Daewoo Doosan Mega 200-V Operation & Maintenance Manual – PDF DOWNLOAD

Description

Daewoo Doosan Mega 200-V Operation & Maintenance Manual – PDF DOWNLOAD

DESCRIPTION:

Daewoo Doosan Mega 200-V Operation & Maintenance Manual – PDF DOWNLOAD

• 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.

• The 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.

• There are several specific warning signs on this machine. The exact location of hazards and the description of the hazards are reviewed in this section. Please become familiarized with all warning signs.
• Make sure that all of the warning signs are legible. Clean the warning signs or replace the warning signs if you cannot read the words. Replace the illustrations if the illustrations are not visible. When you clean the warning signs, use a cloth, water and soap.
• Do not use solvent, gasoline, or other harsh chemicals to clean the safety signs. Solvents, gasoline, or other harsh chemicals could loosen the adhesive that secures the warning sign.
• Loose adhesive will allow the warning sign to fall off. Replace any safety sign that is damaged, or missing. If a safety sign is attached to a part that is replaced, install a safety sign on the replacement part.
  

TABLE OF CONTENTS:

Daewoo Doosan Mega 200-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........................................................  9
	General Safety Essentials................................................................................... 10
		Accessory Applications.................................................................................. 10
	Location of Safety Labels................................................................................... 10
		1. Warning for operation, inspection and maintenance (41902545A)....................................... 12
		2. Warnings when opening engine hood (19000694)........................................................ 12
		3. Warning for handling accumulator (19000703)......................................................... 13
			Accumulator......................................................................................... 13
		4. Keep Out of steering turn area (41901992A).......................................................... 14
		5. Warning for high temperature hydraulic oil (19000691)............................................... 14
		6. Warning for high temperature coolant (19000692)..................................................... 15
		7. Warning for battery maintenance (21902533A)......................................................... 15
		8. Warning for performing maintenance on front attachment (41902546A).................................. 16
		9. Warning to use Wheel Block (41902547A).............................................................. 16
		10. Warning Tag (19000695)............................................................................. 17
	Unauthorized Modifications.................................................................................. 18
	General Hazard Information.................................................................................. 18
		Safety Rules............................................................................................ 18
		Safety Features......................................................................................... 18
		Inside Operator's Compartment........................................................................... 19
		Clothing and Personal Protective Items.................................................................. 19
		Breathing Masks, Ear Protection May Be Required......................................................... 20
		Vibration Level Information............................................................................. 20
		Asbestos Dust Hazard Prevention......................................................................... 20
		Mounting and Dismounting................................................................................ 21
		Fuel, Oil and Hydraulic Fluid Fire Hazards.............................................................. 21
		Precautions When Handling Fluids at High Temperature.................................................... 22
		Injury from Work Equipment.............................................................................. 22
		Fire Extinguisher and First Aid Kit..................................................................... 23
		Protection from Falling or Flying Objects............................................................... 23
		Install Additional Safety Equipment If Conditions Require............................................... 24
		Maintain Standard Safety Equipment in Good Condition.................................................... 24
		Attachment Precautions.................................................................................. 25
		Accumulator............................................................................................. 25
		Engine Ventilation...................................................................................... 25
	Before Starting Engine...................................................................................... 26
		Work Site Precautions................................................................................... 26
		Checks Before Starting Engine........................................................................... 27
		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............................................................................... 31
		Use Solid Support Blocking.............................................................................. 32
		Digging Beneath Overhangs............................................................................... 32
		Digging Beneath Wheel Loader............................................................................ 32
		Stay Alert for People Moving Through Work Area.......................................................... 32
		Be Aware of and Conform to Local Regulations............................................................ 32
		Never Use Ether Starting Aids........................................................................... 33
		Observe General Safety Rules............................................................................ 33
		Take Time to Provide Good Visibility.................................................................... 33
		Keep "Pinch Point" Areas Clear  Use Caution in Reverse................................................. 34
		Operate Carefully on Snow and Ice and in Very Cold Temperatures......................................... 34
		Parking Machine......................................................................................... 34
		Shutdown Control Functions.............................................................................. 35
		Never Let Anyone Ride on Attachment..................................................................... 35
	Maintenance................................................................................................. 36
		Use Warning Tag During Service.......................................................................... 36
		clean Before Inspection or Maintenance.................................................................. 36
		Proper Tools............................................................................................ 37
		Use of Lighting......................................................................................... 37
		Fire Prevention and Explosion Prevention................................................................ 37
		Burn Prevention......................................................................................... 38
		Welding Repairs......................................................................................... 39
		Precautions for Removal, Installation, and Storage of Attachments....................................... 39
		Precautions When Working on Machine..................................................................... 40
		Lock Inspection Covers.................................................................................. 40
		Crushing Prevention and Cutting Prevention.............................................................. 40
		Do Not Run Engine If Repairs or Work Are Being Performed Alone.......................................... 40
		Always Use Adequate Equipment Supports and Blocking..................................................... 41
		Do Not Work on Hot Engines or Hot Cooling or Hydraulic Systems.......................................... 41
		Hydraulic Cylinder Seals Require Periodic Replacement................................................... 41
		Highpressure Hydraulic Lines Can Store a Great Deal of Energy.......................................... 41
		Cool Down Is Required Before Radiator or Reservoir Checks............................................... 41
		Precautions with Highpressure Line, Tubes and Hoses.................................................... 42
		Obtain Immediate Medical Attention if Pressurized Oil Pierces Skin...................................... 42
		Use Correct Replacement Fasteners Tightened to Proper Torque............................................ 43
		Safety Critical Parts Must Be Replaced Periodically..................................................... 43
		Dispose of All Petroleum Based Oils and Fluids Properly................................................. 43
		Check Tire Pressure and Condition....................................................................... 43
	Battery..................................................................................................... 44
		Battery Hazard Prevention............................................................................... 44
		Disconnect Batteries Before Electrical Service or Electrical Welding.................................... 44
		Use Low Heat Portable Lighting.......................................................................... 45
		Boost Starting or Charging Engine Batteries............................................................. 45
	Towing...................................................................................................... 46
		Precautions When Towing................................................................................. 46
	Shipping and Transportation................................................................................. 47
		Obey State and Local OvertheRoad Regulations.......................................................... 47
Operating Controls.............................................................................................. 49
	Component Locations......................................................................................... 50
		MEGA 200V (Tier II).................................................................................... 50
	Control Identification...................................................................................... 52
	Steering Console and Pedals................................................................................. 53
		1. Starter Switch....................................................................................... 54
		2. Horn Button (Two Places)............................................................................. 54
		3. Combination Switch................................................................................... 55
		4. Accelerator Pedal.................................................................................... 56
		5. Steering Tilt Knob................................................................................... 56
		6. Brake Pedal (Right and Left Pedals).................................................................. 57
		7. Steering Wheel....................................................................................... 57
		8. Kickdown Button (Two places)........................................................................ 58
		9. Transmission Lever................................................................................... 58
		10. FRONT INSTRUMENT PANEL.............................................................................. 59
		11. Transmission Display................................................................................ 59
		12. Auxiliary Instrument Panel.......................................................................... 60
		13. Kysor Warning System Indicator Light................................................................ 60
	Transmission Display........................................................................................ 61
	Front Instrument Panel...................................................................................... 62
		Gauges.................................................................................................. 63
		Warning and Indicator Lights............................................................................ 63
		SWITCHES................................................................................................ 63
		1. Fuel Gauge........................................................................................... 63
		2. Speedometer.......................................................................................... 64
		3. Hour Meter........................................................................................... 64
		4. Tachometer........................................................................................... 64
		5. Engine Coolant Temperature Gauge..................................................................... 65
		6. Transmission Oil Temperature Gauge................................................................... 65
		7. Preheat Indicator Light.............................................................................. 65
		8. Air Cleaner Clogged Warning Light.................................................................... 66
		9. Engine Coolant Temperature Warning Light............................................................. 66
		10. Engine Oil Pressure Warning Light................................................................... 66
		11. Battery Warning Light............................................................................... 66
		12. Left Turn and Hazard Warning Light.................................................................. 67
		13. High Beam Indicator Light........................................................................... 67
		14. Right Turn and Hazard Warning Light................................................................. 67
		15. Work Light Indicator Light.......................................................................... 67
		16. Brake FLUID Pressure Warning Light.................................................................. 68
		17. Unused Light........................................................................................ 68
		18. Parking Brake Indicator Light....................................................................... 68
		19. Emergency Steering Indicator Light (option)......................................................... 69
		20. Hazard Warning light Switch......................................................................... 69
		21. BLANK (EMPTY SWITCH SOCKET)......................................................................... 70
		22. Bucket Float Switch (Option)........................................................................ 70
	Auxiliary Instrument Panel.................................................................................. 72
		1. Transmission Oil Temperature Gauge................................................................... 72
		2. Engine Oil Pressure Gauge............................................................................ 73
		3. Coupler Starter Switch............................................................................... 73
		4. Battery Charge Gauge................................................................................. 73
	Right Side Switch Panel..................................................................................... 74
		1. Pilot Control Valve Lever (Joystick) (S/N 3008 thru 3130)............................................ 75
		2. Kickdown Button (TWO PLACES)........................................................................ 76
		3. Horn Button (Two Places)............................................................................. 76
		4. Cigar Lighter........................................................................................ 77
		5. Headlight Switch..................................................................................... 78
		6. front Work Light Switch.............................................................................. 78
		7. Rear Work Light Switch............................................................................... 79
		8. Rear Wiper Switch.................................................................................... 79
		9. Rotating BeacoN Switch (OPTion)...................................................................... 80
		10. Cup Holder.......................................................................................... 80
		11. Parking Brake switch................................................................................ 80
		12. Pilot cutoff switch................................................................................. 81
		13. Transmission Cutoff Switch.......................................................................... 81
		14. Automatic Transmission Switch....................................................................... 82
		15. emergency Steering Test Switch...................................................................... 82
		16. Fuel Filter Heater Switch........................................................................... 83
		17. Reverse Fan Switch.................................................................................. 83
		18. Quick Coupler Switch................................................................................ 83
	Various Cabin Locations..................................................................................... 84
		1. CAB LIGHT............................................................................................ 85
		2. Stereo............................................................................................... 85
		3. Heater and Air conditioner Control Panel............................................................. 85
		4. Speakers............................................................................................. 85
		5. Storage Box.......................................................................................... 86
		6. Washer Tank.......................................................................................... 86
		7. Hot/Cold Refrigerator................................................................................ 86
		8. ElectricAL Box....................................................................................... 86
		9. Fuse Box Two......................................................................................... 87
		10. Fuse Box One........................................................................................ 87
		11. Fan................................................................................................. 87
	Heater and Air Conditioner Operation........................................................................ 88
		Location of Controls and Vents.......................................................................... 88
		Operation Panel......................................................................................... 89
		1. Fan and Air Conditioner Switch....................................................................... 89
		2. Blower Fan Switches.................................................................................. 90
		3. Temperature Control Switch........................................................................... 90
		4. Selector Switch for Wind Direction................................................................... 90
		5. Ventilation Selector Switch.......................................................................... 91
		Memory Function of Used Mode............................................................................ 92
		Additional Operating Instruction........................................................................ 92
	Stereo...................................................................................................... 93
		1. OnOff / Volume Control Knob......................................................................... 93
		2. Balance / Fader Control.............................................................................. 93
		3. Bass / Treble Control................................................................................ 93
		4. AM/FM Band Selector.................................................................................. 94
		5. Automatic Memory (AME)............................................................................... 94
		6. Tape Eject Button.................................................................................... 94
		7. Cassette Slot........................................................................................ 94
		8. & 9. Play Direction Button........................................................................... 94
		10. Automatic Selector.................................................................................. 94
		11. Dolby B Selector.................................................................................... 94
		12. Metal Selector...................................................................................... 95
		Care of Stereo.......................................................................................... 95
	Seat Adjustment............................................................................................. 97
		1. Adjusting Seat Forward/ Backward Lever............................................................... 97
		2 & 3. Adjusting Seat's Angle and Height Lever.......................................................... 97
		4. Weight Adjustment Knob............................................................................... 97
		5. Backrest Adjustment Lever............................................................................ 97
		6. Angle Adjustment of Armrest.......................................................................... 98
		7. Headrest............................................................................................. 98
		Recommendations for Limiting Vibrations:................................................................ 98
	Seat Belt................................................................................................... 99
		Seat Belt Locking and Unlocking......................................................................... 99
	Door Side Latch.............................................................................................100
	Fuse Box/Relay..............................................................................................101
		Fuse Boxes..............................................................................................101
		Relay...................................................................................................103
	Miscellaneous Electrical Devices............................................................................104
		Circuit Breaker.........................................................................................104
		Fusible Link............................................................................................104
		Electrical System Master Switch.........................................................................105
		Engine Block Heater.....................................................................................105
Operation.......................................................................................................107
	Instrument Panel Control Functions..........................................................................107
		Monitoring System.......................................................................................107
	New Machine Breakin Procedures.............................................................................107
	Engine Start and Stop.......................................................................................108
		Engine Start............................................................................................108
		Cold Weather Engine Start...............................................................................110
		Starting with Auxiliary Batteries.......................................................................113
		Engine Shutdown.........................................................................................114
		Hydraulic System Warmup................................................................................115
		Hydraulic System Warmup – Cold Weather.................................................................115
	Machine Travel..............................................................................................116
	Machine Shut Down...........................................................................................119
	Additional Braking..........................................................................................121
	Boom Raise Kickout.........................................................................................121
	Bucket Angle Indicator......................................................................................122
	Boom Lower Kickout (Option)................................................................................123
	Adjustment of Bucket Position Switch........................................................................124
	Towing Machine..............................................................................................125
		Hand Pump System........................................................................................126
			Raising Loader Arms and Bucket......................................................................126
			Releasing Parking Brake.............................................................................128
	If Engine Stalls While Traveling............................................................................130
	Allowable Water Depth.......................................................................................130
Inspection, Maintenance and Adjustment..........................................................................131
	Preventive Maintenance......................................................................................131
		Serial Numbers..........................................................................................131
			Machine Serial Number...............................................................................131
			Engine Serial Number................................................................................132
		Safety Precautions......................................................................................132
	Table of Recommended Lubricants.............................................................................133
	Fluid Capacities............................................................................................136
	Lubrication and Service Chart...............................................................................137
	Maintenance Intervals.......................................................................................139
		10 Hour / Daily Service.................................................................................139
		50 Hour / Weekly Service................................................................................139
		500 Hour / 3 Month Service..............................................................................140
		1,000 Hour / 6 Month Service............................................................................140
		1,500 Hour / 9 Month Service............................................................................140
		2,000 Hour / Yearly Service.............................................................................140
		12,000 Hour / Six Year Service..........................................................................140
	10 Hour / Daily Service.....................................................................................141
		Grease Front Attachment Pins............................................................................141
		Inspect All Tires for Correct Tire Pressure and Signs of Damage or Abnormal Wear........................141
		Check Engine Oil Level..................................................................................141
		Check Transmission Oil Level............................................................................142
		Check Hydraulic System Oil Level........................................................................143
		Check for Leaks In Hydraulic System.....................................................................144
		fill Fuel Tank..........................................................................................145
		Check for Leaks In Fuel System..........................................................................145
		Drain Fuel Condensation.................................................................................145
		Check Coolant Level.....................................................................................147
		Check Level of Window Washer Liquid.....................................................................148
		Inspect the Bucket Teeth and Side Cutters for Signs of Wear.............................................148
		Inspect Seat Belt for Proper Operation..................................................................148
		Inspect the Structure for Cracks and Faulty Welds.......................................................148
		Check the Operation of All Switches.....................................................................148
		Check the Operation of All Exterior Lights, Horn and Control Console Indicator and Monitor Lights.......148
		Start Engine, Check Starting Ability, and Observe Exhaust Color at Startup and at Normal Operati.......148
		Check Operation of All Controls.........................................................................149
		Inspect Engine Fan Blade................................................................................149
		Check Engine Drive Belt Wear............................................................................150
		Check Air Intake System.................................................................................151
	50 Hour / Weekly Service....................................................................................152
		Perform All Daily Service Checks........................................................................152
		Grease Front Attachment Pins............................................................................152
		Grease Steering Cylinder Rod and Head Ends..............................................................157
		Grease Upper and Lower Center Pins......................................................................157
		Change Engine Oil and Filter............................................................................157
		Hydraulic Full Flow Filter Replacement..................................................................158
		Check Water Pump Belt Tension...........................................................................158
		Clean Exterior of Radiator, Oil Cooler and Air Conditioner Condenser....................................158
	250 Hour / Monthly Service..................................................................................159
		Perform All Daily, 50 Hour Service Checks...............................................................159
		Change Engine Oil and Filter............................................................................159
		Replace Hydraulic System brake and Pilot Filter.........................................................160
		Check Engine Air Intake Precleaner......................................................................161
		Hydraulic Full Flow Filter Replacement..................................................................161
		Drain Water From Hydraulic Oil Tank.....................................................................162
		Clean Air Cleaner.......................................................................................163
		Check Water Pump Belt Tension...........................................................................164
		Grease Drive Shafts.....................................................................................165
		Axle Differential and Planetaries Oil Replacement (after first 250 hours)...............................165
		Replacement of Transmission Oil and Filter (After First 250 Hours)......................................165
	500 Hour / 3 Month Service..................................................................................166
		Perform All Daily, 50 and 250 Hour Service Checks.......................................................166
		Replace Fuel Filter.....................................................................................166
		Clean Exterior of Radiator, Oil Cooler and Air Conditioner Condenser....................................167
		Clean Air Conditioner Filter............................................................................168
	1,000 Hour / 6 Month Service................................................................................169
		Perform All Daily, 50, 250 and 500 Hour Service Checks..................................................169
		Drain and Replace Transmission Oil and filter...........................................................169
		Clean Fuel Tank and Strainer............................................................................170
		Clean Fuel Injection Priming Pump Strainer..............................................................171
		Replace Air Conditioner Filter..........................................................................171
		Check Air Conditioner Refrigerant.......................................................................172
		Check and Adjust Engine.................................................................................172
	1,500 Hour / 9 Month Service................................................................................173
		Perform All 50, 250 and 500 Hour Service Checks.........................................................173
		Replace Outer and Inner Air Cleaner Filters.............................................................173
		Axle Differential and Planetaries Oil Replacement.......................................................173
	2,000 Hour / Yearly Service.................................................................................175
		Perform All Daily, 50, 250, 500 and 1,000 Hour Service Checks...........................................175
		Change Radiator Coolant.................................................................................175
		Check Steering, Brake, Drive Shaft, Engine and Fuel System..............................................177
		Replace Pipes and Hoses.................................................................................177
		Bleed Brakes............................................................................................178
		Drain and Replace Hydraulic Oil.........................................................................179
		Clean Hydraulic Oil Suction Strainer....................................................................180
		Check Brake Accumulator.................................................................................181
	12,000 Hour / Six Year Service..............................................................................182
		Hose Inservice Lifetime Limit (European Standard ISO8331 and EN982CEN)...............................182
	Severe Conditions Maintenance...............................................................................183
	Bolt Torque Chart...........................................................................................184
		Tightening Torque Specifications for Metric Bolts (For coated threads, prelubricated assemblies)........184
	Electrical System...........................................................................................185
		Check Battery Condition.................................................................................185
	Engine Cooling System.......................................................................................186
		General.................................................................................................186
			Types of Antifreeze.................................................................................186
		Antifreeze Concentration Tables.........................................................................187
	Fuel Transfer Pump..........................................................................................188
	Handling of Accumulator.....................................................................................190
	Hydraulic Pressures Checks..................................................................................191
		Main Pump Pressure......................................................................................191
		Control Lever Activation Pressure.......................................................................191
		Steering Pump Pressure..................................................................................192
		Transmission Clutch Pressure............................................................................192
		Brake Charge Pressure...................................................................................192
		Service Brake Outlet Pressure...........................................................................193
		Parking Brake Release Pressure..........................................................................193
		Fan Motor Pressure......................................................................................193
	Long Term Storage...........................................................................................194
		Cleaning................................................................................................194
		Hydraulic System........................................................................................194
		Lubrication.............................................................................................194
		Battery.................................................................................................194
		Cooling System Care.....................................................................................194
	Parking Brake Adjustment....................................................................................195
		Front Axle Service Brakes...............................................................................195
		Front Axle Parking Brake Emergency Release..............................................................195
		Rear Axle Service Brake.................................................................................195
	Tires and Wheels............................................................................................196
		Wheel Nut Torque........................................................................................196
		Check Tire For Damage...................................................................................197
Transportation..................................................................................................199
	Loading Machine on a Trailer................................................................................199
	Summary of Safety Precautions for Lifting...................................................................200
Troubleshooting.................................................................................................201
	Braking.....................................................................................................201
	Electrical System...........................................................................................201
	Engine......................................................................................................202
	Hydraulic System............................................................................................204
	Travel System...............................................................................................206
		General.................................................................................................206
		Transmission Error Codes................................................................................208
	Steering....................................................................................................211
Specifications..................................................................................................213
	Mega 200V..................................................................................................213
		General specifications..................................................................................213
		Working Range and Dimensions............................................................................216
	Working Capacities..........................................................................................218
		Bucket Capacity.........................................................................................218
		Tipping Load............................................................................................218
		Material Weight.........................................................................................218
	Approximate Weight of Workload Materials....................................................................218
Index...........................................................................................................221
Appendix A  ACS Industries.....................................................................................225
Appendix B - Asbury.............................................................................................235

DAEWOO DOOSAN MEGA 200-V OPERATION & MAINTENANCE MANUAL – PDF DOWNLOAD:

IMAGES PREVIEW OF THE MANUAL:

 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