Daewoo Doosan Wheel Loader Mega 250-V Shop Manual K1000898E – PDF DOWNLOAD
DESCRIPTION:
Daewoo Doosan Wheel Loader Mega 250-V Shop Manual K1000898E – PDF DOWNLOAD
Mega 250-V
Shop Manual
K1000898E
Serial Number 3001 and Up
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 :
- 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 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.
TABLE OF CONTENTS:
Daewoo Doosan Wheel Loader Mega 250-V Shop Manual K1000898E – PDF DOWNLOAD
Publication Request for Proposed Revision....................................................................... 7 Safety.......................................................................................................... 9 Wheel Loader Safety S0103010K............................................................................... 11 To the Operator of a DOOSAN Daewoo Wheel Loader......................................................... 13 Learn Signal Words Used with Safety Alert Symbol.................................................... 15 General Safety Essentials............................................................................... 16 Accessory Applications.............................................................................. 16 Location of Safety Labels............................................................................... 16 Unauthorized Modifications.............................................................................. 16 General Hazard Information.............................................................................. 17 Safety Rules........................................................................................ 17 Safety Features..................................................................................... 17 Inside Operator's Compartment....................................................................... 18 Clothing and Personal Protective Items.............................................................. 18 Breathing Masks, Ear Protection May Be Required..................................................... 19 Vibration Level Information......................................................................... 19 Asbestos Dust Hazard Prevention..................................................................... 19 Mounting and Dismounting............................................................................ 20 Fuel, Oil and Hydraulic Fluid Fire Hazards.......................................................... 20 Precautions When Handling Fluids at High Temperature................................................ 21 Injury from Work Equipment.......................................................................... 21 Fire Extinguisher and First Aid Kit................................................................. 22 Protection from Falling or Flying Objects........................................................... 22 Install Additional Safety Equipment If Conditions Require........................................... 23 Maintain Standard Safety Equipment in Good Condition................................................ 23 Attachment Precautions.............................................................................. 24 Accumulator......................................................................................... 24 Engine Ventilation.................................................................................. 24 Before Starting Engine.................................................................................. 25 Work Site Precautions............................................................................... 25 Checks Before Starting Engine....................................................................... 26 Engine Starting..................................................................................... 26 Before Operating Machine............................................................................ 27 Machine Operation....................................................................................... 28 Operate While Seated at Operator's Station ONLY..................................................... 28 Seat Belts Must Be Used at All Times................................................................ 28 Movement Alarms..................................................................................... 28 Travel Precautions.................................................................................. 29 Sloping Terrain Requires Caution.................................................................... 29 Avoid High Voltage Cables........................................................................... 30 Before Starting to Dig, Contact Authorities......................................................... 30 Be Aware of Height Obstacles........................................................................ 30 Use Care on Loose Support........................................................................... 30 Use Solid Support Blocking.......................................................................... 31 Digging Beneath Overhangs........................................................................... 31 Digging Beneath Wheel Loader........................................................................ 31 Stay Alert for People Moving Through Work Area...................................................... 31 Be Aware of and Conform to Local Regulations........................................................ 31 Never Use Ether Starting Aids....................................................................... 32 Observe General Safety Rules........................................................................ 32 Take Time to Provide Good Visibility................................................................ 32 Keep "Pinch Point" Areas Clear Use Caution in Reverse............................................. 33 Operate Carefully on Snow and Ice and in Very Cold Temperatures..................................... 33 Parking Machine..................................................................................... 33 Shutdown Control Functions.......................................................................... 34 Never Let Anyone Ride on Attachment................................................................. 34 Maintenance............................................................................................. 35 Use Warning Tag During Service...................................................................... 35 clean Before Inspection or Maintenance.............................................................. 35 Proper Tools........................................................................................ 36 Use of Lighting..................................................................................... 36 Fire Prevention and Explosion Prevention............................................................ 36 Burn Prevention..................................................................................... 37 Welding Repairs..................................................................................... 38 Precautions for Removal, Installation, and Storage of Attachments................................... 38 Precautions When Working on Machine................................................................. 39 Lock Inspection Covers.............................................................................. 39 Crushing Prevention and Cutting Prevention.......................................................... 39 Do Not Run Engine If Repairs or Work Are Being Performed Alone...................................... 39 Always Use Adequate Equipment Supports and Blocking................................................. 40 Do Not Work on Hot Engines or Hot Cooling or Hydraulic Systems...................................... 40 Hydraulic Cylinder Seals Require Periodic Replacement............................................... 40 Highpressure Hydraulic Lines Can Store a Great Deal of Energy...................................... 40 Precautions with Highpressure Line, Tubes and Hoses................................................ 41 Obtain Immediate Medical Attention if Pressurized Oil Pierces Skin.................................. 41 Use Correct Replacement Fasteners Tightened to Proper Torque........................................ 42 Safety Critical Parts Must Be Replaced Periodically................................................. 42 Dispose of All Petroleum Based Oils and Fluids Properly............................................. 42 Check Tire Pressure and Condition................................................................... 42 Battery................................................................................................. 43 Battery Hazard Prevention........................................................................... 43 Disconnect Batteries Before Electrical Service or Electrical Welding................................ 43 Use Low Heat Portable Lighting...................................................................... 44 Boost Starting or Charging Engine Batteries......................................................... 44 Towing.................................................................................................. 45 Precautions When Towing............................................................................. 45 Shipping and Transportation............................................................................. 46 Obey State and Local OvertheRoad Regulations...................................................... 46 Summary of Safety Precautions for Lifting........................................................... 46 Specifications.................................................................................................. 47 Specifications for Mega 250V S0203115...................................................................... 49 Component Locations..................................................................................... 52 General Specifications.................................................................................. 56 Engine Performance Curves............................................................................... 59 Working Range and Dimensions............................................................................ 62 Working Capacities...................................................................................... 65 Bucket Capacity..................................................................................... 65 Tipping Load........................................................................................ 65 Material Weight......................................................................................... 65 Approximate Weight of Workload Materials............................................................ 65 General Maintenance............................................................................................. 69 General Maintenance Procedures S0302000..................................................................... 71 Welding Precautions and Guidelines...................................................................... 73 Hydraulic System General Precautions.................................................................. 74 Maintenance Service and Repair Procedure................................................................ 75 General Precautions................................................................................. 75 Hydraulic System Cleanliness and Oil Leaks.............................................................. 76 Maintenance Precautions for Hydraulic System Service................................................ 76 Oil Leakage Precautions............................................................................. 76 Cleaning and Inspection................................................................................. 77 General Guidelines.................................................................................. 77 Bearing inspection.................................................................................. 78 Normal Bearing.................................................................................. 79 Bent Cage....................................................................................... 79 Galling......................................................................................... 79 Abrasive Step Wear.............................................................................. 80 Etching......................................................................................... 80 Misalignment.................................................................................... 80 Indentations.................................................................................... 80 Fatigue Spalling................................................................................ 81 Brinelling...................................................................................... 81 Cage Wear....................................................................................... 81 Abrasive Roller Wear............................................................................ 81 Cracked Inner Race.............................................................................. 82 Smears.......................................................................................... 82 Frettage........................................................................................ 82 Heat Discoloration.............................................................................. 83 Stain Discoloration............................................................................. 83 Standard Torques S0309000................................................................................... 85 Torque Values for Standard Metric Fasteners............................................................. 87 Torque Values for Standard U.S. Fasteners............................................................... 88 Type 8 Phosphate Coated Hardware........................................................................ 90 Torque Values for Hose Clamps........................................................................... 91 Torque Values for Split Flanges......................................................................... 92 Torque Wrench Extension Tools........................................................................... 93 Torque Multiplication............................................................................... 93 Other Uses for Torque Wrench Extension Tools........................................................ 94 Tightening Torque Specifications (Metric)........................................................... 94 I. "Loctite" Fastener Adhesives................................................................. 95 II. "Loctite" Pipe Thread Sealant............................................................... 95 III. "Loctite" gasket/flange sealer............................................................. 95 IV. "Loctite" retaining compounds............................................................... 96 V. "Loctite" Adhesives.......................................................................... 96 Upper Structure................................................................................................. 97 Counterweight S0403030K..................................................................................... 99 Specifications..........................................................................................101 Counterweight...........................................................................................101 Fuel Transfer Pump S0405500.................................................................................103 General Description.....................................................................................105 Theory of Operation.................................................................................105 Troubleshooting.........................................................................................106 Replacement of Rotor and Vane...........................................................................106 Replacement of Rear Cover...............................................................................107 Replacement of Armature.................................................................................108 Hydraulic Oil Tank S0406060C................................................................................109 General Description.....................................................................................111 Parts List (M200V).................................................................................111 Parts List (M250V).................................................................................113 Specifications......................................................................................115 Lower Structure and Chassis.....................................................................................117 Center Joint (Articulation Joint) S0502050C.................................................................119 General Description.....................................................................................121 Maintenance Standard................................................................................122 Engine and Drive Train..........................................................................................125 Rear Axle (ZFMTL 3075) S0602270...........................................................................127 General Description.....................................................................................131 Outline.............................................................................................131 Mega 250V......................................................................................132 Lubrication Instructions............................................................................134 Oil Drain.......................................................................................135 Oil Filling.....................................................................................135 Check...........................................................................................135 Oil Change Intervals............................................................................135 Oil Level Check.................................................................................135 Bleeders........................................................................................135 Brake...........................................................................................135 Brake Bleeding at Vehicle.......................................................................135 Make Wear Measurement on Multidisk Brake............................................................136 Wear measurement Multidisk brake..............................................................136 Inscriptions on Model Identification Plate..........................................................137 Torque Limits for Screws............................................................................138 Torque Limits for Screws (In Nm) According to ZFStandards 148..................................138 Examples of geartoothcontact patterns for the gleason geartooth system...........................139 Special Tool............................................................................................142 List of Special Tools for Disassembly and Reassembly................................................142 ZFMultitrac Rigid Axle MTL 3075.......................................................................152 Disassembly of output and brake.....................................................................152 Reassembly of Output and Brake......................................................................162 Disassembly of differential carrier and brake tubes.................................................175 Disassembly of differential carrier.............................................................175 Disassembly of limited slip differential........................................................178 Disassembly of drive pinion.....................................................................180 Disassembly of brake tubes......................................................................182 Reassembly of brake tubes and differential carrier..................................................184 Reassembly of brake tubes.......................................................................184 Reassembly of differential carrier..............................................................186 Determine shim thickness for a perfect tooth contact pattern....................................186 Install drive pinion............................................................................188 Reassembly of limited slip differential.........................................................192 Determine disk clearance 0.2 0.8mm...........................................................195 Adjust backlash and bearing preload.............................................................198 Front Axle (ZFMTL 3085) S0602280..........................................................................201 General Description.....................................................................................205 Outline.............................................................................................205 Mega 250V......................................................................................206 Lubrication instructions............................................................................208 Oil drain.......................................................................................209 Oil filling.....................................................................................209 Check...........................................................................................209 Oil change intervals............................................................................209 Oil level check.................................................................................209 Bleeders........................................................................................209 Brake...........................................................................................209 Brake bleeding at the vehicle...................................................................209 Make Wear Measurement on Multidisk Brake............................................................210 Wear measurement Multidisk brake..............................................................210 Inscriptions on Model Identification Plate..........................................................211 Torque Limits for Screws............................................................................212 Torque Limits for Screws (In Nm) According to ZFStandards 148..................................212 Examples of geartoothcontact patterns for the gleason geartooth system...........................213 Special Tool............................................................................................216 List of Special Tools for Disassembly and Reassembly................................................216 ZFMultitrac Rigid Axle MTL 3085.......................................................................225 Disassembly of output and brake.....................................................................225 Reassembly of Output and Brake......................................................................234 Disassembly of differential carrier and brake tubes.................................................247 Disassembly of differential carrier.............................................................247 Disassembly of limited slip differential........................................................250 Disassembly of drive pinion.....................................................................252 Disassembly of brake tubes......................................................................254 Reassembly of brake tubes and differential carrier..................................................255 Reassembly of oil pipes.........................................................................255 Reassembly of differential carrier..............................................................258 Determine shim thickness for a perfect tooth contact pattern....................................258 Install drive pinion............................................................................259 Reassemble of limited slip differential.........................................................263 Determine disk clearance 0.2 0.8mm...........................................................265 Adjustment of backlash and bearing preload......................................................268 Parking Brake Caliper (ZF) S0603001.........................................................................273 Functional Characteristics and Maintenance Instructions.................................................275 Functional Characteristics of Springloaded Sliding Caliper Brakes..................................275 Mounting and Basic Setting Regulations..............................................................276 Adjusting Regulations...............................................................................276 Emergency release of parking brake..................................................................276 Maintenance and Repair Work.........................................................................277 Maintenance and Exchange of Brake Pads..........................................................277 Changing Seal...................................................................................278 General.............................................................................................278 Air Conditioner S0605050K...................................................................................279 General Description.....................................................................................281 Refrigerant Circulation.................................................................................282 Control Panel...........................................................................................284 Control Specifications..................................................................................285 Temperature Level Control and Display...................................................................286 Air Discharge According to Path Selection...............................................................287 Vent................................................................................................287 Foot................................................................................................288 Defroster...........................................................................................289 Airconditioning System Circuit Diagram.................................................................290 Troubleshooting.........................................................................................292 Refrigerant Pressure Check..........................................................................292 Weight of R134a Gas Used In Machines....................................................................295 Refrigerant System Repairs..............................................................................297 Refrigerant Safe Handling Procedures................................................................297 Repair and Replacement Procedure....................................................................298 Refrigerant Recovery................................................................................300 Vacuuming Refrigerant System........................................................................300 Leakage Check.......................................................................................302 Refrigerant Charging................................................................................302 Inspecting System for Leakage.......................................................................304 Transmission and Torque Converter (ZF4WG190) S0607140.....................................................305 Drive Train Description.................................................................................310 Transmission and Torque Converter.......................................................................312 Powershift Transmission.............................................................................313 Transmission Control................................................................................313 The Chart of Measuring Points and Connection 4 WG190...............................................315 Oil Circuit Diagram 4WG190.........................................................................317 Transmission Electric Components........................................................................319 TCU (Transmission Control Unit).....................................................................320 Transmission Control Valve..........................................................................320 Transmission Oil Temperature Sensor.................................................................321 Engine Pickup Sensor................................................................................321 Central Gear Pickup Sensor..........................................................................321 Turbine Pickup Sensor...............................................................................322 Output Speed Sensor.................................................................................322 Shift Lever Switch (DW3)...........................................................................322 Auto Selector Switch................................................................................324 Display.............................................................................................324 Transmission Electrical Circuits........................................................................325 T/M Controller Circuit..............................................................................325 Traveling Circuits..................................................................................326 Neutral.........................................................................................326 Forward First Gear..............................................................................327 Forward Second Gear.............................................................................328 Forward Third Gear..............................................................................329 Forward Fourth Gear.............................................................................330 Reverse First Gear..............................................................................331 Reverse Second Gear.............................................................................332 Reverse Third Gear..............................................................................333 Downshift...........................................................................................334 Overview........................................................................................334 Kickdown: Forward Second Gear to Forward First Gear (Auto Selector Switch "O" Manual Mode)....335 Downshift (Auto Selector Switch "I" Auto Mode)................................................336 Transmission Cut Off................................................................................337 LIS (Load Isolation System) Option................................................................338 Installation View.......................................................................................339 Inner Section.......................................................................................339 Front View..........................................................................................340 Side View...........................................................................................341 Rear View...........................................................................................342 Special Tools...........................................................................................343 Gearshift System....................................................................................343 Engine Connection...................................................................................345 Pressure Oil Pump...................................................................................346 Gearbox Housing.....................................................................................347 Input...............................................................................................349 Clutch..............................................................................................350 Clutch KV.......................................................................................350 Clutch KR.......................................................................................351 Clutch K1.......................................................................................352 Clutch K2.......................................................................................353 Clutch K3.......................................................................................354 Clutch K4.......................................................................................355 Output..............................................................................................356 Power Takeoff......................................................................................357 Hydraulic Control Unit (HSG94).........................................................................358 Disassembly.........................................................................................359 Reassembly..........................................................................................362 Transmission Disassembly................................................................................369 Hydraulic Control Unit (HSG94) and Duct Plate......................................................369 Engine Connection Converter.......................................................................370 Hydraulic Pump......................................................................................372 Converter Back Pressure Valve.......................................................................373 Remove Output, Input and Clutches...................................................................374 Disassemble Clutch KV and KR......................................................................379 Disassemble Clutch K1, K2 and K3..................................................................382 Dissemble Clutch K4...............................................................................384 Disassemble Drive Shaft.............................................................................385 Transmission Reassembly.................................................................................387 Install Oil Tube....................................................................................387 Reassemble Clutch KV and KR.......................................................................389 Reassemble Clutch K1, K2 and K3...................................................................395 Reassemble Clutch K4..............................................................................402 Preassemble Drive Shaft.............................................................................409 Preassemble and Install Output......................................................................410 Install Preassembled Drive Shaft and Clutches.......................................................412 Install Pump Shaft (Power Takeoff).................................................................415 Install Output Flanges..............................................................................416 Converter Back Pressure Valve.......................................................................418 Oil Feed Housing Transmission Pump................................................................418 Engine Connection Converter.......................................................................420 Converter Safety Valve..............................................................................423 Mount Duct Plate and Hydraulic Control Unit.........................................................423 Install Plugs and Oil Level Tube....................................................................424 Speed Sensor and Inductive Transmitters.............................................................426 Setting Inductive Transmitter.......................................................................427 Speed Sensor (Hall Sensor) N Output and Speedometer.................................................429 Transmission Error Codes (ZF) S0607900C.....................................................................431 Introduction............................................................................................434 Abbreviations...........................................................................................434 Display.................................................................................................434 Description of Fault Codes..........................................................................435 Display During Operation................................................................................436 Definition of Operating Modes...........................................................................438 Normal..............................................................................................438 Substitute Clutch Control...........................................................................438 Limphome...........................................................................................438 Transmission shut Down..............................................................................438 TCU Shut Down.......................................................................................438 Clutch Pack and Solenoid Valve Crossreference Table....................................................439 Table of Fault Codes....................................................................................440 Table of Fault Codes ERGOControl.....................................................................462 Measurement of Resistance at Actuator/ sensors and Cable................................................465 Actuator............................................................................................465 Cable...............................................................................................465 Hydraulics......................................................................................................467 Accumulator S0703010K.......................................................................................469 General Description.....................................................................................471 Specifications......................................................................................472 Cylinders S0705005K.........................................................................................475 General Description.....................................................................................478 Theory of Operation.................................................................................479 Parts List..........................................................................................480 Bucket Hydraulic Cylinder.......................................................................480 Lift Hydraulic Cylinder.........................................................................482 Steering Hydraulic Cylinder.....................................................................484 Troubleshooting, Testing and Adjustment.................................................................486 Disassembly.............................................................................................490 Cleaning and Inspection (Wear Limits and Tolerances)....................................................492 Reassembly..............................................................................................493 Fan Drive Hydraulic Motor (Haldex) S0707110C................................................................501 General Description.....................................................................................504 Theory of Operation.................................................................................504 Mega 200V......................................................................................504 Mega 250V......................................................................................506 Parts List..........................................................................................508 Specifications......................................................................................509 Troubleshooting, Testing and Adjustment.................................................................510 Tools Required..........................................................................................510 Disassembly.............................................................................................511 Inspect Parts for Wear..................................................................................514 General Information.....................................................................................515 Reverse Shaft Rotation of Pump..........................................................................515 Reassembly..............................................................................................516 Main Pump (Denison T67CCA Series) S0708500C.................................................................521 General Description.....................................................................................523 Theory of Operation.................................................................................523 Parts List..........................................................................................524 Service Kits........................................................................................526 Dimensions..........................................................................................527 Specification.......................................................................................528 Model Number Code Series T6DC...................................................................528 Specifications..................................................................................528 Special Tools...........................................................................................529 Seal Driver.........................................................................................529 Protective Cone.....................................................................................529 Disassembly.............................................................................................530 Reassembly..............................................................................................534 Brake Pedal Valve S0709271..................................................................................539 General Description.....................................................................................541 Theory of Operation.................................................................................541 Specification.......................................................................................542 Brake System............................................................................................543 Brake and Pilot Supply Valve........................................................................543 Brake, Pilot and Fan Motor Supply Valve.............................................................544 Brake, Pilot and Fan Motor Supply Valve.................................................................545 Brake and Pilot Supply Valve........................................................................545 Specifications..................................................................................546 Brake, Pilot and Fan Motor Supply Valve.............................................................547 Specifications..................................................................................548 Main Control Valve (Toshiba) S0709456K......................................................................549 General Description.....................................................................................551 Specifications..........................................................................................553 Operation...............................................................................................554 Neutral.............................................................................................554 Bucket/option Spool Operation.......................................................................554 Boom Spool Operation................................................................................555 Boom Float......................................................................................555 Relief Valve........................................................................................555 Main Relief Valve...............................................................................555 Port Relief Valve...............................................................................555 Operation (Main Relief Valve).......................................................................556 Operation in Inoperative State..................................................................556 Operation (A)...................................................................................556 Operation (B)...................................................................................556 Operation (Port Relief Valve).......................................................................557 In the Inoperative State........................................................................557 Operation (A)...................................................................................557 Operation (B)...................................................................................557 Operation (C)...................................................................................558 Sucking Operation...............................................................................558 Pilot Control Valve S07094765...............................................................................559 General Description.....................................................................................561 Pilot Valve Operation...............................................................................561 Parts List..........................................................................................562 Pilot System............................................................................................564 Mega 250V..........................................................................................565 Pilot Control Valve (FNR) S07094776.........................................................................567 Joystick Valve Assembly.................................................................................569 HRC6 LV...............................................................................................571 Dual Axis Section...................................................................................572 Single Axis Section.................................................................................573 Dual Axis: Actuation Components and Flange......................................................574 Single Axis: Actuation Components and Flange....................................................575 Spring capsule assemblies and joint plate.......................................................576 Valve Body, Bushing Assembly and Shuttle Valve..................................................577 Priority Valve S0709650.....................................................................................579 General Description.....................................................................................581 Theory of Operation.................................................................................581 Parts List..........................................................................................583 Specifications......................................................................................584 Special Tools...........................................................................................584 Disassembly.............................................................................................584 Cleaning and Inspection (Wear Limits and Tolerances)....................................................586 Reassembly..............................................................................................587 EHPS (Electric Hydraulic Power Steering) S0709715...........................................................591 Steering Control System.................................................................................594 EHPS Valve..........................................................................................594 Description of operation of EHPS with integrated priority valve.................................595 Steering Spool at Neutral Position..................................................................596 Steering Spool Operated.............................................................................597 1. Turning Left.................................................................................597 2. Turning Right................................................................................598 Pressure Reducing Valves............................................................................599 Pilot Relief Valve..............................................................................600 Function................................................................................................601 Picture of Components in the EHPS...................................................................601 Power Steering Unit S0709735................................................................................603 General Description.....................................................................................605 Steering Unit.......................................................................................605 Function............................................................................................605 Exploded View of a Steering Unit................................................................606 Unloader Valve S0709865.....................................................................................607 General Description.....................................................................................609 Theory of Operation.................................................................................609 Unloader Cartridge Identification...................................................................611 Specifications......................................................................................612 Hydraulic Schematic (Mega 250V) S0793005C..................................................................613 General Description.....................................................................................615 Mega 250V (Tier I) S/N 1001 thru 2000..................................................................616 Mega 250V (Tier II) S/N 2001 thru 3000.................................................................618 Mega 250V (Tier I) S/N 3001 thru 4000..................................................................620 Mega 250V (Tier II) S/N 4001 and Up....................................................................622 Electrical System...............................................................................................625 Electrical System S0802017C.................................................................................627 Overview................................................................................................631 Electric Wire Color.................................................................................631 Electric Supply System..................................................................................632 Engine Starting Circuit.................................................................................634 Operation During Start Process......................................................................634 Operation After Start Process (Mega 200V)..........................................................636 Operation After Start Process (Mega (250V).........................................................637 Engine Preheating System................................................................................638 Mega 200V / 250V (Tier I).........................................................................638 Mega 200V / 250V (Tier II)........................................................................642 Principle of Operation..........................................................................642 Engine Stop System......................................................................................646 Operation In Engine Running Mode....................................................................646 Operation In Engine Stop Mode.......................................................................648 Charging System.........................................................................................650 Monitoring System.......................................................................................651 Instrument Panel....................................................................................652 Function Check......................................................................................653 Monitoring System Schematic.........................................................................654 Mega 200V......................................................................................654 Mega 250V......................................................................................656 Operation...........................................................................................658 Instruments.....................................................................................658 Indicator Lights................................................................................660 Initial Operation...............................................................................661 Control Unit Operation..........................................................................662 Characteristic of Operation.....................................................................663 Windshield Wiper........................................................................................664 Front windshield wiper..............................................................................664 Front Windshield Wiper Circuit..................................................................664 Rear Windshield wiper...............................................................................665 Lighting System.........................................................................................668 Light Circuit (Mega 200V)..........................................................................668 Light Circuit (Mega 250V)..........................................................................672 Emergency Steering System (Option)......................................................................675 Block Diagram.......................................................................................675 Emergency Steering System Components................................................................676 Emergency Steering Timer........................................................................676 Emergency Steering Pump.........................................................................677 Emergency Steering Switch.......................................................................677 Emergency Steering System Electric Circuit..........................................................678 Electric Detent System..................................................................................679 Electric Circuit....................................................................................679 Boom Kickout.......................................................................................680 Return To Dig.......................................................................................681 Proximity Switch................................................................................681 Electrical Schematic (Mega 250V) S0893005C.................................................................683 General Description.....................................................................................685 Mega 250V (Tier I).....................................................................................686 Mega 250V (Tier II)....................................................................................688 Attachments.....................................................................................................691
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PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
R.D