Doosan DL250 Wheel Loader Workshop Repair Service Manual PDF K1023773E Serial 5001 and Up - MDSDL250OPES.zip
A full repair and service manual, complete with electrical wiring diagrams, for the Doosan DL250 Wheel Loader — containing every piece of workshop data needed to service, troubleshoot, fix, and rebuild the machine just like an experienced technician.
The Doosan DL250 Wheel Loader workshop service repair manual covers:
* 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.
Total Pages: 800 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English
K1023773E - Doosan DL250 Wheel Loader Shop Manual.pdf
K1023773E; Serial Number 5001 and Up; 800 pages
TABLE OF CONTENTS
Safety
Wheel Loader Safety... SP000865
Specifications
Specification for DL250... SP000866
General Maintenance
General Maintenance Procedures ... SP000097
Standard Torques ... SP000813
Drive Train
Transmission and Torque Converter... SP000867
Transmission Error Codes (ZF)... SP001056
Front Axle (ZF-MT-L 3085)... SP000868
Rear Axle (ZF-MT-L 3075) ... SP000869
Drive Shaft ... SP000870
Brake
Service Brake... SP000871
Brake Supply Valve... SP000872
Parking Brake ... SP000873
Brake Pedal Valve... SP000874
Accumulator... SP000875
Steering
Steering ... SP000876
Cushion Valve... SP000328
Emergency Steering ... SP000877
Frame
Articulation Center ... SP000878
Counterweight... SP000130
Tank
Oil Tank... SP000879
Fuel Tank... SP000880
Hydraulics
Cylinders... SP001027
Main Pump... SP001035
Main Control Valve... SP000881
Load Isolation System... SP000882
Cooling System... SP000883
Pilot System... SP000884
Hydraulic Schematic DL250... SP000886
Electrical System
Air Conditioner ... SP001211
Electrical System ... SP000924
Electrical Schematic DL200/ DL250... SP000925
MAIN SECTIONS
Table of Contents...3
Safety...5
Wheel Loader Safety...7
Safety Precautions...11
Applicable Models...11
To the Operator of a Wheel Loader...12
Learn the Signal Words Used with the Safety Alert Symbol...14
General Safety Essentials...16
Accessory Applications...16
Location of Safety Labels...16
Unauthorized Modifications...17
General Hazard Information...17
Safety Rules...17
Safety Features...17
Inside Operator's Compartment...18
Clothing and Personal Protective Items...19
Breathing Masks, Ear Protection May Be Required...19
Vibration Level Information...19
Asbestos Dust Hazard Prevention...20
Mounting and Dismounting...20
Fuel, Oil and Hydraulic Fluid Fire Hazards...21
Precautions When Handling Fluids at High Temperature...21
Injury from Work Equipment...22
Fire Extinguisher and First Aid Kit...22
Protection from Falling or Flying Objects...23
Install Additional Safety Equipment If Conditions Require...23
Maintain Standard Safety Equipment in Good Condition...23
Attachment Precautions...24
Accumulator...24
Engine Ventilation...24
Before Starting Engine...25
Work Site Precautions...25
Checks Before Starting Engine...26
Engine Starting...27
Before Operating Machine...28
Machine Operation...29
Operate While Seated at Operator's Station ONLY...29
Seat Belts Should Be Used at All Times...29
Movement Alarms...29
Travel Precautions...30
Sloping Terrain Requires Caution...30
Avoid High Voltage Cables...31
Before Starting to Dig, Contact Authorities...31
Be Aware of Height Obstacles...31
Use Care on Loose Support...32
Use Solid Support Blocking...32
Digging Beneath Overhangs...32
Digging Beneath Wheel Loader...32
Stay Alert for People Moving Through Work Area...33
Be Aware of and Conform to Local Regulations...33
Never Use Ether Starting Aids...33
Observe General Safety Rules...34
Take Time to Provide Good Visibility...34
Keep "Pinch Point" Areas Clear Use Caution in Reverse...35
Operate Carefully on Snow and Ice and in Very Cold Temperatures...35
Parking Machine...36
Shutdown Control Functions...36
Never Let Anyone Ride on Attachment...36
Maintenance...37
Use Warning Tag During Service...37
Clean Before Inspection or Maintenance...37
Proper Tools...38
Use of Lighting...38
Fire Prevention and Explosion Prevention...38
Burn Prevention...39
Welding Repairs...40
Treatment for Electrical Welding to the Body Structure...41
Precautions for Removal, Installation, and Storage of Attachments...41
Precautions When Working on Machine...41
Lock Inspection Covers...42
Crushing Prevention and Cutting Prevention...42
Do Not Run Engine If Repairs or Work Are Being Performed Alone...42
Always Use Adequate Equipment Supports and Blocking...42
Do Not Work on Hot Engines or Hot Cooling or Hydraulic Systems...43
Hydraulic Cylinder Seals Require Periodic Replacement...43
Highpressure Hydraulic Lines Can Store a Great Deal of Energy...43
Precautions with Highpressure Line, Tubes and Hoses...44
Obtain Immediate Medical Attention if Pressurized Oil Pierces Skin...44
Use Correct Replacement Fasteners Tightened to Proper Torque...45
Safety Critical Parts Must Be Replaced Periodically...45
Dispose of All Petroleum Based Oils and Fluids Properly...45
Check Tire Pressure and Condition...45
Battery...46
Battery Hazard Prevention...46
Disconnect Batteries Before Electrical Service or Electrical Welding...47
Use Low Heat Portable Lighting...47
Boost Starting or Charging Engine Batteries...47
Towing...48
Precautions When Towing...48
Shipping and Transportation...49
Obey State and Local OvertheRoad Regulations...49
Summary of Safety Precautions for Lifting...49
Specifications...51
Specification for DL250...53
Safety Precautions...57
Applicable Models...57
Component Locations...58
General Specifications...60
Engine Performance Curves...62
Working Range and Dimensions...64
Working Capacities...67
Bucket Capacity...67
Tipping Load...67
Material Weight...67
Approximate Weight of Workload Materials...67
General Maintenance...71
General Maintenance Procedures...73
Safety Precautions...77
Applicable Models...77
Welding Precautions and Guidelines...78
Hydraulic System General Precautions...79
Maintenance Service and Repair Procedure...81
General Precautions...81
Hydraulic System Cleanliness and Oil Leaks...82
Maintenance Precautions for Hydraulic System Service...82
Oil Leakage Precautions...83
Cleaning and Inspection...84
General Guidelines...84
Bearing inspection...85
Normal Bearing...86
Bent Cage...86
Galling...87
Abrasive Step Wear...87
Etching...88
Misalignment...88
Indentations...88
Fatigue Spalling...89
Brinelling...89
Cage Wear...89
Abrasive Roller Wear...90
Cracked Inner Race...90
Smears...90
Frettage...91
Heat Discoloration...91
Stain Discoloration...91
Standard Torques...93
Safety Precautions...97
Applicable Models...97
Torque Values for Standard Metric Fasteners...98
Torque Values for Standard U.S. Fasteners...99
Type 8 Phosphate Coated Hardware...101
Torque Values for Hose Clamps...102
Torque Values for Split Flanges...103
Torque Wrench Extension Tools...104
Torque Multiplication...104
Other Uses for Torque Wrench Extension Tools...105
Tightening Torque Specifications (Metric)...106
I. "Loctite" Fastener Adhesives...107
II. "Loctite" Pipe Thread Sealant...107
III. "Loctite" gasket/flange sealer...107
IV. "Loctite" retaining compounds...108
V. "Loctite" Adhesives...108
Drive Train...109
Transmission and Torque Converter...111
Safety Precautions...117
Applicable Models...117
General...118
Transmission and Torque Converter...120
Powershift Transmission...121
Transmission Control...121
The Chart of Measuring Points and Connection 4 WG190...123
Oil Circuit Diagram 4WG190...125
Transmission Electrical Components...128
TCU (Transmission Control Unit)...130
Transmission Control Valve...130
Transmission Oil Temperature Sensor...130
Engine Pickup Sensor...131
Central Gear Pickup Sensor...131
Turbine Pickup Sensor...131
Output Speed Sensor...132
Shift Lever Switch (DW3)...132
Forward, Reverse Switch Lever (Optional)...133
Finger Tip Work Lever...134
2-Lever (Optional)...134
3-Lever (Optional)...134
Switch Circuit...135
Auto Selector Switch...135
Display...136
Transmission Faults Codes...137
Fault Display...137
CAN Message...137
Description of Fault Codes...137
Abbreviations...138
Definition of Operation Modes...138
Normal...138
Substitute Clutch Control...138
Limphome...138
Transmission Shut Down...139
TCU Shut Down...139
Table of Fault Codes...139
Measurement of Resistance at Actuator/ sensors and Cable...139
Actuator...139
Cable...139
Transmission Electrical Circuits...140
T/M Controller Circuit...140
Traveling Circuits...141
Neutral...142
Forward First Gear...143
Forward Second Gear...144
Forward Third Gear...145
Forward Fourth Gear...146
Reverse First Gear...147
Reverse Second Gear...148
Reverse Third Gear...149
Downshift...149
Overview...149
Kickdown: Forward Second Gear to Forward First Gear (Auto Selector Switch "O" Manual Mode)...150
Downshift (Auto Selector Switch "Second Gear" Auto Mode)...151
Downshift (Auto Selector Switch "Third Gear" Auto Mode)...152
Transmission Cutoff...153
LIS (Load Isolation System) Optional...154
Aeb Starter...155
Introduction...155
Procedure to Start AEB...156
Display During AEB-mode...156
Installation View...158
Inner Section...158
Front View...159
Side View...160
Rear View...161
Special Tools...162
Gearshift System...162
Engine Connection...164
Pressure Oil Pump...165
Gearbox Housing...166
Input...168
Clutch...169
Clutch KV...169
Clutch KR...170
Clutch K1...171
Clutch K2...172
Clutch K3...173
Clutch K4...174
Output...175
Power Takeoff...176
Hydraulic Control Unit (HSG94)...177
Disassembly...179
Reassembly...182
Transmission Disassembly...187
Hydraulic Control Unit (HSG94) and Duct plate...187
Engine Connection Converter...188
Hydraulic Pump...191