Complete repair service manual for Daewoo / Doosan Mega 300 Wheel Loader, with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.
Daewoo M300 Wheel Loader service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
023-00041AE – Mega 300-V Shop Manual.pdf
2023-7105E – Mega 300-III Shop Manual.pdf
02200015BE – Mega 300-V Operation and Maintenance Manual.pdf
M300-III(DE12T) Electrical Schematics.pdf
M300-III Hydraulic Diagram.pdf
M300-V Electrical Circuit.pdf
M300-V Hydraulic Circuit.pdf
M300-V INJ. Pump Calibration Data.pdf
M300-V Performance Data.pdf
Total Pages: 1,012 pages
File Format: PDF
Language: English
TABLE OF CONTENTS
Safety
Wheel Loader Safety .. S0103010K
Specifications
Specifications for Mega 300-V.. S0203080K
General Maintenance
General Maintenance Procedures …S0302000
Standard Torques ..S0309000
Upper Structure
Counterweight… S0403030K
Fuel Transfer Pump …S0405500
Hydraulic Oil Tank .. S0406050K
Lower Structure and Chassis
Center Joint (Articulation Joint)… S0502030K
Engine and Drive Train
Front Axle (Volvo SLA 15/W).. S0602180K
Rear Axle (Volvo SLA 12/W) .. S0602190K
Parking Brake Caliper (Volvo) …S0603000
Air Conditioner .. S0605050K
Transmission and Torque Converter (ZF 4WG-210) .. S0607090K
Transmission Error Codes (ZF) .. S0607900C
Hydraulics
Accumulator…S0703000
Cylinders… S0705005K
Fan Drive Hydraulic Motor (Haldex) … S0707100K
Main Pump (Denison) … S0708485K
Brake Pedal Valve .. S0709250K
Main Control Valve (Toshiba) … S0709456K
Pilot Control Valve .. S0709477K
Priority Valve (Danfoss) .. S0709651K
Power Steering Unit.. S0709730K
Restriction Valve… S0709751K
Hydraulic Schematic (Mega 300-V) .. S0793070K
Electrical System
Electrical System .. S0802200K
Electrical Schematic (Mega 300-V) .. S0893070K
Attachments
02200015BE – Mega 300-V Operation and Maintenance Manual…2
Safety…8
To the Operator of a Daewoo Wheel Loader…8
General Safety Essentials…9
Location of Safety Labels…10
Unauthorized Modifications…18
Work Site Precautions…18
Operation…20
Equipment…25
Maintenance…29
Shipping and Transportation…32
Operating Controls…34
Component Locations…35
Control Identification…37
Steering Console and Pedals…38
Transmission Display…45
Front Instrument Panel…47
Right Side Switch Panel…56
Various Cabin Locations…66
Heater and Air Conditioner Operation…70
Stereo…75
Seat Adjustment…79
Seat Belt…81
Door side latch…82
Fuse Box/Relay…83
Window Glass Breaking Tool…86
Operation…88
Instrument Panel Control Functions…88
New Machine Break-in Procedures…88
Engine Start and Stop…89
Machine Travel…98
Machine Shut Down…100
Additional Braking…102
Boom Raise Kickout…103
Bucket Angle Indicator…103
Boom Lower Kickout (Option)…104
Adjustment of Bucket Position Switch…104
Towing Machine…105
If Engine Stalls While Traveling…106
Allowable Water Depth…106
Inspection, Maintenance and Adjustment…108
Preventive Maintenance…108
Table of Recommended Lubricants…110
Fluid Capacities…112
Maintenance Intervals…113
10 Hour / Daily Service…116
50 Hour / Weekly Service…127
250 Hour / Monthly Service…134
500 Hour / 3 Month Service…142
1,000 Hour / 6 Month Service…145
1,500 Hour / 9 Month Service…151
2,000 Hour / Yearly Service…153
12,000 Hour / Six Year Service…158
Severe Conditions Maintenance…159
General Maintenance…160
Parking Brake Adjustment…162
Check Hydraulic Pressures…163
Tires and Wheels…167
Electrical System…169
Bolt Torque Chart…170
Long Term Storage…171
Transportation…172
Loading Machine on a Trailer…172
Summary of Safety Precautions for Lifting…173
Troubleshooting…174
Engine…174
Hydraulic System…176
Travel System…178
Steering…182
Braking…183
Electrical System…183
Specifications…184
General Specifications…184
Working Range and Dimensions…187
Working Capacities…189
Approximate Weight of Workload Materials…189
Index…192
023-00041AE – Mega 300-V Shop Manual…198
Safety…204
Wheel Loader Safety S0103010K…206
To the Operator of a Daewoo Wheel Loader…208
Learn Signal Words Used with Safety Alert Symbol…210
General Safety Essentials…211
Accessory Applications…211
Location of Safety Labels…211
Unauthorized Modifications…211
General Hazard Information…212
Safety Rules…212
Safety Features…212
Inside Operator's Compartment…213
Clothing and Personal Protective Items…213
Breathing Masks, Ear Protection May Be Required…214
Asbestos Dust Hazard Prevention…214
Mounting and Dismounting…214
Fuel, Oil and Hydraulic Fluid Fire Hazards…215
Precautions When Handling Fluids at High Temperature…215
Injury from Work Equipment…216
Fire Extinguisher and First Aid Kit…216
Protection from Falling or Flying Objects…217
Install Additional Safety Equipment If Conditions Require…217
Maintain Standard Safety Equipment in Good Condition…217
Attachment Precautions…218
Accumulator…218
Engine Ventilation…218
Window Glass Breaking Tool…219
Before Starting Engine…220
Work Site Precautions…220
Checks Before Starting Engine…221
Engine Starting…221
Before Operating Machine…222
Machine Operation…223
Operate While Seated at Operator’s Station ONLY…223
Seat Belts Should Be Used at All Times…223
Movement Alarms…223
Travel Precautions…224
Sloping Terrain Requires Caution…224
Avoid High-voltage Cables…225
Before Starting to Dig, Contact Authorities…225
Be Aware of Height Obstacles…225
Use Care on Loose Support…225
Use Solid Support Blocking…226
Digging Beneath Overhangs…226
Digging Beneath Wheel Loader…226
Stay Alert for People Moving Through Work Area…226
Be Aware of and Conform to Local Regulations…226
Never Use Ether Starting Aids…227
Observe General Safety Rules…227
Take Time to Provide Good Visibility…227
Keep "Pinch Point" Areas Clear – Use Caution in Reverse…228
Operate Carefully on Snow and Ice and in Very Cold Temperatures…228
Parking Machine…228
Shutdown Control Functions…229
Never Let Anyone Ride on Attachment…229
Maintenance…230
Use Warning Tag During Service…230
clean Before Inspection or Maintenance…230
Proper Tools…231
Use of Lighting…231
Fire Prevention and Explosion Prevention…231
Burn Prevention…232
Welding Repairs…233
Precautions for Removal, Installation, and Storage of Attachments…233
Precautions When Working on Machine…234
Lock Inspection Covers…234
Crushing Prevention and Cutting Prevention…234
Do Not Run Engine If Repairs or Work Are Being Performed Alone…234
Always Use Adequate Equipment Supports and Blocking…235
Do Not Work on Hot Engines or Hot Cooling or Hydraulic Systems…235
Hydraulic Cylinder Seals Require Periodic Replacement…235
High Pressure Hydraulic Lines Can Store a Great Deal of Energy…235
Precautions with High Pressure Line, Tubes and Hoses…236
Obtain Immediate Medical Attention if Pressurized Oil Pierces Skin…236
Use Correct Replacement Fasteners Tightened to Proper Torque…237
Safety-critical Parts Must Be Replaced Periodically…237
Dispose of All Petroleum-based Oils and Fluids Properly…237
Check Tire Pressure and Condition…237
Battery…238
Battery Hazard Prevention…238
Disconnect Batteries Before Electrical Service or Electrical Welding…238
Use Low Heat Portable Lighting…239
Boost Starting or Charging Engine Batteries…239
Towing…240
Precautions When Towing…240
Shipping and Transportation…241
Obey State and Local Over-the-Road Regulations…241
Summary of Safety Precautions for Lifting…241
Specifications…242
Specifications for Mega 300-V S0203080K…244
Component Locations…247
General Specifications…249
Engine Performance Curves…251
Working Range and Dimensions…255
Working Capacities…258
Bucket Capacity…258
Tipping Load…258
Material Weight…258
Approximate Weight of Workload Materials…258
General Maintenance…262
General Maintenance Procedures S0302000…264
Welding Precautions and Guidelines…266
Hydraulic System – General Precautions…267
Maintenance Service and Repair Procedure…268
General Precautions…268
Hydraulic System Cleanliness and Oil Leaks…269
Maintenance Precautions for Hydraulic System Service…269
Oil Leakage Precautions…269
Cleaning and Inspection…270
General Guidelines…270
Bearing inspection…271
Standard Torques S0309000…278
Torque Values for Standard Metric Fasteners…280
Torque Values for Standard U.S. Fasteners…281
Type 8 Phosphate Coated Hardware…283
Torque Values for Hose Clamps…284
Torque Values for Split Flanges…285
Torque Wrench Extension Tools…286
Torque Multiplication…286
Other Uses for Torque Wrench Extension Tools…287
Tightening Torque Specifications (Metric)…287
Upper Structure…290
Counterweight S0403030K…292
Specifications…294
Counterweight…294
Fuel Transfer Pump S0405500…296
General Description…298
Theory of Operation…298
Troubleshooting…299
Replacement of Rotor and Vane…299
Replacement of Rear Cover…300
Replacement of Armature…301
Hydraulic Oil Tank S0406050K…302
General Description…304
Parts List…304
Specifications…305
Lower Structure and Chassis…306
Center Joint (Articulation Joint) S0502030K…308
General Description…310
Maintenance Standard…311
Engine and Drive Train…314
Front Axle (Volvo SLA15/W) S0602180K…316
General Description…320
Outline…320
Drive Axle…320
Differential (Standard)…323
Parking Brake Operation…324
Parts List…326
Scheduled Maintenance…335
After First 250 Hours…335
Every 150 hours…335
Every 1500 Hours…336
Lubricant Specifications…336
General Disassembly and Reassembly Instructions…337
General Instructions…337
Assembling Leakproof Components…338
Axle Disassembly…338
Drain Oil…338
Final Drive…339
Differential Assembly…343
Overhauling Super Max Trac Assembly…346
Checking Clearance on Assembled Disc Packs…346
Axle Reassembly…347
Determining Thickness of Adjustment Shims…347
Inner Oil Recirculation Piping…348
Differential Assembly…349
Axial Position of Bevel Pinion…349
Adjusting Backlash…350
Adjusting Tooth Contact…351
Securing Differential to Axle Housing…354
Final Drive…355
Determining Space Available to Form Brake Disc Pack…357
Parking Brake (S/N 1001 thru 2000)…359
Disassembly…360
Reassembly…360
Adjustment…360
Parking Brake (S/N 2001 and Up)…361
Rear Axle (Volvo SLA12/W) S0602190K…362
General Description…366
Outline…366
Drive Axle…366
Differential (Standard)…369
Parts List…372
Scheduled Maintenance…377
After First 250 Hours…377
Every 150 hours…378
Every 1500 Hours…378
Lubricant Specifications…378
General Disassembly and Reassembly Instructions…379
General Instructions…379
Assembling Leakproof Components…380
Axle Disassembly…380
Drain Oil…380
Final Drive…381
Differential Assembly…386
Overhauling Super Max Trac Assembly…389
Checking Clearance on Assembled Disc Packs…389
Axle Reassembly…390
Determining Thickness of Adjustment Shims…390
Differential Assembly…391
Axial Position of Bevel Pinion…391
Adjusting Backlash…392
Adjusting Tooth Contact…393
Securing Differential to Axle Housing…396
Final Drive…397
Determining Space Available to Form Brake Disc Pack…399
Parking Brake Caliper (Volvo) S0603000…400
General Description…402
Operation…402
Parking Brake Applied…403
Parking Brake Released…403
Parts List…404
Special Tools and Materials…404
Lubricants and Sealants…404
Troubleshooting, Testing and Adjustment…405
Parking Brake System…405
Checking and Adjusting Parking Brake…405
Measuring Pad Thickness…405
Measuring Disc / Pad Clearance…405
Measuring Procedure…406
Adjustment…406
Releasing the Parking Brake in Emergency Case…407
Disassembly…408
General…408
Changing Brake Pads…408
Work Sequence During Change of Brake Pads…408
Cleaning and Inspection (Wear Limits and Tolerances)…410
Reassembly…412
Air Conditioner S0605050K…418
General Description…420
Refrigerant Circulation…421
Control Panel…423
Control Specifications…424
Temperature Level Control and Display…425
Air Discharge According to Path Selection…426
Air-conditioning System Circuit Diagram…429
Troubleshooting…431
Weight of R134a Gas Used In Machines…435
Refrigerant System Repairs…437
Refrigerant Safe Handling Procedures…437
Repair and Replacement Procedure…438
Refrigerant Recovery…440
Vacuuming Refrigerant System…440
Leakage Check…441
Refrigerant Charging…442
Inspecting System For Leakage…444
Transmission and Torque Converter (ZF4WG210) S0607090K…446
Drive Train Description…451
Transmission and Torque Converter…452
Powershift Transmission…453
Transmission Control…453
Schedule of Measuring Points and Connection 4 WG-210…455
Oil Circuit Diagram 4WG-210 Forward 1st Speed…457
Transmission Electrical Components…459
TCU (Transmission Control Unit)…460
Transmission Control Valve…460
Transmission Oil Temperature Sensor…461
Engine Pick-up Sensor…461
Central Gear Pick-up Sensor…461
Turbine Pick-Up Sensor…462
Output Speed Sensor…462
Shift Lever Switch (DW-3)…462
Auto Select Switch…464
Display…464
Transmission Faults Codes…465
Fault Display…465
CAN – Message…465
Description of Fault Codes…465
Abbreviations…466
Definition of Operation Modes…466
Table of Fault Codes…467
Measurement of Resistance at Actuator/sensors and Cable…467
Transmission Electrical Circuits…469
Transmission Controller Circuit…469
Traveling Circuits…471
Kick-down…479
Transmission Cutoff…484
LIS (Load Isolation System) – Option…486
Installation View (S/N 1001 thru 2000)…489
Inner Section…489
Front View…490
Front View with Disc Brake…491
Side View…492
Side View with Disc Brake…493
Rear View…494
Rear View with Disc Brake…495
Installation View (S/N 2001 and Up)…497
Inner Section…497
Front View…498
Front View with Disc Brake…499
Side View…500
Side View with Disc Brake…501
Rear View…502
Rear View with Disc Brake…503
Special Tools…504
Gearshift System…504
Engine Connection…506
Pressure Oil Pump…507
Gearbox Housing…508
Input…510
Coupling…511
Output…517
Power Take-off…518
Hydraulic Control Unit (HSG-94)…519
Disassembly…521
Reassembly…524
Transmission Disassembly…530
Hydraulic Control Unit (HSG-94) and Duct plate…530
Engine Connection – Converter…531
Hydraulic Pump…533
Converter Back Pressure Valve…534
Remove Output, Input and Clutches…535
Disassemble Clutch – KV and KR…540
Disassemble Clutch – K1, K2 and K3…543
Disassemble Clutch – K4…545
Disassemble Drive Shaft…546
Transmission Reassembly…548
Install Oil Tube…548
Reassemble Clutch – KV and KR…550
Reassemble Clutch – K1, K2 and K3…557
Reassemble Clutch – K4…564
Pre-assemble Drive Shaft…570
Pre-assemble and Install Output…571
Install Pre-assembled Drive Shaft and Clutches…573
Install Pump Shaft (Power Take-off)…576
Install Output Flanges…577
Converter Back Pressure Valve…579
Oil Feed Housing – Transmission Pump…579
Engine Connection – Converter…581
Converter Safety Valve…584
Mount Duct Plate and Hydraulic Control Unit…584
Install Plugs and Oil Level Tube…585
Speed Sensor and Inductive Transmitters…586
Transmission Error Codes (ZF) S0607900C…588
Introduction…591
Abbreviations…591
Display…591
Description of Fault Codes…592
Display During Operation…593
Definition of Operating Modes…595
Normal…595
Substitute Clutch Control…595
Limp-home…595
Transmission shut Down…595
TCU Shut Down…595
Clutch Pack and Solenoid Valve Cross-reference Table…596
Table of Fault Codes…597
Table of Fault Codes – ERGO-Control…619
Measurement of Resistance at Actuator/ sensors and Cable…622
Actuator…622
Cable…622
Hydraulics…624
Accumulator S0703000…626
General Description…628
Specifications…629
Accumulator Charging…632
Charging the Accumulator with Nitrogen…632
Cylinders S0705005K…634
General Description…637
Theory of Operation…638
Parts List…639
Troubleshooting, Testing and Adjustment…645
Disassembly…649
Cleaning and Inspection (Wear Limits and Tolerances)…651
Reassembly…652
Fan Drive Hydraulic Motor (Haldex) S0707100K…660
General Description…662
Theory of Operation…662
Parts List…664
Specifications…665
Main Pump (Denison) S0708485K…666
General Description…669
General…669
Description…669
Theory of Operation…670
Parts List…673
Specifications…675
Special Tools…676
Seal Driver…676
Protective Cone…676
Troubleshooting…677
Overhaul…679
General…679
Changing Rotation…680
Changing Cartridges…681
Changing Port Locations…681
Changing Shaft or Shaft Seal…682
Disassembly of Pump…683
Reassembly of Pump…684
Disassembly of "C" Cartridge…687
Reassembly of "C" Cartridge…688
Disassembly of "D" Cartridge…689
Reassembly of "D" Cartridge…690
Installation…691
Mounting…691
Piping…691
Fluids…692
Start-up Procedures…694
Pre-start Check…694
Priming…694
Brake Pedal Valve S0709250K…696
General Description…698
Theory of Operation…698
Specification…699
Brake System (S/N 1001 thru 2000)…700
Brake System (S/N 2001 and Up)…701
Brake, Pilot and Fan Motor Supply Valve…702
Specifications (S/N 1001 thru 2000)…703
Specifications (S/N 2001 and Up)…704
Main Control Valve (Toshiba) S0709456K…706
General Description…708
Specifications…710
Operation…711
Neutral…711
Bucket/option Spool Operation…711
Boom Spool Operation…712
Relief Valve…712
Operation (Main Relief Valve)…713
Operation (Port Relief Valve)…714
Pilot Control Valve S0709477K…716
General Description (S/N 1001 thru 2000)…718
Pilot Valve Operation…718
General Description (S/N 2001 and up)…720
Pilot Valve Operation…720
Standard…721
Option…723
Pilot System…725
Priority Valve (Danfoss) S0709651K…728
General Description…731
Theory of Operation…731
Parts List…732
Specifications…733
Disassembly…733
Reassembly…736
Power Steering Unit S0709730K…738
General Description…740
Power Steering System…740
Gerotor Operation…742
Cushion Valve Operation…743
Parts List…745
Specifications…746
Special Tools…747
Troubleshooting, Testing and Adjustment…749
Disassembly…750
Cleaning and Inspection…754
Reassembly…755
Installation…766
Restriction Valve S0709751K…768
General Description…770
Theory of Operation…770
UNLOADING CIRCUIT (S/N 1001 thru 2000)…771
UNLOADING CIRCUIT (S/N 2001 and Up)…772
Unloader Cartridge Identification (S/N 1001 thru 2000)…773
Unloader Cartridge Identification (S/N 2001 and Up)…774
Specifications…775
Hydraulic Schematic (Mega 300-V) S0793070K…776
General Description…778
Mega 300-V (Tier I) (S/N 1001 thru 2000)…779
Mega 300-V (Tier II) (S/N 2001 and Up)…781
Electrical System…784
Electrical System S0802200K…786
Overview…789
Electric Supply System…791
Engine Starting Circuit…793
Operation During Start Process…793
Operation After Start Process…795
Engine Preheating System (S/N 1001 thru 2000)…797
Principle of Operation…797
Engine Preheating System (S/N 2001 and Up)…799
Principle Of Operation…799
Engine Stop System…801
Operation In Engine Running Mode…801
Operation In Engine Stop Mode…803
Charging System…805
Monitoring System…806
Monitoring System (S/N 1001 thru 2000)…806
Instrument Panel (S/N 1001 thru 2000)…807
Function Check (S/N 1001 thru 2000)…808
Monitoring System Schematic (S/N 1001 thru 2000)…809
Monitoring System (S/N 2001 and Up)…811
Instrument Panel (S/N 2001 and Up)…812
Function Check (S/N 2001 and Up)…813
Monitoring System Schematic (S/N 2001 and Up)…813
Operation…815
Windshield Wiper…821
Front windshield wiper…821
Rear Windshield wiper…822
Lighting System…825
Light Circuit (S/N 1001 thru 2000)…825
Light Circuit (S/N 2001 and Up)…829
Emergency Steering System (Option)…833
Block Diagram…833
Emergency Steering System Components…834
Emergency Steering System Electric Circuit…836
Electric Detent System…837
Electric Circuit…837
Boom Kick-Out…837
Return To Dig…838
Electrical Schematic (Mega 300-V) S0893070K…840
General Description…842
Mega 300-V…843
Attachments…846
2023-7105E – Mega 300-III Shop Manual
M300-III Hydraulic Diagram…1125
M300-III(DE12T) Electrical Schematics…1126
M300-V Electrical Circuit…1127
M300-V Hydraulic Circuit…1128
M300-V INJ. Pump Calibration Data…1129
M300-V Performance Data…1130
Daewoo Mega 300 Wheel Loader Repair Service Manuals