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