Daewoo Doosan Mega 200-V Shop Manual 023-00093E – PDF DOWNLOAD

Description

Daewoo Doosan Mega 200-V Shop Manual 023-00093E – PDF DOWNLOAD

DESCRIPTION:

Daewoo Doosan Mega 200-V Shop Manual 023-00093E – PDF DOWNLOAD

GENERAL SAFETY ESSENTIALS:

ACCESSORY APPLICATIONS:

• This wheel loader has been designed primarily for moving earth with a bucket. For use as a grapple or for other object handling, contact DOOSAN. 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.

LOCATION OF SAFETY LABELS:

• Location of safety labels (decals) can vary from unit to unit. Refer to appropriate Operation and Maintenance Manual, and Parts Manual for your unit. There are several specific warning signs on this machine. The exact location of hazards and the description of the hazards are reviewed in the appropriate Operation and Maintenance Manual.
• 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.

UNAUTHORIZED MODIFICATIONS:

• Any modification made without authorization or written approval from DOOSAN can create a safety hazard, for which the machine owner must be held responsible. For safety’s sake, replace all OEM parts with the correct authorized or genuine DOOSAN part.
• For example, not taking the time to replace fasteners, bolts or nuts with the correct replacement parts could lead to a condition in which the safety of critical assemblies is dangerously compromised.

TABLE OF CONTENTS:

Daewoo Doosan Mega 200-V Shop Manual 023-00093E – PDF DOWNLOAD

Publication Request for Proposed Revision.......................................................................  7
Safety..........................................................................................................  9
	Wheel Loader Safety S0103010K............................................................................... 11
		To the Operator of a DOOSAN Daewoo Wheel Loader......................................................... 13
			Learn Signal Words Used with Safety Alert Symbol.................................................... 15
		General Safety Essentials............................................................................... 16
			Accessory Applications.............................................................................. 16
		Location of Safety Labels............................................................................... 16
		Unauthorized Modifications.............................................................................. 16
		General Hazard Information.............................................................................. 17
			Safety Rules........................................................................................ 17
			Safety Features..................................................................................... 17
			Inside Operator's Compartment....................................................................... 18
			Clothing and Personal Protective Items.............................................................. 18
			Breathing Masks, Ear Protection May Be Required..................................................... 19
			Vibration Level Information......................................................................... 19
			Asbestos Dust Hazard Prevention..................................................................... 19
			Mounting and Dismounting............................................................................ 20
			Fuel, Oil and Hydraulic Fluid Fire Hazards.......................................................... 20
			Precautions When Handling Fluids at High Temperature................................................ 21
			Injury from Work Equipment.......................................................................... 21
			Fire Extinguisher and First Aid Kit................................................................. 22
			Protection from Falling or Flying Objects........................................................... 22
			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..................................................................................... 26
			Before Operating Machine............................................................................ 27
		Machine Operation....................................................................................... 28
			Operate While Seated at Operator's Station ONLY..................................................... 28
			Seat Belts Must Be Used at All Times................................................................ 28
			Movement Alarms..................................................................................... 28
			Travel Precautions.................................................................................. 29
			Sloping Terrain Requires Caution.................................................................... 29
			Avoid High Voltage Cables........................................................................... 30
			Before Starting to Dig, Contact Authorities......................................................... 30
			Be Aware of Height Obstacles........................................................................ 30
			Use Care on Loose Support........................................................................... 30
			Use Solid Support Blocking.......................................................................... 31
			Digging Beneath Overhangs........................................................................... 31
			Digging Beneath Wheel Loader........................................................................ 31
			Stay Alert for People Moving Through Work Area...................................................... 31
			Be Aware of and Conform to Local Regulations........................................................ 31
			Never Use Ether Starting Aids....................................................................... 32
			Observe General Safety Rules........................................................................ 32
			Take Time to Provide Good Visibility................................................................ 32
			Keep "Pinch Point" Areas Clear  Use Caution in Reverse............................................. 33
			Operate Carefully on Snow and Ice and in Very Cold Temperatures..................................... 33
			Parking Machine..................................................................................... 33
			Shutdown Control Functions.......................................................................... 34
			Never Let Anyone Ride on Attachment................................................................. 34
		Maintenance............................................................................................. 35
			Use Warning Tag During Service...................................................................... 35
			clean Before Inspection or Maintenance.............................................................. 35
			Proper Tools........................................................................................ 36
			Use of Lighting..................................................................................... 36
			Fire Prevention and Explosion Prevention............................................................ 36
			Burn Prevention..................................................................................... 37
			Welding Repairs..................................................................................... 38
			Precautions for Removal, Installation, and Storage of Attachments................................... 38
			Precautions When Working on Machine................................................................. 39
			Lock Inspection Covers.............................................................................. 39
			Crushing Prevention and Cutting Prevention.......................................................... 39
			Do Not Run Engine If Repairs or Work Are Being Performed Alone...................................... 39
			Always Use Adequate Equipment Supports and Blocking................................................. 40
			Do Not Work on Hot Engines or Hot Cooling or Hydraulic Systems...................................... 40
			Hydraulic Cylinder Seals Require Periodic Replacement............................................... 40
			Highpressure Hydraulic Lines Can Store a Great Deal of Energy...................................... 40
			Precautions with Highpressure Line, Tubes and Hoses................................................ 41
			Obtain Immediate Medical Attention if Pressurized Oil Pierces Skin.................................. 41
			Use Correct Replacement Fasteners Tightened to Proper Torque........................................ 42
			Safety Critical Parts Must Be Replaced Periodically................................................. 42
			Dispose of All Petroleum Based Oils and Fluids Properly............................................. 42
			Check Tire Pressure and Condition................................................................... 42
		Battery................................................................................................. 43
			Battery Hazard Prevention........................................................................... 43
			Disconnect Batteries Before Electrical Service or Electrical Welding................................ 43
			Use Low Heat Portable Lighting...................................................................... 44
			Boost Starting or Charging Engine Batteries......................................................... 44
		Towing.................................................................................................. 45
			Precautions When Towing............................................................................. 45
		Shipping and Transportation............................................................................. 46
			Obey State and Local OvertheRoad Regulations...................................................... 46
			Summary of Safety Precautions for Lifting........................................................... 46
Specifications.................................................................................................. 47
	Specifications for Mega 200-V S0203101C..................................................................... 49
		Component Locations..................................................................................... 52
			Standard............................................................................................ 52
		General Specifications.................................................................................. 54
		Engine Performance Curves............................................................................... 56
		Working Range and Dimensions............................................................................ 58
		Working Capacities...................................................................................... 60
			Bucket Capacity..................................................................................... 60
			Tipping Load........................................................................................ 60
		Material Weight......................................................................................... 60
			Approximate Weight of Workload Materials............................................................ 60
General Maintenance............................................................................................. 63
	General Maintenance Procedures S0302000..................................................................... 65
		Welding Precautions and Guidelines...................................................................... 67
		Hydraulic System  General Precautions.................................................................. 68
		Maintenance Service and Repair Procedure................................................................ 69
			General Precautions................................................................................. 69
		Hydraulic System Cleanliness and Oil Leaks.............................................................. 70
			Maintenance Precautions for Hydraulic System Service................................................ 70
			Oil Leakage Precautions............................................................................. 70
		Cleaning and Inspection................................................................................. 71
			General Guidelines.................................................................................. 71
			Bearing inspection.................................................................................. 72
				Normal Bearing.................................................................................. 73
				Bent Cage....................................................................................... 73
				Galling......................................................................................... 73
				Abrasive Step Wear.............................................................................. 74
				Etching......................................................................................... 74
				Misalignment.................................................................................... 74
				Indentations.................................................................................... 74
				Fatigue Spalling................................................................................ 75
				Brinelling...................................................................................... 75
				Cage Wear....................................................................................... 75
				Abrasive Roller Wear............................................................................ 75
				Cracked Inner Race.............................................................................. 76
				Smears.......................................................................................... 76
				Frettage........................................................................................ 76
				Heat Discoloration.............................................................................. 77
				Stain Discoloration............................................................................. 77
	Standard Torques S0309000................................................................................... 79
		Torque Values for Standard Metric Fasteners............................................................. 81
		Torque Values for Standard U.S. Fasteners............................................................... 82
		Type 8 Phosphate Coated Hardware........................................................................ 84
		Torque Values for Hose Clamps........................................................................... 85
		Torque Values for Split Flanges......................................................................... 86
		Torque Wrench Extension Tools........................................................................... 87
			Torque Multiplication............................................................................... 87
			Other Uses for Torque Wrench Extension Tools........................................................ 88
			Tightening Torque Specifications (Metric)........................................................... 88
				I. "Loctite" Fastener Adhesives................................................................. 89
				II. "Loctite" Pipe Thread Sealant............................................................... 89
				III. "Loctite" gasket/flange sealer............................................................. 89
				IV. "Loctite" retaining compounds............................................................... 90
				V. "Loctite" Adhesives.......................................................................... 90
Upper Structure................................................................................................. 91
	Counterweight S0403030K..................................................................................... 93
		Specifications.......................................................................................... 95
		Counterweight........................................................................................... 95
	Fuel Transfer Pump S0405500................................................................................. 97
		General Description..................................................................................... 99
			Theory of Operation................................................................................. 99
		Troubleshooting.........................................................................................100
		Replacement of Rotor and Vane...........................................................................100
		Replacement of Rear Cover...............................................................................101
		Replacement of Armature.................................................................................102
	Hydraulic Oil Tank S0406060C................................................................................103
		General Description.....................................................................................105
			Parts List (M200V).................................................................................105
			Parts List (M250V).................................................................................107
			Specifications......................................................................................109
Lower Structure and Chassis.....................................................................................111
	Center Joint (Articulation Joint) S0502040C.................................................................113
		General Description.....................................................................................115
			Maintenance Standard................................................................................116
Engine and Drive Train..........................................................................................119
	Axle (Clark-Hurth / Dana) S0602200C.........................................................................121
		Introduction............................................................................................124
		General Description.....................................................................................125
			Outline.............................................................................................125
			Differential (Standard).............................................................................128
				Differential Operation..........................................................................128
			Self Locking Differential...........................................................................129
		Troubleshooting.........................................................................................130
		Special Tools...........................................................................................133
		Clark-Hurth / Dana Axle Identification..................................................................136
			Maintenance and Lubrication.........................................................................137
			Brake Disk..........................................................................................137
				Wear Check and Replacement......................................................................137
				Adjustment of Brake Disk Gap....................................................................138
			Safety Brake........................................................................................140
				Adjustment of Safety Brake......................................................................144
			Wheel Hub...........................................................................................146
			Planetary Reduction Gears...........................................................................150
			Bevel Pinion Support (Rear Axle)....................................................................152
			Self Locking Differential...........................................................................159
	Parking Brake (DANA) S0603005K..............................................................................163
		Front Axle Housing......................................................................................165
		Parking Brake...........................................................................................166
			Front Axle Parking Brake Emergency Release..........................................................166
			Applying Parking Brake..............................................................................167
			Releasing Parking Brake.............................................................................168
	Air Conditioner S0605050K...................................................................................169
		General Description.....................................................................................171
		Refrigerant Circulation.................................................................................172
		Control Panel...........................................................................................174
		Control Specifications..................................................................................175
		Temperature Level Control and Display...................................................................176
		Air Discharge According to Path Selection...............................................................177
			Vent................................................................................................177
			Foot................................................................................................178
			Defroster...........................................................................................179
		Airconditioning System Circuit Diagram.................................................................180
		Troubleshooting.........................................................................................182
			Refrigerant Pressure Check..........................................................................182
		Weight of R134a Gas Used In Machines....................................................................185
		Refrigerant System Repairs..............................................................................187
			Refrigerant Safe Handling Procedures................................................................187
			Repair and Replacement Procedure....................................................................188
			Refrigerant Recovery................................................................................190
			Vacuuming Refrigerant System........................................................................190
			Leakage Check.......................................................................................192
			Refrigerant Charging................................................................................192
			Inspecting System for Leakage.......................................................................194
	Transmission and Torque Converter (ZF4WG-160) S0607110C....................................................195
		Drive Train Description.................................................................................199
		Transmission and Torque Converter.......................................................................200
			Powershift Transmission.............................................................................201
			Transmission Control................................................................................201
			Schedule of Measuring Points and Connection 4WG-160.................................................203
			Oil Circuit Diagram 4WG - 160 Forward 1st Speed.....................................................205
		Transmission Electric Components........................................................................207
			TCU (Transmission Control Unit).....................................................................208
			Transmission Control Valve..........................................................................208
			Transmission Oil Temperature Sensor.................................................................209
			Engine Pickup Sensor................................................................................209
			Central Gear Pickup Sensor..........................................................................209
			Turbine Pickup Sensor...............................................................................210
			Output Speed Sensor.................................................................................210
			Shift Lever Switch (DW-3)...........................................................................210
			Auto Selector Switch................................................................................212
			Display.............................................................................................212
		Transmission Electrical Circuits........................................................................213
			T/M Controller Circuit..............................................................................213
			Traveling Circuits..................................................................................214
				Neutral.........................................................................................214
				Forward First Gear..............................................................................215
				Forward Second Gear.............................................................................216
				Forward Third Gear..............................................................................217
				Forward Fourth Gear.............................................................................218
				Reverse First Gear..............................................................................219
				Reverse Second Gear.............................................................................220
				Reverse Third Gear..............................................................................221
			Downshift...........................................................................................222
				Overview........................................................................................222
				Kick-down: Forward Second Gear to Forward First Gear (Auto Selector Switch "O"- Manual Mode)....223
				Downshift (Auto Selector Switch "I" - Auto Mode)................................................224
			Transmission Cut Off................................................................................225
		Installation View.......................................................................................226
			Inner Section.......................................................................................226
			Front View..........................................................................................228
			Side View...........................................................................................229
			Rear View...........................................................................................230
		Special Tools...........................................................................................231
			Engine Connection...................................................................................231
			Input...............................................................................................232
			Gearbox Housing.....................................................................................233
			Coupling............................................................................................234
				Coupling K1.....................................................................................234
				Coupling K2.....................................................................................235
				Coupling K4.....................................................................................236
				Coupling KV.....................................................................................237
				Coupling KR.....................................................................................238
			Output..............................................................................................239
			Gearshift System....................................................................................240
			Pressure Regulator..................................................................................243
			Pressure Oil Pump...................................................................................244
			Filter..............................................................................................245
			Oil Pipes...........................................................................................246
		Hydraulic Control Unit (HSG-94).........................................................................247
			Disassembly.........................................................................................248
			Reassembly..........................................................................................251
		Powershift Transmission.................................................................................258
			Disassembly.........................................................................................258
				Remove Filter Unit..............................................................................258
				Remove Hydraulic Control Unit (HGS-94) and Duct Plate from Gearbox Housing......................259
				Remove and Dismantle Converter Safety Valve.....................................................259
				Engine Connection - Converter...................................................................260
				Remove Transmission Pump........................................................................263
				Converter Pressure Valve........................................................................264
				Remove Outputs Input and Clutches...............................................................265
				Dismantle Clutch KV and KR......................................................................270
				Dismantle Clutch K1. K2 and K3..................................................................272
				Dismantle Clutch K4.............................................................................274
				Dismantle Input Shaft...........................................................................275
			Reassembly..........................................................................................276
				Mount Oil Pipes.................................................................................276
				Plate Pack KV and KR............................................................................282
				Reassemble Clutches K1, K2 and K3...............................................................287
				Reassemble Clutch K4............................................................................292
				Preassemble Input Shaft.........................................................................298
				Install Preassembled Output Shaft and Clutches..................................................300
				Output..........................................................................................303
				Converter Pressure Valve........................................................................306
				Oil Feed Housing - Transmission Pump............................................................307
				Converter Safety Valve..........................................................................310
				Attaching Duct Plate............................................................................311
				Attaching Hydraulic Control Unit................................................................311
				Filter..........................................................................................313
				Speed Sensor and Inductive Transmitter..........................................................314
	Transmission Error Codes (ZF) S0607900C.....................................................................317
		Introduction............................................................................................320
		Abbreviations...........................................................................................320
		Display.................................................................................................320
			Description of Fault Codes..........................................................................321
		Display During Operation................................................................................322
		Definition of Operating Modes...........................................................................324
			Normal..............................................................................................324
			Substitute Clutch Control...........................................................................324
			Limphome...........................................................................................324
			Transmission shut Down..............................................................................324
			TCU Shut Down.......................................................................................324
		Clutch Pack and Solenoid Valve Crossreference Table....................................................325
		Table of Fault Codes....................................................................................326
		Table of Fault Codes  ERGOControl.....................................................................348
		Measurement of Resistance at Actuator/ sensors and Cable................................................351
			Actuator............................................................................................351
			Cable...............................................................................................351
Hydraulics......................................................................................................353
	Accumulator S0703010K.......................................................................................355
		General Description.....................................................................................357
			Specifications......................................................................................358
	Cylinders S0705015K.........................................................................................361
		General Description.....................................................................................363
			Theory of Operation.................................................................................364
			Parts List..........................................................................................366
				Bucket Hydraulic Cylinder.......................................................................366
				Lift Hydraulic Cylinder.........................................................................368
				Steering Hydraulic Cylinder.....................................................................370
		Troubleshooting, Testing and Adjustment.................................................................372
		Disassembly.............................................................................................376
		Cleaning and Inspection (Wear Limits and Tolerances)....................................................378
		Reassembly..............................................................................................379
	Fan Drive Hydraulic Motor (Haldex) S070711C.................................................................387
		General Description.....................................................................................389
			Theory of Operation.................................................................................389
				Mega 200-V......................................................................................389
			Parts List..........................................................................................390
			Specifications......................................................................................391
		Troubleshooting, Testing and Adjustment.................................................................392
		Tools Required..........................................................................................392
		Disassembly.............................................................................................393
		Inspect Parts for Wear..................................................................................396
		General Information.....................................................................................397
		Reverse Shaft Rotation of Pump..........................................................................397
		Reassembly..............................................................................................398
	Main Pump (Parker) S0708510C................................................................................403
		General Description.....................................................................................406
			Principals of Working...............................................................................406
			Parts List..........................................................................................408
				Standard........................................................................................408
				Low Noise Option Kit............................................................................410
	Main Control Valve (Husco) S0709457C........................................................................413
		General Description.....................................................................................415
		Specifications..........................................................................................417
		Operation...............................................................................................418
			Neutral.............................................................................................418
			Bucket/option Spool Operation.......................................................................418
			Boom Spool Operation................................................................................419
				Boom Float......................................................................................419
			Relief Valve........................................................................................419
				Main Relief Valve...............................................................................419
				Port Relief Valve...............................................................................419
			Operation (Main Relief Valve).......................................................................420
				Operation in Inoperative State..................................................................420
				Operation (A)...................................................................................420
				Operation (B)...................................................................................420
			Operation (Port Relief Valve).......................................................................421
				In the Inoperative State........................................................................421
				Operation (A)...................................................................................421
				Operation (B)...................................................................................421
				Operation (C)...................................................................................422
				Sucking Operation...............................................................................422
	Brake Pedal Valve S0709261C.................................................................................423
		General Description.....................................................................................425
			Theory of Operation.................................................................................425
			Specification.......................................................................................426
		Brake System............................................................................................427
			Standard............................................................................................427
			Standard............................................................................................428
			Specifications......................................................................................429
	Pilot Control Valve S0709479C...............................................................................431
		General Description.....................................................................................433
			Pilot Valve Operation...............................................................................433
		Pilot System............................................................................................436
			Mega 200-V..........................................................................................437
	Priority Valve S0709650.....................................................................................439
		General Description.....................................................................................441
			Theory of Operation.................................................................................441
			Parts List..........................................................................................443
			Specifications......................................................................................444
		Special Tools...........................................................................................444
		Disassembly.............................................................................................444
		Cleaning and Inspection (Wear Limits and Tolerances)....................................................446
		Reassembly..............................................................................................447
	Power Steering Unit S0709705C...............................................................................451
		General Description.....................................................................................453
			Power Steering System...............................................................................453
				Power Steering Unit.............................................................................453
				Mega 200-V......................................................................................454
				Mega250-V.......................................................................................455
				Neutral Operation...............................................................................456
				Right Turn......................................................................................456
				Left Turn.......................................................................................456
			Gerotor Operation...................................................................................456
			Cushion Valve Operation.............................................................................457
				Function........................................................................................457
				Working Principle...............................................................................457
			Parts List..........................................................................................458
			Specifications......................................................................................459
		Special Tools...........................................................................................460
		Troubleshooting, Testing and Adjustment.................................................................462
		Disassembly.............................................................................................463
		Cleaning and Inspection.................................................................................467
		Reassembly..............................................................................................468
		Installation............................................................................................479
	Restriction Valve S0709753C.................................................................................481
		General Description.....................................................................................483
			Theory of Operation.................................................................................483
			Restriction Valve Identification....................................................................484
			Specifications......................................................................................485
	Hydraulic Schematic (Mega 200-V) S0793015C..................................................................487
		General Description.....................................................................................489
		Mega 200-V (Standard) (S/N 1001 thru 3000)..............................................................490
		Mega 200-V (Option) (S/N 1001 thru 3000)................................................................492
		Mega 200-V (S/N 3001 and Up)............................................................................494
Electrical System...............................................................................................497
	Electrical System S0802016C.................................................................................499
		Overview................................................................................................501
			Electric Wire Color.................................................................................501
		Electric Supply System..................................................................................502
		Engine Starting Circuit.................................................................................504
			Operation During Start Process......................................................................504
			Operation After Start Process.......................................................................506
		Engine Preheating System................................................................................508
			Principle of Operation..............................................................................508
		Engine Stop System......................................................................................510
			Operation In Engine Running Mode....................................................................510
			Operation In Engine Stop Mode.......................................................................512
		Charging System.........................................................................................514
		Monitoring System.......................................................................................515
			Instrument Panel....................................................................................516
			Function Check......................................................................................517
			Monitoring System Schematic.........................................................................518
			Operation...........................................................................................520
				Instruments.....................................................................................520
				Indicator Lights................................................................................522
				Initial Operation...............................................................................523
				Control Unit Operation..........................................................................524
				Characteristic of Operation.....................................................................525
		Windshield Wiper........................................................................................526
			Front windshield wiper..............................................................................526
				Front Windshield Wiper Circuit..................................................................526
			Rear Windshield wiper...............................................................................527
		Lighting System.........................................................................................530
			Light Circuit.......................................................................................530
		Emergency Steering System (Option)......................................................................533
			Block Diagram.......................................................................................533
			Emergency Steering System Components................................................................534
				Emergency Steering Timer........................................................................534
				Emergency Steering Pump.........................................................................535
				Emergency Steering Switch.......................................................................535
			Emergency Steering System Electric Circuit..........................................................536
		Electric Detent System..................................................................................537
			Electric Circuit....................................................................................537
			Boom Kick-out.......................................................................................538
			Return To Dig.......................................................................................539
				Proximity Switch................................................................................539
	Electrical Schematic (Mega 200-V) S0893015C.................................................................541
		General Description.....................................................................................543
		Mega 200-V (Tier I) (S/N 1001 thru 2000)................................................................544
		Mega 200-V (Tier II) (S/N 2001 thru 3000)...............................................................546
		Mega 200-V (S/N 3001 and Up)............................................................................548
Attachments.....................................................................................................551

DAEWOO DOOSAN MEGA 200-V SHOP MANUAL 023-00093E – PDF DOWNLOAD:

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