Daewoo Mega 250-V Wheeled Loader Workshop Service Manual and Operation Maintenance Manual PDF Download - MDOOM250OPEK.zip

A full service guide featuring wiring schematics for the Daewoo Mega 250-V Wheeled Loader, packed with every technical detail needed to service, troubleshoot, fix, and overhaul the machine the way expert technicians do.

The Daewoo Mega 250-V Wheeled Loaders workshop service & repair manual contains:

* Numbered table of contents easy to use so that you can find the information you need fast.

* Detailed sub-steps expand on repair procedure information

* Numbered instructions guide you through every repair procedure step by step.

* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.

* Notes, cautions and warnings throughout each chapter pinpoint critical information.

* Bold figure number help you quickly match illustrations with instructions.

* Detailed illustrations, drawings and photos guide you through every procedure.

* Enlarged inset helps you identify and examine parts in detail.

MANUAL LIST:

M250-V Hydraulic Schematics.pdf

M250-V Electric Schematics.pdf

023-00050AE - Mega 250-V Shop Manual.pdf

022-00027AE - Mega 250-V Operation & Maintenance Manual.pdf

Total Pages: 733 pages

File Format: PDF (bookmarked, Searchable, Printable, high quality)

Language: English

022-00027AE - Mega 250-V Operation & Maintenance Manual....2

Safety....8

To the Operator of a Daewoo Wheel Loader....8

General Safety Essentials....9

Location of Safety Labels....10

Unauthorized Modifications....18

Work Site Precautions....18

Operation....20

Equipment....25

Maintenance....29

Shipping and Transportation....33

Operating Controls....34

Component Locations....35

Control Identification....39

Steering Console and Pedals....40

Transmission Display....47

Front Instrument Panel....49

Right Side Switch Panel....58

Various Cabin Locations....68

Heater and Air Conditioner Operation....72

Stereo....77

Seat Adjustment....81

Seat Belt....83

Door Side Latch....84

Fuse Box/Relay....85

Window Glass Breaking Tool....88

Operation....90

Instrument Panel Control Functions....90

New Machine Break-in Procedures....90

Engine Start and Stop....91

Machine Travel....100

Machine Shut Down....102

Additional Braking....104

Boom Raise Kickout....105

Bucket Angle Indicator....105

Boom Lower Kickout (Option)....106

Adjustment of Bucket Position Switch....106

Towing Machine....107

If Engine Stalls While Traveling....108

Allowable Water Depth....108

Inspection, Maintenance and Adjustment....110

Preventive Maintenance....110

Table of Recommended Lubricants....112

Fluid Capacities....114

Maintenance Intervals....115

10 Hour / Daily Service....117

50 Hour / Weekly Service....127

250 Hour / Monthly Service....134

500 Hour / 3 Month Service....143

1,000 Hour / 6 Month Service....146

1,500 Hour / 9 Month Service....152

2,000 Hour / Yearly Service....154

12,000 Hour / Six Year Service....157

Severe Conditions Maintenance....158

General Maintenance....159

Parking Brake Adjustment....161

Check Hydraulic Pressures....162

Tires and Wheels....166

Electrical System....168

Bolt Torque Chart....169

Long Term Storage....170

Transportation....172

Loading Machine on a Trailer....172

Summary of Safety Precautions for Lifting....173

Troubleshooting....174

Engine....174

Hydraulic System....177

Travel System....179

Steering....184

Braking....185

Electrical System....185

Specifications....186

General Specifications....186

Working Range and Dimensions....189

Working Capacities....191

Approximate Weight of Workload Materials....191

Index....194

023-00050AE - Mega 250-V Shop Manual....200

Safety....206

Wheel Loader Safety S0103010K....208

To the Operator of a Daewoo Wheel Loader....210

Learn Signal Words Used with Safety Alert Symbol....212

General Safety Essentials....213

Accessory Applications....213

Location of Safety Labels....213

Unauthorized Modifications....213

General Hazard Information....214

Safety Rules....214

Safety Features....214

Inside Operator's Compartment....215

Clothing and Personal Protective Items....215

Breathing Masks, Ear Protection May Be Required....216

Asbestos Dust Hazard Prevention....216

Mounting and Dismounting....216

Fuel, Oil and Hydraulic Fluid Fire Hazards....217

Precautions When Handling Fluids at High Temperature....217

Injury from Work Equipment....218

Fire Extinguisher and First Aid Kit....218

Protection from Falling or Flying Objects....219

Install Additional Safety Equipment If Conditions Require....219

Maintain Standard Safety Equipment in Good Condition....219

Attachment Precautions....220

Accumulator....220

Engine Ventilation....220

Window Glass Breaking Tool....221

Before Starting Engine....222

Work Site Precautions....222

Checks Before Starting Engine....223

Engine Starting....223

Before Operating Machine....224

Machine Operation....225

Operate While Seated at Operator’s Station ONLY....225

Seat Belts Should Be Used at All Times....225

Movement Alarms....225

Travel Precautions....226

Sloping Terrain Requires Caution....226

Avoid High-voltage Cables....227

Before Starting to Dig, Contact Authorities....227

Be Aware of Height Obstacles....227

Use Care on Loose Support....227

Use Solid Support Blocking....228

Digging Beneath Overhangs....228

Digging Beneath Wheel Loader....228

Stay Alert for People Moving Through Work Area....228

Be Aware of and Conform to Local Regulations....228

Never Use Ether Starting Aids....229

Observe General Safety Rules....229

Take Time to Provide Good Visibility....229

Keep "Pinch Point" Areas Clear - Use Caution in Reverse....230

Operate Carefully on Snow and Ice and in Very Cold Temperatures....230

Parking Machine....230

Shutdown Control Functions....231

Never Let Anyone Ride on Attachment....231

Maintenance....232

Use Warning Tag During Service....232

clean Before Inspection or Maintenance....232

Proper Tools....233

Use of Lighting....233

Fire Prevention and Explosion Prevention....233

Burn Prevention....234

Welding Repairs....235

Precautions for Removal, Installation, and Storage of Attachments....235

Precautions When Working on Machine....236

Lock Inspection Covers....236

Crushing Prevention and Cutting Prevention....236

Do Not Run Engine If Repairs or Work Are Being Performed Alone....236

Always Use Adequate Equipment Supports and Blocking....237

Do Not Work on Hot Engines or Hot Cooling or Hydraulic Systems....237

Hydraulic Cylinder Seals Require Periodic Replacement....237

High Pressure Hydraulic Lines Can Store a Great Deal of Energy....237

Precautions with High Pressure Line, Tubes and Hoses....238

Obtain Immediate Medical Attention if Pressurized Oil Pierces Skin.....238

Use Correct Replacement Fasteners Tightened to Proper Torque....239

Safety-critical Parts Must Be Replaced Periodically....239

Dispose of All Petroleum-based Oils and Fluids Properly....239

Check Tire Pressure and Condition....239

Battery....240

Battery Hazard Prevention....240

Disconnect Batteries Before Electrical Service or Electrical Welding....240

Use Low Heat Portable Lighting....241

Boost Starting or Charging Engine Batteries....241

Towing....242

Precautions When Towing....242

Shipping and Transportation....243

Obey State and Local Over-the-Road Regulations....243

Summary of Safety Precautions for Lifting....243

Specifications....244

Specifications for Mega 250-V S0203110C....246

Component Locations....249

General Specifications....255

Engine Performance Curves....257

Working Range and Dimensions....261

Working Capacities....264

Bucket Capacity....264

Tipping Load....264

Material Weight....264

Approximate Weight of Workload Materials....264

General Maintenance....268

General Maintenance Procedures S0302000....270

Welding Precautions and Guidelines....272

Hydraulic System - General Precautions....273

Maintenance Service and Repair Procedure....274

General Precautions....274

Hydraulic System Cleanliness and Oil Leaks....275

Maintenance Precautions for Hydraulic System Service....275

Oil Leakage Precautions....275

Cleaning and Inspection....276

General Guidelines....276

Bearing inspection....277

Standard Torques S0309000....284

Torque Values for Standard Metric Fasteners....286

Torque Values for Standard U.S. Fasteners....287

Type 8 Phosphate Coated Hardware....289

Torque Values for Hose Clamps....290

Torque Values for Split Flanges....291

Torque Wrench Extension Tools....292

Torque Multiplication....292

Other Uses for Torque Wrench Extension Tools....293

Tightening Torque Specifications (Metric)....293

Upper Structure....296

Counterweight S0403030K....298

Specifications....300

Counterweight....300

Fuel Transfer Pump S0405500....302

General Description....304

Theory of Operation....304

Troubleshooting....305

Replacement of Rotor and Vane....305

Replacement of Rear Cover....306

Replacement of Armature....307

Hydraulic Oil Tank S0406060C....308

General Description....311

Parts List (M200-V)....311

Parts List (M250-V)....313

Specifications....315

Lower Structure and Chassis....316

Center Joint (Articulation Joint) S0502050C....318

General Description....320

Maintenance Standard....321

Engine and Drive Train....324

Axle (Volvo) S0602210C....326

Introduction....328

General Description....329

Outline....329

Disassembly and Assembly of Axle Units....332

Disassembly of Final Drive (Planetaries)....333

Disassembly of Differential Unit....336

Cleaning and Inspection (Wear Limits and Tolerances)....339

Assembly of Differential Unit....341

Assembly of Final Drive (Planetaries)....346

Special Tool....349

Brake Bleeding Procedure....351

Parking Brake Caliper (Volvo) S0603000....352

General Description....354

Operation....354

Parking Brake Applied....355

Parking Brake Released....355

Parts List....356

Special Tools and Materials....356

Lubricants and Sealants....356

Troubleshooting, Testing and Adjustment....357

Parking Brake System....357

Checking and Adjusting Parking Brake....357

Measuring Pad Thickness....357

Measuring Disc / Pad Clearance....357

Measuring Procedure....358

Adjustment....358

Releasing the Parking Brake in Emergency Case....359

Disassembly....360

General....360

Changing Brake Pads....360

Work Sequence During Change of Brake Pads....360

Cleaning and Inspection (Wear Limits and Tolerances)....362

Reassembly....364

Air Conditioner S0605050K....370

General Description....372

Refrigerant Circulation....373

Control Panel....375

Control Specifications....376

Temperature Level Control and Display....377

Air Discharge According to Path Selection....378

Air-conditioning System Circuit Diagram....381

Troubleshooting....383

Weight of R134a Gas Used In Machines....387

Refrigerant System Repairs....389

Refrigerant Safe Handling Procedures....389

Repair and Replacement Procedure....390

Refrigerant Recovery....392

Vacuuming Refrigerant System....392

Leakage Check....393

Refrigerant Charging....394

Inspecting System For Leakage....396

Transmission and Torque Converter (ZF4WG190) S0607120C....398

Drive Train Description....402

Transmission and Torque Converter....403

Powershift Transmission....404

Transmission Control....404

The Chart of Measuring Points and Connection 4 WG-190....406

Oil Circuit Diagram 4WG-190....408

Transmission Electric Components....410

TCU (Transmission Control Unit)....411

Transmission Control Valve....411