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.

022-00029AE Operation and Maintenance Manual Safety 1-5
.
Figure 1 ROPS CANOPY MACHINE WITH CABIN
16
8
2
4
9
5
12
10
5
9
11
2
8
3
7
3
AQO0320L

1-6 Safety 022-00029AE Operation and Maintenance Manual
Figure 2 CAB MACHINE
16
8
2
4
9
5
12
10
3
5
9
11
2
8
7
3
AQO0330L

022-00029AE Operation and Maintenance Manual Safety 1-7
1. WARNING FOR OPERATION, INSPECTION AND MAINTENANCE (4190-2545, 190-00092)
2. WARNING FOR CRUSH HAZARD (4190-2548)
CAUTION!
• Read manual and labels before
operation and maintenance.
Follow instructions and warnings
in manual and on labels on
machine.
• Sound horn to alert people
nearby before operating, and
make sure all persons are clear
of area.
• Always make sure when leaving
operator’s seat to:
• Lower bucket or other
working tools to ground.
• "LOCK" transmission selector in "NEUTRAL."
• Set park brake.
• Turn starter switch "OFF." Remove key from switch.
• If hydraulic components and units are ABNORMAL, consult nearest DOOSAN dealer
or authorized service shop. Do not attempt to make an overhaul.
DANGER!
Crushing Injury
Make sure people are clear of machine
before starting engine or moving steering
wheel.
ACO1360L
HAOJ370L

1-8 Safety 022-00029AE Operation and Maintenance Manual
3. WARNINGS WHEN OPENING ENGINE HOOD (2190-2525, 190-00095)
4. WARNING FOR HANDLING ACCUMULATOR (2190-2528, 190-00099)
Accumulator
The pilot control system is equipped with an accumulator. For a brief period of time after the engine has
been shut down, the accumulator will store a pressure charge that may enable hydraulic controls to be
activated. Activation of any controls may enable the selected function to operate under force of gravity.
WARNING!
Before opening bonnet, stop engine.
WARNING!
Explosion hazard:
• Keep away from flame.
• Do not weld or drill.
CAUTION!
Any raised attachment will lower to ground if accumulator holds a charge.
ACO1420L
ACO1480L

022-00029AE Operation and Maintenance Manual Safety 1-9
When performing maintenance on the pilot control system, the hydraulic pressure in the system must be
released as describe in “Handling of Accumulator” on page 4-52.
5. KEEP OUT OF STEERING TURN AREA (4190-1992, 190-00120)
6. WARNING FOR HIGH TEMPERATURE HYDRAULIC OIL (2190-2529, 190-00097)
IMPORTANT
Refer to Shop Manual for service procedures. Do not release any pilot lines until pressure within
accumulator has been released.
DANGER!
Keep out of steering turn area.
WARNING!
HYDRAULIC OIL
To prevent hot oil from spurting out:
• Turn engine off.
• Allow oil to cool.
• Slowly loosen cap to relieve
pressure before removing.
AMO0410L
ACO1410L

1-10 Safety 022-00029AE Operation and Maintenance Manual
7. WARNING FOR HIGH TEMPERATURE COOLANT (2190-2531, 190-00097)
8. WARNING FOR BATTERY MAINTENANCE (2190-2533, 190-00100)
WARNING!
To prevent hot water from spurting out:
• Turn engine "OFF."
• Allow water to cool.
• Slowly loosen cap to relieve
pressure before removing.
DANGER!
• Battery fumes can explode.
Keep sparks and flames away
from batteries.
• Always avoid storing metals
like tools or inflammable
materials around or on
batteries. Explosion or fire can
be caused by short circuiting
batteries.
• Sulfuric acid in battery is
poisonous. It is strong enough
to burn skin, eat holes in
clothing, and cause blindness if
splashed in eyes.
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to
help neutralize acid.
3. Flush your eyes with water for 10-15 minutes.
Get medical attention immediately.
ACO1410L
ACO1400L

022-00029AE Operation and Maintenance Manual Safety 1-11
9. WARNING FOR RIDING ON MACHINE (4190-1989, 190-00107)
10. WARNING FOR PERFORMING MAINTENANCE ON FRONT ATTACHMENT
(4190-2546, 190-00105)
WARNING!
For your safety, do not stand on ladder
when machine is in motion.
DANGER!
To avoid injury, securely brace lift arm
before disassembly of valve or piping.
AMO0420L
AMO0430L

1-12 Safety 022-00029AE Operation and Maintenance Manual
11. WARNING TO USE SAFETY LOCK (4190-1993, 190-00121)
12. WARNING TAG (2190-2549, 190-00098)
WARNING!
Safety lock must be in "LOCK" position
when servicing pivot area or transporting
machine.
WARNING!
Don’t touch when performing inspection
or maintenance.
AMO0440L
ACO1450L

022-00029AE Operation and Maintenance Manual Safety 1-13
UNAUTHORIZED MODIFICATIONS
Any modification made without authorization or written approval from DOOSAN 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 DOOSAN 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.
GENERAL HAZARD INFORMATION
SAFETY RULES
Only trained and authorized personnel can operate and maintain the machine.
Follow all safety rules, precautions and instructions when operating or performing maintenance on the
machine.
Do not operate the machine if you are not feeling well, if you are taking medication that makes you feel
sleepy, if you have been drinking, or if you are suffering from emotional problems. These problems will
interfere with your sense of judgement in emergencies and may cause accidents.
When working with another operator or with a person on work site traffic duty, be sure that all personnel
know the nature of the work and understand all hand signals that are to be used.
Always observe strictly any other rules related to safety.
SAFETY FEATURES
Be sure that all guards and covers are installed in their proper position. Have guards and covers repaired
immediately if damaged.
Be sure that you understand the method of use of safety features such as transmission lever neutral lock
and the seat belt, and use them properly.
Never remove any safety features. Always keep them in good operating condition.
Failure to use safety features according to the instructions in the Operation and Maintenance Manual could
result in serious bodily injury.

1-14 Safety 022-00029AE Operation and Maintenance Manual
INSIDE OPERATOR'S COMPARTMENT
When entering the operator's compartment, always remove all mud and oil from the soles of your shoes. If
you operate the accelerator and brake pedals with mud or oil stuck to your shoes, your foot may slip and
this may cause a serious accident.
Clean grease and dirt from pedals and controls. This contributes to safe operation. Cleaning also provides
an opportunity to inspect equipment. Minor damage can be repaired or corrected before major problems
result.
Keep cab floor and consoles free of tools and personal items.
Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire.
Do not leave lighters laying around the operator's compartment. If the temperature inside the operator's
compartment becomes high, there is danger that the lighter may explode.
Do not use cellular telephones inside the operator's compartment when driving or operating the machine.
There is danger that this may lead to an unexpected accident.
Never bring any dangerous objects such as flammable or explosive items into the operator's cab.
To ensure safety, do not use the radio or music headphones when operating the machine. There is danger
that this may lead to a serious accident.
When operating the machine, do not put your hands or head out of the window.
When standing up from the operator's seat, always place transmission neutral lock lever in the "LOCK"
position and set pilot cutoff switch to "O" (OFF) position. If you accidentally touch the work equipment
levers when they are not locked, the machine may suddenly move and cause serous injury or damage.
When leaving the machine, lower the work equipment completely to the ground, set transmission neutral
lock lever in the "LOCK" position, set pilot cutoff switch to "O" (OFF) position, "APPLY" parking brake, and
shut down engine. Use the key to lock all the equipment. Always remove the key and take it with you.
CLOTHING AND PERSONAL PROTECTIVE
ITEMS
Contain long hair, and avoid loose clothing and
jewelry. They can catch on controls or in
protruding parts and cause serious injury or
death.
Do not wear oily clothes. They are highly
flammable.
Full eye protection, a hard hat, safety shoes and
gloves may be required at the work site.
While working on the machine, never use
inadequate tools. They could break or slip,
causing injury, or they may not adequately
perform intended functions.
HAOA020L
Figure 3