Complete service repair manual with Electrical Wiring Diagrams for Daewoo / Doosan MEGA 400-V Wheel Loader , with all the service information to maintain, diagnose, repair, and rebuild like professional mechanics.
Daewoo M400-V Wheel Loader workshop 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.
023-00040E – Daewoo MEGA 400-V SHOP MANUAL (Serial Number 1001 and Up).pdf
OPERATION MANUAL.pdf
ELECTRICAL SHEMATIC.pdf
M400 HİDROLİK ŞEMA.pdf
MG400-V ELECTRICAL SYSTEM.pdf
MG400-V HYD.CONT.UNIT HSG.94.pdf
MG400-V HYDRAULIC.pdf
MG400-V LOWERSTRUCTURE.pdf
MG400-V M.C.V. TOSHIBA.pdf
MG400-V POWER STEERING UNIT.pdf
MG400-V SPECIFICATIONS.pdf
MG400-V TM & CONV. ZF.pdf
MG400-V TM ERROR CODES ZF.pdf
MG400-V TRANSM. REASSEMBLY.pdf
MG400-V UPPERSTRUCTURE.pdf
S0602150K.pdf
S0607080K – Doosan M500, M500 Tier 2 Transmission ZF 4WG-310 Service Manual.pdf
Total Pages: 1,202 pages
File Format: PDF
Language: English
TABLE OF CONTENTS
Return to Master Table of Contents
Safety
Wheel Loader Safety .. S0103010K
Specifications
Specifications for Mega 400-V.. S0203060K
General Maintenance
General Maintenance Procedures …S0302000
Standard Torques ..S0309000
Upper Structure
Counterweight… S0403030K
Fuel Transfer Pump …S0405500
Hydraulic oil tank .. S0406030K
Lower Structure and Chassis
Center Joint (Articulation Joint)… S0502010K
Engine and Drive Train
Front Axle … S0602150K
Rear Axle .. S0602160K
Air-Conditioner.. S0605050K
Transmission and Torque Converter (ZF) .. S0607070K
Transmission Error Codes (ZF) .. S0607900C
Hydraulics
Accumulator…S0703000
Cylinders..S0705010
Fan Drive Hydraulic Motor (Haldex) … S0707100K
Main Pump (Denison T6DMY Series)… S0708460K
Steering and Brake Pump (Denison T67DB Siries).. S0708470K
Brake Pedal Valve .. S0709230K
Main Control Valve (Toshiba) … S0709455K
Pilot Control Valve .. S0709475K
Flow Amplifier (Danfoss)… S0709665K
Power Steering Unit.. S0709730K
Unloader Valve … S0709850K
Hydraulic Schematic (Mega 400-V) .. S0793050K
Electrical System
Electrical System .. S0802180K
Electrical Schematic (Mega 400-V) .. S0893050K
023-00040E – Daewoo MG400-V SHOP MANUAL (Serial Number 1001 and Up)….2
Safety….6
Wheel Loader Safety S0103010K….8
To the Operator of a Daewoo Wheel Loader….10
Learn Signal Words Used with Safety Alert Symbol….11
General Safety Essentials….11
Accessory Applications….11
Location of Safety Labels….12
Unauthorized Modifications….12
Work-Site Precautions….13
Attachment Precautions….13
Avoid High-voltage Cables….13
Before Starting to Dig, Contact Authorities….13
Be Aware of Height Obstacles….13
Use Care on Loose Support….13
Use Solid Support Blocking….14
Digging Beneath Overhangs….14
Digging Beneath Wheel Loader….14
Sloping Terrain Requires Caution….14
Stay Alert for People Moving through Work Area….15
Be Aware of and Conform to Local Regulations….15
Operation….15
Operate While Seated at Operator’s Station ONLY….15
Before Starting Engine, do a “pre-start” safety check:….16
Never Use Ether Starting Aids….16
Mounting and Dismounting….16
Observe General Safety Rules….17
Engine Ventilation….17
Asbestos Dust Hazard Prevention….17
Take Time to Provide Good Visibility….17
Fuel, Oil and Hydraulic Fluid Fire Hazards….18
Boost Starting or Charging Engine Batteries….18
Keep “Pinch Point” Areas Clear – Use Caution in Reverse….19
Travel Precautions….19
Operate Carefully on Snow and Ice and in Very Cold Temperatures….19
Parking Machine….19
Shutdown Control Functions….20
Equipment….20
Rough Operation May Require Use of Certified Safety Equipment….20
Install Additional Safety Equipment If Conditions Require….21
Movement Alarms….21
Seat Belts Should Be Used at All Times….21
Window Glass Breaking Tool….21
Keep a Fire Extinguisher at Hand….22
Maintain Standard Safety Equipment in Good Condition….22
Safety-critical Parts Must Be Replaced Periodically….22
Hydraulic Cylinder Seals Require Periodic Replacement….22
High Pressure Hydraulic Lines Can Store a Great Deal of Energy….22
Operator’s Cab Should Be Kept Clean….22
Wear Eye Protection and Safety Clothing – Use Proper Tools….23
Breathing Masks, Ear Protection May Be Required….23
Asbestos Fiber Hazard….23
Battery Electrolyte and Explosive Gases Can Be Lethal….23
Disconnect Batteries Before Electrical Service or Electrical Welding….23
Use Low Heat Portable Lighting….24
Maintenance….24
Use Warning Tag during Service….24
Do Not Run Engine If Repairs or Work Are Being Performed Alone….24
Always Use Adequate Equipment Supports and Blocking….24
Do Not Work on Hot Engines or Hot Cooling or Hydraulic Systems….24
Cool-down Is Required Prior to Radiator or Reservoir Checks….25
Pressurized Hydraulic Oil Fluid Leaks Can Be Dangerous….25
Obtain immediate medical attention if pressurized oil pierces skin…..25
Use Correct Replacement Fasteners Tightened to Proper Torque….25
Dispose of All Petroleum-based Oils and Fluids Properly….26
Check Tire Pressure and Condition….26
Shipping and Transportation….27
Obey State and Local Over-the-Road Regulations….27
Summary of Safety Precautions for Lifting….27
Specifications….28
Specifications for Mega 400-V S0203060K….30
Component Locations….33
General Specifications….35
Engine Performance Curves….37
Working Range and Dimensions….39
Working Capacities….42
Bucket Capacity….42
Tipping Load….42
Material Weight….42
Approximate Weight of Workload Materials….42
General Maintenance….46
General Maintenance Procedures S0302000….48
Welding Precautions and Guidelines….50
Hydraulic System – General Precautions….51
Maintenance Service and Repair Procedure….52
General Precautions….52
Hydraulic System Cleanliness and Oil Leaks….53
Maintenance Precautions for Hydraulic System Service….53
Oil Leakage Precautions….53
Cleaning and Inspection….54
General Guidelines….54
Bearing inspection….55
Standard Torques S0309000….62
Torque Values for Standard Metric Fasteners….64
Torque Values for Standard U.S. Fasteners….65
Type 8 Phosphate Coated Hardware….67
Torque Values for Hose Clamps….68
Torque Values for Split Flanges….69
Torque Wrench Extension Tools….70
Torque Multiplication….70
Other Uses for Torque Wrench Extension Tools….71
Tightening Torque Specifications (Metric)….71
Upper Structure….74
Counterweight S0403030K….76
Specifications….78
Counterweight….78
Fuel Transfer Pump S0405500….80
General Description….82
Theory of Operation….82
Replacement of Rotor and Vane….83
Replacement of Rear Cover….83
Replacement of Armature….84
Hydraulic oil tank S0406030K….86
General Description….88
Parts List….88
Specifications….89
Lower Structure and Chassis….90
Center Joint (Articulation Joint) S0502010K….92
General Description….94
Maintenance Standard….95
Engine and Drive Train….98
Front Axle S0602150K….100
General Description….104
Outline….104
Drive Axle….104
Differential (Standard)….107
Parking Brake Operation….108
Parts List….110
Scheduled Maintenance….117
After First 250 Hours….117
Every 150 hours….117
Every 1500 Hours….118
Lubricant Specifications….118
General Disassembly and Reassembly Instructions….119
General Instructions….119
Assembling Leakproof Components….120
Axle Disassembly….120
Drain Oil….120
Final Drive….121
Differential Assembly….125
Overhauling Super Max Trac Assembly….129
Checking Clearance on Assembled Disc Packs….130
Axle Reassembly….131
Determining Thickness of Adjustment Shims….131
Inner Oil Recirculation Piping….132
Differential Assembly….133
Axial Position of Bevel Pinion….133
Adjusting Backlash….134
Adjusting Tooth Contact….135
Securing Differential to Axle Housing….138
Final Drive….139
Determining Space Available to Form Brake Disc Pack….141
Parking Brake….143
Disassembly….144
Reassembly….144
Adjustment….144
Rear Axle S0602160K….146
General Description….148
Outline….148
Drive Axle….148
Differential (Standard)….151
Parts List….154
Scheduled Maintenance….159
After First 250 Hours….159
Every 150 hours….160
Every 1500 Hours….160
Lubricant Specifications….160
General Disassembly and Reassembly Instructions….161
General Instructions….161
Assembling Leakproof Components….162
Axle Disassembly….162
Drain Oil….162
Final Drive….163
Differential Assembly….168
Overhauling Super Max Trac Assembly….170
Checking Clearance on Assembled Disc Packs….171
Axle Reassembly….172
Determining Thickness of Adjustment Shims….172
Differential Assembly….173
Axial Position of Bevel Pinion….173
Adjusting Backlash….174
Adjusting Tooth Contact….175
Securing Differential to Axle Housing….178
Final Drive….179
Determining Space Available to Form Brake Disc Pack….181
Air-Conditioner S0605050K….182
General Description….184
Refrigerant Circulation….185
Control Panel….187
Control Specifications….188
Temperature Level Control and Display….189
Air Discharge According to Path Selection….190
Air-conditioning System Circuit Diagram….193
Troubleshooting….195
Refrigerant System Repairs….198
Refrigerant Safe Handling Procedures….198
Repair and Replacement Procedure….199
Refrigerant Recovery….201
Vacuuming Refrigerant System….201
Leakage Check….202
Refrigerant Charging….203
Inspecting System For Leakage….205
Transmission and Torque Converter (ZF) S0607070K….206
Drive Train Description….210
Transmission and Torque Converter….211
Powershift Transmission….212
Transmission Control….212
Schedule of Measuring Points and Connection 4 WG-260….213
Oil Circuit Diagram 4WG – 260 Forward 1st Speed….216
Transmission Electric Components….218
TCU (Transmission Control Unit)….219
Transmission Control Valve….219
Transmission Oil Temperature Sensor….220
Engine Pick-Up Sensor….220
Central Gear Pick-Up Sensor….220
Turbine Pick-Up Sensor….221
Output Speed Sensor….221
Shift Lever Switch (DW-3)….221
Auto Select Switch….223
Display….223
Transmission Electrical Circuits….224
T/M Controller Circuit….224
Travelling Circuits….225
Downshift….233
Transmission Cut Off….236
LIS (Load Isolation System) – Option….237
Installation View….239
Inner Section….239
Front View….241
Side View….242
Rear View….243
Hydraulic Control Unit (HSG94)….244
Disassembly….245
Reassembly….248
Transmission Disassembly….255
Converter-Input….255
Drive Shaft Pump Power Take-off….258
Transmission Pump….260
Output- Layshaft Assembly….260
Disassemble Clutches and Layshaft Gear….265
Disassemble Power Take-off II….266
Disassemble Clutches….267
Transmission Reassembly….276
Power Take-off II….276
Clutch K3/K4….278
Clutch KR/K2….289
Clutch – KV/K1….297
Install Multi-disk Clutches, Layshaft Gear and Output Gear….305
Install Filter….320
Hydraulic Pump….320
Drive Shaft (Power Take-off Pump)….322
Input – Converter….326
Converter….331
Mount Hydraulic Control Unit (HSG94)….332
Inductive Transmitter and Speed Sensor….335
Setting Inductive Transmitter….337
Speed Sensor (Hall Sensor) N Output And Speedometer….339
Transmission Error Codes (ZF) S0607900C….340
Abbreviations….342
Display….342
Display during operation….343
Definition of operating modes….345
Normal….345
Substitute Clutch Control….345
Limp-home….345
Transmission-shutdown….345
TCU-shutdown….345
Table of fault codes….346
Measurement of Resistance at Actuator/ sensors and Cable….364
Actuator….364
Cable….364
Hydraulics….366
Accumulator S0703000….368
General Description….370
Specifications….371
Accumulator Charging….373
Charging the Accumulator with Nitrogen….373
Cylinders S0705010….376
General Description….378
Theory of Operation….379
Parts List….380
Troubleshooting, Testing and Adjustment….382
Disassembly….385
Cleaning and Inspection (Wear Limits and Tolerances)….387
Reassembly….388
Fan Drive Hydraulic Motor (Haldex) S0707100K….396
General Description….398
Theory of Operation….398
Parts List….400
Specifications….401
Main Pump (Denison T6DMY Series) S0708460K….402
General Description….404
Construction….404
Principles of Operation….406
Parts List….413
Specifications….414
Special Tools and Materials….415
Special Tools….415
Troubleshooting, Testing and Adjustment….416
Disassembly….418
Cleaning and Inspection (Wear Limits and Tolerances)….422
Reassembly….423
Start-up Procedures….426
Steering and Brake Pump (Denison T67DB Siries) S0708470K….428
General Description….430
Parts List….431
Special Tools….433
Troubleshooting, Testing and Adjustment….434
Service and Maintenance….435
Circuit Inspection….435
Adding Hydraulic Oil to System….435
Adjustments….435
Lubrication….435
Replacement Parts….436
Disassembly….437
Baisc Pump Disassembly….439
Cartridge Disassembly….440
Cleaning and Inspection (Wear Limits and Tolerances)….443
Cleaning….443
Inspection, Repair and Replacement….443
Reassembly….445
Cartridge Assembly….446
Basic Pump Assembly….449
Start-up Procedures….450
Start-up….450
Test….450
Brake Pedal Valve S0709230K….452
General Description….454
Theory of Operation….454
Specification….455
Brake System….456
Brake, Pilot, and Fan Motor Supply Valve….457
Specifications….458
Main Control Valve (Toshiba) S0709455K….460
General Description….462
Specifications….464
Operation….465
Neutral….465
Bucket/option Spool Operation….465
Boom Spool Operation….466
Relief Valve….466
Operation (Main Relief Valve)….467
Operation (Port Relief Valve)….468
Pilot Control Valve S0709475K….470
General Description….472
Pilot Valve Operation….472
Pilot System….475
Flow Amplifier (Danfoss) S0709665K….478
General Description….480
Parts List….481
Specifications….482
Special Tools and Materials….483
Special tools….483
Troubleshooting, Testing and Adjustment….484
Steering System with OSQA/B and OSPBX-LS….485
Disassembly….486
Cleaning and Inspection (Wear Limits and Tolerances)….506
Cleaning….506
Inspection and replacement….506
Lubrication….506
Reassembly….506
Power Steering Unit S0709730K….526
General Description….528
Power Steering System….528
Gerotor Operation….530
Cushion Valve Operation….531
Parts List….533
Specifications….534
Special Tools….535
Troubleshooting, Testing and Adjustment….537
Disassembly….538
Cleaning and Inspection….542
Reassembly….543
Installation….554
Unloader Valve S0709850K….556
General Description….558
Theory of Operation….558
Unloader Cartridge Identification….560
Specifications….561
Hydraulic Schematic (Mega 400-V) S0793050K….562
General Description….564
Mega 400-V….565
Electrical System….568
Electrical System S0802180K….570
Overview….572
Electric Supply System….573
Engine Starting Circuit….575
Operation During Start Process….575
Operation After Start Process….577
Engine Preheating System….579
Principle Of Operation….579
Engine Stop System….581
Operation In Engine Running Mode….581
Operation In Engine Stop Mode….583
Charging System….585
Monitoring System….586
Instrument Panel….587
Function Check….588
Monitoring System Schematic….589
Operation….591
Windshield Wiper….597
Front windshield wiper….597
Rear Windshield wiper….598
Lighting System….601
Light Circuit….601
Emergency Steering System (Option)….605
Block Diagram….605
Emergency Steering System Components….606
Emergency Steering System Electric Circuit….608
Electric Detent System….609
Electric Circuit….609
Boom Kick-Out….609
Return To Dig….610
Electrical Schematic (Mega 400-V) S0893050K….612
General Description….614
Mega 400-V….615
Attachments….618
ELECTRICAL SHEMATIC….620
M400 HİDROLİK ŞEMA….621
MG400-V ELECTRICAL SYSTEM….622
MG400-V HYD.CONT.UNIT HSG.94….672
MG400-V HYDRAULIC….704
MG400-V LOWERSTRUCTURE….798
MG400-V M.C.V. TOSHIBA….806
MG400-V POWER STEERING UNIT….872
MG400-V SPECIFICATIONS….914
MG400-V TM & CONV. ZF….932
MG400-V TM ERROR CODES ZF….970
MG400-V TRANSM. REASSEMBLY….996
MG400-V UPPERSTRUCTURE….1040
OPERATION MANUAL….1056
Safety….1062
To the Operator of a Daewoo Wheel Loader….1062
Learn Signal Words Used with Safety Alert Symbol….1063
General Safety Essentials….1063
Accessory Applications….1063
Location of Safety Labels….1064
1. Warning for operation, inspection and maintenance (4190-2545, 190-00092)….1065
2. Warnings for Engine Fan (2190-2525, 190-00557)….1065
3. Warnings when opening engine hood (2190-2525, 190-00095)….1066
4. Warning for handling accumulator (2190-2528, 190-00099)….1067
5. Keep Out of steering turn area (4190-1992, 190-00120)….1068
6. Warning for high temperature hydraulic oil (2190-2529, 190-00097)….1068
7. Warning for high temperature coolant (2190-2531, 190-00097)….1069
8. Warning for battery maintenance (2190-2533, 190-00100)….1069
9. Warning for riding on machine (4190-1989, 190-00107)….1070
10. Warning for performing maintenance on front attachment (4190-2546, 190-00105)….1070
11. Warning to use safety lock (4190-1993, 190-00121)….1071
12. Warning Tag (2190-2549, 190-00098)….1071
Unauthorized Modifications….1072
Work-Site Precautions….1072
Attachment Precautions….1072
Avoid High-voltage Cables….1072
Before Starting to Dig, Contact Authorities….1073
Be Aware of Height Obstacles….1073
Use Care on Loose Support….1073
Use Solid Support Blocking….1073
Digging Beneath Overhangs….1073
Digging Beneath Wheel Loader….1073
Sloping Terrain Requires Caution….1073
Stay Alert for People Moving through Work Area….1074
Be Aware of and Conform to Local Regulations….1074
Operation….1074
Operate While Seated at Operator’s Station ONLY….1074
Before Starting Engine, do a "pre-start" safety check:….1075
Never Use Ether Starting Aids….1075
Mounting and Dismounting….1075
Observe General Safety Rules….1076
Engine Ventilation….1076
Asbestos Dust Hazard Prevention….1076
Take Time to Provide Good Visibility….1076
Fuel, Oil and Hydraulic Fluid Fire Hazards….1077
Boost Starting or Charging Engine Batteries….1077
Keep "Pinch Point" Areas Clear – Use Caution in Reverse….1078
Travel Precautions….1078
Operate Carefully on Snow and Ice and in Very Cold Temperatures….1078
Parking Machine….1078
Shutdown Control Functions….1079
Equipment….1079
Rough Operation May Require Use of Certified Safety Equipment….1079
Install Additional Safety Equipment If Conditions Require….1080
Movement Alarms….1080
Seat Belts Should Be Used at All Times….1080
Window Glass Breaking Tool….1080
Keep a Fire Extinguisher at Hand….1081
Maintain Standard Safety Equipment in Good Condition….1081
Safety-critical Parts Must Be Replaced Periodically….1081
Hydraulic Cylinder Seals Require Periodic Replacement….1081
High Pressure Hydraulic Lines Can Store a Great Deal of Energy….1081
Operator’s Cab Should Be Kept Clean….1081
Wear Eye Protection and Safety Clothing – Use Proper Tools….1082
Breathing Masks, Ear Protection May Be Required….1082
Asbestos Fiber Hazard….1082
Battery Electrolyte and Explosive Gases Can Be Lethal….1082
Disconnect Batteries Before Electrical Service or Electrical Welding….1082
Use Low Heat Portable Lighting….1083
Maintenance….1083
Use Warning Tag during Service….1083
Do Not Run Engine If Repairs or Work Are Being Performed Alone….1083
Always Use Adequate Equipment Supports and Blocking….1083
Do Not Work on Hot Engines or Hot Cooling or Hydraulic Systems….1083
Cool-down Is Required Prior to Radiator or Reservoir Checks….1084
Pressurized Hydraulic Oil Fluid Leaks Can Be Dangerous….1084
Obtain immediate medical attention if pressurized oil pierces skin….1084
Use Correct Replacement Fasteners Tightened to Proper Torque….1084
Dispose of All Petroleum-based Oils and Fluids Properly….1085
Check Tire Pressure and Condition….1085
Shipping and Transportation….1085
Obey State and Local Over-the-Road Regulations….1085
Operating Controls….1086
Component Locations….1087
Control Identification….1089
Steering Console and Pedals….1090
1. Starter Switch….1091
2. Horn Button (Two Places)….1091
3. Combination Switch….1092
4. Accelerator Pedal….1093
5. Steering Tilt Knob….1093
6. Brake Pedal (Right and Left Pedals)….1094
7. Steering Wheel….1094
8. Kick-Down Switch (Two places)….1095
9. Transmission Lever….1095
10. FRONT INSTRUMENT PANEL….1096
Transmission Display….1097
Front Instrument Panel….1099
Gauges….1100
Warning and Indicator Lights….1100
SWITCHES….1100
1. Fuel Gauge….1100
2. Speedometer….1101
3. Hour Meter….1101
4. Tachometer….1101
5. Coolant Temperature Gauge….1102
6. Transmission Oil Temperature Gauge….1102
7. Preheat Cycle Indicator Light….1102
8. Air Filter Indicator Light….1103
9. Coolant Temperature Warning Light….1103
10. Engine Oil Pressure Warning Light….1103
11. Battery Warning Light….1103
12. Left Turn and Hazard Warning Light….1104
13. High Beam Indicator Light….1104
14. Right Turn and Hazard Warning Light….1104
15. Work Light Indicator Light….1104
16. Brake FLUID Warning Light….1105
17. Brake And Pilot Oil Filter Clogging Warning Light….1105
18. Parking Brake Indicator Light….1105
19. Emergency Steering Indicator Light (Option)….1106
20. Hazard Warning light Switch….1106
21. Load Isolation System (Lis) Switch (OPTION)….1107
22. Float Kick-out Switch (Option)….1107
Right Side Switch Panel….1108
1. Pilot Control Valve Lever (Joystick)….1109
1a. Pilot Control Valve Lever (Option)….1109
1B. ergo-II pilot control valve lever (Joystick) (Option)….1110
2. Kick-Down Switch (TWO PLACES)….1111
3. Horn Button (Two Places)….1111
4. Cigar Lighter….1112
5. Headlight Switch….1112
6. front Work Light Switch….1113
7. Rear Work Light Switch….1113
8. Rear Wiper Switch….1114
9. Rotating BeacoN Switch (Option)….1114
10. Cup Holder….1114
11. Parking Brake switch….1115
12. Pilot cut-off switch….1115
13. Transmission Cut-Off Switch….1116
14. Automatic Transmission Switch….1116
15. emergency Steering Test Switch (option)….1117
Various Cabin Locations….1118
1. CAB LIGHT….1119
2. Stereo….1119
3. Heating and AIR-CONditioning CONTROL PANEL….1119
4. Speakers….1119
5. Storage Box….1120
6. Washer Tank….1120
7. Hot/Cold Refrigerator….1120
8. Electric Box….1120
9. Fuse Box Two….1121
10. Fuse Box One….1121
Heater and Air Conditioner Operation….1122
Location of Controls and Vents….1122
Operation Panel….1123
1. Fan and Air-Conditioner Switch….1123
2. Blower Fan Switches….1124
3. Temperature Control Switch….1124
4. Selection Switch for Wind Direction….1124
5. Ventilation Selection Switch….1125
Memory Function of Used Mode….1125
Additional Operating Instruction….1125
Stereo….1126
1. On-Off / Volume Control Knob….1126
2. Balance / Fader Control….1126
3. Bass/Treble Control….1126
4. AM/FM Band Selection….1127
5. Automatic Memory (AME)….1127
6. Tape Eject Button….1127
7. Cassette Slot….1127
8. & 9. Play Direction Button….1127
10. Automatic Selection….1127
11. Dolby B Selection….1127
12. Metal Selection….1128
Care of Stereo….1128
Seat Adjustment….1130
1. Adjusting Seat Forward/ Backward Lever….1130
2 & 3. Adjusting Seat's Angle and Height Lever….1130
4. Weight Adjustment Knob….1130
5. Backrest Adjustment Lever….1130
6. Angle Adjustment of Armrest….1131
7. Headrest….1131
Seat Belt….1132
Seat Belt Locking and Unlocking….1132
Door side latch….1133
Fuse Box/Relay….1134
Fuse Boxes….1134
Relay….1136
Circuit Breaker….1136
Fusible Link….1136
Window Glass Breaking Tool….1137
Operation….1138
Instrument Panel Control Functions….1138
Monitoring System….1138
New Machine Break-in Procedures….1138
Engine Start and Stop….1139
Engine Start….1139
Cold Weather Engine Start….1142
Starting with Auxiliary Batteries….1145
Engine Stop….1146
Hydraulic System Warm-up….1147
Hydraulic System Warm-up – Cold Weather….1147
Machine Travel….1148
Machine Shutdown….1150
Additional Braking….1152
Boom Raise Kickout….1153
Bucket Angle Indicator….1153
Boom Lower Kickout (Option)….1154
Adjustment of Bucket Position Switch….1154
Towing Machine….1155
If Engine Stalls While Traveling….1156
Allowable Water Depth….1156
Inspection, Maintenance and Adjustment….1158
Preventive Maintenance….1158
Serial Numbers….1158
Safety Precautions….1159
Table of Recommended Lubricants….1160
Fluid Capacities….1162
Maintenance Intervals….1163
10 Hour / Daily Service….1163
50 Hour / Weekly Service….1163
250 Hour / Monthly Service….1163
500 Hour / 3 Month Service….1164
1,000 Hour / 6 Month Service….1164
1,500 Hour / 9 Month Service….1164
2,000 Hour / Annually Service….1164
10 Hour / Daily Service….1165
Grease Front Attachment Pins….1165
Inspect All Tires for Correct Tire Pressure and Signs of Damage or Abnormal Wear….1165
Check Engine Oil Level….1165
Check Transmission Oil Level….1166
Check Hydraulic System Oil Level….1167
Check for Leaks in the Hydraulic System….1168
fill Fuel Tank….1169
Check for Leaks in the Fuel System….1169
Drain Fuel Condensation….1170
Check Coolant Level….1170
Check Antifreeze Protection Levels….1171
Check Level of Window Washer Liquid….1171
Inspect the Bucket Teeth and Side Cutters for Signs of Wear….1171
Inspect Seat Belt for Proper Operation….1172
Inspect the Structure for Cracks and Faulty Welds….1172
Check the Operation of All Switches….1172
Check the Operation of All Exterior Lights, Horn and Control Console Indicator and Monitor Lights….1172
Start Engine, Check Starting Ability, and Observe Exhaust Color at Start-up and at Normal Operati…..1172
Check Operation of All Controls….1172
Inspect Engine Fan Blade….1173
Check Engine Drive Belt Wear….1173
Check Air Intake System….1174
50 Hour / Weekly Service….1175
Perform All 10 Hour / Daily Service Checks….1175
Grease Front Attachment Pins….1175
Grease Steering Cylinder Rod and HEAD Ends….1180
Grease Upper and Lower Center Pins….1180
Change Engine Oil and Filter….1180
Hydraulic Full Flow Filter Replacement….1181
Check Air-Conditioning and Alternator Belt Tension….1181
Clean exterior of radiator, oil cooler and air-conditioner evaporator….1181
250 Hour / Monthly Service….1182
Perform All 10 Hour / Daily, 50 Hour Service Checks….1182
Replace Hydraulic System brake and Pilot Filter….1182
Check Engine Air Pre-cleaner….1183
Hydraulic Full Flow Filter Replacement….1183
Drain Water From Hydraulic Oil Tank….1185
Clean Air Cleaner….1185
Check Air-conditioning and Alternator Belt Tension….1186
Grease Drive Shafts….1187
Change Engine Oil….1188
Axle Differential and Planetaries Oil Replacement (after first 250 hours)….1188
Replacement Of Transmission Oil and Filter (After First 250 Hours)….1188
500 Hour / 3 Month Service….1189
Perform All 10 Hour / Daily, 50, and 250 Hour Service Checks….1189
Replace Fuel Filter….1189
Clean Exterior of Radiator, Oil Cooler and Air-conditioner Evaporator….1190
Change Engine Oil and Filter….1191
1,000 Hour / 6 Month Service….1193
Perform All 10 Hour / Daily, 50, 250, and 500 Hour Service Checks….1193
Change Radiator Coolant….1193
Drain and Replace Transmission Oil and filter….1195
Clean Fuel Tank and Strainer….1196
Check air conditioner refrigerant….1197
Check and adjust engine….1197
1,500 Hour / 9 Month Service….1198
Perform All 10, 50, 250, and 500 Hour Service Checks….1198
Replace Outer and Inner Air Cleaner Elements….1198
Axle Differential and Planetaries Oil Replacement….1198
2,000 Hour / Annually Service….1200
Perform All 10 Hour / Daily, 50, 250, 500 and 1000 Hour Service Checks….1200
Check Steering, Brake, Drive Shaft, Engine, and Fuel System….1200
Replace Hoses….1200
Bleed Brakes….1200
Drain and Replace Hydraulic Oil….1201
Clean Hydraulic Oil Suction Strainer….1203
Check Brake Accumulator….1203
Severe Conditions Maintenance….1204
General Maintenance….1205
Fuel Transfer Pump….1205
Parking Brake Adjustment….1207
Check Hydraulic Pressures….1208
Main Pump Pressure….1208
Unloading Valve Pressure….1208
Steering Pump Pressure….1209
Transmission Clutch Pressure….1209
Brake Charge Pressure….1209
Control Lever Activation Pressure….1209
Service Brake Outlet Pressure….1210
Fan Motor Pressure….1210
Tires and Wheels….1211
Wheel Nut Torque….1211
CHECK TIRE FOR DAMAGE….1212
Electrical System….1213
Check Battery Condition….1213
Bolt Torque Chart….1214
Tightening Torque Specifications for Metric Bolts (For coated threads, pre- lubricated assemblies)….1214
Long Term Storage….1215
Cleaning….1215
Hydraulic System….1215
Lubrication….1215
Battery….1215
Cooling System Care….1215
Transportation….1216
Loading Machine on a Trailer….1216
Summary of Safety Precautions for Lifting….1217
Troubleshooting….1218
Engine….1218
Hydraulic System….1221
Travel System….1223
General….1223
Transmission Error Codes….1225
Steering….1228
Braking….1229
Electrical System….1229
Specifications….1230
General Specifications….1230
Working Range and Dimensions….1231
Working Capacities….1233
Bucket Capacity….1233
Tipping Load….1233
Material Weight….1233
Approximate Weight of Workload Materials….1233
Index….1236
S0602150K….1240
S0607080K – Doosan M500, M500 Tier 2 Transmission ZF 4WG-310 Service Manual….1348
Daewoo MEGA 400-V Wheel Loader Repair Service Manuals