Daewoo Wheel Loader Shop Manual

TM D A E W O O W H E E L L O A D E R Shop Manual Printed in U.S.A. June 1997 Copyright 1997 Serial Number 0001 and Up 2023-7105E

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TABLE OF CONTENTS SAFETY To the Operator of a Daewoo Wheel Loader 1-1 Basic Wheel Loader Operating Safety 1-1 General Safety Essentials 1-1 Locations of Safety Labels 1-2 Summary of Safety Precautions for Lifting 1-5 Operation 1-7 Equipment 1-10 Maintenance 1-11 Shipping and Transportation 1-13 SPECIFICATIONS Component Locations 2-1 General Specifications 2-2 Excavator Engine Specifications 2-3 Engine Performance Curves 2-4 Working Range and Dimensions 2-5 Working Capacities 2-7 Approximate Weight of Workload Materials 2-8 INSPECTION, MAINTENANCE AND ADJUSTMENT Preventive Maintenance 3-1 Safety Precautions 3-1 Maintenance Intervals 3-2 Table of Recommended Lubricants 3-3 Inspection and Maintenance 3-4 Daily or Every 10 Operating Hours 3-7 Weekly or Every 50 Operating Hours 3-10 Every 250 Operating Hours 3-12 Every 500 Operating Hours 3-13 Every 1,000 Operating Hours 3-13 Every 1,500 Operating Hours 3-18 Annually or Every 2,000 Operating Hours 3-18 Severe Conditions Maintenance 3-20 General Maintenance 3-21 Check Hydraulic Pressures 3-22 Tires and Wheels 3-25 Electrical System 3-26 Bolt Torque Chart 3-27 Long Term Storage 3-28 TORQUE CONVERTER AND TRANSMISSION Drive Train 4-1 Transmission 4-2 Transmission Troubleshooting 4-5 Control Valve 4-7 Second Gear Valve 4-12 Transmission WG-180 Control Valve 4-18 Transmission Disassembly 4-21 Mega 300-III Shop Manual i

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Transmission Assembly 4-42 Power Disengagement Gearbox 4-82 Differential Type Output Gearing 4-87 WK Torque Converter 4-98 WK Converter Clutch Valve 4-109 POWER STEERING Power Steering System 5-1 Steering System Troubleshooting 5-5 Steering Unit 5-6 Priority Valve 5-19 AXLES Front and Rear Axles 6-1 Axle Troubleshooting 6-2 Front Axle Housing 6-3 Axle Differential 6-4 Planetary Gear Set 6-7 Parking Brake 6-9 Rear Axle 6-11 Brake System 6-13 HYDRAULIC SYSTEM Hydraulic Circuits Description 7-1 Hydraulic Pump 7-3 Hydraulic Circuits and Components 7-18 Manually Controlled Pilot Valve 7-23 Automatic Bucket Return-to-Dig System 7-24 Automatic Boom Kick-out System 7-25 Automatic Boom Float System 7-25 Hydraulic Cylinders 7-27 Accumulator 7-40 Hydraulic System Schematic 7-45 ENGINE Engine Specifications (D2366T) 8-1 Valve Adjustment Sequence 8-2 Engine Cylinder Compression Test 8-2 Wear Limits of Major Engine Components 8-2 Engine Oil Pump Overhaul and Rebuilding 8-7 Fuel Injection Pump Installation, Alignment and Timing 8-9 Cylinder Head Bolt Torque Requirements 8-11 ELECTRICAL SYSTEM Electrical Schematic 9-1 24 Volt Operation 9-1 Wiring Color Code for Electrical Schematic Diagrams 9-1 Engine Start Circuit 9-2 Engine Stop Motor 9-4 Engine Intake Preheat Circuit 9-6 Windshield Wiper Circuit 9-8 Electrical System Schematic 9-11 INDEX 10-1 ii Mega 300-III Shop Manual

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SAFETY To the Operator of a Daewoo Wheel Loader General Safety Essentials Accessory Applications The 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 the machine for activities for which it was not intended. DO NOT use the bucket for lifting work, unless lift slings are used in the approved configuration. DANGER!!! Improper use of the Wheel Loader could cause serious injury or death.

Before oper- ating the wheel loader, or performing maintenance, the operator or technician must read and understand the entire Operation and Maintenance Manual. Any Operation, Maintenance, Traveling or Shipping methods that do not follow the Safety guidelines printed in this Manual could cause serious injury or death. Working in rough terrain, use of an accessory hydraulic hammer (breaker), demolition applica- tions, or other hazardous operation may require installation of additional protective structures to safeguard the operator.

Static Tipping Load The machine can lift a maximum of 14,500 kg (31,967 lb) with the bucket in the Straight Ahead position, and a maximum of 12,000 kg (26,455 lb) with the bucket in the Fully Turned position. Hooks and slings must be attached to an eye that is in the center of the bucket. All lifts must be made with the machine standing on a firm and level surface. Loads must be balanced and supported evenly. Use taglines to keep the load steady if wind condi- tions and large surface area are a problem. Work crew hand signals, individual tasks and safe proce- dures should all be universally understood before the lift is made.

Basic Wheel Loader Operating Safety The safety information on the following pages is organized into the following topics. I. General Safety Essentials III. Summary of Safety Precautions for Lifting II. Locations of Safety Labels IV. Operation V. Equipment NOTE VI. Maintenance Before using the wheel loader to make lifts, check the statutes at all levels of government that might have jurisdiction. Some governing bodies may require that all heavy lifting be done with a crane that is specifically designed for making lifts. When making lifts, always follow all instructions, guide- lines, and restrictions for Safe Lifting in the Operation and Maintenance and Shop Manuals. VII.

Shipping and Transportation Mega 300-III Shop Manual SAFETY 1-1

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