Doosan Mega 500-V User manual

022-00029AE Operation and Maintenance Manual Copyright 2001 DOOSAN
DOOSAN 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
022-00029AE
Serial Number 2001 and Up
August 2001
Mega 500-V (TIER II)

022-00029AE Operation and Maintenance Manual Table of Contents I
TABLE OF CONTENTS
Safety ...................................................................................................1-1
To the Operator of a Wheel Loader ............................................................. -
General Safety Essentials ........................................................................... -4
Location of Safety Labels ............................................................................ -4
Unauthorized Modifications....................................................................... - 3
General Hazard Information ...................................................................... - 3
Before Starting Engine .............................................................................. -2
Machine Operation.................................................................................... -24
Maintenance.............................................................................................. -3
Battery....................................................................................................... -39
Towing ....................................................................................................... -4
Shipping and Transportation...................................................................... -42
Operating Controls .............................................................................2-1
Component Locations .................................................................................2-2
Control Identification....................................................................................2-4
Steering Console and Pedals......................................................................2-5
Front Instrument panel ..............................................................................2- 2
Transmission Display.................................................................................2-2
Right Side Switch Panel ............................................................................2-22
Various Cabin Locations............................................................................2-33
Heater and Air Conditioner Operation.......................................................2-37
Stereo........................................................................................................2-42
Seat Adjustment........................................................................................2-46
Seat Belt....................................................................................................2-48
Door Side Latch.........................................................................................2-49
Fuse Box/Relay .........................................................................................2-50
Window Glass Breaking Tool..................................................................... 2-53
Operation .............................................................................................3-1

II Table of Contents 022-00029AE Operation and Maintenance Manual
Instrument Panel Control Functions ............................................................3-1
New Machine Break-in Procedures.............................................................3-1
Engine Start and Stop..................................................................................3-2
Machine Travel............................................................................................3-9
Machine Shutdown....................................................................................3-12
Additional Braking .....................................................................................3-14
Boom Raise Kickout ..................................................................................3-14
Boom Lower Kickout (Option) ...................................................................3-15
Bucket Angle Indicator ..............................................................................3-16
Adjustment of Bucket Position Switch .......................................................3-16
Towing Machine.........................................................................................3-17
If Engine Stalls While Traveling.................................................................3-20
Allowable Water Depth..............................................................................3-20
Inspection, Maintenance and Adjustment ....................................... 4-1
Preventive Maintenance..............................................................................4-1
Table of Recommended Lubricants.............................................................4-3
Fluid Capacities...........................................................................................4-5
Maintenance Intervals .................................................................................4-6
10 Hour / Daily Service................................................................................4-8
50 Hour / Weekly Service..........................................................................4-18
250 Hour / Monthly Service .......................................................................4-25
500 Hour / 3 Month Service.......................................................................4-35
1,000 Hour / 6 Month Service....................................................................4-37
1,500 Hour / 9 Month Service....................................................................4-42
2,000 Hour / Annual Service .....................................................................4-44
Severe Conditions Maintenance ...............................................................4-49
Fuel Transfer Pump...................................................................................4-50
Handling of Accumulator ...........................................................................4-52
Check Hydraulic Pressures .......................................................................4-53
Tires and Wheels ......................................................................................4-57
Electrical System.......................................................................................4-59
Bolt Torque Chart ......................................................................................4-60

022-00029AE Operation and Maintenance Manual Table of Contents III
Long Term Storage....................................................................................4-61
Transportation.................................................................................... 5-1
Loading Machine on a Trailer......................................................................5-1
Summary of Safety Precautions for Lifting ..................................................5-2
Troubleshooting................................................................................. 6-1
Engine .........................................................................................................6-1
Hydraulic System ........................................................................................6-3
Travel System .............................................................................................6-5
Steering .....................................................................................................6-10
Braking ...................................................................................................... 6-11
Electrical System....................................................................................... 6-11
Specifications..................................................................................... 7-1
General Specifications ................................................................................7-1
Working Range and Dimensions.................................................................7-2
Working Capacities .....................................................................................7-4
Approximate Weight of Workload Materials ................................................7-4
Index.................................................................................................... 1-1

022-00029AE Operation and Maintenance Manual Safety 1-1
1 SAFETY
TO THE OPERATOR OF A WHEEL LOADER
Please respect the importance of taking responsi ility for your own safety, and that other people who may
e affected y your actions.
Safety information on the following pages is organized into the following topics.
1. “General Safety Essentials” on page 1-4
2. “Location of Safety La els” on page 1-4
3. “Unauthorized Modifications” on page 1-13
4. “General Hazard Information” on page 1-13
5. “Before Starting Engine” on page 1-21
6. “Machine Operation” on page 1-24
7. “Maintenance” on page 1-31
8. “Battery” on page 1-39
9. “Towing” on page 1-41
10. “Shipping and Transportation” on page 1-42
DANGER!
Unsafe use of the wheel loader ould lead to serious injury or death. Operating pro edures,
maintenan e and equipment pra ti es or traveling or shipping methods that do not follow the
safety guidelines on the following pages ould ause serious, potentially fatal injuries or
extensive damage to the ma hine or nearby property.

1-2 Safety 022-00029AE Operation and Maintenance Manual
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.
DOOSAN 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
DOOSAN or your DOOSAN distributor before operating the machine.

022-00029AE Operation and Maintenance Manual Safety 1-3
LEARN SIGNAL WORDS 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 1-4 on.
DOOSAN 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 DOOSAN
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.

1-4 Safety 022-00029AE Operation and Maintenance Manual
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 DOOSAN. 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
There are several specific warning signs on this machine. The exact location of hazards and the
description of the hazards are reviewed in this section.
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.