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Daewoo Doosan MG 400-V shop 023-00040AE-1manual – PDF DOWNLOAD
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Description
Daewoo Doosan MG 400-V shop 023-00040AE-1manual – PDF DOWNLOAD
DESCRIPTION:
Daewoo Doosan MG 400-V shop 023-00040AE-1manual – PDF DOWNLOAD
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
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 MG 400-V shop 023-00040AE-1manual – PDF DOWNLOAD
Safety.............................................................................. 9 Wheel Loader Safety S0103010K................................................... 0 To the Operator of a 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....................................................... 0 Stay Alert for People Moving through Work Area.......................... 18 Be Aware of and Conform to Local Regulations............................ 18 Operation................................................................... 18 Operate While Seated at Operator’s Station ONLY......................... 18 Before Starting Engine, do a “pre-start” safety check:.................. 19 Never Use Ether Starting Aids........................................... 19 Mounting and Dismounting................................................ 19 Observe General Safety Rules............................................ 20 Engine Ventilation...................................................... 20 Asbestos Dust Hazard Prevention......................................... 20 Take Time to Provide Good Visibility.................................... 20 Fuel, Oil and Hydraulic Fluid Fire Hazards.............................. 21 Boost Starting or Charging Engine Batteries............................. 21 Shutdown Control Functions.............................................. 23 Equipment................................................................... 23 Rough Operation May Require Use of Certified Safety Equipment........... 23 Install Additional Safety Equipment If Conditions Require............... 24 Movement Alarms......................................................... 24 Seat Belts Should Be Used at All Times.................................. 24 Window Glass Breaking Tool.............................................. 24 Wear Eye Protection and Safety Clothing – Use Proper Tools.............. 26 Breathing Masks, Ear Protection May Be Required......................... 26 Asbestos Fiber Hazard................................................... 26 Battery Electrolyte and Explosive Gases Can Be Lethal................... 26 Disconnect Batteries Before Electrical Service or Electrical Welding.... 26 Maintenance................................................................. 0 Cool-down Is Required Prior to Radiator or Reservoir Checks............. 28 Pressurized Hydraulic Oil Fluid Leaks Can Be Dangerous.................. 28 Obtain immediate medical attention if pressurized oil pierces skin...... 28 Use Correct Replacement Fasteners Tightened to Proper Torque............ 28 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-V S0203060K......................................... 0 Component Locations......................................................... 36 Engine Performance Curves................................................... 40 Working Range and Dimensions................................................ 42 General Maintenance................................................................. 47 General Maintenance Procedures S0302000......................................... 0 Hydraulic System - General Precautions...................................... 52 Maintenance Service and Repair Procedure.................................... 53 General Precautions..................................................... 53 Hydraulic System Cleanliness and Oil Leaks.................................. 54 Maintenance Precautions for Hydraulic System Service.................... 54 Oil Leakage Precautions................................................. 54 Cleaning and Inspection..................................................... 55 General Guidelines...................................................... 55 Bearing inspection...................................................... 56 Upper Structure..................................................................... 71 Fuel Transfer Pump S0405500..................................................... 0 Replacement of Rotor and Vane............................................... 80 Replacement of Rear Cover................................................... 80 Replacement of Armature..................................................... 81 Hydraulic oil tank S0406030K.................................................... 0 General Description......................................................... 85 Parts List.............................................................. 85 Lower Structure and Chassis......................................................... 87 Center Joint (Articulation Joint) S0502010K..................................... 0 General Description......................................................... 91 Maintenance Standard.................................................... 92 Engine and Drive Train.............................................................. 95 Front Axle S0602150K............................................................ 0 General Description......................................................... 0 Differential (Standard).................................................104 Parts List..............................................................107 Scheduled Maintenance.......................................................114 After First 250 Hours...................................................114 Every 150 hours.........................................................114 Every 1500 Hours........................................................115 Lubricant Specifications................................................115 General Disassembly and Reassembly Instructions.............................116 General Instructions....................................................116 Assembling Leakproof Components.........................................117 Axle Disassembly............................................................117 Drain Oil...............................................................117 Final Drive.............................................................118 Differential Assembly...................................................122 Axle Reassembly.............................................................128 Determining Thickness of Adjustment Shims...............................128 Inner Oil Recirculation Piping..........................................129 Differential Assembly...................................................130 Axial Position of Bevel Pinion..........................................130 Adjusting Tooth Contact.................................................132 Final Drive.............................................................136 Parking Brake...............................................................140 Rear Axle S0602160K............................................................. 0 General Description......................................................... 0 Differential (Standard).................................................148 Parts List..............................................................151 Scheduled Maintenance.......................................................156 After First 250 Hours...................................................156 Every 150 hours.........................................................157 Every 1500 Hours........................................................157 Lubricant Specifications................................................157 General Disassembly and Reassembly Instructions.............................158 General Instructions....................................................158 Assembling Leakproof Components.........................................159 Axle Disassembly............................................................159 Drain Oil...............................................................159 Final Drive.............................................................160 Differential Assembly...................................................165 Axle Reassembly.............................................................169 Determining Thickness of Adjustment Shims...............................169 Differential Assembly...................................................170 Axial Position of Bevel Pinion..........................................170 Adjusting Tooth Contact.................................................172 Final Drive.............................................................176 Air-Conditioner S0605050K....................................................... 0 General Description.........................................................181 Refrigerant Circulation.....................................................182 Control Panel...............................................................184 Control Specifications......................................................185 Temperature Level Control and Display.......................................186 Air Discharge According to Path Selection...................................187 Air-conditioning System Circuit Diagram.....................................190 Refrigerant System Repairs.................................................. 0 Repair and Replacement Procedure........................................196 Inspecting System For Leakage...........................................202 Transmission and Torque Converter (ZF) S0607070K................................ 0 Drive Train Description.....................................................207 Transmission Electric Components............................................215 TCU (Transmission Control Unit).........................................216 Transmission Control Valve..............................................216 Auto Select Switch......................................................220 Display.................................................................220 Transmission Electrical Circuits............................................221 T/M Controller Circuit..................................................221 Travelling Circuits.....................................................222 Downshift...............................................................230 Transmission Cut Off....................................................233 Installation View...........................................................236 Inner Section...........................................................236 Front View..............................................................238 Side View...............................................................239 Rear View...............................................................240 Hydraulic Control Unit (HSG94).............................................241 Disassembly.............................................................242 Reassembly..............................................................245 Transmission Disassembly....................................................252 Converter-Input.........................................................252 Drive Shaft Pump Power Take-off.........................................255 Transmission Pump.......................................................257 Output- Layshaft Assembly...............................................257 Disassemble Clutches and Layshaft Gear..................................262 Disassemble Power Take-off II...........................................263 Transmission Reassembly..................................................... 0 Clutch K3/K4............................................................275 Install Multi-disk Clutches, Layshaft Gear and Output Gear..............302 Inductive Transmitter and Speed Sensor..................................332 Transmission Error Codes (ZF) S0607900C......................................... 0 Abbreviations...............................................................339 Display.....................................................................339 Display during operation....................................................340 Definition of operating modes...............................................342 Normal..................................................................342 Substitute Clutch Control...............................................342 Limp-home...............................................................342 Transmission-shutdown...................................................342 TCU-shutdown............................................................342 Table of fault codes........................................................343 Measurement of Resistance at Actuator/ sensors and Cable....................361 Actuator................................................................361 Cable...................................................................361 Hydraulics..........................................................................363 Cylinders S0705010.............................................................. 0 General Description.........................................................375 Theory of Operation.....................................................376 Parts List..............................................................377 Troubleshooting, Testing and Adjustment.....................................379 Disassembly.................................................................382 Cleaning and Inspection (Wear Limits and Tolerances)........................384 Reassembly..................................................................385 Fan Drive Hydraulic Motor (Haldex) S0707100K.................................... 0 General Description......................................................... 0 Parts List..............................................................397 Main Pump (Denison T6DMY Series) S0708460K...................................... 0 General Description.........................................................401 Construction............................................................401 Principles of Operation.................................................403 Parts List..............................................................410 Troubleshooting, Testing and Adjustment.....................................413 Disassembly.................................................................415 Reassembly..................................................................420 Start-up Procedures.........................................................423 Steering and Brake Pump (Denison T67DB Siries) S0708470K........................ 0 General Description.........................................................427 Parts List..............................................................428 Troubleshooting, Testing and Adjustment.....................................431 Service and Maintenance.....................................................432 Circuit Inspection......................................................432 Adding Hydraulic Oil to System..........................................432 Adjustments.............................................................432 Lubrication.............................................................432 Replacement Parts.......................................................433 Disassembly.................................................................434 Baisc Pump Disassembly..................................................436 Cartridge Disassembly...................................................437 Reassembly..................................................................442 Cartridge Assembly......................................................443 Basic Pump Assembly.....................................................446 Brake Pedal Valve S0709230K..................................................... 0 General Description......................................................... 0 Specification...........................................................452 Brake System................................................................453 Brake, Pilot, and Fan Motor Supply Valve....................................454 Specifications..........................................................455 Main Control Valve (Toshiba) S0709455K.......................................... 0 General Description.........................................................459 Specifications..............................................................461 Operation...................................................................462 Neutral.................................................................462 Bucket/option Spool Operation...........................................462 Boom Spool Operation....................................................463 Relief Valve............................................................463 Operation (Main Relief Valve)...........................................464 Operation (Port Relief Valve)...........................................465 Pilot Control Valve S0709475K................................................... 0 General Description.........................................................469 Pilot Valve Operation...................................................469 Flow Amplifier (Danfoss) S0709665K.............................................. 0 General Description.........................................................477 Parts List..............................................................478 Special Tools and Materials.................................................480 Special tools...........................................................480 Troubleshooting, Testing and Adjustment.....................................481 Steering System with OSQA/B and OSPBX-LS................................482 Disassembly.................................................................483 Cleaning and Inspection (Wear Limits and Tolerances)........................503 Cleaning................................................................503 Inspection and replacement..............................................503 Lubrication.............................................................503 Reassembly..................................................................503 Power Steering Unit S0709730K................................................... 0 General Description.........................................................525 Power Steering System...................................................525 Gerotor Operation.......................................................527 Cushion Valve Operation.................................................528 Parts List..............................................................530 Special Tools...............................................................532 Troubleshooting, Testing and Adjustment.....................................534 Disassembly.................................................................535 Cleaning and Inspection.....................................................539 Unloader Valve S0709850K........................................................ 0 General Description......................................................... 0 Unloader Cartridge Identification.......................................557 Specifications..........................................................558 Hydraulic Schematic (Mega 400-V) S0793050K...................................... 0 General Description.........................................................561 Mega 400-V..................................................................562 Electrical System...................................................................565 Electrical System S0802180K..................................................... 0 Electric Supply System......................................................570 Engine Starting Circuit.....................................................572 Operation During Start Process..........................................572 Operation After Start Process...........................................574 Engine Preheating System....................................................576 Principle Of Operation..................................................576 Engine Stop System..........................................................578 Operation In Engine Running Mode........................................578 Operation In Engine Stop Mode...........................................580 Charging System.............................................................582 Monitoring System...........................................................583 Instrument Panel........................................................584 Function Check..........................................................585 Monitoring System Schematic.............................................586 Operation...............................................................588 Windshield Wiper............................................................594 Front windshield wiper..................................................594 Rear Windshield wiper...................................................595 Lighting System.............................................................598 Light Circuit...........................................................598 Emergency Steering System (Option)..........................................602 Block Diagram...........................................................602 Emergency Steering System Components....................................603 Emergency Steering System Electric Circuit..............................605 Electric Detent System......................................................606 Electric Circuit........................................................606 Boom Kick-Out...........................................................606 Return To Dig...........................................................607 Electrical Schematic (Mega 400-V) S0893050K..................................... 0 General Description.........................................................611 Mega 400-V..................................................................612 Attachments.........................................................................615
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PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
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