Daewoo Mega 500-V Wheel Loader Manuals

Manuals and User Guides for Daewoo Mega 500-V Wheel Loader. We have 1 Daewoo Mega 500-V Wheel Loader manual available for free PDF download: Shop Manual

Daewoo Mega 500-V Shop Manual

Daewoo Mega 500-V Shop Manual (686 pages)

Brand: Daewoo | Category: Front End Loaders | Size: 40 MB

Table of Contents

Attachments

3
- Table of Contents
  2
- Table of Contents
  3
- Safety
  4
- Wheel Loader Safety
  5
- To the Operator of a Daewoo Wheel Loader
  7
- General Safety Essentials
  10
- Location of Safety Labels
  10
- Unauthorized Modifications
  10
- General Hazard Information
  11
- Before Starting Engine
  19
- Machine Operation
  22
- Maintenance
  29
- Battery
  37
- Towing
  39
- Shipping and Transportation
  40
- Specifications
  41
- Specifications for Mega 500-V
  42
- General Maintenance
  56
- General Maintenance Procedures
  57
Section 2

58
Section 3

72
Section 4

89
- General Description
  90
- Theory of Operation
  90
- Replacement of Rotor and Vane
  91
- Troubleshooting
  91
- Replacement of Rear Cover
  92
- Replacement of Armature
  93
- Hydraulic Oil Tank
  94
- Lower Structure and Chassis
  98
- Center Joint (Articulation Joint)
  99
- Engine and Drive Train
  105
- Axle (ZF AP 420R)
  106
Section 5

107
- General Description
  110
- Specifications
  110
- Torque Limits for Screws
  111
- Torque Limits for Screws (in Nm) According to ZF-Standards 148
  111
- Torque Limits for Locking Screws (in Nm)
  112
- Torque Limits for Locking Screws with Locked Toothing (in Nm)
  112
- Brake
  113
- Lubrication Instructions
  113
- Oil Change Intervals (Generally)
  113
- Oil Level
  113
- Oil Level Check
  113
- Point of Grease Lubrication
  113
- Type of Lubrication
  113
- List of Lubricants TE-ML 05
  114
- Examples of Gear-Tooth-Contact Patterns for the Gleason Gear-Tooth System
  116
- Special Tools
  120
- Final Drive
  121
- Differential (Version - Screwed Bearing Caps)
  127
- Differential Carrier "CK
  127
- Differential Carrier "RK
  129
- Differential Carrier "DK
  131
- Differential (Version - Cast-On Bearing Caps)
  133
- Differential Carrier "DK
  133
- Differential Carrier "HK
  135
- Differential (Version - Cast-On and Screwed Bearing Caps)
  137
- Differential Carrier "LK
  137
- Final Drive
  139
- Planetary Rigid Axle AP 407 - 420 Disassembly
  139
- Differential Disassembly (Version - Screwed Bearing Caps)
  145
- Differential
  147
- Drive Unit
  148
- Differential Disassembly (Version - Cast-On Bearing Caps)
  151
- Differential
  152
- Drive Unit
  155
- Differential Disassembly (Version - Screwed and Cast-On Bearing Caps)
  157
- Differential
  159
- Drive Unit
  160
- Final Drive Reassembly
  163
- Hub Carrier
  163
- Check Rolling Resistance of Wheel Bearing
  165
- Hub
  166
- Complete Internal Gear Carrier
  167
- Internal Gear Carrier
  169
- Adjusting Plate Clearance According to Table
  172
- Determine Sun-Gear Shaft Play
  175
- Illustrated Table
  178
- Determine Thickness of Shim
  179
- Differential Reassembly (Version - Screwed Bearing Caps)
  179
- Adjust Rolling Resistance of Drive Pinion Bearing
  183
- Differential
  186
- Determine Plate Clearance
  189
- Adjustment of Bearing Preload and Backlash
  191
- Illustrated Table
  194
- Determine Thickness of Shim
  195
- Differential Reassembly (Version - Cast-On Bearing Caps)
  195
- Adjustment of Drive Pinion Bearing Rolling Resistance
  199
- Differential
  202
- Determination of Plate Clearance
  205
- Illustrated Table
  210
- Determine Thickness of Shim
  211
- Differential Reassembly (Version - Screwed and Cast-On Bearing Caps)
  211
- Adjustment of Drive Pinion Bearing Rolling Resistance
  213
- Differential
  217
- Determination of Plate Clearance
  220
- Adjustment of Bearing Preload and Backlash
  222
- Illustrated Table
  225
- Air-Conditioner
  226
Section 6

227
- General Description
  228
- Refrigerant Circulation
  229
- Control Panel
  231
- Control Specifications
  232
- Temperature Level Control and Display
  233
- Air Discharge According to Path Selection
  234
- Air-Conditioning System Circuit Diagram
  237
- Troubleshooting
  239
- Weight of R134A Gas Used in Machines
  242
- Refrigerant Safe Handling Procedures
  243
- Refrigerant System Repairs
  243
- Repair and Replacement Procedure
  244
- Refrigerant Recovery
  246
- Vacuuming Refrigerant System
  246
- Leakage Check
  247
- Refrigerant Charging
  248
- Inspecting System for Leakage
  250
- Transmission and Torque Converter (ZF 4WG-310)
  252
Section 7

253
- Drive Train Description
  256
- Transmission and Torque Converter
  257
- Powershift Transmission
  258
- Transmission Control
  258
- Oil Circuit Diagram 4WG-310 Forward 1St Speed
  262
- Schedule of Measuring Points and Connection 4WG-310
  262
- Transmission Electric Components
  265
- TCU (Transmission Control Unit)
  266
- Transmission Control Valve
  267
- Transmission Oil Temperature Sensor
  267
- Central Gear Pick-Up Sensor
  268
- Engine Pick-Up Sensor
  268
- Turbine Pick-Up Sensor
  268
- Output Speed Sensor
  269
- Shift Lever Switch (DW-3)
  269
- Auto Select Switch
  270
- Display
  270
- CAN - Message
  272
- Description of Fault Codes
  272
- Fault Display
  272
- Transmission Faults Codes
  272
- Abbreviations
  273
- Definition of Operation Modes
  273
- Limp-Home
  273
- Normal
  273
- Substitute Clutch Control
  273
- TCU Shutdown
  273
- Transmission Shutdown
  273
- Actuator
  274
- Cable
  274
- Measurement of Resistance at Actuator/Sensors and Cable
  274
- Table of Fault Codes
  274
- Transmission Electrical Circuits
  275
- Neutral
  277
- Transmission Controller Circuit
  277
- Travelling Circuits
  277
- Forward First Gear
  278
- Forward Second Gear
  279
- Forward Third Gear
  280
- Forward Fourth Gear
  281
- Reverse First Gear
  282
- Reverse Second Gear
  283
- Reverse Third Gear
  284
- (Auto Selector Switch "O" - Manual Mode)
  285
- Downshift
  285
- Kick-Down: Forward Second Gear to Forward First Gear
  285
- Overview
  285
- Downshift (Auto Selector Switch "I" - Auto Mode)
  287
- Transmission Cutoff
  289
- Inner Section
  291
- Installation View
  291
- Front View
  293
- Side View
  294
- Rear View
  295
- Hydraulic Control Unit (HSG-94)
  297
- Disassembly
  298
- Reassembly
  302
- Converter-Input
  310
- Transmission Disassembly
  310
- Output- Layshaft Assembly
  315
- Transmission Pump
  315
- Multidisk Clutches
  320
- Power Take-Off
  321
- Multidisk Clutch Kv/K1
  328
- Power Take-Off
  333
- Transmission Reassembly
  333
- Multidisk Clutch - K4
  338
- Reassemble Multidisk Clutch Kr/K2
  347
- Multidisk Clutch - KR
  349
- Multidisk Clutch - K2
  354
- Reassemble Multidisk Clutch Kv / K1
  361
- Multidisk Clutch - KV
  363
- Multidisk Clutch - K4
  368
- Install Countershaft Gear and Multidisk Clutches
  374
- Pre-Assemble and Mount Housing Cover
  379
- Install Countershaft Axle
  390
- Hydraulic Pump
  391
- Axle Disconnection
  393
- Filter
  394
- Input Shaft (Power Take-Off Pump)
  395
- Input - Converter Bell
  399
- Converter
  404
- Inductive Transmitters and Speed Sensor
  406
- Transmission Error Codes (ZF)
  412
Section 8

413
- Abbreviations
  414
- Introduction
  414
- Display
  415
- Description of Fault Codes
  416
- Display During Operation
  417
- Definition of Operating Modes
  419
- Limp-Home
  419
- Normal
  419
- Substitute Clutch Control
  419
- TCU Shut down
  419
- Transmission Shut down
  419
- Clutch Pack and Solenoid Valve Cross-Reference Table
  420
- Table of Fault Codes
  421
- Table of Fault Codes - ERGO-Control
  443
- Actuator
  446
- Cable
  446
- Measurement of Resistance at Actuator/Sensors and Cable
  446
- Accumulator
  449
Section 9

458
- General Description
  459
- Theory of Operation
  460
- Parts List
  461
- Troubleshooting, Testing and Adjustment
  463
- Cylinders
  465
- Disassembly
  467
- Cleaning and Inspection (Wear Limits and Tolerances)
  469
- Reassembly
  470
- Main Pump (Denison T6DMY Series)
  479
Section 10

480
- Construction
  481
- General Description
  481
- Principles of Operation
  483
- Parts List
  490
- Specifications
  491
- Special Tools
  492
- Special Tools and Materials
  492
- Troubleshooting, Testing and Adjustment
  493
- Disassembly
  495
- Cleaning and Inspection (Wear Limits and Tolerances)
  499
- Reassembly
  500
- Start-Up Procedures
  503
- Steering and Brake Pump (Denison T67DB Series)
  505
Section 11

506
- General Description
  507
- Parts List
  508
- Special Tools
  510
- Troubleshooting, Testing and Adjustment
  511
- Adding Hydraulic Oil to System
  512
- Adjustments
  512
- Circuit Inspection
  512
- Lubrication
  512
- Service and Maintenance
  512
- Replacement Parts
  513
- Disassembly
  514
- Basic Pump Disassembly
  516
- Cartridge Disassembly
  517
- Cleaning
  520
- Cleaning and Inspection (Wear Limits and Tolerances)
  520
- Inspection, Repair and Replacement
  520
- Reassembly
  522
- Cartridge Assembly
  523
- Basic Pump Assembly
  526
- Start-Up
  527
- Start-Up Procedures
  527
- Test
  527
- Brake Pedal Valve
  529
Section 12

530
- General Description
  531
- Theory of Operation
  531
- Specification
  533
- Brake System
  534
- Brake, Pilot and Parking Brake Supply Valve
  535
- Specifications
  536
- Main Control Valve (Toshiba)
  537
Section 13

538
- General Description
  539
- Specifications
  541
- Bucket/Option Spool Operation
  542
- Neutral
  542
- Operation
  542
- Boom Float
  543
- Boom Spool Operation
  543
- Main Relief Valve
  543
- Port Relief Valve
  543
- Relief Valve
  543
- Operation (A)
  544
- Operation (B)
  544
- Operation (Main Relief Valve)
  544
- Operation in Inoperative State
  544
- In the Inoperative State
  545
- Operation (A)
  545
- Operation (B)
  545
- Operation (Port Relief Valve)
  545
- Operation (C)
  546
- Sucking Operation
  546
- Pilot Control Valve
  547
- Flow Amplifier (Danfoss)
  555
Section 14

556
- General Description
  557
- Parts List
  558
- Specifications
  559
- Special Tools
  560
- Special Tools and Materials
  560
- Troubleshooting, Testing and Adjustment
  561
- Steering System with OSQA/B and OSPBX-LS
  562
- Disassembly
  563
- Cleaning
  583
- Cleaning and Inspection (Wear Limits and Tolerances)
  583
- Inspection and Replacement
  583
- Lubrication
  583
- Reassembly
  583
- Power Steering Unit
  603
- Restriction Valve
  633
- Hydraulic Schematic (Mega 500-V)
  639
- Electrical System
  645
Section 15

647
- Electric Wire Color
  648
- Overview
  648
- Electric Supply System
  649
- Engine Starting Circuit
  651
- Operation During Start Process
  651
- Operation after Start Process
  653
- Cold Weather Starting Aid System (Option)
  655
- Principle of Operation
  656
- Engine Stop and Derating System
  657
- Operation in Engine Stop Mode
  657
- Operation in Engine Derating
  659
- Charging System
  661
- Monitoring System
  662
- Instrument Panel
  663
- Function Check
  664
- Monitoring System Schematic
  665
- Instruments
  667
- Operation
  667
- Indicator Lights
  668
- Initial Operation
  670
- Control Unit Operation
  671
- Characteristic of Operation
  672
- Front Windshield Wiper
  673
- Front Windshield Wiper Circuit
  673
- Windshield Wiper
  673
- Rear Windshield Wiper
  674
- Light Circuit
  677
- Lighting System
  677
- Electrical Schematic (Mega 500-V)
  680

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