Daewoo Doosan Mega 400-V Operation and Maintenance Manual 022-00074E – PDF DOWNLOAD
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Daewoo Doosan Mega 400-V Operation and Maintenance Manual 022-00074E – PDF DOWNLOAD
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Daewoo Doosan Mega 400-V Operation and Maintenance Manual 022-00074E – PDF DOWNLOAD
DESCRIPTION:
Daewoo Doosan Mega 400-V Operation and Maintenance Manual 022-00074E – 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 1-4
2. “Location of Safety Labels” on page 1-4
3. “Unauthorized Modifications” on page 1-13
4. “General Hazard Information” on page 1-13
5. “Before Starting Engine” on page 1-21
6. “Machine Operation” on page 1-24
7. “Maintenance” on page 1-31
8. “Battery” on page 1-39
9. “Towing” on page 1-41
10. “Shipping and Transportation” on page 1-42
- 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.
- Daewoo 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 Daewoo or your Daewoo distributor before operating the machine.
GENERAL SAFETY ESSENTIALS
ACCESSORY APPLICATIONS
The wheel loader has been designed primarily for moving earth with a bucket. For use as a grapple or for other object handling, contact Daewoo. Lifting-work applications are permitted in approved lift configuration, to rated capacity only, with no side-loading (unless prohibited by local regulation). Do not use machine for activities for which it was not intended. Do not use bucket for lifting work, unless lift slings are used in approved configuration.
LOCATION OF SAFETY LABELS
There are several specific warning signs on this machine. The exact location of hazards and the description of the hazards are reviewed in this section. Please become familiarized with all warning signs. Make sure that all of the warning signs are legible. Clean the warning signs or replace the warning signs if you cannot read the words. Replace the illustrations if the illustrations are not visible. When you clean the warning signs, use a cloth, water and soap. Do not use solvent, gasoline, or other harsh chemicals to clean the safety signs. Solvents, gasoline, or other harsh chemicals could loosen the adhesive that secures the warning sign. Loose adhesive will allow the warning sign to fall off. Replace any safety sign that is damaged, or missing. If a safety sign is attached to a part that is replaced, install a safety sign on the replacement part
TABLE OF CONTENTS:
Daewoo Doosan Mega 400-V Operation and Maintenance Manual 022-00074E – PDF DOWNLOAD
Safety.......................................................................................................... 7 To the Operator of a Daewoo Wheel Loader.................................................................... 7 Learn Signal Words Used with Safety Alert Symbol........................................................ 9 General Safety Essentials................................................................................... 10 Accessory Applications.................................................................................. 10 Location of Safety Labels................................................................................... 10 1. Warning for operation, inspection and maintenance (41902545A, 19000092)............................ 12 2. Warnings for Engine Fan (21903315, 19000557)....................................................... 12 3. Warnings when opening engine hood (19000095)........................................................ 13 4. Warning for Using Wheel Block (41902547)............................................................ 13 5. Warning for handling accumulator (19000703, 19000099).............................................. 14 6. Keep Out of steering turn area (41901992A, 19000120)............................................... 15 7. Warning for high temperature hydraulic oil (19000691, 19000097).................................... 15 8. Warning for high temperature coolant (19000692, 19000097).......................................... 16 9. Warning for battery maintenance (21902533A, 19000100).............................................. 16 10. Warning for performing maintenance on front attachment (41902546A, 19000105)...................... 17 11. Warning to use safety lock (19000121).............................................................. 17 12. Warning Tag (19000695, 19000098).................................................................. 18 Unauthorized Modifications.................................................................................. 19 General Hazard Information.................................................................................. 19 Safety Rules............................................................................................ 19 Safety Features......................................................................................... 19 Inside Operator's Compartment........................................................................... 20 Clothing and Personal Protective Items.................................................................. 20 Breathing Masks, Ear Protection May Be Required......................................................... 21 Vibration Level Information............................................................................. 21 Asbestos Dust Hazard Prevention......................................................................... 21 Mounting and Dismounting................................................................................ 22 Fuel, Oil and Hydraulic Fluid Fire Hazards.............................................................. 22 Precautions When Handling Fluids at High Temperature.................................................... 23 Injury from Work Equipment.............................................................................. 23 Fire Extinguisher and First Aid Kit..................................................................... 24 Protection from Falling or Flying Objects............................................................... 24 Install Additional Safety Equipment If Conditions Require............................................... 25 Maintain Standard Safety Equipment in Good Condition.................................................... 25 Attachment Precautions.................................................................................. 26 Accumulator............................................................................................. 26 Engine Ventilation...................................................................................... 26 Before Starting Engine...................................................................................... 27 Work Site Precautions................................................................................... 27 Checks Before Starting Engine........................................................................... 28 Engine Starting......................................................................................... 28 Before Operating Machine................................................................................ 29 Machine Operation........................................................................................... 30 Operate While Seated at Operator's Station ONLY......................................................... 30 Seat Belts Should Be Used at All Times.................................................................. 30 Movement Alarms......................................................................................... 30 Travel Precautions...................................................................................... 31 Sloping Terrain Requires Caution........................................................................ 31 Avoid High Voltage Cables............................................................................... 32 Before Starting to Dig, Contact Authorities............................................................. 32 Be Aware of Height Obstacles............................................................................ 32 Use Care on Loose Support............................................................................... 32 Use Solid Support Blocking.............................................................................. 33 Digging Beneath Overhangs............................................................................... 33 Digging Beneath Wheel Loader............................................................................ 33 Stay Alert for People Moving Through Work Area.......................................................... 33 Be Aware of and Conform to Local Regulations............................................................ 33 Never Use Ether Starting Aids........................................................................... 34 Observe General Safety Rules............................................................................ 34 Take Time to Provide Good Visibility.................................................................... 34 Keep "Pinch Point" Areas Clear Use Caution in Reverse................................................. 35 Operate Carefully on Snow and Ice and in Very Cold Temperatures......................................... 35 Parking Machine......................................................................................... 35 Shutdown Control Functions.............................................................................. 36 Never Let Anyone Ride on Attachment..................................................................... 36 Maintenance................................................................................................. 37 Use Warning Tag During Service.......................................................................... 37 clean Before Inspection or Maintenance.................................................................. 37 Proper Tools............................................................................................ 38 Use of Lighting......................................................................................... 38 Fire Prevention and Explosion Prevention................................................................ 38 Burn Prevention......................................................................................... 39 Welding Repairs......................................................................................... 40 Precautions for Removal, Installation, and Storage of Attachments....................................... 40 Precautions When Working on Machine..................................................................... 41 Lock Inspection Covers.................................................................................. 41 Crushing Prevention and Cutting Prevention.............................................................. 41 Do Not Run Engine If Repairs or Work Are Being Performed Alone.......................................... 41 Always Use Adequate Equipment Supports and Blocking..................................................... 42 Do Not Work on Hot Engines or Hot Cooling or Hydraulic Systems.......................................... 42 Hydraulic Cylinder Seals Require Periodic Replacement................................................... 42 Highpressure Hydraulic Lines Can Store a Great Deal of Energy.......................................... 42 Cool Down Is Required Before Radiator or Reservoir Checks............................................... 42 Precautions with Highpressure Line, Tubes and Hoses.................................................... 43 Obtain Immediate Medical Attention if Pressurized Oil Pierces Skin...................................... 43 Use Correct Replacement Fasteners Tightened to Proper Torque............................................ 44 Safety Critical Parts Must Be Replaced Periodically..................................................... 44 Dispose of All Petroleum Based Oils and Fluids Properly................................................. 44 Check Tire Pressure and Condition....................................................................... 44 Battery..................................................................................................... 45 Battery Hazard Prevention............................................................................... 45 Disconnect Batteries Before Electrical Service or Electrical Welding.................................... 45 Use Low Heat Portable Lighting.......................................................................... 46 Boost Starting or Charging Engine Batteries............................................................. 46 Towing...................................................................................................... 47 Precautions When Towing................................................................................. 47 Shipping and Transportation................................................................................. 48 Obey State and Local OvertheRoad Regulations.......................................................... 48 Operating Controls.............................................................................................. 49 Component Locations......................................................................................... 50 Control Identification...................................................................................... 52 Steering Console and Pedals................................................................................. 53 1. Starter Switch....................................................................................... 54 2. Horn Button (Two Places)............................................................................. 54 3. Combination Switch................................................................................... 55 4. Accelerator Pedal.................................................................................... 56 5. Steering Wheel Adjustment Lever...................................................................... 56 6. Brake Pedal (Right and Left Pedals).................................................................. 57 7. Steering Wheel....................................................................................... 58 8. Kickdown Switch (Two places)........................................................................ 58 9. Transmission Lever................................................................................... 59 10. FRONT INSTRUMENT PANEL.............................................................................. 60 11. Transmission Display................................................................................ 60 Transmission Display........................................................................................ 61 Front Instrument Panel...................................................................................... 62 Gauges.................................................................................................. 63 Warning and Indicator Lights............................................................................ 63 SWITCHES................................................................................................ 63 1. Fuel Gauge........................................................................................... 63 2. Speedometer.......................................................................................... 64 3. Hour Meter........................................................................................... 64 4. Tachometer........................................................................................... 64 5. Engine Coolant Temperature Gauge..................................................................... 65 6. Transmission Oil Temperature Gauge................................................................... 65 7. Preheat Indicator Light.............................................................................. 65 8. Air Cleaner Clogged Warning Light.................................................................... 66 9. Engine Coolant Temperature Warning Light............................................................. 66 10. Engine Oil Pressure Warning Light................................................................... 66 11. Battery Warning Light............................................................................... 66 12. Left Turn and Hazard Warning Light.................................................................. 67 13. High Beam Indicator Light........................................................................... 67 14. Right Turn and Hazard Warning Light................................................................. 67 15. Work Light Indicator Light.......................................................................... 67 16. Brake Fluid Pressure Warning Light.................................................................. 68 17. F/R (Forward/Reverse) Selector Indicator Light (Option)............................................. 68 18. Parking Brake Indicator Light....................................................................... 68 19. Emergency Steering Indicator Light (Option)......................................................... 69 20. Hazard Warning light Switch......................................................................... 69 21. LIS (Load Isolation System) Switch (OPTION)......................................................... 70 22. Float Kickout Switch (Option)...................................................................... 70 Right Side Switch Panel..................................................................................... 71 1. Pilot Control Valve Lever (Joystick)................................................................. 72 1A. Pilot Control Valve Lever (Joystick) (Option)....................................................... 72 1B. Pilot Control Valve Lever (Two Lever) (Option)...................................................... 73 2. Kickdown Switch (TWO PLACES)........................................................................ 75 3. Horn Button (Two Places)............................................................................. 75 4. Cigar Lighter........................................................................................ 76 5. Headlight Switch..................................................................................... 77 6. front Work Light Switch.............................................................................. 77 7. Rear Work Light Switch............................................................................... 78 8. Rear Wiper Switch.................................................................................... 78 9. Rotating Beacon Light Switch (Option)................................................................ 79 10. Cup Holder.......................................................................................... 79 11. Parking Brake switch................................................................................ 79 12. Pilot cutoff switch................................................................................. 80 13. Transmission Cutoff Switch.......................................................................... 80 14. Automatic Transmission Switch....................................................................... 81 15. emergency Steering Test Switch (option)............................................................. 81 16. F/R (Forward/Reverse) Selector Switch (Option)...................................................... 82 17. F/R (Forward/Reverse) Control Switch (Option)....................................................... 82 Various Cabin Locations..................................................................................... 83 1. CAB LIGHT............................................................................................ 84 2. Stereo............................................................................................... 84 3. Heater and Air Conditioner Control Panel............................................................. 84 4. Speakers............................................................................................. 84 5. Storage Box.......................................................................................... 85 6. Washer Tank.......................................................................................... 85 7. Hot/Cold Refrigerator................................................................................ 85 8. Electrical Box....................................................................................... 85 9. Fuse Box Two......................................................................................... 86 10. Fuse Box One........................................................................................ 86 Heater and Air Conditioner Operation........................................................................ 87 Location of Controls and Vents.......................................................................... 87 Operation Panel......................................................................................... 88 1. Fan and Air Conditioner Switch....................................................................... 88 2. Blower Fan Switches.................................................................................. 89 3. Temperature Control Switch........................................................................... 89 4. Selector Switch for Wind Direction................................................................... 89 5. Ventilation Selector Switch.......................................................................... 90 Memory Function of Used Mode............................................................................ 90 Additional Operating Instruction........................................................................ 91 Stereo...................................................................................................... 92 1. OnOff / Volume Control Knob......................................................................... 92 2. Balance / Fader Control.............................................................................. 92 3. Bass/Treble Control.................................................................................. 92 4. AM/FM Band Selector.................................................................................. 93 5. Automatic Memory (AME)............................................................................... 93 6. Tape Eject Button.................................................................................... 93 7. Cassette Slot........................................................................................ 93 8. & 9. Play Direction Button........................................................................... 93 10. Automatic Selector.................................................................................. 93 11. Dolby B Selector.................................................................................... 93 12. Metal Selector...................................................................................... 94 Care of Stereo.......................................................................................... 94 Seat Adjustment (Standard).................................................................................. 96 1. Adjusting Seat Forward/ Backward Lever............................................................... 96 2 & 3. Adjusting Seat's Angle and Height Lever.......................................................... 96 4. Weight Adjustment Knob............................................................................... 96 5. Backrest Adjustment Lever............................................................................ 96 6. Angle Adjustment of Armrest.......................................................................... 97 7. Headrest............................................................................................. 97 Recommendations for Limiting Vibrations................................................................. 97 Seat Adjustment (Option).................................................................................... 98 1. Adjusting Seat Forward/ Backward Lever............................................................... 98 2. Seat Height & Firmness / Adjustment Knob............................................................. 98 3. Backrest Adjustment Lever............................................................................ 98 4. Lumbar Control Knob.................................................................................. 98 5. Angle Adjustment of Armrest.......................................................................... 98 6. Adjustment of Upper Backrest (6, Figure 101)......................................................... 98 Seat Belt................................................................................................... 99 Seat Belt Locking and Unlocking......................................................................... 99 Door Side Latch.............................................................................................100 Fuse Box/Relay..............................................................................................101 Fuse Boxes..............................................................................................101 Relay...................................................................................................103 Circuit Breaker.........................................................................................103 Fusible Link............................................................................................104 Operation.......................................................................................................105 Instrument Panel Control Functions..........................................................................105 Monitoring System.......................................................................................105 New Machine Breakin Procedures.............................................................................105 Engine Start and Stop.......................................................................................106 Engine Start............................................................................................106 Cold Weather Engine Start...............................................................................109 Starting with Auxiliary Batteries.......................................................................112 Engine Shut Down........................................................................................113 Hydraulic System Warmup................................................................................114 Hydraulic System Warmup – Cold Weather.................................................................114 Machine Travel (Standard Transmission Controls).............................................................115 Machine Shut Down...........................................................................................117 F/R (Forward/Reverse) Travel Control System (Option)........................................................120 Additional Braking..........................................................................................121 Boom Raise Kickout.........................................................................................121 Bucket Angle Indicator......................................................................................122 Boom Lower Kickout (Option)................................................................................123 Adjustment of Bucket Position Switch........................................................................123 Towing Machine..............................................................................................124 If Engine Stalls While Traveling............................................................................125 Allowable Water Depth.......................................................................................125 Inspection, Maintenance and Adjustment..........................................................................127 Preventive Maintenance......................................................................................127 Serial Numbers..........................................................................................127 Safety Precautions......................................................................................128 Table of Recommended Lubricants.............................................................................129 Fluid Capacities............................................................................................131 Lubrication and Service Chart...............................................................................131 Maintenance Intervals.......................................................................................134 10 Hour / Daily Service.................................................................................134 50 Hour / Weekly Service................................................................................134 250 Hour / Monthly Service..............................................................................134 500 Hour / 3 Month Service..............................................................................135 1,000 Hour / 6 Month Service............................................................................135 1,500 Hour / 9 Month Service............................................................................135 2,000 Hour / Yearly Service.............................................................................135 12,000 Hour / Six Year Service..........................................................................135 10 Hour / Daily Service.....................................................................................136 Grease Front Attachment Pins............................................................................136 Inspect All Tires for Correct Tire Pressure and Signs of Damage or Abnormal Wear........................136 Check Engine Oil Level..................................................................................136 Check Transmission Oil Level............................................................................137 Check Hydraulic System Oil Level........................................................................138 Check for Leaks In Hydraulic System.....................................................................139 fill Fuel Tank..........................................................................................140 Check for Leaks in Fuel System..........................................................................140 Drain Fuel Condensation.................................................................................141 Check Coolant Level.....................................................................................142 Check Level of Window Washer Liquid.....................................................................143 Inspect the Bucket Teeth and Side Cutters for Signs of Wear.............................................143 Inspect Seat Belt for Proper Operation..................................................................143 Inspect the Structure for Cracks and Faulty Welds.......................................................143 Check the Operation of All Switches.....................................................................143 Check the Operation of All Exterior Lights, Horn and Control Console Indicator and Monitor Lights.......143 Start Engine, Check Starting Ability, and Observe Exhaust Color at Startup and at Normal Operati.......144 Check Operation of All Controls.........................................................................144 Inspect Engine Fan Blade................................................................................144 Check Engine Drive Belt Wear............................................................................145 Check Air Intake System.................................................................................146 50 Hour / Weekly Service....................................................................................147 Perform All Daily Service Checks........................................................................147 Grease Front Attachment Pins............................................................................147 Grease Steering Cylinder Rod and HEAD Ends..............................................................152 Grease Upper and Lower Center Pins......................................................................152 Change Engine Oil and Filter............................................................................152 Hydraulic Full Flow Filter Replacement..................................................................152 Check Air Conditioner and Alternator Belt Tension.......................................................153 Clean Exterior of Radiator, Oil Cooler and Air Conditioner Condenser....................................153 250 Hour / Monthly Service..................................................................................154 Perform All Daily and 50 Hour Service Checks............................................................154 Replace Hydraulic System brake and Pilot Filter.........................................................154 Check Engine Air Intake Precleaner......................................................................155 Drain Water From Hydraulic Oil Tank.....................................................................155 Clean Air Cleaner.......................................................................................156 Check Air Conditioner and Alternator Belt Tension.......................................................157 Grease Drive Shafts.....................................................................................157 Change Engine Oil and Filter............................................................................158 Replacement of Transmission Oil and Filter (After First 250 Hours)......................................159 500 Hour / 3 Month Service..................................................................................160 Perform All Daily, 50 and 250 Hour Service Checks.......................................................160 Replace Fuel Filter.....................................................................................160 Hydraulic Full Flow Filter Replacement..................................................................161 Clean Exterior of Radiator, Oil Cooler and Air Conditioner Condenser....................................162 Clean AirConditioning Filter...........................................................................162 Axle Differential and Planetaries Oil Replacement (After First 500 Hours)...............................163 1,000 Hour / 6 Month Service................................................................................164 Perform All Daily, 50, 250, and 500 Hour Service Checks.................................................164 Drain and Replace Transmission Oil and filter...........................................................164 Axle Differential and Planetaries Oil Replacement.......................................................165 Axle Brake Disk Wear Measurement........................................................................167 Clean Fuel Tank and Strainer............................................................................168 Check Air Conditioner Refrigerant.......................................................................168 Check and Adjust Engine.................................................................................169 Change Air Conditioner Filter...........................................................................169 1,500 Hour / 9 Month Service................................................................................170 Perform All 10, 50, 250 and 500 Hour Service Checks.....................................................170 Replace Outer and Inner Air Cleaner Elements............................................................170 2,000 Hour / Yearly Service.................................................................................171 Perform All Daily, 50, 250, 500 and 1,000 Hour Service Checks...........................................171 Check Steering, Brake, Drive Shaft, Engine, and Fuel System.............................................171 Replace Pipes and Hoses.................................................................................171 Bleed Brakes............................................................................................171 Change Radiator Coolant.................................................................................172 Drain and Replace Hydraulic Oil.........................................................................174 Clean Hydraulic Oil Suction Strainer....................................................................176 Check Brake Accumulator.................................................................................176 12,000 Hour / Six Year Service..............................................................................177 Hose Inservice Lifetime Limit (European Standard ISO8331 and EN982CEN)...............................177 Bolt Torque Chart...........................................................................................178 Tightening Torque Specifications for Metric Bolts (For coated threads, prelubricated assemblies)........178 Electrical System...........................................................................................179 Check Battery Condition.................................................................................179 Engine Cooling System.......................................................................................180 General.................................................................................................180 Antifreeze Concentration Tables.........................................................................181 Fuel Transfer Pump..........................................................................................182 Handling of Accumulator.....................................................................................184 Hydraulic Pressures.........................................................................................185 Main Pump Pressure......................................................................................185 Unloader Valve Pressure.................................................................................185 Steering Pump Pressure..................................................................................186 Transmission Clutch Pressure............................................................................186 Brake Charge Pressure...................................................................................186 Control Lever Activation Pressure.......................................................................186 Service Brake Outlet Pressure...........................................................................187 Fan Motor Pressure and Fan rpm..........................................................................187 Long Term Storage...........................................................................................188 Cleaning................................................................................................188 Hydraulic System........................................................................................188 Lubrication.............................................................................................188 Battery.................................................................................................188 Cooling System Care.....................................................................................188 Parking Brake Adjustment....................................................................................189 Emergency Release of the Parking Brake..................................................................189 Adjusting regulations...................................................................................190 Severe Conditions Maintenance...............................................................................191 Tires and Wheels............................................................................................192 Wheel Nut Torque........................................................................................192 Check Tire for Damage...................................................................................193 Transportation..................................................................................................195 Loading Machine on a Trailer................................................................................195 Summary of Safety Precautions for Lifting...................................................................196 Troubleshooting.................................................................................................197 Braking.....................................................................................................197 Electrical System...........................................................................................197 Engine......................................................................................................198 Hydraulic System............................................................................................200 Steering....................................................................................................202 Travel System...............................................................................................203 General.................................................................................................203 Transmission Error Codes................................................................................205 Specifications..................................................................................................209 General Specifications......................................................................................209 Working Range and Dimensions................................................................................210 Working Capacities..........................................................................................212 Bucket Capacity.........................................................................................212 Tipping Load............................................................................................212 Material Weight.........................................................................................212 Approximate Weight of Workload Materials....................................................................212 Index...........................................................................................................215
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