Daewoo Doosan WHEEL LOADER M400-V Shop Manual 023-00092AE-1 – PDF DOWNLOAD

Description

Daewoo Doosan WHEEL LOADER M400-V Shop Manual 023-00092AE-1 – PDF DOWNLOAD

DESCRIPTION:

Daewoo Doosan WHEEL LOADER M400-V Shop Manual 023-00092AE-1 – PDF DOWNLOAD

TO THE OPERATOR OF A DOOSAN WHEEL LOADER

• Unsafe use of the wheel loader could lead to serious injury or death. Operating procedures, maintenance and equipment practices or traveling or shipping methods that do not follow the safety guidelines on the following pages could cause serious, potentially fatal injuries or extensive damage to the machine or nearby property
• 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 6.
2. “Location of Safety Labels” on page 6.
3. “Unauthorized Modifications” on page 6.
4. “General Hazard Information” on page 7.
5. “Before Starting Engine” on page 15.
6. “Machine Operation” on page 18.
7. “Maintenance” on page 25.
8. “Battery” on page 33.
9. “Towing” on page 35.
10. “Shipping and Transportation” on page 36.

• Improper operation and maintenance of this machine can be hazardous and could result in serious injury or death. Operator and maintenance personnel should read this manual thoroughly before beginning operation or maintenance. Keep this manual in the storage compartment to the rear of the operator’s seat, and have all personnel involved in working on the machine periodically read the manual. Some actions involved in operation and maintenance of the machine can cause a serious accident, if they are not done in a manner described in this manual. The procedures and precautions given in this manual apply only to intended uses of the machine.
• If you use your machine for any unintended uses that are not specifically prohibited, you must be sure that it is safe for any others. In no event should you or others engage in prohibited uses or actions as described in this manual. Daewoo delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped.
• If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety devices and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regulations of your country, consult Daewoo or your Daewoo distributor before operating the machine.

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.

Safety precautions are described in SAFETY from page 6 on.

Daewoo cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore the safety messages in this manual and on the machine may not include all possible safety precautions. If any procedures or actions not specifically recommended or allowed in this manual are used, you must be sure that you and others can do such procedures and actions safely and without damaging the machine. If your unsure about the safety of some procedures, contact a DAEWOO distributor

GENERAL SAFETY ESSENTIALS

ACCESSORY APPLICATIONS

This 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. There are several specific warning signs on this machine. The exact location of hazards and the description of the hazards are reviewed in the appropriate Operation and Maintenance Manual. Please become familiarized with all warning signs. Make sure that all of the warning signs are legible. Clean the warning signs or replace the warning signs if you cannot read the words. Replace the illustrations if the illustrations are not visible. When you clean the warning signs, use a cloth, water and soap. Do not use solvent, gasoline, or other harsh chemicals to clean the safety signs. Solvents, gasoline, or other harsh chemicals could loosen the adhesive that secures the warning sign. Loose adhesive will allow the warning sign to fall off. Replace any safety sign that is damaged, or missing. If a safety sign is attached to a part that is replaced, install a safety sign on the replacement part.

UNAUTHORIZED MODIFICATIONS

Any modification made without authorization or written approval from Daewoo can create a safety hazard, for which the machine owner must be held responsible. For safety’s sake, replace all OEM parts with the correct authorized or genuine Daewoo part. For example, not taking the time to replace fasteners, bolts or nuts with the correct replacement parts could lead to a condition in which the safety of critical assemblies is dangerously compromisedUNAUTHORIZED MODIFICATIONS Any modification made without authorization or written approval from Daewoo can create a safety hazard, for which the machine owner must be held responsible. For safety’s sake, replace all OEM parts with the correct authorized or genuine Daewoo part. For example, not taking the time to replace fasteners, bolts or nuts with the correct replacement parts could lead to a condition in which the safety of critical assemblies is dangerously compromised

GENERAL HAZARD INFORMATION

SAFETY RULES

Only trained and authorized personnel can operate and maintain the machine. Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine. Do not operate the machine if you are not feeling well, if you are taking medication that makes you feel sleepy, if you have been drinking, or if you are suffering from emotional problems. These problems will interfere with your sense of judgement in emergencies and may cause accidents. When working with another operator or with a person on work site traffic duty, be sure that all personnel know the nature of the work and understand all hand signals that are to be used. Always observe strictly any other rules related to safety.

SAFETY FEATURES

Be sure that all guards and covers are installed in their proper position. Have guards and covers repaired immediately if damaged. Be sure that you understand the method of use of safety features such as transmission lever neutral lock and the seat belt, and use them properly. Never remove any safety features. Always keep them in good operating condition. Failure to use safety features according to the instructions in the Operation and Maintenance Manual could result in serious bodily injury

TABLE OF CONTENTS:

Daewoo Doosan WHEEL LOADER M400-V Shop Manual 023-00092AE-1 – PDF DOWNLOAD

Safety……………………………………………………………………………………………. 9
Wheel Loader Safety S0103020K……………………………………………………………………. 0
To the Operator of a Daewoo Wheel Loader………………………………………………………. 13
Learn Signal Words Used with Safety Alert Symbol……………………………………………. 15
General Safety Essentials……………………………………………………………………. 16
Accessory Applications…………………………………………………………………… 16
Location of Safety Labels……………………………………………………………………. 16
Unauthorized Modifications…………………………………………………………………… 16
General Hazard Information…………………………………………………………………… 17
Safety Rules……………………………………………………………………………. 17
Safety Features…………………………………………………………………………. 17
Inside Operator’s Compartment…………………………………………………………….. 18
Clothing and Personal Protective Items…………………………………………………….. 18
Breathing Masks, Ear Protection May Be Required…………………………………………….. 19
Vibration Level Information………………………………………………………………. 19
Asbestos Dust Hazard Prevention…………………………………………………………… 19
Mounting and Dismounting…………………………………………………………………. 20
Fuel, Oil and Hydraulic Fluid Fire Hazards…………………………………………………. 20
Precautions When Handling Fluids at High Temperature………………………………………… 21
Injury from Work Equipment……………………………………………………………….. 21
Fire Extinguisher and First Aid Kit……………………………………………………….. 22
Protection from Falling or Flying Objects………………………………………………….. 22
Install Additional Safety Equipment If Conditions Require……………………………………. 23
Maintain Standard Safety Equipment in Good Condition………………………………………… 23
Attachment Precautions…………………………………………………………………… 24
Accumulator…………………………………………………………………………….. 24
Engine Ventilation………………………………………………………………………. 24
Before Starting Engine………………………………………………………………………. 25
Work Site Precautions……………………………………………………………………. 25
Checks Before Starting Engine…………………………………………………………….. 26
Engine Starting…………………………………………………………………………. 26
Before Operating Machine…………………………………………………………………. 27
Machine Operation…………………………………………………………………………… 28
Operate While Seated at Operator’s Station ONLY…………………………………………….. 28
Seat Belts Should Be Used at All Times…………………………………………………….. 28
Movement Alarms…………………………………………………………………………. 28
Travel Precautions………………………………………………………………………. 29
Sloping Terrain Requires Caution………………………………………………………….. 29
Avoid High Voltage Cables………………………………………………………………… 30
Before Starting to Dig, Contact Authorities………………………………………………… 30
Be Aware of Height Obstacles……………………………………………………………… 30
Use Care on Loose Support………………………………………………………………… 30
Use Solid Support Blocking……………………………………………………………….. 31
Digging Beneath Overhangs………………………………………………………………… 31
Digging Beneath Wheel Loader……………………………………………………………… 31
Stay Alert for People Moving Through Work Area……………………………………………… 31
Be Aware of and Conform to Local Regulations……………………………………………….. 31
Never Use Ether Starting Aids…………………………………………………………….. 32
Observe General Safety Rules……………………………………………………………… 32
Take Time to Provide Good Visibility………………………………………………………. 32
Keep “Pinch Point” Areas Clear  Use Caution in Reverse……………………………………… 33
Operate Carefully on Snow and Ice and in Very Cold Temperatures………………………………. 33
Parking Machine…………………………………………………………………………. 33
Shutdown Control Functions……………………………………………………………….. 34
Never Let Anyone Ride on Attachment……………………………………………………….. 34
Maintenance………………………………………………………………………………… 35
Use Warning Tag During Service……………………………………………………………. 35
clean Before Inspection or Maintenance…………………………………………………….. 35
Proper Tools……………………………………………………………………………. 36
Use of Lighting…………………………………………………………………………. 36
Fire Prevention and Explosion Prevention…………………………………………………… 36
Burn Prevention…………………………………………………………………………. 37
Welding Repairs…………………………………………………………………………. 38
Precautions for Removal, Installation, and Storage of Attachments…………………………….. 38
Precautions When Working on Machine……………………………………………………….. 39
Lock Inspection Covers…………………………………………………………………… 39
Crushing Prevention and Cutting Prevention…………………………………………………. 39
Do Not Run Engine If Repairs or Work Are Being Performed Alone……………………………….. 39
Always Use Adequate Equipment Supports and Blocking…………………………………………. 40
Do Not Work on Hot Engines or Hot Cooling or Hydraulic Systems……………………………….. 40
Hydraulic Cylinder Seals Require Periodic Replacement……………………………………….. 40
Highpressure Hydraulic Lines Can Store a Great Deal of Energy……………………………….. 40
Precautions with Highpressure Line, Tubes and Hoses………………………………………… 41
Obtain Immediate Medical Attention if Pressurized Oil Pierces Skin……………………………. 41
Use Correct Replacement Fasteners Tightened to Proper Torque…………………………………. 42
Safety Critical Parts Must Be Replaced Periodically…………………………………………. 42
Dispose of All Petroleum Based Oils and Fluids Properly……………………………………… 42
Check Tire Pressure and Condition…………………………………………………………. 42
Battery……………………………………………………………………………………. 43
Battery Hazard Prevention………………………………………………………………… 43
Disconnect Batteries Before Electrical Service or Electrical Welding………………………….. 43
Use Low Heat Portable Lighting……………………………………………………………. 44
Boost Starting or Charging Engine Batteries………………………………………………… 44
Towing…………………………………………………………………………………….. 45
Precautions When Towing………………………………………………………………….. 45
Shipping and Transportation………………………………………………………………….. 46
Obey State and Local OvertheRoad Regulations……………………………………………… 46
Summary of Safety Precautions for Lifting………………………………………………….. 46
Specifications…………………………………………………………………………………….. 47
Specifications for Mega 400-V S0203065K…………………………………………………………… 0
Component Locations…………………………………………………………………………. 52
General Specifications………………………………………………………………………. 54
Working Range and Dimensions…………………………………………………………………. 58
Working Capacities………………………………………………………………………….. 61
Bucket Capacity…………………………………………………………………………. 61
Tipping Load……………………………………………………………………………. 61
Material Weight…………………………………………………………………………….. 61
Approximate Weight of Workload Materials…………………………………………………… 61
General Maintenance………………………………………………………………………………… 65
General Maintenance Procedures S0302000…………………………………………………………… 0
Welding Precautions and Guidelines……………………………………………………………. 69
Hydraulic System  General Precautions………………………………………………………… 70
Maintenance Service and Repair Procedure………………………………………………………. 71
General Precautions……………………………………………………………………… 71
Hydraulic System Cleanliness and Oil Leaks…………………………………………………….. 72
Maintenance Precautions for Hydraulic System Service………………………………………… 72
Oil Leakage Precautions………………………………………………………………….. 72
Cleaning and Inspection……………………………………………………………………… 73
General Guidelines………………………………………………………………………. 73
Bearing inspection………………………………………………………………………. 74
Standard Torques S0309000……………………………………………………………………….. 0
Torque Values for Standard Metric Fasteners……………………………………………………. 83
Torque Values for Standard U.S. Fasteners……………………………………………………… 84
Type 8 Phosphate Coated Hardware……………………………………………………………… 86
Torque Values for Hose Clamps………………………………………………………………… 87
Torque Values for Split Flanges………………………………………………………………. 88
Torque Wrench Extension Tools………………………………………………………………… 89
Torque Multiplication……………………………………………………………………. 89
Other Uses for Torque Wrench Extension Tools……………………………………………….. 90
Tightening Torque Specifications (Metric)………………………………………………….. 90
Upper Structure……………………………………………………………………………………. 93
Counterweight S0403030K…………………………………………………………………………. 0
Specifications……………………………………………………………………………… 97
Counterweight………………………………………………………………………………. 97
Fuel Transfer Pump S0405500……………………………………………………………………… 0
General Description………………………………………………………………………….101
Theory of Operation………………………………………………………………………101
Troubleshooting……………………………………………………………………………..102
Replacement of Rotor and Vane…………………………………………………………………102
Replacement of Rear Cover…………………………………………………………………….103
Replacement of Armature………………………………………………………………………104
Hydraulic Oil Tank S0406030K…………………………………………………………………….. 0
General Description………………………………………………………………………….107
Parts List………………………………………………………………………………107
Specifications…………………………………………………………………………..108
Lower Structure and Chassis………………………………………………………………………….109
Center Joint (Articulation Joint) S0502010K……………………………………………………….. 0
General Description………………………………………………………………………….113
Maintenance Standard……………………………………………………………………..114
Engine and Drive Train………………………………………………………………………………117
Front Axle (ZF – MT-L 3105) S0602230C…………………………………………………………….. 0
General Description………………………………………………………………………….123
Outline…………………………………………………………………………………123
Drive Axle………………………………………………………………………………123
Differential…………………………………………………………………………….126
Axle Hub Section…………………………………………………………………………128
Axle Differential Section…………………………………………………………………129
Lubrication Instructions………………………………………………………………….130
Make Wear Measurement on Multidisk Brake……………………………………………………132
Inscriptions on Model Identification Plate………………………………………………….133
Torque Limits for Screws………………………………………………………………….134
Examples of Gear Tooth Contact Patterns for the Gleason Geartooth System………………………135
Special Tool………………………………………………………………………………..138
List of Special Tools for Disassembly and Reassembly…………………………………………138
ZF  Multitrac Rigid Axle MTL 3095……………………………………………………………148
Disassembly of Output and Brake……………………………………………………………148
Reassembly of Output and Brake…………………………………………………………….158
Disassembly of Differential Carrier and Brake Tubes………………………………………….171
Reassembly of Oil Pipes and Differential Carrier…………………………………………….181
Parking Brake……………………………………………………………………………….200
Functional Characteristics and Maintenance Instructions for Spring Loaded Sliding Caliper Brakes….200
1. Functional Characteristics of Spring Loaded Sliding Caliper Brakes………………………….200
2. Mounting and Basic Setting Regulations…………………………………………………..201
3. Adjusting Regulations………………………………………………………………….201
4. Emergency Release of Parking Brake………………………………………………………202
5. Maintenance and Repair Work…………………………………………………………….202
6. General………………………………………………………………………………204
Rear Axle (ZF – MT-L 3095) S0602240C……………………………………………………………… 0
General Description………………………………………………………………………….209
Outline…………………………………………………………………………………209
Drive Axle………………………………………………………………………………209
Differential (Standard)…………………………………………………………………..212
Lubrication Instructions………………………………………………………………….214
Make Wear Measurement on Multidisk Brake……………………………………………………216
Inscriptions on Model Identification Plate………………………………………………….217
Torque Limits for Screws………………………………………………………………….218
Examples of Gear Tooth Contact Patterns for the Gleason Geartooth System………………………219
Special Tool………………………………………………………………………………..222
List of Special Tools for Disassembly and Reassembly…………………………………………222
ZF  Multitrac Rigid Axle MTL 3095……………………………………………………………232
Disassembly of Output and Brake……………………………………………………………232
Reassembly of Output and Brake…………………………………………………………….242
Disassembly of Differential Carrier and Brake Tubes………………………………………….255
Reassembly of Brake Tubes and Differential Carrier…………………………………………..264
Air Conditioner S0605050K……………………………………………………………………….. 0
Refrigerant Circulation………………………………………………………………………284
Control Panel……………………………………………………………………………….286
Control Specifications……………………………………………………………………….287
Temperature Level Control and Display………………………………………………………….288
Air Discharge According to Path Selection………………………………………………………289
Airconditioning System Circuit Diagram………………………………………………………..292
Troubleshooting……………………………………………………………………………..294
Weight of R134a Gas Used In Machines…………………………………………………………..298
Refrigerant System Repairs……………………………………………………………………300
Refrigerant Safe Handling Procedures……………………………………………………….300
Repair and Replacement Procedure…………………………………………………………..301
Refrigerant Recovery……………………………………………………………………..303
Vacuuming Refrigerant System………………………………………………………………303
Leakage Check……………………………………………………………………………305
Refrigerant Charging……………………………………………………………………..305
Inspecting System for Leakage……………………………………………………………..307
Transmission and Torque Converter (ZF4WG260) S0607070K……………………………………………. 0
Drive Train Description………………………………………………………………………313
Transmission and Torque Converter……………………………………………………………..314
Powershift Transmission…………………………………………………………………..315
Transmission Control……………………………………………………………………..315
Schedule of Measuring Points and Connection 4 WG260…………………………………………316
Oil Circuit Diagram 4WG  260 Forward 1st Speed……………………………………………..319
Transmission Electric Components………………………………………………………………321
TCU (Transmission Control Unit)……………………………………………………………322
Transmission Control Valve………………………………………………………………..322
Transmission Oil Temperature Sensor………………………………………………………..322
Engine Pickup Sensor……………………………………………………………………..323
Central Gear Pickup Sensor………………………………………………………………..323
Turbine Pickup Sensor…………………………………………………………………….323
Output Speed Sensor………………………………………………………………………324
Shift Lever Switch (DW3)…………………………………………………………………324
Auto Selector Switch……………………………………………………………………..326
Display…………………………………………………………………………………326
Transmission Faults Codes…………………………………………………………………….327
Fault Display……………………………………………………………………………327
CAN  Message……………………………………………………………………………327
Description of Fault Codes………………………………………………………………..327
Abbreviations……………………………………………………………………………328
Definition of Operation Modes……………………………………………………………..328
Table of Fault Codes……………………………………………………………………..329
Measurement of Resistance at Actuator/sensors and Cable………………………………………329
Transmission Electrical Circuits………………………………………………………………330
T/M Controller Circuit……………………………………………………………………330
Traveling Circuits……………………………………………………………………….331
Downshift……………………………………………………………………………….339
Transmission Cutoff………………………………………………………………………342
LIS (Load Isolation System)  Option……………………………………………………….343
Installation View……………………………………………………………………………344
Inner Section……………………………………………………………………………344
Front View………………………………………………………………………………346
Side View……………………………………………………………………………….347
Rear View……………………………………………………………………………….348
Hydraulic Control Unit (HSG94)……………………………………………………………….349
Disassembly……………………………………………………………………………..350
Reassembly………………………………………………………………………………353
Transmission Disassembly……………………………………………………………………..360
Converter Input………………………………………………………………………….360
Drive Shaft Pump Power Takeoff……………………………………………………………363
Transmission Pump………………………………………………………………………..365
Output Layshaft Assembly…………………………………………………………………365
Disassemble Clutches and Layshaft Gear……………………………………………………..370
Disassemble Power Takeoff II……………………………………………………………..371
Disassemble Clutches……………………………………………………………………..372
Transmission Reassembly………………………………………………………………………381
Power Takeoff II………………………………………………………………………..381
Clutch K3/K4…………………………………………………………………………….383
Clutch KR/K2…………………………………………………………………………….394
Clutch  KV/K1…………………………………………………………………………..402
Install Multidisk Clutches, Layshaft Gear and Output Gear…………………………………….410
Install Filter…………………………………………………………………………..425
Hydraulic Pump…………………………………………………………………………..425
Drive Shaft (Power Takeoff Pump)………………………………………………………….427
Input  Converter………………………………………………………………………..431
Converter……………………………………………………………………………….436
Mount Hydraulic Control Unit (HSG94)………………………………………………………437
Inductive Transmitter and Speed Sensor……………………………………………………..440
Setting Inductive Transmitter……………………………………………………………..442
Speed Sensor (Hall Sensor) N Output and Speedometer………………………………………….444
Transmission Error Codes (ZF) S0607900C…………………………………………………………… 0
Introduction………………………………………………………………………………..448
Abbreviations……………………………………………………………………………….448
Display…………………………………………………………………………………….448
Description of Fault Codes………………………………………………………………..449
Display During Operation……………………………………………………………………..450
Definition of Operating Modes…………………………………………………………………452
Normal………………………………………………………………………………….452
Substitute Clutch Control…………………………………………………………………452
Limphome……………………………………………………………………………….452
Transmission shut Down……………………………………………………………………452
TCU Shut Down……………………………………………………………………………452
Clutch Pack and Solenoid Valve Crossreference Table…………………………………………….453
Table of Fault Codes…………………………………………………………………………454
Table of Fault Codes  ERGOControl……………………………………………………………476
Measurement of Resistance at Actuator/ sensors and Cable…………………………………………479
Actuator………………………………………………………………………………..479
Cable…………………………………………………………………………………..479
Hydraulics…………………………………………………………………………………………481
Accumulator S0703000……………………………………………………………………………. 0
General Description………………………………………………………………………….485
Specifications…………………………………………………………………………..486
Accumulator Charging…………………………………………………………………………489
Charging the Accumulator with Nitrogen……………………………………………………..489
Cylinders S0705010……………………………………………………………………………… 0
General Description………………………………………………………………………….493
Theory of Operation………………………………………………………………………494
Parts List………………………………………………………………………………495
Troubleshooting, Testing and Adjustment………………………………………………………..497
Disassembly…………………………………………………………………………………501
Cleaning and Inspection (Wear Limits and Tolerances)…………………………………………….503
Reassembly………………………………………………………………………………….504
Fan Drive Hydraulic Motor (Haldex) S0707100K………………………………………………………. 0
General Description………………………………………………………………………….515
Theory of Operation………………………………………………………………………515
Parts List………………………………………………………………………………517
Specifications…………………………………………………………………………..518
Main Pump (Denison T6DMY Series) S0708460K………………………………………………………… 0
General Description………………………………………………………………………….521
Construction…………………………………………………………………………….521
Principles of Operation…………………………………………………………………..523
Parts List………………………………………………………………………………530
Specifications…………………………………………………………………………..531
Special Tools and Materials…………………………………………………………………..532
Special Tools……………………………………………………………………………532
Troubleshooting, Testing and Adjustment………………………………………………………..533
Disassembly…………………………………………………………………………………535
Cleaning and Inspection (Wear Limits and Tolerances)…………………………………………….539
Reassembly………………………………………………………………………………….540
Startup Procedures………………………………………………………………………….543
Steering and Brake Pump (Denison T67DB Series) S0708470K……………………………………………. 0
General Description………………………………………………………………………….547
Parts List………………………………………………………………………………548
Special Tools……………………………………………………………………………….550
Troubleshooting, Testing and Adjustment………………………………………………………..551
Service and Maintenance………………………………………………………………………552
Circuit Inspection……………………………………………………………………….552
Adding Hydraulic Oil to System…………………………………………………………….552
Adjustments……………………………………………………………………………..552
Lubrication……………………………………………………………………………..552
Replacement Parts………………………………………………………………………..553
Disassembly…………………………………………………………………………………554
Basic Pump Disassembly……………………………………………………………………556
Cartridge Disassembly…………………………………………………………………….557
Cleaning and Inspection (Wear Limits and Tolerances)…………………………………………….560
Cleaning………………………………………………………………………………..560
Inspection, Repair and Replacement…………………………………………………………560
Reassembly………………………………………………………………………………….562
Cartridge Assembly……………………………………………………………………….563
Basic Pump Assembly………………………………………………………………………566
Startup Procedures………………………………………………………………………….567
Startup………………………………………………………………………………..567
Test……………………………………………………………………………………567
Brake Pedal Valve S0709231K……………………………………………………………………… 0
General Description………………………………………………………………………….571
Theory of Operation………………………………………………………………………571
Specification……………………………………………………………………………572
Main Control Valve (Toshiba) S0709455K……………………………………………………………. 0
General Description………………………………………………………………………….579
Specifications………………………………………………………………………………581
Operation…………………………………………………………………………………..582
Neutral…………………………………………………………………………………582
Bucket/option Spool Operation……………………………………………………………..582
Boom Spool Operation……………………………………………………………………..583
Relief Valve…………………………………………………………………………….583
Operation (Main Relief Valve)……………………………………………………………..584
Operation (Port Relief Valve)……………………………………………………………..585
Pilot Control Valve S07094755K…………………………………………………………………… 0
General Description………………………………………………………………………….605
Pilot Valve Operation…………………………………………………………………….605
Pilot System………………………………………………………………………………..608
Flow Amplifier (Danfoss) S0709665K……………………………………………………………….. 0
General Description………………………………………………………………………….613
Parts List………………………………………………………………………………614
Specifications…………………………………………………………………………..615
Special Tools and Materials…………………………………………………………………..616
Special tools……………………………………………………………………………616
Troubleshooting, Testing and Adjustment………………………………………………………..617
Steering System with OSQA/B and OSPBXLS……………………………………………………618
Disassembly…………………………………………………………………………………619
Cleaning and Inspection (Wear Limits and Tolerances)…………………………………………….639
Cleaning………………………………………………………………………………..639
Inspection and replacement………………………………………………………………..639
Lubrication……………………………………………………………………………..639
Reassembly………………………………………………………………………………….639
Power Steering Unit S0709730K……………………………………………………………………. 0
General Description………………………………………………………………………….661
Power Steering System…………………………………………………………………….661
Gerotor Operation………………………………………………………………………..663
Cushion Valve Operation…………………………………………………………………..664
Parts List………………………………………………………………………………666
Specifications…………………………………………………………………………..667
Special Tools……………………………………………………………………………….668
Troubleshooting, Testing and Adjustment………………………………………………………..670
Disassembly…………………………………………………………………………………671
Cleaning and Inspection………………………………………………………………………675
Reassembly………………………………………………………………………………….676
Installation………………………………………………………………………………..687
Unloader Valve S0709851K………………………………………………………………………… 0
General Description…………………………………………………………………………. 0
Specifications…………………………………………………………………………..694
Hydraulic Schematic (Mega 400V) S0793050K………………………………………………………… 0
General Description………………………………………………………………………….697
Mega 400V (S/N 1001 thru 3000)……………………………………………………………….698
Mega 400V (S/N 3001 and Up)………………………………………………………………….700
Electrical System…………………………………………………………………………………..703
Electrical System S0802185K……………………………………………………………………… 0
Overview……………………………………………………………………………………707
Electric Supply System……………………………………………………………………….708
Engine Starting Circuit………………………………………………………………………710
Operation During Start Process…………………………………………………………….710
Operation After Start Process……………………………………………………………..712
Engine Preheating System……………………………………………………………………..713
Engine Stop System…………………………………………………………………………..716
Operation In Engine Running Mode…………………………………………………………..716
Operation In Engine Stop Mode……………………………………………………………..718
Charging System……………………………………………………………………………..720
Monitoring System……………………………………………………………………………721
Instrument Panel…………………………………………………………………………722
Function Check…………………………………………………………………………..723
Monitoring System Schematic……………………………………………………………….724
Operation……………………………………………………………………………….726
Windshield Wiper…………………………………………………………………………….732
Front windshield wiper……………………………………………………………………732
Rear Windshield wiper…………………………………………………………………….733
Lighting System……………………………………………………………………………..736
Light Circuit……………………………………………………………………………736
Emergency Steering System (Option)…………………………………………………………….739
Block Diagram……………………………………………………………………………739
Emergency Steering System Components……………………………………………………….740
Emergency Steering System Electric Circuit………………………………………………….742
Electric Detent System……………………………………………………………………….743
Electric Circuit…………………………………………………………………………743
Boom Kickout……………………………………………………………………………743
Return To Dig……………………………………………………………………………744
Electrical Schematic (Mega 400V) S0893050K……………………………………………………….. 0
General Description………………………………………………………………………….747
Mega 400V………………………………………………………………………………….748
Attachments………………………………………………………………………………………..751

Contact us: [email protected]

IMAGES PREVIEW OF THE MANUAL:

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]

S.M