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

Description

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

DESCRIPTION:

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

• DOOSAN reserves the right to improve our products in a continuing process to provide the best possible product to the market place. These improvements can be implemented at any time with no obligation to change materials on previously sold products.
• It is recommended that consumers periodically contact their distributors for recent documentation on purchased equipment. This documentation may include attachments and optional equipment that is not available in your machine’s package.
• Please call your distributor for additional items that you may require. Illustrations used throughout this manual are used only as a representation of the actual piece of equipment, and may vary from the actual item.

TO THE OPERATOR OF A DOOSAN DAEWOO WHEEL LOADER

• Unsafe use of the wheel loader could lead to serious injury or death. Operating procedures, maintenance and equipment practices or traveling or shipping methods that do not follow the safety guidelines on the following pages could cause serious, potentially fatal injuries or extensive damage to the machine or nearby property.
• 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

• Improper operation and maintenance of this machine can be hazardous and could result in serious injury or death. Operator and maintenance personnel should read this manual thoroughly before beginning operation or maintenance.
• Keep this manual in the storage compartment to the rear of the operator’s seat, and have all personnel involved in working on the machine periodically read the manual. Some actions involved in operation and maintenance of the machine can cause a serious accident, if they are not done in a manner described in this manual.
• The procedures and precautions given in this manual apply only to intended uses of the machine. If you use your machine for any unintended uses that are not specifically prohibited, you must be sure that it is safe for any others. In no event should you or others engage in prohibited uses or actions as described in this manual.
• DOOSAN delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped. If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety devices and specifications that are necessary for use in your country.
• If there is any question about whether your product complies with the applicable standards and regulations of your country, consult DOOSAN or your DOOSAN distributor before operating the machine.

LEARN SIGNAL WORDS USED WITH SAFETY ALERT SYMBOL

The words “CAUTION,” “WARNING,” and “DANGER” used throughout this manual and on decals on the machine indicate degree of risk of hazards or unsafe practices. All three degrees of risk indicate that safety is involved. Observe precautions indicated whenever you see the Safety Alert “Triangle,” no matter which signal word appears next to the “Exclamation Point” symbol

Safety precautions are described in SAFETY from page 6 on.

DOOSAN cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore the safety messages in this manual and on the machine may not include all possible safety precautions. If any procedures or actions not specifically recommended or allowed in this manual are used, you must be sure that you and others can do such procedures and actions safely and without damaging the machine. If you are unsure about the safety of some procedures, contact a DOOSAN distributor.

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.

GENERAL HAZARD INFORMATION SAFETY RULES

Only trained and authorized personnel can operate and maintain the machine. Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine. Do not operate the machine if you are not feeling well, if you are taking medication that makes you feel sleepy, if you have been drinking, or if you are suffering from emotional problems. These problems will interfere with your sense of judgement in emergencies and may cause accidents. When working with another operator or with a person on work site traffic duty, be sure that all personnel know the nature of the work and understand all hand signals that are to be used. Always observe strictly any other rules related to safety.

SAFETY FEATURES

Be sure that all guards and covers are installed in their proper position. Have guards and covers repaired immediately if damaged. Be sure that you understand the method of use of safety features such as transmission lever neutral lock and the seat belt, and use them properly. Never remove any safety features. Always keep them in good operating condition. Failure to use safety features according to the instructions in the Operation and Maintenance Manual could result in serious bodily injury

TABLE OF CONTENTS:

Daewoo Doosan Mega 300-V Shop Manual 023-00041AE – 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 300-V S0203080K..................................................................... 49
		Component Locations..................................................................................... 52
		General Specifications.................................................................................. 55
		Engine Performance Curves............................................................................... 56
		Working Range and Dimensions............................................................................ 60
		Working Capacities...................................................................................... 63
			Bucket Capacity..................................................................................... 63
			Tipping Load........................................................................................ 63
		Material Weight......................................................................................... 63
			Approximate Weight of Workload Materials............................................................ 63
General Maintenance............................................................................................. 67
	General Maintenance Procedures S0302000..................................................................... 69
		Welding Precautions and Guidelines...................................................................... 71
		Hydraulic System  General Precautions.................................................................. 72
		Maintenance Service and Repair Procedure................................................................ 73
			General Precautions................................................................................. 73
		Hydraulic System Cleanliness and Oil Leaks.............................................................. 74
			Maintenance Precautions for Hydraulic System Service................................................ 74
			Oil Leakage Precautions............................................................................. 74
		Cleaning and Inspection................................................................................. 75
			General Guidelines.................................................................................. 75
			Bearing inspection.................................................................................. 76
				Normal Bearing.................................................................................. 77
				Bent Cage....................................................................................... 77
				Galling......................................................................................... 77
				Abrasive Step Wear.............................................................................. 78
				Etching......................................................................................... 78
				Misalignment.................................................................................... 78
				Indentations.................................................................................... 78
				Fatigue Spalling................................................................................ 79
				Brinelling...................................................................................... 79
				Cage Wear....................................................................................... 79
				Abrasive Roller Wear............................................................................ 79
				Cracked Inner Race.............................................................................. 80
				Smears.......................................................................................... 80
				Frettage........................................................................................ 80
				Heat Discoloration.............................................................................. 81
				Stain Discoloration............................................................................. 81
	Standard Torques S0309000................................................................................... 83
		Torque Values for Standard Metric Fasteners............................................................. 85
		Torque Values for Standard U.S. Fasteners............................................................... 86
		Type 8 Phosphate Coated Hardware........................................................................ 88
		Torque Values for Hose Clamps........................................................................... 89
		Torque Values for Split Flanges......................................................................... 90
		Torque Wrench Extension Tools........................................................................... 91
			Torque Multiplication............................................................................... 91
			Other Uses for Torque Wrench Extension Tools........................................................ 92
			Tightening Torque Specifications (Metric)........................................................... 92
				I. "Loctite" Fastener Adhesives................................................................. 93
				II. "Loctite" Pipe Thread Sealant............................................................... 93
				III. "Loctite" gasket/flange sealer............................................................. 93
				IV. "Loctite" retaining compounds............................................................... 94
				V. "Loctite" Adhesives.......................................................................... 94
Upper Structure................................................................................................. 95
	Counterweight S0403030K..................................................................................... 97
		Specifications.......................................................................................... 99
		Counterweight........................................................................................... 99
	Fuel Transfer Pump S0405500.................................................................................101
		General Description.....................................................................................103
			Theory of Operation.................................................................................103
		Troubleshooting.........................................................................................104
		Replacement of Rotor and Vane...........................................................................104
		Replacement of Rear Cover...............................................................................105
		Replacement of Armature.................................................................................106
	Hydraulic Oil Tank S0406050K................................................................................107
		General Description.....................................................................................109
			Parts List..........................................................................................109
			Specifications......................................................................................110
Lower Structure and Chassis.....................................................................................111
	Center Joint (Articulation Joint) S0502030K.................................................................113
		General Description.....................................................................................115
			Maintenance Standard................................................................................116
Engine and Drive Train..........................................................................................119
	Front Axle (Volvo SLA15/W) S0602180K.......................................................................121
		General Description.....................................................................................125
			Outline.............................................................................................125
			Drive Axle..........................................................................................125
				Axle Mount......................................................................................125
			Differential (Standard).............................................................................128
				Differential Operation..........................................................................128
				Limited Slip Differential Cross Section (Option)................................................128
			Parking Brake Operation.............................................................................129
			Parts List..........................................................................................131
				Front Axle Housing..............................................................................131
				Front Axle Differential.........................................................................132
				Front Planetary Gear Set........................................................................134
				Parking Brake...................................................................................136
		Scheduled Maintenance...................................................................................140
			After First 250 Hours...............................................................................140
			Every 150 hours.....................................................................................140
			Every 1,500 Hours...................................................................................141
			Lubricant Specifications............................................................................141
		General Disassembly and Reassembly Instructions.........................................................142
			General Instructions................................................................................142
			Assembling Leakproof Components.....................................................................143
		Axle Disassembly........................................................................................143
			Drain Oil...........................................................................................143
			Final Drive.........................................................................................144
			Differential Assembly...............................................................................148
			Overhauling Super Max Trac Assembly.................................................................151
			Checking Clearance on Assembled Disk Packs..........................................................151
		Axle Reassembly.........................................................................................152
			Determining Thickness of Adjustment Shims...........................................................152
			Inner Oil Recirculation Piping......................................................................153
			Differential Assembly...............................................................................154
			Axial Position of Bevel Pinion......................................................................154
			Adjusting Backlash..................................................................................155
			Adjusting Tooth Contact.............................................................................156
				Correct Pattern.................................................................................156
				Increase Pinion Distance........................................................................156
				Decrease Pinion Distance........................................................................157
			Securing Differential to Axle Housing...............................................................159
			Final Drive.........................................................................................160
			Determining Space Available to Form Brake Disk Pack.................................................162
		Parking Brake (S/N 1001 thru 2000)......................................................................164
			Disassembly.........................................................................................165
			Reassembly..........................................................................................165
			Adjustment..........................................................................................165
		Parking Brake (S/N 2001 and Up).........................................................................166
	Rear Axle (Volvo SLA12/W) S0602190K........................................................................167
		General Description.....................................................................................171
			Outline.............................................................................................171
			Drive Axle..........................................................................................171
				Axle Mount......................................................................................171
			Differential (Standard).............................................................................174
				Differential Operation..........................................................................174
				Limited Slip Differential Cross Section (Option)................................................174
			Parts List..........................................................................................177
				Rear Axle Housing...............................................................................177
				Rear Axle Differential..........................................................................178
				Rear Axle Planetary Gear Set....................................................................180
		Scheduled Maintenance...................................................................................182
			After First 250 Hours...............................................................................182
			Every 150 hours.....................................................................................183
			Every 1,500 Hours...................................................................................183
			Lubricant Specifications............................................................................183
		General Disassembly and Reassembly Instructions.........................................................184
			General Instructions................................................................................184
			Assembling Leakproof Components.....................................................................185
		Axle Disassembly........................................................................................185
			Drain Oil...........................................................................................185
			Final Drive.........................................................................................186
			Differential Assembly...............................................................................191
			Overhauling Super Max Trac Assembly.................................................................194
			Checking Clearance on Assembled Disk Packs..........................................................194
		Axle Reassembly.........................................................................................195
			Determining Thickness of Adjustment Shims...........................................................195
			Differential Assembly...............................................................................196
			Axial Position of Bevel Pinion......................................................................196
			Adjusting Backlash..................................................................................197
			Adjusting Tooth Contact.............................................................................198
				Correct Pattern.................................................................................198
				Increase Pinion Distance........................................................................198
				Decrease Pinion Distance........................................................................199
			Securing Differential to Axle Housing...............................................................201
			Final Drive.........................................................................................202
			Determining Space Available to Form Brake Disk Pack.................................................204
	Parking Brake Caliper (Volvo) S0603000......................................................................205
		General Description.....................................................................................207
			Operation...........................................................................................207
			Parking Brake Applied...............................................................................208
			Parking Brake Released..............................................................................208
			Parts List..........................................................................................209
		Special Tools and Materials.............................................................................209
			Lubricants and Sealants.............................................................................209
		Troubleshooting, Testing and Adjustment.................................................................210
			Parking Brake System................................................................................210
			Checking and Adjusting Parking Brake................................................................210
			Measuring Pad Thickness.............................................................................210
			Measuring Disk / Pad Clearance......................................................................210
			Measuring Procedure.................................................................................211
			Adjustment..........................................................................................211
			Releasing the Parking Brake in Emergency Case.......................................................212
		Disassembly.............................................................................................213
			General.............................................................................................213
			Changing Brake Pads.................................................................................213
			Work Sequence During Change of Brake Pads...........................................................213
		Cleaning and Inspection (Wear Limits and Tolerances)....................................................215
		Reassembly..............................................................................................217
	Air Conditioner S0605050K...................................................................................223
		General Description.....................................................................................225
		Refrigerant Circulation.................................................................................226
		Control Panel...........................................................................................228
		Control Specifications..................................................................................229
		Temperature Level Control and Display...................................................................230
		Air Discharge According to Path Selection...............................................................231
			Vent................................................................................................231
			Foot................................................................................................232
			Defroster...........................................................................................233
		Airconditioning System Circuit Diagram.................................................................234
		Troubleshooting.........................................................................................236
			Refrigerant Pressure Check..........................................................................236
		Weight of R134a Gas Used In Machines....................................................................239
		Refrigerant System Repairs..............................................................................241
			Refrigerant Safe Handling Procedures................................................................241
			Repair and Replacement Procedure....................................................................242
			Refrigerant Recovery................................................................................244
			Vacuuming Refrigerant System........................................................................244
			Leakage Check.......................................................................................246
			Refrigerant Charging................................................................................246
			Inspecting System for Leakage.......................................................................248
	Transmission and Torque Converter (ZF4WG210) S0607090K....................................................249
		Drive Train Description.................................................................................254
		Transmission and Torque Converter.......................................................................256
			Powershift Transmission.............................................................................257
			Transmission Control................................................................................257
			Schedule of Measuring Points and Connection 4 WG210................................................259
			Oil Circuit Diagram 4WG210 Forward 1st Speed.......................................................261
		Transmission Electrical Components......................................................................264
			TCU (Transmission Control Unit).....................................................................265
			Transmission Control Valve..........................................................................266
			Transmission Oil Temperature Sensor.................................................................266
			Engine Pickup Sensor................................................................................267
			Central Gear Pickup Sensor..........................................................................267
			Turbine Pickup Sensor...............................................................................267
			Output Speed Sensor.................................................................................268
			Shift Lever Switch (DW3)...........................................................................268
			Auto Selector Switch................................................................................270
			Display.............................................................................................270
		Transmission Faults Codes...............................................................................271
			Fault Display.......................................................................................271
			CAN  Message.......................................................................................271
			Description of Fault Codes..........................................................................271
			Abbreviations.......................................................................................272
			Definition of Operation Modes.......................................................................272
				Normal..........................................................................................272
				Substitute Clutch Control.......................................................................272
				Limphome.......................................................................................272
				Transmission Shut Down..........................................................................272
				TCU Shut Down...................................................................................272
			Table of Fault Codes................................................................................273
			Measurement of Resistance at Actuator/sensors and Cable.............................................273
				Actuator........................................................................................273
				Cable...........................................................................................273
		Transmission Electrical Circuits........................................................................274
			Transmission Controller Circuit.....................................................................274
			Traveling Circuits..................................................................................276
				Neutral.........................................................................................276
				Forward First Gear..............................................................................277
				Forward Second Gear.............................................................................278
				Forward Third Gear..............................................................................279
				Forward Fourth Gear.............................................................................280
				Reverse First Gear..............................................................................281
				Reverse Second Gear.............................................................................282
				Reverse Third Gear..............................................................................283
			Kickdown...........................................................................................284
				Overview........................................................................................284
				Kickdown: Forward Second Gear to Forward First Gear (Auto Selector Switch "O" Manual Mode)....286
				Kickdown (Auto Selector Switch "I"  Auto Mode)................................................288
			Transmission Cutoff.................................................................................289
			LIS (Load Isolation System)  Option................................................................291
		Installation View (S/N 1001 thru 2000)..................................................................294
			Inner Section.......................................................................................294
			Front View..........................................................................................295
			Front View with Disk Brake..........................................................................296
			Side View...........................................................................................297
			Side View with Disk Brake...........................................................................298
			Rear View...........................................................................................299
			Rear View with Disk Brake...........................................................................300
		Installation View (S/N 2001 thru 3000, 3001 and Up).....................................................301
			Inner Section.......................................................................................301
			Front View..........................................................................................302
			Front View with Disk Brake..........................................................................303
			Side View...........................................................................................304
			Side View with Disk Brake...........................................................................305
			Rear View...........................................................................................306
			Rear View with Disk Brake...........................................................................307
		Special Tools...........................................................................................308
			Gearshift System....................................................................................308
			Engine Connection...................................................................................310
			Pressure Oil Pump...................................................................................311
			Gearbox Housing.....................................................................................312
			Input...............................................................................................314
			Coupling............................................................................................315
			Output..............................................................................................321
			Power Takeoff......................................................................................322
		Hydraulic Control Unit (HSG94).........................................................................323
			Disassembly.........................................................................................325
			Reassembly..........................................................................................328
		Transmission Disassembly................................................................................334
			Hydraulic Control Unit (HSG94) and Duct plate......................................................334
			Engine Connection  Converter.......................................................................335
			Hydraulic Pump......................................................................................337
			Converter Back Pressure Valve.......................................................................338
			Remove Output, Input and Clutches...................................................................339
			Disassemble Clutch  KV and KR......................................................................344
			Disassemble Clutch  K1, K2 and K3..................................................................347
			Disassemble Clutch  K4.............................................................................349
			Disassemble Drive Shaft.............................................................................350
		Transmission Reassembly.................................................................................352
			Install Oil Tube....................................................................................352
			Reassemble Clutch  KV and KR.......................................................................354
			Reassemble Clutch  K1, K2 and K3...................................................................360
			Reassemble Clutch  K4..............................................................................367
			Preassemble Drive Shaft.............................................................................374
			Preassemble and Install Output......................................................................375
			Install Preassembled Drive Shaft and Clutches.......................................................377
			Install Pump Shaft (Power Takeoff).................................................................380
			Install Output Flanges..............................................................................382
			Converter Back Pressure Valve.......................................................................383
			Oil Feed Housing  Transmission Pump................................................................383
			Engine Connection  Converter.......................................................................385
			Converter Safety Valve..............................................................................388
			Mount Duct Plate and Hydraulic Control Unit.........................................................388
			Install Plugs and Oil Level Tube....................................................................389
			Speed Sensor and Inductive Transmitters.............................................................390
	Transmission Error Codes (ZF) S0607900C.....................................................................393
		Introduction............................................................................................396
		Abbreviations...........................................................................................396
		Display.................................................................................................396
			Description of Fault Codes..........................................................................397
		Display During Operation................................................................................398
		Definition of Operating Modes...........................................................................400
			Normal..............................................................................................400
			Substitute Clutch Control...........................................................................400
			Limphome...........................................................................................400
			Transmission shut Down..............................................................................400
			TCU Shut Down.......................................................................................400
		Clutch Pack and Solenoid Valve Crossreference Table....................................................401
		Table of Fault Codes....................................................................................402
		Table of Fault Codes  ERGOControl.....................................................................424
		Measurement of Resistance at Actuator/ sensors and Cable................................................427
			Actuator............................................................................................427
			Cable...............................................................................................427
Hydraulics......................................................................................................429
	Accumulator S0703000........................................................................................431
		General Description.....................................................................................433
			Specifications......................................................................................434
		Accumulator Charging....................................................................................437
			Charging the Accumulator with Nitrogen..............................................................437
	Cylinders S0705005K.........................................................................................439
		General Description.....................................................................................442
			Theory of Operation.................................................................................443
			Parts List..........................................................................................444
				Bucket Hydraulic Cylinder.......................................................................444
				Lift Hydraulic Cylinder.........................................................................446
				Steering Hydraulic Cylinder.....................................................................448
		Troubleshooting, Testing and Adjustment.................................................................450
		Disassembly.............................................................................................454
		Cleaning and Inspection (Wear Limits and Tolerances)....................................................456
		Reassembly..............................................................................................457
	Cylinders S0705010..........................................................................................465
		General Description.....................................................................................467
			Theory of Operation.................................................................................468
			Parts List..........................................................................................469
				Lift Cylinder...................................................................................469
				Bucket Cylinder.................................................................................470
		Troubleshooting, Testing and Adjustment.................................................................471
		Disassembly.............................................................................................475
		Cleaning and Inspection (Wear Limits and Tolerances)....................................................477
		Reassembly..............................................................................................478
	Fan Drive Hydraulic Motor (Haldex) S0707100K................................................................487
		General Description.....................................................................................489
			Theory of Operation.................................................................................489
			Parts List..........................................................................................491
			Specifications......................................................................................492
	Main Pump (Denison) S0708485K...............................................................................493
		General Description.....................................................................................496
			General.............................................................................................496
			Description.........................................................................................496
			Theory of Operation.................................................................................497
			Parts List..........................................................................................500
			Specifications......................................................................................502
		Special Tools...........................................................................................503
			Seal Driver.........................................................................................503
			Protective Cone.....................................................................................503
		Troubleshooting.........................................................................................504
		Overhaul................................................................................................506
			General.............................................................................................506
			Changing Rotation...................................................................................507
			Changing Cartridges.................................................................................508
			Changing Port Locations.............................................................................508
			Changing Shaft or Shaft Seal........................................................................509
			Disassembly of Pump.................................................................................510
				End Cap.........................................................................................510
				Shaft End.......................................................................................511
				Shaft...........................................................................................511
			Reassembly of Pump..................................................................................511
				Shaft End.......................................................................................511
				Center Housing and "D" Unitized Cartridge (P1)..................................................512
				"C" Unitized Cartridge (P2) and End Cap.........................................................512
				Unitized Pumping Cartridges.....................................................................513
			Disassembly of "C" Cartridge........................................................................514
			Reassembly of "C" Cartridge.........................................................................515
			Disassembly of "D" Cartridge........................................................................516
			Reassembly of "D" Cartridge.........................................................................517
		Installation............................................................................................518
			Mounting............................................................................................518
			Piping..............................................................................................518
			Fluids..............................................................................................519
				Type............................................................................................519
				Antiwear Additives..............................................................................519
				Non Petroleum Base or Fire Resistant Fluids.....................................................519
				Operating Temperature...........................................................................519
				Pump inlet Conditions...........................................................................520
		Startup Procedures.....................................................................................521
			Prestart Check......................................................................................521
			Priming.............................................................................................521
	Brake Pedal Valve S0709250K.................................................................................523
		General Description.....................................................................................525
			Theory of Operation.................................................................................525
			Specification.......................................................................................526
		Brake System (S/N 1001 thru 2000).......................................................................527
		Brake System (S/N 2001 thru 3000, 3001 and Up)..........................................................528
		Brake, Pilot and Fan Motor Supply Valve.................................................................530
			S/N 1001 thru 3000..................................................................................530
			S/N 3001 and Up.....................................................................................531
		Hydraulic Circuit.......................................................................................532
			S/N 1001 thru 2000..................................................................................532
			S/N 2001 thru 3000, 3001 and Up.....................................................................532
		Specifications..........................................................................................533
			S/N 1001 thru 2000..................................................................................533
			S/N 2001 thru 3000, S/N 3001 and Up.................................................................533
	Main Control Valve (Toshiba) S0709456K......................................................................535
		General Description.....................................................................................537
		Specifications..........................................................................................539
		Operation...............................................................................................540
			Neutral.............................................................................................540
			Bucket/option Spool Operation.......................................................................540
			Boom Spool Operation................................................................................541
				Boom Float......................................................................................541
			Relief Valve........................................................................................541
				Main Relief Valve...............................................................................541
				Port Relief Valve...............................................................................541
			Operation (Main Relief Valve).......................................................................542
				Operation in Inoperative State..................................................................542
				Operation (A)...................................................................................542
				Operation (B)...................................................................................542
			Operation (Port Relief Valve).......................................................................543
				In the Inoperative State........................................................................543
				Operation (A)...................................................................................543
				Operation (B)...................................................................................543
				Operation (C)...................................................................................544
				Sucking Operation...............................................................................544
	Pilot Control Valve S0709477K...............................................................................545
		General Description (S/N 1001 thru 2000)................................................................547
			Pilot Valve Operation...............................................................................547
		General Description (S/N 2001 and up)...................................................................549
			Pilot Valve Operation...............................................................................549
			Standard............................................................................................550
			Option..............................................................................................552
		Pilot System............................................................................................554
	Priority Valve (Danfoss) S0709651K..........................................................................557
		General Description.....................................................................................560
			Theory of Operation.................................................................................560
			Parts List..........................................................................................561
			Specifications......................................................................................562
		Disassembly.............................................................................................562
		Reassembly..............................................................................................565
	Power Steering Unit S0709730K...............................................................................567
		General Description.....................................................................................569
			Power Steering System...............................................................................569
				Power Steering Unit.............................................................................569
				Neutral Operation...............................................................................571
				Right Turn......................................................................................571
				Left Turn.......................................................................................571
			Gerotor Operation...................................................................................571
			Cushion Valve Operation.............................................................................572
				Function........................................................................................572
				Working Principle...............................................................................572
			Parts List..........................................................................................574
			Specifications......................................................................................575
		Special Tools...........................................................................................576
		Troubleshooting, Testing and Adjustment.................................................................578
		Disassembly.............................................................................................579
		Cleaning and Inspection.................................................................................583
		Reassembly..............................................................................................584
		Installation............................................................................................595
	Restriction Valve S0709751K.................................................................................597
		General Description.....................................................................................599
			Theory of Operation.................................................................................599
			UNLOADING CIRCUIT (S/N 1001 thru 2000)..............................................................600
			UNLOADING CIRCUIT (S/N 2001 thru 3000, 3001 and Up).................................................601
			Unloader Cartridge Identification (S/N 1001 thru 2000)..............................................602
			Unloader Cartridge Identification (S/N 2001 thru 3000, 3001 and Up).................................603
			Specifications......................................................................................604
	Hydraulic Schematic (Mega 300V) S0793070K..................................................................605
		General Description.....................................................................................607
		Mega 300V (Tier I) (S/N 1001 thru 2000)................................................................608
		Mega 300V (Tier II) (S/N 2001 thru 3000)...............................................................610
		Mega 300V (S/N 3001 and Up)............................................................................612
Electrical System...............................................................................................615
	Electrical System S0802200K.................................................................................617
		Overview................................................................................................621
			Electric Wire Color.................................................................................621
		Electric Supply System..................................................................................622
		Engine Starting Circuit.................................................................................624
			Operation During Start Process......................................................................624
			Operation After Start Process.......................................................................626
		Engine Preheating System (S/N 1001 thru 2000)...........................................................628
			Principle of Operation..............................................................................628
		Engine Preheating System (S/N 2001 thru 3000)...........................................................630
			Principle of Operation..............................................................................630
		Engine Stop System......................................................................................632
			Operation In Engine Running Mode....................................................................632
			Operation In Engine Stop Mode.......................................................................634
		Charging System.........................................................................................636
		Monitoring System.......................................................................................637
			Monitoring System (S/N 1001 thru 2000)..............................................................637
			Instrument Panel (S/N 1001 thru 2000)...............................................................638
			Function Check (S/N 1001 thru 2000).................................................................639
			Monitoring System Schematic (S/N 1001 thru 2000)....................................................640
			Monitoring System (S/N 2001 thru 3000)..............................................................642
			Instrument Panel (S/N 2001 thru 3000)...............................................................643
			Function Check (S/N 2001 thru 3000).................................................................644
			Monitoring System Schematic (S/N 2001 thru 3000)....................................................644
			Operation...........................................................................................646
				Instruments.....................................................................................646
				Indicator Lights................................................................................647
				Initial Operation...............................................................................649
				Control Unit Operation..........................................................................649
				Characteristic of Operation.....................................................................651
		Windshield Wiper........................................................................................652
			Front Windshield Wiper..............................................................................652
				Front Windshield Wiper Circuit..................................................................652
			Rear Windshield Wiper...............................................................................653
		Lighting System.........................................................................................656
			Light Circuit (S/N 1001 thru 2000)..................................................................656
			Light Circuit (S/N 2001 thru 3000)..................................................................660
		Emergency Steering System (Option)......................................................................664
			Block Diagram.......................................................................................664
			Emergency Steering System Components................................................................665
				Emergency Steering Timer........................................................................665
				Emergency Steering Pump.........................................................................666
				Emergency Steering Switch.......................................................................666
			Emergency Steering System Electric Circuit..........................................................667
		Electric Detent System..................................................................................668
			Electric Circuit....................................................................................668
			Boom Kick-out.......................................................................................668
			Return To Dig.......................................................................................669
				Proximity Switch................................................................................669
	Electrical Schematic (Mega 300V) S0893070K.................................................................671
		General Description.....................................................................................673
		Mega 300V..............................................................................................674
Attachments.....................................................................................................677

DAEWOO DOOSAN MEGA 300-V SHOP MANUAL 023-00041AE – PDF DOWNLOAD:

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