Page 1 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.
Page 3: Table Of Contents
TABLE OF CONTENTS Safety ..................1-1 To the Operator of a Daewoo Wheel Loader ........1-1 General Safety Essentials ..............1-2 Location of Safety Labels ..............1-3 Unauthorized Modifications .............. 1-10 Work Site Precautions..............1-10 Operation..................1-12 Equipment ..................1-17 Maintenance..................
Page 4 Engine Start and Stop ................ 3-2 Machine Travel ................. 3-11 Machine Shut Down .................3-13 Additional Braking ................3-15 Boom Raise Kickout .................3-16 Bucket Angle Indicator ..............3-16 Boom Lower Kickout (Option)............3-17 Adjustment of Bucket Position Switch ..........3-18 Towing Machine................3-19 If Engine Stalls While Traveling ............
Page 5 Travel System ..................6-6 Steering .................... 6-11 Braking ..................... 6-12 Electrical System................6-12 Specifications ................7-1 Mega 200-V..................7-1 Mega 200-VTC ................... 7-4 Working Capacities ................7-7 Approximate Weight of Workload Materials ........7-7 Index ..................8-1 Operation and Maintenance Manual...
Page 7: Safety
1SAFETY TO THE OPERATOR OF A DAEWOO WHEEL LOADER DANGER! Improper use of wheel loader could cause serious injury or death. Before operating wheel loader, or performing maintenance, operator or technician must read and understand entire Operation and Maintenance Manual.
Page 8: General Safety Essentials
Wheel loader has been designed primarily for moving earth with a bucket. For use as a grapple or for other object handling, contact Daewoo. Lifting-work applications are permitted in approved lift configuration, to rated capacity only, with no side-loading (unless prohibited by local regulation). Do not use machine for activities for which it was not intended.
Page 9: Location Of Safety Labels
There are other labels in addition to safety labels that follow so handle them in the same way. Safety labels may be available in languages other than English. To find out what labels are available, contact your Daewoo distributor. 8 10...
Page 10 • Turn starter switch "OFF." Remove key from switch. • If hydraulic components and units are ABNORMAL, consult nearest DAEWOO dealer or authorized service shop. Do not attempt to make an overhaul. WARNINGS WHEN OPENING ENGINE HOOD (2190-2525, 190-00095) WARNING!
Page 11 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.
Page 12 KEEP OUT OF STEERING TURN AREA (4190-1992, 190-00120) DANGER! Keep out of steering turn area. AMO0410L WARNING FOR HIGH TEMPERATURE HYDRAULIC OIL (2190-2529, 190-00097) WARNING! HYDRAULIC OIL To prevent hot oil from spurting out: • Turn engine off. • Allow oil to cool. •...
Page 13 WARNING FOR HIGH TEMPERATURE COOLANT (2190-2531, 190-00097) WARNING! To prevent hot water from spurting out: • Turn engine "OFF." • Allow water to cool. • Slowly loosen cap to relieve pressure before removing. ACO1410L WARNING FOR BATTERY MAINTENANCE (2190-2533, 190-00100) DANGER! •...
Page 14 WARNING FOR RIDING ON MACHINE (4190-1989, 190-00107) WARNING! For your safety, do not stand on ladder when machine is in motion. AMO0420L WARNING FOR PERFORMING MAINTENANCE ON FRONT ATTACHMENT (4190-2546, 190-00105) DANGER! To avoid injury, securely brace lift arm before disassembly of valve or piping. AMO0430L 1-8 Safety 022-00028AE Operation and Maintenance Manual...
Page 15 10. WARNING TO USE SAFETY LOCK (4190-1993, 190-00121) WARNING! Safety lock must be in "LOCK" position when servicing pivot area or transporting machine. AMO0440L 11. WARNING TAG (2190-2549, 190-00098) WARNING! Do not touch when performing inspection or maintenance. ACO1450L 022-00028AE Operation and Maintenance Manual Safety 1-9...
Page 16: Unauthorized Modifications
For safety’s sake, replace all OEM parts with correct authorized or genuine Daewoo part. For example, not taking time to replace fasteners, bolts or nuts with correct replacement parts could lead to a condition in which safety of critical assemblies is dangerously compromised.
Page 17 BEFORE STARTING TO DIG, CONTACT AUTHORITIES Below ground hazards also include natural gas lines, water mains, tunnels and buried foundations. Know what’s underneath work site before starting to dig. BE AWARE OF HEIGHT OBSTACLES Any type of object in vicinity of boom could represent a potential hazard, or cause operator to react suddenly and cause an accident.
Page 18: Operation
STAY ALERT FOR PEOPLE MOVING THROUGH WORK AREA When loading a truck you should always know where the driver is. Avoid loading over the cab of a truck even if the driver is in a safe spot. Someone else could have gone inside, for any number of reasons.
Page 19 BEFORE STARTING ENGINE, DO A "PRE-START" SAFETY CHECK: • Walk around your machine before getting in operator’s cab. Look for evidence of leaking fluid, loose fasteners, misaligned assemblies or any other indications of possible equipment hazard. • All equipment covers and machinery safety guards must be in place, to protect against injury while machine is being operated.
Page 20 OBSERVE GENERAL SAFETY RULES Only trained and authorized personnel, with a good knowledge and awareness of safe procedures, may be allowed to operate or perform maintenance or service on wheel loader. All personnel at work site should be aware of assigned individual responsibilities and tasks. Communication and hand signals used should be understood by everyone.
Page 21 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.
Page 22 KEEP "PINCH POINT" AREAS CLEAR – USE CAUTION IN REVERSE Use a signal person in high traffic areas and whenever operator’s view is not clear, such as when traveling in reverse. Anyone standing near wheels, or working assemblies of the attachment, is at risk of being caught between moving parts of machine.
Page 23: Equipment
SHUTDOWN CONTROL FUNCTIONS After bucket has been lowered to overnight storage position, move all switches and controls to "OFF" position. Move parking brake switch to "LOCK" position. This will apply parking brake. Move pilot cutoff switch to "LOCK" position. This will disable bucket control lever. Move key in starter switch to "OFF" position, and remove key from switch.
Page 24 Laminate glass protection for the front, side or rear windows may also be recommended depending upon particular site conditions. Contact your Daewoo distributor for available safety guards and/or recommendations if there is any danger of getting hit by objects that could strike the operator’s cab. Make sure that all other work site crew members are kept well away from wheel loader and safe from potential hazards.
Page 25 HYDRAULIC CYLINDER SEALS REQUIRE PERIODIC REPLACEMENT Check cylinder drift rate at regular intervals. Overhaul seal kits are available through Daewoo. HIGH PRESSURE HYDRAULIC LINES CAN STORE A GREAT DEAL OF ENERGY Exposed hydraulic hoses on arm or boom could react with explosive force if struck by a falling rock, overhead obstacle or other work site hazard.
Page 26 CLOTHING AND PERSONAL PROTECTIVE ITEMS Contain long hair, and avoid loose clothing and jewelry. They can catch on controls or in protruding parts and cause serious injury or death. Do not wear oily clothes. They are highly flammable. Full eye protection, a hard hat, safety shoes and gloves may be required at the work site.
Page 27 BATTERY ELECTROLYTE AND EXPLOSIVE GASES CAN BE LETHAL Flush eyes with water for 10-15 minutes if acid is splashed in face. Anyone who swallows acid must have immediate medical aid. Call Poison Control listed in the front cover of the telephone directory.
Page 28: Maintenance
– and other machine areas if required – with a warning notice. WARNING Warning tags for controls are available from Daewoo distributors; see Figure 21. HAOC920L Figure 21 DO NOT RUN ENGINE IF REPAIRS OR WORK ARE BEING PERFORMED ALONE You should always have at least two people working together if engine must be run during service.
Page 29 PRECAUTIONS WITH HIGH PRESSURE LINE, TUBES AND HOSES When inspecting or replacing high-pressure piping or hoses, check that the pressure has been released from the circuit. Failure to release the pressure may lead to serious injury. Always do the following; •...
Page 30: Shipping And Transportation
USE CORRECT REPLACEMENT FASTENERS TIGHTENED TO PROPER TORQUE Refer to "General Maintenance" section of Shop Manual for information on tightening torques and recommended assembly compounds and always use correct part. Poor or incorrect fastener connections can dangerously weaken assemblies. DISPOSE OF ALL PETROLEUM-BASED OILS AND FLUIDS PROPERLY Physical contact with used motor oil may pose a health risk.
Page 31 2OPERATING CONTROLS "Operating Controls" section presented here consists of the following groups: “Component Locations” on page 2-2 “Control Identification” on page 2-8 “Steering Console and Pedals” on page 2-9 “Transmission Display” on page 2-16 “Front Instrument Panel” on page 2-18 “Right Side Switch Panel”...
Page 32: Component Locations
COMPONENT LOCATIONS MEGA 200-V (Tier I) The following figure identifies the location of major machine components. 41 40 39 APO0010L Figure 1 2-2 Operating Controls 022-00028AE Operation and Maintenance Manual...
Page 33 BUCKET TOOTH 24. RADIATOR BUCKET 25. GRILL AIR CONDITIONER CONDENSER 26. FAN REAR WHEEL COVER 27. FUEL TANK ENGINE OIL FILTER 28. ENGINE OIL FILLER PIPE BATTERY BOX 29. ENGINE OIL LEVEL GAUGE REAR LAMP 30. REMOTE ENGINE OIL DRAIN PORT COUNTERWEIGHT 31.
Page 34 MEGA 200-V (Tier II) (Tier I - European low noise kit) The following figure identifies the location of major machine components. 41 40 39 APO0020L Figure 2 2-4 Operating Controls 022-00028AE Operation and Maintenance Manual...
Page 35 BUCKET TOOTH 23. ENGINE BUCKET 24. RADIATOR AIR CONDITIONER CONDENSER 25. GRILL REAR WHEEL COVER 26. FAN ENGINE OIL FILTER 27. FUEL TANK BATTERY BOX 28. ENGINE OIL FILLER PIPE REAR LAMP 29. ENGINE OIL LEVEL GAUGE COUNTERWEIGHT 30. REMOTE ENGINE OIL DRAIN PORT FAN MOTOR 31.
Page 36 MEGA 200-VTC Figure 3 identifies the location of major machine components. BFO0010L Figure 3 2-6 Operating Controls 022-00028AE Operation and Maintenance Manual...
Page 37 BUCKET TOOTH 25. GRILL BUCKET 26. FAN AIR CONDITIONER CONDENSER 27. FUEL TANK REAR WHEEL COVER 28. ENGINE OIL FILLER PIPE ENGINE OIL FILTER 29. ENGINE OIL LEVEL GAUGE BATTERY BOX 30. REMOTE ENGINE OIL DRAIN PORT REAR LAMP 31. REAR AXLE PIVOT COUNTERWEIGHT 32.
Page 38: Control Identification
CONTROL IDENTIFICATION Figure 4, identifies controls in operator’s cab. APO0030L Figure 4 STEERING CONSOLE AND PEDALS (See RIGHT SIDE SWITCH PANEL (See page page 2-9) 2-41) VARIOUS CABIN LOCATIONS (See page SEAT ADJUSTMENT (See page 2-51) 2-38) 2-8 Operating Controls 022-00028AE Operation and Maintenance Manual...
Page 39: Steering Console And Pedals
STEERING CONSOLE AND PEDALS APO0040L Figure 5 STARTER SWITCH KICK-DOWN SWITCH HORN BUTTON TRANSMISSION LEVER COMBINATION SWITCH LEVER 10. FRONT INSTRUMENT PANEL (See page ACCELERATOR PEDAL 2-18) STEERING TILT KNOB 11. TRANSMISSION DISPLAY (See page BRAKE PEDALS 2-16) STEERING WHEEL 022-00028AE Operation and Maintenance Manual Operating Controls 2-9...
Page 40 STARTER SWITCH A four-position starter switch is used to start or shut down engine for equipment operation. "OFF" position. Key can be inserted or removed at this position. When key is moved to this position, engine will stop running. In this position, with engine "OFF," alternator light and engine oil light will turn "ON."...
Page 41 Figure 8 COMBINATION SWITCH Left Side Directional Switch Pushing lever forward, activates left outside directional lights directional indicator light instrument panel. Right Side Directional Switch - Pulling lever back, activates right outside directional lights directional indicator light instrument panel. AHO0920L NOTE: When turn is completed the Figure 9...
Page 42 Push Down - Locks into position and lights up the high beams. Neutral Position - Normal low beams. Pull Up - Momentarily turns "ON" both the low beams and high beams. (Returns to "NEUTRAL" position when released.) NOTE: High and low beams will only function with headlight...
Page 43 BRAKE PEDAL (RIGHT AND LEFT PEDALS) Pressing brake pedal will apply the brakes to the loader. The brake pedal modes can be switched over from inching to no- inching or vice-versa, by using the Transmission cutoff switch (See page 2-36). CAUTION! Figure 13 When descending on an incline, slow...
Page 44 KICK-DOWN SWITCH (TWO PLACES) When transmission in 2nd gear, pressing this switch will shift transmission into 1st gear. This will allow the driver to perform a quick digging movement. NOTE: Kick-down "RELEASED" when transmission is placed in "NEUTRAL" position or the switch is pressed again.
Page 45 A transmission neutral lever lock is in base of transmission lever. This neutral lever lock prevents the transmission lever from being moved out of "NEUTRAL." "NEUTRAL LOCK" position. Prevents lever from being moved out of "NEUTRAL." "DRIVE" position. Allows lever to be moved from "NEUTRAL"...
Page 46: Transmission Display
TRANSMISSION DISPLAY A transmission display is to the left of the steering wheel on the dash. The LCD indicates, gears, direction of travel, error codes, and activated kick-down. Figure 21 Figure 22, shows the transmission display in detail. Indicates travel direction gear selection.
Page 47 022-00028AE Operation and Maintenance Manual Operating Controls 2-17...
Page 48: Front Instrument Panel
FRONT INSTRUMENT PANEL 11 12 APO0060L Figure 24 2-18 Operating Controls 022-00028AE Operation and Maintenance Manual...
Page 49 GAUGES FUEL GAUGE TACHOMETER SPEEDOMETER COOLANT TEMP. GAUGE HOUR METER TRANSMISSION OIL TEMP. GAUGE WARNING AND INDICATOR LIGHTS PREHEAT CYCLE INDICATOR LIGHT 13. HIGH BEAM INDICATOR LIGHT AIR FILTER INDICATOR LIGHT 14. RIGHT TURN AND HAZARD WARNING COOLANT TEMPERATURE WARNING LIGHT LIGHT 15.
Page 50 SPEEDOMETER This meter displays speed at which vehicle is traveling. HBOI230L Figure 26 HOUR METER A LCD meter that records total time that starter switch is turned "ON" up to 99,999.9 hours. When engine is running, the hourglass icon blinks every four seconds.
Page 51 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.
Page 52 AIR FILTER INDICATOR LIGHT When this light turns "ON," dirt has built up in the air filter and is beginning to restrict flow of air. Clean or replace air filter element before continuing to operate machine. To turn indicator light "OFF," turn starter switch "OFF"...
Page 53 12. LEFT TURN AND HAZARD WARNING LIGHT This light blinks when left turn signal is turned "ON." Both lights blink when warning lights are turned "ON." NOTE: If left and right turn indicators blink together, or if they blink faster than normal, a light bulb is not operating or flasher solenoid is damaged.
Page 54 16. BRAKE FLUID WARNING LIGHT This light turns "ON" when pressure drops in brake fluid circuit. When light turns "ON," an alarm also sounds. WARNING! Never operate or travel machine when this light is "ON" or when alarm sounding. Always investigate HA0O2024 cause of the drop in brake fluid...
Page 55 19. EMERGENCY STEERING INDICATOR LIGHT (OPTION) This light turns "ON" when the emergency steering system is activated due to a hydraulic failure. Immediately stop operation, stop machine, "APPLY" parking brake, and shut down engine. DANGER! AJO0450L Emergency steering indicator light. If Figure 42 this light turns "ON"...
Page 56 21. BLANK (EMPTY SWITCH SOCKET) A blank socket is provided for addition of accessory switches. HAOA734L Figure 44 22. BUCKET FLOAT SWITCH (OPTION) Bucket float allows the bucket to follow the contour of the ground/working surface. When pressing this switch and setting work lever to floating position, lever is locked (detent) and boom is lowered.
Page 57: Right Side Switch Panel
RIGHT SIDE SWITCH PANEL AJO0070L Figure 46 PILOT CONTROL VALVE LEVER REAR WORK LIGHT SWITCH (JOYSTICK) REAR WIPER SWITCH 1A. PILOT CONTROL VALVE LEVER ROTATING BEACON SWITCH (OPTION) (OPTION) 10. CUP HOLDER 1B. ERGO-II PILOT CONTROL VALVE LEVER 11. PARKING BRAKE SWITCH (JOYSTICK) (OPTION) 12.
Page 58 PILOT CONTROL VALVE LEVER (JOYSTICK) Used to position bucket and boom. This lever is capable of raising or lowering boom, and crowding or dumping bucket. When machine is being traveled, the lever (joystick) can be "LOCKED" out, to prevent any movement of bucket or boom. To "LOCK"...
Page 59 1B. ERGO-II PILOT CONTROL VALVE LEVER (JOYSTICK) (OPTION) Ergo-II lever is a pilot control valve lever that incorporates transmission control functions. It is used to reduce hand and arm movement for he otherwise complex operation of machine. Forward, Neutral Reverse Switches.
Page 60 KICK-DOWN SWITCH (TWO PLACES) Kick-down Switch Function When transmission is in 2nd gear, pressing this switch (Figure 52) will shift transmission into 1st gear. This will allow the driver to perform a quick digging movement. Kick-down function range: • Automatic: 2nd, 3rd, 4th. •...
Page 61 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...
Page 62 HEADLIGHT SWITCH In this position, this switch turns "OFF" clearance, tail, instrument panel, switch and headlights. NOTE: If the switch is not in this position with the engine not running, the pilot buzzer will sound to warn the operator that batteries being discharged.
Page 63 REAR WORK LIGHT SWITCH In this position, this switch turns "OFF" work lights mounted on the rear top of cab. In this position, this switch turns "ON" work lights mounted on the rear top of cab. CAUTION! AHO0851L Do not turn "ON" the work light when Figure 58 traveling on public roads.
Page 64 REAR WIPER SWITCH In this position, this switch turns "OFF" windshield wiper mounted on rear windshield of operator’s cab. In this position, windshield washer fluid sprays onto the rear windshield while running the rear wiper. When released, the switch returns to the "O"...
Page 65 11. PARKING BRAKE SWITCH In this position, the parking brake is "RELEASED" and the monitor light on the front instrument panel turns "OFF." In this position, the parking brake is "APPLIED" and the monitor light on the front instrument panel comes "ON."...
Page 66 13. TRANSMISSION CUTOFF SWITCH This switch changes over the modes of the brake pedal, inching and no-inching. In this position, the "NO INCHING" mode is selected. In the "NO INCHING" mode, the power transmission line still connected when the brake pedal is pressed, thus, making it easier to start off on an incline.
Page 67 15. EMERGENCY STEERING TEST SWITCH (OPTION) This switch is used to test whether the emergency steering system is properly functioning. The system should be tested during the start-up procedure ensure that the system is functioning. Test emergency steering system using the following procedure;...
Page 68: Various Cabin Locations
VARIOUS CABIN LOCATIONS HAAA3710 Figure 67 CAB LIGHT WASHER TANK STEREO HOT/COLD REFRIGERATOR HEATER AND AIR CONDITIONER ELECTRICAL BOX CONTROL PANEL FUSE BOX TWO SPEAKERS 10. FUSE BOX ONE STORAGE BOX 2-38 Operating Controls 022-00028AE Operation and Maintenance Manual...
Page 69 CAB LIGHT A cab light is on the front of the ceiling. You can turn the light "ON" and "OFF" by pressing its switch. HBOI400L Figure 68 STEREO For operation of stereo see “Stereo” on page 2-47. HAOA951L Figure 69 HEATER AND AIR CONDITIONER CONTROL PANEL For operation of heater and air conditioner...
Page 70 STORAGE BOX There is a storage box (1, Figure 72) behind the seat. Keep the operation maintenance manual and other documents in this compartment. HBOI431L Figure 72 WASHER TANK Contains windshield washer fluid. HBOM680I Figure 73 HOT/COLD REFRIGERATOR There is a hot/cold refrigerator (1, Figure 74) behind and to the left of the seat.
Page 71 FUSE BOX TWO Fuse box two is just above the windshield washer fluid tank. 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.
Page 72: Heater And Air Conditioner Operation
HEATER AND AIR CONDITIONER OPERATION LOCATION OF CONTROLS AND VENTS HBOI310L Figure 78 OPERATION PANEL FOOT NOZZLE FRONT NOZZLE (AIR CONDITIONER) REAR NOZZLE FRONT NOZZLE (DEFROSTER) The heater and air conditioner are combined into one unit to the right side of the operator’s seat. If necessary, the operator can control inner temperature using the operation panel.
Page 73 OPERATION PANEL HAOA801L Figure 79 FAN AND AIR CONDITIONER SWITCH SELECTION SWITCH FOR WIND BLOWER FAN SWITCHES DIRECTION TEMPERATURE CONTROL SWITCH VENTILATION SELECTION SWITCH When a switch is selected, the LED above that switch will turn "ON" and give an activation sound. When the light switch is turned "ON,"...
Page 74 BLOWER FAN SWITCHES These switches are used to control the speed of the blower fan. "LO" Switch - Used for low blower speed. "MID" Switch - Used for intermediate blower speed. "HI" Switch - Used for high blower speed. NOTE: If you do not select a blower HAOC940L speed...
Page 75 Used to direct air flow to lower portion of operator’s cab. HBOI330L Figure 84 Used to direct air flow for defrosting front window of operator’s cab. HBOI340L Figure 85 VENTILATION SELECTION SWITCH "A" Switch - Draws fresh air into operator’s compartment. "B"...
Page 76 MEMORY FUNCTION OF USED MODE The air conditioner panel has a memory function. When the starter switch is turned "OFF" the settings for the panel will be stored. When the excavator is started, the last setting will be used. ADDITIONAL OPERATING INSTRUCTION A proper indoor temperature in summer is 5 - 6°...
Page 77: Stereo
STEREO Figure 87 ON-OFF / VOLUME CONTROL KNOB CASSETTE SLOT BALANCE / FADER CONTROL 8. & 9. PLAY DIRECTION BUTTON BASS/TREBLE CONTROL 10. AUTOMATIC SELECTION AM/FM BAND SELECTION 11. DOLBY B SELECTION AUTOMATIC MEMORY (AME) 12. METAL SELECTION TAPE EJECT BUTTON 13.
Page 78 To adjust bass tone level press on control and it will pop out. Rotate control counterclockwise to decrease bass and clockwise to increase bass. AM/FM BAND SELECTION This button sets radio to either AM-1, AM-2, FM-1 or FM-2 frequency bands. Each frequency bands will enable the stereo to store 6 preset radio station frequencies.
Page 79 12. METAL SELECTION If tape being listened to is either a metal or chromium type of tape, press preset selector button 2 to select "MTL" setting. "MTL" will appear on display. Press this control a second time to turn this setting "OFF."...
Page 80 Do not store cassette tapes in the following places or under the following conditions. Damage to tape and stereo may result. • Direct sunlight. • Humid place. • Dusty place. • Around heater or heater vents which discharge heat. • Around speakers and other magnet devices that generate a strong HLB2014L...
Page 81: Seat Adjustment
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.
Page 82 ANGLE ADJUSTMENT OF ARMREST Adjustment angle of left and right armrest (6, Figure 97) is done by turning a dial in bottom of armrest. When you adjust angle, manually raise armrest before turning dial. HEADREST Headrest (7, Figure 97) can be adjusted forward/backward and up/down.
Page 83: Seat Belt
SEAT BELT WARNING! Seat belt is for operator's safety and should be worn at all times. Before driving machine, adjust seat to desired position for maximum comfort and machine control, then fasten seat belt. Seat belts must be worn across pelvic region and adjusted snugly to lessen chance and severity of injury in event of an accident.
Page 84: Door Side Latch
DOOR SIDE LATCH The door side latch (1, Figure 100) is used to secured the door to the side of the cab when it is opened. NOTE: Keep the door closed and locked when machine is not in use. Figure 100 To release door from side of cab, push the latch lever (Figure 101) down.
Page 85: Fuse Box/Relay
FUSE BOX/RELAY FUSE BOXES There are two fuse boxes inside the cab. Fuse box one (1, Figure 102) is in the rear side of right control stand. A usage diagram of fuses is shown inside of fuse box. Spare fuses are mounted on the inside of fuse box cover (10A - Qty.
Page 86 Fuse Box One Name Capacity Gauge Panel Transmission Front Wiper, Horn Parking Brake, Pilot Cutoff, Log Fork (Option) AJO0470L Headlight, Stop Light Figure 103 FUSE BOX ONE Condenser Fan, Preheat Emergency Steer (Option), Spare Air Conditioner, Heater Working Light (Front), Rotating Beacon (Option) Working Light (Rear) Turn Signal Light, Hazard...
Page 87 RELAY The relays are in the electrical box under the seat. If the problem is not solved after replacing the fuse, check the function of the relay. APO0210L Figure 105 Figure 106 CIRCUIT BREAKER A circuit breaker is next to the relay by the batteries back unit...
Page 88: Window Glass Breaking Tool
WINDOW GLASS BREAKING TOOL This loader is equipped with a glass breaking tool. It is in the lower right side of the cab just rear of the door. This tool can be used in case of an emergency situation which requires the breaking of glass to exit from the operator’s cabin.
Page 89: Operation
NEW MACHINE BREAK-IN PROCEDURES All Daewoo wheel loaders are inspected and adjusted before leaving the factory. However, it is required that the operator follow these steps during initial break-in period. Failure to follow these steps may result in damage to equipment or reduced performance.
Page 90: Engine Start And Stop
ENGINE START AND STOP ENGINE START Set parking brake switch to "I" (APPLIED) position. This will ensure that the parking brake is "APPLIED." HA0O2019 Figure 1 Move all control levers to "NEUTRAL" position. IMPORTANT transmission lever "NEUTRAL" position, engine will not start.
Page 91 Set pilot cutoff switch to "O" (LOCK) position. This will "LOCK" pilot control valve lever (joystick). HBOI111L Figure 4 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.
Page 92 engine systems (oil pressure, oil temperature, coolant temperature, etc.) are in normal operating range. If any engine system is not normal, turn starter key to "OFF" position. Indicator Instrument Panel Light Or Gauge Reading Fuel Gauge Engine Coolant Temperature Gauge WHITE RANGE Transmission Oil Temperature Gauge Engine Oil Pressure Warning Light...
Page 93 COLD WEATHER ENGINE START Set parking brake switch to the "I" (APPLIED) position. This will ensure that the parking brake is "APPLIED." HA0O2019 Figure 8 Move all control levers to "NEUTRAL" position. IMPORTANT transmission lever "NEUTRAL" position, engine will not start.
Page 94 Turn starter key to "PREHEAT" position. When preheater indicator light turns "ON," preheat cycle is complete. HAOC020L Figure 12 Rotate starter key to "I" (ON) position. All indicator lights should turn "ON." HAOB320L Figure 13 Rotate starter key to "START" position. Starter motor should crank immediately, and engine should start within a few seconds.
Page 95 Release starter key when engine starts. Key will return to "I" (ON) position. IMPORTANT engine does start after approximately seconds cranking, release starter key. Wait 5 minutes for starter motor to cool down. Repeat step 8. 10. After engine starts, check all indicator HAOB360L lights and gauges to be certain that all Figure 15...
Page 96 STARTING WITH AUXILIARY BATTERIES WARNING! Wear safety glasses. Never connect negative leads to positive terminals and vice versa. DO NOT connect auxiliary or booster battery ground terminal directly to battery terminal. Locate and use a ground point on machine frame. Depleted batteries generate hydrogen gas.
Page 97 ENGINE STOP Move transmission lever to "NEUTRAL" position. Figure 17 Make sure transmission neutral lock is in the "N" (NEUTRAL LOCK) position. Figure 18 Set parking brake switch to the "I" (APPLIED) position. This will ensure that the parking brake is "APPLIED." HA0O2019 Figure 19 Set bucket on ground.
Page 98 Rotate starter key to "O" (OFF) position. Remove key. HAOC342L Figure 21 HYDRAULIC SYSTEM WARM-UP Correct operating temperature of hydraulic oil is 50° - 80°C (120° - 175°F). Make sure to follow procedures listed below for hydraulic fluid warm-up. Run engine at idle (no load) for 5 minutes. Run engine for approximately 5 minutes at middle of speed range, without a load.
Page 99: Machine Travel
MACHINE TRAVEL WARNING! If vehicle is moved while parking brake is engaged, serious damage to parking brake disc will result. Select a transmission gear that is appropriate for top speed that will be traveled. Choosing a gear that is too high will reduce acceleration and will unnecessarily heat transmission converter oil.
Page 100 Set pilot cutoff switch to "O" (LOCKED) position. This will prevent boom and bucket from accidentally moving during travel, as a result of accidentally touching pilot control valve lever (joystick). HBOI111L Figure 24 Press brake pedal. Figure 25 Set transmission neutral lock is in the "D" (DRIVE) position.
Page 101: Machine Shut Down
Place transmission lever in desired gear. Shift gears one by one. Do not skip from 1st to 3rd, for example. Shift transmission lever to "FORWARD" position. Figure 28 Release the brake pedal while slowly pressing the accelerator pedal. WARNING! When traveling at high speed or on a steep hill, make...
Page 102 Put transmission lever in "NEUTRAL." Figure 31 Set transmission neutral lock is in the "N" (NEUTRAL LOCK) position. CAUTION! "LOCK" transmission lever. When ever machine is parked, "LOCK" transmission lever in "NEUTRAL" to prevent accidental machine movement. Figure 32 Set parking brake switch to the "I" (APPLIED) position.
Page 103: Additional Braking
Rotate starter key to "O" (OFF) position. Remove key. HAOC342L Figure 35 If machine is parked on a slope, install wheel chocks in front of and behind vehicle wheels. WARNING! Always secure machine with wheel chocks when parked on a slope. Leaving machine in gear will provide braking effect...
Page 104: Boom Raise Kickout
BOOM RAISE KICKOUT Placing bucket lever in "Boom Raise Detent" position will lock bucket lever in raise boom position. Boom will raise until trip plate (1, Figure 37) makes contact with bucket height limit switch (2). When limit switch is tripped, boom will stop raising and bucket lever will automatically returned...
Page 105: Boom Lower Kickout (Option)
BOOM LOWER KICKOUT (OPTION) Placing bucket lever in "L" position will lock control lever in lower boom position. Boom will move downward until trip plate (2, Figure 40) makes contact with bucket lower limit switch (1). When limit switch is tripped, boom will stop lowering and bucket lever will automatically be returned to "NEUTRAL"...
Page 106: Adjustment Of Bucket Position Switch
ADJUSTMENT OF BUCKET POSITION SWITCH MEGA 200-V When bucket lever is held in crowd detent position, after bucket has been dumped, bucket will pivot toward crowd position. Once full crowd position has been reached, bucket lever will automatically return to "NEUTRAL"...
Page 107: Towing Machine
TOWING MACHINE When necessary to tow another vehicle, the tow rope must be tied to the towing pin on the counterweight at the rear of vehicle. NOTE: The loader must be used for towing only in an emergency. WARNING! Do not tow machine at a speed over 10 km/ h (6 MPH) and do not tow machine farther than 10 Km (6 miles).
Page 108: If Engine Stalls While Traveling
IF ENGINE STALLS WHILE TRAVELING BRAKE SYSTEM: The brakes can be applied approximately 9 times by pressing the brake pedal due to the oil pressure stored in the accumulator after engine is turned "OFF" if the engine stalls while traveling, move to an out of traffic area and park.
Page 109 4INSPECTION, MAINTENANCE AND ADJUSTMENT Routine maintenance and inspections are required to keep your machine in the correct operating condition. The following pages list the inspection intervals, the system or component checks and location references. NOTE: The following pages list the service checks their...
Page 110 The engine name plate (identification label) is attached to rocker cover (Figure 3). The engine serial number is stamped on the left rear of the engine block, under exhaust manifold. Please make note of these numbers and their locations. These will be required whenever warranty service work is requested.
Page 111: Table Of Recommended Lubricants
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...
Page 112 SAE 15W40 API CD and above CAUTION! Do not mix oils from different manufacturers. Daewoo does not endorse specific brands but does suggest that owners select quality oils whose suppliers provide assurance that required standards will always be met or exceeded.
Page 113: Fluid Capacities
FLUID CAPACITIES Component Capacity Engine Oil Pan with Filter 21 liters (5.5 U.S. gal.) NOTE: The filter holds an additional 1 liter (1 qt) of oil. Cooling System 31 liters (8.2 U.S. gal.) Fuel Tank 260 liters (69 U.S. gal.) Hydraulic Oil Tank 150 liters (40 U.S.
Page 114: Maintenance Intervals
MAINTENANCE INTERVALS 10 HOUR / DAILY SERVICE • Grease Front Attachment Pins (See page • Inspect the Bucket Teeth and Side Cutters 4-8)* for Signs of Wear (See page 4-14) • Inspect All Tires for Correct Tire Pressure • Inspect Seat Belt for Proper Operation (See and Signs of Damage or Abnormal Wear page 4-15) (See page 4-8)
Page 115 500 HOUR / 3 MONTH SERVICE • Perform All 10 Hour / Daily, 50, and 250 • Clean Exterior of Radiator, Oil Cooler and Hour Service Checks (See page 4-34) Air conditioner Condenser (See page 4-35) • Replace Fuel Filter (See page 4-34) •...
Page 116: 10 Hour / Daily Service
10 HOUR / DAILY SERVICE GREASE FRONT ATTACHMENT PINS NOTE: Fittings are greased daily, or every 10 hours, for the first 100 hours of operation to comply with new machine break-in requirements. After that, greasing should be done every 50 hours.
Page 117 CHECK TRANSMISSION OIL LEVEL NOTE: When checking level using a dipstick always remove and wipe it clean before making final level check. Use two people to perform this operation. Start engine and move machine to a level area. Place transmission lever in "NEUTRAL." Apply parking brake.
Page 118 CHECK HYDRAULIC SYSTEM OIL LEVEL WARNING! The hydraulic oil will be hot after normal machine operation. Allow system to cool before attempting to service any of the hydraulic components. The hydraulic tank is pressurized. Turn the breather slowly allow HAOA060L pressurized air to vent.
Page 119 The hydraulic oil filler cover also serves as the hydraulic oil strainer access cover. It is important to replace this cover and the components in the proper order and alignment. The filter element (2, Figure 12), retaining rod (2) and spring (4) are assembled as shown in Figure 12.
Page 120 FILL FUEL TANK WARNING! Use extreme safety precautions while refueling to prevent explosions or fire. Immediately clean up any spilt fuel. At end of each work day, fill fuel tank. Add fuel through fuel filler pipe (Figure 14). When working at a temperature of 0°C Figure 14 (32°F) or higher, use ASTM No.
Page 121 DRAIN FUEL CONDENSATION AOO0040L APO0070L Figure 17 Figure 16 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.
Page 122 Do not allow replaceable bucket teeth to wear down to the point that bucket adapter is exposed. (Figure 21) NOTE: These instructions are only for Daewoo OEM buckets. If you are using other manufacturers’ buckets, refer to their specific Figure 21 instructions.
Page 123 INSPECT SEAT BELT FOR PROPER OPERATION INSPECT THE STRUCTURE FOR CRACKS AND FAULTY WELDS During the daily walk-around inspection and when greasing the machine, look for any visible damage to the machine. Repair or replace any damaged parts before operating machine. CHECK THE OPERATION OF ALL SWITCHES Verify working condition of all switches before starting engine.
Page 124 INSPECT ENGINE FAN BLADE WARNING! Personal injury can result from a fan blade failure. Never pull or pry on the fan. This can damage the fan blade(s) and cause fan failure. NOTE: Manually rotate the crankshaft by using a wrench on the Figure 22 accessory drive pulley nut.
Page 125 Figure 24 Check the engine intake hose, and hose bands for damage and tightness. If damaged, wrinkled or loose, replace or retighten or contact your nearest Daewoo loader dealer. IMPORTANT Severe engine damage will result from running with unfiltered air.
Page 126: Hour / Weekly Service
PERFORM ALL 10 HOUR / DAILY SERVICE CHECKS GREASE FRONT ATTACHMENT PINS MEGA 200-V 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.
Page 127 Bucket hinge pins, locations (Figure 27). Figure 27 Lever link connecting pin, 1 location (Figure 28). Figure 28 Bucket link connecting pin, 1 location (Figure 29). Figure 29 Arm-lever connecting pin, 1 location. (Figure 30). Figure 30 022-00028AE Operation and Maintenance Manual Inspection, Maintenance and Adjustment 4-19...
Page 128 Bucket cylinder rod end, 1 location. (Figure 31). Figure 31 Lift cylinder heads (left, right), 2 locations (Figure 32). Figure 32 Lift cylinder rod ends, 2 locations. (Figure 33). Figure 33 4-20 Inspection, Maintenance and Adjustment 022-00028AE Operation and Maintenance Manual...
Page 129 Remote location points. AJO0150L Figure 34 REMOTE FITTINGS FOR LOADER ARM REMOTE FITTINGS FOR BUCKET FOOT ENDS (50 HOUR) (Figure 35 and CYLINDER HEAD (50 HOUR) (Figure 35 Figure 36). and Figure 37). Figure 35 022-00028AE Operation and Maintenance Manual Inspection, Maintenance and Adjustment 4-21...
Page 130 Loader foot ends, locations on each side of machine. Greased from two remote grease points (1, Figure 34). Figure 36 Bucket cylinder head, 1 point. Greased from remote grease point (2, Figure 34). Figure 37 Rear Axle pivot (1, Figure 38), 2 locations on each side of machine.
Page 131 MEGA 200-VTC 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. BFO0030P Figure 40 Bucket hinge pins, 2 locations on...
Page 132 Bucket lever connecting pins, 2 locations. Lever link connecting pins, 2 locations. Bucket cylinder rod ends, 2 locations. (Figure 42) Figure 42 Bucket cylinder heads, 2 locations. lever connecting pins, locations. Lever link connecting pins, 2 locations. (Figure 43) Link foot pins, 2 locations. Figure 43 Lift cylinder heads (left, right), 2 locations.
Page 133 Steering cylinder head ends, 2 locations. Use remote grease fittings mounted on frame.(1,2 Figure 46). Reference Remote Grease Number Fittings 1 and 2 Steering Cylinder 50 Hours Head Ends Drive Shaft 250 Hours Center Bearing Figure 46 GREASE UPPER AND LOWER CENTER PINS Center pins, Upper (Figure 47) and Lower (Figure 48).
Page 134 CLEAN EXTERIOR OF RADIATOR, OIL COOLER AND AIR CONDITIONER CONDENSER Dust and dirt accumulation on fins of radiator, oil cooler, and additional transmission cooler and air conditioner condenser greatly reduce their cooling efficiency. Use compressed air, water and steam to clean fins on radiator, oil cooler, and transmission cooler. NOTE: On an especially dusty work site, clean fins every 50 hours.
Page 135: Hour / Monthly Service
250 HOUR / MONTHLY SERVICE PERFORM ALL 10 HOUR / DAILY, 50 HOUR SERVICE CHECKS CHANGE ENGINE OIL AND FILTER NOTE: Change engine oil and filter after first 50 hours on a new machine and every 250 hours thereafter. CAUTION! Never attempt to change oil or filter on a hot engine.
Page 136 Fill engine with correct oil through oil fill port (2, Figure 51). Refer to Lubrication Table of this manual for recommended oil for the operating conditions. Start engine and check engine oil pressure light. Shut down engine. Look for signs of leaks at filter.
Page 137 CHECK ENGINE AIR PRE-CLEANER The engine is equipped with a pre-cleaner. Dust, insects, rainwater etc., can be present in the air. The pre-cleaner collects this material and discharges it. This prevents material from being drawn into air cleaner. The pre-cleaner does not need periodic cleaning or replacement.
Page 138 HYDRAULIC FULL FLOW FILTER REPLACEMENT WARNING! The hydraulic oil will be hot after normal machine operation. Allow system to cool before attempting to service any of the hydraulic components. The hydraulic tank is pressurized. Loosen hydraulic oil fill cap slightly to allow pressurized air to vent.
Page 139 DRAIN WATER FROM HYDRAULIC OIL TANK WARNING! Be certain that hydraulic oil has cooled before draining water and sediment. Hot oil could splash and cause burns. The hydraulic tank is pressurized. Press button in center of breather to allow pressurized air to vent.
Page 140 Clean outer filter by blowing compressed air from inside of filter towards the outside. Do not use more than 205 kPa (30 psi) air pressure. Clean the inside of air filter housing and inside of air filter housing cover. CAUTION! Never clean the inside of air filter HAOC570L housing while the inner element is...
Page 141 GREASE DRIVE SHAFTS Grease fitting for center bearing, 1 location. remote grease fitting mounted on frame (3, Figure 61). Reference Remote Grease Number Fittings 1 and 2 Steering Cylinder 50 Hours Head Ends Drive Shaft 250 Hours Center Bearing Figure 61 Figure 62 AXLE DIFFERENTIAL AND PLANETARIES OIL REPLACEMENT (AFTER FIRST 250 HOURS) NOTE:...
Page 142: 500 Hour / 3 Month Service
500 HOUR / 3 MONTH SERVICE PERFORM ALL 10 HOUR / DAILY, 50, AND 250 HOUR SERVICE CHECKS REPLACE FUEL FILTER WARNING! Exchange filter after waiting for engine to cool. Be careful of fire hazards. Do not smoke. Locate fuel filter inside engine...
Page 143 CLEAN EXTERIOR OF RADIATOR, OIL COOLER AND AIR CONDITIONER CONDENSER Dust and dirt accumulation on fins of radiator and oil cooler (Figure 64), and air conditioner condenser (Figure 65) greatly reduce their cooling efficiency. compressed air, water and steam to clean fins radiator, cooler,...
Page 144 CLEAN AIR CONDITIONER FILTER The unit is equipped with an air filtration system which filters out dirt and dust particles from air being circulated into operator’s cab. The air conditioner filter is in the right side switch panel console. Open access cover on the lower right side of cab on the outside to gain access to filter.
Page 145: 1,000 Hour / 6 Month Service
1,000 HOUR / 6 MONTH SERVICE PERFORM ALL 10 HOUR / DAILY, 50, 250, AND 500 HOUR SERVICE CHECKS CHANGE RADIATOR COOLANT WARNING! Allow the engine to cool before releasing the radiator cap. Make sure to loosen the cap slowly to release any remaining pressure.
Page 146 Remove coolant drain plug (Figure 71) from engine. APO0170L Figure 71 Open heater shutoff valve (Figure 72) to allow coolant to drain from heater core. Install drain plug, and close drain valve after coolant has completely drained from system. Fill cooling system with a flushing solution. NOTE: When filling...
Page 147 DRAIN AND REPLACE TRANSMISSION OIL AND FILTER NOTE: Transmission oil and filter must be changed after first 250 hours of operation to comply with new machine break-in requirements. After first change, oil and filter must be changed every 1,000 hours. Start machine and drive it until transmission fluid has warmed to 82 –...
Page 148 CLEAN FUEL TANK AND STRAINER WARNING! Fuel is flammable and harmful to skin. • Do not smoke while draining moisture and sediment from fuel tank. • Do not drain fuel with engine running. • Do not allow fuel to remain on skin for an extended period of time. Wash thoroughly with soap and water.
Page 149 CLEAN FUEL INJECTION PRIMING PUMP STRAINER Remove fitting, fuel line and strainer from bottom of priming pump. Clean strainer. Position strainer in priming pump and install fuel line and fitting. Figure 78 REPLACE AIR CONDITIONER FILTER NOTE: This unit is equipped with an air filtration system which filters out dirt and dust particles from air being circulated into operator’s cab.
Page 150 High No bubble is seen. recharging refrigerant. A flow of bubbles is visible. CHECK AND ADJUST ENGINE Contact your nearest Daewoo loader dealer. Engine dealer for checking and adjusting the following items: • Engine Compression Pressure. • Injection Pressure.
Page 151: 1,500 Hour / 9 Month Service
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.
Page 152 Clean area around level plug (1, Figure 80) and drain plug (2) on center differential. Remove level plug and drain plug. Allow oil to drain into a container. Install drain plug into center differential, and tighten it. Pump oil into plug hole for level plug on center differential.
Page 153: 2,000 Hour / Yearly Service
2,000 HOUR / YEARLY SERVICE PERFORM ALL 10 HOUR / DAILY, 50, 250, 500 AND 1,000 HOUR SERVICE CHECKS CHECK STEERING, BRAKE, DRIVE SHAFT, ENGINE AND FUEL SYSTEM REPLACE PIPES AND HOSES Replace pipes that carry brake fluid to wheel brakes i.e., service brake pipe (1, Figure 82) parking brake pipe (2).
Page 154 Perform bleeding procedure on other three wheels. DRAIN AND REPLACE HYDRAULIC OIL CAUTION! Be certain that hydraulic oil has cooled before draining it. Hot oil could splash and cause burns. Raise boom to its highest position. Tilt bucket back as far as possible, and shut down engine.
Page 155 Count the number of times you can depress the right hand brake pedal before the brake warning light comes on. If the number counted is less than five (5), there is some problem with the accumulator. Contact your nearest Daewoo dealer. 022-00028AE Operation and Maintenance Manual Inspection, Maintenance and Adjustment 4-47...
Page 156: 12,000 Hour / Six Year Service
12,000 HOUR / SIX YEAR SERVICE HOSE IN-SERVICE LIFETIME LIMIT (EUROPEAN STANDARD ISO 8331 AND EN982 CEN) European regulations state that the in-service life of any hydraulic hose may not exceed six years. Daewoo recommends the following; • Hoses at the customer premises can not be stored more than 2 years before being discarded or installed on a machine.
Page 157: Severe Conditions Maintenance
SEVERE CONDITIONS MAINTENANCE OPERATING CONDITION REQUIRED MAINTENANCE Mud, Water, Rain Check for loose fittings, obvious damage to machine, or any fluid leakage. After completing operations, clean mud, rocks, or debris from machine. Inspect for damage, cracked welds, or loosened parts. Perform all daily lubrication and service.
Page 158: General Maintenance
GENERAL MAINTENANCE FUEL TRANSFER PUMP WARNING! Do not dry operate fuel pump for more than 15 seconds. • Cooling and lubrication of pump is achieved by fuel passing through the pump. If the pump is dry operated, the heat generated by the moving parts will cause damage to the pump rotors, vanes and seals.
Page 159 AHO0790L Figure 90 Remove strainer cap (4, Figure 90) from inlet hose. NOTE: Keep strainer cap in a safe location to reseal strainer after refueling is complete. Insert inlet hose (5, Figure 90) into refueling tank. Turn fuel pump switch to "ON" position. NOTE: The transfer pump rate of flow is approximately 20 liters /...
Page 160: Parking Brake Adjustment
PARKING BRAKE ADJUSTMENT To adjust parking brake, perform the following steps: Jack up machine enough to allow tires to rotate freely. Turn “OFF” engine and place transmission lever in “NEUTRAL.” Turn ignition switch to “ON” position. Move parking brake switch to “UNLOCKED” position. FRONT AXLE SERVICE BRAKES Checking clearance between brake pad and brake disc in the front axle.
Page 161: Check Hydraulic Pressures
CHECK HYDRAULIC PRESSURES Hydraulic pressure for most systems can be check by using the remote test ports shown in (Figure 93). Reference Description Number Main Pump Pressure Control Lever Activation Pressure Steering Pump Pressure Figure 93 Transmission Clutch Pressure Brake Charge Pressure MAIN PUMP PRESSURE P - From pump R - To Tank...
Page 162 CONTROL LEVER ACTIVATION PRESSURE (S/N 1001 thru 2000 Europe Low Noise Kit) (S/N 2001 and Up) Attach gauge to port (2, Figure 93). Adjust relief cartridge (3, Figure 96) on brake and pilot and fan motor supply valve (1, Figure 96). Relief pressure should be set at 28 kg/cm (398 psi).
Page 163 BRAKE CHARGE PRESSURE (S/N 1001 thru 2000) Attach gauge to port (5, Figure 93). Adjust brake charge valve cartridge (2, Figure 99) on brake and pilot supply valve (1, Figure 99). Relief pressure for brake charging is 140/120 kg/cm (1,990/1,707 psi).
Page 164 FAN MOTOR PRESSURE (S/N 1001 thru 2000 Europe Low Noise Kit) (S/N 2001 and Up) Attach gauge to inlet port of fan motor (1, Figure 102). Adjust screw on relief valve cartridge (2, Figure 102). NOTE: Outlet pressure should be 87 ±5 kg/cm (1,237 ±70 psi).
Page 165: Tires And Wheels
TIRES AND WHEELS Properly inflated tire (2, Figure 103) is an important factor in determining tire performance and tire life. A tire that is under-inflated (1, Figure 103) does not properly support machine, and will wear out quickly. Over-inflated tires (3, Figure 103) have poor traction and puncture easily.
Page 166 Improper servicing or changing tires and rims can cause explosion resulting in serious injury or death. Do not service or change tires and rims unless properly trained and equipped. Contact your nearest Daewoo loader dealer or tire manufacturer’s local dealer for tire servicing or changing. WARNING! Overheated tire may explode causing serious injury or death.
Page 167: Electrical System
ELECTRICAL SYSTEM CHECK BATTERY CONDITION WARNING! Before starting any battery service work, make sure to shut the engine off and turn the starter switch to the "OFF" position. The batteries create hydrogen gas. An explosion hazard exists, particularly with a deeply discharged battery.
Page 168: Bolt Torque Chart
BOLT TORQUE CHART TIGHTENING TORQUE SPECIFICATIONS FOR METRIC BOLTS (FOR COATED THREADS, PRE- LUBRICATED ASSEMBLIES) Grade Gr. 8.8 Gr. 10.9 Gr. 12.9 Dia. kg•m ft lb kg•m ft lb kg•m ft lb 5 mm x std 0.59 0.79 6 mm x std 1.00 1.38 1.66...
Page 169: Long Term Storage
LONG TERM STORAGE CLEANING Pressure wash machine. Inspect machine for any damage or missing parts. Drive machine to check steering linkage for damage. HYDRAULIC SYSTEM Start engine and allow it to idle for a few minutes. Drive machine around for 2 – 3 minutes. Raise and lower boom 2 –...
Page 171: Transportation
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. Park the trailer on a flat firm roadbed. Keep a fairly long distance between the road shoulder and the machine.
Page 172: Summary Of Safety Precautions For Lifting
10. Determine the route for transporting the machine by taking into account the width, height and weight of the machine and the truck. SUMMARY OF SAFETY PRECAUTIONS FOR LIFTING To make safe lifts, the following items must be evaluated by operator and work site crew. •...
Page 173: Troubleshooting
TROUBLESHOOTING ENGINE Problem Cause Remedy Starter does not operate. Blown fuse. Replace fuse. Low battery power. Charge battery. Poor terminal contact. Clean and tighten connections. Starter switch failed. Replace switch. Starter relay failed. Replace relay. Starter control failed. Replace controller. Wiring harness faulty.
Page 174 Add oil. surges. Plugged air intake system. Clean system and replace filter. Injection pump Contact your Daewoo dealer. adjustment. Plugged fuel filter. Replace fuel filter. Water or dirt in fuel system. Clean system and add new fuel. Clogged or dirty fuel injectors.
Page 175 Clean. Scale or mineral build up inside Flush or professionally clean. radiator. Defective alarm switch (gauge is Contact your Daewoo dealer. in green). Low water pump flow. Thermostat stuck or missing. Engine does not start when the Fuel filter element clogging.
Page 176: Hydraulic System
HYDRAULIC SYSTEM Problem Cause Remedy None of the controls function Hydraulic pump failed. Contact your Daewoo (loud noise from pumps). dealer. Low hydraulic oil level. Add hydraulic oil as required. Suction line plugged or damaged. Clean or replace as required.
Page 177 Cause Remedy Oil temperature too high. Debris in exterior of cooler. Clean exterior of cooler. Oil cooler faulty. Contact your Daewoo dealer. Fan belt loose. Tighten fan belting as required. Actuators on one side of boom Overload relief valve is not operating Repair valve or replace.
Page 178: Travel System
TRAVEL SYSTEM GENERAL Problem Cause Remedy Machine will not travel. Transmission clutch pressure Adjust pressure. incorrect. Transmission charge pump Replace pump. damaged. Damage to transmission control Repair wiring. valve wiring harness. Burned travel relay or fuse Replace relay or fuse. Forward/Reverse solenoid Clean and repair.
Page 179 Problem Cause Remedy Drive shaft vibration Noisy Bent drive shaft. Replace drive shaft. universal joints. Loose universal joints. Tighten bolts that secure joints. Worn or damaged universal joint. Replace universal joint. Loose universal joints. Tighten bolts that secure universal joints. Lack of lubrication.
Page 180 TRANSMISSION ERROR CODES The first number of the error code is the category that it is grouped into. They are as follows for the first number. Digital Input Signals Analog Input Signals Speed Signals Speed Signals Analog Current Output Signals Analog Current Output Signals Digital Output Signals Digital Output Signals...
Page 181 Error Code Meaning Of Error Code Remarks Number Short circuit to ground or open circuit at internal speed input. Logical error at internal speed input. Short circuit to battery voltage at output speed input. Short circuit to ground or open circuit at output speed input. Logical error at output speed input.
Page 182 Error Code Meaning Of Error Code Remarks Number Open circuit at relay reverse warning alarm. Short circuit to battery voltage at relay starter interlock. Short circuit to ground at relay starter interlock. Open circuit at relay starter interlock. Short circuit to battery voltage at park brake solenoid. Short circuit to ground at park brake solenoid.
Page 183: Steering
STEERING Problem Cause Remedy Steering Wheel is hard to turn. Sediment blocking direction change Clean and repair. spool orifice, inside priority valve. Sediment blocking amplifying spool Clean and repair. orifice, inside priority valve. Sediment blocking load sensing line Clean and repair. orifice, inside priority valve.
Page 184: Braking
BRAKING Problem Cause Remedy Reduced brake action. Low secondary pressure in brake Repair or replace brake valve. valve. Worn brake discs. Replace brake discs. Damaged brake discs. Replace brake discs. Damaged brake valve block. Replace valve. Air in brake hydraulics due to leak in Repair leak, bleed system.
Page 185: Specifications
7SPECIFICATIONS MEGA 200-V GENERAL SPECIFICATIONS COMPONENT SPECIFICATION 1.8 m (2.4 yd STD. Bucket Cap. 1.9 m (2.5 yd 11,000 kg (24,251 lb) Vehicle Weight 11,200 kg (24,692 lb) Engine Model DB58TI DB58TIS Emission Tier I Tier II Type Turbo, Intercooler...
Page 186 force, and faster cycle times. The maximum horsepower occurs at 2000 rpm when power is needed during the working cycle. WORKING RANGE AND DIMENSIONS Figure 1, illustrates exterior machine dimensions and working range of machine when it is equipped with a standard bucket.
Page 187 Dimension Category Standard Option Overall Length (A) 7,025 mm (23' 1'') Overall Width (B) 2,450 mm (8' 0'') 2,550 mm (8' 4'') Overall Height (C) 3,180 mm (10' 5'') 3,260 mm (10' 8'') Bucket Width (D) 2,450 mm (8' 0'') 2,550 mm (8' 4'') Wheel Base (E) 2,900 mm (9' 6'')
Page 188: Mega 200-Vtc
MEGA 200-VTC GENERAL SPECIFICATIONS COMPONENT SPECIFICATION STD. Bucket Capacity 1.8 m (2.4 yd 1.9 m (2.5 yd Vehicle Weight 11,000 kg (24,251 lb) 11,200 kg (24,692 lb) Engine Model DB58TI DB58TIS Emission Tier I Tier II Type Turbo, Intercooler Turbo, Charge Air Intercooler Horsepower (see note) 140 ps (138 hp) @ 2,200 Rated.
Page 189 WORKING RANGE AND DIMENSIONS Figure 2 illustrates exterior machine dimensions and working range of machine when it is equipped with a standard bucket. BFO0020L Figure 2 022-00028AE Operation and Maintenance Manual Specifications 7-5...
Page 190 Dimension Category Standard Option Overall Length (A) 7,280 mm (23' 10'') 7,280 (23' 10'') Overall Width, without bucket (B) 2,381 mm (7' 10'') Overall Height (C) 3,180 mm (10' 5'') 3,260 mm (10' 8'') Bucket Width (D) 2,450 mm (8' 0.5'') 2,550 mm (8' 4'') Wheel Base (E) 2,900 mm (9' 6.1'')
Page 191: Working Capacities
WORKING CAPACITIES BUCKET CAPACITY Standard toothed bucket has a capacity of 1.8 m (2.4 yd 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.
Page 192 LOW WEIGHT OR MEDIUM WEIGHT OR HIGH WEIGHT OR DENSITY DENSITY DENSITY MATERIAL 1,100 KG/M 1,600 KG/M 2,000 KG/M (1,850 LB/YD ), OR (2,700 LB/YD ), OR (3,370 LB/YD ), OR LESS LESS LESS Cement, Portland, DRY 1,362 kg/m --------------------- --------------------- clinkers (2,295 lb/yd...
Page 193 LOW WEIGHT OR MEDIUM WEIGHT OR HIGH WEIGHT OR DENSITY DENSITY DENSITY MATERIAL 1,100 KG/M 1,600 KG/M 2,000 KG/M (1,850 LB/YD ), OR (2,700 LB/YD ), OR (3,370 LB/YD ), OR LESS LESS LESS Snow, light density 529 kg/m --------------------- --------------------- (891 lb/yd Sand, DRY, loose...
Page 195 1INDEX 3-18 Numerics Position Switch 4-14 Teeth and Side Cutters 4-37 1,000 Hour / 6 Month Service 4-43 1,500 Hour / 9 Month Service 10 Hour / Daily Service 4-48 12,000 Hour / Six Year Service 2-39 Cab Light 4-45 2,000 Hour / Annually Service 2-31 Cigar Lighter...
Page 196 4-55 Fluid Capacities Parking Brake Release Pressure 2-18 4-55 Front Instrument Panel Service Brake Outlet Pressure 2-32 4-54 Front Work Light Switch Steering Pump Pressure 4-41 4-28 Fuel Injection Priming Pump Strainer System Pilot Filter - Replace 3-10 Fuel System System Warm-up 4-13 3-10...
Page 197 3-11 2-39 Machine Travel Speakers 1-22 2-20 Maintenance Speedometer 4-50 2-10 Maintenance - General Starter Switch Maintenance Intervals Start-up Material Weight Cold Weather Engine Start 1-13 Mounting and Dismounting Engine Start 3-10 Hydraulic System Warm-up Hydraulic System Warm-up – Cold Weather 3-10 New Machine Break-in Procedures Starting with Auxiliary Batteries...
Page 198 2-20 1-10 Tachometer Unauthorized Modifications Tipping Load 4-57 Tires and Wheels 3-19 Towing Machine 1-15 Visibility Transmission 2-36 Cut-off Switch 2-16 Display 2-40 Washer Tank Error Codes 4-25, 4-32 Water Pump Belt Tension 2-14 Lever Weight of Workload Materials 4-33, 4-39 Oil - Drain and Replace 4-57 Wheel Nut Torque...
Page 199 HAS THIS BEEN DISCUSSED WITH A DAEWOO SERVICE REPRESENTATIVE: IF YES - WHO: (It is advised to discuss this with a Daewoo service representative to ensure that the above correction is appropriate and valid.) Mail to: Daewoo Heavy Industries America Corporation...

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