Daewoo Mega 500-V Install guide

023-00033E Shop Manual
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.
Shop Manual
023-00033E
Serial Number 1001 and Up
Mega 500-V

Table of Contents
Page I
1 TABLE OF CONTENTS
Return to Master Table of Contents
Safety
Wheel Loader Safety.......................................................................... S0103010K
Specifications
Specifications for Mega 500-V............................................................ S0203070K
General Maintenance
General Maintenance Procedures.........................................................S0302000
Standard Torques..................................................................................S0309000
Upper Structure
Counterweight..................................................................................... S0403040K
Fuel Transfer Pump...............................................................................S0405500
Hydraulic Oil Tank ..............................................................................S0406040K
Lower Structure and Chassis
Center Joint (Articulation Joint)........................................................... S0502020K
Engine and DriveTrain
Axle (ZF AP 420R).............................................................................. S0602170K
Air-Conditioner.................................................................................... S0605050K
Transmission and Torque Converter (ZF 4WG-310).......................... S0607080K
Transmission Error Codes (ZF)..........................................................S0607900C
Hydraulics
Accumulator...........................................................................................S0703000
Cylinders................................................................................................S0705010
Main Pump (Denison T6DMY Series)................................................. S0708460K
Steering and Brake Pump (Denison T67DB Series)........................... S0708470K

Table of Contents
Page II
Brake Pedal Valve.............................................................................. S0709240K
Main Control Valve (Toshiba)............................................................. S0709455K
Pilot Control Valve.............................................................................. S0709476K
Flow Amplifier (Danfoss)..................................................................... S0709665K
Power Steering Unit............................................................................ S0709730K
Restriction Valve................................................................................. S0709750K
Hydraulic Schematic (Mega 500-V).................................................... S0793060K
Electrical System
Electrical System................................................................................ S0802190K
Electrical Schematic (Mega 500-V) ....................................................S0893060K
Attachments

1 SAFETY

S0103010K
Page 1
Wheel Loader Safety
S0103010K
2 WHEEL LOADER
SAFETY
WHEEL LOADER SAFETYS0103010K
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
MODEL SERIAL NUMBER RANGE
Mega 200-V 1001 and Up
Mega 250-V 1001 and Up
Mega 300-V 1001 and Up
Mega 400-V 1001 and Up
Mega 500-V 1001 and Up
Copyright 2001 Daewoo
November 2001

S0103010K
Page 2 Wheel Loader Safety
TABLE OF CONTENTS
To the Operator of a Daewoo Wheel Loader..................................................3
General Safety Essentials..............................................................................6
Location of Safety Labels...............................................................................6
Unauthorized Modifications............................................................................6
General Hazard Information...........................................................................7
Before Starting Engine.................................................................................15
Machine Operation.......................................................................................18
Maintenance.................................................................................................25
Battery..........................................................................................................33
Towing..........................................................................................................35
Shipping and Transportation.........................................................................36

S0103010K
Page 3
Wheel Loader Safety
TO THE OPERATOR OF A DAEWOOWHEEL LOADER
Please respect the importance of taking responsibility for your own safety, and that other people who may
be affected by your actions.
Safety information on the following pages is organized into the following topics.
1. “General Safety Essentials” on page 6.
2. “Location of Safety Labels” on page 6.
3. “Unauthorized Modifications” on page 6.
4. “General Hazard Information” on page 7.
5. “Before Starting Engine” on page 15.
6. “Machine Operation” on page 18.
7. “Maintenance” on page 25.
8. “Battery” on page 33.
9. “Towing” on page 35.
10. “Shipping and Transportation” on page 36.
DANGER!
Unsafe use of the wheel loader could lead to serious injury or death. Operating procedures,
maintenance and equipment practices or traveling or shipping methods that do not follow the
safety guidelines on the following pages could cause serious, potentially fatal injuries or
extensive damage to the machine or nearby property.

S0103010K
Page 4 Wheel Loader Safety
WARNING!
Improper operation and maintenance of this machine can be hazardous and could result in
serious injury or death.
Operator and maintenance personnel should read this manual thoroughly before beginning
operation or maintenance.
Keep this manual in the storage compartment to the rear of the operator’s seat, and have all
personnel involved in working on the machine read the manual periodically.
Some actions involved in operation and maintenance of the machine can cause a serious
accident, if they are not done in a manner described in this manual.
The procedures and precautions given in this manual apply only to intended uses of the
machine.
If you use your machine for any unintended uses that are not specifically prohibited, you must
be sure that it is safe for any others. In no event should you or others engage in prohibited uses
or actions as described in this manual.
Daewoo delivers machines that comply with all applicable regulations and standards of the
country to which it has been shipped. If this machine has been purchased in another country or
purchased from someone in another country, it may lack certain safety devices and
specifications that are necessary for use in your country. If there is any question about whether
your product complies with the applicable standards and regulations of your country, consult
Daewoo or your Daewoo distributor before operating the machine.

S0103010K
Page 5
Wheel Loader Safety
LEARN SIGNALWORDS USED WITH SAFETY ALERT SYMBOL
Words " CAUTION ," " WARNING ," and " DANGER " used throughout this manual and on labels on machine
indicate hazards or unsafe practices. All three statements indicate that safety is involved. Observe
precautions indicated whenever you see the Safety Alert "Triangle," no matter which signal word appears
next to the "Exclamation Point" symbol.
Safety precautions are described in SAFETY from page 6 on.
Daewoo cannot predict every circumstance that might involve a potential hazard in operation and
maintenance. Therefore the safety messages in this manual and on the machine may not include all
possible safety precautions. If any procedures or actions not specifically recommended or allowed in this
manual are used, you must be sure that you and others can do such procedures and actions safely and
without damaging the machine. If your unsure about the safety of some procedures, contact a DAEWOO
distributor.
SAFETY ALERT SYMBOL
Be Prepared - Get to Know All Operating and Safety Instructions
This is the Safety Alert Symbol. Wherever it appears - in this manual or on safety signs on the
machine - you should be alert to potential for personal injury or accidents. Always observe
safety precautions and follow recommended procedures.
CAUTION!
This word is used on safety messages and safety labels and indicates potential of a hazardous
situation that, if not avoided, could result in minor or moderate injury. It may also be used to alert
against a generally unsafe practice.
WARNING!
This word is used on safety messages and safety labels and indicates potential of a hazardous
situation that, if not avoided, could result in serious injury or death. It may also be used to alert
against a highly unsafe practice.
DANGER!
This word is used on safety messages and safety labels and indicates imminent hazard of a
situation that, if not avoided, is very likely to cause death or extremely serious injury. It may also
be used to alert against equipment that may explode or detonate if handled or treated carelessly.

S0103010K
Page 6 Wheel Loader Safety
GENERAL SAFETY ESSENTIALS
ACCESSORY APPLICATIONS
This 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. Do not use bucket for lifting work, unless lift slings are
used in approved configuration.
LOCATION OF SAFETY LABELS
Location of safety labels (decals) can vary from unit to unit. Refer to appropriate Operation and
Maintenance Manual, and Parts Manual for your unit.
There are several specific warning signs on this machine. The exact location of hazards and the
description of the hazards are reviewed in the appropriate Operation and Maintenance Manual.
Please become familiarized with all warning signs.
Make sure that all of the warning signs are legible.Clean the warning signs or replace the warning signs if
you cannot read the words. Replace the illustrations if the illustrations are not visible. When you clean the
warning signs, use a cloth, water and soap. Do not use solvent, gasoline, or other harsh chemicals to clean
the safety signs. Solvents, gasoline, or other harsh chemicals could loosen the adhesive that secures the
warning sign. Loose adhesive will allow the warning sign to fall off.
Replace any safety sign that is damaged, or missing. If a safety sign is attached to a part that is replaced,
install a safety sign on the replacement part.
UNAUTHORIZED MODIFICATIONS
Any modification made without authorization or written approval from Daewoo can create a safety hazard,
for which the machine owner must be held responsible.
For safety’s sake, replace all OEM parts with the correct authorized or genuine Daewoo part. For example,
not taking the time to replace fasteners, bolts or nuts with the correct replacement parts could lead to a
condition in which the safety of critical assemblies is dangerously compromised.