Daewoo Mega 200-V User Manual

022-00028AE Operation and Maintenance Manual Copyright 2003 Daewoo
Daewoo reserves the right to improve our products in a continuing process to provide the best possible
product to the market place. These improvements can be implemented at any time with no obligation to
change materials on previously sold products. It is recommended that consumers periodically contact their
distributors for recent documentation on purchased equipment.
This documentation may include attachments and optional equipment that is not available in your
machine’s package. Please call your distributor for additional items that you may require.
Illustrations used throughout this manual are used only as a representation of the actual piece of
equipment, and may vary from the actual item.
Operation and Maintenance Manual
022-00028AE
S/N 1001 and Up (Tier I & II)
February 2003
Mega 200-V
Mega 200-VTC

Daewoo Mega 200-V Specifications

General

Brand	Daewoo
Model	Mega 200-V
Category	Construction Equipment
Language	English

Summary

Safety

To the Operator of a Daewoo Wheel Loader

Emphasizes operator responsibility for safety and understanding the manual.

General Safety Essentials

Covers fundamental safety principles, accessory applications, and signal words.

Location of Safety Labels

Details the importance, placement, and maintenance of safety labels on the machine.

Unauthorized Modifications

Warns against modifications that can create safety hazards and holds the owner responsible.

Work Site Precautions

Addresses hazards like high-voltage cables and general work site safety measures.

Equipment

Discusses the need for certified safety equipment like FOPS/ROPS for rough operations.

Personal Protective Items

Outlines necessary clothing, eye protection, and respiratory gear for safe operation.

Battery Safety

Covers hazards related to battery electrolyte, explosive gases, and proper handling.

Operating Controls

Component Locations

Identifies the position of major machine components with detailed diagrams.

Control Identification

Illustrates and identifies various controls within the operator's cab.

Steering Console and Pedals

Details the steering wheel, pedals, and related controls for operation.

Front Instrument Panel

Explains the gauges, warning lights, and switches on the main dashboard.

Right Side Switch Panel

Describes the switches and controls located on the operator's right side panel.

Various Cabin Locations

Shows the placement of various cabin features like lights, stereo, and storage.

Heater and Air Conditioner Operation

Explains how to operate the cabin's heating, cooling, and ventilation systems.

Seat Adjustment

Details how to adjust the operator's seat for comfort, control, and safety.

Seat Belt

Explains the proper use, importance, and function of the seat belt.

Fuse Box/Relay

Locates and explains the function of the machine's fuse boxes and relays.

Window Glass Breaking Tool

Explains the location and use of the emergency glass breaking tool for cab exit.

Operation

Instrument Panel Control Functions

Describes the functions of the instrument panel indicators, gauges, and monitoring system.

New Machine Break-in Procedures

Outlines the essential initial break-in steps for new machines to prevent damage.

Engine Start and Stop

Provides step-by-step instructions for starting and safely stopping the engine.

Cold Weather Engine Start

Details specific procedures and precautions for starting the engine in cold conditions.

Machine Travel

Covers the procedures, precautions, and warnings for moving the machine.

Machine Shut Down

Explains the correct process for safely shutting down the machine after operation.

Boom Raise Kickout

Explains the automatic boom raise limiting function and its adjustment.

Adjustment of Bucket Position Switch

Guides on adjusting the switch for desired automatic bucket digging positioning.

Towing Machine

Provides instructions and safety precautions for towing the machine or being towed.

Inspection, Maintenance and Adjustment

Serial Numbers

Explains the location of the machine's serial number plates for identification.

Safety Precautions

Lists general safety measures to follow before performing any maintenance checks.

Table of Recommended Lubricants

Lists recommended lubricants for various machine components by manufacturer.

Fluid Capacities

Details the required fluid capacities for the engine, cooling, fuel, hydraulic, and axle systems.

Maintenance Intervals

Outlines the schedule for routine service checks and tasks based on operating hours.

Grease Front Attachment Pins

Specifies greasing points and intervals for front attachments.

Change Engine Oil and Filter

Provides step-by-step instructions for changing engine oil and the oil filter.

Replace Hydraulic System Brake and Pilot Filter

Guides on replacing the hydraulic system brake and pilot filters.

Clean Exterior of Radiator, Oil Cooler and Air Conditioner Condenser

Instructions for cleaning cooling system components to maintain efficiency.

Clean Air Conditioner Filter

Steps for cleaning and replacing the air conditioner filter.

Change Radiator Coolant

Procedures for draining, flushing, and refilling the radiator coolant.

Drain and Replace Transmission Oil and Filter

Steps for changing transmission oil and filter based on service intervals.

Bleed Brakes

Instructions on how to remove air from the brake hydraulic system.

Drain and Replace Hydraulic Oil

Steps for draining and refilling the hydraulic oil reservoir.

Check Brake Accumulator

Describes how to test the brake accumulator's precharge for proper function.

Severe Conditions Maintenance

Maintenance requirements for operating in mud, dust, heat, rocky terrain, or extreme cold.

Parking Brake Adjustment

Instructions for adjusting the parking brake for proper operation.

Check Hydraulic Pressures

How to check hydraulic system pressures using remote test ports.

Tires and Wheels

Information on tire inflation, condition, and wheel nut torque specifications.

Check Tire for Damage

Guidelines for identifying tire damage that requires replacement for safety.

Electrical System

Covers battery condition checks, safety warnings, and electrical system inspection.

Bolt Torque Chart

Provides tightening torque specifications for metric bolts used on the machine.

Long Term Storage

Procedures for cleaning, lubricating, and preparing the machine for long-term storage.

Transportation

Loading Machine on a Trailer

Steps and safety precautions for loading the machine onto a transport trailer.

Summary of Safety Precautions for Lifting

Key safety considerations for evaluating and performing safe machine lifts.

Troubleshooting

Engine

Lists common engine problems, their potential causes, and recommended remedies.

Hydraulic System

Troubleshooting guide for issues related to the hydraulic system's functionality.

Travel System

Addresses problems related to the machine's travel system, including movement and power.

Steering

Troubleshooting guide for steering-related problems like hard turning or shaking.

Braking

Common issues and solutions for the braking system's performance and release.

Electrical System

Troubleshooting steps for battery issues, charging problems, and wiring faults.

Transmission Error Codes

Explains various error codes related to the transmission system's operation.

Specifications

General Specifications

Provides overall technical specifications including bucket capacity, weight, and engine details.

Working Range and Dimensions

Illustrates machine dimensions and operational working ranges with diagrams.

Working Capacities

Details bucket capacity and material weights for workload estimation.