operation of gauges, cameras (if equipped)
and angle of mirrors, and check that pilot cutoff
switch is set to "O" (OFF) position.
• Check that pedals move freely, and pilot control lever
(s) returns to "NEUTRAL" when released.
• Check that attachment is properly attached and
locked.
IMPORTANT
Only use Ultra Low Sulfur Diesel (ULSD) fuel and
API-CJ-4/ACEA-E9 grade engine oil.
Make sure that the machine is equipped with a lighting system
that is adequate for job conditions and check that lights are
working properly.
Before performing checks, move machine to an area where
there are no obstructions, and operate slowly. Do not allow
personnel near machine.
Know maximum operating dimensions of your machine.
Work Site
Before starting operations, thoroughly check work area for any
hazards, such as underground utility lines, overhead electrical
lines, unstable ground, excessive slopes, etc.
Before starting engine and moving machine, make sure that no
one is underneath machine, around machine, or on machine.
Know width and length of your machine and work equipment to
maintain proper clearance when you operate machine or work
equipment near fences or near boundary obstacles.
Figure 18
WARNING
No Entry
FG013735
Wheel Loader Safety
SP002397
Page 21
Know appropriate work site hand signals and personnel that are
authorized to give hand signals. Follow hand signals from only
one person.
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 work site.
Erect barricades or fences, post "No Entry" signs, and take other
steps to prevent people from coming close to or entering work
site. If people come too close to a moving machine, they may be
struck or caught by machine, and this can result in death or
serious injury.
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 avoid
standing in front of or over a tire. Do not change a tire unless you
understand proper tire maintenance procedures and are using
proper equipment.
Refer to Operation and Maintenance Manual.
Mounting/Dismounting
Before getting on or off machine, if there is any oil, grease, or
mud on handrails or steps, wipe it off immediately. Always keep
these parts clean. Repair any damage and tighten any loose
bolts.
Never jump on or off machine. In particular, never get on or off a
moving machine. These actions can result in death or serious
injury.
When getting on or off machine, always face machine. Maintain
three-point contact (both feet and one hand or one foot and both
hands) with handrails and steps to ensure that you support
yourself securely.
Never hold onto any control levers when getting on or off
machine.
Securely latch door. If you grip handrail inside door when
moving on platform outside of door, and door latch is not
securely engaged, door may move and cause you to fall
resulting in death or serious injury.
Use points marked by arrows in diagram when getting on or off
machine.
Do not carry tools or supplies when you mount or dismount the
machine.
HA3O1003
Figure 19
Page 22
SP002397Wheel Loader Safety
Cleaning
Remove all straw, wood chips, leaves, grass, paper and other
flammable debris accumulated in engine compartment,
and around battery. Remove
handrails, and steps.
Do not leave tools or spare parts in operator's cabin. Vibration of
machine during operation can cause tools or spare parts to fall
and damage or break control levers or switches. Tools and
spare parts can also get caught in spaces between control
levers and cause accidental movement of work equipment
causing death or serious injury.
When entering operator's cabin, always remove all mud and oil
from your shoes. If you operate travel pedal with mud or oil stuck
to your shoes, your foot could slip off the control, or dirt and
debris may interfere with proper operation of control levers.
After using ashtray, make sure that any matches or cigarettes
are properly extinguished, and be sure to close ashtray.
Clean window glass and working lights for good visibility.
Do not stick suction pads to window glass. Suction pads act as a
lens and can cause fire.
Never bring flammable or explosive items into operator's cabin.
Do not leave cigarette lighters laying around operator's cabin. If
temperature inside operator's cabin becomes too high, there is a
potential hazard that lighter could explode.
any dirt from window glass, mirrors,
mufflers
Secure all loose items such as lunch boxes, and other items that
are not a part of the machine itself.
Operator Station
Inspect condition of seat belt and mounting hardware. Replace
any parts that are worn or damaged. Do not use a seat belt
extension on a retractable seat belt.
Adjust seat so full pedal travel can be achieved with operator's
back against back of seat.
Keep all windows and doors closed on machine.
Adjust operator's seat to a position where it is easy to perform
operations, and check that there is no damage or excessive
wear to seat belt or mounting clamps.
Never reach in through a window to work a control. Do not try to
operate the machine unless in operator's seat with the seat belt
fastened.
Adjust and clean mirrors so area to rear of machine can be seen
clearly from operator's seat.
When standing up from operator's seat, always place pilot cutoff
switch in "O" (OFF) position. If you accidentally move work
equipment levers when they are not locked, the machine could
suddenly move and cause damage, death or serious injury.
Wheel Loader Safety
SP002397
Page 23
Seat Belt
Check seat belt daily for correct function.
Inspect seat belt system more often if machine is exposed to
severe environmental conditions or applications. Conduct the
following inspections and replace seat belt system as
necessary:
1. Check webbing. If system is equipped with a retractor, pull
webbing completely out and inspect full length of webbing.
Look for cuts, wear, fraying, dirt and stiffness.
2. Check buckle and latch for correct operation.
3. Make sure latch plate is not excessively worn,
buckle is not damaged or casing is broken.
4. Check retractor web storage device (if equipped) by
extending webbing and checking that it spools out and
retracts correctly.
5. Check webbing in areas exposed to ultraviolet (UV) rays
from sun or extreme dust or dirt. If original color of webbing
in these areas is extremely faded and/or webbing is
packed with dirt, webbing strength may be reduced.
NOTE: Contact your DOOSAN distributor for seat belt
system replacement parts.
deformed or
WARNING
AVOID DEATH OR SERIOUS INJURY
Failure to properly inspect and maintain seat belt and
seat belt system can cause lack of operator restraint
and can result in death or serious injury.
Before fastening seat belt, check that there is no
problem in belt mounting bracket. If it is worn or
damaged, replace seat belt immediately. Fasten seat
belt so it is not twisted.
Always wear seat belt when operating machine.
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SP002397Wheel Loader Safety
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