PDF Shop Manual Daewoo Doosan Mega 250-V Wheel Loader - 2 MB
This is the complete shop manual for the Daewoo Doosan Mega 250-V wheel loader.
It offers detailed, step-by-step instructions for all repair and maintenance procedures.
The manual covers the engine, transmission, hydraulics, electrical systems, and more.
This is the same guide used by factory-trained technicians to diagnose and fix problems, making it an invaluable resource for any owner or mechanic.
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Mega 250-V
Shop Manual
023-00050AE
S/N 1001 thru 2000 (Tier I)
S/N 2001 thru 3000 (Tier II)
DOOSAN 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.
023-00050AE Shop Manual
--- Page 3 ---
S0103010K
2WHEEL LOADER
SAFETY
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that are in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
WHEEL LOADER SAFETYS0103010K
MODEL SERIAL NUMBER RANGE
Mega 200-V (Tier I & II) 1001 and Up
Mega 250-V (Tier I) 1001 thru 2000
Mega 250-V (Tier I) 3001 thru 4000
Mega 250-V (Tier II) 2001 thru 3000
Mega 250-V (Tier II) 4001 and Up
Mega 300-V (Tier I) 1001 thru 2000
Mega 300-V (Tier II) 2001 thru 3000
Mega 300-V 3001 and Up
Mega 400-V 1001 and Up
Mega 500-V (Tier I) 1001 thru 2000
Mega 500-V (Tier II) 2001 and Up
Copyright DOOSAN 2004
March 2004
Wheel Loader Safety S0103010K
Page 1
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PRECAUTIONS WHEN HANDLING FLUIDS
AT HIGH TEMPERATURE
Immediately after operations are stopped, the
coolant, engine oil, and hydraulic oil are at high
temperature and the radiator and hydraulic tank
are still under pressure. Attempting to remove
the cap, drain the oil or coolant, or replace the
filters may lead to serious burns. Always wait for
the temperature to go down, and follow the
specified procedures when carrying out these
operations.
HAOA050L
Figure 5
To prevent hot coolant from spurting out, shut
down engine, wait for the coolant to cool, then
loosen the cap slowly to relieve the pressure.
To prevent hot oil from spurting out, shut down
engine, wait for the oil to cool, then loosen the
cap slowly to relieve the pressure.
HAOA060L
Figure 6
INJURY FROM WORK EQUIPMENT
Do not enter or put your hand, arm or any other
part of your body between movable parts, such
as between the work equipment and cylinders,
or between the machine and work equipment.
If the control levers are operated, the clearance
between the machine and the work equipment
will change and this may lead to serious
damage or personal injury.
If going between movable parts is necessary,
always position and secure the work equipment HDO1010L
so that it cannot move. Figure 7
Wheel Loader Safety S0103010K
Page 11
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USE SOLID SUPPORT BLOCKING
Never rely on lift jacks or other inadequate
supports when work is being done. Block
wheels fore and aft to prevent any movement.
DIGGING BENEATH OVERHANGS
Digging beneath an overhang is dangerous.
Overhang could collapse on top of operator and
cause serious injury or death. Go on to another
digging area before steep overhangs are
formed. Know height and reach limits of wheel HDO1042L
loader and plan ahead while working. Park Figure 17
wheel loader away from overhangs before work
shut down.
DIGGING BENEATH WHEEL LOADER
Digging beneath wheel loader is dangerous. Earth beneath could collapse. This could cause wheel loader
to tip, which could cause serious injury or death to operator. Working around deep pits, trenching or along
high walls may require support blocks, especially after heavy rainfalls or during spring thaws.
STAY ALERT FOR PEOPLE MOVING
THROUGH WORK AREA
When loading a truck you should always know
where the driver is.
Avoid loading over the cabin of a truck even if
the driver is in a safe spot. Someone else could
have gone inside, for any number of reasons.
Avoid working where unseen passersby might
be.
Slow down work cycle and use slower travel
speeds in congested or populated areas. Use a HAOA171L
commonly understood signal so that other Figure 18
members of work crew can warn operator to
slow or halt work in an impending hazardous
situation.
BE AWARE OF AND CONFORM TO LOCAL REGULATIONS
Minimum levels of insurance coverage, work permits or certification, physical barriers around work site or
restricted hours of operation may be mandated by governing authorities. There may also be guidelines,
standards or restrictions on equipment that may be used to perform certain kinds of work. Check and
follow all local requirements, which may also be related to below ground hazards and power lines.
Wheel Loader Safety S0103010K
Page 21
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PRECAUTIONS WITH HIGH-PRESSURE LINE, TUBES AND HOSES
When inspecting or replacing high-pressure piping or hoses, check that the pressure has been released
from the circuit. Failure to release the pressure may lead to serious injury. Always do the following:
• Wear protective glasses and leather gloves.
• Fluid leaks from hydraulic hoses or pressurized components can be difficult to see but
pressurized oil has enough force to pierce the skin and cause serious injury. Always use a piece
of wood or cardboard to check for suspected hydraulic leaks. Never use your hands or expose
your fingers.
• Do not bend high-pressure lines. Do not strike high-pressure lines. Do not install lines, tubes or
hoses that are bent or damaged.
• Make sure that all clamps, guards and heat shields are installed correctly to prevent vibration,
rubbing against other parts, and excessive heat during operation.
– If any of the following conditions are found, replace the part.
– Damage or leakage from hose end.
– Wear, damage, cutting of covering, or exposure of strengthening wire layer.
– Cover portion is swollen in places.
– There is twisting or crushing at movable parts of hose.
– Foreign material is embedded in the covering.
– Hose end is deformed.
NOTE: Refer to "Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 CEN)"
in Operation and Maintenance Manual, for additional European regulations.
X X O
HAOA420L
Figure 29
OBTAIN IMMEDIATE MEDICAL ATTENTION IF PRESSURIZED OIL PIERCES SKIN.
WARNING!
Failure to obtain prompt medical assistance could result in gangrene or other serious damage to
tissue.
Wheel Loader Safety S0103010K
Page 31
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TABLE OF CONTENTS
Component Locations .................................................................................... 4
General Specifications ................................................................................. 10
Engine Performance Curves ........................................................................ 13
Working Range and Dimensions.................................................................. 16
Working Capacities ...................................................................................... 19
Bucket Capacity .................................................................................... 19
Tipping Load ......................................................................................... 19
Material Weight ............................................................................................ 19
Approximate Weight of Workload Materials .......................................... 19
Specifications for Mega 250-V S0203110C
Page 3
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ENGINE PERFORMANCE CURVES
70
TORQUE (kg.m)
170 60
50
160
POWER OUTPUT (ps)
140
FUEL CONSUMPTION (g/ps.h)
120
180
160
100 140
1000 1200 1400 1600 1800 2000 2200 2400
REVOLUTION (rpm)
AOS0950L
Figure 4 (S/N 1001 thru 2000)
Specifications for Mega 250-V S0203110C
Page 13
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Normal Bearing
Smooth even surfaces with no discoloration or
marks.
Figure 2
Bent Cage
Cage damage due to improper handling or tool
usage.
Replace bearing.
Figure 3
Figure 4
Galling
Metal smears on roller ends due to overheat,
lubricant failure or overload.
Replace bearing - check seals and check for
proper lubrication.
Figure 5
General Maintenance Procedures S0302000
Page 9
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The following General Torque Values must be used in all cases where SPECIAL TORQUE VALUES are
not given.
NOTE: TORQUE VALUES LISTED THROUGHOUT THIS MANUAL ARE LUBRICATED
(WET) THREADS; VALUES MUST BE INCREASED 1/3 FOR NONLUBRICATED
(DRY) THREADS.
HEAT TREATED MATERIAL GRADE 5 AND GRADE 8
GRADE 5 GRADE 8
THREAD SIZE
(3 RADIAL DASHES ON HEAD) (6 RADIAL DASHES ON HEAD)
NEWTON
FOOT POUNDS FOOT POUNDS NEWTON METER
METER
(ft lb) (ft lb) (Nm)
(Nm)
1/4" - 20 6 8 9 12
1/4" - 28 7 9 11 15
5/16" - 18 13 18 18 24
5/16" - 24 15 20 21 28
3/8" - 16 24 33 34 46
3/8" - 24 27 37 38 52
7/16" - 14 38 52 54 73
7/16" - 20 42 57 60 81
1/2" - 13 58 79 82 111
1/2" - 20 65 88 90 122
9/16" - 12 84 114 120 163
9/16" - 18 93 126 132 179
5/8" - 11 115 156 165 224
5/8" - 18 130 176 185 251
3/4" - 10 205 278 290 393
3/4" - 16 240 312 320 434
7/8" - 9 305 414 455 617
7/8" - 14 334 454 515 698
1" - 8 455 617 695 942
1" - 14 510 691 785 1064
1 1/8" - 7 610 827 990 1342
1 1/8" - 12 685 929 1110 1505
1 1/4" - 7 860 1166 1400 1898
1 1/4" - 12 955 1295 1550 2102
1 3/8" - 6 1130 1532 1830 2481
1 3/8" - 12 1290 1749 2085 2827
1 1/2" - 6 1400 2034 2430 3295
1 1/2" - 12 1690 2291 2730 3701
1 3/4" - 5 2370 3213 3810 5166
2" - 4 1/2 3550 4813 5760 7810
NOTE: If any bolts and nuts are found loose or at values less than what the chart states, it is
recommended that the loose bolt and/or nut be replaced with a new one.
Standard Torques S0309000
Page 5
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S0403030K
R3
1COUNTERWEIGHT
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that are in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
COUNTERWEIGHT S0403030K
MODEL SERIAL NUMBER RANGE
Mega 200-V (Tier I & II) 1001 and Up
Mega 250-V (Tier I) 1001 thru 2000
Mega 250-V (Tier II) 2001 and Up
Mega 300-V (Tier I) 1001 thru 2000
Mega 300-V (Tier II) 2001 thru 3000
Mega 300-V 3001 and Up
Mega 400-V 1001 and Up
Copyright DOOSAN 2004
July 2004
Counterweight S0403030K
Page 1
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S0406060C
R1
1HYDRAULIC OIL TANK
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that are in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
HYDRAULIC OIL TANKS0406060C
MODEL SERIAL NUMBER RANGE
Mega 200-V (Tier I & II) 1001 and Up
Mega 250-V (Tier I) 1001 thru 2000
Mega 250-V (Tier I) 3001 thru 4000
Mega 250-V (Tier II) 2001 and Up
Mega 250-V (Tier II) 4001 and Up
Copyright DOOSAN 2002
December 2002
Hydraulic Oil Tank S0406060C
Page 1
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S0502050C
1CENTER JOINT
(ARTICULATION JOINT)
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that are in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
CENTER JOINT (ARTICULATION JOINT)S0502050C
MODEL SERIAL NUMBER RANGE
Mega 250-V (Tier I) 1001 thru 2000
Mega 250-V (Tier I) 3001 thru 4000
Mega 250-V (Tier II) 2001 thru 3000
Mega 250-V (Tier II) 4001 and Up
Copyright DOOSAN 2002
November 2002
Center Joint (Articulation Joint) S0502050C
Page 1
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INTRODUCTION
The efficiency and continued operation of the axles depends on constant and correct maintenance, and
also on efficient repair work when there is a breakdown or malfunction. The instructions in this manual
have been based on a complete overhaul of an axle. However, the mechanic must decide whether or not it
is necessary to disassemble the individual components when only partial repair work is required. This
manual provides a guide, which uses diagrams illustrating various phases of operations, allowing accurate
work to take place. Therefore all information required for correct disassembly, relative checks, and
assembly of each individual component, has been provided.
NOTE: Throughout the phases of repair or maintenance, it is advisable to use proper equipment
and tools such as: trestles, supporting benches, plastic or copper hammers, appropriate
levers, extractors and specific spanners or wrenches. So that work is facilitated and
working surfaces and mechanics themselves are protected. Before disassembly, it is best
to thoroughly clean axles, removing any encrusted dirt or accumulated greases, then drain
oil through oil drain plugs.
IMPORTANT
All disassembled axles and components must be thoroughly cleaned with appropriate products
and then restored or replaced if damage, wear, cracking, or seizing have occurred. In particular,
thoroughly check the condition of all moving parts (bearings, gears, crown wheel and pinion,
and shafts) and sealing parts (O-rings and oil seals), that are subject to major stress and wear. In
any case, it is advisable to replace seals and O-rings every time a component is overhauled or
repaired. During assembly sealing rings must be lubricated on the sealing edge. In case of
crown wheel and pinion, replacement of one requires replacement of the other. During assembly
proper preloading and backlash of parts must be maintained.
Axle (Volvo) S0602210C
Page 3
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DISASSEMBLY OF DIFFERENTIAL UNIT
Figure 4
NOTE: Check wear condition of components and replace as required.
1. Match mark the differential carrier and the axle housing to aid reassembly.
2. Remove cap screws (1, Figure 4) retaining differential unit, then remove it from the axle housing.
3. Disassemble differential gear:
A. Remove left and right spring pins (2, Figure 4).
B. Loosen adjusting nut (3, Figure 4).
NOTE: Mark cap and carrier "A" to match parts at reassembly.
C. Remove cap screws (4, Figure 4), caps (5) and adjusting nuts (3).
D. Lift out differential gear unit from carrier (6, Figure 4).
4. Disassemble bevel pinion:
A. Straighten locking notches on pinion nut collar then remove pinion nut (7, Figure 4) and washer
(8).
B. Remove flange (9, Figure 4).
C. Remove oil seal (10, Figure 4).
D. Press bevel pinion (11, Figure 4) from carrier (6).
NOTE: Take care not to damage the threads.
E. Remove bearing cone (12, Figure 4).
F. Remove bearing cup (12 and 13, Figure 4) from differential carrier (6).
G. Pull out shims (16, Figure 4).
Axle (Volvo) S0602210C
Page 13
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ASSEMBLY OF FINAL DRIVE (PLANETARIES)
17 12
15
14
11
10
9
36
13
16
7 3
6
8
4
3 34
2
26
5
35
24
32
31
30
29
27
1 28
25
22
21
23
20
19
18
BAS0140L
Figure 13
1. Assemble wheel hub:
A. Install spindle (33, Figure 13) on the axle housing so that the brake bleed port is in the original
upper position.
NOTE:Apply proper sealing compound on the housing joining face.
B. Tighten cap screws (32, Figure 13).
NOTE:Mount with Loctite #270.
NOTE:Tightening torque: 28.5 - 31.5 kg•m (206 - 227 ft lb).
C. Press fit outer races of wheel bearings (25, Figure 13 and 27) into wheel hub (26).
NOTE:Make sure they rest against the seats.
D. Install oil seal (31, Figure 13) using a proper seal driver.
Axle (Volvo) S0602210C
Page 23
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PARTS LIST
Figure 4
Reference Reference
Description Description
Number Number
1 Caliper 5 Disk Spring Stack
2 Pad 6 Adjuster Screw
3 Push. Rod 7 Guide Pins
4 Piston 8 Oil Chamber
SPECIAL TOOLS AND MATERIALS
LUBRICANTS AND SEALANTS
Fuchs Renocal FN 745
Parking Brake Caliper (Volvo) S0603000
Page 5
--- Page 19 ---
7. Insert disk spring stack (5, Figure 17)
completely into piston (6). Do not change
the disk springs within the stack.
NOTE: The orientation of the installed
disk spring stack with 5 disk
springs has to be in accordance
with Figure 18. The orientation
of the installed spring stack with
6 disk spring has to be
according to Figure 19. The
installation or replacement of
the disk spring stack is only
allowed as a complete Figure 17
assembly.
8. Grease disk spring stack.
Figure 18
Figure 19
Parking Brake Caliper (Volvo) S0603000
Page 15
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CONTROL SPECIFICATIONS
Control Item Control Switch Control Specifications
Temperature "COOL" Switch
MAX COOL
Control
"WARM" Switch 100%
50%
MAX HOT
0%
HDA6049L
Figure 6
Temperature control switch consists of a 24 step
variable selector. The display uses 7, Green / Red
two-color LED's to display the selected temperature.
Blower Fan "OFF" Switch
Speed Control
"LOW" Switch
"MID" Switch
HI RELAY
"HI" Switch
MID RELAY
LOW RELAY
OFF LOW MID HI
HDA6050L
Figure 7
Compressor Temperature Sensor
Control
COMP ON
COMP OFF
1.5 C 4.0 C
HDA6051L
Figure 8
Air Conditioner S0605050K
Page 7
--- Page 21 ---
WEIGHT OF R134A GAS USED IN MACHINES
Model Weight of Gas
Mega 130 850 ±20 grams (30 ±0.7 oz)
Mega 160 850 ±20 grams (30 ±0.7 oz)
Mega 200-III 850 ±20 grams (30 ±0.7 oz)
Mega 200-V 850 ±20 grams (30 ±0.7 oz)
Mega 250-III 850 ±20 grams (30 ±0.7 oz)
Mega 250-V (Tier I) 850 ±20 grams (30 ±0.7 oz)
Mega 250-V (Tier II) 850 ±20 grams (30 ±0.7 oz)
Mega 300-III 950 ±20 grams (33 ±0.7 oz)
Mega 300-V (Tier I) 850 ±20 grams (30 ±0.7 oz)
Mega 300-V (Tier II) 850 ±20 grams (30 ±0.7 oz)
Mega 300-V 850 ±20 grams (30 ±0.7 oz)
Mega 400-III 950 ±20 grams (33 ±0.7 oz)
Mega 400-III PLUS 850 ±20 grams (30 ±0.7 oz)
Mega 400-V 850 ±20 grams (30 ±0.7 oz)
Mega 500-V 850 ±20 grams (30 ±0.7 oz)
Solar 130-III 950 ±20 grams (33 ±0.7 oz)
Solar 130LC-V 850 ±20 grams (30 ±0.7 oz)
Solar 130W-III 950 ±20 grams (33 ±0.7 oz)
Solar 130W-V 850 ±20 grams (30 ±0.7 oz)
Solar 140LC-V 850 ±20 grams (30 ±0.7 oz)
Solar 140W-V 850 ±20 grams (30 ±0.7 oz)
Solar 160W-V 850 ±20 grams (30 ±0.7 oz)
Solar 170LC-V 850 ±20 grams (30 ±0.7 oz)
Solar 170W-III 1100 ±20 grams (38 ±0.7 oz)
Solar 175LC-V 850 ±20 grams (30 ±0.7 oz)
Solar 180W-V 850 ±20 grams (30 ±0.7 oz)
Solar 200W-III 1100 ±20 grams (38 ±0.7 oz)
Solar 200W-V 850 ±20 grams (30 ±0.7 oz)
Solar 210W-V 850 ±20 grams (30 ±0.7 oz)
Solar 220LC-III 950 ±20 grams (33 ±0.7 oz)
Solar 220LC-V 850 ±20 grams (30 ±0.7 oz)
Solar 220LL 850 ±20 grams (30 ±0.7 oz)
Solar 225LC-V 850 ±20 grams (30 ±0.7 oz)
Solar 225NLC-V 850 ±20 grams (30 ±0.7 oz)
Solar 225LL 850 ±20 grams (30 ±0.7 oz.)
Solar 250LC-V 850 ±20 grams (30 ±0.7 oz)
Solar 255LC-V 850 ±20 grams (30 ±0.7 oz)
Solar 280LC-III 1250 ±20 grams (44 ±0.7 oz)
Solar 290LC-V 850 ±20 grams (30 ±0.7 oz)
Air Conditioner S0605050K
Page 17
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S0607120C
1TRANSMISSION AND
TORQUE CONVERTER
(ZF 4WG-190)
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that are in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
TRANSMISSION AND TORQUE CONVERTER (ZF 4WG-190)S0607120C
MODEL SERIAL NUMBER RANGE
Mega 250-V (Tier I) 1001 thru 2000
Mega 250-V (Tier II) 2001 and Up
Copyright DOOSAN 2001
November 2001
Transmission and Torque Converter (ZF 4WG- S0607120C
190) Page 1