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Daewoo Doosan DL250-3 DL250TC WHEEL LOADER Shop Manual 950106-00985AE – PDF DOWNLOAD
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Daewoo Doosan DL250-3 DL250TC WHEEL LOADER Shop Manual 950106-00985AE – PDF DOWNLOAD
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Description
Daewoo Doosan DL250-3 DL250TC WHEEL LOADER Shop Manual 950106-00985AE – PDF DOWNLOAD
DESCRIPTION:
Daewoo Doosan DL250-3 DL250TC WHEEL LOADER Shop Manual 950106-00985AE – PDF DOWNLOAD
GENERAL
- Only trained and authorized personnel should operate and maintain the machine. Follow all safety rules, regulations and instructions when operating or performing maintenance on machine.
- Do not operate machine if you are under the influence of drugs or alcohol. An operator who is taking prescription drugs must get medical advice to determine if he or she can safely operate a machine.
- When working with other personnel on a work site, be sure that all personnel know the nature of work and understand all hand signals that are to be used.
- Be sure that all guards and shields are installed in their proper location. Have guards and shields repaired or replaced immediately if damaged.
- Be sure that you understand the use and maintenance of all safety features such as pilot cutoff switch and seat belt. Use them at all times.
- Never remove, modify or disable any safety features. Always keep them in good operating condition.
- Always check for and know the location of underground and overhead utility lines before working.
- Failure to use and maintain safety features according to instructions in this manual, Safety Manual and Shop Manual can result in death or serious injury
Know Your Machine
Know how to operate your machine. Know the purpose of all controls, gauges, signals, indicators and monitor displays. Know the rated load capacity, speed range, braking and steering characteristics, turning radius and operating clearances. Keep in mind that rain, snow, ice, loose gravel, soft ground, slopes, etc., can change operating capabilities of your machine.
Proper Work Tools and Attachments
- Only use work tools and attachments that are recommended by DOOSAN for use on DOOSAN machines. When installing and using optional attachments, read instruction manual for attachment, and general information related to attachments in this manual. Because DOOSAN cannot anticipate, identify or test all attachments that owners may want to install on their machines, contact DOOSAN for written authorization and approval of attachments, and their compatibility with optional kits.
- Attachments and attachment control systems that are compatible with the machine are required for safe and reliable machine operation.
- Do not exceed maximum operating weight (machine weight plus attachment) that is listed on ROPS certification plate. Make sure that all guards and shields are in place on machine and on work tool. Depending on type or combination of work equipment, there is a potential that work equipment could interfere with the cabin or other parts of machine.
- Before using unfamiliar work equipment, check if there is any potential for interference, and operate with caution. While you are performing any maintenance, testing, or adjustments to attachments, stay clear of the following areas: cutting edges, pinch points, and crushing surfaces. Never use attachment as a work platform or manlift.
- Contact your DOOSAN distributor about auxiliary hydraulic kits for attachments installation. If you are in doubt about the compatibility of a particular attachment with the machine, consult your DOOSAN distributor.
TABLE OF CONTENTS:
Daewoo Doosan DL250-3 DL250TC WHEEL LOADER Shop Manual 950106-00985AE – PDF DOWNLOAD
DL250-3 - DL250TC-3............................................................................................. 0 Table of Contents........................................................................................... 7 Safety...................................................................................................... 9 Wheel Loader Safety..................................................................................... 11 Safety Instructions................................................................................. 15 Applicable Models................................................................................... 15 Safety Messages..................................................................................... 16 Signal Words.................................................................................... 16 Safety Decals....................................................................................... 17 General............................................................................................. 18 Know Your Machine............................................................................... 18 Proper Work Tools and Attachments............................................................... 18 Pressurized Fluids.............................................................................. 19 Flying or Falling Objects....................................................................... 20 Personal Protective Equipment (PPE)............................................................. 20 Correction of Machine Problems.................................................................. 21 Crushing and Cutting............................................................................ 21 Hot Coolant and Oils - Burn Prevention.......................................................... 22 Fire and Explosion Prevention................................................................... 22 Fire Extinguisher and First-Aid Kit (Emergency Medical Kit)..................................... 26 Electrical System and Electrical Shock.......................................................... 26 Roll-over Protective Structure (ROPS)/ Falling Object Protective Structure (FOPS)............... 27 Transportation...................................................................................... 29 Obey State and Local Over-the-Road Laws & Regulations........................................... 29 Loading and Unloading........................................................................... 29 Transporting Machine............................................................................ 30 Operation........................................................................................... 31 Before Engine Starting.......................................................................... 31 Work Site....................................................................................... 31 Check Tire Pressure and Condition............................................................... 32 Mounting/Dismounting............................................................................ 32 Cleaning........................................................................................ 33 Operator Station................................................................................ 33 Seat Belt....................................................................................... 34 Visibility Information.......................................................................... 35 Boost Starting or Charging Engine Batteries..................................................... 36 Starting Engine................................................................................. 37 Traveling....................................................................................... 38 Lifting and Digging............................................................................. 39 Digging Beneath Overhangs....................................................................... 40 Digging Beneath Wheel Loader.................................................................... 40 Operation on Slopes............................................................................. 40 Towing.......................................................................................... 42 Attachment...................................................................................... 43 Equipment Lowering with Engine Stopped.......................................................... 44 Preventing Risk of Injuries or Death From Boom and Bucket....................................... 44 Engine Stop..................................................................................... 45 Parking Machine................................................................................. 46 Preservation/Storing Machine.................................................................... 47 Maintenance......................................................................................... 49 Warning Tag..................................................................................... 52 Cleaning........................................................................................ 53 Proper Tools and Clothing....................................................................... 53 Disassembling Precautions....................................................................... 53 Use of Lighting................................................................................. 54 Fire and Explosion Prevention................................................................... 54 Burn Prevention................................................................................. 55 Rubber That Contains Fluorides.................................................................. 56 Rubber and Plastics............................................................................. 57 Welding Repairs................................................................................. 58 Working on Machine.............................................................................. 59 Lock Inspection Covers.......................................................................... 60 Accumulator..................................................................................... 60 Compressed Air.................................................................................. 60 High-pressure Lines, Tubes and Hoses............................................................ 61 Supports and Blocking for Work Equipment........................................................ 62 Battery......................................................................................... 62 Environment and Circumstances....................................................................... 64 Work Site Areas Requiring Extra Caution......................................................... 64 High-voltage Cables............................................................................. 66 Underground Operation........................................................................... 66 Working in Water................................................................................ 67 Working in Contaminated Environment............................................................. 67 Operation in Extreme Conditions................................................................. 68 Exhaust Ventilation............................................................................. 72 Asbestos Information............................................................................ 72 Silica Dust Information......................................................................... 73 Disposal of Hazardous Materials................................................................. 73 Sound........................................................................................... 73 Vibration....................................................................................... 74 Before Returning the Machine to the Customer.................................................... 74 Specifications.............................................................................................. 75 Specification for DL250-3 / DL250TC-3................................................................... 77 Safety Instructions................................................................................. 81 Applicable Models................................................................................... 81 Component Locations................................................................................. 82 General Specifications.............................................................................. 86 Engine Performance Curves (Per KS-R1004 Standard)................................................... 88 Working Range and Dimensions........................................................................ 90 Working Capacities.................................................................................. 94 Bucket Capacity................................................................................. 94 Stability....................................................................................... 94 Material Weight..................................................................................... 95 Approximate Weight of Workload Materials........................................................ 95 General Maintenance......................................................................................... 99 General Maintenance Instructions........................................................................101 Safety Instructions.................................................................................105 Applicable Models...................................................................................105 Welding Precautions and Instructions................................................................106 Hydraulic System - General Precautions..............................................................107 Maintenance Service and Repair Procedure............................................................109 General Precautions.............................................................................109 Hydraulic System Cleanliness and Oil Leaks..........................................................110 Maintenance Precautions for Hydraulic System Service............................................110 Oil Leakage Precautions.........................................................................111 Cleaning and Inspection.............................................................................112 General Instructions............................................................................112 Bearing Inspection..............................................................................113 Standard Torques........................................................................................121 Safety Instructions.................................................................................125 Applicable Models...................................................................................125 Torque Values for Standard Metric Fasteners.........................................................126 Torque Values for Standard U.S. Fasteners...........................................................127 Type 8 Phosphate Coated Hardware....................................................................129 Torque Values for Hose Clamps.......................................................................130 ORFS Swivel Nut Recommended Torque..................................................................130 Torque Values for Split Flanges.....................................................................131 Torque Wrench Extension Tools.......................................................................132 Torque Multiplication...........................................................................132 Other Uses for Torque Wrench Extension Tools....................................................133 Tightening Torque Specifications (Metric).......................................................134 Drivetrain..................................................................................................137 Transmission and Torque Converter (ZF 4WG-190)..........................................................139 Safety Instructions.................................................................................143 Applicable Models...................................................................................143 General.............................................................................................144 Torque Limits for Screws........................................................................145 Labeling of Identification Plate for ZF Powershift Transmission.....................................146 Configuration 4 WG-190..............................................................................147 Measuring Points and Connections 4 WG-190...........................................................150 Required Oil Grade..............................................................................151 Special Tools.......................................................................................152 List of Special Tools for Disassembly and Reassembly............................................152 Disassembly.........................................................................................158 Electro-hydraulic Control and ZF Fine Filter (Replaceable Filter)...............................158 Inductive Sensor, Hall Sensor, Breather, Oil Filler and Oil Drain Plug..........................163 Engine Connection (Direct Mount)................................................................164 Engine Connection (Remote Mount)................................................................164 Oil Pressure Pump...............................................................................166 Converter Back-pressure Valve...................................................................168 Emergency Steering Pump.........................................................................169 Outputs and Closure Parts Pump Shaft (PTO-Shaft)................................................170 Removal of Input Shaft, Output Shaft, Pump Shaft (PTO-shaft) and Clutches.......................175 Clutches KV/KR/K1/K2/K3/K4 Input and Output Shaft...............................................179 Reassembly..........................................................................................203 Clutches KV/KR/K1/K2/K3/K4 Input and Output Shaft...............................................203 Installation of Input Shaft, Output Shaft, Pump Shaft (Power-takeoff Shaft) and Clutches............241 Assembly............................................................................................248 Outputs and Closure Parts Pump Shaft (PTO-shaft)................................................248 Reassembly..........................................................................................258 Converter Back-pressure Valve...................................................................258 Oil Pressure Pump...............................................................................259 Engine Connection (Direct Mount)................................................................262 Engine Connection (Remote Mount)................................................................263 Engine Connection (Remote Mount Fordable Version):..............................................265 Emergency Steering Pump.........................................................................269 Inductive Sensor, Hall Sensor, Breather, Oil Filler and Oil Drain Plug..........................271 Electro-hydraulic Control with Proportional Valves:.............................................272 Parking Brake.......................................................................................280 Functional Characteristics and Maintenance Instructions for TM 64/97 KNOTT......................280 Maintenance and Repair Instructions TM 99/07 KNOTT..............................................285 Maintenance and Repair Instructions TM 63/97 KNOTT..............................................297 Transmission Error Codes (ZF)...........................................................................305 Safety Instructions.................................................................................309 Applicable Models...................................................................................309 Definition of Operating Modes.......................................................................310 Normal..........................................................................................310 Substitute Clutch Control.......................................................................310 Limp-home.......................................................................................310 Transmission Shut Down..........................................................................310 TCU Shut Down...................................................................................311 TCU Key Off.....................................................................................311 TCU Idle........................................................................................311 Table of Fault Codes................................................................................312 Measurement of Resistance at Actuator/ Sensors and Cable............................................334 Actuator........................................................................................334 Cable...........................................................................................334 Front Axle (ZF-MT-L 3085 II)............................................................................335 Safety Instructions.................................................................................339 Applicable Models...................................................................................339 Lubrication and Maintenance Instructions............................................................340 Oil Grade.......................................................................................340 Oil Change......................................................................................340 Carry Out Wear Measurement on the Multidisk Brake...............................................342 Inscriptions on Model Identification Plate......................................................343 Tightening Torques for Screws...................................................................344 Special Tools.......................................................................................345 List of Special Tools for Disassembly and Reassembly............................................345 ZF - Multitrac Rigid Axle MT-L 3085 II / MT-L 3095 II...............................................353 Disassembly Output and Brake....................................................................353 Disassembly Axle Housing........................................................................359 Disassembly Input...............................................................................360 Disassembly Differentials.......................................................................363 Reassembly Differentials........................................................................370 Reassembly Input................................................................................382 Reassembly Axle Housing.........................................................................390 Reassembly Output and Brake.....................................................................392 Rear Axle (ZF-MT-L 3075 II).............................................................................405 Safety Instructions.................................................................................409 Applicable Models...................................................................................409 Lubrication and Maintenance Instructions............................................................410 Oil Grade.......................................................................................410 Oil Change......................................................................................410 Make Wear Measurement on the Multidisk Brake....................................................412 Inscriptions on Model Identification Plate......................................................413 Tightening Torques for Screws...................................................................414 Special Tools.......................................................................................415 List of Special Tools for Disassembly and Reassembly............................................415 Disassembly Output and Brake....................................................................422 Disassembly Axle Housing........................................................................429 Disassembly Input...............................................................................431 Disassembly Differentials.......................................................................434 Reassembly Differentials........................................................................440 Reassembly Input................................................................................453 Reassembly Axle Housing.........................................................................462 Reassembly Output and Brake.....................................................................464 Driveshaft..............................................................................................475 Safety Instructions.................................................................................479 Applicable Models...................................................................................479 Driveshaft Weight...............................................................................480 Driveshaft Coupling Dimension...................................................................480 Driveshaft Tightening Torque....................................................................480 Brake.......................................................................................................481 Service Brake...........................................................................................483 Safety Instructions.................................................................................487 Applicable Models...................................................................................487 General Description.................................................................................488 Service Brake System................................................................................489 Brake Supply Valve......................................................................................491 Safety Instructions.................................................................................495 Applicable Models...................................................................................495 Supply Valve........................................................................................496 Charging Block..........................................................................................499 Safety Instructions.................................................................................503 Applicable Models...................................................................................503 Charging Block......................................................................................504 Parts List......................................................................................504 Parking Brake...........................................................................................507 Safety Instructions.................................................................................511 Applicable Models...................................................................................511 General Description.................................................................................512 Functional Characteristics and Maintenance Instructions.............................................513 Functional Characteristics of Spring Loaded Sliding Caliper Brakes..............................513 Mounting and Basic Setting Regulations..........................................................515 Adjusting Regulations...........................................................................516 Emergency Release of Parking Brake..............................................................516 Maintenance and Repair Work.....................................................................517 General.........................................................................................519 Brake Pedal Valve.......................................................................................521 Safety Instructions.................................................................................525 Applicable Models...................................................................................525 General Description.................................................................................526 Theory of Operation.............................................................................526 Specification...................................................................................528 Accumulator.............................................................................................529 Safety Instructions.................................................................................533 Applicable Models...................................................................................533 General Description.................................................................................534 Specifications..................................................................................536 Steering....................................................................................................537 Power Steering System...................................................................................539 Safety Instructions.................................................................................543 Applicable Models...................................................................................543 General Description.................................................................................544 Disassembly.........................................................................................545 Assembly............................................................................................552 Priority Valve..........................................................................................561 Safety Instructions.................................................................................565 Applicable Models...................................................................................565 General Description.................................................................................566 Tool List.......................................................................................566 Disassembly.........................................................................................567 Assembly............................................................................................569 Emergency Steering......................................................................................571 Safety Instructions.................................................................................575 Applicable Models...................................................................................575 General Description.................................................................................576 Emergency Steering Function Test................................................................578 Emergency Steering Automatic Test...............................................................578 Pump and DC Motor...................................................................................580 Frame.......................................................................................................581 Articulation Center.....................................................................................583 Safety Instructions.................................................................................587 Applicable Models...................................................................................587 General Description.................................................................................588 Maintenance Standard............................................................................588 Counterweight...........................................................................................591 Safety Instructions.................................................................................595 Applicable Models...................................................................................595 Specifications......................................................................................596 Counterweight.......................................................................................596 Tank........................................................................................................597 Oil Tank................................................................................................599 Safety Instructions.................................................................................603 Applicable Models...................................................................................603 General Description.................................................................................604 Parts List......................................................................................604 Specifications..................................................................................605 Fuel Tank...............................................................................................607 Safety Instructions.................................................................................611 Applicable Models...................................................................................611 General Description.................................................................................612 Parts List......................................................................................612 Specifications..................................................................................613 Fuel Sender Setting.........................................................................613 Hydraulics..................................................................................................615 Main Pump...............................................................................................617 Safety Instructions.................................................................................621 Applicable Models...................................................................................621 Specification.......................................................................................622 Sectional View......................................................................................622 General Repair Instructions.........................................................................623 Seal Kits and Subassemblies.........................................................................625 Sealing of the Driveshaft...........................................................................628 Sealing of the Regulator Housing....................................................................630 Projection of Pump Support/Checking of the Directional Valve........................................631 Removing of the Impeller............................................................................633 Disassembly of the Regulator........................................................................635 Removing of the Port Plate..........................................................................636 Removing of the Rotary Group........................................................................637 Disassembly of the Rotary Group.....................................................................639 Disassembly of the Hydraulic Control................................................................640 Inspection Notes....................................................................................641 Blind Threaded Hole in Driveshaft...............................................................642 Pump Assembly.......................................................................................657 Inspection Notes....................................................................................660 Pump Assembly.......................................................................................662 Tightening Torques..................................................................................669 Tightening Torques for Shaft Bolts (Metric ISO Standard Thread).................................669 Tightening Torques for Locking Screws VSTI (Metric ISO Fine Thread).............................669 Tightening Torques for Seal-lock Nuts (Metric ISO-Standard Thread)..............................670 Tightening Torques for Cross-slotted Lens Head Screws DIN 7985 (Metric ISO- Standard Thread)....670 Safety Instructions.................................................................................671 General Advice..................................................................................671 Before Starting.................................................................................671 Start...........................................................................................671 Attention.......................................................................................672 Hydraulic Equipment.............................................................................672 Main Control Valve......................................................................................673 Safety Instructions.................................................................................677 Applicable Models...................................................................................677 General Description.................................................................................678 Disassembly/Reassembly..............................................................................680 Load Isolation System...................................................................................689 Safety Instructions.................................................................................693 Applicable Models...................................................................................693 General Description.................................................................................694 Overview........................................................................................695 Hydraulic Circuit...............................................................................696 Accumulator Charging Method.....................................................................696 LIS Valve.......................................................................................698 Accumulator.....................................................................................700 Cooling System..........................................................................................701 Safety Instructions.................................................................................705 Applicable Models...................................................................................705 General.............................................................................................706 Function........................................................................................707 Fan Motor Pressure and Fan Speed................................................................708 Fan and Brake Pump..............................................................................710 Tightening Torques..............................................................................729 Fan Motor...........................................................................................730 Specifications..................................................................................730 Parts List......................................................................................730 Disassembly.....................................................................................731 Inspect Parts for Wear..........................................................................734 Reassembly......................................................................................735 Fan Control Valve...................................................................................738 Specifications..................................................................................738 Parts List......................................................................................738 Pilot System............................................................................................739 Safety Instructions.................................................................................743 Applicable Models...................................................................................743 Function............................................................................................744 Fingertip Joystick..................................................................................745 Specification...................................................................................745 Parts List......................................................................................746 Parts List......................................................................................750 Hydraulic Schematic DL250-3 / DL250TC-3.................................................................753 Safety Instructions.................................................................................757 Applicable Models...................................................................................757 DL250-3.............................................................................................759 DL250TC-3...........................................................................................760 Electrical System...........................................................................................761 Air Conditioner.........................................................................................763 Safety Instructions.................................................................................767 Applicable Models...................................................................................767 General Description.................................................................................768 Internal and External Filters...................................................................769 Air-conditioning System Layout..................................................................770 Air Conditioner/heater Circuit Diagram..........................................................771 Air Conditioner/Heater Unit.....................................................................772 Ambient Air Temperature Sensor..................................................................777 Sun Sensor......................................................................................778 Control Panel...................................................................................778 Compressor......................................................................................785 Receiver Dryer..................................................................................785 Troubleshooting.....................................................................................786 Eight of R134a Gas Used In Machines.................................................................788 Refrigerant System Repairs..........................................................................789 Refrigerant Safe Handling Procedures............................................................789 Repair and Replacement Procedure................................................................790 Refrigerant Recovery............................................................................792 Vacuuming Refrigerant System....................................................................792 Leakage Check...................................................................................794 Refrigerant Charging............................................................................794 Inspecting System For Leakage...................................................................796 Electrical System.......................................................................................797 Safety Instructions.................................................................................802 Applicable Models...................................................................................802 Overview............................................................................................803 Electric Supply System..............................................................................804 Engine Starting Circuit.............................................................................806 Operation During Start Process..................................................................806 Operation After Start Process...................................................................808 Engine Stop System..................................................................................809 Charging System.....................................................................................810 Monitoring System...................................................................................811 Instrument Panel................................................................................812 Function Check..................................................................................814 Monitoring System Schematic.....................................................................814 Operation...........................................................................................816 Instruments Gauge...............................................................................816 Indicator Lights................................................................................816 Initial Operation...............................................................................818 Multifunction Display...........................................................................819 Indication of Warning Lights....................................................................821 Indication of Indicator Lights..................................................................823 Graphic Information Area Display....................................................................825 Overview........................................................................................825 Main Menus for the Graphic Display Area.........................................................825 Menu Selector Buttons...........................................................................826 User Menu...........................................................................................827 Service Menu........................................................................................834 Entering/Accessing and Exiting/Escaping Menus...................................................834 Service Menu Selections.........................................................................835 Windshield Wiper....................................................................................857 Front Windshield Wiper..........................................................................857 Rear Windshield Wiper...........................................................................859 Lighting System.....................................................................................862 Light Circuit...................................................................................862 Power Mode Control..................................................................................866 Engine Control System...............................................................................867 Accelerator Pedal...............................................................................868 Auto Idle Control...............................................................................869 Electric Detent System..............................................................................870 Electrical Circuit..............................................................................870 Boom Kick-out...................................................................................871 Return To Dig...................................................................................872 Cooling Fan Control System..........................................................................873 Outline.........................................................................................873 Diagram.........................................................................................873 Electrical Diagram..............................................................................874 Parts of Cooling Fan Control System.............................................................875 Operation of Cooling Fan Control System.........................................................877 Emergency Steering System (Option)..................................................................879 Block Diagram...................................................................................879 Emergency Steering System Components............................................................880 Emergency Steering System Electrical Circuit....................................................883 Electrical Schematic DL200-3 / DL200TC-3 / DL220-3 / DL250-3 / DL250TC-3................................885 Safety Instructions.................................................................................889 Applicable Models...................................................................................889 DL200-3 / DL200TC-3 / DL220-3 / DL250-3 / DL250TC-3.................................................891
DAEWOO DOOSAN DL250-3 DL250TC WHEEL LOADER SHOP MANUAL 950106-00985AE – PDF DOWNLOAD:
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