Daewoo Doosan Mega 400-V Shop Manual 023-00040E – PDF DOWNLOAD

Description

Daewoo Doosan Mega 400-V Shop Manual 023-00040E – PDF DOWNLOAD

FILE DETAILS:

Daewoo Doosan Mega 400-V Shop Manual 023-00040E – PDF DOWNLOAD

Language :English
Pages :618
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Daewoo Doosan Mega 400-V Shop Manual 023-00040E – PDF DOWNLOAD

Shop Manual
023-00040E
Serial Number 1001 and Up

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 Daewoo. 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:

Safety 5
Wheel Loader Safety S0103010K 7
To the Operator of a Daewoo Wheel Loader 9
Learn Signal Words Used with Safety Alert Symbol 10
General Safety Essentials 10
Accessory Applications 10
Location of Safety Labels 11
Unauthorized Modifications 11
Work-Site Precautions 12
Attachment Precautions 12
Avoid High-voltage Cables 12
Before Starting to Dig, Contact Authorities 12
Be Aware of Height Obstacles 12
Use Care on Loose Support 12
Use Solid Support Blocking 13
Digging Beneath Overhangs 13
Digging Beneath Wheel Loader 13
Sloping Terrain Requires Caution 13
Stay Alert for People Moving through Work Area 14
Be Aware of and Conform to Local Regulations 14
Operation 14
Operate While Seated at Operator’s Station ONLY 14
Before Starting Engine, do a “pre-start” safety check: 15
Never Use Ether Starting Aids 15
Mounting and Dismounting 15
Observe General Safety Rules 16
Engine Ventilation 16
Asbestos Dust Hazard Prevention 16
Take Time to Provide Good Visibility 16
Fuel, Oil and Hydraulic Fluid Fire Hazards 17
Boost Starting or Charging Engine Batteries 17
Keep “Pinch Point” Areas Clear – Use Caution in Reverse 18
Travel Precautions 18
Operate Carefully on Snow and Ice and in Very Cold Temperatures 18
Parking Machine 18
Shutdown Control Functions 19
Equipment 19
Rough Operation May Require Use of Certified Safety Equipment 19
Install Additional Safety Equipment If Conditions Require 20
Movement Alarms 20
Seat Belts Should Be Used at All Times 20
Window Glass Breaking Tool 20
Keep a Fire Extinguisher at Hand 21
Maintain Standard Safety Equipment in Good Condition 21
Safety-critical Parts Must Be Replaced Periodically 21
Hydraulic Cylinder Seals Require Periodic Replacement 21
High Pressure Hydraulic Lines Can Store a Great Deal of Energy 21
Operator’s Cab Should Be Kept Clean 21
Wear Eye Protection and Safety Clothing – Use Proper Tools 22
Breathing Masks, Ear Protection May Be Required 22
Asbestos Fiber Hazard 22
Battery Electrolyte and Explosive Gases Can Be Lethal 22
Disconnect Batteries Before Electrical Service or Electrical Welding 22
Use Low Heat Portable Lighting 23
Maintenance 23
Use Warning Tag during Service 23
Do Not Run Engine If Repairs or Work Are Being Performed Alone 23
Always Use Adequate Equipment Supports and Blocking 23
Do Not Work on Hot Engines or Hot Cooling or Hydraulic Systems 23
Cool-down Is Required Prior to Radiator or Reservoir Checks 24
Pressurized Hydraulic Oil Fluid Leaks Can Be Dangerous 24
Obtain immediate medical attention if pressurized oil pierces skin 24
Use Correct Replacement Fasteners Tightened to Proper Torque 24
Dispose of All Petroleum-based Oils and Fluids Properly 25
Check Tire Pressure and Condition 25
Shipping and Transportation 26
Obey State and Local Over-the-Road Regulations 26
Summary of Safety Precautions for Lifting 26
Specifications 27
Specifications for Mega 400-V S0203060K 29
Component Locations 32
General Specifications 34
Engine Performance Curves 36
Working Range and Dimensions 38
Working Capacities 41
Bucket Capacity 41
Tipping Load 41
Material Weight 41
Approximate Weight of Workload Materials 41
General Maintenance 45
General Maintenance Procedures S0302000 47
Welding Precautions and Guidelines 49
Hydraulic System – General Precautions 50
Maintenance Service and Repair Procedure 51
General Precautions 51
Hydraulic System Cleanliness and Oil Leaks 52
Maintenance Precautions for Hydraulic System Service 52
Oil Leakage Precautions 52
Cleaning and Inspection 53
General Guidelines 53
Bearing inspection 54
Standard Torques S0309000 61
Torque Values for Standard Metric Fasteners 63
Torque Values for Standard US Fasteners 64
Type 8 Phosphate Coated Hardware 66
Torque Values for Hose Clamps 67
Torque Values for Split Flanges 68
Torque Wrench Extension Tools 69
Torque Multiplication 69
Other Uses for Torque Wrench Extension Tools 70
Tightening Torque Specifications (Metric) 70
Upper Structure 73
Counterweight S0403030K 75
Specifications 77
Counterweight 77
Fuel Transfer Pump S0405500 79
General Description 81
Theory of Operation 81
Replacement of Rotor and Vane 82
Replacement of Rear Cover 82
Replacement of Armature 83
Hydraulic oil tank S0406030K 85
General Description 87
Parts List 87
Specifications 88
Lower Structure and Chassis 89
Center Joint (Articulation Joint) S0502010K 91
General Description 93
Maintenance Standard 94
Engine and Drive Train 97
Front Axle S0602150K 99
General Description103
Outline103
Drive Axle103
Differential (Standard)106
Parking Brake Operation107
Parts List109
Scheduled Maintenance116
After First 250 Hours116
Every 150 hours116
Every 1500 Hours117
Lubricant Specifications117
General Disassembly and Reassembly Instructions118
General Instructions118
Assembling Leakproof Components119
Axle Disassembly119
Drain Oil119
Final Drive120
Differential Assembly124
Overhauling Super Max Trac Assembly128
Checking Clearance on Assembled Disc Packs129
Axle Reassembly130
Determining Thickness of Adjustment Shims130
Inner Oil Recirculation Piping131
Differential Assembly132
Axial Position of Bevel Pinion132
Adjusting Backlash133
Adjusting Tooth Contact134
Securing Differential to Axle Housing137
Final Drive138
Determining Space Available to Form Brake Disc Pack140
Parking Brake142
Disassembly143
Reassembly143
Adjustment143
Rear Axle S0602160K145
General Description147
Outline147
Drive Axle147
Differential (Standard)150
Parts List153
Scheduled Maintenance158
After First 250 Hours158
Every 150 hours159
Every 1500 Hours159
Lubricant Specifications159
General Disassembly and Reassembly Instructions160
General Instructions160
Assembling Leakproof Components161
Axle Disassembly161
Drain Oil161
Final Drive162
Differential Assembly167
Overhauling Super Max Trac Assembly169
Checking Clearance on Assembled Disc Packs170
Axle Reassembly171
Determining Thickness of Adjustment Shims171
Differential Assembly172
Axial Position of Bevel Pinion172
Adjusting Backlash173
Adjusting Tooth Contact174
Securing Differential to Axle Housing177
Final Drive178
Determining Space Available to Form Brake Disc Pack180
Air-Conditioner S0605050K181
General Description183
Refrigerant Circulation184
Control Panel186
Control Specifications187
Temperature Level Control and Display188
Air Discharge According to Path Selection189
Air-conditioning System Circuit Diagram192
Troubleshooting194
Refrigerant System Repairs197
Refrigerant Safe Handling Procedures197
Repair and Replacement Procedure198
Refrigerant Recovery200
Vacuuming Refrigerant System200
Leakage Check201
Refrigerant Charging202
Inspecting System For Leakage204
Transmission and Torque Converter (ZF) S0607070K205
Drive Train Description209
Transmission and Torque Converter210
Powershift Transmission211
Transmission Control211
Schedule of Measuring Points and Connection 4 WG-260212
Oil Circuit Diagram 4WG – 260 Forward 1st Speed215
Transmission Electric Components217
TCU (Transmission Control Unit)218
Transmission Control Valve218
Transmission Oil Temperature Sensor219
Engine Pick-Up Sensor219
Central Gear Pick-Up Sensor219
Turbine Pick-Up Sensor220
Output Speed Sensor220
Shift Lever Switch (DW-3)220
Auto Select Switch222
Display222
Transmission Electrical Circuits223
T/M Controller Circuit223
Travelling Circuits224
Downshift232
Transmission Cut Off235
LIS (Load Isolation System) – Option236
Installation View238
Inner Section238
Front View240
Side View241
Rear View242
Hydraulic Control Unit (HSG94)243
Disassembly244
Reassembly247
Transmission Disassembly254
Converter-Input254
Drive Shaft Pump Power Take-off257
Transmission Pump259
Output- Layshaft Assembly259
Disassemble Clutches and Layshaft Gear264
Disassemble Power Take-off II265
Disassemble Clutches266
Transmission Reassembly275
Power Take-off II275
Clutch K3/K4277
Clutch KR/K2288
Clutch – KV/K1296
Install Multi-disk Clutches, Layshaft Gear and Output Gear304
Install Filter319
Hydraulic Pump319
Drive Shaft (Power Take-off Pump)321
Input – Converter325
Converter330
Mount Hydraulic Control Unit (HSG94)331
Inductive Transmitter and Speed Sensor334
Setting Inductive Transmitter336
Speed Sensor (Hall Sensor) N Output And Speedometer338
Transmission Error Codes (ZF) S0607900C339
Abbreviations341
Display341
Display during operation342
Definition of operating modes344
Normal344
Substitute Clutch Control344
Limp-home344
Transmission-shutdown344
TCU-shutdown344
Table of fault codes345
Measurement of Resistance at Actuator/ sensors and Cable363
Actuator363
Cable363
Hydraulics365
Accumulator S0703000367
General Description369
Specifications370
Accumulator Charging372
Charging the Accumulator with Nitrogen372
Cylinders S0705010375
General Description377
Theory of Operation378
Parts List379
Troubleshooting, Testing and Adjustment381
Disassembly384
Cleaning and Inspection (Wear Limits and Tolerances)386
Reassembly387
Fan Drive Hydraulic Motor (Haldex) S0707100K395
General Description397
Theory of Operation397
Parts List399
Specifications400
Main Pump (Denison T6DMY Series) S0708460K401
General Description403
Construction403
Principles of Operation405
Parts List412
Specifications413
Special Tools and Materials414
Special Tools414
Troubleshooting, Testing and Adjustment415
Disassembly417
Cleaning and Inspection (Wear Limits and Tolerances)421
Reassembly422
Start-up Procedures425
Steering and Brake Pump (Denison T67DB Siries) S0708470K427
General Description429
Parts List430
Special Tools432
Troubleshooting, Testing and Adjustment433
Service and Maintenance434
Circuit Inspection434
Adding Hydraulic Oil to System434
Adjustments434
Lubrication434
Replacement Parts435
Disassembly436
Baisc Pump Disassembly438
Cartridge Disassembly439
Cleaning and Inspection (Wear Limits and Tolerances)442
Cleaning442
Inspection, Repair and Replacement442
Reassembly444
Cartridge Assembly445
Basic Pump Assembly448
Start-up Procedures449
Start-up449
Test449
Brake Pedal Valve S0709230K451
General Description453
Theory of Operation453
Specification454
Brake System455
Brake, Pilot, and Fan Motor Supply Valve456
Specifications457
Main Control Valve (Toshiba) S0709455K459
General Description461
Specifications463
Operation464
Neutral464
Bucket/option Spool Operation464
Boom Spool Operation465
Relief Valve465
Operation (Main Relief Valve)466
Operation (Port Relief Valve)467
Pilot Control Valve S0709475K469
General Description471
Pilot Valve Operation471
Pilot System474
Flow Amplifier (Danfoss) S0709665K477
General Description479
Parts List480
Specifications481
Special Tools and Materials482
Special tools482
Troubleshooting, Testing and Adjustment483
Steering System with OSQA/B and OSPBX-LS484
Disassembly485
Cleaning and Inspection (Wear Limits and Tolerances)505
Cleaning505
Inspection and replacement505
Lubrication505
Reassembly505
Power Steering Unit S0709730K525
General Description527
Power Steering System527
Gerotor Operation529
Cushion Valve Operation530
Parts List532
Specifications533
Special Tools534
Troubleshooting, Testing and Adjustment536
Disassembly537
Cleaning and Inspection541
Reassembly542
Installation553
Unloader Valve S0709850K555
General Description557
Theory of Operation557
Unloader Cartridge Identification559
Specifications560
Hydraulic Schematic (Mega 400-V) S0793050K561
General Description563
Mega 400-V564
Electrical System567
Electrical System S0802180K569
Overview571
Electric Supply System572
Engine Starting Circuit574
Operation During Start Process574
Operation After Start Process576
Engine Preheating System578
Principle Of Operation578
Engine Stop System580
Operation In Engine Running Mode580
Operation In Engine Stop Mode582
Charging System584
Monitoring System585
Instrument Panel586
Function Check587
Monitoring System Schematic588
Operation590
Windshield Wiper596
Front windshield wiper596
Rear Windshield wiper597
Lighting System600
Light Circuit600
Emergency Steering System (Option)604
Block Diagram604
Emergency Steering System Components605
Emergency Steering System Electric Circuit607
Electric Detent System608
Electric Circuit608
Boom Kick-Out608
Return To Dig609
Electrical Schematic (Mega 400-V) S0893050K611
General Description613
Mega 400-V614
Attachments617

S.M 14/2/2025