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Daewoo Doosan Mega 400-V Wheel Loader Service Repair Manual (Serial Number 3001 and Up)

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Daewoo Doosan Mega 400-V Wheel Loader Service Repair Manual (Serial Number 3001 and Up)

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  1. Mega 400-V Shop Manual 023-00092E Serial Number 3001 and Up 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. 023-00092E Shop Manual

  2. 1TABLE OF CONTENTS Safety Wheel Loader Safety.......................................................................... S0103020K Specifications Specifications for Mega 400-V............................................................ S0203065K 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 (ZF - MT-L 3105)...............................................................S0602230C Rear Axle (ZF - MT-L 3095)................................................................S0602240C Air Conditioner.................................................................................... S0605050K Transmission and Torque Converter (ZF 4WG-260).......................... S0607070K Transmission Error Codes (ZF)..........................................................S0607900C Hydraulics Accumulator...........................................................................................S0703000 Cylinders................................................................................................S0705010 Fan Drive Hydraulic Motor (Haldex) ................................................... S0707100K Main Pump (Denison T6DMY Series)................................................. S0708460K Table of Contents Page 1

  3. Steering and Brake Pump (Denison T67DB Series)........................... S0708470K Brake Pedal Valve.............................................................................. S0709231K Main Control Valve (Toshiba)............................................................. S0709455K Pilot Control Valve............................................................................ S07094755K Flow Amplifier (Danfoss)..................................................................... S0709665K Power Steering Unit............................................................................ S0709730K Unloader Valve................................................................................... S0709851K Hydraulic Schematic (Mega 400-V).................................................... S0793050K Electrical System Electrical System................................................................................ S0802185K Electrical Schematic (Mega 400-V) .................................................... S0893050K Attachments Table of Contents Page 2

  4. ZF - MULTITRAC RIGID AXLE MT-L 3095 DISASSEMBLY OF OUTPUT AND BRAKE 1. Fasten axle on assembly truck. (S) Assembly truck 5870 350 000 (S) Holding fixtures 5870 350 077 (S) Clamps 5870 350 075 Figure 16 2. Remove drain plugs (3x, Figure 17 and Figure 18) and drain oil from axle casing. Figure 17 Figure 18 S0602230C Page 30 Front Axle (ZF - MT-L 3105)

  5. 3. Remove cover from output shaft. (S) Pry bar set 5870 345 065 Figure 19 4. Remove slotted pin using striker (S) from bore in slotted nut. (S) Striker 5870 650 001 Figure 20 5. Remove slotted nut. (S) Socket spanner (S) Centering bracket Figure 21 6. Secure output using lifting tackle (S) and remove hexagon screws. (S) Lifting bracket 5870 281 043 Figure 22 Front Axle (ZF - MT-L 3105) S0602230C Page 31

  6. 7. Separate complete output from axle casing. NOTE: Pay attention to released O-ring (see arrow). Figure 23 8. Remove stub shaft from sun gear shaft. NOTE: Pay released shim(s). attention too possibly Figure 24 9. Remove shim(s) from sun gear shaft. Figure 25 10. Remove sun gear shaft from planet gears. Figure 26 S0602230C Page 32 Front Axle (ZF - MT-L 3105)

  7. 11. Lift planet carrier from brake housing. (S) Internal extractor 5870 300 019 Figure 27 12. Remove retaining ring. (S) Set of external pliers 5870 900 015 Figure 28 13. Remove planet gear and remove released inner bearing race. (S) Three-armed puller 5873 971 002 Figure 29 14. Remove inner bearing race. (S) Gripping insert 5873 001 020 (S) Basic set 5873 001 000 Figure 30 Front Axle (ZF - MT-L 3105) S0602230C Page 33

  8. 15. Separate ring gear from brake housing using two-armed puller (S). (S) Two-armed puller 5870 970 007 Figure 31 16. Remove O-rings (see arrows) from annular grooves of ring gear. Figure 32 17. Remove O-ring (see arrow) from recess of brake housing. Figure 33 18. Remove disk pack from brake housing. Figure 34 S0602230C Page 34 Front Axle (ZF - MT-L 3105)

  9. 19. Install slotted pins (6x) in support shim until they are flush mounted. Figure 35 20. Remove retaining ring. (S) Set of external pliers 5870 900 016 Figure 36 21. Remove piston from brake housing using compressed air. Figure 37 22. Remove support shim from piston using automatic piston adjusting. Figure 38 Front Axle (ZF - MT-L 3105) S0602230C Page 35

  10. 23. Remove slotted pins (6x) from support shim. Figure 39 24. Preload cup springs using a press and remove retaining ring. (S) Assembly pliers 5870 900 051 (S) Assembly fixture 5870 345 096 Figure 40 25. Remove pin from support shim and remove released cup springs. Figure 41 26. Press gripping rings from pin. Figure 42 S0602230C Page 36 Front Axle (ZF - MT-L 3105)

  11. 27. Lift piston from brake housing. (S) Adjusting device 5870 400 001 Figure 43 28. Remove guide ring, support rings and U-rings from annular grooves of brake housing. NOTE: See Figure 45, for installation position of single parts. Figure 44 Reference Number 1 2 3 4 5 6 7 Description Brake housing Guide ring Support ring U-ring U-ring Support ring Output shaft Figure 45 Front Axle (ZF - MT-L 3105) S0602230C Page 37

  12. 29. Remove brake housing using two-armed puller (S) from output shaft and remove released inner bearing race. (S) Two-armed puller 5870 970 007 (S) Clamping bracket 5870 654 034 (S) Press bush 5870 506 140 Figure 46 30. Lift brake housing with lifting tackle (S) from output shaft. (S) Lifting chain 5870 281 047 (S) Eyebolts 5870 204 071 Figure 47 31. If necessary drive both outer bearing races from bearing bores in brake housing. Figure 48 32. Press shaft seal out of brake housing. (S) Pry bar set 5870 345 065 Figure 49 S0602230C Page 38 Front Axle (ZF - MT-L 3105)

  13. 33. Remove inner bearing race from output shaft. (S) Rapid grip 5873 014 011 (S) Basic set 5873 004 001 Figure 50 34. Remove bearing sheet from output shaft. (S) Pry bar set 5870 345 065 Figure 51 Front Axle (ZF - MT-L 3105) S0602230C Page 39

  14. REASSEMBLY OF OUTPUT AND BRAKE 1. Insert wheel bolt into output shaft until seated. (S) Wheel bolt puller - basic set 5870 610 010 (S) Insert (7/8" - 14 UNF) 5870 610 011 Figure 52 2. Assemble bearing sheet (shaft seal / Part 2). Figure 53 3. Press bearing sheet over collar of output shaft. (S) Pressure ring 5870 506 141 NOTE: The exact installation position of bearing sheet obtained by using specified pressure ring. will be Figure 54 4. Heat roller bearing and install it until seated. NOTE: After cooling down bearing. it has to be subsequently. installed Figure 55 S0602230C Page 40 Front Axle (ZF - MT-L 3105)

  15. 5. Press both outer bearing races into brake housing until seated. Figure 56 6. Install shaft seal with sealing lip showing to oil chamber, see Figure 58. (S) Driver 5870 051 052 NOTE: The exact installation position of shaft seal will be obtained by using specified driver (S). NOTE: Just before installation, wet outer diameter of shaft seal with mineral spirits. Figure 57 Reference Number 1 2 * Description Shaft seal Brake housing Grease filling NOTE: Fill space between sealing and dust lips with grease. Figure 58 7. Install preassembled brake housing using lifting tackle (S) over output shaft until seated. (S) Lifting chain 5870 281 047 (S) Eyebolts 5870 204 071 Figure 59 Front Axle (ZF - MT-L 3105) S0602230C Page 41

  16. 8. Heat roller bearing and install it until seated. Figure 60 9. Insert support and U-rings into annular grooves of brake housing. NOTE: Pay attention to installation position, see Figure 62. Figure 61 Reference Number 1 2 3 4 5 6 7 Description Brake housing Guide ring Support ring U-ring U-ring Support ring Output shaft Figure 62 S0602230C Page 42 Front Axle (ZF - MT-L 3105)

  17. 10. Clean annular groove of brake housing with mineral spirits. Then insert guide ring into annular groove (also see Figure 62) and secure with Loctite #415 at its extremities. NOTE: Guide ring must have contact on whole circumference. NOTE: Upon installation orifice of guide ring must show upwards (12 o'clock). Figure 63 11. Insert piston into brake housing and install it cautiously until seated. NOTE: Apply sufficiently oil on sliding surface of piston or support rings, U-rings and guide ring (use W-10 oils). Figure 64 12. Insert pins into assembly fixture (S) until seated. (S) Assembly fixture 5870 345 096 Figure 65 13. Press gripping rings (4x, see arrows) onto pins until seated on assembly fixture (S). NOTE: The dimension (see Figure 68) of gripping rings is obtained when using specified fixture. exact installation assembly NOTE: Observe installation position, install gripping orifices offset by 180° to each other. rings with Figure 66 Front Axle (ZF - MT-L 3105) S0602230C Page 43

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  19. 14. Install cup springs (7 pieces each / pin). NOTE: Pay attention to installation position of cup springs, see Figure 68. Figure 67 Reference Number 1 2 3 4 5 X Description Pin Gripping rings Cup springs Support shim Retaining Ring Installation dimension Gripping rings 10.5 +0.3mm Figure 68 15. Insert preassembled pins into support shim and secure using retaining ring.4 (S) Assembly pliers 5870 900 051 NOTE: Pay attention to clearance of cup springs. Figure 69 16. Insert preassembled support shim into piston. Figure 70 S0602230C Page 44 Front Axle (ZF - MT-L 3105)

  20. 17. Install support shim using retaining ring. Figure 71 18. Drive slotted pins (6x) into bores of support shim to lock retaining ring. (S) Drive mandrel 5870 705 011 NOTE: Pay attention to installation position, see Figure 73. Figure 72 Reference Number 1 2 3 4 5 X Description Brake housing Retaining Ring Slotted pin Support shim Piston Installation dimension 4.0 - 0.5mm Figure 73 19. Drive stop bolt into planet carrier until seated. Then wet spline with anticorrosive Weicon Anti Size (ZF Part Number: 0671 196 001) (see arrow). Figure 74 Front Axle (ZF - MT-L 3105) S0602230C Page 45

  21. 20. Insert planet carrier into spline of output shaft until seated. Figure 75 21. Install outer and inner clutch disks alternately starting with an outer clutch disk. NOTE: Oil clutch disks according to ZF List of Lubricants TE-ML 05. Figure 76 22. Insert O-ring (see arrow) into recess of brake housing. Figure 77 23. Grease both O-rings (see arrows) and insert them into annular grooves of ring gear. Figure 78 S0602230C Page 46 Front Axle (ZF - MT-L 3105)

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