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Daewoo Doosan Mega 250-V Shop Manual – PDF DOWNLOAD
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Daewoo Doosan Mega 250-V Shop Manual – PDF DOWNLOAD
Mega 250-V
Shop Manual
023-00050AE
S/N 1001 thru 2000 (Tier I)
S/N 2001 and Up (Tier II)
023-00050AE
S/N 1001 thru 2000 (Tier I)
S/N 2001 and Up (Tier II)
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Description
Daewoo Doosan Mega 250-V Shop Manual – PDF DOWNLOAD
DESCRIPTION:
Daewoo Doosan Mega 250-V Shop Manual – PDF DOWNLOAD
Mega 250-V
Shop Manual
023-00050AE
S/N 1001 thru 2000 (Tier I)
S/N 2001 and Up (Tier II)
023-00050AE
S/N 1001 thru 2000 (Tier I)
S/N 2001 and Up (Tier II)
- Daewoo reserves the right to improve our products in a continuing process to provide the best possible product to the market place. These improvements can be implemented at any time with no obligation to change materials on previously sold products.
- It is recommended that consumers periodically contact their distributors for recent documentation on purchased equipment. This documentation may include attachments and optional equipment that is not available in your machine’s package.
- Please call your distributor for additional items that you may require. Illustrations used throughout this manual are used only as a representation of the actual piece of equipment, and may vary from the actual item. Shop Manual 023-00050AE S/N 1001 thru 2000 (Tier I) S/N 2001 and Up (Tier II)
GENERAL SAFETY ESSENTIALS ;
ACCESSORY APPLICATIONS :
- This wheel loader has been designed primarily for moving earth with a bucket. For use as a grapple or for other object handling, contact Daewoo. Lifting-work applications are permitted in approved lift configuration, to rated capacity only, with no side-loading (unless prohibited by local regulation).
- Do not use machine for activities for which it was not intended. Do not use bucket for lifting work, unless lift slings are used in approved configuration.
LOCATION OF SAFETY LABELS :
- Location of safety labels (decals) can vary from unit to unit. Refer to appropriate Operation and Maintenance Manual, and Parts Manual for your unit. There are several specific warning signs on this machine.
- The exact location of hazards and the description of the hazards are reviewed in the appropriate Operation and Maintenance Manual. Please become familiarized with all warning signs.
- Make sure that all of the warning signs are legible. Clean the warning signs or replace the warning signs if you cannot read the words. Replace the illustrations if the illustrations are not visible. When you clean the warning signs, use a cloth, water and soap. Do not use solvent, gasoline, or other harsh chemicals to clean the safety signs. Solvents, gasoline, or other harsh chemicals could loosen the adhesive that secures the warning sign.
- Loose adhesive will allow the warning sign to fall off. Replace any safety sign that is damaged, or missing. If a safety sign is attached to a part that is replaced, install a safety sign on the replacement part.
UNAUTHORIZED MODIFICATIONS :
- Any modification made without authorization or written approval from Daewoo can create a safety hazard, for which the machine owner must be held responsible. For safety’s sake, replace all OEM parts with the correct authorized or genuine Daewoo part.
- For example, not taking the time to replace fasteners, bolts or nuts with the correct replacement parts could lead to a condition in which the safety of critical assemblies is dangerously compromised.
TABLE OF CONTENTS:
Daewoo Doosan Mega 250-V Shop Manual – PDF DOWNLOAD
Safety.............................................................................. 7 Wheel Loader Safety S0103010K................................................... 9 To the Operator of a Daewoo Wheel Loader.................................... 11 Learn Signal Words Used with Safety Alert Symbol........................ 13 General Safety Essentials................................................... 14 Accessory Applications.................................................. 14 Location of Safety Labels................................................... 14 Unauthorized Modifications.................................................. 14 General Hazard Information.................................................. 15 Safety Rules............................................................ 15 Safety Features......................................................... 15 Inside Operator's Compartment........................................... 16 Clothing and Personal Protective Items.................................. 16 Breathing Masks, Ear Protection May Be Required......................... 17 Asbestos Dust Hazard Prevention......................................... 17 Mounting and Dismounting................................................ 17 Fuel, Oil and Hydraulic Fluid Fire Hazards.............................. 18 Precautions When Handling Fluids at High Temperature.................... 18 Injury from Work Equipment.............................................. 19 Fire Extinguisher and First Aid Kit..................................... 19 Protection from Falling or Flying Objects............................... 20 Install Additional Safety Equipment If Conditions Require............... 20 Maintain Standard Safety Equipment in Good Condition.................... 20 Attachment Precautions.................................................. 21 Accumulator............................................................. 21 Engine Ventilation...................................................... 21 Window Glass Breaking Tool.............................................. 22 Before Starting Engine...................................................... 23 Work Site Precautions................................................... 23 Checks Before Starting Engine........................................... 24 Engine Starting......................................................... 24 Before Operating Machine................................................ 25 Machine Operation........................................................... 26 Operate While Seated at Operator’s Station ONLY......................... 26 Seat Belts Should Be Used at All Times.................................. 26 Movement Alarms......................................................... 26 Travel Precautions...................................................... 27 Sloping Terrain Requires Caution........................................ 27 Avoid High-voltage Cables............................................... 28 Before Starting to Dig, Contact Authorities............................. 28 Be Aware of Height Obstacles............................................ 28 Use Care on Loose Support............................................... 28 Use Solid Support Blocking.............................................. 29 Digging Beneath Overhangs............................................... 29 Digging Beneath Wheel Loader............................................ 29 Stay Alert for People Moving Through Work Area.......................... 29 Be Aware of and Conform to Local Regulations............................ 29 Never Use Ether Starting Aids........................................... 30 Observe General Safety Rules............................................ 30 Take Time to Provide Good Visibility.................................... 30 Keep "Pinch Point" Areas Clear - Use Caution in Reverse................. 31 Operate Carefully on Snow and Ice and in Very Cold Temperatures......... 31 Parking Machine......................................................... 31 Shutdown Control Functions.............................................. 32 Never Let Anyone Ride on Attachment..................................... 32 Maintenance................................................................. 33 Use Warning Tag During Service.......................................... 33 clean Before Inspection or Maintenance.................................. 33 Proper Tools............................................................ 34 Use of Lighting......................................................... 34 Fire Prevention and Explosion Prevention................................ 34 Burn Prevention......................................................... 35 Welding Repairs......................................................... 36 Precautions for Removal, Installation, and Storage of Attachments....... 36 Precautions When Working on Machine..................................... 37 Lock Inspection Covers.................................................. 37 Crushing Prevention and Cutting Prevention.............................. 37 Do Not Run Engine If Repairs or Work Are Being Performed Alone.......... 37 Always Use Adequate Equipment Supports and Blocking..................... 38 Do Not Work on Hot Engines or Hot Cooling or Hydraulic Systems.......... 38 Hydraulic Cylinder Seals Require Periodic Replacement................... 38 High Pressure Hydraulic Lines Can Store a Great Deal of Energy.......... 38 Precautions with High Pressure Line, Tubes and Hoses.................... 39 Obtain Immediate Medical Attention if Pressurized Oil Pierces Skin...... 39 Use Correct Replacement Fasteners Tightened to Proper Torque............ 40 Safety-critical Parts Must Be Replaced Periodically..................... 40 Dispose of All Petroleum-based Oils and Fluids Properly................. 40 Check Tire Pressure and Condition....................................... 40 Battery..................................................................... 41 Battery Hazard Prevention............................................... 41 Disconnect Batteries Before Electrical Service or Electrical Welding.... 41 Use Low Heat Portable Lighting.......................................... 42 Boost Starting or Charging Engine Batteries............................. 42 Towing...................................................................... 43 Precautions When Towing................................................. 43 Shipping and Transportation................................................. 44 Obey State and Local Over-the-Road Regulations.......................... 44 Summary of Safety Precautions for Lifting............................... 44 Specifications...................................................................... 45 Specifications for Mega 250-V S0203110C......................................... 47 Component Locations......................................................... 50 General Specifications...................................................... 56 Engine Performance Curves................................................... 58 Working Range and Dimensions................................................ 62 Working Capacities.......................................................... 65 Bucket Capacity......................................................... 65 Tipping Load............................................................ 65 Material Weight............................................................. 65 Approximate Weight of Workload Materials................................ 65 General Maintenance................................................................. 69 General Maintenance Procedures S0302000......................................... 71 Welding Precautions and Guidelines.......................................... 73 Hydraulic System - General Precautions...................................... 74 Maintenance Service and Repair Procedure.................................... 75 General Precautions..................................................... 75 Hydraulic System Cleanliness and Oil Leaks.................................. 76 Maintenance Precautions for Hydraulic System Service.................... 76 Oil Leakage Precautions................................................. 76 Cleaning and Inspection..................................................... 77 General Guidelines...................................................... 77 Bearing inspection...................................................... 78 Standard Torques S0309000....................................................... 85 Torque Values for Standard Metric Fasteners................................. 87 Torque Values for Standard U.S. Fasteners................................... 88 Type 8 Phosphate Coated Hardware............................................ 90 Torque Values for Hose Clamps............................................... 91 Torque Values for Split Flanges............................................. 92 Torque Wrench Extension Tools............................................... 93 Torque Multiplication................................................... 93 Other Uses for Torque Wrench Extension Tools............................ 94 Tightening Torque Specifications (Metric)............................... 94 Upper Structure..................................................................... 97 Counterweight S0403030K......................................................... 99 Specifications..............................................................101 Counterweight...............................................................101 Fuel Transfer Pump S0405500.....................................................103 General Description.........................................................105 Theory of Operation.....................................................105 Troubleshooting.............................................................106 Replacement of Rotor and Vane...............................................106 Replacement of Rear Cover...................................................107 Replacement of Armature.....................................................108 Hydraulic Oil Tank S0406060C....................................................109 General Description.........................................................112 Parts List (M200-V).....................................................112 Parts List (M250-V).....................................................114 Specifications..........................................................116 Lower Structure and Chassis.........................................................117 Center Joint (Articulation Joint) S0502050C.....................................119 General Description.........................................................121 Maintenance Standard....................................................122 Engine and Drive Train..............................................................125 Axle (Volvo) S0602210C..........................................................127 Introduction................................................................129 General Description.........................................................130 Outline.................................................................130 Disassembly and Assembly of Axle Units......................................133 Disassembly of Final Drive (Planetaries)................................134 Disassembly of Differential Unit........................................137 Cleaning and Inspection (Wear Limits and Tolerances)....................140 Assembly of Differential Unit...........................................142 Assembly of Final Drive (Planetaries)...................................147 Special Tool............................................................150 Brake Bleeding Procedure....................................................152 Parking Brake Caliper (Volvo) S0603000..........................................153 General Description.........................................................155 Operation...............................................................155 Parking Brake Applied...................................................156 Parking Brake Released..................................................156 Parts List..............................................................157 Special Tools and Materials.................................................157 Lubricants and Sealants.................................................157 Troubleshooting, Testing and Adjustment.....................................158 Parking Brake System....................................................158 Checking and Adjusting Parking Brake....................................158 Measuring Pad Thickness.................................................158 Measuring Disc / Pad Clearance..........................................158 Measuring Procedure.....................................................159 Adjustment..............................................................159 Releasing the Parking Brake in Emergency Case...........................160 Disassembly.................................................................161 General.................................................................161 Changing Brake Pads.....................................................161 Work Sequence During Change of Brake Pads...............................161 Cleaning and Inspection (Wear Limits and Tolerances)........................163 Reassembly..................................................................165 Air Conditioner S0605050K.......................................................171 General Description.........................................................173 Refrigerant Circulation.....................................................174 Control Panel...............................................................176 Control Specifications......................................................177 Temperature Level Control and Display.......................................178 Air Discharge According to Path Selection...................................179 Air-conditioning System Circuit Diagram.....................................182 Troubleshooting.............................................................184 Weight of R134a Gas Used In Machines........................................188 Refrigerant System Repairs..................................................190 Refrigerant Safe Handling Procedures....................................190 Repair and Replacement Procedure........................................191 Refrigerant Recovery....................................................193 Vacuuming Refrigerant System............................................193 Leakage Check...........................................................194 Refrigerant Charging....................................................195 Inspecting System For Leakage...........................................197 Transmission and Torque Converter (ZF4WG190) S0607120C........................199 Drive Train Description.....................................................203 Transmission and Torque Converter...........................................204 Powershift Transmission.................................................205 Transmission Control....................................................205 The Chart of Measuring Points and Connection 4 WG-190...................207 Oil Circuit Diagram 4WG-190.............................................209 Transmission Electric Components............................................211 TCU (Transmission Control Unit).........................................212 Transmission Control Valve..............................................212 Transmission Oil Temperature Sensor.....................................213 Engine Pick-Up Sensor...................................................213 Central Gear Pick-Up Sensor.............................................213 Turbine Pick-Up Sensor..................................................214 Output Speed Sensor.....................................................214 Shift Lever Switch (DW-3)...............................................214 Auto Select Switch......................................................216 Display.................................................................216 Transmission Electrical Circuits............................................217 T/M Controller Circuit..................................................217 Traveling Circuits......................................................218 Downshift...............................................................226 Transmission Cut Off....................................................229 LIS (Load Isolation System) - Option....................................230 Installation View...........................................................231 Inner Section...........................................................231 Front View..............................................................232 Side View...............................................................233 Rear View...............................................................234 Special Tools...............................................................235 Gearshift System........................................................235 Engine Connection.......................................................237 Pressure Oil Pump.......................................................238 Gearbox Housing.........................................................239 Input...................................................................241 Clutch..................................................................242 Output..................................................................248 Power Take-off..........................................................249 Hydraulic Control Unit (HSG94).............................................250 Disassembly.............................................................251 Reassembly..............................................................254 Transmission Disassembly....................................................261 Hydraulic Control unit (HSG-94) and Duct plate..........................261 Engine Connection - Converter...........................................262 Hydraulic Pump..........................................................264 Converter Back Pressure Valve...........................................265 Remove output, Input and Clutches.......................................266 Disassemble Clutch - KV and KR..........................................271 Disassemble Clutch - K1, K2 and K3......................................274 Dissemble Clutch - K4...................................................276 Disassemble Drive Shaft.................................................277 Transmission Reassembly.....................................................279 Install Oil Tube........................................................279 Reassemble Clutch - KV and KR...........................................281 Reassemble Clutch - K1, K2 and K3.......................................288 Reassemble Clutch - K4..................................................295 Pre-assemble Drive Shaft................................................301 Pre-assemble and Install Output.........................................302 Install Pre-assembled Drive Shaft and Clutches..........................304 Install Pump Shaft (Power Take-off).....................................307 Install Output Flanges..................................................308 Converter Back Pressure Valve...........................................310 Oil Feed Housing - Transmission Pump....................................310 Engine Connection - Converter...........................................312 Converter Safety Valve..................................................315 Mount Duct Plate and Hydraulic Control Unit.............................315 Install Plugs and Oil Level Tube........................................316 Speed Sensor and Inductive Transmitters.................................318 Setting Inductive Transmitter...........................................319 Speed Sensor (Hall Sensor) N Output and Speedometer.....................320 Transmission Error Codes (ZF) S0607900C.........................................323 Introduction................................................................326 Abbreviations...............................................................326 Display.....................................................................326 Description of Fault Codes..............................................327 Display During Operation....................................................328 Definition of Operating Modes...............................................330 Normal..................................................................330 Substitute Clutch Control...............................................330 Limp-home...............................................................330 Transmission shut Down..................................................330 TCU Shut Down...........................................................330 Clutch Pack and Solenoid Valve Cross-reference Table........................331 Table of Fault Codes........................................................332 Table of Fault Codes - ERGO-Control.........................................354 Measurement of Resistance at Actuator/ sensors and Cable....................357 Actuator................................................................357 Cable...................................................................357 Hydraulics..........................................................................359 Accumulator S0703010K...........................................................361 General Description.........................................................363 Specifications..........................................................364 Cylinders S0705005K.............................................................367 General Description.........................................................370 Theory of Operation.....................................................371 Parts List..............................................................372 Troubleshooting, Testing and Adjustment.....................................378 Disassembly.................................................................382 Cleaning and Inspection (Wear Limits and Tolerances)........................384 Reassembly..................................................................385 Fan Drive Hydraulic Motor (Haldex) S0707110C....................................393 General Description.........................................................396 Theory of Operation.....................................................396 Parts List..............................................................400 Specifications..........................................................401 Troubleshooting, Testing and Adjustment.....................................402 Tools Required..............................................................402 Disassembly.................................................................403 Inspect Parts for Wear......................................................406 General Information.........................................................407 Reverse Shaft Rotation of Pump..............................................407 Reassembly..................................................................408 Main Pump (Denison T67CCA Series) S0708500C.....................................413 General Description.........................................................415 Theory of Operation.....................................................415 Parts List..............................................................416 Service Kits............................................................418 Dimensions..............................................................419 Specification...........................................................420 Special Tools...............................................................421 Seal Driver.............................................................421 Protective Cone.........................................................421 Disassembly.................................................................422 Reassembly..................................................................426 Brake Pedal Valve S0709270C.....................................................431 General Description.........................................................433 Theory of Operation.....................................................433 Specification...........................................................434 Brake System................................................................435 Brake and Pilot Supply Valve............................................435 Brake, Pilot and Fan Motor Supply Valve.................................436 Brake, Pilot and Fan Motor Supply Valve.....................................437 Brake and Pilot Supply Valve............................................437 Brake, Pilot and Fan Motor Supply Valve.................................439 Main Control Valve (Toshiba) S0709456K..........................................441 General Description.........................................................443 Specifications..............................................................445 Operation...................................................................446 Neutral.................................................................446 Bucket/option Spool Operation...........................................446 Boom Spool Operation....................................................447 Relief Valve............................................................447 Operation (Main Relief Valve)...........................................448 Operation (Port Relief Valve)...........................................449 Pilot Control Valve S0709478C...................................................451 General Description.........................................................453 Pilot Valve Operation...................................................453 Standard................................................................454 Option..................................................................456 Pilot System................................................................458 Mega 200-V..............................................................459 Mega 250-V..............................................................460 Priority Valve S0709650.........................................................461 General Description.........................................................463 Theory of Operation.....................................................463 Parts List..............................................................465 Specifications..........................................................466 Special Tools...............................................................466 Disassembly.................................................................466 Cleaning and Inspection (Wear Limits and Tolerances)........................468 Reassembly..................................................................469 Power Steering Unit S0709705C...................................................473 General Description.........................................................475 Power Steering System...................................................475 Gerotor Operation.......................................................478 Cushion Valve Operation.................................................479 Parts List..............................................................480 Specifications..........................................................481 Special Tools...............................................................482 Troubleshooting, Testing and Adjustment.....................................484 Disassembly.................................................................485 Cleaning and Inspection.....................................................489 Reassembly..................................................................490 Installation................................................................501 Unloader Valve S0709860C........................................................503 General Description.........................................................506 Theory of Operation.....................................................506 Unloader Cartridge Identification.......................................508 Specifications..........................................................509 Hydraulic Schematic (Mega 250-V) S0793005C......................................511 General Description.........................................................513 Mega 250-V..................................................................514 Electrical System...................................................................519 Electrical System S0802015C.....................................................521 Overview....................................................................524 Electric Supply System......................................................525 Engine Starting Circuit.....................................................527 Operation During Start Process..........................................527 Operation After Start Process (Mega 200-V)..............................529 Operation After Start Process (Mega (250-V).............................530 Engine Preheating System....................................................531 Mega 200-V / 250-V (Tier I).............................................531 Mega 200-V / 250-V (Tier II)............................................534 Engine Stop System..........................................................537 Operation In Engine Running Mode........................................537 Operation In Engine Stop Mode...........................................540 Charging System.............................................................542 Monitoring System...........................................................543 Instrument Panel........................................................544 Function Check..........................................................545 Monitoring System Schematic.............................................546 Operation...............................................................550 Windshield Wiper............................................................556 Front windshield wiper..................................................556 Rear Windshield wiper...................................................557 Lighting System.............................................................560 Light Circuit (Mega 200-V)..............................................560 Light Circuit (Mega 250-V)..............................................564 Emergency Steering System (Option)..........................................567 Block Diagram...........................................................567 Emergency Steering System Components....................................568 Emergency Steering System Electric Circuit..............................570 Electric Detent System......................................................571 Electric Circuit........................................................571 Boom Kick-Out...........................................................572 Return To Dig...........................................................573 Electrical Schematic (Mega 250-V) S0893005C.....................................575 General Description.........................................................577 Mega 250-V (Tier I).........................................................578 Mega 250-V (Tier II)........................................................580 Attachments.........................................................................583
DAEWOO DOOSAN MEGA 250-V SHOP MANUAL – PDF DOWNLOAD:
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