Daewoo Doosan Mega 400-V Operation and Maintenance Manual 022-00016AE – PDF DOWNLOAD

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Daewoo Doosan Mega 400-V Operation and Maintenance Manual 022-00016AE – PDF DOWNLOAD

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

TO THE OPERATOR OF A DAEWOO WHEEL LOADER

• Improper use of wheel loader could cause serious injury or death. Before operating wheel loader, or performing maintenance, operator or technician must read and understand entire Operation and Maintenance Manual. Any operation, maintenance, traveling or shipping methods  that do not follow safety guidelines printed in this Manual could cause serious injury or death
• 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 1-2
2. “Location of Safety Labels” on page 1-3
3. “Unauthorized Modifications” on page 1-11
4. “Work-Site Precautions” on page 1-11
5. “Operation” on page 1-13
6. “Equipment” on page 1-18
7. “Maintenance” on page 1-22
8. “Shipping and Transportation” on page 1-24

LEARN SIGNAL WORDS USED WITH SAFETY ALERT SYMBOL

Words “CAUTION,” “WARNING,” and “DANGER” used throughout this manual and on labels on machine indicate hazards or unsafe practices. All three statements 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

GENERAL SAFETY ESSENTIALS

ACCESSORY APPLICATIONS

Wheel loader has been designed primarily for moving earth with a bucket. For use as a grapple or for other object handling, contact Daewoo. Lifting-work applications are permitted in approved lift configuration, to rated capacity only, with no side-loading (unless prohibited by local regulation). Do not use machine for activities for which it was not intended. Do not use bucket for lifting work, unless lift slings are used in approved configuration

LOCATION OF SAFETY LABELS

Always keep these labels clean. If they are lost or damaged, attach them again or replace them with a new label. Make sure replacement parts have current labels. There are other labels in addition to safety labels that follow so handle them in the same way. Safety labels may be available in languages other than English. To find out what labels are available, contact your Daewoo distributor

TABLE OF CONTENTS:

Daewoo Doosan Mega 400-V Operation and Maintenance Manual 022-00016AE – PDF DOWNLOAD

Safety..........................................................................................................  7
	To the Operator of a Daewoo Wheel Loader....................................................................  7
		Learn Signal Words Used with Safety Alert Symbol........................................................  8
	General Safety Essentials...................................................................................  8
		Accessory Applications..................................................................................  8
	Location of Safety Labels...................................................................................  9
		1. Warning for operation, inspection and maintenance (4190-2545, 190-00092)............................. 10
		2. Warnings for Engine Fan (2190-2525, 190-00557)....................................................... 10
		3. Warnings when opening engine hood (2190-2525, 190-00095)............................................. 11
		4. Warning for handling accumulator (2190-2528, 190-00099).............................................. 12
		5. Keep Out of steering turn area (4190-1992, 190-00120)................................................ 13
		6. Warning for high temperature hydraulic oil (2190-2529, 190-00097).................................... 13
		7. Warning for high temperature coolant (2190-2531, 190-00097).......................................... 14
		8. Warning for battery maintenance (2190-2533, 190-00100)............................................... 14
		9. Warning for riding on machine (4190-1989, 190-00107)................................................. 15
		10. Warning for performing maintenance on front attachment (4190-2546, 190-00105)....................... 15
		11. Warning to use safety lock (4190-1993, 190-00121)................................................... 16
		12. Warning Tag (2190-2549, 190-00098).................................................................. 16
	Unauthorized Modifications.................................................................................. 17
	Work-Site Precautions....................................................................................... 17
		Attachment Precautions.................................................................................. 17
		Avoid High-voltage Cables............................................................................... 17
		Before Starting to Dig, Contact Authorities............................................................. 18
		Be Aware of Height Obstacles............................................................................ 18
		Use Care on Loose Support............................................................................... 18
		Use Solid Support Blocking.............................................................................. 18
		Digging Beneath Overhangs............................................................................... 18
		Digging Beneath Wheel Loader............................................................................ 18
		Sloping Terrain Requires Caution........................................................................ 18
		Stay Alert for People Moving through Work Area.......................................................... 19
		Be Aware of and Conform to Local Regulations............................................................ 19
	Operation................................................................................................... 19
		Operate While Seated at Operator’s Station ONLY......................................................... 19
		Before Starting Engine, do a "pre-start" safety check:.................................................. 20
		Never Use Ether Starting Aids........................................................................... 20
		Mounting and Dismounting................................................................................ 20
		Observe General Safety Rules............................................................................ 21
		Engine Ventilation...................................................................................... 21
		Asbestos Dust Hazard Prevention......................................................................... 21
		Take Time to Provide Good Visibility.................................................................... 21
		Fuel, Oil and Hydraulic Fluid Fire Hazards.............................................................. 22
		Boost Starting or Charging Engine Batteries............................................................. 22
		Keep "Pinch Point" Areas Clear – Use Caution in Reverse................................................. 23
		Travel Precautions...................................................................................... 23
		Operate Carefully on Snow and Ice and in Very Cold Temperatures......................................... 23
		Parking Machine......................................................................................... 23
		Shutdown Control Functions.............................................................................. 24
	Equipment................................................................................................... 24
		Rough Operation May Require Use of Certified Safety Equipment........................................... 24
		Install Additional Safety Equipment If Conditions Require............................................... 25
		Movement Alarms......................................................................................... 25
		Seat Belts Should Be Used at All Times.................................................................. 25
		Window Glass Breaking Tool.............................................................................. 25
		Keep a Fire Extinguisher at Hand........................................................................ 26
		Maintain Standard Safety Equipment in Good Condition.................................................... 26
		Safety-critical Parts Must Be Replaced Periodically..................................................... 26
		Hydraulic Cylinder Seals Require Periodic Replacement................................................... 26
		High Pressure Hydraulic Lines Can Store a Great Deal of Energy.......................................... 26
		Operator’s Cab Should Be Kept Clean..................................................................... 26
		Wear Eye Protection and Safety Clothing – Use Proper Tools.............................................. 27
		Breathing Masks, Ear Protection May Be Required......................................................... 27
		Asbestos Fiber Hazard................................................................................... 27
		Battery Electrolyte and Explosive Gases Can Be Lethal................................................... 27
		Disconnect Batteries Before Electrical Service or Electrical Welding.................................... 27
		Use Low Heat Portable Lighting.......................................................................... 28
	Maintenance................................................................................................. 28
		Use Warning Tag during Service.......................................................................... 28
		Do Not Run Engine If Repairs or Work Are Being Performed Alone.......................................... 28
		Always Use Adequate Equipment Supports and Blocking..................................................... 28
		Do Not Work on Hot Engines or Hot Cooling or Hydraulic Systems.......................................... 28
		Cool-down Is Required Prior to Radiator or Reservoir Checks............................................. 29
		Pressurized Hydraulic Oil Fluid Leaks Can Be Dangerous.................................................. 29
		Obtain immediate medical attention if pressurized oil pierces skin...................................... 29
		Use Correct Replacement Fasteners Tightened to Proper Torque............................................ 29
		Dispose of All Petroleum-based Oils and Fluids Properly................................................. 30
		Check Tire Pressure and Condition....................................................................... 30
	Shipping and Transportation................................................................................. 30
		Obey State and Local Over-the-Road Regulations.......................................................... 30
Operating Controls.............................................................................................. 31
	Component Locations......................................................................................... 32
	Control Identification...................................................................................... 34
	Steering Console and Pedals................................................................................. 35
		1. Starter Switch....................................................................................... 36
		2. Horn Button (Two Places)............................................................................. 36
		3. Combination Switch................................................................................... 37
		4. Accelerator Pedal.................................................................................... 38
		5. Steering Tilt Knob................................................................................... 38
		6. Brake Pedal (Right and Left Pedals).................................................................. 39
		7. Steering Wheel....................................................................................... 39
		8. Kick-Down Switch (Two places)........................................................................ 40
		9. Transmission Lever................................................................................... 40
		10. FRONT INSTRUMENT PANEL.............................................................................. 41
	Transmission Display........................................................................................ 42
	Front Instrument Panel...................................................................................... 44
		Gauges.................................................................................................. 45
		Warning and Indicator Lights............................................................................ 45
		SWITCHES................................................................................................ 45
		1. Fuel Gauge........................................................................................... 45
		2. Speedometer.......................................................................................... 46
		3. Hour Meter........................................................................................... 46
		4. Tachometer........................................................................................... 46
		5. Coolant Temperature Gauge............................................................................ 47
		6. Transmission Oil Temperature Gauge................................................................... 47
		7. Preheat Cycle Indicator Light........................................................................ 47
		8. Air Filter Indicator Light........................................................................... 48
		9. Coolant Temperature Warning Light.................................................................... 48
		10. Engine Oil Pressure Warning Light................................................................... 48
		11. Battery Warning Light............................................................................... 48
		12. Left Turn and Hazard Warning Light.................................................................. 49
		13. High Beam Indicator Light........................................................................... 49
		14. Right Turn and Hazard Warning Light................................................................. 49
		15. Work Light Indicator Light.......................................................................... 49
		16. Brake FLUID Warning Light........................................................................... 50
		17. Brake And Pilot Oil Filter Clogging Warning Light................................................... 50
		18. Parking Brake Indicator Light....................................................................... 50
		19. Emergency Steering Indicator Light (Option)......................................................... 51
		20. Hazard Warning light Switch......................................................................... 51
		21. Load Isolation System (Lis) Switch (OPTION)......................................................... 52
		22. Float Kick-out Switch (Option)...................................................................... 52
	Right Side Switch Panel..................................................................................... 53
		1. Pilot Control Valve Lever (Joystick)................................................................. 54
		1a. Pilot Control Valve Lever (Option).................................................................. 54
		1B. ergo-II pilot control valve lever (Joystick) (Option)............................................... 55
		2. Kick-Down Switch (TWO PLACES)........................................................................ 56
		3. Horn Button (Two Places)............................................................................. 56
		4. Cigar Lighter........................................................................................ 57
		5. Headlight Switch..................................................................................... 57
		6. front Work Light Switch.............................................................................. 58
		7. Rear Work Light Switch............................................................................... 58
		8. Rear Wiper Switch.................................................................................... 59
		9. Rotating BeacoN Switch (Option)...................................................................... 59
		10. Cup Holder.......................................................................................... 59
		11. Parking Brake switch................................................................................ 60
		12. Pilot cut-off switch................................................................................ 60
		13. Transmission Cut-Off Switch......................................................................... 61
		14. Automatic Transmission Switch....................................................................... 61
		15. emergency Steering Test Switch (option)............................................................. 62
	Various Cabin Locations..................................................................................... 63
		1. CAB LIGHT............................................................................................ 64
		2. Stereo............................................................................................... 64
		3. Heating and AIR-CONditioning CONTROL PANEL........................................................... 64
		4. Speakers............................................................................................. 64
		5. Storage Box.......................................................................................... 65
		6. Washer Tank.......................................................................................... 65
		7. Hot/Cold Refrigerator................................................................................ 65
		8. Electric Box......................................................................................... 65
		9. Fuse Box Two......................................................................................... 66
		10. Fuse Box One........................................................................................ 66
	Heater and Air Conditioner Operation........................................................................ 67
		Location of Controls and Vents.......................................................................... 67
		Operation Panel......................................................................................... 68
		1. Fan and Air-Conditioner Switch....................................................................... 68
		2. Blower Fan Switches.................................................................................. 69
		3. Temperature Control Switch........................................................................... 69
		4. Selection Switch for Wind Direction.................................................................. 69
		5. Ventilation Selection Switch......................................................................... 70
		Memory Function of Used Mode............................................................................ 70
		Additional Operating Instruction........................................................................ 70
	Stereo...................................................................................................... 71
		1. On-Off / Volume Control Knob......................................................................... 71
		2. Balance / Fader Control.............................................................................. 71
		3. Bass/Treble Control.................................................................................. 71
		4. AM/FM Band Selection................................................................................. 72
		5. Automatic Memory (AME)............................................................................... 72
		6. Tape Eject Button.................................................................................... 72
		7. Cassette Slot........................................................................................ 72
		8. & 9. Play Direction Button........................................................................... 72
		10. Automatic Selection................................................................................. 72
		11. Dolby B Selection................................................................................... 72
		12. Metal Selection..................................................................................... 73
		Care of Stereo.......................................................................................... 73
	Seat Adjustment............................................................................................. 75
		1. Adjusting Seat Forward/ Backward Lever............................................................... 75
		2 & 3. Adjusting Seat's Angle and Height Lever.......................................................... 75
		4. Weight Adjustment Knob............................................................................... 75
		5. Backrest Adjustment Lever............................................................................ 75
		6. Angle Adjustment of Armrest.......................................................................... 76
		7. Headrest............................................................................................. 76
	Seat Belt................................................................................................... 77
		Seat Belt Locking and Unlocking......................................................................... 77
	Door side latch............................................................................................. 78
	Fuse Box/Relay.............................................................................................. 79
		Fuse Boxes.............................................................................................. 79
		Relay................................................................................................... 81
		Circuit Breaker......................................................................................... 81
		Fusible Link............................................................................................ 81
	Window Glass Breaking Tool.................................................................................. 82
Operation....................................................................................................... 83
	Instrument Panel Control Functions.......................................................................... 83
		Monitoring System....................................................................................... 83
	New Machine Break-in Procedures............................................................................. 83
	Engine Start and Stop....................................................................................... 84
		Engine Start............................................................................................ 84
		Cold Weather Engine Start............................................................................... 87
		Starting with Auxiliary Batteries....................................................................... 90
		Engine Stop............................................................................................. 91
		Hydraulic System Warm-up................................................................................ 92
		Hydraulic System Warm-up – Cold Weather................................................................. 92
	Machine Travel.............................................................................................. 93
	Machine Shutdown............................................................................................ 95
	Additional Braking.......................................................................................... 97
	Boom Raise Kickout.......................................................................................... 98
	Bucket Angle Indicator...................................................................................... 98
	Boom Lower Kickout (Option)................................................................................. 99
	Adjustment of Bucket Position Switch........................................................................ 99
	Towing Machine..............................................................................................100
	If Engine Stalls While Traveling............................................................................101
	Allowable Water Depth.......................................................................................101
Inspection, Maintenance and Adjustment..........................................................................103
	Preventive Maintenance......................................................................................103
		Serial Numbers..........................................................................................103
		Safety Precautions......................................................................................104
	Table of Recommended Lubricants.............................................................................105
	Fluid Capacities............................................................................................107
	Maintenance Intervals.......................................................................................108
		10 Hour / Daily Service.................................................................................108
		50 Hour / Weekly Service................................................................................108
		250 Hour / Monthly Service..............................................................................108
		500 Hour / 3 Month Service..............................................................................109
		1,000 Hour / 6 Month Service............................................................................109
		1,500 Hour / 9 Month Service............................................................................109
		2,000 Hour / Annually Service...........................................................................109
	10 Hour / Daily Service.....................................................................................110
		Grease Front Attachment Pins............................................................................110
		Inspect All Tires for Correct Tire Pressure and Signs of Damage or Abnormal Wear........................110
		Check Engine Oil Level..................................................................................110
		Check Transmission Oil Level............................................................................111
		Check Hydraulic System Oil Level........................................................................112
		Check for Leaks in the Hydraulic System.................................................................113
		fill Fuel Tank..........................................................................................114
		Check for Leaks in the Fuel System......................................................................114
		Drain Fuel Condensation.................................................................................115
		Check Coolant Level.....................................................................................115
		Check Antifreeze Protection Levels......................................................................116
		Check Level of Window Washer Liquid.....................................................................116
		Inspect the Bucket Teeth and Side Cutters for Signs of Wear.............................................116
		Inspect Seat Belt for Proper Operation..................................................................117
		Inspect the Structure for Cracks and Faulty Welds.......................................................117
		Check the Operation of All Switches.....................................................................117
		Check the Operation of All Exterior Lights, Horn and Control Console Indicator and Monitor Lights.......117
		Start Engine, Check Starting Ability, and Observe Exhaust Color at Start-up and at Normal Operati.......117
		Check Operation of All Controls.........................................................................117
		Inspect Engine Fan Blade................................................................................118
		Check Engine Drive Belt Wear............................................................................118
		Check Air Intake System.................................................................................119
	50 Hour / Weekly Service....................................................................................120
		Perform All 10 Hour / Daily Service Checks..............................................................120
		Grease Front Attachment Pins............................................................................120
		Grease Steering Cylinder Rod and HEAD Ends..............................................................125
		Grease Upper and Lower Center Pins......................................................................125
		Change Engine Oil and Filter............................................................................125
		Hydraulic Full Flow Filter Replacement..................................................................126
		Check Air-Conditioning and Alternator Belt Tension......................................................126
		Clean exterior of radiator, oil cooler and air-conditioner evaporator...................................126
	250 Hour / Monthly Service..................................................................................127
		Perform All 10 Hour / Daily, 50 Hour Service Checks.....................................................127
		Replace Hydraulic System brake and Pilot Filter.........................................................127
		Check Engine Air Pre-cleaner............................................................................128
		Hydraulic Full Flow Filter Replacement..................................................................128
		Drain Water From Hydraulic Oil Tank.....................................................................130
		Clean Air Cleaner.......................................................................................130
		Check Air-conditioning and Alternator Belt Tension......................................................131
		Grease Drive Shafts.....................................................................................132
		Change Engine Oil.......................................................................................133
		Axle Differential and Planetaries Oil Replacement (after first 250 hours)...............................133
		Replacement Of Transmission Oil and Filter (After First 250 Hours)......................................133
	500 Hour / 3 Month Service..................................................................................134
		Perform All 10 Hour / Daily, 50, and 250 Hour Service Checks............................................134
		Replace Fuel Filter.....................................................................................134
		Clean Exterior of Radiator, Oil Cooler and Air-conditioner Evaporator...................................135
		Change Engine Oil and Filter............................................................................136
	1,000 Hour / 6 Month Service................................................................................138
		Perform All 10 Hour / Daily, 50, 250, and 500 Hour Service Checks.......................................138
		Change Radiator Coolant.................................................................................138
		Drain and Replace Transmission Oil and filter...........................................................140
		Clean Fuel Tank and Strainer............................................................................141
		Check air conditioner refrigerant.......................................................................142
		Check and adjust engine.................................................................................142
	1,500 Hour / 9 Month Service................................................................................143
		Perform All 10, 50, 250, and 500 Hour Service Checks....................................................143
		Replace Outer and Inner Air Cleaner Elements............................................................143
		Axle Differential and Planetaries Oil Replacement.......................................................143
	2,000 Hour / Annually Service...............................................................................145
		Perform All 10 Hour / Daily, 50, 250, 500 and 1000 Hour Service Checks..................................145
		Check Steering, Brake, Drive Shaft, Engine, and Fuel System.............................................145
		Replace Hoses...........................................................................................145
		Bleed Brakes............................................................................................145
		Drain and Replace Hydraulic Oil.........................................................................146
		Clean Hydraulic Oil Suction Strainer....................................................................148
		Check Brake Accumulator.................................................................................148
	Severe Conditions Maintenance...............................................................................149
	General Maintenance.........................................................................................150
		Fuel Transfer Pump......................................................................................150
	Parking Brake Adjustment....................................................................................152
	Check Hydraulic Pressures...................................................................................153
		Main Pump Pressure......................................................................................153
		Unloading Valve Pressure................................................................................153
		Steering Pump Pressure..................................................................................154
		Transmission Clutch Pressure............................................................................154
		Brake Charge Pressure...................................................................................154
		Control Lever Activation Pressure.......................................................................154
		Service Brake Outlet Pressure...........................................................................155
		Fan Motor Pressure......................................................................................155
	Tires and Wheels............................................................................................156
		Wheel Nut Torque........................................................................................156
		CHECK TIRE FOR DAMAGE...................................................................................157
	Electrical System...........................................................................................158
		Check Battery Condition.................................................................................158
	Bolt Torque Chart...........................................................................................159
		Tightening Torque Specifications for Metric Bolts (For coated threads, pre- lubricated assemblies)......159
	Long Term Storage...........................................................................................160
		Cleaning................................................................................................160
		Hydraulic System........................................................................................160
		Lubrication.............................................................................................160
		Battery.................................................................................................160
		Cooling System Care.....................................................................................160
Transportation..................................................................................................161
	Loading Machine on a Trailer................................................................................161
	Summary of Safety Precautions for Lifting...................................................................162
Troubleshooting.................................................................................................163
	Engine......................................................................................................163
	Hydraulic System............................................................................................166
	Travel System...............................................................................................168
		General.................................................................................................168
		Transmission Error Codes................................................................................170
	Steering....................................................................................................173
	Braking.....................................................................................................174
	Electrical System...........................................................................................174
Specifications..................................................................................................175
	General Specifications......................................................................................175
	Working Range and Dimensions................................................................................176
	Working Capacities..........................................................................................178
		Bucket Capacity.........................................................................................178
		Tipping Load............................................................................................178
		Material Weight.........................................................................................178
	Approximate Weight of Workload Materials....................................................................178
Index...........................................................................................................181

DAEWOO DOOSAN MEGA 400-V OPERATION AND MAINTENANCE MANUAL 022-00016AE – PDF DOWNLOAD:

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