Doosan DL250A - User Manual

This document is a Shop Manual for the Doosan DL250A Wheel Loader, covering models with serial numbers 10001 and up, published in June 2012. It serves as a comprehensive guide for the maintenance, repair, and safe operation of the machine.

Function Description:

The Doosan DL250A Wheel Loader is a heavy-duty construction machine designed for various tasks such as loading, digging, and material handling. It is equipped with a powerful engine, a robust drivetrain, and a hydraulic system to operate its work tools and attachments. The manual emphasizes the importance of safety instructions, proper maintenance, and adherence to operational guidelines to ensure efficient and safe use of the loader.

Important Technical Specifications (as inferred from the Table of Contents):

Model: DL250A Wheel Loader
Serial Number Range: 10001 and Up (also applies to DL300A, DL420A, DL550A models within the same serial range for safety instructions)
Drivetrain:
- Transmission and Torque Converter (SP002672)
- Transmission Error Codes (ZF) (SP002673)
- Front Axle (ZF-MT-L 3085 II) (SP002474)
- Rear Axle (ZF-MT-L 3075 II) (SP002598)
- Driveshaft (SP002674)
Brake System:
- Service Brake (SP002675)
- Brake Supply Valve (SP002676)
- Parking Brake (SP000873)
- Brake Pedal Valve (SP000874)
- Accumulator (SP002677)
Steering System:
- Power Steering System (SP002599)
- Steering (SP002293)
- Emergency Steering (SP002294)
Frame:
- Articulation Center (SP000878)
- Counterweight (SP000130)
Tank Capacities:
- Oil Tank (SP002679)
- Fuel Tank (SP002680)
Hydraulics:
- Cylinders (SP001027)
- Main Pump (SP001035)
- Main Control Valve (SP000881)
- Load Isolation System (SP002678)
- Unloader Valve (SP002681)
- Pilot System (SP002683)
- Hydraulic Schematic DL250A (SP002693)
Electrical System:
- Air Conditioner (SP000172)
- Electrical System (SP002694)
- Electrical Schematic DL250A (SP002695)
Safety Features:
- ROPS (Rollover Protective Structure) certified cabin.
- Safety decals and messages for various hazards.
- Procedures for handling pressurized fluids, fire prevention, and electrical safety.
- Recommendations for Personal Protective Equipment (PPE).

Usage Features:

The manual outlines critical aspects for operating the DL250A Wheel Loader safely and effectively. It stresses the importance of reading and understanding the Operation and Maintenance Manual, as well as all safety decals on the machine. Operators must be trained and authorized, free from the influence of drugs or alcohol, and familiar with all controls, gauges, and machine capabilities. The manual covers general operation, transportation, and maintenance procedures. It advises against operating the machine if any problems are detected and emphasizes the need for correct function checks after any adjustments, repairs, or service. The use of recommended work tools and attachments is highlighted, along with warnings against exceeding maximum operating weight and modifying the ROPS structure. Specific instructions are provided for loading and unloading, including selecting firm, level ground, using adequate ramps, and maintaining safe distances.

Maintenance Features:

The manual provides detailed guidance on maintaining the DL250A Wheel Loader to ensure its longevity and safe operation. Key maintenance aspects include:

General Maintenance Instructions: (SP002454) and Standard Torques (SP002404) are provided.
Regular Inspections: Daily checks for electrical wiring, connections, and flammable debris accumulation in the engine compartment and cooling system.
Fluid Management: Procedures for handling hot coolant and oils, including waiting for temperatures to cool and relieving pressure before opening caps or disconnecting lines. Instructions for proper disposal of liquids are also included.
Fire Prevention: Emphasizes adding fuel, oil, antifreeze, and hydraulic fluid in well-ventilated areas with the engine off and away from flames. It also covers the safe handling of flammable materials and the importance of keeping a fire extinguisher nearby.
Electrical System Maintenance: Keeping battery terminals clean and tight, repairing damaged wires, and using appropriate tools (voltmeter/hydrometer) for charge checks. Warnings against jump-starting frozen or damaged batteries and smoking in charging areas are given.
Hydraulic System Maintenance: Checking hydraulic tubes, hoses, and fittings for damage, wear, or leaks, ensuring proper routing and secure clamps.
Welding and Grinding: Instructions for cleaning the machine, disconnecting batteries and electronic controllers, covering flammable parts, and using PPE when welding or grinding painted parts. Warnings against welding on lines or tanks containing flammable fluids are also included.
First-Aid Kit and Emergency Numbers: Recommends keeping a first-aid kit and emergency contact numbers readily available.
ROPS Maintenance: Stresses not to modify or remove the ROPS structure and to contact a DOOSAN distributor if it is damaged. Always wear a seat belt when operating.
Problem Correction: Advises stopping the machine immediately and taking corrective actions if any abnormal noises, vibrations, smells, incorrect gauges, smoke, oil leakage, or warming alerts are observed.
Crushing and Cutting Prevention: Warnings to keep objects away from moving fan blades and to avoid placing body parts between movable components. Proper support of raised equipment before maintenance is crucial.

The manual serves as an essential resource for anyone involved in the operation, maintenance, or repair of the Doosan DL250A Wheel Loader, promoting safety and operational efficiency through detailed instructions and warnings.