Doosan DL250-3 Operation & Maintenance Manual
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Doosan DL250-3 Operation & Maintenance Manual

Doosan DL250-3 Operation & Maintenance Manual

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WHEEL LOADER
Operation &
Maintenance
Manual
DL250-3 / DL250TC-3
Serial Number 10001 and Up
950106-00984BNA-2
January 2015

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Summary of Contents for Doosan DL250-3

  • Page 1 950106-00984BNA-2 January 2015 WHEEL LOADER Operation & Maintenance Manual DL250-3 / DL250TC-3 Serial Number 10001 and Up...
  • Page 3 Operation & Maintenance Manual DL250-3 / DL250TC-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 950106-00984BNA-2 world. January 2015 Copyright DOOSAN 2015...

  • Page 5: Table Of Contents

    Multifunction Gauge and Graphic Information Display..... 2-23 Right Side Switch Panel..............2-52 Various Cabin Locations ..............2-67 Heater and Air Conditioner Operation..........2-72 Stereo/CD Player (Optional) ............2-78 Seat Adjustment Mechanical Suspension (Standard)..... 2-79 Seat Adjustment W/Air Suspension and Heater ......2-82 DL250-3/DL250TC-3 Table of Contents...
  • Page 6 Handling Oil, Fuel, Coolant .............. 4-10 Electrical System Maintenance............4-14 Recommend Fuel, Coolant, and Lubricant ........4-15 Preventive Maintenance ..............4-22 Table of Recommended Lubricants ..........4-24 Transmission Oil ................4-27 Axle Oils................... 4-28 Fluid Capacities ................4-30 Table of Contents DL250-3/DL250TC-3...
  • Page 7 Severe Conditions Maintenance ............ 4-106 Tires ....................4-107 Transportation ................5-1 Transporting Machine ................ 5-1 Lifting Machine................... 5-5 Troubleshooting ................6-1 Braking....................6-1 Electrical System ................6-2 Engine....................6-2 Hydraulic System ................6-5 Steering....................6-7 Travel System ..................6-8 Table of Contents DL250-3/DL250TC-3...
  • Page 8 Specification ................7-1 General Specifications ............... 7-1 Working Range and Dimensions ............7-4 Working Capacities ................7-8 Approximate Weight of Workload Materials........7-9 Index ...................8-1 Table of Contents DL250-3/DL250TC-3...

  • Page 9: Foreword

    Contact your DOOSAN distributor for further information. Engine DL250-3, DL250TC-3 has a Doosan DL06K 5.9 liter engine. The engine has intercooling and is fitted with common rail system. The common rail system is positioned at an angle above the pistons and are controlled by the camshaft and a engine management system (EMS).
  • Page 10 (overhead protection) and ROPS is an abbreviation of Roll-over Protective Structure (roll-over protection) for a seat belted operator. Never perform 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 Doosan approval. Foreword DL250-3/DL250TC-3...

  • Page 11: Ce Marking, Emc Directive

    Figure 1 As proof that requirements are met, the machine is supplied with an EU Declaration of Conformity, issued by DOOSAN CE for each machine. This EU declaration also covers attachments manufactured by DOOSAN CE. The documentation must be retained for at least ten years.

  • Page 12: Eu Emc Directive

    A machine or device which meets the requirements must be CE marked. Doosan machines have been tested particularly for electromagnetic interference. The CE marking of the machine and the Declaration of Conformity also cover the EMC directive.

  • Page 13: Product Plates

    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. Foreword DL250-3/DL250TC-3...

  • Page 14: Safety Messages

    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. Foreword DL250-3/DL250TC-3...

  • Page 15: Aem Safety Manual (North America Only)

    The AEM Safety Manual delivered with the machine gives general safety information. The AEM Safety Manual must be read and understood before beginning operation or maintenance and is not intended to replace the Operation & Maintenance Manual delivered with the machine. Figure 3 Foreword DL250-3/DL250TC-3...

  • Page 16: Federal Emission Control Systems

    The warranty period shall begin on the date the engine is delivered to the first ultimate purchaser who, in good faith, purchases the engine for purposes other than imminent resale. Foreword DL250-3/DL250TC-3...
  • Page 17 Any replacement part, as defined in Section 1900 (b), Title 13 of the California Code of Regulations, may be used in the performance of any maintenance or repairs and must be provided without charge to the owner. Foreword DL250-3/DL250TC-3...
  • Page 18 DEF (AdBlue) tank level sensor DEF (AdBlue) tank pump DEF (AdBlue) tank temperature sensor DEF (AdBlue) hose DEF (AdBlue) injector DEF(AdBlue) injector pressure sensor DEF (AdBlue) injector temperature sensor Catalyst temperature sensor SCR control unit (EEC3) SCR Catalyst NOX sensor Foreword DL250-3/DL250TC-3 0-10...
  • Page 19 The receipts must be transferred to each subsequent owner of the engine with the emission warranted engine. Scania cannot, however, deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance. Foreword DL250-3/DL250TC-3 0-11...
  • Page 20 The replacement of expendable maintenance items such as filters, hoses, belts, oil, thermostat, exhaust system and coolant made in connection with scheduled maintenance services once these parts have been replaced. Replacement items which are not genuine Scania parts or not authorized by Scania. Foreword DL250-3/DL250TC-3 0-12...

  • Page 21: California Emission Control Warranty Statement

    If the you do not receive the warranty service to which you believe you are entitled under the Warranty provisions, or if you need additional support or information concerning the Warranty, contact your Doosan or Scania engine distributor. California Emission Control Warranty Statement...

  • Page 22: Catalytic Converter

    Eye contact: Rinse eyes with water immediately. If irritation persists, seek immediate medical attention. • Skin contact: Wash with water and soap. Remove contaminated clothes. • Ingestion: If large amounts have been ingested, drink plenty of water and induce vomiting. Then seek medical attention. Foreword DL250-3/DL250TC-3 0-14...
  • Page 23 Do not dispose of the used SCR catalytic converter or its constituent parts into any waterways, storm drains or sanitary sewers. WARNING AVOID DEATH OR SERIOUS INJURY The SCR catalytic converter contains vanadium pentoxide, a chemical known to the State of California to cause cancer. Foreword DL250-3/DL250TC-3 0-15...
  • Page 24 Work done on the SCR catalytic converter may generate waste considered by the State of California to be a hazardous waste subject to Title 22, California Code of Regulations. Before disposing of hazardous waste, review follow applicable federal California requirements. Foreword DL250-3/DL250TC-3 0-16...

  • Page 25: Safety

    Safety DL250-3/DL250TC-3 Safety...

  • Page 26: Safety Decals

    Safety Decals With Text Safety decals with text consist of a signal word, pictorial and a text message panel. In some cases, a pictorial panel may not be part of the safety decal. Safety DL250-3/DL250TC-3...
  • Page 27 The safety information panel uses pictorials and/or prohibition signs to identify the actions necessary to avoid the hazard. Avoidance Panel Horizontal Configuration Hazard Avoidance Panel Panel FG018723 Figure 1 Safety DL250-3/DL250TC-3...

  • Page 28: Information And Location For Safety Decals

    Information and Location for Safety Decals 11(LIS) (Brake) (Steering) (Pilot) WL1400802 Figure 2 Safety DL250-3/DL250TC-3...
  • Page 29 • TO LEAVE THE WHEEL LOADER: Lower the attachment to the ground and make sure all controls are in neutral. Engage the parking brake. Set pilot cutoff switch to OFF position. Stop the engine and remove the key. Safety DL250-3/DL250TC-3...
  • Page 30 Do not weld on or drill holes in the protective structure. • Replacing ROPS, if damaged or modified. Refer to “Rollover Protective Structure (ROPS) / Falling Object Protective Structure (FOPS)” on page 1-23 for more information. 950205-04645 WL1400814 Safety DL250-3/DL250TC-3...
  • Page 31 • If battery acid contact occurs: Flush your skin with water immediately and apply baking soda or lime to neutralize the acid. Flush your eyes with water for 10 ~ 15 minutes. Get medical attention immediately. Safety DL250-3/DL250TC-3...
  • Page 32 11. Pressurized Gas and Fluid (950205-03782) WARNING AVOID DEATH OR SERIOUS INJURY • Heat or impact can cause the accumulator to explode. • Keep away from flame. EX1301187 • Do not weld on or drill into accumulator. Safety DL250-3/DL250TC-3...
  • Page 33 ROLL AWAY CAN CAUSE DEATH OR SERIOUS INJURY • Before disengaging park brake, block wheels to 950205-01691B prevent machine movement. WL1400815 Additional Decal 15. Electric Welding Attention (950212-02440) IMPORTANT Electrical welding on the frame can damage the engine's electronic control unit (ECU). 950212-02440 EX1402396 Safety DL250-3/DL250TC-3...
  • Page 34 Pace transmission lever in neutral position and WL1400810 engage parking brake. Check the transmission oil level using the dipstick or gauge. If necessary, add transmission oil (Spec. SAE 15W40) Correct oil level (Oil temp. 80°C (176°F)): Hot zone (dipstick type)/Red line (gauge type) Safety DL250-3/DL250TC-3 1-10...
  • Page 35 See the Operation & Maintenance Manual for more information. ISO 22241 DIN 70070 950205-01489A WL1300370 21. DEF (AdBlue) Filter (950205-02449) IMPORTANT ® DEF (AdBlue ) Filter Operation & Maintenance Manual information on the DEF filter. 950205-02449 WL1300373 Safety DL250-3/DL250TC-3 1-11...
  • Page 36 Only use Ultra Low Sulfur Diesel (ULSD) fuel and API CI-4/ACEA E5, E7 or API CJ-4/ACEA E9 grade engine oil with this machine. EX1301196 EX1301194 23. Pressure Diagnostic Ports PRESSURE DIAGNOSTIC PORTS See “Hydraulic Pressure Checks” on page 4-99. 950205-XXXXX WL1400826 Safety DL250-3/DL250TC-3 1-12...
  • Page 37 Mirror heater ON/OFF Fuel Heater Fuel heater ON/OFF Rotating Beacon Rotating beacon ON/OFF Emergency For emergency steering test: Steering Test Press and hold switch to test steering operation See Operation and Maintenance Manual for more information 950205-XXXXX WL1400811 Safety DL250-3/DL250TC-3 1-13...

  • Page 38: General

    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.

  • Page 39: Pressurized Fluids

    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.

  • Page 40: Flying Or Falling 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 HAOA110L guards. Figure 4 To prevent personnel from being struck by flying objects, keep personnel out of work area.

  • Page 41: Crushing And Cutting

    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. Safety DL250-3/DL250TC-3 1-17...

  • Page 42: Hot Coolant And Oils - Burn Prevention

    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. FG018458 Figure 11 Safety DL250-3/DL250TC-3 1-18...
  • Page 43 With a Booster Cable” on page 3-11, in this 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. Safety DL250-3/DL250TC-3 1-19...
  • Page 44 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. FG018458 Figure 13 Safety DL250-3/DL250TC-3 1-20...

  • Page 45: Fire Extinguisher And First-Aid Kit (Emergency Medical Kit)

    Check and service fire extinguisher at regular intervals and make sure that all work site crew members are adequately trained in its use. HDO1009L Figure 14 • Inspect fire extinguisher and service fire extinguisher regularly. • Follow instructions on extinguisher instruction plate. Safety DL250-3/DL250TC-3 1-21...

  • Page 46: Electrical System And Electrical Shock

    Never touch injector terminal or inside of engine controller. NOTE: If it is necessary to touch injector terminal or inside WL1300010 engine controller, contact your DOOSAN distributor. Figure 16 Safety DL250-3/DL250TC-3 1-22...
  • Page 47 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 roll-over and falling objects, and result in death or serious injury.
  • Page 48 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.

  • Page 49: Transportation

    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. Safety DL250-3/DL250TC-3 1-25...
  • Page 50 • 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. Safety DL250-3/DL250TC-3 1-26...

  • Page 51: Operation

    WARNING No Entry equipment near fences or near boundary obstacles. FG013735 Figure 19 Know appropriate work site hand signals and personnel that are authorized to give hand signals. Follow hand signals from only one person. Safety DL250-3/DL250TC-3 1-27...

  • Page 52: Check Tire Pressure And Condition

    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. Safety DL250-3/DL250TC-3 1-28...

  • Page 53: Operator Station

    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. Safety DL250-3/DL250TC-3 1-29...
  • Page 54 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. WARNING AVOID DEATH OR SERIOUS INJURY...

  • Page 55: Visibility Information

    Inspect equipment and repair immediately if there are problems with visual aids. If machine cannot be fixed immediately, DO NOT use the machine. Contact your DOOSAN distributor and arrange for repairs. Safety DL250-3/DL250TC-3...

  • Page 56: Boost Starting Or Charging Engine Batteries

    Refer to “Starting Engine With a Booster Cable” on page 3-11, in this manual for proper procedures. • Connect positive (+) cable first when installing cables and disconnect negative (-) cable first when removing them. Safety DL250-3/DL250TC-3 1-32...

  • Page 57: Starting Engine

    Also, a white residue, because of water vapor inside engine, can form at the engine oil fill location. These conditions will not affect engine performance or damage the engine or other exhaust system components. Safety DL250-3/DL250TC-3 1-33...
  • Page 58 • When operating in areas with poor visibility, designate a flagman to direct work site traffic. • Keep unauthorized personnel away from turning radius or FG019361 travel path of the machine. Figure 23 Safety DL250-3/DL250TC-3 1-34...
  • Page 59 When traveling on rough ground, travel at low speed, and avoid sudden changes in direction. Know permitted ground pressure. Ground pressure of the machine may change depending on attachment and load. Keep height and length of attachment in mind. Safety DL250-3/DL250TC-3 1-35...

  • Page 60: Lifting And Digging

    This could cause wheel loader to tip or rollover, which could cause death or serious injury to operator. Working around deep pits, trenching or along high walls may require support blocks, especially after heavy rains or during spring thaws. Safety DL250-3/DL250TC-3 1-36...

  • Page 61: Operation On Slopes

    Keep the machine under control. Do not overload the machine beyond capacity. • Do not turn on slopes or travel across slopes. Always go down to a flat place to change position of the machine, then travel backup the slope again. WL1400868 Figure 25 Safety DL250-3/DL250TC-3 1-37...
  • Page 62 • Check towrope or tow bar for damage and make sure it has sufficient strength for work. • When necessary to descend a grade, another towing vehicle must be used in rear to provide additional braking. Safety DL250-3/DL250TC-3 1-38...
  • Page 63 Always attach wire rope onto left and right hooks and secure in position. • If engine on problem machine will not start or there is a FG019101 failure in brake system, always contact your DOOSAN Figure 26 distributor before towing. • Never go between towing machine and towed machine during towing operation.

  • Page 64: Equipment Lowering With Engine Stopped

    When stopping or parking machine, lower front structure to ground. If this is not done, sudden collapse of front structure caused from a hydraulic hose failure can result in death or serious injury. FG023188 Figure 29 Safety DL250-3/DL250TC-3 1-40...

  • Page 65: Engine Stop

    After the machine is parked, allow engine to run for at least five (5) minutes before stopping the engine. This allows hot areas of engine to begin to cool gradually. • Do not leave operator's seat when there is a raised load. Safety DL250-3/DL250TC-3 1-41...

  • Page 66: Parking Machine

    Machine movement will occur if any controls are moved. This can result in death or serious injury. Always move hydraulic lockout control to "LOCK" position before stopping the engine or immediately after engine stops running. Safety DL250-3/DL250TC-3 1-42...

  • Page 67: Preservation/Storing Machine

    Turning off electrical current with battery disconnect switch. • Parking machine where risk of theft, burglary and damage is minimized. • Removing valuables from cabin such as cellular phone, computer, radio and bags. See “Long Term Storage” on page 4-103, for more information. Safety DL250-3/DL250TC-3 1-43...
  • Page 68 Tension of all belts. • Air pressure. • Air cleaner. • Batteries and electrical connections. • Lubricate all greasing points. • Wipe off grease from piston rods. • Inspect for signs of nests (i.e. birds, rodents, etc.) Safety DL250-3/DL250TC-3 1-44...

  • Page 69: Maintenance

    Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can result in death or serious injury. • Never service DOOSAN equipment without instructions. • Always lower lift arm and attachment to ground before doing any maintenance. •...
  • Page 70 Maintenance procedures which are not in this manual must be performed ONLY BY QUALIFIED SERVICE PERSONNEL. Always use genuine DOOSAN replacement parts. • Only authorized personnel should service and repair the machine. Do not allow unauthorized personnel access to the machine or into work area.

  • Page 71: Warning Tag

    Attach a "DO NOT OPERATE" warning tag to starter switch or to controls before servicing or repairing equipment. Warning tags are available from your DOOSAN distributor. Safety DL250-3/DL250TC-3 1-47...

  • Page 72: Proper Tools And Clothing

    Hitting hard metal pins, bucket teeth, cutting edges or bearings with a hammer, can cause metal pieces to break or fly off resulting in serious injury. Always wear safety goggles and leather gloves. Keep personnel and bystanders away. Safety DL250-3/DL250TC-3 1-48...

  • Page 73: Use Of Lighting

    Check electrical wires daily for wires that are loose or frayed. Tighten all loose, and repair or replace all frayed, electrical wires before operating machine. Remove all flammable materials and debris from the engine compartment, exhaust system components and hydraulic lines. Safety DL250-3/DL250TC-3 1-49...

  • Page 74: Burn Prevention

    Do not smoke while you are checking battery electrolyte level. Electrolyte is an acid. Electrolyte can cause personal injury. Do not allow electrolyte to contact skin, eyes or other body parts. Always wear safety goggles and face protection when working with batteries. Safety DL250-3/DL250TC-3 1-50...

  • Page 75: Rubber That Contains Fluorides

    (a solution or suspension of calcium hydroxide, i.e. slaked lime in water). After the work has been completed, the gloves must be washed in limewater and then discarded. Safety DL250-3/DL250TC-3 1-51...

  • Page 76: Rubber And Plastics

    Hydrofluoric Acid Burn Jelly or something similar. Seek medical advice. Symptom may not appear until several hours afterwards. Discard gloves, rags etc. which are suspected of having touched burned rubber that contains fluorides. Safety DL250-3/DL250TC-3 1-52...

  • Page 77: Welding Repairs

    • Wear protective clothing. • Make sure there is good ventilation. • Remove all flammable objects and make sure a fire extinguisher is available for immediate use. Safety DL250-3/DL250TC-3 1-53...

  • Page 78: Working On Machine

    Do not work under the machine if machine is lifted off ground and the machine is supported only with work equipment. If any control levers are moved, or there is damage to hydraulic system, work equipment or the machine will suddenly drop causing death or serious injury. Safety DL250-3/DL250TC-3 1-54...

  • Page 79: Lock Inspection Covers

    Contact your DOOSAN distributor for assistance. • Wear safety goggles and leather gloves when working on an accumulator. Hydraulic oil under pressure can penetrate skin and result in death or serious injury.

  • Page 80: Supports And Blocking For Work Equipment

    Connection fittings are damaged or leaking. NOTE: Refer “Hose In-service Lifetime Limit (European Standard ISO 8331 EN982 CEN)” on page 4-88, for additional European regulations. High-pressure is generated inside fuel lines when engine is running. Before performing inspection or maintenance of fuel Safety DL250-3/DL250TC-3 1-56...
  • Page 81 Do not use or charge battery if battery electrolyte level is below LOW LEVEL line. This can cause an explosion. Periodically check battery electrolyte level and add distilled water to bring electrolyte level to FULL LEVEL line. Safety DL250-3/DL250TC-3 1-57...
  • Page 82 After charging, secure battery back in machine. When repairing or welding electrical system, wait for approximately one minute after turning engine starter switch key "OFF". Then disconnect negative (-) terminal of battery to stop flow of electricity. Safety DL250-3/DL250TC-3 1-58...

  • Page 83: Environment And Circumstances

    Do not travel too close to edge of a drop-off. When working on or from top of buildings or other structures, check if structure can support weight of machine and attachment. If a building structure collapses, this can cause death or serious injury. Safety DL250-3/DL250TC-3 1-59...
  • Page 84 Do not panic and do not raise bucket, if ground should begin to collapse. Lower work equipment to improve stability of machine. Never dig under machine, if there is a potential of causing a landslide. Safety DL250-3/DL250TC-3 1-60...

  • Page 85: High-Voltage Cables

    Also check which rules apply to ground personnel regarding exposing cables, utilities and electrical lines. FG019379 Figure 47 Consider all electrical cables as live. Safety DL250-3/DL250TC-3 1-61...

  • Page 86: Working In Contaminated Environment

    Working in Contaminated Environment When working within area which is contaminated or where there is a health risk, check local laws and regulations and contact your DOOSAN distributor for assistance with identifying what additional safety precautions need to be taken. Safety...

  • Page 87: Operation In Extreme Conditions

    To prevent fuel from being clogged due to formation of wax in fuel, make sure that wax formation point of fuel is lower than atmospheric temperature. Safety DL250-3/DL250TC-3 1-63...
  • Page 88 • Formation of scale and rust in cooling system occurs more rapidly in extremely high temperatures. Change antifreeze each year to keep corrosion inhibitor at full strength. Safety DL250-3/DL250TC-3 1-64...
  • Page 89 Operation of machine can cause dust in almost any area. However, when in predominantly dusty or sandy areas, additional precautions must be taken. Keep cooling system fins and cooling areas clean. Blow out with compressed air, if possible, as often as necessary. Safety DL250-3/DL250TC-3 1-65...
  • Page 90 Operation at High Altitudes Operation instructions at high altitudes are the same as those provided for extreme cold. Before operating at high altitudes, engine fuel and air mixture may have to be adjusted according to appropriate engine manual. Safety DL250-3/DL250TC-3 1-66...

  • Page 91: Exhaust Ventilation

    Diesel engine exhaust contains combustible materials which can be harmful to your health. Always run engine in a well ventilated area. If you are in an enclosed area, vent exhaust to outside. Safety DL250-3/DL250TC-3 1-67...

  • Page 92: Asbestos Information

    OSHA or other work site rules, laws and regulations. Use a respirator, water spray or other means to control dust. Silica dust can cause lung disease and is known to the state of California to cause cancer. Safety DL250-3/DL250TC-3 1-68...

  • Page 93: Disposal Of Hazardous Materials

    Sound pressure level (LpA) at operator position 72 dB(A) (Measurement according to ISO 6396) Sound power level (LwA) around the machine (Measurement according to 2001/14/EC with 104 dB(A) applicable appendices and measuring method according to ISO 6395) Safety DL250-3/DL250TC-3 1-69...

  • Page 94: Vibration Information

    Provide machines and schedule time to maintain terrain conditions. Use a seat in conformance with ISO 7096 and keep the seat maintained and adjusted: • Adjust the seat and suspension for the weight and size of the operator; Safety DL250-3/DL250TC-3 1-70...
  • Page 95 Provide breaks to reduce long periods of sitting; • Avoid jumping down from the cab or access system; • Minimize repeated handling and lifting of loads; • Minimize any shocks and jolts during sports and leisure activities. Safety DL250-3/DL250TC-3 1-71...
  • Page 96 Safety DL250-3/DL250TC-3 1-72...

  • Page 97: Operating Controls

    These lights will only show there is a problem that needs correction. IMPORTANT When any one or more of the warning symbols on the control console come "ON", immediately stop operation. Investigate and correct problem before proceeding with operation. DL250-3/DL250TC-3 Operating Controls...

  • Page 98: Component Locations

    COMPONENT LOCATIONS The following figure identifies the location of major machine components. DL250-3 39 40 42 43 16 17 18 19 20 21 22 23 15 16 12 13 14 FG028723 Figure 1 Operating Controls DL250-3/DL250TC-3...
  • Page 99 Front Axle Work Light Loader Arm Air Conditioner Unit Engine Oil Level Dipstick Engine Air Intake Precleaner Engine Oil Fill Cap Air Cleaner Transmission Muffler Tail Pipe Transmission Oil Filter Muffler Parking Brake CAC Cooler Driveshaft (Center) DL250-3/DL250TC-3 Operating Controls...
  • Page 100 DL250TC-3 16 17 17 18 24 25 11 12 13 Opposite Side FG028685 Figure 2 Operating Controls DL250-3/DL250TC-3...
  • Page 101 Transmission Oil Filter Operator's Cabin Parking Brake Work Light Center Pin Air Conditioner Unit Steering Wheel Cylinder Oil Tank Driveshaft (Center) Engine Air Intake Precleaner Driveshaft (Front) Air Cleaner Front Axle Muffler Tail Pipe Boom Cylinder Muffler Loader Arm DL250-3/DL250TC-3 Operating Controls...

  • Page 102: Operator's Area

    Figure 3, identifies controls in operator's cabin. FG018933 Figure 3 Reference Reference Description Description Number Number Steering Console and Pedal Right Side Switch Panel (See page 3-7) (See page 3-52) Various Cabin Locations Seat Adjustment (See page 3-67) (See page 3-79) Operating Controls DL250-3/DL250TC-3...

  • Page 103: Steering Console And Pedals

    Steering Wheel Not Used Kick-down Button Boom Kick-out Switch Transmission Lever Diesel Particulate Filter (DPF) Front Instrument Panel Switch (See page 3-18) LIS Switch (Optional) Hour Meter Not Used Hazard Warning Light Switch Differential Lock Button (Manual) Operating Controls DL250-3/DL250TC-3...
  • Page 104 (Figure 6) or the left button at the tip of the finger tip lever (optional) of the two levers (Figure 7), will sound the horn. NOTE: Starter switch must be "ON". FG018935 Figure 5 FG018937 Figure 6 WL1300162 Figure 7 Operating Controls DL250-3/DL250TC-3...

  • Page 105: Combination Switch

    Pull up to 2nd step - The high beams turn "ON". (It returns to "NEUTRAL" position when released.) For turn off, pull up 2nd step again. NOTE: High and low beams will only function with the headlight switch in the "||" position. FG018957 Figure 9 Operating Controls DL250-3/DL250TC-3...

  • Page 106: Accelerator Pedal

    12) to desired position. Push lever down (Tilt angle is 21°). Adjusting Steering Wheel Telescopic Pull lever (1, Figure 12) upward and move wheel (2, Figure FG018959 12) to desired position. Push lever down (telescopic stroke Figure 11 is 80 mm). FG018960 Figure 12 Operating Controls DL250-3/DL250TC-3 2-10...

  • Page 107: Brake Pedal (Right And Left Pedals)

    Do not use brake pedal as a footrest. This will cause brake disk to wear faster than normal, and this could reduce braking capability. 6. Steering Wheel Rotating steering wheel controls position of front wheels and this determines direction of machine travel. FG018981 Figure 14 Operating Controls DL250-3/DL250TC-3 2-11...
  • Page 108 (Right one of two levers). NOTE: If the machine is equipped with there is an additional kick-down button. See “2. Kick-down Button (Two Places)” on page 3-58. FG023248 Figure 17 Operating Controls DL250-3/DL250TC-3 2-12...

  • Page 109: Transmission Lever

    FG019005 Figure 19 AVOID INJURY "LOCK" transmission lever. Whenever machine is parked, "LOCK" transmission lever in "NEUTRAL" to prevent accidental machine movement. 9. Front Instrument Panel See “Front Instrument Panel” on page 3-18 FG024325 Figure 20 Operating Controls DL250-3/DL250TC-3 2-13...

  • Page 110: Hour Meter

    "ON". NOTE: Hazard warning lights will function with starter switch in "OFF" position. 12. Display Screen Control Switch See “Multifunction Gauge and Graphic Information Display” on page 3-23 FG019009 Figure 23 Operating Controls DL250-3/DL250TC-3 2-14...
  • Page 111 "ON". CAUTION AVOID INJURY The actuation of the differential lock (pressing differential lock button, manual mode) could influence driveability while steering. Differential lock actuation is only be recommended when driving straight. 15. Not Used Operating Controls DL250-3/DL250TC-3 2-15...
  • Page 112 (forced) regeneration switch. NOTE: Turn "off" cutoff switch and "on" parking brake switch before forced regeneration. If the machine is moved or stopped while manual (forced) regeneration is in process, the regeneration will need to be restarted. Operating Controls DL250-3/DL250TC-3 2-16...
  • Page 113 4 km/h (2.5 MPH) or if reverse travel speed is less than 2 km/h (1.2 MPH). 19. Not Used 20. Differential Lock Button (Manual) Depress switch to "LOCK" front axle differential and release switch to "UNLOCK" differential. FG019121 Figure 29 Operating Controls DL250-3/DL250TC-3 2-17...

  • Page 114: Front Instrument Panel

    Light Light (Optional) Right Turn and Hazard Warning High Beam Indicator Light Light Air Cleaner Clogged Warning Parking Brake Indicator Light Light Work Light Indicator Light Brake Fluid Pressure Warning Light Mirror Heating Indicator Light (Optional) Operating Controls DL250-3/DL250TC-3 2-18...

  • Page 115: Password Activated

    FG004182 Figure 31 2. Multifunction Gauge and Graphic Information Display See “Multifunction Gauge and Graphic Information Display” on page 3-25 This section will have a more in-depth explanation of the display area. FG024327 Figure 32 Operating Controls DL250-3/DL250TC-3 2-19...

  • Page 116: Left Turn And Hazard Warning Light

    If the machine is moved while this light is turned "ON", it could cause premature wear or damage the brake Figure 35 system. Always "RELEASE" parking brake and make sure this light is "OFF" before operating machine. Operating Controls DL250-3/DL250TC-3 2-20...

  • Page 117: Work Light Indicator Light

    AVOID DEATH OR SERIOUS INJURY If the emergency steering indicator light turns "ON" while operating, immediately stop operation. Inspect and repair system before continuing to operate machine. NOTE: The light will also turn "ON" when the system is being tested. Operating Controls DL250-3/DL250TC-3 2-21...

  • Page 118: High Beam Indicator Light

    AVOID DEATH OR SERIOUS INJURY HA0O2024 Never operate machine when this light is "ON" or when alarm is sounding. Always check for cause of Figure 41 drop in brake fluid pressure, and repair problem before operating machine. Operating Controls DL250-3/DL250TC-3 2-22...

  • Page 119: Multifunction Gauge And Graphic Information Display

    ) button, is used to move a menu item "UP" or to "LEFT". FG019322 Figure 43 Down Arrow Button Down arrow ( ) button, is used to move a menu item "DOWN" or to "RIGHT". FG019323 Figure 44 Operating Controls DL250-3/DL250TC-3 2-23...
  • Page 120 FG015189 Figure 45 Selector Button SELECTION ( ) button, is used to set a menu or clear the operating hour of filter/oil. FG019324 Figure 46 Operating Controls DL250-3/DL250TC-3 2-24...
  • Page 121 Figure 47 Reference Reference Description Description Number Number Fuel Gauge Engine Speed Engine Coolant Temperature ECO Bar Gauge Multifunction Display Transmission Oil Temperature Display Warning Symbols Gauge Indicator Symbols Transmission Actual Gear Digital Clock Transmission Select Gear Operating Controls DL250-3/DL250TC-3 2-25...
  • Page 122 "ON" and be displayed on the in screen. Allow engine to run at "LOW IDLE" until Figure 50 temperature gauge registers in white zone again. NOTE: “9. Display Warning Symbols” page 2-29, for location of this warning symbol and others. Operating Controls DL250-3/DL250TC-3 2-26...
  • Page 123 Figure 54 – Red color: red colored ECO symbol indicates fast engine load or working with equipment under load. – Gray color: gray colored ECO symbol is displayed in cases other than the above 3 conditions. Operating Controls DL250-3/DL250TC-3 2-27...
  • Page 124 Figure 56 To initialize trip meter, press SELECTION ( button for three (3) seconds. To reset trip meter to 0 km, press SELECTION ( button for 3 seconds while instrument display is flashing. FG024333 Figure 57 Operating Controls DL250-3/DL250TC-3 2-28...
  • Page 125 Engine Warning Symbol FG024335 Water In Fuel Warning Symbol Figure 60 Engine Stop Symbol Preheating Indicator Symbol Diesel Particulate Filter (DPF) Regeneration Warning Symbol Diesel Particulate Filter (DPF) High Temperature Warning Symbol Quick Coupler Release Warning Symbol Operating Controls DL250-3/DL250TC-3 2-29...
  • Page 126 FG019122 Figure 63 Engine Warning Symbol This symbol indicates that engine needs to be checked. NOTE: If this symbol turns "ON", stop machine and repair cause of the problem. AQO0040L Figure 64 Operating Controls DL250-3/DL250TC-3 2-30...
  • Page 127 (Figure 68). NOTE: Run machine at "LOW IDLE" and do not stop engine until regeneration cycle is FG018399 completed. See “Engine Exhaust Emission Figure 68 Control System” on page 3-13 for more information. Operating Controls DL250-3/DL250TC-3 2-31...
  • Page 128 This symbol indicates when the quick coupler is released. WARNING AVOID DEATH OR SERIOUS INJURY DO NOT OPERATE machine and attachment if FG002195 quick coupler switch is in "I" ( ) position. Figure 70 Attachment can fall off causing death or serious injury. Operating Controls DL250-3/DL250TC-3 2-32...
  • Page 129 When Auto 2-4 mode is selected, symbol is shown on lower part of screen. FG019131 Figure 73 Engine Power Mode - Power When power mode is selected, symbol is shown on lower part of screen. FG019132 Figure 74 Operating Controls DL250-3/DL250TC-3 2-33...
  • Page 130 Auto Idle When auto idle is operating, symbol is shown on lower part of screen. FG019135 Figure 77 2nd Gear Mode When 2nd gear is selected, symbol is shown on lower part of screen. BSO0510L Figure 78 Operating Controls DL250-3/DL250TC-3 2-34...
  • Page 131 Reverse Fan When reverse fan is operating, symbol is shown on lower part of screen. FG004185 Figure 81 Transmission Cutoff When transmission cutoff is selected, symbol is shown on lower part of screen. FG019138 Figure 82 Operating Controls DL250-3/DL250TC-3 2-35...
  • Page 132 The digital clock shows current time. The displayed contents are as follows. Display Description HH:mm AM/PM Hour Minute AM (PM) AM (PM) Refer to “User Menu Access and Escape Buttons” on FG019345 page 2-39 for time. Figure 85 Operating Controls DL250-3/DL250TC-3 2-36...

  • Page 133: Warning Pop-Up

    Go to Warning Display Move selection window to warning display by pressing UP ) button. FG024336 Figure 86 Enter Checking Mode Enter individual symbol checking mode by pressing SELECTION ( ) button. FG024337 Figure 87 Operating Controls DL250-3/DL250TC-3 2-37...
  • Page 134 Select warning symbol by pressing SELECTION ( button to read warning message. 010-4104-1697 Low E/G Oil Pressure Check E/G Oil Pressure FG024338 Figure 88 Delete Warning Pop-up Press ESC button to delete warning pop-up. FG024339 Figure 89 Operating Controls DL250-3/DL250TC-3 2-38...
  • Page 135 Press ESC button to return to previous screen. Vehicle State Vehicle Setup GP Setup WARNING FG019142 AVOID DEATH OR SERIOUS INJURY Figure 91 Do not use buttons to change menu state when traveling or operating machine. Operating Controls DL250-3/DL250TC-3 2-39...
  • Page 136 The screen displays information on filter/oil use time, Vehicle State replacement period, and remaining time. Monitoring At Vehicle State, if cursor is placed on Filter/Oil Filter/Oil Information information, press SELECTION ( ) button to display filter/oil information. Vehicle Information FG019145 Figure 94 Operating Controls DL250-3/DL250TC-3 2-40...
  • Page 137 ) button to change replacement period. NOTE: Press UP ( ) or DOWN ( ) button to locate it at NO. Then, press SELECTION ) button to allow pop-up window to disappear without changing replacement panel. Operating Controls DL250-3/DL250TC-3 2-41...
  • Page 138 Replacement period is 500hr exceeded! CHANGE: E/G Oil Filter AVOID DEATH OR SERIOUS INJURY TIME: REMAIN: 495hr 500hr CHANGE: E/G Oil Do not use buttons to change Vehicle State menu when traveling or operating machine. FG019150 Figure 100 Operating Controls DL250-3/DL250TC-3 2-42...
  • Page 139 Reverse Fan Auto Period Setting In "Vehicle Setup" window, with cursor on "Reverse Fan Auto Period Setting" menu, press SELECTION ) button to enter "Reverse Fan Auto Period Setting" window. FG021976 Figure 104 Operating Controls DL250-3/DL250TC-3 2-43...
  • Page 140 ) button and make selection with YES NO SELECTION ( ) button. – Auto idle disable can be changed with same method described above. FG019155 – Pressing ESC button cancels change and Figure 108 removes pop-up window. Operating Controls DL250-3/DL250TC-3 2-44...
  • Page 141 1 2 3 4 5 6 7 8 9 Enter Password IMPORTANT FG019188 If password input errors have been made three Figure 112 times in a row, screen will move to default screen. After that, starting will be locked for 10 minutes. Operating Controls DL250-3/DL250TC-3 2-45...
  • Page 142 Input a new four-digit password (repeat it twice). – On Password Setting screen, select lock (applied) or unlock (not applied). FG019191 Figure 115 IMPORTANT Be careful not to forget your password. If you have forgotten your password, contact a DOOSAN distributor. Operating Controls DL250-3/DL250TC-3 2-46...
  • Page 143 Service Phone Number Setting FG019194 Figure 118 The selected style screen is displayed as normal Default Screen Setting display screen. The screen is set as style #1 at factory. Style #1 Style #2 FG019195 Figure 119 Operating Controls DL250-3/DL250TC-3 2-47...
  • Page 144 If set up is completed, Press SELECTION ( button to store set up details. TIME : 06 Press ESC button to return to previous screen. DATE 2010 / 09 FG018538 Figure 122 Operating Controls DL250-3/DL250TC-3 2-48...
  • Page 145 1 2 3 4 5 6 7 8 9 0 FG019200 Figure 124 When you input service phone numbers, if warning/ alarm is given, check input phone numbers in pop-up window. 010-4104-1697 Low E/G Oil Pressure Check E/G Oil Pressure FG024338 Figure 125 Operating Controls DL250-3/DL250TC-3 2-49...
  • Page 146 DOWN ( ) button and move cursor to select a language. Then, press SELECTION ( ) button to select language. English Francaise Press ESC button to return to previous screen. Deutsch Nederlandse Italiano FG019203 Figure 129 Operating Controls DL250-3/DL250TC-3 2-50...
  • Page 147 ) button and move cursor to a desired Maintenance Notification Enable Pop up location. Then, press SELECTION ( ) button to select Enable or Disable. Only Warning Pop-up is enabled as default setting. FG019205 Figure 131 Operating Controls DL250-3/DL250TC-3 2-51...

  • Page 148: Right Side Switch Panel

    Rear Work Light Switch Starter Switch Rear Wiper Switch Power Mode Switch Cigarette Lighter Transmission Shift Switch Power Socket for 12 Volt Pilot Cutoff Switch F/R (Forward/Reverse) Selector Parking Brake Switch Switch Transmission Cutoff Switch F/R (Forward/Reverse) Control Switch Operating Controls DL250-3/DL250TC-3 2-52...

  • Page 149: Fnr Lever (Standard

    (Figure 148) to "LOCKED" position, especially when you are driving machine. WARNING AVOID DEATH OR SERIOUS INJURY Do not control joystick or lever when people are near the bucket. Operating Controls DL250-3/DL250TC-3 2-53...
  • Page 150 When this button is pressed for forward travel at same time as "KD" (5, Figure 133) button is pressed, machine can travel forward. When machine is driven, it can change travel direction without pressing "KD" (5, Figure 133) button. Operating Controls DL250-3/DL250TC-3 2-54...
  • Page 151 Move left control lever (L2, Figure 137) push forward (5, Figure 136) to dump bucket, or pull back (6, Figure 136) to crowd bucket and pull completely back (7, Figure 136) to crowd bucket with lever detent. Operating Controls DL250-3/DL250TC-3 2-55...
  • Page 152 LOADER ARM RAISE WITH DETENT • H: Horn Button BUCKET DUMP Kick-down BUCKET CROWD • KD: Kick-down Switch BOOM CROWD WITH DETENT ACTIVATE ONR OF OPERATIONS OF OPTIONAL TOOL ACTIVATE THE OTHER OPERATIONS OF OPTIONAL TOOL Operating Controls DL250-3/DL250TC-3 2-56...
  • Page 153 Position 7 (7, Figure 138): Activate the other operations for the 4th spool of MCV with lever detent. (For instance, turn right log grabber) WARNING AVOID DEATH OR SERIOUS INJURY Do not use horn button on joystick to honk with 4 spool MCV. DL250-3/DL250TC-3 Operating Controls 2-57...

  • Page 154: Kick-Down Button (Two Places)

    Pressing lowest button at tip of pilot control valve lever (joystick) (Figure 142) or button at end of combination switch (Figure 143) will sound horn. NOTE: Starter switch must be "ON". FG018937 Figure 142 FG018935 Figure 143 Operating Controls DL250-3/DL250TC-3 2-58...

  • Page 155: Starter Switch

    "I" (ON) position. Do not operate starter switch for more than 15 seconds at a time. This will help prevent damage to starter. WARNING AVOID DEATH OR SERIOUS INJURY DO NOT USE STARTING FLUIDS. The starting system could cause starting fluid to explode. Operating Controls DL250-3/DL250TC-3 2-59...

  • Page 156: Power Mode Switch

    • P: 20% Later shift to higher gear than S mode • S: Normal mode • E: 20% Earlier shift to higher gear than S mode T/M shifting mode is changed automatically related with engine mode. Operating Controls DL250-3/DL250TC-3 2-60...

  • Page 157: Pilot Cutoff Switch

    CAUTION FG019169 Figure 148 AVOID INJURY When driving or parking, the pilot cutoff switch must be set to "O" (OFF) position so the operator can fully control the movement of the joystick functions., Operating Controls DL250-3/DL250TC-3 2-61...

  • Page 158: Parking Brake Switch

    In this position, the "INCHING" mode is selected. In this mode, the transmission is put in "NEUTRAL" by pressing the left brake pedal. This mode is suitable for a load handling operation. When the Operating Controls DL250-3/DL250TC-3 2-62...

  • Page 159: Headlight Switch

    In this position, clearance, tail, instrument panel and switch lights are turned "ON". FG016017 In this position, clearance, tail, instrument panel, Figure 153 switch lights and headlight are turned "ON". Operating Controls DL250-3/DL250TC-3 2-63...

  • Page 160: Front Work Light Switch

    In this position, windshield washer fluid sprays onto the rear windshield while running the rear wiper. When released, the switch returns to "O" (OFF) position. In this position, windshield wiper mounted on rear windshield of operator's cabin is turned "ON". FG019214 Figure 156 Operating Controls DL250-3/DL250TC-3 2-64...

  • Page 161: Cigarette Lighter

    F/R control switch must be in FG003977 "NEUTRAL". Figure 159 2) If the transmission lever is actuated (moved), the gearshift functions of the F/R control switch are turned "OFF/DEACTIVATED", and forward/ reverse travel is again controlled by the transmission lever. Operating Controls DL250-3/DL250TC-3 2-65...

  • Page 162: F/R (Forward/Reverse) Control Switch

    If the transmission lever is moved out of Figure 160 "NEUTRAL" while operating the F/R control switch, the transmission lever will override the switch. The F/R control switch system will require, that F/R selector switch be pressed again, with transmission lever "NEUTRAL". Operating Controls DL250-3/DL250TC-3 2-66...

  • Page 163: Various Cabin Locations

    Emergency Steering Switch and Stereo/CD Player (Optional) Automatic Test (Optional) Heater and Air Conditioner Control Panel Rotating Beacon Light Switch (Optional) Speakers Fuel Heater Switch (Optional) Storage Compartments Unified Antenna Electrical Box Quick Coupler Switch (Optional) Fuse Box Operating Controls DL250-3/DL250TC-3 2-67...

  • Page 164: Cabin Light

    3. Heater and Air Conditioner Control Panel For operation of heater and air conditioner, “Heater and Air OUTSIDE AUTO AUTO Conditioner Operation” on page 2-72. TEMP MODE FG019209 Figure 164 4. Speakers Emits sound generated by stereo. HBOM350L Figure 165 Operating Controls DL250-3/DL250TC-3 2-68...

  • Page 165: Storage Compartments

    This switch is used to operate a heater installed in the mirror. Press the switch and the mirror heater will remove frost and ice from mirror. In this position, mirror heater is turned "OFF". In this position, mirror heater is turned "ON". FG019224 Figure 169 Operating Controls DL250-3/DL250TC-3 2-69...
  • Page 166 10. Rotating Beacon Light Switch (Optional) If unit is equipped with a rotating beacon warning light, push this switch to activate it. In this position, beacon is turned "OFF". In this position, beacon is turned "ON". FG016020 Figure 171 Operating Controls DL250-3/DL250TC-3 2-70...
  • Page 167 "UNLOCK" position. Figure 174 WARNING AVOID DEATH OR SERIOUS INJURY DO NOT OPERATE machine and attachment if quick coupler switch is in "I" ( ) position. Attachment can fall off causing death or serious injury. Operating Controls DL250-3/DL250TC-3 2-71...

  • Page 168: Heater And Air Conditioner Operation

    Rear Nozzle Front Nozzle (Defroster) The heater and air conditioner are combined into one unit to the right side of the operator's seat. If necessary, the operator can control interior cabin temperature using the operation panel. Operating Controls DL250-3/DL250TC-3 2-72...

  • Page 169: Control Panel

    When the system is in "AUTO" mode, specifications can be manually changed by pushing another button. If a function is manually changed, the word "AUTO" does FG000088 not appear in the LCD display, but the unchanged Figure 177 functions will remain in "AUTO" mode. Operating Controls DL250-3/DL250TC-3 2-73...
  • Page 170 Temperature Unit Selector Button This button gives the choice to select either °C or °F. FG000094 Figure 180 Mode Selector Button This button is used to select which combination air outlets will be used. MODE FG000096 Figure 181 Operating Controls DL250-3/DL250TC-3 2-74...
  • Page 171 Used to direct airflow to lower portion of operator's cabin and feet. This mode is mainly used for heating. FG019230 Figure 184 Used to direct airflow to the front window and to operator's feet. FG019232 Figure 185 Operating Controls DL250-3/DL250TC-3 2-75...
  • Page 172 Figure 188 Air Conditioner Button This button is used to turn the air conditioner "ON" or "OFF". When this function is activated, an "A/C" is displayed in the upper left corner of the LCD. FG000105 Figure 189 Operating Controls DL250-3/DL250TC-3 2-76...

  • Page 173: Memory Function

    The blower button must be on "Three Bars". If operating the air conditioner or heater for a long time, operate the air inlet selector button and when smoking, vent the air to the outside to prevent irritation to eyes. Operating Controls DL250-3/DL250TC-3 2-77...

  • Page 174: Stereo/Cd Player (Optional)

    FM Selection USB Loading Port USB Selection Sound Mode Selector Display Mode Control CD Player (Optional) TUNE VOLUME AM/FM SOUND TRACK ST RDS REG TA TP PTY AF DIR INT RPT RDM EQ FG017017 Figure 193 Operating Controls DL250-3/DL250TC-3 2-78...

  • Page 175: Seat Adjustment Mechanical Suspension (Standard)

    Pulling up left side lever (3, Figure 195) allows seat backrest to be tilted forward or backward. 4. Lumbar Control Knob Rotate lumbar control knob (4, Figure 195) to increase or decrease or decrease support to lower back. Operating Controls DL250-3/DL250TC-3 2-79...

  • Page 176: Angle Adjustment Of Armrest

    (safety) thermostat that operates between 32° - 41°C (90° - 106°F). At 41°C (106°F), the secondary (safety) thermostat stops heating the seat. If the seat is heating up to a higher then normal temperature, have seat serviced immediately. Operating Controls DL250-3/DL250TC-3 2-80...

  • Page 177: Recommendations For Limiting Vibrations

    Recommendations for Limiting Vibrations Select the right machine, equipment and attachments for a particular application. Replace any damaged seat by a DOOSAN genuine part. Keep the seat maintained and adjusted. • Adjust the seat and suspension for the weight and size of the operator.

  • Page 178: Seat Adjustment W/Air Suspension And Heater

    Lift backrest tilt adjustment lever (3, Figure 197) and allow cushion to angle forward or lean backward into desired position and release handle. 4. Lumbar Control Knob Rotate lumbar control knob (4, Figure 198) to increase or decrease support to lower back. Operating Controls DL250-3/DL250TC-3 2-82...
  • Page 179 (safety) thermostat that operates between 38° - 43°C (100°F - 109°F). At 43°C (109°F), the secondary (safety) thermostat stops heating the seat. If the seat is heating up to a higher then normal temperature, have seat serviced immediately. Operating Controls DL250-3/DL250TC-3 2-83...

  • Page 180: Seat Belt

    Adjust belt length so it is comfortably tight against operator's pelvic region (hipbone). HAOB140L Figure 199 Press button (3, Figure 200) in center of buckle (2) and pull out belt (1) to unlock. HAOB150L Figure 200 Operating Controls DL250-3/DL250TC-3 2-84...

  • Page 181: Door Side Latch

    To release doors from both sides of the cabin, pull handles (Figure 203 and Figure 204) in direction of arrows. The handles are located on both sides of the operator's seat. FG021113 Figure 203 FG021114 Figure 204 Operating Controls DL250-3/DL250TC-3 2-85...

  • Page 182: Arm Rest

    AVOID DEATH OR SERIOUS INJURY FG019244 If any fuse is blown, turn "OFF" the starter switch and shut Figure 206 off the power supply. Repair the cause if needed and replace the fuse with a new one. Operating Controls DL250-3/DL250TC-3 2-86...
  • Page 183 Position Light (Right) Hour meter Air Conditioner, Heater Fuel Heater (Optional) Headlight Work Light (Rear) Seat Suspension (Optional), Spare Seat Warmer (Optional), Mirror Heater Work Light (Front) Engine Controller GPS, Stereo Engine Controller Memory Backup, Pilot Buzzer Operating Controls DL250-3/DL250TC-3 2-87...

  • Page 184: Circuit Breaker

    AVOID DEATH OR SERIOUS INJURY When changing the fusible link, replace the fusible link with the same capacity part. Otherwise, a fire could break out in the wiring harness and/or other components of the circuit. Always use original DOOSAN parts. Operating Controls DL250-3/DL250TC-3 2-88...

  • Page 185: Wheel Chocks

    A pair of wheel chocks are supplied with the machine, and are stored on the frame. These wheel chocks must be used always when it is necessary to secure the machine for repairs or for transport. WL1300316 Figure 211 WL1300317 Figure 212 Operating Controls DL250-3/DL250TC-3 2-89...
  • Page 186 Operating Controls DL250-3/DL250TC-3 2-90...

  • Page 187: Operation

    New Machine Break-in Procedures All DOOSAN machines are inspected before leaving the factory. However, it is required that operator follow these steps during the initial break-in period. Failure to follow these steps can result in damage to the equipment or reduced performance.

  • Page 188: Starting And Stopping Engine

    Check for damage, wear, crack, oil leakage, play in work equipment, cylinders, linkages and hoses. • Check the frame, transmission and axles for; damage, cracks, oil leakage and loose bolts. • Check for problems in doors, handrails, steps and loose bolts. Operation DL250-3/DL250TC-3...
  • Page 189 After starting machine • Check that all operational controls and components are in proper operating condition and are functioning correctly. Stop operation and correct any problems before continuing work. Operation DL250-3/DL250TC-3...
  • Page 190 14. Check inflation pressure of tires. 15. The level in the reductant tank. (if the engine is equipped with an Selective Catalytic Reduction System. (SCR)) IMPORTANT Running the engine without reductant will damage the Selective Catalytic Reduction (SCR) system. Operation DL250-3/DL250TC-3...

  • Page 191: Operational Checks Before Starting Engine

    Hydraulic oil temperature gauge FG018147 Figure 1 • Engine rpm (0 rpm) digital readout NOTE: If all the indicator lights do not come "ON" when the key is first turned, correct the cause of the problem before machine operation. Operation DL250-3/DL250TC-3...

  • Page 192: Engine Start

    Figure 2 If the machine has a battery disconnect switch: Turn "ON" the power using the battery disconnect switch. The battery disconnect switch is located in the battery box of the left side of machine. FG020630 Figure 3 Operation DL250-3/DL250TC-3...
  • Page 193 FG019167 Figure 5 Make sure transmission neutral lock is in the "N" (NEUTRAL LOCK) position. FG019168 Figure 6 Set pilot cutoff switch to "O" position. This will "LOCK" pilot control valve lever (joystick). FG019178 Figure 7 Operation DL250-3/DL250TC-3...
  • Page 194 IMPORTANT The starter motor can only be cranked twice for 30 seconds at a time. After that, it must rest and cool for at least five (5) minutes before attempting to start the engine again. FG018149 Figure 11 Operation DL250-3/DL250TC-3...
  • Page 195 Allowing the engine to idle will dissipate heat. After engine has cooled, check coolant level, look for signs of leaks, clogged or dirty radiator fins (radiator core), and fan belt tension. Operation DL250-3/DL250TC-3...

  • Page 196: Automatic Warming Up Operation

    If the fuel temperature is above 5°C (41°F), heating system is not activated. In this position, the fuel heater system is turned "OFF". FG019172 In this position, the fuel heater system is turned "ON". Figure 14 NOTE: The starter switch must be "ON". Operation DL250-3/DL250TC-3 3-10...
  • Page 197 (-) terminal of the booster batteries (3), and then BLACK make ground connection to the upper frame (5) of the machine to be started with the other end of black (-) cable ARO0440L (2, Figure 15). Figure 15 Operation DL250-3/DL250TC-3 3-11...

  • Page 198: Coolant Temperature

    If operated for extended periods under an extremely light load, the engine may have difficulty in maintaining normal operating temperature. At an increased load, the temperature rises to the normal value. IMPORTANT An excessively high coolant temperature can damage the engine. Operation DL250-3/DL250TC-3 3-12...
  • Page 199 If you have any questions about the operation or maintenance of your emission control system, contact your DOOSAN distributor. WARNING AVOID DEATH OR SERIOUS INJURY Exhaust gas temperature and exhaust system components are very hot during regeneration.
  • Page 200 If manual (forced) regeneration is necessary after the inhibited regeneration switch is turned "ON", press inhibited regeneration switch again to turn "OFF" the inhibit symbol. Press switch to manual (forced) regeneration position activate system. FG018400 Figure 19 Operation DL250-3/DL250TC-3 3-14...
  • Page 201 (Forced) regeneration. • Soot quantity in DPF is 120% or less: Manual (Forced) regeneration. • Soot quantity in DPF is 120% or more: regeneration is impossible, service the emission control system. Contact your DOOSAN distributor more information. Operation DL250-3/DL250TC-3 3-15...
  • Page 202 50%. If this occurs, service the emission control system. Contact your DOOSAN distributor for more information. Active regeneration can occur anytime the engine is running, while operating the machine or when the machine is parked.
  • Page 203 Turn off the Manual (Forced) regeneration switch NOTE: To deactivate manual (forced) regeneration for an emergency. However, this may reduce the effectiveness regeneration. Therefore, choose the proper location and sufficient time to conduct manual (forced) regeneration. FG024346 Figure 23 Operation DL250-3/DL250TC-3 3-17...
  • Page 204 The frequency of ash cleaning depends upon the operating conditions, environment, and engine oil used. The cleaning is recommended to be done after every 4,500 hours of operation. Contact your DOOSAN distributor for DPF cleaning. FG018403 Figure 24 DPF Ash Cleaning Equipment...

  • Page 205: Oil Pressure

    Allow engine to idle for three - five (3 - 5) minutes to cool down, before stopping the engine. If not allowed to idle, heat surge may develop which will damage the engine. Park machine on firm and level ground. Operation DL250-3/DL250TC-3 3-19...
  • Page 206 Lower bucket or work tool to the ground. Put pilot cutoff switch to "O" (LOCK) position. This will "LOCK" pilot control valve lever (joystick). Allow engine to idle for 3 - 5 minutes to cool down. FG019178 Figure 28 Operation DL250-3/DL250TC-3 3-20...

  • Page 207: Checks And Maintenance After Stopping Engine

    Check that power supply has been turned "OFF". Check the cooling system for the correct antifreeze mixture. At temperatures below 0°C (32°F): prepare for the next start by connecting the engine heater (if equipped). Operation DL250-3/DL250TC-3 3-21...

  • Page 208: Machine Travel

    Lock out all control systems and stop engine to avoid accidental activation of controls. Unlatch articulated frame lock bar between front and rear frames before traveling. Secure lock plate to rear frame (Figure 30). FG026945 Figure 30 Operation DL250-3/DL250TC-3 3-22...
  • Page 209 (joystick) is activated. FG019178 Figure 32 Press brake pedal. FG002183 Figure 33 Set transmission neutral lock in the "D" (DRIVE) position. FG019168 Figure 34 Operation DL250-3/DL250TC-3 3-23...
  • Page 210 When traveling at high-speed or on a steep hill, do not make sharp changes in direction. This could cause vehicle to tip or rollover. FG019168 When traveling or changing direction, always look in Figure 37 travel direction. Keep bystanders away from work area. Operation DL250-3/DL250TC-3 3-24...

  • Page 211: If Engine Stalls While Traveling

    Do not enter rivers whose riverbed is steep or has a rapid flow. IMPORTANT Avoid use of the machine in salt water. Salt water will cause rust which will shorten the life of the machine. Operation DL250-3/DL250TC-3 3-25...

  • Page 212: Towing

    • Check towrope or tow bar for damage and make sure it has sufficient strength for work. • When necessary to descend a grade, another towing vehicle must be used in rear to provide additional braking. Operation DL250-3/DL250TC-3 3-26...
  • Page 213 • If engine on problem machine will not start or there is FG019101 a failure in brake system, always contact your Figure 38 DOOSAN distributor. • Never go between towing machine and towed machine during towing operation. • Do not perform towing on steep slopes, so select a place where slope is gradual.

  • Page 214: F/R (Forward/Reverse) Travel Control System

    The transmission lever is moved out of "NEUTRAL" into "FORWARD" or "REVERSE". FG015182 Figure 41 The starter switch is turned "OFF". When the system is deactivated, the F/R selector indicator light will be turned "OFF". Operation DL250-3/DL250TC-3 3-28...

  • Page 215: Machine Shut Down

    AVOID INJURY "LOCK" transmission lever. Whenever machine is parked, "LOCK" transmission lever in "NEUTRAL" to prevent accidental machine movement. Set parking brake switch to "I" (ENGAGED) position. This will ensure that parking brake is "ENGAGED". WL1300285 Figure 44 Operation DL250-3/DL250TC-3 3-29...
  • Page 216 Leaving machine in gear will provide no braking effect because transmission clutch 2876A is hydraulically operated. When engine is turned Figure 47 "OFF", there is no hydraulic pressure in transmission and clutch is not engaged. Operation DL250-3/DL250TC-3 3-30...

  • Page 217: Operation Of Attachment

    Top side of bucket indicates angle of bottom of bucket. Top of side plate is parallel with bottom of bucket. If bottom of bucket is not visible, top of side plate will be visible. FG024793 Figure 49 Operation DL250-3/DL250TC-3 3-31...

  • Page 218: Adjustment Of Bucket Position Switch

    (usually flat). To adjust bucket to desired preselected digging position, FG023191 perform the following steps. Figure 50 DL250-3 Operate controls to place bucket on ground and in desired digging position (usually flat). Return bucket lever to its "NEUTRAL" position.

  • Page 219: Operation Under Abnormal Conditions

    Keep engine in good mechanical condition for easy starting and good performance during adverse weather. Use engine oil with proper specifications for expected temperatures. Refer “Table Recommended Lubricants” on page 4-24, in this manual or Shop Manual for details. Operation DL250-3/DL250TC-3 3-33...
  • Page 220 10. Clean off all mud, snow and ice to prevent freezing. Cover machine with a tarp if possible and keep ends of tarp from freezing to ground. Operation DL250-3/DL250TC-3 3-34...

  • Page 221: Operation In Extreme Heat

    Protect all unfinished, exposed surfaces with a film of preservative lubricating oil. Protect cables and terminals with ignition insulation compound. Apply paint or suitable rust preventive to damaged surfaces to protect them from rust and corrosion. Operation DL250-3/DL250TC-3 3-35...

  • Page 222: Operation In Dusty And Sandy Areas

    When exposed to saltwater, dry machine thoroughly and rinse with freshwater as soon as possible. Keep all exposed surfaces coated with preservative lubricating oil. Pay attention to damaged paint surfaces. Keep all painted surfaces in good repair. Operation DL250-3/DL250TC-3 3-36...

  • Page 223: Operation At High Altitudes

    During electrical storms, do not enter or exit machine. • If you are off machine, keep away from machine until storm passes. • If you are in cabin, remain seated with engine off until storm passes. Do not touch controls or anything metal. Operation DL250-3/DL250TC-3 3-37...

  • Page 224: Long Term Storage

    NOTE: When sealing with tape, be sure to extend tape approximately one inch (25 mm) beyond opening to ensure a good seal. Operation DL250-3/DL250TC-3 3-38...

  • Page 225: During Storage

    If there is water in the oil, change all the oil. • Change all filters. • Inspect for signs of nests. (i.e. birds, rodents, etc.) • When starting the engine after long-term storage, follow the "Hydraulic Oil Warm-up" procedures listed in this manual. Operation DL250-3/DL250TC-3 3-39...
  • Page 226 Operation DL250-3/DL250TC-3 3-40...

  • Page 227: Inspection, Maintenance And Adjustment

    Check operational hour meter reading every day to see if necessary maintenance is scheduled to be performed. DOOSAN Genuine Replacement Parts Use DOOSAN genuine parts specified in Parts Book as replacement parts. DOOSAN Genuine Lubricants For lubrication of the machine, use DOOSAN genuine lubricants.
  • Page 228 Avoid Mixing Lubricants If a different brand or grade of oil has to be added, drain all old oil before adding new brand or grade of oil. Never mix different brands or grades of oil. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3...
  • Page 229 For details of checks when operating engine, see “Safety Precautions” on page 4-4 and pay careful attention to safety. – Are inspection and maintenance items working properly? – Is there any leakage of fuel or oil when engine speed is raised? Inspection, Maintenance and Adjustment DL250-3/DL250TC-3...

  • Page 230: Safety Precautions

    1,000 operating hours. The performing of these inspections is a condition for the warranty to apply. Condition Test A "Condition Test" is done at authorized dealer workshops and provides information about general condition of machine. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3...

  • Page 231: Machine Setup Position For Maintenance

    Park machine on firm and level ground. Move transmission lever to "NEUTRAL" position. FG019167 Figure 1 Make sure transmission neutral lock is in the "N" (NEUTRAL LOCK) position. FG019168 Figure 2 Inspection, Maintenance and Adjustment DL250-3/DL250TC-3...
  • Page 232 OPERATE" Warning Tag on cabin door or work lever. WARNING AVOID DEATH OR SERIOUS INJURY engine must running while performing maintenance, always have one person in cabin always. Never leave cabin with engine running. EX1301177 Figure 6 Inspection, Maintenance and Adjustment DL250-3/DL250TC-3...

  • Page 233: Maintenance Handling Access

    Do not use hand grip (A, Figure 7) of cabin door as a support when entering, leaving or climbing the machine. It is not strong enough to be used as a support. It should only be used for closing the door. FG020094 Figure 9 Inspection, Maintenance and Adjustment DL250-3/DL250TC-3...

  • Page 234: Service Position

    Attach a black and yellow label to the steering wheel. Connect the articulated frame lock bar. Block the wheels in a suitable way (with, for example, wheel chocks). Allow the engine and hot machine parts to cool. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3...

  • Page 235: Service Points

    Oil Separator Transmission Oil Filter Fuel Filter Ventilation Filters, Cabin Air Cleaner Breather of Hydraulic Oil Filing Point, Washer Fluid Filling Point, Hydraulic Oil Draining, Hydraulic Oil Level Sight Gauge, Hydraulic Oil Filling Point, Transmission Inspection, Maintenance and Adjustment DL250-3/DL250TC-3...

  • Page 236: Handling Oil, Fuel, Coolant

    Having too much or too little oil can cause operational problems. • If oil is not clear in color, there may be water or air getting into circuit. In such cases, contact your DOOSAN distributor. • When changing oil, always replace related filters at same time. NOTE: Only use Ultra Low Sulfur Diesel (ULSD) fuel and API CJ-4/ACEA E9 grade engine oil.
  • Page 237 Increase the wear. • Increase the corrosion. • Increase the deposits. • Lower fuel economy. • Shorten the time period between Oil drain intervals (more frequent oil drain intervals). • Increase overall operating costs. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-11...

  • Page 238: Coolant And Water For Dilution

    Failures that result from use of improper fuels are not DOOSAN factory defects. Therefore the cost of repairs would not be covered by a DOOSAN warranty. Coolant and Water for Dilution • The coolant has the important function of preventing corrosion and preventing freezing.
  • Page 239 If any metal particles are found, contact your DOOSAN distributor. • Do not open packages of spare filters until just before they are to be used. • Always use DOOSAN genuine filters. DL250-3/DL250TC-3 Inspection, Maintenance and Adjustment 4-13...

  • Page 240: Electrical System Maintenance

    Service relating to the electrical system is: checking fan belt tension, checking damage or wear to the fan belt, and checking battery electrolyte level. • Never install any electric components other than those specified by DOOSAN. • External electromagnetic interference cause malfunction of the control system controller.

  • Page 241: Recommend Fuel, Coolant, And Lubricant

    • If the machine is operated at temperatures below -20°C (-4°F), a separate device is needed, so discuss with a DOOSAN distributor. • Only use Ultra Low Sulfur Diesel (ULSD) fuel and API CJ-4/ACEA E9 grade engine oil.
  • Page 242 Use a ladder when changing light bulbs or performing other service work high up on the machine. • Use a long handled window scraper and brush or a ladder when cleaning outside of windows. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-16...
  • Page 243 "OFF". Such pipes and hoses should only be disconnected by trained personnel. • When looking for leaks, use a piece of paper or wood, not your hand. Always wear eye and face protection. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-17...

  • Page 244: Fire Prevention Measures

    NOTE: If a high-pressure jet is used for cleaning prevent damage to electrical connectors and insulation by covering and protecting the components. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-18...

  • Page 245: Working On Painted Surfaces

    In addition to the health hazard, welding over a painted surface will also be of an inferior quality and strength. Never weld directly on a painted surface. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-19...

  • Page 246: Methods And Precautionary Measures When Removing Paint

    (a solution or suspension of calcium hydroxide, i.e. slaked lime in water). After the work has been completed, the gloves must be washed in limewater and then discarded. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-20...
  • Page 247 Hydrofluoric Acid Burn Jelly or something similar. Seek medical advice immediately. Symptoms may not appear until several hours after initial contact. Discard gloves, rags etc. which are suspected of having touched burned rubber that contains fluorides. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-21...

  • Page 248: Preventive Maintenance

    Record of these numbers and their locations. These will be required whenever warranty or service work is requested. Keep this number on file, in case the machine is stolen. Doosan Infracore Co., Ltd. 7-11, Hwasu-dong, Dong-gu, Incheon, Korea MODEL PRODUCT IDENTIFICATION NUMBER...

  • Page 249: Component Serial Numbers

    The engine serial number (ESN) and control parts list (CPL) provide information for service and ordering parts. The engine data plate must not be changed unless approved by DOOSAN. The data plate is located on the fuel pump side of the engine, on the rocker housing.

  • Page 250: Table Of Recommended Lubricants

    TABLE OF RECOMMENDED LUBRICANTS IMPORTANT It is highly recommend to use DOOSAN Genuine Products, or products which meet the specifications below. Using other products can damage equipment. NOTE: Refer to Maintenance Intervals Table for application points. Ambient Temperature Reservoir Kind of Fluid 122 °F...
  • Page 251 SM, or ACEA specification, category E9. **** Hydraulic oil change interval is 2,000 hours, only when DOOSAN Genuine Oil is used. If other brands of oil is used, guaranteed change interval is 1,000 hours. Note that mixing ratio is for reference purpose only, and is not an absolute standard.
  • Page 252 Mixing ratio is for reference purpose only and is not an absolute standard. IMPORTANT Do not mix oils from different manufacturers. DOOSAN does not endorse specific brands but does recommend that owners select quality oils whose manufacturers provide assurance that the required standards will always be met or exceeded.

  • Page 253: Transmission Oil

    Lubricant Classes for Service Fills (1) "03A, 03B, 03C, 03D, 03E, 03G, 03H, 03K only at Ambient Temperatures Below - 10°C: 03F" (1) The current list can be requested from any DOOSAN, ZF after-sales service center or accessed on the Internet under www.zf.com...

  • Page 254: Axle Oils

    Examples of oils which meet the requirements according to the table on the next page. Lubricant Classes for Service Fills (1) ZF-Powerfluid Plus, 05F (1) The current list can be requested from any DOOSAN, ZF after-sales service center or accessed on the Internet under www.zf.com Oil Change Intervals...
  • Page 255 DOOSAN engines. DOOSAN engine oils that meet API CJ-4 are required for use in the applications listed below. DOOSAN engine oils meeting the API CJ-4 and ACEA E9 oil categories have been developed with limited sulfated ash, phosphorus, and sulfur.

  • Page 256: Fluid Capacities

    176 liters Hydraulic Oil Tank (46.5 U.S. gal.) 45 liters Transmission (11.9 U.S. gal.) Front Axle Differential / Front 35 liters (9.2 U.S. gal.) Axles Rear Axle Differential / Rear 21.5 liters (5.7 U.S. gal.) Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-30...

  • Page 257: Lubrication And Service Chart

    Air Conditioner Filter Engine Oil Drain Water Engine Oil Filter Gear Oil (Axle) Hydraulic Oil Brake Filter Hydraulic Oil Return Filter Level check Coolant Hydraulic Oil Tank Breather Air Cleaner Filter Fuel Cap Filter Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-31...
  • Page 258 Lubrication and Service Chart DL250-3 13, 21 4500h 2000h 1500h 1000h 500h 250h 250h 500h 1000h 1500h 2000h 4500h WL1300283 Figure 20 Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-32...
  • Page 259 DL250TC-3 4500h 2000h 1500h 1000h 500h 250h 250h 500h 1000h 1500h 2000h 4500h 13,21 WL1300284 Figure 21 Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-33...
  • Page 260 This capacity may include the tank (reservoir), lines, pipes and components and attachment. Observe all sight gauge and level indicators in order to ensure that the systems and compartment are refilled to the proper level. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-34...

  • Page 261: Maintenance Intervals

    5-59 Check Engine Drive Belt Wear 5-59 Grease Driveshafts 5-60 Change Transmission Oil and Filter (After First 250 Hours) 5-61 Change Hydraulic Full Flow Filter (After First 250 Hours) 5-61 Fuel Water Trap 5-62 Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-35...
  • Page 262 5-85 Check Brake Accumulator 5-86 4,500 Hour / Biennial Service Clean Diesel Particulate Filter (DPF) 5-87 12,000 Hour / 6 Year Service Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 CEN) 5-88 Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-36...

  • Page 263: 10 Hour / Daily Service

    If oil is above "HIGH" mark on dipstick, oil must be drained to return oil to proper level. Add oil through engine oil fill cap (2 or 3, Figure 22), if the oil level is below the "LOW" mark. FG000616 Figure 23 Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-37...

  • Page 264: Check Transmission Oil Level

    To add oil, remove transmission oil dip stick gauge from transmission oil fill pipe. Refer to “Table of Recommended Lubricants” on page 4-24, of this manual for recommended oil for the operation conditions. Stop engine when done. COLD HAAD4540 Figure 26 Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-38...

  • Page 265: Check Hydraulic System Oil Level

    If filter assembly was removed, insert assembly into the tank and make sure it is securely in place. FG002188 Figure 30 Check O-ring for damage and replace if necessary. Check position of O-ring at surface of hole. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-39...

  • Page 266: Check For Leaks In Hydraulic System

    Securely tighten cap after fueling. NOTE: If breather holes in cap are clogged, a vacuum may form in the tank preventing proper fuel flow to engine. Keep holes in fuel cap clean. FG001690 Figure 33 Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-40...

  • Page 267: Check For Leaks In Fuel System

    If temperature is below freezing, see “Antifreeze Concentration Tables” page 4-93 antifreeze protection. Use the table to calculate FG023200 a proper mixture of antifreeze and water to Figure 36 provide level of protection necessary for expected temperature. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-41...

  • Page 268: Check Level Of Windshield Washer Liquid

    Do not allow replaceable bucket teeth to wear down to the point that bucket adapter is exposed. (Figure 38) NOTE: These instructions are only for DOOSAN OEM buckets. If you are using other manufacturer's buckets, refer to their specific instructions.

  • Page 269: Check Air Intake System

    Check the engine intake hose and hose clamps for damage and tightness. NOTE: If damaged, wrinkled or loose, replace, tighten or contact your DOOSAN distributor. IMPORTANT Severe engine damage will result from running with unfiltered air. Do not operate engine if any leaks or defects are found on air intake system.

  • Page 270: Check Operation Of All Switches

    With engine at rated speed, operate all the controls. Follow cold weather hydraulic system warm-up procedures. Note any slow operations or unusual movements. Determine the cause and repair all problems before operating. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-44...

  • Page 271: 50 Hour / Weekly Service

    50 HOUR / WEEKLY SERVICE Perform All Daily Service Checks Grease Front Attachment Pins DL250-3 The following fittings must be greased daily, or every 10 hours, for first 100 hours of operation to comply with new machine break-in requirements. After that, greasing must be done every 50 hours.
  • Page 272 Lift cylinder rod (left, right), 2 locations (Figure 45). FG023215 Figure 45 Remote location points. Remote fittings for bucket cylinder head (50 HOUR), (1, Figure 46). Remote fittings for loader arm foot end (50 HOUR), (2, Figure 46). FG006255 Figure 46 Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-46...
  • Page 273 Lever-link connecting pin, 1 location (Figure 49). FG023205 Figure 49 Grease rear axle pivot (1, Figure 50), 3 locations on right side of machine. Use remote grease fittings mounted on frame shown in Figure 51. FG023206 Figure 50 Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-47...
  • Page 274 100 hours of operation to comply with new machine break-in requirements. After that, greasing must be done every 50 hours. If bucket is being used in water, grease fittings immediately after machine is removed from water. FG028730 Figure 52 Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-48...
  • Page 275 2 locations. Lever link connecting pins, 2 locations. Link foot pins, 2 locations. (Figure FG008098 Figure 55 Lift cylinder heads (left, right), 2 locations. Lift cylinder rod ends, 2 Llocations. (Figure 56) FG008099 Figure 56 Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-49...
  • Page 276 Rear axle pivot (1, Figure 58), 3 locations on right side of machine. Use remote grease fittings mounted on frame shown in Figure 59. FG017601 Figure 58 PIVOT COVER REAR PIVOT FRONT PIVOT FG006257 Figure 59 Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-50...

  • Page 277: Grease Steering Cylinder Rod And Head Ends

    (1 and 2, Figure 61). Reference Remote Grease Number Fittings 1 and 2, Steering Cylinder 50 Hours Head Ends 3, 250 Hours Drive Shaft Center Bearing FG026980 Figure 61 FG026981 Figure 62 Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-51...

  • Page 278: Grease Upper And Lower Center Pins

    50 hours of operation to comply with new machine break-in requirements. After first check, air conditioner and alternator belt must be checked every 250 hours. Follow procedure printed under hour maintenance interval “Check Belt Tension” on page 4-59. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-52...

  • Page 279: Clean Exterior Of Radiator, Oil Cooler And Air Conditioner Condenser

    FG019015 Figure 66 WARNING AVOID DEATH OR SERIOUS INJURY All service and inspection of the air-conditioning system must be performed with the starter switch in the "O" (OFF) position. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-53...

  • Page 280: 250 Hour / Monthly Service

    Start the engine. Raise the work equipment so it is about 400 mm above the ground. Move the machine to a flat and level area. Apply the service brake. (Figure 67) WL1400677 Figure 67 Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-54...
  • Page 281 Figure 71 Reduce the engine speed to low idle. Move the 1. Brake Pedal transmission lever to the neutral position. Engage the 2. Accelerator Pedal parking brake. Lower the work equipment to the ground. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-55...
  • Page 282 Check for adequate traction. Drive the wheel loader up the incline with the heavy end of the machine facing uphill. (Figure 72) WL1400681 Figure 72 Apply the service brake. (Figure 73) WL1400677 Figure 73 Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-56...
  • Page 283 Lower the work equipment to the ground. 11. Stop engine. Remove key. If the machine moved during the test, contact your dealer for a brake inspection. Make any necessary repairs before the machine is returned to operation. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-57...

  • Page 284: Check Engine Air Intake Precleaner (Optional)

    (See Figure 29 on page 5-39). Loosen drain valve from bottom of tank (Figure 78). Allow all water and sediment to drain out. Tighten drain valve. FG027004 NOTE: Dispose drained fluids according Figure 78 applicable environmental laws and regulations. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-58...

  • Page 285: Check Belt Tension

    Replace the belt if it is frayed or has pieces of material missing. Before installing new belts, make sure all pulley grooves are clean and not worn. Replace pulley, if damaged, or if the grooves are worn. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-59...

  • Page 286: Grease Driveshafts

    (3, Figure 81). Reference Remote Grease Number Fittings 1 and 2, Steering Cylinder 50 Hours Head Ends 3, 250 Hours Drive Shaft Center Bearing FG026979 Figure 81 FG026980 Figure 82 Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-60...

  • Page 287: Change Transmission Oil And Filter (After First 250 Hours)

    Change Hydraulic Full Flow Filter (After First 250 Hours) Replace hydraulic full flow filter after first 250 hours of operation or rebuild and every 1,000 hours thereafter. Follow procedure under 1,000 hour maintenance interval (See page 5-75). DL250-3/DL250TC-3 Inspection, Maintenance and Adjustment 4-61...

  • Page 288: Fuel Water Trap

    Loosen drain valve (B, Figure 85). Drain water from water trap (A, Figure 85). open close Tighten draining nipple. FG000438 NOTE: Take care of waste oil and liquid in an Figure 86 environmentally safe way! Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-62...

  • Page 289: Clean Air Conditioner Inner Filter

    FG019015 Figure 87 WARNING AVOID DEATH OR SERIOUS INJURY All service and inspection of the air-conditioning system must be performed with the starter switch in the "O" (OFF) position. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-63...

  • Page 290: 500 Hour / 3 Month Service

    Fill engine with correct oil through oil fill port. Start engine and check engine oil pressure warning light. Stop engine. Look for signs of leaks at filter. Recheck oil level. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-64...

  • Page 291: Clean Exterior Of Radiator, Oil Cooler And Air Conditioner Condenser

    Start engine. After engine has run for a couple of minutes, stop engine and look for signs of leaks. If the engine does not start, fuel system may need priming. Prime hand pump on the engine fuel filter. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-65...

  • Page 292: Change Outer Air Cleaner Filter

    205 kPa (30 psi) air pressure. WARNING AVOID DEATH OR SERIOUS INJURY If using compressed air to clean the filter, make sure that proper eye protection is worn. HAOC570L Figure 94 Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-66...
  • Page 293 FG019015 Figure 96 WARNING AVOID DEATH OR SERIOUS INJURY All service and inspection of the air-conditioning system must be performed with the starter switch in the "O" (OFF) position. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-67...

  • Page 294: Change Axle Differential And Planetaries Oil (After First 500 Hours)

    Install new filter. Apply a small amount of oil around filter gasket. Screw filter on head until gasket contacts head by hand, turn filter 3/4 - 1 turn more with filter wrench. Figure 98 Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-68...

  • Page 295: 1,000 Hour / 6 Month Service

    16. Thread filter onto filter head. Tighten filter 1/2 turn after filter gasket contacts filter head. Filter must be torqued to 1.6 - 2.1 kg•m (11.5 - 15 ft lb). FG023221 Figure 100 Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-69...

  • Page 296: Change Air Conditioner Inner Filter

    If the machine is being operated in a dusty environment, the cleaning and replacement must be performed more frequently. Check and Adjust Engine Contact your DOOSAN distributor. Engine dealer for checking and adjusting the following items: • Engine compression pressure.

  • Page 297: Clean Fuel Tank And Strainer

    11. Install the inspection cover with a new gasket. Tighten the bolts. Do not overtighten. 12. Close drain valve. 13. Fill fuel tank. 14. Check for any leaks at cover and plug. FG024315 Figure 103 Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-71...

  • Page 298: Check Air Conditioner Refrigerant

    Almost clear. Normal Any bubbles disappear if the engine speed is increased to 1,500 rpm. Contact your local DOOSAN High No bubbles are seen. distributor inspection recharging refrigerant. A flow of bubbles is visible. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-72...

  • Page 299: Air Cleaner

    Clogged Warning Light” on page 2-22. Do not, under any circumstances, run the engine without a filter or with a damaged one. Always have a spare filter on hand and keep the filter well protected from dirt. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-73...

  • Page 300: Change Air Breather Filter

    (2, Figure 105). Figure 105 10. Change a filter cartridge (3, Figure 105) and assemble the breather cap by tightening bolt. NOTE: Used filter should always be disposed of according to applicable environmental laws and regulations. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-74...

  • Page 301: Change Hydraulic Full Flow Filter

    (3) into place on filter (6). Set cover (2, Figure 106) into place over filter (6). Install bolts (1) through cover (2) and tighten them. FG024316 10. Tighten breather cap on tank. Figure 106 Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-75...

  • Page 302: Change Fuel Cap Filter

    FG015684 Figure 108 After disassembly, carefully lay it as shown in Figure 109. FG015685 Figure 109 After disassembly (Figure 109), disengage rubber as shown on (Figure 110). FG015686 Figure 110 Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-76...
  • Page 303 After disassembly as shown on (Figure 110), you may now exchange it to a new filter as shown on (Figure 111). FG015687 Figure 111 After exchanging to a new filter, you may now assemble back in reverse order. FG015688 Figure 112 Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-77...

  • Page 304: 1,500 Hour / 9 Month Service

    Remove plugs and allow oil to drain into a suitable container. NOTE: See “Fluid Capacities” on page 4-30 for capacity. NOTE: Dispose drained fluids according applicable environmental laws and regulations. NOTE: Plug Size: M24 x 1.5 Tightening Torque: 7.1 kg•m (51 ft lb) Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-78...
  • Page 305 Plug Size (1, Figure 115): M36 x 1.5 Tightening Torque: 13.2 kg•m (95 ft lb) Plug Size (2, Figure 115): M36 x 1.5 Tightening Torque: 13.2 kg•m (95 ft lb) FG019084 Figure 115 (Rear Axle) Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-79...

  • Page 306: 2,000 Hour / Yearly Service

    Never remove air cleaner filter while engine is running. This will allow dirt to be sucked into engine and cause serious engine damage. Always turn engine "OFF" before servicing air cleaner. NOTE: Replace outer filter after cleaning 4 times or every 1,000 hours. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-80...

  • Page 307: Check Steering, Brake, Driveshaft, Engine, And Fuel System

    If any brake or steering hoses become damaged or appear defective in any way, replace them immediately despite time interval since their last replacement. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-81...

  • Page 308: Change Radiator Coolant

    Run engine at low idle until coolant temperature gauge reaches the "BLUE ZONE". Run engine for another ten minutes. Allow engine to cool. Drain flushing fluid and fill system with water. Run engine again to allow water to completely circulate. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-82...

  • Page 309: Change Hydraulic Oil And Clean Oil Suction Strainer

    (Figure 121). Then operate controls to lower boom. (Figure 122). This will drain oil out of boom and bucket cylinders. Replace full flow hydraulic filters as described under “Change Hydraulic Full Flow Filter” on page 4-75. FG023226 Figure 121 Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-83...
  • Page 310 Check tank sight gauge. (See Figure 28 on page 5-39). Oil level must be between upper limit and lower limit on sight gauge. Remove cover and add oil if necessary. FG023228 Figure 124 FG023229 Figure 125 Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-84...

  • Page 311: Bleed Brakes

    Open bleeder screw using 14 mm wrench. Close bleeder screw. Release brake pedal. Repeat steps 4 thru 7, until air bubbles are not seen in the HLB3018L brake line. Figure 127 Perform bleeding procedure on other three locations. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-85...

  • Page 312: Check Brake Accumulator

    10. Count the number of times you can depress the right-hand brake pedal before the brake warning light comes on. 11. If the number counted is less than five (5), there is some problem with the accumulator. Contact your DOOSAN distributor. Inspection, Maintenance and Adjustment...

  • Page 313: 4,500 Hour / Biennial Service

    IMPORTANT Regular ash cleaning is necessary to prevent engine performance and fuel efficiency from deteriorating. IMPORTANT When DPF cleaning is needed, contact DOOSAN distributor for more information. For details, “DPF Cleaning (Removing Ash in DPF)” on page 3-18. Inspection, Maintenance and Adjustment...

  • Page 314: 12,000 Hour / 6 Year Service

    Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 CEN) European regulations state that in-service life of any hydraulic hose may not exceed six (6) years. DOOSAN recommends the following: • Hoses at the customer premises cannot be stored more than two (2) years before being discarded or installed on a machine.

  • Page 315: Standard Bolt Torque Chart

    22 mm x std. 54.90 77.86 93.08 22 mm x 1.5 61.00 86.02 105.00 24 mm x std. 71.00 100.00 120.00 24 mm x 2.0 78.00 109.95 130.00 27 mm x 2.0 115.06 160.00 1157 195.00 1410 Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-89...

  • Page 316: Electrical System

    Colors may vary from one battery manufacturer to another. Always refer to instructions on battery. The batteries should always be replaced in pairs. Using an old battery with a new one will shorten the life span of the new battery. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-90...

  • Page 317: Engine Cooling System

    Do not use more than 50% antifreeze in the mixture unless additional antifreeze protection is required. Never use more than 60% antifreeze under any condition. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-91...
  • Page 318 Do not mix solutions from different manufacturers. Otherwise, the performance may be deteriorated. It is recommended to use the standard product from DOOSAN. In extreme temperatures, the performance of the coolant must be checked frequently and the coolant change cycle adjusted as necessary.

  • Page 319: Antifreeze Concentration Tables

    Antifreeze Concentration Tables Ethylene Glycol - DOOSAN Genuine Antifreeze Solution (for all seasons) (2,000 Hour/1 Year) Ambient Temperature Cooling Water Antifreeze -20°C (-4°F) -25°C (-13°F) -30°C (-22°F) -40°C (-40°F) NOTE: The concentration shall be kept at 50% and in worst case at 30% minimum for the least corrosion resistance.

  • Page 320: Handling Of Accumulator

    • Do not weld on accumulators, or try attaching anything to them. • When replacing an accumulators, contact a DOOSAN distributor to ensure that gas is properly released. • Wear safety goggles and protective gloves when working on an accumulator. Hydraulic oil under the pressure can penetrate the skin and cause serious injuries.

  • Page 321: Brake Accumulators

    Stop engine. Allow enough time that steering cylinder pressure is decreasing by own internal leakage. FG027029 Remove accumulators by unscrewing them very slowly. Figure 132 NOTE: This also applies to the hoses related with accumulators. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-95...

  • Page 322: Fuel Transfer Pump (Optional)

    Make sure direction of check valve is in line with flow direction of fuel. Any pump parts or components that become lost, damaged or inoperable, must be immediately replaced. Do not stand on fuel transfer pump box. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-96...
  • Page 323 A thermal limiter, built into the motor, will automatically shut off power if motor is overheating to protect it from being damaged. FUEL FUEL TANK FG000161 Figure 133 Reference Reference Description Description Number Number Body Strainer Cap Check Valve Inlet Hose Strainer Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-97...
  • Page 324 Install strainer cap (4, Figure 133) on inlet strainer (3, FG020161 Figure 133) and return hose (5, Figure 133) to storage Figure 134 position. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-98...

  • Page 325: Hydraulic Pressure Checks

    (0 ±5 bar (0 ±71 psi)) Transmission Clutch Pressure Attach gauge to port (TM, Figure 135). Clutch pressure cannot be adjusted. NOTE: Transmission clutch pressure is 16 - 18 kg/cm (16 ±18 bar (228 - 256 psi)). Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-99...
  • Page 326 DMS. Service Brake Outlet Pressure Attach gauge to brake pressure test port (Figure 139) of front axle. Outlet pressure must 75 ±5 kg/cm (74 ±5 bar (1,138 ±71 psi)). FG023230 Figure 139 Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-100...

  • Page 327: Fan Motor Pressure And Fan Speed

    Maximum Speed Fan Speed 1600 ±50 Fan Motor Pressure 163 ±10 (160 ±10 (2,318 ±142)) kg/cm (bar (psi)) Control Current 200 ±25 Pressure (kg/cm ) Control current (A) FG019077 Figure 140 Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-101...
  • Page 328 Connect the pressure gauge to the pressure port shown in Figure 141. Check the maximum pressure by pressing accelerator pedal to "HIGH IDLE", and reading the pressure on gauge. If fan speed requires adjusting, adjust control current by DMS. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-102...

  • Page 329: Long Term Storage

    If desired, cooling system can be completely drained. If system is drained, place a sign in operator's cabin to warn operator there is no coolant in engine. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-103...

  • Page 330: Parking Brake Adjustment

    The machine does not have any brake function and must be secured, by proper means, against moving. Before putting the machine into operation again, the brake has to be properly adjusted according to specifications. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-104...

  • Page 331: Adjustment Procedure For Parking Brake

    (5). Mount the screw cap (6, Figure 142) and manually tighten as far as possible manually. Actuate the brake valve several times and check the braking efficiency of the parking brake a slope. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-105...

  • Page 332: Severe Conditions Maintenance

    Use a gauge to check antifreeze to be sure that it will provide protection for coldest temperature expected. Use a hydrometer to check condition of batteries. In extremely cold weather, remove batteries at night and store them in a warm area. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-106...

  • Page 333: Tires

    After having changed a tire or if the wheel has been removed and installed for any other reason, the wheel bolts must be checked for tightness after eight hours of operation. Tighten wheel nuts to 85 kg•m (615 ft lb). Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-107...

  • Page 334: Wheel Nut Torque

    Stay away until tire and rim cools down. If the following problems are found in tires, for safety reasons Tread the tires must be replaced with new tires. For the replacement contact DOOSAN distributor or a tire Side walls manufacturer's local dealer. Breakers •...

  • Page 335: Recommended Air Pressure

    If L5 tires are used for loading and carrying operations, special attention must be paid to the transporting distances. Radial tires are preferred for loading and carrying operation, as the build up of heat is less with this type of tire. Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-109...
  • Page 336 Inspection, Maintenance and Adjustment DL250-3/DL250TC-3 4-110...

  • Page 337: Transportation

    If required, add blocking under the ramp to provide additional support. The ramp angle must be less than a 15° angle. Ramps FG028819 steeper than this can cause traction or stability problems Figure 1 when loading or unloading. Transportation DL250-3/DL250TC-3...
  • Page 338 Set pilot cutoff switch to "O" (LOCKED) position. (Figure FG028821 Figure 3 Stop engine by turning key to "O" (OFF) position (Figure 10. Remove key from starter switch. FG018156 Figure 4 11. Install articulated frame lock. (Figure 5). FG028839 Figure 5 Transportation DL250-3/DL250TC-3...
  • Page 339 NOTE: To avoid air being forced down the exhaust pipe when transporting, it must be covered with suitable protection (2, Figure 7) (not plastic). This will prevent turbocharger damage. FG028822 Figure 8 Transportation DL250-3/DL250TC-3...
  • Page 340 Set articulated frame lock to "UNLOCK" position. Turn battery disconnect switch to "ON" direction. Start the engine. Set pilot cutoff switch to "I" (UNLOCKED) position. Set parking brake switch to "O" (DISENGAGED) position. 10. Drive machine slowly for unloading. FG028835 Figure 10 Transportation DL250-3/DL250TC-3...

  • Page 341: Lifting Machine

    Place protective material between the cables and the machine to prevent damage. The maximum angle between the cables must not exceed 45°. 10. While machine is lifted, keep the machine horizontal and lift the machine slowly to keep it balanced. Transportation DL250-3/DL250TC-3...
  • Page 342 Transportation DL250-3/DL250TC-3...

  • Page 343: Troubleshooting

    If the cause of the operating problem cannot be determined, contact your DOOSAN distributor. Never perform an adjustment or the disassembly of the hydraulic, electrical or electronic components without first contacting a DOOSAN distributor.

  • Page 344: Electrical System

    Water or dirt in fuel system. fuel filter and new fuel. Air in fuel system. Purge air from system. Engine stop control failed. Contact your DOOSAN dealer. Blown fuse. Replace fuse. Engine starts, runs only at low Engine oil viscosity incorrect.
  • Page 345 Replace fuel filter. Water or dirt in fuel system. Clean system and add new fuel. Clogged or dirty fuel injectors. Contact your DOOSAN distributor. Engine has poor power. Plugged air intake system. Clean system and replace filter. Clogged or dirty fuel injectors.
  • Page 346 Clean. Scale or mineral build up inside Flush or professionally clean. radiator. Defective alarm switch (gauge is in Contact your DOOSAN distributor. green). Low water pump flow. Thermostat stuck or missing. Engine does not start when the Fuel filter clogged.

  • Page 347: Hydraulic System

    HYDRAULIC SYSTEM Problem Cause Remedy None of the controls function (loud Hydraulic pump failed. Contact your DOOSAN dealer. noise from pumps). Low hydraulic oil level. Add hydraulic oil as required. Suction line plugged or damaged. Clean or replace as required.
  • Page 348 Clean and repair valve. Check valve internal leakage. Repair or replace valve. Damaged cylinder or pump. Repair or replace pump or cylinder. Cylinder internal leakage. Repair or replace cylinder. Damaged cylinder rod. Replace rod. Pilot valve failure. Replace pilot valve. Troubleshooting DL250-3/DL250TC-3...

  • Page 349: Steering

    Damage to control spring damping Replace priority valve. inside priority valve. Steering wheel shakes. Bearing chattering in axle end Replace bearing. differential. Tire pressure not equal in left side Equalize tire pressure. and right side tires. Troubleshooting DL250-3/DL250TC-3...

  • Page 350: Travel System

    Low transmission fluid, or low Add fluid or change fluid. quality fluid. Worn transmission parts. Replace parts. Broken gears or bearings. Replace parts. Transmission fails to operate. Damaged transmission clutch Replace disks. disks. Damaged wires in transmission Repair wires. control wire harness. Troubleshooting DL250-3/DL250TC-3...
  • Page 351 Lubricate universal joints. Worn slip joint spline. Replace slip joint. Noisy Front or Rear Axle. Worn or broken gears. Replace gears. Low oil level, poor quality oil. Add oil, change oil. Worn bearings. Replace bearings. Worn shaft spline. Replace spline. Troubleshooting DL250-3/DL250TC-3...
  • Page 352 Troubleshooting DL250-3/DL250TC-3 6-10...

  • Page 353: Specification

    14,200 kg (31,310 lb) Engine Emission US EPA Tier 4i (EU Stage IIIB) Maker and Model Doosan Infracore / DL06K 4-Cycle Water Cooled, Turbocharge, Direct Injection, Exhaust Type Gas Recirculation Rated Gross Power 128 kW (172 HP) @ 2,100 rpm (SAE J1995)
  • Page 354 14,100 kg (31,090 lb) Engine Emission US EPA Tier 4i (EU Stage IIIB) Maker and Model Doosan Infracore / DL06K 4-Cycle Water Cooled, Turbocharge, Direct Injection, Exhaust Type Gas Recirculation Rated Gross Power 128 kW (172 HP) @ 2,100 rpm (SAE J1995)
  • Page 355 Specification DL250-3/DL250TC-3...

  • Page 356: Working Range And Dimensions

    WORKING RANGE AND DIMENSIONS DL250-3 Figure 1, illustrates exterior machine dimensions and working range of machine when it is equipped with a standard bucket. I" H" B(D) FG024319 Figure 1 Specification DL250-3/DL250TC-3...
  • Page 357 Maximum Dump Angle at Fully 47 ° Raised Maximum Tilt Angle at Fully Raised 61 ° Turning Radius 5,475 mm (Outer Tire Edge) (18') 5,415 mm (Counterweight Edge) (17' 9") 6,095 mm 6,070 mm (Bucket Edge) (20' (19' 11") DL250-3/DL250TC-3 Specification...
  • Page 358 DL250TC-3 Figure 2, illustrates exterior machine dimensions and working range of machine when it is equipped with a standard bucket. I" H" B(D) FG028530 Figure 2 Specification DL250-3/DL250TC-3...
  • Page 359 Maximum Dump Angle at Fully 50 ° Raised Maximum Tilt Angle at Fully Raised 51 ° Turning Radius 5,475 mm (Outer Tire Edge) (18') 5,415 mm (Counterweight Edge) (17' 9") 6,095 mm 6,070 mm (Bucket Edge) (20' (19' 11") DL250-3/DL250TC-3 Specification...

  • Page 360: Working Capacities

    WORKING CAPACITIES Bucket Capacity Standard bucket (BOC) has a capacity of 2.6 m (3.4 yd Stability DL250-3 [Unit: kg (lb)] Bucket Mount Pin On Remark Configuration Bolt-on Edge (2.6 m * Base On 20.5R25 (L2) Lifting Capacity @ Max. Height 7,610 (16,780) Static Tipping Load @ Max.

  • Page 361: Approximate Weight Of Workload Materials

    (2,295 lb/yd 1,522 kg/m Dolomite, crushed (2,565 lb/yd 1,202 kg/m Earth, loamy, DRY, loose (2,025 lb/yd 1,522 kg/m Earth, DRY, packed (2,565 lb/yd 1,762 kg/m Earth, WET, muddy (2,970 lb/yd Gypsum, calcined, (heated, pow- 961 kg/m der) (1,620 lb/yd Specification DL250-3/DL250TC-3...
  • Page 362 929 kg/m Salt (1,566 lb/yd 529 kg/m Snow, light density (891 lb/yd 1,522 kg/m Sand, DRY, loose (2,565 lb/yd 1,922 kg/m Sand, WET, packed (3,240 lb/yd 1,362 kg/m Shale, broken (2,295 lb/yd 529 kg/m Sulfur, broken (891 lb/yd Specification DL250-3/DL250TC-3 7-10...

  • Page 363: Index

    Check Drained Oil and Used Filter 4-80 1-28 Brake Disk Wear Check Tire Pressure and Condition 4-68 Differential Checks After Inspection and Maintenance Works 4-68, 4-78 Planetaries 4-64 Axle Differential Checks and Maintenance After Stopping Engine Checks Before Starting Engine 2-65 Cigarette Lighter Index DL250-3/DL250TC-3...
  • Page 364 2-66 Door Side Latch F/R (Forward/Reverse) Control Switch 2-65 DOOSAN Genuine Lubricants F/R (Forward/Reverse) Selector Switch 3-28 DOOSAN Genuine Replacement Parts F/R (Forward/Reverse) Travel Control System 2-23 4-42 Down Arrow Button Fan Blade Inspection 3-18 DPF Cleaning (Removing Ash in DPF)
  • Page 365 Handling Oil, Fuel, Coolant 2-14 Hazard Warning Light Switch 2-63 2-12, 2-58 Headlight Switch Kick-down Button 1-14 Heater and Air Conditioner Know Your Machine 2-77 Additional Operating Instructions 2-73 Control Panel 2-77 Memory Function 4-41 Leaks in Fuel System Index DL250-3/DL250TC-3...
  • Page 366 Pressurized Fluids Multifunction Gauge Graphic Information Pressurized Gas and Fluid 2-23, 2-25 Display Preventing Risk of Injuries or Death From Boom and 1-40 Bucket 4-22 Preventive Maintenance 1-20 4-22 Never Use Ether Starting Aids Product Identification Number (PIN) Index DL250-3/DL250TC-3...
  • Page 367 2-64 Service Position Rear Wiper Switch 2-64 Shutdown Rear Work Light Switch 3-19 2-70 Engine Stop Rotating Beacon Light Switch 3-29 2-24 Machine Selector Button 2-59 Signal Words Starter Switch 1-68 2-62 Silica Dust Information Transmission Cutoff Switch Index DL250-3/DL250TC-3...
  • Page 368 Working Capacities Travel System Troubleshooting 1-62 Working In Contaminated Environment 1-34 Traveling 1-62 Working In Water Troubleshooting 1-54 Working on Machine Braking 4-19 Working on Painted Surfaces Working Range and Dimensions 1-12 Ultra Low Sulfur Diesel Fuell (Optional) Index DL250-3/DL250TC-3...
  • Page 370 2905 Shawnee Industrial Way Suite 100 Suwanee, GA 30024...

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