Daewoo Doosan Mega 300-V Shop Manual 023-00041AE – PDF DOWNLOAD

Description

Daewoo Doosan Mega 300-V Shop Manual 023-00041AE – PDF DOWNLOAD

FILE DETAILS:

Daewoo Doosan Mega 300-V Shop Manual 023-00041AE – PDF DOWNLOAD

Language :English
Pages :650
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Daewoo Doosan Mega 300-V Shop Manual 023-00041AE – PDF DOWNLOAD

023-00041AE
Serial Number 1001 and Up (Tier I & II)

TO THE OPERATOR OF A DAEWOO WHEEL LOADER

Please respect the importance of taking responsibility for your own safety, and that other people who may
be affected by your actions.
Safety information on the following pages is organized into the following topics.
1. “General Safety Essentials” on page 6.
2. “Location of Safety Labels” on page 6.
3. “Unauthorized Modifications” on page 6.
4. “General Hazard Information” on page 7.
5. “Before Starting Engine” on page 15.
6. “Machine Operation” on page 18.
7. “Maintenance” on page 25.
8. “Battery” on page 33.
9. “Towing” on page 35.
10. “Shipping and Transportation” on page 36.

TABLE OF CONTENTS:

Daewoo Doosan Mega 300-V Shop Manual 023-00041AE – PDF DOWNLOAD

023-00041AE
Serial Number 1001 and Up (Tier I & II)

Safety 7
Wheel Loader Safety S0103010K 9
To the Operator of a Daewoo Wheel Loader 11
Learn Signal Words Used with Safety Alert Symbol 13
General Safety Essentials 14
Accessory Applications 14
Location of Safety Labels 14
Unauthorized Modifications 14
General Hazard Information 15
Safety Rules 15
Safety Features 15
Inside Operator’s Compartment 16
Clothing and Personal Protective Items 16
Breathing Masks, Ear Protection May Be Required 17
Asbestos Dust Hazard Prevention 17
Mounting and Dismounting 17
Fuel, Oil and Hydraulic Fluid Fire Hazards 18
Precautions When Handling Fluids at High Temperature 18
Injury from Work Equipment 19
Fire Extinguisher and First Aid Kit 19
Protection from Falling or Flying Objects 20
Install Additional Safety Equipment If Conditions Require 20
Maintain Standard Safety Equipment in Good Condition 20
Attachment Precautions 21
Accumulator 21
Engine Ventilation 21
Window Glass Breaking Tool 22
Before Starting Engine 23
Work Site Precautions 23
Checks Before Starting Engine 24
Engine Starting 24
Before Operating Machine 25
Machine Operation 26
Operate While Seated at Operator’s Station ONLY 26
Seat Belts Should Be Used at All Times 26
Movement Alarms 26
Travel Precautions 27
Sloping Terrain Requires Caution 27
Avoid High-voltage Cables 28
Before Starting to Dig, Contact Authorities 28
Be Aware of Height Obstacles 28
Use Care on Loose Support 28
Use Solid Support Blocking 29
Digging Beneath Overhangs 29
Digging Beneath Wheel Loader 29
Stay Alert for People Moving Through Work Area 29
Be Aware of and Conform to Local Regulations 29
Never Use Ether Starting Aids 30
Observe General Safety Rules 30
Take Time to Provide Good Visibility 30
Keep “Pinch Point” Areas Clear – Use Caution in Reverse 31
Operate Carefully on Snow and Ice and in Very Cold Temperatures 31
Parking Machine 31
Shutdown Control Functions 32
Never Let Anyone Ride on Attachment 32
Maintenance 33
Use Warning Tag During Service 33
clean Before Inspection or Maintenance 33
Proper Tools 34
Use of Lighting 34
Fire Prevention and Explosion Prevention 34
Burn Prevention 35
Welding Repairs 36
Precautions for Removal, Installation, and Storage of Attachments 36
Precautions When Working on Machine 37
Lock Inspection Covers 37
Crushing Prevention and Cutting Prevention 37
Do Not Run Engine If Repairs or Work Are Being Performed Alone 37
Always Use Adequate Equipment Supports and Blocking 38
Do Not Work on Hot Engines or Hot Cooling or Hydraulic Systems 38
Hydraulic Cylinder Seals Require Periodic Replacement 38
High Pressure Hydraulic Lines Can Store a Great Deal of Energy 38
Precautions with High Pressure Line, Tubes and Hoses 39
Obtain Immediate Medical Attention if Pressurized Oil Pierces Skin 39
Use Correct Replacement Fasteners Tightened to Proper Torque 40
Safety-critical Parts Must Be Replaced Periodically 40
Dispose of All Petroleum-based Oils and Fluids Properly 40
Check Tire Pressure and Condition 40
Battery 41
Battery Hazard Prevention 41
Disconnect Batteries Before Electrical Service or Electrical Welding 41
Use Low Heat Portable Lighting 42
Boost Starting or Charging Engine Batteries 42
Towing 43
Precautions When Towing 43
Shipping and Transportation 44
Obey State and Local Over-the-Road Regulations 44
Summary of Safety Precautions for Lifting 44
Specifications 45
Specifications for Mega 300-V S0203080K 47
Component Locations 50
General Specifications 52
Engine Performance Curves 54
Working Range and Dimensions 58
Working Capacities 61
Bucket Capacity 61
Tipping Load 61
Material Weight 61
Approximate Weight of Workload Materials 61
General Maintenance 65
General Maintenance Procedures S0302000 67
Welding Precautions and Guidelines 69
Hydraulic System – General Precautions 70
Maintenance Service and Repair Procedure 71
General Precautions 71
Hydraulic System Cleanliness and Oil Leaks 72
Maintenance Precautions for Hydraulic System Service 72
Oil Leakage Precautions 72
Cleaning and Inspection 73
General Guidelines 73
Bearing inspection 74
Standard Torques S0309000 81
Torque Values for Standard Metric Fasteners 83
Torque Values for Standard US Fasteners 84
Type 8 Phosphate Coated Hardware 86
Torque Values for Hose Clamps 87
Torque Values for Split Flanges 88
Torque Wrench Extension Tools 89
Torque Multiplication 89
Other Uses for Torque Wrench Extension Tools 90
Tightening Torque Specifications (Metric) 90
Upper Structure 93
Counterweight S0403030K 95
Specifications 97
Counterweight 97
Fuel Transfer Pump S0405500 99
General Description101
Theory of Operation101
Troubleshooting102
Replacement of Rotor and Vane102
Replacement of Rear Cover103
Replacement of Armature104
Hydraulic Oil Tank S0406050K105
General Description107
Parts List107
Specifications108
Lower Structure and Chassis109
Center Joint (Articulation Joint) S0502030K111
General Description113
Maintenance Standard114
Engine and Drive Train117
Front Axle (Volvo SLA15/W) S0602180K119
General Description123
Outline123
Drive Axle123
Differential (Standard)126
Parking Brake Operation127
Parts List129
Scheduled Maintenance138
After First 250 Hours138
Every 150 hours138
Every 1500 Hours139
Lubricant Specifications139
General Disassembly and Reassembly Instructions140
General Instructions140
Assembling Leakproof Components141
Axle Disassembly141
Drain Oil141
Final Drive142
Differential Assembly146
Overhauling Super Max Trac Assembly149
Checking Clearance on Assembled Disc Packs149
Axle Reassembly150
Determining Thickness of Adjustment Shims150
Inner Oil Recirculation Piping151
Differential Assembly152
Axial Position of Bevel Pinion152
Adjusting Backlash153
Adjusting Tooth Contact154
Securing Differential to Axle Housing157
Final Drive158
Determining Space Available to Form Brake Disc Pack160
Parking Brake (S/N 1001 thru 2000)162
Disassembly163
Reassembly163
Adjustment163
Parking Brake (S/N 2001 and Up)164
Rear Axle (Volvo SLA12/W) S0602190K165
General Description169
Outline169
Drive Axle169
Differential (Standard)172
Parts List175
Scheduled Maintenance180
After First 250 Hours180
Every 150 hours181
Every 1500 Hours181
Lubricant Specifications181
General Disassembly and Reassembly Instructions182
General Instructions182
Assembling Leakproof Components183
Axle Disassembly183
Drain Oil183
Final Drive184
Differential Assembly189
Overhauling Super Max Trac Assembly192
Checking Clearance on Assembled Disc Packs192
Axle Reassembly193
Determining Thickness of Adjustment Shims193
Differential Assembly194
Axial Position of Bevel Pinion194
Adjusting Backlash195
Adjusting Tooth Contact196
Securing Differential to Axle Housing199
Final Drive200
Determining Space Available to Form Brake Disc Pack202
Parking Brake Caliper (Volvo) S0603000203
General Description205
Operation205
Parking Brake Applied206
Parking Brake Released206
Parts List207
Special Tools and Materials207
Lubricants and Sealants207
Troubleshooting, Testing and Adjustment208
Parking Brake System208
Checking and Adjusting Parking Brake208
Measuring Pad Thickness208
Measuring Disc / Pad Clearance208
Measuring Procedure209
Adjustment209
Releasing the Parking Brake in Emergency Case210
Disassembly211
General211
Changing Brake Pads211
Work Sequence During Change of Brake Pads211
Cleaning and Inspection (Wear Limits and Tolerances)213
Reassembly215
Air Conditioner S0605050K221
General Description223
Refrigerant Circulation224
Control Panel226
Control Specifications227
Temperature Level Control and Display228
Air Discharge According to Path Selection229
Air-conditioning System Circuit Diagram232
Troubleshooting234
Weight of R134a Gas Used In Machines238
Refrigerant System Repairs240
Refrigerant Safe Handling Procedures240
Repair and Replacement Procedure241
Refrigerant Recovery243
Vacuuming Refrigerant System243
Leakage Check244
Refrigerant Charging245
Inspecting System For Leakage247
Transmission and Torque Converter (ZF4WG210) S0607090K249
Drive Train Description254
Transmission and Torque Converter255
Powershift Transmission256
Transmission Control256
Schedule of Measuring Points and Connection 4 WG-210258
Oil Circuit Diagram 4WG-210 Forward 1st Speed260
Transmission Electrical Components262
TCU (Transmission Control Unit)263
Transmission Control Valve263
Transmission Oil Temperature Sensor264
Engine Pick-up Sensor264
Central Gear Pick-up Sensor264
Turbine Pick-Up Sensor265
Output Speed Sensor265
Shift Lever Switch (DW-3)265
Auto Select Switch267
Display267
Transmission Faults Codes268
Fault Display268
CAN – Message268
Description of Fault Codes268
Abbreviations269
Definition of Operation Modes269
Table of Fault Codes270
Measurement of Resistance at Actuator/sensors and Cable270
Transmission Electrical Circuits272
Transmission Controller Circuit272
Traveling Circuits274
Kick-down282
Transmission Cutoff287
LIS (Load Isolation System) – Option289
Installation View (S/N 1001 thru 2000)292
Inner Section292
Front View293
Front View with Disc Brake294
Side View295
Side View with Disc Brake296
Rear View297
Rear View with Disc Brake298
Installation View (S/N 2001 and Up)300
Inner Section300
Front View301
Front View with Disc Brake302
Side View303
Side View with Disc Brake304
Rear View305
Rear View with Disc Brake306
Special Tools307
Gearshift System307
Engine Connection309
Pressure Oil Pump310
Gearbox Housing311
Input313
Coupling314
Output320
Power Take-off321
Hydraulic Control Unit (HSG-94)322
Disassembly324
Reassembly327
Transmission Disassembly333
Hydraulic Control Unit (HSG-94) and Duct plate333
Engine Connection – Converter334
Hydraulic Pump336
Converter Back Pressure Valve337
Remove Output, Input and Clutches338
Disassemble Clutch – KV and KR343
Disassemble Clutch – K1, K2 and K3346
Disassemble Clutch – K4348
Disassemble Drive Shaft349
Transmission Reassembly351
Install Oil Tube351
Reassemble Clutch – KV and KR353
Reassemble Clutch – K1, K2 and K3360
Reassemble Clutch – K4367
Pre-assemble Drive Shaft373
Pre-assemble and Install Output374
Install Pre-assembled Drive Shaft and Clutches376
Install Pump Shaft (Power Take-off)379
Install Output Flanges380
Converter Back Pressure Valve382
Oil Feed Housing – Transmission Pump382
Engine Connection – Converter384
Converter Safety Valve387
Mount Duct Plate and Hydraulic Control Unit387
Install Plugs and Oil Level Tube388
Speed Sensor and Inductive Transmitters389
Transmission Error Codes (ZF) S0607900C391
Introduction394
Abbreviations394
Display394
Description of Fault Codes395
Display During Operation396
Definition of Operating Modes398
Normal398
Substitute Clutch Control398
Limp-home398
Transmission shut Down398
TCU Shut Down398
Clutch Pack and Solenoid Valve Cross-reference Table399
Table of Fault Codes400
Table of Fault Codes – ERGO-Control422
Measurement of Resistance at Actuator/ sensors and Cable425
Actuator425
Cable425
Hydraulics427
Accumulator S0703000429
General Description431
Specifications432
Accumulator Charging435
Charging the Accumulator with Nitrogen435
Cylinders S0705005K437
General Description440
Theory of Operation441
Parts List442
Troubleshooting, Testing and Adjustment448
Disassembly452
Cleaning and Inspection (Wear Limits and Tolerances)454
Reassembly455
Fan Drive Hydraulic Motor (Haldex) S0707100K463
General Description465
Theory of Operation465
Parts List467
Specifications468
Main Pump (Denison) S0708485K469
General Description472
General472
Description472
Theory of Operation473
Parts List476
Specifications478
Special Tools479
Seal Driver479
Protective Cone479
Troubleshooting480
Overhaul482
General482
Changing Rotation483
Changing Cartridges484
Changing Port Locations484
Changing Shaft or Shaft Seal485
Disassembly of Pump486
Reassembly of Pump487
Disassembly of “C” Cartridge490
Reassembly of “C” Cartridge491
Disassembly of “D” Cartridge492
Reassembly of “D” Cartridge493
Installation494
Mounting494
Piping494
Fluids495
Start-up Procedures497
Pre-start Check497
Priming497
Brake Pedal Valve S0709250K499
General Description501
Theory of Operation501
Specification502
Brake System (S/N 1001 thru 2000)503
Brake System (S/N 2001 and Up)504
Brake, Pilot and Fan Motor Supply Valve505
Specifications (S/N 1001 thru 2000)506
Specifications (S/N 2001 and Up)507
Main Control Valve (Toshiba) S0709456K509
General Description511
Specifications513
Operation514
Neutral514
Bucket/option Spool Operation514
Boom Spool Operation515
Relief Valve515
Operation (Main Relief Valve)516
Operation (Port Relief Valve)517
Pilot Control Valve S0709477K519
General Description (S/N 1001 thru 2000)521
Pilot Valve Operation521
General Description (S/N 2001 and up)523
Pilot Valve Operation523
Standard524
Option526
Pilot System528
Priority Valve (Danfoss) S0709651K531
General Description534
Theory of Operation534
Parts List535
Specifications536
Disassembly536
Reassembly539
Power Steering Unit S0709730K541
General Description543
Power Steering System543
Gerotor Operation545
Cushion Valve Operation546
Parts List548
Specifications549
Special Tools550
Troubleshooting, Testing and Adjustment552
Disassembly553
Cleaning and Inspection557
Reassembly558
Installation569
Restriction Valve S0709751K571
General Description573
Theory of Operation573
UNLOADING CIRCUIT (S/N 1001 thru 2000)574
UNLOADING CIRCUIT (S/N 2001 and Up)575
Unloader Cartridge Identification (S/N 1001 thru 2000)576
Unloader Cartridge Identification (S/N 2001 and Up)577
Specifications578
Hydraulic Schematic (Mega 300-V) S0793070K579
General Description581
Mega 300-V (Tier I) (S/N 1001 thru 2000)582
Mega 300-V (Tier II) (S/N 2001 and Up)584
Electrical System587
Electrical System S0802200K589
Overview592
Electric Supply System594
Engine Starting Circuit596
Operation During Start Process596
Operation After Start Process598
Engine Preheating System (S/N 1001 thru 2000)600
Principle of Operation600
Engine Preheating System (S/N 2001 and Up)602
Principle Of Operation602
Engine Stop System604
Operation In Engine Running Mode604
Operation In Engine Stop Mode606
Charging System608
Monitoring System609
Monitoring System (S/N 1001 thru 2000)609
Instrument Panel (S/N 1001 thru 2000)610
Function Check (S/N 1001 thru 2000)611
Monitoring System Schematic (S/N 1001 thru 2000)612
Monitoring System (S/N 2001 and Up)614
Instrument Panel (S/N 2001 and Up)615
Function Check (S/N 2001 and Up)616
Monitoring System Schematic (S/N 2001 and Up)616
Operation618
Windshield Wiper624
Front windshield wiper624
Rear Windshield wiper625
Lighting System628
Light Circuit (S/N 1001 thru 2000)628
Light Circuit (S/N 2001 and Up)632
Emergency Steering System (Option)636
Block Diagram636
Emergency Steering System Components637
Emergency Steering System Electric Circuit639
Electric Detent System640
Electric Circuit640
Boom Kick-Out640
Return To Dig641
Electrical Schematic (Mega 300-V) S0893070K643
General Description645
Mega 300-V646
Attachments649

S.M 14/2/2025