PDF Operation & Maintenance Manual Daewoo Doosan Mega 200-V Mega 200-VTC - 2 MB
This comprehensive manual provides all the necessary information for the operation and maintenance of the Daewoo Doosan Mega 200-V and 200-VTC wheel loaders.
It details operating procedures, safety precautions, and scheduled maintenance intervals.
Adhering to the guidelines in this manual will help you maximize the performance and lifespan of your machine.
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Mega 200-V
Mega 200-VTC
Operation and Maintenance Manual
022-00028AE
S/N 1001 and Up (Tier I & II)
February 2003
Daewoo reserves the right to improve our products in a continuing process to provide the best possible
product to the market place. These improvements can be implemented at any time with no obligation to
change materials on previously sold products. It is recommended that consumers periodically contact their
distributors for recent documentation on purchased equipment.
This documentation may include attachments and optional equipment that is not available in your
machine’s package. Please call your distributor for additional items that you may require.
Illustrations used throughout this manual are used only as a representation of the actual piece of
equipment, and may vary from the actual item.
022-00028AE Operation and Maintenance Manual Copyright 2003 Daewoo
--- Page 3 ---
3. WARNING FOR HANDLING ACCUMULATOR (2190-2528, 190-00099)
WARNING!
Explosion hazard:
• Keep away from flame.
• Do not weld or drill.
ACO1480L
Accumulator
Wheel loader pilot control system is equipped with an accumulator. Accumulator will store a pressure
charge that may enable hydraulic controls to be activated for a brief period of time after engine has been
shut down. Activation of any controls may enable selected function to operate under force of gravity.
CAUTION!
Any raised attachment will lower to ground if accumulator holds a charge.
When shutting machine down, lower front attachment to ground. After engine has been shut down, turn key
to "ON" position and move joystick controls to release pressure in accumulator. Remove key.
IMPORTANT
Refer to Shop Manual for service procedures. Do not release any pilot lines until pressure within
accumulator has been released.
022-00028AE Operation and Maintenance Manual Safety 1-5
--- Page 4 ---
TAKE TIME TO PROVIDE GOOD VISIBILITY
Halt work if visibility is poor. Strong rains, snow, fog and extremely dusty conditions can all obscure visibility
so badly that it is best to wait for weather to change or dust to settle before continuing operation.
Night work in areas of limited visibility should be halted if installation of extra work lights on machine (or
work area) is necessary.
Keep dirt and dust off of windows and off lens surfaces of work lights. Stop working if lights, windows or
mirrors need cleaning or adjustment.
FUEL, OIL AND HYDRAULIC FLUID FIRE
HAZARDS
Add fuel, oil, antifreeze and hydraulic fluid to
machine only in a well-ventilated area. Machine
must be parked with controls, lights and
switches turned "OFF." Engine must be "OFF"
and any flames, glowing embers, auxiliary
heating units or spark-causing equipment must
be doused, turned "OFF" and/or kept well clear
of machine.
Static electricity can produce dangerous sparks
HAOA120L
at fuel filling nozzle. In very cold, dry weather or
other conditions that could produce static Figure 10
discharge, keep tip of fuel nozzle in constant
contact with neck of fuel filling nozzle, to provide
a ground.
Keep fuel and other fluid reservoir caps tight
and do not start engine until caps have been
secured.
BOOST STARTING OR CHARGING ENGINE
BATTERIES
Turn "OFF" all electrical equipment before
connecting leads to battery. This includes
electrical switches on battery charger or boost
starting equipment.
When boost-starting from another machine or
vehicle do not allow two machines to touch.
Wear safety glasses or goggles while required
parallel battery connections – positive to
positive and negative to negative – are made.
HAOA310L
24 volt battery units consisting of two series- Figure 11
connected twelve volt batteries have a cable
connecting one positive terminal on one of the
12 volt batteries to a negative terminal on the other battery. Booster or charger cable connections must be
made between nonseries-connected positive terminals and between negative terminal of booster battery
and metal frame of machine being boosted or charged. Refer to procedure and illustration in “Starting with
Auxiliary Batteries” on page 3-8.
Connect positive cable first when installing cables and disconnect negative cable first when removing
them. Final cable connection, at metal frame of machine being charged or boost-started, should be as far
away from batteries as possible.
022-00028AE Operation and Maintenance Manual Safety 1-15
--- Page 5 ---
2OPERATING CONTROLS
"Operating Controls" section presented here consists of the following groups:
1. “Component Locations” on page 2-2
2. “Control Identification” on page 2-8
3. “Steering Console and Pedals” on page 2-9
4. “Transmission Display” on page 2-16
5. “Front Instrument Panel” on page 2-18
6. “Right Side Switch Panel” on page 2-27
7. “Various Cabin Locations” on page 2-38
8. “Heater and Air Conditioner Operation” on page 2-42
9. “Stereo” on page 2-47
10. “Seat Adjustment” on page 2-51
11. “Seat Belt” on page 2-53
12. “Door Side Latch” on page 2-54
13. “Fuse Box/Relay” on page 2-55
14. “Window Glass Breaking Tool” on page 2-58
Each group is explained with a point location drawing or photo and a brief description of each control,
switch, gauge or valve.
Indicator lights work in addition to gauges on instrument panel. Operators should monitor machine
pressure on instrument panel along with indicator lights. These lights will only give operators an indication
that there is a problem.
WARNING!
Warning lights. When any one or more of the warning lights on the control console turn "ON,"
immediately discontinue operation and shut down unit. Investigate and correct problem before
proceeding with operation.
022-00028AE Operation and Maintenance Manual Operating Controls 2-1
--- Page 6 ---
Figure 8
3. COMBINATION SWITCH
A. Left Side Directional Switch -
Pushing lever forward, activates left
A
outside directional lights and C
directional indicator light on
instrument panel.
D
B. Right Side Directional Switch - B
Pulling lever back, activates right
outside directional lights and E
directional indicator light on
instrument panel. AHO0920L
NOTE: When turn is completed the Figure 9
lever automatically returns to
the "NEUTRAL" position.
Should it not, it can be manually
returned by hand.
NOTE: Turn signals will function with starter switch in "OFF" position.
C. Window Washer Switch - When the outside area of the lever is pressed, it activates the washer
pump and sprays fluid on the windshield. (Only while being pressed.)
CAUTION!
The washer pump can be damaged if it is activated while there is no fluid in the tank.
The fluid level should be checked regularly and refilled if necessary.
Using soap or other solvents instead of the recommended washer fluid may damage
the wiper blades and the paint finish.
Only use recommended washer fluid or equivalent.
D. Horn Button - The center button on end of lever activates horn. (Only while being pressed.)
E. Wiper Switch - Activates wipers when outside area of lever is rotated.
J: Intermittent Mode - wipes every 5 seconds.
0: Stop (Off).
I: Normal Speed Mode.
II: High Speed Mode.
022-00028AE Operation and Maintenance Manual Operating Controls 2-11
--- Page 7 ---
5. COOLANT TEMPERATURE GAUGE
This gauge displays temperature of engine
coolant.
CAUTION!
When the pointer indicates "H" mark
(red zone), it means the engine is
overheated. Stop the operation, let
the engine run at low rpm and wait
HBOI260L
for it to cool down.
Figure 29
Do not shut down engine. If engine is
shut down heat surge may occur.
6. TRANSMISSION OIL TEMPERATURE
GAUGE
This gauge displays temperature of oil in
transmission converter and transmission
circuit.
CAUTION!
When the pointer indicates "H" mark
(red zone), it means the transmission
is overheated. Stop the operation, let HBOI270L
the engine run at low rpm and wait Figure 30
for transmission to cool down.
7. PREHEAT CYCLE INDICATOR LIGHT
When this light turns "ON" it means that
engine preheat cycle is complete. When
radiator temperature is below 10°C
(-12°F), this light will turn "ON"
approximately 3.5 seconds after starter
switch is turned to preheat position.
HAOA639L
Figure 31
022-00028AE Operation and Maintenance Manual Operating Controls 2-21
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3. HORN BUTTON (TWO PLACES)
Pressing the left button at the tip of the
pilot control valve lever (joystick) (Figure
53) or the button at the end of the
combination switch (Figure 54) will sound
the horn.
NOTE: Starter switch must be "ON."
Figure 53
AHO0890L
Figure 54
4. CIGAR LIGHTER
Push the lighter all the way into the socket
and release your hand. After pushing it in,
it will be ejected when it is heated. If it
does not eject after a short time, pull it out
and have it serviced.
IMPORTANT
The cigar lighter is powered by a 24
volt circuit. Never plug any 12 volt
device into the cigar lighter. HAOA780L
Figure 55
022-00028AE Operation and Maintenance Manual Operating Controls 2-31
--- Page 9 ---
9. FUSE BOX TWO
Fuse box two is just above the windshield
washer fluid tank. For a detailed
explanation of fuses see “Fuse Box/Relay”
on page 2-55.
Figure 76
10. FUSE BOX ONE
The fuse box one is at the rear side of right
control stand. For a detailed explanation of
fuses “Fuse Box/Relay” on page 2-55
Figure 77
022-00028AE Operation and Maintenance Manual Operating Controls 2-41
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SEAT ADJUSTMENT
WARNING!
Whenever operator or operating condition
has changed, check to see that seating
position is suitable for the condition at
hand. Always fasten your seat belt while
operating vehicle. Adjust backrest so that
the operator can fully reach and operate
pedals.
HAOB110L
Figure 95
1. ADJUSTING SEAT FORWARD/
BACKWARD LEVER
Holding lever (3, Figure 96), raise it up,
while pushing or pulling seat to desired
position. Release lever once desired
position is reached. Adjustment range is
160 mm (6.3 in). 4 5
1
2 & 3. ADJUSTING SEAT'S ANGLE AND
HEIGHT LEVER
3
Pulling left lever (3, Figure 96) up allows 2 HBOI350L
rear part of seat to be moved up or down. Figure 96
Pulling lever (2) up allows front part of seat
to be moved up or down. Adjust seat
according to operator’s size and work
conditions. Adjustment range is 60 mm
(2.36 in) for both front and rear.
4. WEIGHT ADJUSTMENT KNOB
Turning knob (4, Figure 96) to right makes suspension harder. Turning knob to left makes suspension
softer. Adjust according to operator’s weight by checking weight indicator dial. Adjustment range is
from 50 - 120 kg (110 - 265 lb).
5. BACKREST ADJUSTMENT LEVER
Pulling up right lever (5, Figure 96) allows seat backrest to be moved forward or backward.
022-00028AE Operation and Maintenance Manual Operating Controls 2-51
--- Page 11 ---
4. Set pilot cutoff switch to "O" (LOCK)
position. This will "LOCK" pilot control
valve lever (joystick).
O
I
HBOI111L
Figure 4
5. Rotate starter key to "I" (ON) position. All
indicator lights should turn "ON."
NOTE: If unit is equipped with and
emergency steering system.
Test system before starting
engine. If system does not
function properly, do not start
unit. Follow test procedure
given with test switch.
HAOB320L
Figure 5
6. Rotate starter key to "START" position.
Starter motor should crank immediately,
and engine should start within a few
seconds.
HAOB350L
Figure 6
7. Release starter key when engine starts.
Key will return to "I" (ON) position.
IMPORTANT
If engine does not start after
approximately 15 seconds of
cranking, release Starter Key. Wait 5
minutes for starter motor to cool
down. Repeat step 6.
8. After engine starts, check all indicator HAOB360L
lights and gauges to be certain that all Figure 7
022-00028AE Operation and Maintenance Manual Operation 3-3
--- Page 13 ---
7. Place transmission lever in desired gear.
Shift gears one by one. Do not skip from
1st to 3rd, for example.
8. Shift transmission lever to "FORWARD"
position.
Figure 28
9. Release the brake pedal while slowly
pressing the accelerator pedal.
WARNING!
When traveling at high speed or on a
steep hill, do not make sharp
changes in direction. This could
cause vehicle to overturn.
When traveling or changing
direction, always look carefully to be
certain that no one is in path of Figure 29
vehicle.
MACHINE SHUT DOWN
1. Ease off throttle and apply travel brakes.
Figure 30
022-00028AE Operation and Maintenance Manual Operation 3-13
--- Page 14 ---
TABLE OF RECOMMENDED LUBRICANTS
IMPORTANT
Do not use lubricants other than those recommended, without prior written approval from
Daewoo.
NOTE: Refer to Maintenance Intervals Table for application points.
LUBRICANT LUBRICANT
HYDRAULIC OIL ENGINE OIL AXLE GEAR OIL
MANUFACTURER GREASE
CALTEX CALTEX HD32 CALTEX RPM or MULTIFAC EP MULTIPURPOSE
EP90
DELO 300
EXXON/ESSO NUTO (ANTI- EXXON XD-3 RONEX MP #2 SPARTAN EP220
WEAR) STRAIGHT or
or
WEIGHT or
HD 32 (BELOW EXXON GX
15W40 RONEX MP #1
0°C (32°F)) or 80W90
(COLD TEMPS)
HD 46 (ABOVE
0°C (32°F)) or
TERESSTIC
(ANTI-RUST)
MOBIL MOBIL DELVAC 1300 or MOBIL FAW #2 MOBILUBE LS
80W90
DTE 13M (ALL- SUPER 15W40 or or
TEMP) or
DELVAC 1 or MOBIL FAW #1
DTE 24 (COLD TEMPS)
STRAIGHT
(SUMMER)
WEIGHT
SHELL TELLUS 32 ROTELLA ALVANIA EP #2 SPIRAX HD
80W90
T15W40 or
T30 (WINTER) or
T40 (SUMMER)
PENNZOIL PENNZBELL LONGLIFE PENNZOIL 705 PENZOIL
EP #2 MULTIPUPOSE
AW 32 (BELOW SAE30 or
4092 or
0°C (32°F)) or
SAE40 or
80W90
AW 46 (ABOVE
SAE15W40
0°C (32°F))
DRYDEN PARADENE DIESELALL EP #2 (RED) AP80W90
PLUS or
AW 32 (BELOW
0°C (32°F)) or 30W or
AW 46 (ABOVE 40W or
0°C (32°F))
15W40
022-00028AE Operation and Maintenance Manual Inspection, Maintenance and Adjustment 4-3
--- Page 15 ---
DRAIN FUEL CONDENSATION
AOO0040L APO0070L
Figure 16 Figure 17
1. Open fuel tank drain valve (Figure 16). Allow any condensed water or sediment to drain out of tank.
Also open drain on fuel filter and drain out any water or sediment (Figure 17). Catch drained material
in a container. Properly dispose of drained material.
CHECK COOLANT LEVEL
WARNING!
Never open radiator when it is hot. Scalding liquid inside a hot radiator is under pressure.
Removing cap from a hot radiator could cause a person to be sprayed and burned from liquid
inside. Wait for radiator temperature to cool down before removing cap.
Figure 19
Figure 18
022-00028AE Operation and Maintenance Manual Inspection, Maintenance and Adjustment 4-13
--- Page 16 ---
MEGA 200-VTC
1. Following fittings are greased daily, or every 10 hours, for first 100 hours of operation to comply with
new machine break-in requirements. After that, greasing should be done every 50 hours. If bucket is
being used in water, grease fittings immediately after machine is removed from water.
C
B
A D
BFO0030P
Figure 40
A: Bucket hinge pins, 2 locations on
each side of bucket. Arm link
connecting pins, 2 locations. (Figure
41)
Figure 41
022-00028AE Operation and Maintenance Manual Inspection, Maintenance and Adjustment 4-23
--- Page 17 ---
GREASE DRIVE SHAFTS
1. Grease fitting for center bearing, 1
location. Use remote grease fitting
mounted on frame (3, Figure 61).
Reference Remote Grease
Number Fittings
1 and 2 Steering Cylinder
50 Hours Head Ends
3 Drive Shaft
250 Hours Center Bearing
Figure 61
Figure 62
AXLE DIFFERENTIAL AND PLANETARIES OIL REPLACEMENT (AFTER FIRST 250 HOURS)
NOTE: The differential and planetaries oil should be drained and refilled after first 250 hours of
operation. There after every 1,500 hours of operation. (See page 4-43)
REPLACEMENT OF TRANSMISSION OIL AND FILTER (AFTER FIRST 250 HOURS)
NOTE: Transmission oil and filter must be changed after first 250 hours of operation to comply
with new machine break-in requirements.
NOTE: After first change, oil and filter should be changed every 1,000 hours. Follow procedure
under 1,000 hour maintenance interval. (See page 4-39)
022-00028AE Operation and Maintenance Manual Inspection, Maintenance and Adjustment 4-33
--- Page 18 ---
1,500 HOUR / 9 MONTH SERVICE
PERFORM ALL 10, 50, 250, AND 500 HOUR SERVICE CHECKS
REPLACE OUTER AND INNER AIR CLEANER ELEMENTS
CAUTION!
Never remove air cleaner element while engine is running. This will allow dirt to be sucked into
engine and cause serious engine damage. Always turn engine "OFF" before servicing air
cleaner.
1. Replace inner element when outer element is replaced.
2. After removing outer element, remove wing nut and inner element.
3. Clean out inside of air cleaner housing. DO NOT use compressed air to blow out housing.
4. Install new inner element, and secure it into position with wing nut. DO NOT clean and re-use inner
element.
5. Install new outer element, and secure it into position with wing nut.
6. Install air cleaner cover.
NOTE: Make sure that all gaskets on wing nuts and cover are properly installed and seated.
AXLE DIFFERENTIAL AND PLANETARIES OIL REPLACEMENT
NOTE: Oil in both front and rear axle must be replaced after first 250 hours of operation to comply
with new machine break-in requirements. After that, axle oil check should be done every
250 hours of operation and replacement should be done every 1,500 hours.
Each axle contains a center differential, and a planetary in each end. The same oil lubricates center
differential and planetaries in axle ends, but oil flows very slowly between these points. When checked, oil
must be checked and refilled at all three places at the same time. To drain and replace oil in an axle,
perform the following steps:
1. Drive machine onto a level surface.
Position wheels on axle being drained so
that axle end level plugs (1, Figure 79) are
in the lowest position. Apply parking brake.
Block wheels.
2. Clean area around level plugs on both
ends of axle. Remove plugs.
NOTE: See “Fluid Capacities” on
page 4-5 for capacity.
Figure 79
022-00028AE Operation and Maintenance Manual Inspection, Maintenance and Adjustment 4-43
--- Page 19 ---
CHECK HYDRAULIC PRESSURES
Hydraulic pressure for most systems can be
check by using the remote test ports shown in
(Figure 93).
Reference
Description
Number
1 Main Pump Pressure
2 Control Lever Activation
Pressure
3 Steering Pump Pressure
4 Transmission Clutch Pressure Figure 93
5 Brake Charge Pressure
MAIN PUMP PRESSURE
P - From pump R - To Tank
1. Attach gauge to port (1, Figure 93). 3A - Boom lower 3B - Boom raise
2A - Bucket dump 2A - Bucket crowd
2. Relief cartridge for main pump must open
at 205±5 kg/cm2 (2,915±70 psi).
3. Adjust screw on relief valve cartridge
(Figure 94). Loosen lock nut and turn
screw clockwise to raise relief pressure.
Turn screw counterclockwise to lower relief
pressure.
4. Tighten lock nut after pressure has been APO0120L
adjusted. Figure 94
CONTROL LEVER ACTIVATION PRESSURE
(S/N 1001 thru 2000) 1 2
1. Attach gauge to port (2, Figure 93).
2. Adjust relief cartridge (3, Figure 95) on
brake and pilot supply valve (1, Figure 95).
3
Relief pressure should be set at 28 +3
-2 kg/
+43
cm2 (398 -30 psi).
3. Loosen lock nut on adjusting screw. Turn
adjusting screw clockwise to raise relief
pressure. Turn adjusting screw APO0130L
counterclockwise to lower relief pressure.
Figure 95
4. Tighten lock nut after adjustment has been
made.
022-00028AE Operation and Maintenance Manual Inspection, Maintenance and Adjustment 4-53
--- Page 20 ---
5TRANSPORTATION
LOADING MACHINE ON A TRAILER
When transporting the machine observe the
various road rules, road transportation vehicle
laws and vehicle limit ordinances, etc.
It is a good idea to obtain special platform for
loading and unloading the machine.
1. Park the trailer on a flat firm roadbed. Keep
a fairly long distance between the road
shoulder and the machine.
2. Properly apply the brakes of the trailer and
place wheel chocks in front of and behind
the tires to ensure that the trailer does not
move. Figure 1
3. Fix the ramp in line with the centers of the
trailer and the machine.
4. Determine the position of the ramp, then
slowly load the machine onto to the
specified part of the trailer.
NOTE: Have someone in clear view
and in a safe position provide
directions while loading.
5. Lower the bucket and lock each control
lever using the pilot cutoff switch.
6. Apply the parking brake and set the
articulation stopper in the "LOCKED" Figure 2
position.
7. Tape over the exhaust stack outlet to
prevent turbo "Wind-milling" damage.
8. Place blocks in front of and behind the
tires to prevent the machine from moving.
9. Fasten the machine to the trailer with
chains or cables at lower part of the rear
chassis. Additional chains or cables may
be used but do not damage brake lines or
cylinder rods.
IMPORTANT
Figure 3
Brake pipe runs on axle housing.
Do not fasten axle housing.
022-00028AE Operation and Maintenance Manual Transportation 5-1
--- Page 21 ---
Error Code
Meaning Of Error Code Remarks
Number
38 Short circuit to ground or open circuit at internal speed input.
39 Logical error at internal speed input.
3A Short circuit to battery voltage at output speed input.
3B Short circuit to ground or open circuit at output speed input.
3C Logical error at output speed input.
71 Short circuit to battery voltage at clutch K1.
72 Short circuit to ground at clutch K1.
73 Open circuit at clutch K1.
74 Short circuit to battery voltage at clutch K2.
75 Short circuit to ground at clutch K2.
76 Open circuit at clutch K2.
77 Short circuit to battery voltage at clutch K3.
78 Short circuit to ground at clutch K3.
79 Open circuit at clutch K3.
7A Short circuit to battery voltage at converter clutch. Not used.
7B Short circuit to ground at converter clutch. Not used.
7C Open circuit at converter clutch. Not used.
81 Short circuit to battery voltage at clutch K4.
82 Short circuit to ground at clutch K4.
83 Open circuit at clutch K4.
84 Short circuit to battery voltage at clutch KV.
85 Short circuit to ground at clutch KV.
86 Open circuit at clutch KV.
87 Short circuit to battery voltage at clutch KR.
88 Short circuit to ground at clutch KR.
89 Open circuit at clutch KR.
91 Short circuit to battery voltage at relay reverse warning alarm.
82 Short circuit to ground at relay reverse warning alarm.
022-00028AE Operation and Maintenance Manual Troubleshooting 6-9
--- Page 22 ---
WORKING CAPACITIES
BUCKET CAPACITY
Standard toothed bucket has a capacity of 1.8 m3 (2.4 yd3).
TIPPING LOAD
Static Tipping Load with bucket in Over Front position is 8,500 kg (18,740 lb). With bucket in Fully Turned
position, Static Tipping Load is 7,400 kg (16,315 lb).
MATERIAL WEIGHT
The data below describes weight of a cubic meter (cubic yard) of many types of workload materials.
APPROXIMATE WEIGHT OF WORKLOAD MATERIALS
LOW WEIGHT OR MEDIUM WEIGHT OR HIGH WEIGHT OR
DENSITY DENSITY DENSITY
MATERIAL 1,100 KG/M3 1,600 KG/M3 2,000 KG/M3
(1,850 LB/YD3), OR (2,700 LB/YD3), OR (3,370 LB/YD3), OR
LESS LESS LESS
Charcoal 401 kg/m3
--------------------- ---------------------
(695 lb/yd3)
Coke, blast furnace 433 kg/m3
size --------------------- ---------------------
(729 lb/yd3)
Coke, foundry size 449 kg/m3
--------------------- ---------------------
(756 lb/yd3)
Coal, bituminous slack, 801 kg/m3
piled --------------------- ---------------------
(1,350 lb/yd3)
Coal, bituminous r. of 881 kg/m3
m., piled --------------------- ---------------------
(1,485 lb/yd3)
Coal, anthracite 897 kg/m3
--------------------- ---------------------
(1,512 lb/yd3)
Clay, DRY, in broken 1,009 kg/m3
lumps --------------------- ---------------------
(1,701 lb/yd3)
Clay, DAMP, natural 1,746 kg/m3
bed --------------------- ---------------------
(2,943 lb/yd3)
Cement, Portland, DRY 1,506 kg/m3
granular --------------------- ---------------------
(2,583 lb/yd3)
022-00028AE Operation and Maintenance Manual Specifications 7-7