Daewoo Doosan Wheel Loader Mega250 V Operation & Maintenance Manual -PDF DOWNLOAD
DESCRIPTION:
Daewoo Doosan Wheel Loader Mega250 V Operation & Maintenance Manual -PDF DOWNLOAD
Mega 250-V
Operation and Maintenance Manual
K1000896E
Serial Number 3001 thru 4000
Serial Number 4001 and Up
August 2004
K1000896E
Serial Number 3001 thru 4000
Serial Number 4001 and Up
August 2004
- 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
GENERAL SAFETY ESSENTIALS:
ACCESSORY APPLICATIONS :
- 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:
- 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.
TABLE OF CONTENTS:
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
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PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
R.D