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Daewoo Doosan Mega 400-III PLUS Shop Manual 4023 – 7130 – PDF DOWNLOAD
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Daewoo Doosan Mega 400-III PLUS Shop Manual 4023 – 7130 – PDF DOWNLOAD
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Description
Daewoo Doosan Mega 400-III PLUS Shop Manual 4023 – 7130 – PDF DOWNLOAD
DESCRIPTION:
Daewoo Doosan Mega 400-III PLUS Shop Manual 4023 – 7130 – PDF DOWNLOAD
- 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.
TO THE OPERATOR OF A DOOSAN DAEWOO WHEEL LOADER
- Improper use of wheel loader could cause serious injury or death. Before operating wheel loader, or performing maintenance, operator or technician must read and understand entire Operation and Maintenance Manual. Any operation, maintenance, traveling or shipping methods that do not follow safety guidelines printed in this manual could cause serious injury or death
- Please respect the importance of taking responsibility for your own safety, and that other people who may be affected by your actions
- Safety information on the following pages is organized into the following topics.
1. “General Safety Essentials” on page 4
2. “Location of Safety Labels” on page 5
3. “Unauthorized Modifications” on page 5
4. “Operation” on page 8
5. “Equipment” on page 12
6. “Maintenance” on page 17
7. “Shipping and Transportation” on page 20
GENERAL SAFETY ESSENTIALS
ACCESSORY APPLICATIONS
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. Always replace damaged or faded decals
TABLE OF CONTENTS:
Daewoo Doosan Mega 400-III PLUS Shop Manual 4023 – 7130 – PDF DOWNLOAD
Publication Request for Proposed Revision..................................................................... 7 Safety........................................................................................................ 9 Wheel Loader Safety S0103000.............................................................................. 11 To the Operator of a DOOSAN Daewoo Wheel Loader....................................................... 13 Learn Signal Words Used with Safety Alert Symbol.................................................. 14 General Safety Essentials............................................................................. 14 Accessory Applications............................................................................ 14 Location of Safety Labels............................................................................. 15 Unauthorized Modifications............................................................................ 15 Work Site Precautions................................................................................. 15 Attachment Precautions............................................................................ 15 Avoid High Voltage Cables......................................................................... 15 Before Starting to Dig, Contact Authorities....................................................... 16 Be Aware of Height Obstacles...................................................................... 16 Use Care on Loose Support......................................................................... 16 Use Solid Support Blocking........................................................................ 16 Digging Beneath Overhangs......................................................................... 16 Digging Beneath Wheel Loader...................................................................... 16 Sloping Terrain Requires Caution.................................................................. 17 Stay Alert for People Moving through Work Area.................................................... 17 Be Aware of and Conform to Local Regulations...................................................... 17 Operation............................................................................................. 18 Operate While Seated at Operator's Station ONLY................................................... 18 Before Starting Engine, do a "prestart" safety check:............................................. 18 Never Use Ether Starting Aids..................................................................... 19 Mounting and Dismounting.......................................................................... 19 Observe General Safety Rules...................................................................... 19 Engine Ventilation................................................................................ 19 Asbestos Dust Hazard Prevention................................................................... 20 Take Time to Provide Good Visibility.............................................................. 20 Fuel, Oil and Hydraulic Fluid Fire Hazards........................................................ 20 Boost Starting or Charging Engine Batteries....................................................... 21 Keep "Pinch Point" Areas Clear - Use Caution in Reverse........................................... 21 Travel Precautions................................................................................ 21 Operate Carefully on Snow and Ice and in Very Cold Temperatures................................... 22 Parking Machine................................................................................... 22 Shutdown Control Functions........................................................................ 22 Equipment............................................................................................. 22 Rough Operation May Require Use of Certified Safety Equipment..................................... 22 Install Additional Safety Equipment If Conditions Require......................................... 23 Movement Alarms................................................................................... 23 Seat Belts Must Be Used at All Times.............................................................. 23 Window Glass Breaking Tool........................................................................ 24 Keep a Fire Extinguisher at Hand.................................................................. 24 Maintain Standard Safety Equipment in Good Condition.............................................. 24 Safety Critical Parts Must Be Replaced Periodically............................................... 24 Hydraulic Cylinder Seals Require Periodic Replacement............................................. 25 High-pressure Hydraulic Lines Can Store a Great Deal of Energy.................................... 25 Operator's Cabin Must Be Kept Clean............................................................... 25 Clothing and Personal Protective Items............................................................ 25 Breathing Masks, Ear Protection May Be Required................................................... 25 Battery Electrolyte and Explosive Gases Can Be Lethal............................................. 26 Disconnect Batteries Before Electrical Service or Electrical Welding.............................. 26 Use Low Heat Portable Lighting.................................................................... 26 Maintenance........................................................................................... 27 Use Warning Tag during Service.................................................................... 27 Do Not Run Engine If Repairs or Work Are Being Performed Alone.................................... 27 Always Use Adequate Equipment Supports and Blocking............................................... 27 Do Not Work on Hot Engines or Hot Cooling or Hydraulic Systems.................................... 27 Cool Down Is Required Before Radiator or Reservoir Checks......................................... 27 Precautions with High-pressure Line, Tubes and Hoses.............................................. 28 Obtain immediate medical attention if pressurized oil pierces skin................................ 28 Use Correct Replacement Fasteners Tightened to Proper Torque...................................... 29 Dispose of All Petroleum Based Oils and Fluids Properly........................................... 29 Check Tire Pressure and Condition................................................................. 29 Shipping and Transportation........................................................................... 30 Obey State and Local Over-the-Road Regulations.................................................... 30 Summary of Safety Precautions for Lifting......................................................... 30 Specifications................................................................................................ 31 Specifications for Mega 400-III PLUS S0203020............................................................. 33 Component Locations................................................................................... 36 General Specifications................................................................................ 39 Engine Performance Curves............................................................................. 40 Working Range and Dimensions.......................................................................... 42 Working Capacities.................................................................................... 45 Bucket Capacity................................................................................... 45 Tipping Load...................................................................................... 45 Material Weight....................................................................................... 45 Approximate Weight of Workload Materials.......................................................... 45 General Maintenance........................................................................................... 49 General Maintenance Procedures S0302000................................................................... 51 Welding Precautions and Guidelines.................................................................... 53 Hydraulic System General Precautions................................................................ 54 Maintenance Service and Repair Procedure.............................................................. 55 General Precautions............................................................................... 55 Hydraulic System Cleanliness and Oil Leaks............................................................ 56 Maintenance Precautions for Hydraulic System Service.............................................. 56 Oil Leakage Precautions........................................................................... 56 Cleaning and Inspection............................................................................... 57 General Guidelines................................................................................ 57 Bearing inspection................................................................................ 58 Normal Bearing................................................................................ 59 Bent Cage..................................................................................... 59 Galling....................................................................................... 59 Abrasive Step Wear............................................................................ 60 Etching....................................................................................... 60 Misalignment.................................................................................. 60 Indentations.................................................................................. 60 Fatigue Spalling.............................................................................. 61 Brinelling.................................................................................... 61 Cage Wear..................................................................................... 61 Abrasive Roller Wear.......................................................................... 61 Cracked Inner Race............................................................................ 62 Smears........................................................................................ 62 Frettage...................................................................................... 62 Heat Discoloration............................................................................ 63 Stain Discoloration........................................................................... 63 Standard Torques S0309000................................................................................. 65 Torque Values for Standard Metric Fasteners........................................................... 67 Torque Values for Standard U.S. Fasteners............................................................. 68 Type 8 Phosphate Coated Hardware...................................................................... 70 Torque Values for Hose Clamps......................................................................... 71 Torque Values for Split Flanges....................................................................... 72 Torque Wrench Extension Tools......................................................................... 73 Torque Multiplication............................................................................. 73 Other Uses for Torque Wrench Extension Tools...................................................... 74 Tightening Torque Specifications (Metric)......................................................... 74 I. "Loctite" Fastener Adhesives............................................................... 75 II. "Loctite" Pipe Thread Sealant............................................................. 75 III. "Loctite" gasket/flange sealer........................................................... 75 IV. "Loctite" retaining compounds............................................................. 76 V. "Loctite" Adhesives........................................................................ 76 Upper Structure............................................................................................... 77 Fuel Transfer Pump S0405500............................................................................... 79 General Description................................................................................... 81 Theory of Operation............................................................................... 81 Troubleshooting....................................................................................... 82 Replacement of Rotor and Vane......................................................................... 82 Replacement of Rear Cover............................................................................. 83 Replacement of Armature............................................................................... 84 Lower Structure and Chassis................................................................................... 85 Engine and Drive Train........................................................................................ 87 Front Axle (Graziano) S0602070............................................................................ 89 General Description................................................................................... 92 Outline........................................................................................... 92 When Moving Straight Forward...................................................................... 93 When Slowing...................................................................................... 93 Parking Brake................................................................................. 93 Parts List........................................................................................ 94 Front Axle Housing............................................................................ 94 Limited Slip Differential Cross Section....................................................... 95 Front Axle Differential....................................................................... 96 Front Planetary Gear Set...................................................................... 98 Parking Brake.................................................................................100 Scheduled Maintenance.................................................................................102 After First 200 Hours.............................................................................102 Every 150 hours...................................................................................103 Every 1,500 Hours.................................................................................103 Lubricant Specifications..........................................................................103 General Disassembly and Reassembly Instructions.......................................................104 General Instructions..............................................................................104 Assembling Leakproof Components...................................................................105 Axle Disassembly......................................................................................105 Drain Oil.........................................................................................105 Final Drive.......................................................................................106 Differential Assembly.............................................................................110 Overhauling Super Max Trac Assembly...............................................................113 Checking Clearance on Assembled Disk Packs........................................................113 Axle Reassembly.......................................................................................114 Determining Thickness of Adjustment Shims.........................................................114 Inner Oil Recirculation Piping....................................................................115 Differential Assembly.............................................................................116 Axial Position of Bevel Pinion....................................................................116 Adjusting Backlash................................................................................117 Adjusting Tooth Contact...........................................................................118 Correct Pattern...............................................................................118 Increase Pinion Distance......................................................................118 Decrease Pinion Distance......................................................................119 Securing Differential to Axle Housing.............................................................120 Final Drive.......................................................................................122 Determining Space Available to Form Brake Disk Pack...............................................124 Parking Brake.........................................................................................126 Disassembly.......................................................................................127 Reassembly........................................................................................127 Adjustment........................................................................................127 Rear Axle (Graziano) S0602080.............................................................................129 General Description...................................................................................132 Outline...........................................................................................132 When Moving Straight Forward......................................................................133 When Slowing......................................................................................133 Parts List........................................................................................134 Rear Axle.....................................................................................134 Rear Axle Housing.............................................................................135 Rear Axle Differential........................................................................136 Rear Axle Planetary Gear Set..................................................................138 Scheduled Maintenance.................................................................................140 After First 200 Hours.............................................................................140 Every 150 hours...................................................................................141 Every 1,500 Hours.................................................................................141 Lubricant Specifications..........................................................................141 General Disassembly and Reassembly Instructions.......................................................142 General Instructions..............................................................................142 Assembling Leakproof Components...................................................................143 Axle Disassembly......................................................................................143 Drain Oil.........................................................................................143 Final Drive.......................................................................................144 Differential Assembly.............................................................................148 Overhauling Super Max Trac Assembly...............................................................150 Checking Clearance on Assembled Disk Packs........................................................151 Axle Reassembly.......................................................................................152 Determining Thickness of Adjustment Shims.........................................................152 Differential Assembly.............................................................................153 Axial Position of Bevel Pinion....................................................................153 Adjusting Backlash................................................................................154 Adjusting Tooth Contact...........................................................................155 Correct Pattern...............................................................................155 Increase Pinion Distance......................................................................155 Decrease Pinion Distance......................................................................156 Securing Differential to Axle Housing.............................................................157 Final Drive.......................................................................................158 Determining Space Available to Form Brake Disk Pack...............................................160 Air Conditioner S0605020..................................................................................161 General Description...................................................................................163 Refrigerant Circulation...............................................................................164 Air-conditioning System Circuit Diagram...............................................................166 Troubleshooting.......................................................................................167 Refrigerant Pressure Check........................................................................167 Weight of R134a Gas Used In Machines..................................................................170 Refrigerant System Repairs............................................................................172 Refrigerant Safe Handling Procedures..............................................................172 Repair and Replacement Procedure..................................................................173 Refrigerant Recovery..............................................................................175 Vacuuming Refrigerant System......................................................................175 Leakage Check.....................................................................................176 Refrigerant Charging..............................................................................177 Inspecting System for Leakage.....................................................................179 Transmission and Torque Converter (ZF4WG-260) S0607020...................................................181 Drive Train Description...............................................................................185 Transmission..........................................................................................186 Transmission Faults Codes.............................................................................187 Fault Display.....................................................................................187 CAN - Message.....................................................................................187 Description of Fault Codes........................................................................187 Abbreviations.....................................................................................187 Definition of Operation Modes.....................................................................188 Normal........................................................................................188 Substitute Clutch Control.....................................................................188 Limp-home.....................................................................................188 Transmission Shut Down........................................................................189 TCU Shut Down.................................................................................189 Table of Fault Codes..............................................................................189 Measurement of Resistance at Actuator/sensors and Cable...........................................189 Actuator......................................................................................189 Cable.........................................................................................189 Transmission Electrical Circuits......................................................................191 T/M Controller Circuit............................................................................191 Traveling Circuits................................................................................192 Neutral.......................................................................................192 Forward First Gear............................................................................193 Forward Second Gear...........................................................................194 Forward Third Gear............................................................................195 Forward Fourth Gear...........................................................................196 Reverse First Gear............................................................................197 Reverse Second Gear...........................................................................198 Reverse Third Gear............................................................................199 Kick-down: Forward Second Gear to Forward First Gear (Automatic Switch "OFF"- Manual Mode)....200 Downshift (Automatic Switch "ON" - Auto Mode).................................................202 Transmission Cutoff...............................................................................204 LIS (Load Isolation System) Option................................................................205 Mechanical Layout 4 WG-260............................................................................206 Hydraulic Control Unit (HSG-84).......................................................................207 Disassembly.......................................................................................208 Reassembly........................................................................................211 Transmission Disassembly..............................................................................218 Converter-input...................................................................................218 Drive Shaft Pump Power Take-off...................................................................221 Transmission Pump.................................................................................223 Output- Layshaft Assembly.........................................................................223 Disassemble Clutches and Layshaft Gear............................................................228 Disassemble Power Take-off II.....................................................................229 Disassemble Clutches..............................................................................230 Clutch - K3/K4................................................................................230 Clutch - KR/K2................................................................................233 Clutch - KV/K1................................................................................236 Transmission Reassembly...............................................................................239 Power Take-off II.................................................................................239 Clutch K3/K4......................................................................................241 Clutch K3.....................................................................................241 General Instructions for Plate Installation...................................................243 Clutch - K4...................................................................................247 Clutch KR/K2......................................................................................251 Clutch - KV/K1....................................................................................259 Install Multidisk Clutches, Layshaft Gear and Output Gear.........................................267 Install Filter....................................................................................281 Hydraulic Pump....................................................................................282 Drive Shaft (Power Take-off Pump).................................................................284 Input - Converter.................................................................................287 Converter.........................................................................................292 Mount Hydraulic Control Unit (HSG- 94)............................................................293 Inductive Transmitter and Speed Sensor............................................................297 Setting Inductive Transmitter.....................................................................298 Speed Sensor (Hall Sensor) N Output and Speedometer...............................................300 Transmission Error Codes (ZF) S0607900C...................................................................301 Introduction..........................................................................................304 Abbreviations.........................................................................................304 Display...............................................................................................304 Description of Fault Codes........................................................................305 Display During Operation..............................................................................306 Definition of Operating Modes.........................................................................308 Normal............................................................................................308 Substitute Clutch Control.........................................................................308 Limphome.........................................................................................308 Transmission shut Down............................................................................308 TCU Shut Down.....................................................................................308 Clutch Pack and Solenoid Valve Crossreference Table..................................................309 Table of Fault Codes..................................................................................310 Table of Fault Codes ERGOControl...................................................................332 Measurement of Resistance at Actuator/ sensors and Cable..............................................335 Actuator..........................................................................................335 Cable.............................................................................................335 Hydraulics....................................................................................................337 Hydraulic System S0702040.................................................................................339 Brake System..........................................................................................341 Main Control Valve....................................................................................342 Main Relief Valve.....................................................................................345 Overload Relief Valve.................................................................................346 Restriction Valve.....................................................................................348 Unloading Valve.......................................................................................350 Manually Controlled Pilot Valve.......................................................................352 Pilot Valve Operation.............................................................................352 Hydraulic Pressure Adjustments........................................................................354 Relief Valve......................................................................................354 Unloading Valve...................................................................................355 Brake Pressure Checks.............................................................................355 Transmission Clutch Pressure......................................................................355 Accumulator S0703000......................................................................................357 General Description...................................................................................359 Specifications....................................................................................360 Accumulator Charging..................................................................................363 Charging the Accumulator with Nitrogen............................................................363 Cylinders S0705010........................................................................................365 General Description...................................................................................367 Theory of Operation...............................................................................368 Parts List........................................................................................369 Lift Cylinder.................................................................................369 Bucket Cylinder...............................................................................370 Troubleshooting, Testing and Adjustment...............................................................371 Disassembly...........................................................................................375 Cleaning and Inspection (Wear Limits and Tolerances)..................................................377 Reassembly............................................................................................378 Main Pump (Vickers 35VQ Series) S0708330..................................................................387 General Description...................................................................................389 Construction......................................................................................389 General.......................................................................................389 Assembly and Construction.....................................................................390 Principles of Operation...........................................................................391 Pumping Cartridge.............................................................................391 Hydraulic Balance.............................................................................392 Vane Pressure Feed............................................................................393 Flex Side Plate Operation.....................................................................394 Inlet Bodies..................................................................................395 Parts List........................................................................................398 Specifications....................................................................................399 Special Tools and Materials...........................................................................400 Special Tools.....................................................................................400 Troubleshooting, Testing and Adjustment...............................................................401 Disassembly...........................................................................................403 Cleaning and Inspection (Wear Limits and Tolerances)..................................................407 Reassembly............................................................................................409 Start-up Procedures...................................................................................412 Steering and Brake Pump (Vickers 3520V.QS) S0708400.......................................................413 General Description...................................................................................415 Parts List........................................................................................416 Special Tools.........................................................................................418 Troubleshooting, Testing and Adjustment...............................................................419 Service and Maintenance...............................................................................420 Circuit Inspection................................................................................420 Adding Hydraulic Oil to System....................................................................420 Adjustments.......................................................................................420 Lubrication.......................................................................................420 Replacement Parts.................................................................................421 Disassembly...........................................................................................422 Basic Pump Disassembly............................................................................424 Cartridge Disassembly.............................................................................425 Cleaning and Inspection (Wear Limits and Tolerances)..................................................428 Cleaning..........................................................................................428 Inspection, Repair and Replacement................................................................428 Reassembly............................................................................................430 Cartridge Assembly................................................................................431 Basic Pump Assembly...............................................................................434 Start-up Procedures...................................................................................435 Start-up..........................................................................................435 Test..............................................................................................435 Brake Pedal Valve (Rexroth) S0709200......................................................................437 General Description...................................................................................439 Theory of Operation...............................................................................439 Flow Amplifier (Danfoss) S0709660.........................................................................441 General Description...................................................................................443 Parts List........................................................................................444 Specifications....................................................................................445 Special Tools and Materials...........................................................................446 Special tools.....................................................................................446 Disassembly...........................................................................................447 Cleaning and Inspection (Wear Limits and Tolerances)..................................................467 Reassembly............................................................................................467 Power Steering Unit S0709700..............................................................................487 General Description...................................................................................489 Power Steering System.............................................................................489 Power Steering Unit...........................................................................489 Neutral Operation.............................................................................491 Right Turn....................................................................................491 Left Turn.....................................................................................491 Gerotor Operation.................................................................................491 Cushion Valve Operation...........................................................................492 Function......................................................................................492 Working Principle.............................................................................492 Parts List........................................................................................494 Specifications....................................................................................495 Special Tools.........................................................................................496 Troubleshooting, Testing and Adjustment...............................................................498 Disassembly...........................................................................................499 Cleaning and Inspection...............................................................................503 Reassembly............................................................................................504 Installation..........................................................................................515 Hydraulic Schematic (Mega 400-III PLUS) S0793020..........................................................517 General Description...................................................................................519 Mega 400-III PLUS.....................................................................................520 Electrical System.............................................................................................523 Electrical System S0802050................................................................................525 Troubleshooting - Electrical System...................................................................527 Overview..............................................................................................528 Electric Wire Color...............................................................................528 Electric Supply System................................................................................529 Engine Starting Circuit...............................................................................530 Operation During Start Process....................................................................530 Operation After Start Process.....................................................................531 Operation of the Start Circuit (2) - Immediately After Start..................................532 Engine Stop System....................................................................................533 Operation In Engine Running Mode..................................................................533 Operation In Engine Stop Mode.....................................................................535 Charging System.......................................................................................537 Cylinder Preheat - Intake Air Electrical Heater.......................................................538 Alternator Circuit....................................................................................541 Electrical Monitoring System..........................................................................544 Warning Light and Buzzer Check....................................................................544 Control Unit......................................................................................546 Coolant Temperature and Fuel......................................................................549 Tachometer........................................................................................551 Speedometer.......................................................................................552 Transmission Oil Pressure Gauge...................................................................553 Transmission Oil Temperature Gauge................................................................554 Electrical Schematic (Mega 400-III PLUS) S0893020.........................................................555 General Description...................................................................................557 Mega 400-III PLUS.....................................................................................558 Attachments...................................................................................................561
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