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1. K1023773E Shop Manual
Copyright 2007 Doosan
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.
Shop Manual
K1023773E
Serial Number 5001 and Up
DL250

2. Table of Contents
Page I
1Table 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

3. Table of Contents
Page II
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

4. SP000867
Page 69
Transmission and Torque Converter
Disassembly
1. Figure 67, shows complete control unit.
2. Mark installation position of different covers, housing
and cable harness with valve housing.
3. Remove socket head screws.
4. Separate duct plate, 1st gasket, intermediate plate and
2nd gasket from valve housing.
(S) Box spanner (Torx TX-27) - 5873 042 002
5. Remove retaining clip.
Figure 67
Figure 68
Figure 69
Figure 70

5. SP000867Transmission and Torque Converter
Page 70
6. Remove socket head screws.
7. Separate cover from housing and cable harness.
(S) Box spanner (Torx TX-27) - 5873 042 002
8. Disassemble opposite cover.
9. Disconnect pressure regulator and remove cable
harness.
10. Remove socket head screws, remove fixing plate and
pressure regulators (3x).
(S) Box spanner (Torx TX-27) - 5873 042 002
11. Remove two socket head screws and locate housing
provisionally, using adjusting screws. (Housing is under
spring preload). Remove remaining socket and screws.
(S) Box spanner (Torx TX-27) - 5873 042 002
(S) Adjusting screws - 5870 204 036
Figure 71
Figure 72
Figure 73
Figure 74

6. SP000867
Page 71
Transmission and Torque Converter
12. Separate housing from valve housing by loosening
adjusting screws uniformly.
(S) Adjusting screws - 5870 204 036
13. Remove components (Figure 76).
14. Remove opposite pressure regulators, housing and
components accordingly (Figure 77).
Figure 75
Figure 76
Figure 77

7. SP000867Transmission and Torque Converter
Page 72
Reassembly
NOTE: Check all components for damage and replace if
necessary. Before installation, check free travel of all
moving parts in housing. Spools can be exchanged
individually. Oil components before reassembly
according to ZF-List of lubricants TE-ML 03.
Insert diaphragms with concave side facing up until
seated.
NOTE: Installation position, see arrows.
1. Figure 79, shows the following components:
2. Install components according to Figure 79.
NOTE: Preload compression spring of follow on sitie
slides and locate spool provisionally using
cylindrical pins Ø 5.0 mm (0.1969 in) (assembly
aid), See Figure 80.
3. Install two adjusting screws.
4. Assemble gasket (1, Figure 81) and housing cover
(Figure 81). Position housing cover uniformly, using
adjusting screws, until seated and remove cylindrical
pins (assembly aid) again (Figure 81).
NOTE: Pay attention to different housing covers.
5. Install recess ∅ 15.0 mm (0.5906 in)
(2, Figure 81), facing spring of pressure
reducing valve.
(S) Adjusting screws - 5870 204 036
Figure 78
Figure 79
Reference
Number
Description
1 Vibration Damper (3x
Spool and
Compression Spring)
2 Follow On Site (3x
Spool and
Compression Spring)
3 Pressure Reducing
Valve (1x Spool and
Compression Spring)
Figure 80
Figure 81

8. SP000867
Page 73
Transmission and Torque Converter
6. Fasten housing cover using socket head screws.
NOTE: Torque limit 0.56 kg•m (4 ft lb).
(S) Box spanner (Torx TX-27) - 5873 042 002
7. Install pressure regulators and attach using fixing plates
and socket head screws.
NOTE: Install fixing plate, with claw facing down. Pay
attention to radial installation position of
pressure regulators, see Figure 84.
NOTE: Torque limit 0.56 kg•m (4 ft lb).
(S) Box spanner (Torx TX-27) - 5873 042 002
8. Preassemble opposite side.
A. Figure 85, shows the following components:
Figure 82
Figure 83
Figure 84
Figure 85
Reference
Number
Description
1 Main Pressure Valve
(1x Spool and
Compression Spring.)
2 Follow On Slide (3x
Spool and
Compression Spring)
3 Vibration Damper (3x
Spool and
Compression Spring)

9. SP000867Transmission and Torque Converter
Page 74
B. Install components according to Figure 85.
C. Preload compression springs of follow on slides
and locate spool provisionally using cylindrical pins
∅ 5.0 mm (0.1969 in) (assembly aid). See arrows.
D. Install two adjusting screws.
E. Assemble gasket (1, Figure 86) and housing
cover, and position them uniformly against
shoulder, using adjusting screws.
NOTE: Pay attention to different housing covers,
install recess Ø 19.0 mm (0.7480 in) (2,
Figure 86), facing main pressure valve.
F. Down, fasten housing cover using socket head
screws.
NOTE: Torque limit 0.56 kg•m (4 ft lb).
G. Remove cylindrical pins (assembly aid) again.
(S) Adjusting screws - 5870 204 036
(S) Box spanner (Torx TX-27) - 5873 042 002
H. Install pressure regulators and attach using fixing
plates and socket head screws.
NOTE: Install fixing plates, with claw facing down.
I. Pay attention to radial installation position of
pressure regulators, see Figure 87.
NOTE: Torque limit 5.5 N.
(S) Box spanner (Torx TX-27) - 5873 042 002
J. Install cable harness and connect pressure
regulators (6x).
NOTE: Pay attention to installation position of
cable harness, see also markings (Figure
68).
Figure 86
Figure 87
Figure 88

10. SP000867
Page 75
Transmission and Torque Converter
K. Install female connector against shoulder, with
groove facing guide nose of cover.
L. Install gaskets (Figure 89) and fasten cover using
socket head screws.
NOTE: Torque limit 0.56 kg•m (4 ft lb).
(S) Box spanner (Torx TX-27) - 5873 042 002
M. Install female connector using retaining clamp, see
Figure 90.
N. Install opposite cover.
O. Install two adjusting screws and mount gasket I.
NOTE: Pay attention to different gaskets, see
Figure 91 and Figure 94.
(S) Adjusting screws - 5870 204 063
9. Intermediate plate-version with screens:
A. Insert screens (6x) flash -mounted into bore of
intermediate plate, see Figure 92.
NOTE: Pay attention to installation position
screens are facing up (facing duct plate).
Figure 89
Figure 90
Figure 91
Figure 92

11. SP000867Transmission and Torque Converter
Page 76
B. Mount intermediate plate, with screens with
screens facing up.
C. Mount gasket II.
D. Mount duct plate and fasten it uniformly using
socket head screws.
NOTE: Torque limit 1 kg•m (7 ft lb).
(S) Box spanner (Torx TX-27) - 5873 042 002
E. Install new O-rings on plugs (8x) and install them.
NOTE: Torque limit 0.61 kg•m
(4.4 ft lb).
NOTE: The installation of hydraulic control unit is
described in following section, “Mount
Duct Plate and Hydraulic Control Unit” on
page 1-132.
Figure 93
Figure 94
Figure 95
Figure 96

12. SP000867
Page 77
Transmission and Torque Converter
TRANSMISSION DISASSEMBLY
1. Fasten transmission on the assembly car.
(S) Assembly car - 5870 350 000
(S) Strips - 5870 350 063
(S) Support - 5870 350 090
Hydraulic Control Unit (HSG-94) and
Duct plate
1. Remove two socket head screws and install adjusting
screws.
2. Remove remaining socket head screws and valve
housing from duct plate.
(S) Adjusting screws (M6) - 5870 204 063
(S) Box spanner (Torx TX-27) - 5870 042 002
3. Remove both gaskets and intermediate plate.
4. Remove socket head screws and hex. nuts (Figure 99).
Remove duct plate from gearbox housing. Remove
gasket.
(S) Box spanner (Torx TX-27) - 5870 042 004
Figure 97
Figure 98
Figure 99

13. SP000867Transmission and Torque Converter
Page 78
5. Remove converter safety valve out of housing bore.
Engine Connection - Converter
1. Remove lock plate and hex. head screws.
2. Remove disk and pry drive flange off shaft.
3. Remove screw connection.
NOTE: Mark radial installation position of housing
cover.
4. Separate converter, along with cover from the
transmission, using lifting device.
(S) Set of eyebolts - 5870 204 002
Figure 100
Figure 101
Figure 102
Figure 103

14. SP000867
Page 79
Transmission and Torque Converter
5. Remove drive shaft resp. converter out of cover (ball
bearing).
6. Remove retaining ring and ball bearing.
(S) Set of internal pliers - 5870 900 013
7. Remove hex. head screws and diaphragm from
converter.
8. Remove hex. head screws and drive shaft from
diaphragm.
Figure 104
Figure 105
Figure 106
Figure 107

15. SP000867Transmission and Torque Converter
Page 80
9. Remove inductive transmitter (n Engine).
10. Remove hex. head screws and converter bell.
Figure 108
Figure 109

16. SP000867
Page 81
Transmission and Torque Converter
Hydraulic Pump
1. Remove socket head screws.
2. AInstall device (S) on gear teeth run out of stator shaft
and remove (compl.) using two-armed puller carefully
out of housing bores.
(S) Separating device - 5870 300 024
(S) Two-armed puller - 5870 970 004
3. Separate hydraulic pump from stator shaft.
4. Separate control disk from pump.
NOTE: If traces due to running-in should be
encountered in the pump housing or on the
control disk, the complete pump has to be
replaced.
5. Lay on control disk again and secure it using grooved
pins (2x).
6. Remove socket head screws and two hex. head
screws and oil feed housing.
Remove gasket.
(S) Box spanner (Torx, TX-40) - 5873 023 004
Figure 110
Figure 111
Figure 112
Figure 113

17. SP000867Transmission and Torque Converter
Page 82
Converter Back Pressure Valve
1. Preload compression spring and remove lock plate.
2. Remove released components.
3. Loosen hex head screws. Remove cover and gasket.
Remove Output, Input and Clutches
1. Remove lock plate, loosen hex head screws and pry
converter-side output flange off the shaft.
2. Pry shaft seal out of the housing bore.
3. Tilt transmission 180° and remove rear-side output
flange accordingly.
(S) Pry bar - 5870 345 065
4. Remove speed sensor and both inductive transmitters
(Arrows).
Figure 114
Figure 115
Figure 116
Figure 117

18. SP000867
Page 83
Transmission and Torque Converter
5. Remove hex. nuts and both covers (Arrows).
6. Remove screw connection (housing/housing cover)
7. Remove both cylindrical pins (Arrows).
NOTE: The following figures show the common
removal of all clutches.
8. The removal of single clutches without use of special
tool (Handles - 5870 260 010) is difficult due to
installation arrangement.
NOTE: There is also a danger of injuries.
9. Locate all clutches using handles (S) in the housing
cover.
10. Install eyebolts and hang in the lifting device.
(S) Handles (6 pieces needed) - 5870 260 010
(S) Eyebolt 2x (M20) - 0636 804 003
(S) Eyebolt 1x (M16) - 0636 804 001
(S) Puller device - 5870 000 017
(S) Lifting chain - 5870 281 047
11. Separate housing cover along with clutches from
gearbox housing using lifting device.
Figure 118
Figure 119
Figure 120
Figure 121

19. SP000867Transmission and Torque Converter
Page 84
12. Fasten housing cover on the assembly car.
(S) Assembly car - 5870 350 000
(S) Clamping bracket - 5870 350 089
13. Remove socket head screws, output shaft and two oil
collecting plate.
14. Remove tapered roller bearing.
15. Remove opposite tapered roller bearing.
(S) Grab sleeve - 5873 002 038
(S) Basic set - 5873 002 001
16. Tilt gearbox housing 180°.
17. Figure 125, shows the arrangement of single clutches
and the input in housing cover.
Figure 122
Figure 123
Figure 124
Figure 125
Reference
Number
Description
AN Input
KV Clutch - Forward
KR Clutch - Reverse
K1 Clutch - 1st Speed
K2 Clutch - 2nd Speed
K3 Clutch - 3rd Speed
K4 Clutch - 4th Speed

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21. SP000867
Page 85
Transmission and Torque Converter
18. Remove handles (S) (Figure 126).
(S) Handles - 5870 260 010
19. Remove Clutch-K4 a bit using pry bars and remove
Clutch-K1.
20. Remove Clutch-K2.
21. Remove Clutch-K3.
Figure 126
Figure 127
Figure 128
Figure 129

22. SP000867Transmission and Torque Converter
Page 86
22. Remove Clutch - KV and KR using pry bars and
remove Clutch - K4.
(S) Pry bar - 5870 345 065
23. Remove Clutch - KV and Clutch - KR with input
together out of housing cover.
24. Remove outer bearing races out of housing bores.
25. Tilt housing cover 90°.
26. Remove retaining ring and pump shaft from housing
cover.
27. Remove rectangular ring (Arrow) and press ball bearing
from shaft.
Figure 130
Figure 131
IMPORTANT
If contrary to ZF-Recommendation the tapered roller
bearing of clutches and of input and output are not
replaced, the allocation (inner bearing races to
outer bearing races) must at least be maintained.
Mark inner bearing races and outer bearing races
accordingly to each other.
Figure 132
Figure 133

23. SP000867
Page 87
Transmission and Torque Converter
Disassemble Clutch - KV and KR
1. Remove rectangular ring (Arrow).
NOTE: The following figures show the disassembly of
Clutch - KV. The disassembly of Clutch - KR is
similar.
2. Remove tapered roller bearing from shaft.
3. Remove opposite tapered roller bearing.
(S) Grab sleeve - 5873 001 057
(S) Grab sleeve - 5873 001 059
(S) Basic set - 5873 001 000
4. Remove retaining ring.
5. Separate plate carrier from shaft.
(S) Three Leg Puller - 5870 970 003
Figure 134
Figure 135
Figure 136
Figure 137