Daewoo Mega 250-V Operation And Maintenance Manua Download

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K1000896E Operation and Maintenance Manual

Troubleshooting 6-1

TROUBLESHOOTING

BRAKING

ELECTRICAL SYSTEM

Problem

Possible Causes

Remedies

Reduced brake action.

Low secondary pressure in brake
valve.

Repair or replace brake
valve.

Worn brake disks.

Replace brake disks.

Damaged brake disks.

Replace brake disks.

Damaged brake valve block.

Replace valve.

Air in brake hydraulics due to leak in
brake hose.

Repair leak, bleed system.

After bleeding brakes, brakes
are not fully released.

Damaged brake disks.

Replace disks.

Damaged brake disk return spring.

Replace return springs.

Problem

Possible Causes

Remedies

Battery has no power and will
not accept a charge.

Damaged battery plates.

Replace battery.

Alternator not charging properly.

Repair or replace alternator.

Bad ground.

Clean and tighten.

Loose electrical connector.

Clean and tighten.

Alternator belt loose or damaged.

Tighten or replace.

Battery will accept a charge but
discharges soon after.

Internal battery short.

Replace battery.

Wiring harness short.

Repair wire.

Summary of Contents for Mega 250-V

Page 1: ...mers 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 p...

Page 2: ......

Page 3: ...ping and Transportation 1 25 Operating Controls 2 1 Component Locations 2 2 Control Identification 2 6 Steering Console and Pedals 2 7 Transmission Display 2 15 Front Instrument Panel 2 16 Right Side...

Page 4: ...21 Allowable Water Depth 3 21 Inspection Maintenance and Adjustment 4 1 Preventive Maintenance 4 1 Table of Recommended Lubricants 4 3 Fluid Capacities 4 5 Lubrication and Service Chart 4 5 Maintenan...

Page 5: ...1 Loading Machine on a Trailer 5 1 Summary of Safety Precautions for Lifting 5 2 Troubleshooting 6 1 Braking 6 1 Electrical System 6 1 Engine 6 2 Hydraulic System 6 4 Steering 6 7 Travel System 6 8 S...

Page 6: ......

Page 7: ...ls on page 1 3 3 Unauthorized Modifications on page 1 11 4 Work Site Precautions on page 1 11 5 Operation on page 1 13 6 Equipment on page 1 18 7 Maintenance on page 1 22 8 Shipping and Transportation...

Page 8: ...ties for which it was not intended Do not use bucket for lifting work unless lift slings are used in approved configuration SAFETY ALERT SYMBOL Be Prepared Get to Know All Operating and Safety Instruc...

Page 9: ...e them with a new label Make sure replacement parts have current 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...

Page 10: ...1 4 Safety K1000896E Operation and Maintenance Manual BZO0190L 1 5 2 3 9 11 4 8 10 6 2 7 4 11 8 Figure 2 S N 4001 and Up...

Page 11: ...chine Sound horn to alert people nearby before operating and make sure all persons are clear of area Always make sure when leaving operator s seat to Lower bucket or other working tools to ground LOCK...

Page 12: ...controls may enable selected function to operate under force of gravity When shutting machine down lower front attachment to ground After engine has been shut down turn key to ON position and move jo...

Page 13: ...190 1992A 190 00120 5 WARNING FOR HIGH TEMPERATURE HYDRAULIC OIL 190 00691 190 00097 DANGER Keep out of steering turn area WARNING HYDRAULIC OIL To prevent hot oil from spurting out Turn engine off Al...

Page 14: ...e Keep sparks and flames away from batteries Always avoid storing metals like tools or inflammable materials around or on batteries Explosion or fire can be caused by short circuiting batteries Sulfur...

Page 15: ...ENANCE ON FRONT ATTACHMENT 4190 2546A 190 00105 9 WARNING TO USE SAFETY LOCK 190 00121 DANGER To avoid injury securely brace lift arm before disassembly of valve or piping WARNING Safety lock must be...

Page 16: ...anual 10 WARNING TAG 190 00695 190 00098 11 WARNING FOR WHEEL BLOCK 4190 2547A 190 00207 WARNING Do not touch when performing inspection or maintenance WARNING Block wheels to prevent machine movement...

Page 17: ...AGE CABLES Serious injury or death can result from contact or proximity to high voltage electric lines The bucket does not have to make physical contact with power lines for current to be transmitted...

Page 18: ...ATH OVERHANGS Digging beneath an overhang is dangerous Overhang could collapse on top of operator and cause serious injury or death Go onto another digging area before steep overhangs are formed Know...

Page 19: ...peration may be mandated by governing authorities There may also be guidelines standards or restrictions on equipment that may be used to perform certain kinds of work Check and follow all local requi...

Page 20: ...es could require a warm up or maintenance service before start up Check gauges and monitor displays for normal operation before starting engine Listen for unusual noises and remain alert for other pot...

Page 21: ...Terrain and soil conditions at work site approaching traffic weather related hazards and any above or below ground obstacles or hazards should be observed and monitored by all work crew members ENGINE...

Page 22: ...tact 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 BATTERIE...

Page 23: ...tilt or more OPERATE CAREFULLY ON SNOW AND ICE AND IN VERY COLD TEMPERATURES In icy cold weather avoid sudden travel movements and stay away from even very slight slopes Machine could skid off to one...

Page 24: ...ctive Structure reinforcement system Any reinforcement system that is installed on machine must pass safety and certification standards and carry appropriate labeling and rating information For exampl...

Page 25: ...s running operator should be seated at the control station with seat belt properly engaged KEEP A FIRE EXTINGUISHER AT HAND It is recommended that an appropriately sized 2 27 kg 5 lb or larger multipu...

Page 26: ...react with explosive force if struck by a falling rock overhead obstacle or other work site hazard Extra safety guards may be required NEVER allow hoses to be hit bent or interfered with during operat...

Page 27: ...h the hands arms are subjected is less than 2 5 m s2 Whole Body The weighted root mean square acceleration to which the whole body is subjected is less than 0 5 m s2 Measurements are obtained on a rep...

Page 28: ...TING Hot surfaces on trouble lights or portable work lights can set off fuel or battery explosive gases MAINTENANCE USE WARNING TAG DURING SERVICE Alert others that service or maintenance is being per...

Page 29: ...ping 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 Wear protective glasses and leather gloves F...

Page 30: ...s an environmental contaminant and may only be disposed of at approved collection facilities Never drain any petroleum based product on ground or dispose of old oil in municipal waste collection conta...

Page 31: ...rding weight width and length of a load before making any other preparation for transport Hauling vehicle trailer and load must all be in compliance with local regulations governing intended shipping...

Page 32: ......

Page 33: ...e 2 40 10 Stereo on page 2 45 11 Seat Adjustment on page 2 49 12 Seat Belt on page 2 51 13 Door Side Latch on page 2 52 14 Fuse Box Relay on page 2 53 Each group is explained with a point location dra...

Page 34: ...OMPONENT LOCATIONS The following figure identifies the location of major machine components 43 42 41 40 44 30 36 38 37 34 39 35 31 32 33 28 R 29 R 27 26 5 13 STQAN HH 24 25 17 14 15 16 1 2 19 18 12 22...

Page 35: ...T SUPPORT 17 LADDER 18 WORKING LIGHT 19 OPERATOR S CAB 20 MUFFLER 21 ENGINE AIR PRECLEANER 22 AIR CLEANER 23 ENGINE 24 RADIATOR 25 GRILLE 26 FAN 27 FUEL TANK 28 ENGINE OIL LEVEL GAUGE RIGHT SIDE 29 EN...

Page 36: ...Manual The following figure identifies the location of major machine components 43 42 41 40 44 30 36 38 37 34 39 35 31 32 33 29 R 28 R 27 13 D100 24 25 26 17 14 15 16 1 2 19 18 12 21 TURBO II 20 22 3...

Page 37: ...16 HEADLIGHT SUPPORT 17 LADDER 18 WORKING LIGHT 19 OPERATOR S CAB 20 PRECLEANER 21 AIR CLEANER 22 MUFFLER 23 ENGINE 24 RADIATOR 25 GRILLE 26 FAN 27 FUEL TANK 28 ENGINE OIL LEVEL GAUGE RIGHT SIDE 29 E...

Page 38: ...anual CONTROL IDENTIFICATION Figure 3 identifies controls in operator s cab 1 STEERING CONSOLE AND PEDALS See page 2 7 2 VARIOUS CABIN LOCATIONS See page 2 36 3 RIGHT SIDE SWITCH PANEL See page 2 39 4...

Page 39: ...R SWITCH 2 HORN BUTTON 3 COMBINATION SWITCH LEVER 4 ACCELERATOR PEDAL 5 STEERING WHEEL ADJUSTMENT LEVER 6 BRAKE PEDALS 7 STEERING WHEEL 8 KICK DOWN SWITCH 9 TRANSMISSION LEVER 10 FRONT INSTRUMENT PANE...

Page 40: ...it to return to I ON position Do not crank engine for more than 15 seconds at a time this could damage starter motor Preheat position Used to aid engine starting in cold weather When key is in this p...

Page 41: ...ion 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 D Horn Button The center button on end...

Page 42: ...5 STEERING WHEEL ADJUSTMENT LEVER This lever is used to allow steering wheel to be moved to the most convenient position for the operator To adjust angle of steering wheel pull up the adjustment leve...

Page 43: ...rakes to the loader The brake pedal modes can be switched from INCHING to NO INCHING or vice versa by using the transmission cutoff switch See page 2 31 CAUTION When descending on an incline slow down...

Page 44: ...nd gear pressing this switch will shift transmission into 1st gear This will allow the driver to perform a quick digging movement NOTE Kick down is RELEASED when transmission is placed in NEUTRAL posi...

Page 45: ...tween 1st 2nd 3rd or 4th gear NOTE There is a transmission display on the dash that indicates gears direction of travel error codes and kick down activation See page 2 15 A transmission neutral lever...

Page 46: ...trols K1000896E Operation and Maintenance Manual 10 FRONT INSTRUMENT PANEL See Front Instrument Panel on page 2 16 11 TRANSMISSION DISPLAY See Transmission Display on page 2 15 AOO0291L F R Figure 19...

Page 47: ...odes on page 6 10 NOTE Most codes are only two digits C Indicates that error codes have occurred and are stored D Indicates that operation must be stopped immediately to prevent damage to transmission...

Page 48: ...2 16 Operating Controls K1000896E Operation and Maintenance Manual FRONT INSTRUMENT PANEL Figure 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 BSO0500L F R...

Page 49: ...CATOR LIGHT 18 PARKING BRAKE INDICATOR LIGHT 19 EMERGENCY STEERING INDICATOR LIGHT OPTION SWITCHES 20 HAZARD WARNING LIGHT SWITCH 21 LIS LOAD ISOLATION SYSTEM SWITCH OPTION 22 FLOAT KICK OUT SWITCH OP...

Page 50: ...R 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 This shows that the hour meter is...

Page 51: ...perature is below 10 C 12 F this light will turn ON approximately 19 seconds after starter switch is turned to preheat position CAUTION When the pointer indicates H mark red zone it means the engine i...

Page 52: ...e to rise and may cause engine to siege due to heat surge 10 ENGINE OIL PRESSURE WARNING LIGHT When starter switch is in ON position this red light should ON When engine is running this red light shou...

Page 53: ...13 HIGH BEAM INDICATOR LIGHT This light turns ON when headlights are turned to HIGH BEAM 14 RIGHT TURN AND HAZARD WARNING LIGHT This light blinks when right turn signal is turned ON Both lights blink...

Page 54: ...8 PARKING BRAKE INDICATOR LIGHT When parking brake is APPLIED this light turns ON If vehicle is moved while parking brake is applied a warning alarm will sound WARNING Never operate or travel machine...

Page 55: ...ndicator lights in front and back of the machine light up and flash warning others in the area At the same time the directional indicator lights on the instrument panel will turn ON to warn the operat...

Page 56: ...operates when traveling speed is over 8 km h 5 MPH 22 FLOAT KICK OUT SWITCH OPTION Bucket float allows the bucket to follow the contour of the ground working surface When pressing this switch and set...

Page 57: ...LIGHT SWITCH 7 REAR WORK LIGHT SWITCH 8 REAR WIPER SWITCH 9 ROTATING BEACON LIGHT SWITCH OPTION 10 CUP HOLDER 11 PARKING BRAKE SWITCH 12 PILOT CUTOFF SWITCH 13 TRANSMISSION CUTOFF SWITCH 14 AUTOMATIC...

Page 58: ...n is in 2nd gear pressing this switch Figure 50 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 Manu...

Page 59: ...gure 52 will sound the horn NOTE Starter switch must be ON 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 I...

Page 60: ...strument panel and switch lights II In this position this switch turns ON clearance tail gauge panel and headlights 6 FRONT WORK LIGHT SWITCH O In this position this switch turns OFF work lights mount...

Page 61: ...indshield while running the rear wiper When released the switch returns to the O position II In this position this switch turns ON windshield wiper mounted on rear windshield of operator s cab CAUTION...

Page 62: ...nel turns OFF I In this position the parking brake is APPLIED and the monitor light on the front instrument panel comes ON This brake can also be used as an emergency brake WARNING Set the parking bra...

Page 63: ...both engine braking and the service brake can be used in descending grades I In this position the INCHING mode is selected In this mode the transmission is put in NEUTRAL by pressing the left brake p...

Page 64: ...tioning The system should be tested during the start up procedure ensure that the system is functioning Test emergency steering system using the following procedure A Turn starter switch to I ON posit...

Page 65: ...R Forward Reverse Travel Control System Option on page 3 16 for further information 17 F R FORWARD REVERSE CONTROL SWITCH OPTION To be able to use the forward reverse function the F R selector switch...

Page 66: ...out lever joystick place pilot cutoff switch in LOCKED position Pilot control valve lever joystick operating pattern and description of operation 2 PILOT CONTROL VALVE LEVER JOYSTICK S N 4001 and Up...

Page 67: ...everse travel without pressing KD 5 Figure 68 switch 3 Reverse Switch When this switch is pressed at reverse traveling while KD 5 Figure 68 switch is pressed machine can travel reverse When machine is...

Page 68: ...AB LIGHT 2 STEREO 3 HEATER AND AIR CONDITIONER CONTROL PANEL 4 SPEAKERS 5 STORAGE BOX 6 WASHER TANK 7 HOT COLD REFRIGERATOR 8 ELECTRICAL BOX 9 FUSE BOX TWO 10 FUSE BOX ONE BAN D BAL FAD 2 6 1 TU N E M...

Page 69: ...and OFF by pressing its switch 2 STEREO For operation of stereo see Stereo on page 2 45 3 HEATER AND AIR CONDITIONER CONTROL PANEL For operation of heater and air conditioner see Heater and Air Condit...

Page 70: ...ld washer fluid 7 HOT COLD REFRIGERATOR There is a hot cold refrigerator 1 Figure 76 behind and to the left of the seat Air conditioner and heating unit must be operated after starting the engine for...

Page 71: ...e box two is just above the windshield washer fluid tank For a detailed explanation of fuses see Fuse Box Relay on page 2 53 10 FUSE BOX ONE The fuse box one is at the rear side of right control stand...

Page 72: ...AND VENTS 1 OPERATION PANEL 2 FRONT NOZZLE AIR CONDITIONER 3 FRONT NOZZLE DEFROSTER 4 FOOT NOZZLE 5 REAR NOZZLE The heater and air conditioner are combined into one unit to the right side of the opera...

Page 73: ...5 VENTILATION SELECTOR 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 the panel LED s will turn ON 1 FAN AND AI...

Page 74: ...ATURE CONTROL SWITCH The temperature control consists of 24 stages An LED is turned ON for every three stages Whenever pushing it it changes in stages Pushing it continuously it changes continuously A...

Page 75: ...C Used to direct air flow for defrosting front window of operator s cab 5 VENTILATION SELECTOR SWITCH A A Switch Draws fresh air into operator s compartment B B Switch Recirculates air within the ope...

Page 76: ...s than the outdoor temperature Operate the air conditioner from 20 30 minutes a week to circulate the refrigerant in the system NOTE The blower switch should be on LO speed NOTE The filter should be c...

Page 77: ...When stereo is turned ON LCD display will indicate radio stations and or tape functions 2 BALANCE FADER CONTROL This control adjusts both side to side balance of stereo sound and front to back fading...

Page 78: ...and to be listened to Then use tuning control to select desired station Press and hold any preset keys for approximately 2 seconds a beep will sound when station has been set 6 TAPE EJECT BUTTON Eject...

Page 79: ...io Memory Channel Indicator D Radio Station Frequency E AM FM Band Indicator F Stereo Radio Signal G Dolby Noise Reduction Indicator H Metal Tape Indicator CARE OF STEREO Do not use a tape that has a...

Page 80: ...oid valves Clean head and pinch roller periodically They continuously contact the tape If they are not kept clean stereo and tapes may be damaged Keep them clean for optimum performance If head gets d...

Page 81: ...onditions Adjustment range is 60 mm 2 36 in for both front and rear 4 WEIGHT ADJUSTMENT KNOB Turning knob 4 Figure 98 to right makes suspension harder Turning knob to left makes suspension softer Adju...

Page 82: ...operator Inspect and maintain the suspension and adjustment mechanisms of the seat regularly 3 Check that the machine is properly maintained Tire pressure brakes steering linkages etc 4 Steer brake a...

Page 83: ...st 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 ev...

Page 84: ...latch 1 Figure 102 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 2 To release door from side of cab push the latc...

Page 85: ...l 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 1 15A Qty 1 20A Qty 1 and 30A Qty 1 Fuse box two 2 Figure 104 is just above...

Page 86: ...15A 8 Air Conditioner Heater 30A 9 Working Light Front Rotating Beacon Option 15A 10 Working Light Rear 15A 11 Turn Signal Light Hazard Light Indicate Light 15A 12 Stereo Cab Light Fuel Pump Engine S...

Page 87: ...a short circuit or an overload occurs the circuit breaker automatically cuts off current thus preventing electrical wires from burning FUSIBLE LINK A fusible link Figure 110 is in the battery box If t...

Page 88: ...nance Manual WARNING When changing the fusible link replace the fusible link with the same capacity part Otherwise a fire could break out in the wiring harness and or other components of the circuit A...

Page 89: ...INE 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 Failur...

Page 90: ...ch to I APPLIED position This will ensure that the parking brake is APPLIED 2 Move all control levers to NEUTRAL position 3 Make sure transmission neutral lock is in the N NEUTRAL LOCK position IMPORT...

Page 91: ...art unit Follow test procedure given with test switch 6 Rotate starter key to START position Starter motor should crank immediately and engine should start within a few seconds 7 Release starter key w...

Page 92: ...ine oil Check cause 11 Check for usual engine vibration and noises If any are heard or felt investigate cause NOTE If engine coolant temperature gauge shows red while running take the following action...

Page 93: ...e is APPLIED 2 Move all control levers to NEUTRAL position 3 Make sure transmission neutral lock is in the N NEUTRAL LOCK position 4 Set pilot cutoff switch to O LOCKED position This will LOCK pilot c...

Page 94: ...ter indicator light turns ON preheat cycle is complete 7 Rotate starter key to I ON position All indicator lights should turn ON 8 Rotate starter key to START position Starter motor should crank immed...

Page 95: ...all 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 O OFF position 11 Perform Hydraulic System...

Page 96: ...6 2 Connect negative jumper cable from auxiliary batteries to a ground point on machine frame DO NOT CONNECT DIRECTLY TO NEGATIVE BATTERY TERMINAL 3 Follow normal engine starting procedures 4 After en...

Page 97: ...NEUTRAL LOCK position 3 Set parking brake switch to the I APPLIED position This will ensure that the parking brake is APPLIED 4 Set bucket on ground 5 Put pilot cutoff switch to O LOCK position This...

Page 98: ...oad to circulate the oil through the system Do this for 5 minutes NOTE Do not allow cylinders to pass hydraulic oil over relief valve for more than twenty seconds at a time 5 Cycle boom and bucket abo...

Page 99: ...ack WARNING If vehicle is moved while parking brake is engaged serious damage to parking brake disk will result Select a transmission gear that is appropriate for top speed that will be traveled Choos...

Page 100: ...accidentally moving during travel as a result of accidentally touching pilot control valve lever joystick 4 Press brake pedal 5 Set transmission neutral lock is in the D DRIVE position 6 Set parking...

Page 101: ...tion 9 Release the brake pedal while slowly pressing the accelerator pedal MACHINE SHUT DOWN 1 Ease off throttle and apply travel brakes WARNING When traveling at high speed or on a steep hill do not...

Page 102: ...Set bucket on ground 6 Select pilot cutoff switch to O LOCKED position This will lock pilot control valve lever joystick 7 Allow engine to idle for 1 2 minutes to cool down Stopping a turbocharged en...

Page 103: ...l 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 no braking effect because transmission clutch...

Page 104: ...move the transmission lever between forward and reverse To activate system perform the following steps 1 Place transmission lever in NEUTRAL NOTE Do not move the transmission lever out of NEUTRAL If...

Page 105: ...king force during travel To accomplish this move pilot control valve lever joystick to crowd position and hold it there Hydraulic pump will be driven to supply output at maximum pressure relief pressu...

Page 106: ...nts hydraulic pump from working against relief valve maximum pressure BUCKET ANGLE INDICATOR Upper right side of bucket includes a bracket that indicates angle of bottom of bucket Top of bracket is pa...

Page 107: ...fter lever returns to NEUTRAL bucket will automatically position itself to be in a preselected digging position usually flat To adjust bucket to desired preselected digging position perform the follow...

Page 108: ...ake sure you loader has sufficient braking capacity to stop the towed load Check if the vehicle to be towed can be braked and steered If not do not allow anyone to ride on the towed vehicle Check the...

Page 109: ...brakes to fail ALLOWABLE WATER DEPTH The water depth is an important factor to take into consideration when the loader is working in swampy areas Do not enter water whose depth exceeds the loader s m...

Page 110: ......

Page 111: ...ck may need to be shortened if machine is operating in severe atmospheric conditions Machines working in extremely hot or dusty conditions will require more frequent service checks Total hours of mach...

Page 112: ...anifold SAFETY PRECAUTIONS 1 Before performing any maintenance checks move pilot cutoff switch to LOCKED position Place a Warning Tag on controls so that no one begins to operate machine while mainten...

Page 113: ...TO ANTI WEAR HD 32 BELOW 0 C 32 F or HD 46 ABOVE 0 C 32 F or TERESSTIC ANTI RUST EXXON XD 3 STRAIGHT WEIGHT or 15W40 RONEX MP 2 or RONEX MP 1 COLD TEMPS MOBIL MOBIL DTE 13M ALL TEMP or DTE 24 SUMMER D...

Page 114: ...il SAE 15W40 API CD and above Antifreeze Recommended Concentration Manufacturers Meeting ASTM D3306 50 Antifreeze 50 Distilled Water Dexcool ELC by Chevron Texaco Alugard G48 by BASF Others meeting or...

Page 115: ...S gal 25 4 liters 6 7 U S gal NOTE The filter holds an additional 1 liter 1 qt of oil Cooling System 50 liters 13 U S gal 31 liters 8 U S gal Fuel Tank 270 liters 71 3 U S gal Hydraulic Oil Tank 195...

Page 116: ...n Maintenance and Adjustment K1000896E Operation and Maintenance Manual Description of Lubrication and Service Chart Figure 4 1500h 10h 250h 50h 500h 1000h 2000h 1 9 1 1 14 11 4 3 5 8 12 13 10 7 2 16...

Page 117: ...8 Radiator Coolant Antifreeze 50 L V 9 Front Axle Axle Gear Oil MOBIL FLUID 424 31 L F V 10 Rear Axle Axle Gear Oil MOBIL FLUID 424 24 L F V 11 Transmission Engine Oil 15W40 27 L V F 12 Fuel Filter C...

Page 118: ...emperature Listen for Any Abnormal Sounds See page 4 18 Check Operation of All Controls See page 4 18 Inspect Engine Fan Blade See page 4 18 Check Engine Drive Belt Wear See page 4 19 Check Air Intake...

Page 119: ...Clean Fuel Injection Priming Pump Strainer See page 4 45 Replace Air Conditioner Filter See page 4 45 Check Air Conditioner Refrigerant See page 4 46 Check and Adjust Engine See page 4 46 1 500 HOUR...

Page 120: ...ease fittings immediately after machine is removed from water Follow procedure printed under the 50 hour maintenance interval Grease Front Attachment Pins on page 4 21 INSPECT ALL TIRES FOR CORRECT TI...

Page 121: ...smission lever in NEUTRAL Apply parking brake Shut down engine 4 Block tires Once tires are blocked start engine and have a person remain in the cab 5 With engine running have second person find trans...

Page 122: ...arking brake 3 Lower bucket to ground 4 Check sight gauge that is attached to hydraulic reservoir Oil level must be between upper limit 1 Figure 12 and lower limit 2 shown on gauge WARNING The hydraul...

Page 123: ...oper level by checking sight glass Figure 12 CHECK FOR LEAKS IN HYDRAULIC SYSTEM 1 Perform a daily walk around inspection to make sure that the hoses piping fittings cylinders and hydraulic motors are...

Page 124: ...ecommended Lubricants on page 4 3 of this manual for recommended fuel for the operating conditions 2 Securely tighten cap after fueling NOTE If breather holes in cap are clogged a vacuum may form in t...

Page 125: ...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 and Figure 18 Catch drained material in a conta...

Page 126: ...l of coolant inside radiator If low add coolant to fill radiator to a point that is 10 20 mm 1 2 3 4 below top of overflow pipe If temperature is below freezing see Antifreeze Concentration Tables on...

Page 127: ...are using other manufacturers buckets refer to their specific instructions INSPECT SEAT BELT FOR PROPER OPERATION INSPECT THE STRUCTURE FOR CRACKS AND FAULTY WELDS 1 During the daily walk around insp...

Page 128: ...ose rivets bent or loose blades and for contact between the blade tips and the fan shroud Check the fan to make sure it is securely mounted Tighten the bolts if necessary Replace any fan that is damag...

Page 129: ...amped A misalignment that can be detected by the naked eye is detrimental to belt performance 5 Do not force the belts into the pulley grooves by prying with a screwdriver or pry bar This will damage...

Page 130: ...eck the engine intake hose and hose bands for damage and tightness 3 If damaged wrinkled or loose replace or retighten or contact your nearest Daewoo loader dealer WARNING Hot engine components can ca...

Page 131: ...EASE FRONT ATTACHMENT PINS 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...

Page 132: ...eration and Maintenance Manual A Bucket hinge pins 2 locations Figure 28 Lever link connecting pin 1 location Figure 29 Bucket link connecting pin 1 location Figure 30 B Arm lever connecting pin 1 loc...

Page 133: ...ance Manual Inspection Maintenance and Adjustment 4 23 C Bucket cylinder rod end 1 location Figure 32 D Lift cylinder heads left right 2 locations Figure 33 Lift cylinder rod ends 2 locations Figure 3...

Page 134: ...896E Operation and Maintenance Manual E Remote location points 1 REMOTE FITTINGS FOR LOADER ARM FOOT ENDS 50 HOUR Figure 36 and Figure 37 2 REMOTE FITTINGS FOR BUCKET CYLINDER HEAD 50 HOUR Figure 36 a...

Page 135: ...two remote grease points 1 Figure 35 2 Bucket cylinder head 1 point Greased from remote grease point 2 Figure 35 F Rear Axle pivot 1 Figure 39 and Figure 41 2 locations on each side of machine Use rem...

Page 136: ...ocations one on each side of machine 2 Steering cylinder head ends 2 locations Use remote grease fittings mounted on frame 1 2 Figure 44 Reference Number Remote Grease Fittings 1 and 2 50 Hours Steeri...

Page 137: ...er Follow procedure under 500 hour maintenance interval See page 4 37 CHECK WATER PUMP BELT TENSION 1 Water pump belt tension must be checked after first 50 hours of operation to comply with new machi...

Page 138: ...er in pilot filter Perform the following steps 1 Vent hydraulic oil tank 2 Unscrew element cover 5 Figure 48 Cover is filled with oil Dispose of oil 3 Remove O ring 3 Figure 48 and filter 4 4 Use a no...

Page 139: ...oir breather cap See Figure 13 on page 4 13 Loosen drain valve from bottom of reservoir Figure 50 Allow all water and sediment to drain out Tighten drain valve NOTE Dispose of drained fluids according...

Page 140: ...filter every 1 000 hours of service 2 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 3 Clean the inside of air...

Page 141: ...eflects more than this loosen control link to tighten belt tension until deflection is 10 mm 0 4 Inspect belt for damage If belt is damaged replace it IMPORTANT A loose water pump belt can cause engin...

Page 142: ...nce Manual GREASE DRIVE SHAFTS Grease fitting for center bearing 1 location Use remote grease fitting mounted on frame 3 Figure 57 Reference Number Remote Grease Fittings 1 and 2 50 Hours Steering Cyl...

Page 143: ...coolant temperature gauge reaches the middle of the WHITE ZONE the temperature is about 40 C 104 F NOTE Dispose of drained fluids according to local regulations 2 Replace engine oil filter Figure 60...

Page 144: ...T 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 47 REPLACEMENT OF TRANSMIS...

Page 145: ...o about 40 C 104 F When the needle of the coolant temperature gauge reaches the middle of the WHITE ZONE the temperature is about 40 C 104 F NOTE Dispose of drained fluids according to local regulatio...

Page 146: ...After cleaning filter head install new fuel filter Screw filter on head until gasket contacts head turn filter 1 3 1 2 turn more NOTE Coat fuel filter gasket with fuel NOTE Fill fuel filter with clean...

Page 147: ...rst 50 hours of operation and every 500 Hours thereafter WARNING The hydraulic oil will be hot after normal machine operation Allow system to cool before attempting to service any of the hydraulic com...

Page 148: ...ement is approximately 4 mm 0 157 below edge of reservoir 8 Install a new O ring 4 Figure 67 on cover 2 Set spring 3 into place on element 6 9 Set cover 2 Figure 67 into place over element 6 Install b...

Page 149: ...K1000896E Operation and Maintenance Manual Inspection Maintenance and Adjustment 4 39 Figure 69 AIR CONDITIONER CONDENSER...

Page 150: ...filter and inspect it for damage 3 Use compressed air to clean filter If element is very dirty use a mild soap and water solution to clean it NOTE If water was used to clean filter be sure it is comp...

Page 151: ...Block tires NOTE See Fluid Capacities on page 4 5 for capacity and Table of Recommended Lubricants on page 4 3 4 Remove drain plug Allow all transmission fluid to drain into a receptacle Clean drain p...

Page 152: ...7 Idle engine until transmission fluid temperature reaches 82 93 C 180 200 F Oil level must be at HOT mark or above as shown in Figure 76 NOTE If oil level is above top end of sight gauge completely f...

Page 153: ...nged Brake fluid level changed Braking pressure changed A wear measurement must be made on both output sides Remove screw plug actuate brake and determine Dimension X according to Figure 77 and Figure...

Page 154: ...into a suitable container 4 Remove the nuts with a 17mm wrench to remove the inspection cover 2 Figure 79 5 Clean inside of the tank and suction stainer Figure 80 6 Install the inspection cover with a...

Page 155: ...LACE 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 This filter should be clean...

Page 156: ...Contact your nearest Daewoo loader dealer Engine dealer for checking and adjusting the following items Engine Compression Pressure Injection Pressure Injection Timing WARNING Mixing of tobacco smoke a...

Page 157: ...ach end The same oil lubricates the center differential and planetaries These sections of the axle are connected but the oil flows very slowly between them When checked oil must be checked and refille...

Page 158: ...2 Figure 83 into center differential and tighten Install drain plugs on both ends of axle and tighten 5 Pump oil into level plug hole on center differential Add oil until oil level is even with bottom...

Page 159: ...air to blow out housing 4 Install new inner element and secure it into position with wing nut DO NOT clean and reuse inner element 5 Install new outer element and secure it into position with wing nu...

Page 160: ...maximum performance is to replace hoses on a regular basis If any brake or steering hoses become damaged or appear defective in any way replace them immediately despite time interval since their last...

Page 161: ...scribed in this step until fluid expelled from bleeder hose has no air bubbles present 5 Securely close bleeder screw 1 Figure 86 Install plug in axle 6 Perform bleeding procedure on other three locat...

Page 162: ...88 3 Remove coolant drain plug Figure 89 from engine 4 Open heater shutoff valves Figure 91 and Figure 92 to allow coolant to drain from heater core 5 Install drain plug and close drain valve after c...

Page 163: ...mm 1 2 3 4 below top of overflow pipe DRAIN AND REPLACE HYDRAULIC OIL 1 Raise boom to its highest position Tilt bucket back as far as possible and shut down engine NOTE See Fluid Capacities on page 4...

Page 164: ...ighten the upper cover 6 Start engine and operate controls to raise and lower bucket a few times Figure 97 Raise and lower boom a few times Figure 98 Lower bucket to ground 7 Check reservoir sight gau...

Page 165: ...s to fill the brake accumulator with oil 3 Shut down engine 4 Turn starter switch to ON position 5 Count the number of times you can depress the right hand brake pedal before the brake warning light c...

Page 166: ...cannot be stored more than 2 years before being discarded or installed on a machine In service lifetime of hoses fitted on a machine can never exceed 6 years but replace hoses described in Replace Pi...

Page 167: ...2 Clean radiator and oil cooler fins to remove dirt and dust 3 Clean fuel system intake strainer and fuel filter more frequently 4 Inspect starter motor and alternator and clean as often as necessary...

Page 168: ...84 35 7 05 51 8 30 60 12 mm x std 8 57 62 11 89 86 14 52 105 12 mm x 1 5 9 00 65 12 59 91 14 94 108 14 mm x std 13 55 98 18 95 137 23 10 167 14 mm x 1 5 14 94 108 21 02 152 24 89 180 16 mm x std 20 8...

Page 169: ...always be replaced in pairs Using an old battery with a new one will shorten the life span of the new battery WARNING Before starting any battery service work make sure to shut the engine off and turn...

Page 170: ...oadens the operating temperature range by lowering the coolant s freezing point and by raising its boiling point Do not use more than 50 antifreeze in the mixture unless additional freeze protection i...

Page 171: ...ene glycol ANTIFREEZE CONCENTRATION TABLES Ethylene Glycol Standard Life Antifreeze 1 000 Hour 6 Months Ambient Temperature Cooling Water Antifreeze 10 C 14 F 80 20 15 C 5 F 73 27 20 C 4 F 67 33 25 C...

Page 172: ...lt in causing motor damage 3 Do not use refueling pump for other types of fuel Use only for diesel fuel Do not use refueling pump for other types of fuel which have a low flash point Do not use refuel...

Page 173: ...ON position NOTE The transfer pump rate of flow is approximately 20 liters minute 5 gpm Use extra care not to overfill fuel tank so that fuel does not over flow 4 Once fuel transfer is completed immed...

Page 174: ...lower relief pressure 4 Tighten lock nut after pressure has been adjusted UNLOADING VALVE PRESSURE 1 Attach gage to port 2 Figure 102 2 Relief pressure for unloading is 160 5 kg cm2 2 320 70 psi 3 Adj...

Page 175: ...to raise relief pressure Turn screw counterclockwise to lower relief pressure 4 Install plastic plug after pressure has been adjusted TRANSMISSION CLUTCH PRESSURE 1 Attach gauge to port 4 Figure 102...

Page 176: ...98 psi 3 Loosen lock nut on adjusting screw Turn adjusting screw clockwise to raise relief pressure Turn adjusting screw counterclockwise to lower relief pressure 4 Tighten lock nut after adjustment h...

Page 177: ...1 psi S N 3001 thru 4000 120 150 kg cm2 1 707 2 133 psi S N 4001 and Up FAN MOTOR PRESSURE S N 4001 AND UP 1 Attach gauge to inlet port of fan motor 1 Figure 113 2 Adjust screw on relief valve cartrid...

Page 178: ...g of light oil to all exposed cylinder rods Apply a coating of light oil to all control linkages and all control valve spools Check condition of oil coating each month and add to coating where necessa...

Page 179: ...he parking brake cannot be released by normal hydraulic system pressure or if the engine will not start it must be manually released before towing can take place 1 Before releasing parking brake make...

Page 180: ...ing this adjusting process the parking brake must be released i e the bank of cup springs 3 Figure 114 must be completely pretensioned 1 Park vehicle on an even surface and place wheel chocks in front...

Page 181: ...old the adjusting screw 4 Figure 114 in position with the hexagonal socket wrench and lock with the lock nut 5 6 Mount the screw cap 6 Figure 114 and tighten as far as possible manually 7 Actuate the...

Page 182: ...ine correct pressure for front or rear tires when driving machine or when working machine Check tires for damage and embedded objects Check valve stems for damage WHEEL NUT TORQUE Tighten wheel nuts t...

Page 183: ...age to the carcass exceeds 1 3 of the tire width Tire layers are separated Radial cracks reach the carcass Deformation or damage which makes the tire unsuitable for use WARNING Improper servicing or c...

Page 184: ......

Page 185: ...the trailer and the machine 4 Determine the position of 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 dire...

Page 186: ...FOR LIFTING To make safe lifts the following items must be evaluated by operator and work site crew Condition of ground support Wheel loader configuration and attachments Weight lifting height and li...

Page 187: ...ir leak bleed system After bleeding brakes brakes are not fully released Damaged brake disks Replace disks Damaged brake disk return spring Replace return springs Problem Possible Causes Remedies Batt...

Page 188: ...fuel system Clean system and add new fuel Air in fuel system Purge air from system Engine stop control failed Replace stop control Engine stop relay failed Replace relay Engine starts runs only at lo...

Page 189: ...loose or damaged Tighten or replace as required Temperature sensor faulty Replace sensor Engine oil pressure warning light turns ON and buzzer sounds Low engine oil level Add oil Wrong grade oil for w...

Page 190: ...ged Replace fuel filter Fuel pump failure Contact your Daewoo dealer Incorrect fuel injection timing Insufficient power Air cleaner filter clogged Clean or replace element Fuel filter clogged Replace...

Page 191: ...Hydraulic pumps cavitating Bleed air from hydraulic pumps Only one or two actuators have little or no power Overload relief pressure too low Reset pressure Makeup check valve leaking Clean or replace...

Page 192: ...ngs Tighten fittings Internal damage to control valve housing Replace control valve Control valve spool damaged Replace control valve Sediment inside control valve Clean and repair valve Check valve i...

Page 193: ...t pressure Steering pump failure Repair or replace Leaking steering cylinder Repair cylinder Rust on steering column bearing and spline Lubricate Tire air pressure is low Inflate to proper pressure Hi...

Page 194: ...replace Damaged transmission or axle Repair or replace Wheel brakes not releasing Repair brakes Parking brake not releasing Repair parking brake Machine will travel but has little power Fluid pressur...

Page 195: ...damaged universal joint Replace universal joint Loose universal joints Tighten bolts that secure universal joints Lack of lubrication Lubricate universal joints Worn slip joint spline Replace slip joi...

Page 196: ...ignal 21 Shot circuit to battery voltage at clutch cutoff input 22 Short circuit to ground or open circuit at clutch cutoff input 23 Short circuit to battery voltage at load sensor input Not used 24 S...

Page 197: ...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 convert...

Page 198: ...B5 Slippage at clutch KV B6 Slippage at clutch KR D1 Short circuit to battery voltage at power supply for sensors D2 Short circuit to ground at power supply for sensors D3 Low power at battery D4 High...

Page 199: ...K1000896E Operation and Maintenance Manual Troubleshooting 6 13...

Page 200: ...6 14 Troubleshooting K1000896E Operation and Maintenance Manual...

Page 201: ...00 rpm Gross Rated 155 ps 153 hp 2 200 rpm Net Max 162 ps 160 hp 2 000 rpm Net Rated 165 ps 163 hp 2 200 rpm Gross Max 172 ps 170 hp 2 000 rpm Gross Max Torque SAE J 1349 net SAE J 1995 gross 69 kg m...

Page 202: ...96E Operation and Maintenance Manual Bucket Lower Time 3 3 Sec Bucket Dump Time 1 2 Sec Max Breakout Force 13 200 kg 29 100 lb Static Tipping Load Straight Full Turn 12 000 9 800 kg 26 455 21 605 lb M...

Page 203: ...enance Manual Specifications 7 3 WORKING RANGE AND DIMENSIONS Figure 1 illustrates exterior machine dimensions and working range of machine when it is equipped with a standard bucket J A E G F C B D H...

Page 204: ...11 Bucket Width D 2 740 mm 8 12 Wheel Base E 3 020 mm 9 11 Tread F 2 040 mm 6 8 Ground Clearance G 430 mm 1 5 Dump Height to tooth H 2 760 mm 9 1 Dump Distance to Bucket Edge I 1 060 mm 3 6 Minimum T...

Page 205: ...ials APPROXIMATE WEIGHT OF WORKLOAD MATERIALS MATERIAL LOW WEIGHT OR DENSITY 1 100 KG M3 1 850 LB YD3 OR LESS MEDIUM WEIGHT OR DENSITY 1 600 KG M3 2 700 LB YD3 OR LESS HIGH WEIGHT OR DENSITY 2 000 KG...

Page 206: ...ize 1 522 kg m3 2 565 lb yd3 Gravel DRY packed fragments 1 810 kg m3 3 051 lb yd3 Gravel WET packed fragments 1 922 kg m3 3 240 lb yd3 Limestone graded above 2 1 282 kg m3 2 160 lb yd3 Limestone grade...

Page 207: ...Weights are approximations of estimated average volume and mass Exposure to rain snow or ground water settling or compaction due to overhead weight and chemical or industrial processing or changes due...

Page 208: ......

Page 209: ...ccumulator 4 54 Brake Pedal 2 11 Brakes Additional Braking 3 17 Axle Brake Disk Wear 4 43 Bleeding 4 50 Brake Fluid Warning 2 22 Brake Fluid Warning Light 2 22 Brake Pedal 2 11 Troubleshooting 6 1 Buc...

Page 210: ...res 4 64 Leaks in the Hydraulic System 4 13 Long Term Storage 4 68 Main Pump Pressure 4 64 Parking Brake Release Pressure 4 67 Service Brake Outlet Pressure 4 67 Steering Pump Pressure 4 65 System Pil...

Page 211: ...al Numbers 4 1 Service Chart 4 5 Shipping and Transportation 1 25 Shut Down Engine Shut Down 3 9 Machine 3 13 Shutdown Control Functions 1 18 Sloping Terrain 1 12 Speakers 2 37 Speedometer 2 18 Starte...

Page 212: ...er Joystick 2 26 T Tachometer 2 18 Tipping Load 7 5 Tires and Wheels 4 72 Towing Machine 3 20 Transmission Cutoff Switch 2 31 Display 2 15 Error Codes 6 10 Lever 2 13 Oil Drain and Replace 4 34 4 41 O...

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Daewoo Mega 250-V, Operation And Maintenance Manua

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