Daewoo Doosan Mega 400-V shop manual 023-00040E – PDF DOWNLOAD

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Daewoo Doosan Mega 400-V shop manual 023-00040E – PDF DOWNLOAD

DESCRIPTION:

Daewoo Dooson Mega 400-V shop manual 023-00040E – PDF DOWNLOAD

• 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.

TO THE OPERATOR OF A 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 13
6. “Maintenance” on page 17
7. “Shipping and Transportation” on page 20

LEARN SIGNAL WORDS USED WITH SAFETY ALERT SYMBOL

Words “CAUTION,” “WARNING,” and “DANGER” used throughout this manual and on labels on machine indicate hazards or unsafe practices. All three statements indicate that safety is involved. Observe precautions indicated whenever you see the Safety Alert “Triangle,” no matter which signal word appears next to the “Exclamation Point” symbol

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

UNAUTHORIZED MODIFICATIONS

IMPORTANT

• If you need more information or have any questions or concerns about safe operating procedures or working wheel loader correctly in a particular application or in specific conditions of your individual operating environment, please consult your local Daewoo representative
• Any modification made without authorization or written approval from Daewoo can create a safety hazard, for which machine owner must be held responsible. For safety’s sake, replace all OEM parts with correct authorized or genuine Daewoo part.
• For example, not taking time to replace fasteners, bolts or nuts with correct replacement parts could lead to a condition in which safety of critical assemblies is dangerously compromised

TABLE OF CONTENTS:

Daewoo Doosan Mega 400-V shop manual 023-00040E – PDF DOWNLOAD

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 U.S. 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 Description…………………………………………………103
Outline………………………………………………………..103
Drive Axle……………………………………………………..103
Differential (Standard)………………………………………….106
Parking Brake Operation………………………………………….107
Parts List……………………………………………………..109
Scheduled Maintenance……………………………………………….116
After First 250 Hours……………………………………………116
Every 150 hours…………………………………………………116
Every 1500 Hours………………………………………………..117
Lubricant Specifications…………………………………………117
General Disassembly and Reassembly Instructions………………………..118
General Instructions…………………………………………….118
Assembling Leakproof Components…………………………………..119
Axle Disassembly……………………………………………………119
Drain Oil………………………………………………………119
Final Drive…………………………………………………….120
Differential Assembly……………………………………………124
Overhauling Super Max Trac Assembly……………………………….128
Checking Clearance on Assembled Disc Packs…………………………129
Axle Reassembly…………………………………………………….130
Determining Thickness of Adjustment Shims………………………….130
Inner Oil Recirculation Piping……………………………………131
Differential Assembly……………………………………………132
Axial Position of Bevel Pinion……………………………………132
Adjusting Backlash………………………………………………133
Adjusting Tooth Contact………………………………………….134
Securing Differential to Axle Housing……………………………..137
Final Drive…………………………………………………….138
Determining Space Available to Form Brake Disc Pack…………………140
Parking Brake………………………………………………………142
Disassembly…………………………………………………….143
Reassembly……………………………………………………..143
Adjustment……………………………………………………..143
Rear Axle S0602160K…………………………………………………….145
General Description…………………………………………………147
Outline………………………………………………………..147
Drive Axle……………………………………………………..147
Differential (Standard)………………………………………….150
Parts List……………………………………………………..153
Scheduled Maintenance……………………………………………….158
After First 250 Hours……………………………………………158
Every 150 hours…………………………………………………159
Every 1500 Hours………………………………………………..159
Lubricant Specifications…………………………………………159
General Disassembly and Reassembly Instructions………………………..160
General Instructions…………………………………………….160
Assembling Leakproof Components…………………………………..161
Axle Disassembly……………………………………………………161
Drain Oil………………………………………………………161
Final Drive…………………………………………………….162
Differential Assembly……………………………………………167
Overhauling Super Max Trac Assembly……………………………….169
Checking Clearance on Assembled Disc Packs…………………………170
Axle Reassembly…………………………………………………….171
Determining Thickness of Adjustment Shims………………………….171
Differential Assembly……………………………………………172
Axial Position of Bevel Pinion……………………………………172
Adjusting Backlash………………………………………………173
Adjusting Tooth Contact………………………………………….174
Securing Differential to Axle Housing……………………………..177
Final Drive…………………………………………………….178
Determining Space Available to Form Brake Disc Pack…………………180
Air-Conditioner S0605050K……………………………………………….181
General Description…………………………………………………183
Refrigerant Circulation……………………………………………..184
Control Panel………………………………………………………186
Control Specifications………………………………………………187
Temperature Level Control and Display…………………………………188
Air Discharge According to Path Selection……………………………..189
Air-conditioning System Circuit Diagram……………………………….192
Troubleshooting…………………………………………………….194
Refrigerant System Repairs…………………………………………..197
Refrigerant Safe Handling Procedures………………………………197
Repair and Replacement Procedure………………………………….198
Refrigerant Recovery…………………………………………….200
Vacuuming Refrigerant System……………………………………..200
Leakage Check…………………………………………………..201
Refrigerant Charging…………………………………………….202
Inspecting System For Leakage…………………………………….204
Transmission and Torque Converter (ZF) S0607070K…………………………..205
Drive Train Description……………………………………………..209
Transmission and Torque Converter…………………………………….210
Powershift Transmission………………………………………….211
Transmission Control…………………………………………….211
Schedule of Measuring Points and Connection 4 WG-260………………..212
Oil Circuit Diagram 4WG – 260 Forward 1st Speed…………………….215
Transmission Electric Components……………………………………..217
TCU (Transmission Control Unit)…………………………………..218
Transmission Control Valve……………………………………….218
Transmission Oil Temperature Sensor……………………………….219
Engine Pick-Up Sensor……………………………………………219
Central Gear Pick-Up Sensor………………………………………219
Turbine Pick-Up Sensor…………………………………………..220
Output Speed Sensor……………………………………………..220
Shift Lever Switch (DW-3)………………………………………..220
Auto Select Switch………………………………………………222
Display………………………………………………………..222
Transmission Electrical Circuits……………………………………..223
T/M Controller Circuit…………………………………………..223
Travelling Circuits……………………………………………..224
Downshift………………………………………………………232
Transmission Cut Off…………………………………………….235
LIS (Load Isolation System) – Option………………………………236
Installation View…………………………………………………..238
Inner Section…………………………………………………..238
Front View……………………………………………………..240
Side View………………………………………………………241
Rear View………………………………………………………242
Hydraulic Control Unit (HSG94)………………………………………243
Disassembly…………………………………………………….244
Reassembly……………………………………………………..247
Transmission Disassembly…………………………………………….254
Converter-Input…………………………………………………254
Drive Shaft Pump Power Take-off…………………………………..257
Transmission Pump……………………………………………….259
Output- Layshaft Assembly………………………………………..259
Disassemble Clutches and Layshaft Gear…………………………….264
Disassemble Power Take-off II…………………………………….265
Disassemble Clutches…………………………………………….266
Transmission Reassembly……………………………………………..275
Power Take-off II……………………………………………….275
Clutch K3/K4……………………………………………………277
Clutch KR/K2……………………………………………………288
Clutch – KV/K1………………………………………………….296
Install Multi-disk Clutches, Layshaft Gear and Output Gear…………..304
Install Filter………………………………………………….319
Hydraulic Pump………………………………………………….319
Drive Shaft (Power Take-off Pump)…………………………………321
Input – Converter……………………………………………….325
Converter………………………………………………………330
Mount Hydraulic Control Unit (HSG94)……………………………..331
Inductive Transmitter and Speed Sensor…………………………….334
Setting Inductive Transmitter…………………………………….336
Speed Sensor (Hall Sensor) N Output And Speedometer…………………338
Transmission Error Codes (ZF) S0607900C…………………………………..339
Abbreviations………………………………………………………341
Display……………………………………………………………341
Display during operation…………………………………………….342
Definition of operating modes………………………………………..344
Normal…………………………………………………………344
Substitute Clutch Control………………………………………..344
Limp-home………………………………………………………344
Transmission-shutdown……………………………………………344
TCU-shutdown……………………………………………………344
Table of fault codes………………………………………………..345
Measurement of Resistance at Actuator/ sensors and Cable………………..363
Actuator……………………………………………………….363
Cable………………………………………………………….363
Hydraulics………………………………………………………………..365
Accumulator S0703000……………………………………………………367
General Description…………………………………………………369
Specifications………………………………………………….370
Accumulator Charging………………………………………………..372
Charging the Accumulator with Nitrogen…………………………….372
Cylinders S0705010……………………………………………………..375
General Description…………………………………………………377
Theory of Operation……………………………………………..378
Parts List……………………………………………………..379
Troubleshooting, Testing and Adjustment……………………………….381
Disassembly………………………………………………………..384
Cleaning and Inspection (Wear Limits and Tolerances)……………………386
Reassembly…………………………………………………………387
Fan Drive Hydraulic Motor (Haldex) S0707100K………………………………395
General Description…………………………………………………397
Theory of Operation……………………………………………..397
Parts List……………………………………………………..399
Specifications………………………………………………….400
Main Pump (Denison T6DMY Series) S0708460K………………………………..401
General Description…………………………………………………403
Construction……………………………………………………403
Principles of Operation………………………………………….405
Parts List……………………………………………………..412
Specifications………………………………………………….413
Special Tools and Materials………………………………………….414
Special Tools…………………………………………………..414
Troubleshooting, Testing and Adjustment……………………………….415
Disassembly………………………………………………………..417
Cleaning and Inspection (Wear Limits and Tolerances)……………………421
Reassembly…………………………………………………………422
Start-up Procedures…………………………………………………425
Steering and Brake Pump (Denison T67DB Siries) S0708470K……………………427
General Description…………………………………………………429
Parts List……………………………………………………..430
Special Tools………………………………………………………432
Troubleshooting, Testing and Adjustment……………………………….433
Service and Maintenance……………………………………………..434
Circuit Inspection………………………………………………434
Adding Hydraulic Oil to System……………………………………434
Adjustments…………………………………………………….434
Lubrication…………………………………………………….434
Replacement Parts……………………………………………….435
Disassembly………………………………………………………..436
Baisc Pump Disassembly…………………………………………..438
Cartridge Disassembly……………………………………………439
Cleaning and Inspection (Wear Limits and Tolerances)……………………442
Cleaning……………………………………………………….442
Inspection, Repair and Replacement………………………………..442
Reassembly…………………………………………………………444
Cartridge Assembly………………………………………………445
Basic Pump Assembly……………………………………………..448
Start-up Procedures…………………………………………………449
Start-up……………………………………………………….449
Test…………………………………………………………..449
Brake Pedal Valve S0709230K……………………………………………..451
General Description…………………………………………………453
Theory of Operation……………………………………………..453
Specification…………………………………………………..454
Brake System……………………………………………………….455
Brake, Pilot, and Fan Motor Supply Valve………………………………456
Specifications………………………………………………….457
Main Control Valve (Toshiba) S0709455K……………………………………459
General Description…………………………………………………461
Specifications……………………………………………………..463
Operation………………………………………………………….464
Neutral………………………………………………………..464
Bucket/option Spool Operation…………………………………….464
Boom Spool Operation…………………………………………….465
Relief Valve……………………………………………………465
Operation (Main Relief Valve)…………………………………….466
Operation (Port Relief Valve)…………………………………….467
Pilot Control Valve S0709475K……………………………………………469
General Description…………………………………………………471
Pilot Valve Operation……………………………………………471
Pilot System……………………………………………………….474
Flow Amplifier (Danfoss) S0709665K……………………………………….477
General Description…………………………………………………479
Parts List……………………………………………………..480
Specifications………………………………………………….481
Special Tools and Materials………………………………………….482
Special tools…………………………………………………..482
Troubleshooting, Testing and Adjustment……………………………….483
Steering System with OSQA/B and OSPBX-LS…………………………..484
Disassembly………………………………………………………..485
Cleaning and Inspection (Wear Limits and Tolerances)……………………505
Cleaning……………………………………………………….505
Inspection and replacement……………………………………….505
Lubrication…………………………………………………….505
Reassembly…………………………………………………………505
Power Steering Unit S0709730K……………………………………………525
General Description…………………………………………………527
Power Steering System……………………………………………527
Gerotor Operation……………………………………………….529
Cushion Valve Operation………………………………………….530
Parts List……………………………………………………..532
Specifications………………………………………………….533
Special Tools………………………………………………………534
Troubleshooting, Testing and Adjustment……………………………….536
Disassembly………………………………………………………..537
Cleaning and Inspection……………………………………………..541
Reassembly…………………………………………………………542
Installation……………………………………………………….553
Unloader Valve S0709850K………………………………………………..555
General Description…………………………………………………557
Theory of Operation……………………………………………..557
Unloader Cartridge Identification…………………………………559
Specifications………………………………………………….560
Hydraulic Schematic (Mega 400-V) S0793050K………………………………..561
General Description…………………………………………………563
Mega 400-V…………………………………………………………564
Electrical System………………………………………………………….567
Electrical System S0802180K……………………………………………..569
Overview…………………………………………………………..571
Electric Supply System………………………………………………572
Engine Starting Circuit……………………………………………..574
Operation During Start Process……………………………………574
Operation After Start Process…………………………………….576
Engine Preheating System…………………………………………….578
Principle Of Operation…………………………………………..578
Engine Stop System………………………………………………….580
Operation In Engine Running Mode………………………………….580
Operation In Engine Stop Mode…………………………………….582
Charging System…………………………………………………….584
Monitoring System…………………………………………………..585
Instrument Panel………………………………………………..586
Function Check………………………………………………….587
Monitoring System Schematic………………………………………588
Operation………………………………………………………590
Windshield Wiper……………………………………………………596
Front windshield wiper…………………………………………..596
Rear Windshield wiper……………………………………………597
Lighting System…………………………………………………….600
Light Circuit…………………………………………………..600
Emergency Steering System (Option)……………………………………604
Block Diagram…………………………………………………..604
Emergency Steering System Components………………………………605
Emergency Steering System Electric Circuit…………………………607
Electric Detent System………………………………………………608
Electric Circuit………………………………………………..608
Boom Kick-Out…………………………………………………..608
Return To Dig…………………………………………………..609
Electrical Schematic (Mega 400-V) S0893050K……………………………….611
General Description…………………………………………………613
Mega 400-V…………………………………………………………614
Attachments……………………………………………………………….617

DAEWOO DOOSAN MEGA 400-V SHOP MANUAL 023-00040E – PDF DOWNLOAD:

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