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