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Daewoo Doosan Mega 400-V Wheel Loader Service Repair Manual (Serial Number 1001 and Up)

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Daewoo Doosan Mega 400-V Wheel Loader Service Repair Manual (Serial Number 1001 and Up)

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  1. Mega 400-V Shop Manual 023-00040E Serial Number 1001 and Up February 2001 Daewoo reserves the right to improve our products in a continuing process to provide the best possible product to the market place. These improvements can be implemented at any time with no obligation to change materials on previously sold products. It is recommended that consumers periodically contact their distributors for recent documentation on purchased equipment. This documentation may include attachments and optional equipment that is not available in your machine’s package. Please call your distributor for additional items that you may require. Illustrations used throughout this manual are used only as a representation of the actual piece of equipment, and may vary from the actual item. 023-00040E Shop Manual

  2. 1TABLE OF CONTENTS Return to Master Table of Contents Safety Wheel Loader Safety.......................................................................... S0103010K Specifications Specifications for Mega 400-V............................................................ S0203060K General Maintenance General Maintenance Procedures.........................................................S0302000 Standard Torques..................................................................................S0309000 Upper Structure Counterweight..................................................................................... S0403030K Fuel Transfer Pump...............................................................................S0405500 Hydraulic oil tank ................................................................................ S0406030K Lower Structure and Chassis Center Joint (Articulation Joint)........................................................... S0502010K Engine and Drive Train Front Axle ........................................................................................... S0602150K Rear Axle............................................................................................ S0602160K Air-Conditioner.................................................................................... S0605050K Transmission and Torque Converter (ZF) .......................................... S0607070K Transmission Error Codes (ZF)..........................................................S0607900C Hydraulics Accumulator...........................................................................................S0703000 Cylinders................................................................................................S0705010 Fan Drive Hydraulic Motor (Haldex) ................................................... S0707100K Table of Contents Page 1

  3. Main Pump (Denison T6DMY Series)................................................. S0708460K Steering and Brake Pump (Denison T67DB Siries)............................ S0708470K Brake Pedal Valve.............................................................................. S0709230K Main Control Valve (Toshiba)............................................................. S0709455K Pilot Control Valve.............................................................................. S0709475K Flow Amplifier (Danfoss)..................................................................... S0709665K Power Steering Unit............................................................................ S0709730K Unloader Valve................................................................................... S0709850K Hydraulic Schematic (Mega 400-V).................................................... S0793050K Electrical System Electrical System................................................................................ S0802180K Electrical Schematic (Mega 400-V) .................................................... S0893050K Attachments Table of Contents Page 2

  4. Return to Master Table of Contents TRANSMISSION DISASSEMBLY 1. Fasten transmission on an appropriate support stand. Figure 71 2. Disassemble remove pressure lines and duct plate. complete shift control, Figure 72 CONVERTER-INPUT 1. Separate transmission, using lifting device. torque converter from Figure 73 S0607070K Page 50 Transmission and Torque Converter (ZF)

  5. Return to Master Table of Contents 2. Loosen screw connection. 3. Separate bearing cover from converter bell, using three jacking screws. Figure 74 4. Pull oil feed flange out of converter bell, using special device (S). Figure 75 5. Remove converter safety valve (composed of ball, spring and disk.). Figure 76 6. Separate converter bell from gearbox housing, using lifting device and pry bar. Figure 77 Transmission and Torque Converter (ZF) S0607070K Page 51

  6. Return to Master Table of Contents 7. Remove shim. Figure 78 8. Remove rectangular ring (Figure 79). Figure 79 9. Press drive shaft out of spur gear bearing. Remove released inner bearing race and spur gear. 10. If necessary, drive outer bearing race out of housing bores. Figure 80 11. Press inner bearing race from drive shaft. Figure 81 S0607070K Page 52 Transmission and Torque Converter (ZF)

  7. Return to Master Table of Contents 12. Remove converter pressure valve. Figure 82 DRIVE SHAFT PUMP POWER TAKE-OFF 1. Pull complete drive shaft out of gearbox housing (pump). Figure 83 2. Remove rectangular ring (Figure 84). Figure 84 3. Separate spur gear from shaft and remove snap ring (Figure 85). Figure 85 Transmission and Torque Converter (ZF) S0607070K Page 53

  8. Return to Master Table of Contents 4. Pull inner bearing race from spur gear. Figure 86 5. Loosen socket head screw and remove it along with clamping plate. Figure 87 6. Pull inner bearing race and drive from shaft. NOTE: Support puller on end face/ drive shaft. Pay attention to released shims. Figure 88 7. Separate inner bearing race from driver. NOTE: Pay attention to released shim. 8. Remove snap rings (3x). Figure 89 S0607070K Page 54 Transmission and Torque Converter (ZF)

  9. Return to Master Table of Contents TRANSMISSION PUMP 1. Tilt gearbox housing 180°. 2. Loosen hex. head screws and remove both pump flanges. Figure 90 3. Loosen socket head screws (M8) and position Puller device (s). 4. Pull transmission pump out of housing bore. NOTE: Tapping housing face is a help during extraction operation. Figure 91 OUTPUT- LAYSHAFT ASSEMBLY 1. Loosen screw connection and remove brake caliper. Figure 92 2. Unlock and loosen hex. head screws, tap brake disk loose and separate it from output shaft. Figure 93 Transmission and Torque Converter (ZF) S0607070K Page 55

  10. Return to Master Table of Contents 3. Pry shaft seal out of housing bore. Figure 94 4. Tilt gearbox housing. 5. Remove sealing covers (Figure 95). Figure 95 6. Loosen hex. head screws. Figure 96 7. Pull idler shaft by means of puller out of housing bore. Figure 97 S0607070K Page 56 Transmission and Torque Converter (ZF)

  11. Return to Master Table of Contents 8. Tilt gearbox housing 180°. 9. Loosen hex. head screws and pull bearing cover -K1/KV out of housing bore. Figure 98 10. Loosen hex. head screws and remove bearing cover KR/K2 and K3/K4. Figure 99 11. Remove rectangular rings (3 pieces/axle), see Figure 100. Figure 100 12. Remove snap ring and remove released washers. Figure 101 Transmission and Torque Converter (ZF) S0607070K Page 57

  12. Return to Master Table of Contents 13. Support output flange against gearbox housing, see Figure 102. Figure 102 14. Loosen hex. head screws and separate housing cover from gearbox housing, using forcing screws and lifting device. Figure 103 15. Unlock and loosen hex. head screws. 16. Remove output flange and pry shaft seal out of housing. Figure 104 17. Loosen hex. head screws and remove oil baffle. Figure 105 S0607070K Page 58 Transmission and Torque Converter (ZF)

  13. Return to Master Table of Contents 18. Remove output gear along with shaft. Figure 106 19. Separate output shaft from spur gear. Figure 107 20. Pull inner bearing race from output gear. Figure 108 21. Remove plate. Figure 109 Transmission and Torque Converter (ZF) S0607070K Page 59

  14. Return to Master Table of Contents 22. Drive roller bearing out of housing bore and remove it. Figure 110 DISASSEMBLE CLUTCHES AND LAYSHAFT GEAR 1. Remove clutches - K3/K4, KR/K2 and KV/ K1- by means of lifting device. NOTE: At the removal of the clutch - K3/K4, displace clutch - KR/K2 in direction of arrow (Figure 111). Figure 111 2. Illustration on right shows clutches in removed condition. Figure 112 3. Remove layshaft gear. Figure 113 S0607070K Page 60 Transmission and Torque Converter (ZF)

  15. Return to Master Table of Contents DISASSEMBLE POWER TAKE-OFF II 1. Remove snap ring and remove shim(s). Figure 114 2. Pull PTO shaft by means of internal puller out of housing bore until outer bearing race is released. Figure 115 3. Take shaft out of housing. Figure 116 4. Pull inner bearing race from shaft (Figure 117). 5. Press opposite inner bearing race from shaft. NOTE: Separation of shaft and gear is not possible. Figure 117 Transmission and Torque Converter (ZF) S0607070K Page 61

  16. Return to Master Table of Contents DISASSEMBLE CLUTCHES Clutch - K3/K4 1. Remove three rectangular rings (Figure 118). Figure 118 2. Loosen slotted nut. NOTE: Slotted nut is secured with Loctite. To prevent damage of thread, heat slotted nut prior to loosen it (about 120°C (248°F)). Figure 119 3. Pull off taped roller bearing. Figure 120 4. Removed flanged disk. Figure 121 S0607070K Page 62 Transmission and Torque Converter (ZF)

  17. Return to Master Table of Contents 5. Remove upper roller bearing. Figure 122 6. Remove angle ring, snap ring, and thrust ring. Figure 123 7. Press spur gear K3 from plate carrier and remove released roller bearing. Figure 124 8. Remove split ring. Figure 125 Transmission and Torque Converter (ZF) S0607070K Page 63

  18. Return to Master Table of Contents 9. Remove snap ring and remove compl. Plate pack K3. Figure 126 10. Tilt clutch 180°. 11. Loosen slotted nut. NOTE: Slotted nut is secured with Loctite. To prevent damage of thread, heat slotted nut prior to loosen it (about 120°C (248°F)). Figure 127 12. Pull off tapered roller bearing. Figure 128 13. Pull spur gear from plate carrier. Figure 129 S0607070K Page 64 Transmission and Torque Converter (ZF)

  19. Return to Master Table of Contents 14. Remove oil feed ring and pull ball bearing from plate carrier. Figure 130 15. Remove snap ring and remove compl. plate pack - K4. Figure 131 16. Preload compression spring by means of special device (S). Remove snap ring (Figure 132) and released components. 17. Now, separate piston from plate carrier, using compressed air. 18. Disassemble opposite piston accordingly. Figure 132 Clutch - KR/K2 1. Locate clutch by means of Special device (s) and loosen slotted nut. 2. Loosen opposite slotted nut (Figure 133) accordingly. NOTE: The slotted nuts are secured with Loctite heat prior to loosen them. Figure 133 Transmission and Torque Converter (ZF) S0607070K Page 65

  20. Return to Master Table of Contents 3. Pull off tapered roller bearing. Figure 134 4. Press spur gear K-2 from shaft. 5. Remove released shim and bush. Figure 135 6. Pull off tapered roller bearing. Figure 136 7. On opposite side, pull off tapered roller bearing. Figure 137 S0607070K Page 66 Transmission and Torque Converter (ZF)

  21. Return to Master Table of Contents 8. Pull spur gear KR from shaft. 9. Remove released inner bearing race, disassemble both outer bearing races and snap ring. Figure 138 10. Remove adjusting ring. Figure 139 11. Pull off tapered bearing (spur gear bearing). Figure 140 12. Disassemble plate packs KR and K2 as well as compression springs and piston (accordingly as at clutch K3/K4. Figure 141 Transmission and Torque Converter (ZF) S0607070K Page 67

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  23. Return to Master Table of Contents Clutch - KV/K1 1. Loosen slotted nut. 2. Loosen opposite slotted nut (Figure 142) accordingly. NOTE: The slotted nuts are secured with Loctite and require heating prior to loosen them. Figure 142 3. Remove tapered roller bearing. Figure 143 4. Remove shim. Figure 144 5. Using a suitable puller remove spur gear K1. 6. Now, remove snap ring and drive ball bearing from spur gear bore. Figure 145 S0607070K Page 68 Transmission and Torque Converter (ZF)

  24. Return to Master Table of Contents 7. Remove both rings. Figure 146 8. Using a suitable puller second ball bearing (spur gear bearing). Figure 147 9. On opposite side, pull off tapered roller bearing. Figure 148 10. Pull spur gear KV from shaft. 11. Remove released inner bearing race, disassemble both outer bearing race and snap ring. Figure 149 Transmission and Torque Converter (ZF) S0607070K Page 69

  25. Return to Master Table of Contents 12. Remove adjusting ring. Figure 150 13. Pull off tapered roller bearing (spur gear bearing). 14. Now, remove plate pack KV and K1 as well as compression springs and piston (accordingly as at clutch K3/K4. Figure 151 S0607070K Page 70 Transmission and Torque Converter (ZF)

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