Daewoo Doosan Wheel Loader Mega250 V Operation & Maintenance Manual -PDF DOWNLOAD

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Daewoo Doosan Wheel Loader Mega250 V Operation & Maintenance Manual -PDF DOWNLOAD

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Daewoo Doosan Wheel Loader Mega250 V Operation & Maintenance Manual -PDF DOWNLOAD

• 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

• 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.

• Always keep these labels clean. If they are lost or damaged, attach them again or replace them with a new label. Make sure replacement parts have current labels. There are other labels in addition to safety labels that follow so handle them in the same way.
• Safety labels may be available in languages other than English. To find out what labels are available, contact your Daewoo distributor.

Daewoo Doosan Wheel Loader Mega250 V Operation & Maintenance Manual -PDF DOWNLOAD

Safety..........................................................................................................  7
	To the Operator of a Daewoo Wheel Loader....................................................................  7
		Learn Signal Words Used with Safety Alert Symbol........................................................  8
	General Safety Essentials...................................................................................  8
		Accessory Applications..................................................................................  8
	Location of Safety Labels...................................................................................  9
		1. Warning for operation, inspection and maintenance (41902545A, 19000092)............................ 11
		2. Warnings when opening engine hood (19000095)........................................................ 11
		3. Warning for handling accumulator (19000703, 19000099).............................................. 12
		4. Keep Out of steering turn area (41901992A, 19000120)............................................... 13
		5. Warning for high temperature hydraulic oil (19000691, 19000097).................................... 13
		6. Warning for high temperature coolant (19000692, 19000097).......................................... 14
		7. Warning for battery maintenance (21902533A, 19000100).............................................. 14
		8. Warning for performing maintenance on front attachment (41902546A, 19000105)....................... 15
		9. Warning to use safety lock (19000121)............................................................... 15
		10. Warning Tag (19000695, 19000098).................................................................. 16
		11. Warning for Wheel Block (41902547A, 19000207)..................................................... 16
	Unauthorized Modifications.................................................................................. 17
	Work Site Precautions....................................................................................... 17
		Attachment Precautions.................................................................................. 17
		Avoid High Voltage Cables............................................................................... 17
		Before Starting to Dig, Contact Authorities............................................................. 18
		Be Aware of Height Obstacles............................................................................ 18
		Use Care on Loose Support............................................................................... 18
		Use Solid Support Blocking.............................................................................. 18
		Digging Beneath Overhangs............................................................................... 18
		Digging Beneath Wheel Loader............................................................................ 18
		Sloping Terrain Requires Caution........................................................................ 18
		Stay Alert for People Moving through Work Area.......................................................... 19
		Be Aware of and Conform to Local Regulations............................................................ 19
	Operation................................................................................................... 19
		Operate While Seated at Operator's Station ONLY......................................................... 19
		Before Starting Engine, do a "prestart" safety check:................................................... 20
		Never Use Ether Starting Aids........................................................................... 20
		Mounting and Dismounting................................................................................ 20
		Observe General Safety Rules............................................................................ 21
		Engine Ventilation...................................................................................... 21
		Take Time to Provide Good Visibility.................................................................... 22
		Fuel, Oil and Hydraulic Fluid Fire Hazards.............................................................. 22
		Boost Starting or Charging Engine Batteries............................................................. 22
		Keep "Pinch Point" Areas Clear – Use Caution in Reverse................................................. 23
		Travel Precautions...................................................................................... 23
		Operate Carefully on Snow and Ice and in Very Cold Temperatures......................................... 23
		Parking Machine......................................................................................... 23
		Shutdown Control Functions.............................................................................. 24
	Equipment................................................................................................... 24
		Rough Operation May Require Use of Certified Safety Equipment........................................... 24
		Install Additional Safety Equipment If Conditions Require............................................... 25
		Movement Alarms......................................................................................... 25
		Seat Belts Should Be Used at All Times.................................................................. 25
		Keep a Fire Extinguisher at Hand........................................................................ 25
		Maintain Standard Safety Equipment in Good Condition.................................................... 25
		Safety Critical Parts Must Be Replaced Periodically..................................................... 26
		Hydraulic Cylinder Seals Require Periodic Replacement................................................... 26
		Highpressure Hydraulic Lines Can Store a Great Deal of Energy.......................................... 26
		Operator's Cab Should Be Kept Clean..................................................................... 26
		Clothing and Personal Protective Items.................................................................. 26
		Breathing Masks, Ear Protection May Be Required......................................................... 27
		Vibration Level Information............................................................................. 27
		Asbestos Dust Hazard Prevention......................................................................... 27
		Battery Electrolyte and Explosive Gases Can Be Lethal................................................... 28
		Disconnect Batteries Before Electrical Service or Electrical Welding.................................... 28
		Use Low Heat Portable Lighting.......................................................................... 28
	Maintenance................................................................................................. 28
		Use Warning Tag during Service.......................................................................... 28
		Do Not Run Engine If Repairs or Work Are Being Performed Alone.......................................... 28
		Always Use Adequate Equipment Supports and Blocking..................................................... 28
		Do Not Work on Hot Engines or Hot Cooling or Hydraulic Systems.......................................... 29
		Cool Down Is Required Before Radiator or Reservoir Checks............................................... 29
		Precautions with Highpressure Line, Tubes and Hoses.................................................... 29
		Obtain immediate medical attention if pressurized oil pierces skin...................................... 30
		Use Correct Replacement Fasteners Tightened to Proper Torque............................................ 30
		Dispose of All Petroleum Based Oils and Fluids Properly................................................. 30
		Check Tire Pressure and Condition....................................................................... 30
	Shipping and Transportation................................................................................. 31
		Obey State and Local OvertheRoad Regulations.......................................................... 31
Operating Controls.............................................................................................. 33
	Component Locations......................................................................................... 34
	Control Identification...................................................................................... 38
	Steering Console and Pedals................................................................................. 39
		1. Starter Switch....................................................................................... 40
		2. Horn Button (Two Places)............................................................................. 40
		3. Combination Switch................................................................................... 41
		4. Accelerator Pedal.................................................................................... 42
		5. Steering Wheel Adjustment Lever...................................................................... 42
		6. Brake Pedal (Right and Left Pedals).................................................................. 43
		7. Steering Wheel....................................................................................... 44
		8. Kickdown Switch (Two places)........................................................................ 44
		9. Transmission Lever................................................................................... 45
		10. FRONT INSTRUMENT PANEL.............................................................................. 46
		11. Transmission Display................................................................................ 46
	Transmission Display........................................................................................ 47
	Front Instrument Panel...................................................................................... 48
		Gauges.................................................................................................. 49
		Warning and Indicator Lights............................................................................ 49
		SWITCHES................................................................................................ 49
		1. Fuel Gauge........................................................................................... 49
		2. Speedometer.......................................................................................... 50
		3. Hour Meter........................................................................................... 50
		4. Tachometer........................................................................................... 50
		5. Engine Coolant Temperature Gauge..................................................................... 51
		6. Transmission Oil Temperature Gauge................................................................... 51
		7. Preheat Indicator Light.............................................................................. 51
		8. Air Cleaner Clogged Warning Light.................................................................... 52
		9. Engine Coolant Temperature Warning Light............................................................. 52
		10. Engine Oil Pressure Warning Light................................................................... 52
		11. Battery Warning Light............................................................................... 52
		12. Left Turn and Hazard Warning Light.................................................................. 53
		13. High Beam Indicator Light........................................................................... 53
		14. Right Turn and Hazard Warning Light................................................................. 53
		15. Work Light Indicator Light.......................................................................... 53
		16. Brake FLUID Pressure Warning Light.................................................................. 54
		17. F/R (Forward/Reverse) Selector Indicator Light (Option)............................................. 54
		18. Parking Brake Indicator Light....................................................................... 54
		19. Emergency Steering Indicator Light (option)......................................................... 55
		20. Hazard Warning light Switch......................................................................... 55
		21. LIS (Load Isolation System) Switch (OPTION)......................................................... 56
		22. Float Kickout Switch (Option)...................................................................... 56
	Right Side Switch Panel..................................................................................... 57
		1. Pilot Control Valve Lever (Joystick)................................................................. 58
		2. Kickdown Switch (TWO PLACES)........................................................................ 58
		3. Horn Button (Two Places)............................................................................. 59
		4. Cigar Lighter........................................................................................ 59
		5. Headlight Switch..................................................................................... 60
		6. front Work Light Switch.............................................................................. 60
		7. Rear Work Light Switch............................................................................... 61
		8. Rear Wiper Switch.................................................................................... 61
		9. Rotating BeacoN Light Switch (OPTion)................................................................ 62
		10. Cup Holder.......................................................................................... 62
		11. Parking Brake switch................................................................................ 62
		12. Pilot cutoff switch................................................................................. 63
		13. Transmission Cutoff Switch.......................................................................... 63
		14. Automatic Transmission Switch....................................................................... 64
		15. emergency Steering Test Switch (option)............................................................. 64
		16. F/R (Forward/Reverse) Selector Switch (Option)...................................................... 65
		17. F/R (Forward/Reverse) Control Switch (Option)....................................................... 65
	Pilot Control Valve Lever (Joystick)........................................................................ 66
		1. Pilot Control Valve Lever (Joystick) (S/N 3001 thru 4000)............................................ 66
		2. Pilot Control Valve Lever (Joystick) (S/N 4001 and Up)............................................... 66
	Various Cabin Locations..................................................................................... 68
		1. CAB LIGHT............................................................................................ 69
		2. Stereo............................................................................................... 69
		3. Heater and AIR CONditioner CONTROL PANEL............................................................. 69
		4. Speakers............................................................................................. 69
		5. Storage Box.......................................................................................... 70
		6. Washer Tank.......................................................................................... 70
		7. Hot/Cold Refrigerator................................................................................ 70
		8. Electrical Box....................................................................................... 70
		9. Fuse Box Two......................................................................................... 71
		10. Fuse Box One........................................................................................ 71
	Heater and Air Conditioner Operation........................................................................ 72
		Location of Controls and Vents.......................................................................... 72
		Operation Panel......................................................................................... 73
		1. Fan and Air Conditioner Switch....................................................................... 73
		2. Blower Fan Switches.................................................................................. 74
		3. Temperature Control Switch........................................................................... 74
		4. Selector Switch for Wind Direction................................................................... 74
		5. Ventilation Selector Switch.......................................................................... 75
		Memory Function of Used Mode............................................................................ 76
		Additional Operating Instruction........................................................................ 76
	Stereo...................................................................................................... 77
		1. OnOff / Volume Control Knob......................................................................... 77
		2. Balance / Fader Control.............................................................................. 77
		3. Bass / Treble Control................................................................................ 77
		4. AM/FM Band Selector.................................................................................. 78
		5. Automatic Memory (AME)............................................................................... 78
		6. Tape Eject Button.................................................................................... 78
		7. Cassette Slot........................................................................................ 78
		8. & 9. Play Direction Button........................................................................... 78
		10. Automatic Selector.................................................................................. 78
		11. Dolby B Selector.................................................................................... 78
		12. Metal Selector...................................................................................... 79
		Care of Stereo.......................................................................................... 79
	Seat Adjustment............................................................................................. 81
		1. Adjusting Seat Forward/ Backward Lever............................................................... 81
		2 & 3. Adjusting Seat's Angle and Height Lever.......................................................... 81
		4. Weight Adjustment Knob............................................................................... 81
		5. Backrest Adjustment Lever............................................................................ 81
		6. Angle Adjustment of Armrest.......................................................................... 82
		7. Headrest............................................................................................. 82
		Recommendations for Limiting Vibrations................................................................. 82
	Seat Belt................................................................................................... 83
		Seat Belt Locking and Unlocking......................................................................... 83
	Door Side Latch............................................................................................. 84
	Fuse Box/Relay.............................................................................................. 85
		Fuse Boxes.............................................................................................. 85
		Relay................................................................................................... 87
		Circuit Breaker......................................................................................... 87
		Fusible Link............................................................................................ 87
Operation....................................................................................................... 89
	Instrument Panel Control Functions.......................................................................... 89
		Monitoring System....................................................................................... 89
	New Machine Breakin Procedures............................................................................. 89
	Engine Start and Stop....................................................................................... 90
		Engine Start............................................................................................ 90
		Cold Weather Engine Start............................................................................... 93
		Starting with Auxiliary Batteries....................................................................... 96
		Engine Stop............................................................................................. 97
		Hydraulic System Warmup................................................................................ 98
		Hydraulic System Warmup – Cold Weather................................................................. 98
	Machine Travel (Standard Transmission Controls)............................................................. 99
	Machine Shut Down...........................................................................................101
	F/R (Forward/Reverse) Travel Control System (Option)........................................................104
	Additional Braking..........................................................................................105
	Boom Raise Kickout.........................................................................................105
	Bucket Angle Indicator......................................................................................106
	Boom Lower Kickout (Option)................................................................................107
	Adjustment of Bucket Position Switch........................................................................107
	Towing Machine..............................................................................................108
	If Engine Stalls While Traveling............................................................................109
	Allowable Water Depth.......................................................................................109
Inspection, Maintenance and Adjustment..........................................................................111
	Preventive Maintenance......................................................................................111
		Serial Numbers..........................................................................................111
		Safety Precautions......................................................................................112
	Table of Recommended Lubricants.............................................................................113
	Fluid Capacities............................................................................................115
	Lubrication and Service Chart...............................................................................115
	Maintenance Intervals.......................................................................................118
		10 Hour / Daily Service.................................................................................118
		50 Hour / Weekly Service................................................................................118
		250 Hour / Monthly Service..............................................................................118
		500 Hour / 3 Month Service..............................................................................119
		1,000 Hour / 6 Month Service............................................................................119
		1,500 Hour / 9 Month Service............................................................................119
		2,000 Hour / Yearly Service.............................................................................119
		12,000 Hour / Six Year Service..........................................................................119
	10 Hour / Daily Service.....................................................................................120
		Grease Front Attachment Pins............................................................................120
		Inspect All Tires for Correct Tire Pressure and Signs of Damage or Abnormal Wear........................120
		Check Engine Oil Level..................................................................................120
		Check Transmission Oil Level Sight Gauge................................................................121
		Check Hydraulic System Oil Level........................................................................122
		Check for Leaks in Hydraulic System.....................................................................123
		Fill Fuel Tank..........................................................................................124
		Check for Leaks in Fuel System..........................................................................124
		Drain Fuel Condensation.................................................................................125
		Check Coolant Level.....................................................................................126
		Check Level of Window Washer Liquid.....................................................................127
		Inspect the Bucket Teeth and Side Cutters for Signs of Wear.............................................127
		Inspect Seat Belt for Proper Operation..................................................................127
		Inspect the Structure for Cracks and Faulty Welds.......................................................127
		Check the Operation of All Switches.....................................................................127
		Check the Operation of All Exterior Lights, Horn and Control Console Indicator and Monitor Lights.......127
		Start Engine, Check Starting Ability, and Observe Exhaust Color at Startup and at Normal Operati.......128
		Check Operation of All Controls.........................................................................128
		Inspect Engine Fan Blade................................................................................128
		Check Engine Drive Belt Wear............................................................................129
		Check Air Intake System.................................................................................130
	50 Hour / Weekly Service....................................................................................131
		Perform All Daily Service Checks........................................................................131
		Grease Front Attachment Pins............................................................................131
		Grease Steering Cylinder Rod and Head Ends..............................................................136
		Grease Upper and Lower Center Pins......................................................................137
		Change Engine Oil and Filter............................................................................137
		Hydraulic Full Flow Filter Replacement..................................................................137
		Check Water Pump Belt Tension...........................................................................137
		Clean Exterior of Radiator, Oil Cooler and Air conditioner Condenser....................................137
	250 Hour / Monthly Service..................................................................................138
		Perform All Daily and 50 Hour Service Checks............................................................138
		Replace Hydraulic System brake and Pilot Filter.........................................................138
		Check Engine Air Intake Precleaner......................................................................139
		Drain Water From Hydraulic Oil Tank.....................................................................139
		Clean Air Cleaner.......................................................................................139
		Check Water Pump Belt Tension...........................................................................141
		Grease Drive Shafts.....................................................................................142
		Change Engine Oil and Filter (Tier I engine)............................................................143
		Axle Differential and Planetaries Oil Replacement (after first 250 hours)...............................144
		Replacement Of Transmission Oil and Filter (After First 250 Hours)......................................144
	500 Hour / 3 Month Service..................................................................................145
		Perform All Daily, 50 and 250 Hour Service Checks.......................................................145
		Change Engine Oil and Filter (Tier II engine)...........................................................145
		Replace Fuel Filter.....................................................................................146
		Hydraulic Full Flow Filter Replacement..................................................................147
		Clean Exterior of Radiator, Oil Cooler and Air conditioner Condenser....................................148
		Clean Air Conditioner Filter............................................................................150
	1,000 Hour / 6 Month Service................................................................................151
		Perform All Daily, 50, 250 and 500 Hour Service Checks..................................................151
		Drain and Replace Transmission Oil and filter...........................................................151
		Axle Brake Disk Wear Measurement........................................................................153
		Clean Fuel Tank and Strainer............................................................................154
		Clean Fuel Injection Priming Pump Strainer..............................................................155
		Replace Air Conditioner Filter..........................................................................155
		Check Air Conditioner Refrigerant.......................................................................156
		Check and Adjust Engine.................................................................................156
	1,500 Hour / 9 Month Service................................................................................157
		Perform All Daily, 50, 250 and 500 Hour Service Checks..................................................157
		Axle Differential and Planetaries Oil Replacement.......................................................157
		Replace Outer and Inner Air Cleaner Elements............................................................159
	2,000 Hour / Yearly Service.................................................................................160
		Perform All Daily, 50, 250, 500 and 1,000 Hour Service Checks...........................................160
		Check Steering, Brake, Drive Shaft, Engine, and Fuel System.............................................160
		Replace Pipes and Hoses.................................................................................160
		Bleed Brakes............................................................................................160
		Change Radiator Coolant.................................................................................161
		Drain and Replace Hydraulic Oil.........................................................................163
		Check Brake Accumulator.................................................................................164
	12,000 Hour / Six Year Service..............................................................................166
		Hose Inservice Lifetime Limit (European Standard ISO8331 and EN982CEN)...............................166
	Severe Conditions Maintenance...............................................................................167
	Bolt Torque Chart...........................................................................................168
		Tightening Torque Specifications for Metric Bolts (For coated threads, prelubricated assemblies)........168
	Electrical System...........................................................................................169
		Check Battery Condition.................................................................................169
	Engine Cooling System.......................................................................................170
		General.................................................................................................170
		Antifreeze Concentration Tables.........................................................................171
	Fuel Transfer Pump..........................................................................................172
	Hydraulic Pressure Checks...................................................................................174
		Main Pump Pressure......................................................................................174
		Unloading Valve Pressure................................................................................174
		Steering Pump Pressure..................................................................................175
		Transmission Clutch Pressure............................................................................175
		Brake Charge Pressure (S/N 3001 thru 4000)..............................................................175
		Brake Charge Pressure (S/N 4001 and Up).................................................................176
		Control Lever Activation Pressure (S/N 3001 thru 4000)..................................................176
		Control Lever Activation Pressure (S/N 4001 and Up).....................................................176
		Service Brake Outlet Pressure...........................................................................177
		Parking Brake Release Pressure..........................................................................177
		Fan Motor Pressure (S/N 4001 and Up)....................................................................177
	Long Term Storage...........................................................................................178
		Cleaning................................................................................................178
		Hydraulic System........................................................................................178
		Lubrication.............................................................................................178
		Battery.................................................................................................178
		Cooling System Care.....................................................................................178
	Parking Brake Adjustment....................................................................................179
		Emergency Release of the Parking Brake..................................................................179
		Adjusting regulations...................................................................................180
	Tires and Wheels............................................................................................182
		Wheel Nut Torque........................................................................................182
		Check Tire For Damage...................................................................................183
Transportation..................................................................................................185
	Loading Machine on a Trailer................................................................................185
	Summary of Safety Precautions for Lifting...................................................................186
Troubleshooting.................................................................................................187
	Braking.....................................................................................................187
	Electrical System...........................................................................................187
	Engine......................................................................................................188
	Hydraulic System............................................................................................190
	Steering....................................................................................................193
	Travel System...............................................................................................194
		General.................................................................................................194
		Transmission Error Codes................................................................................196
Specifications..................................................................................................201
	General Specifications......................................................................................201
	Working Range and Dimensions................................................................................203
	Working Capacities..........................................................................................205
		Bucket Capacity.........................................................................................205
		Tipping Load............................................................................................205
		Material Weight.........................................................................................205
	Approximate Weight of Workload Materials....................................................................205
Index...........................................................................................................209

DAEWOO DOOSAN WHEEL LOADER MEGA250 V OPERATION & MAINTENANCE MANUAL -PDF DOWNLOAD:

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• This is the SAME exact manual used by your dealers to fix your vehicle.
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