service repair manual download

1. 023-00092E Shop Manual
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.
Shop Manual
023-00092E
Serial Number 3001 and Up
Mega 400-V

2. Table of Contents
Page 1
1TABLE OF CONTENTS
Safety
Wheel Loader Safety .......................................................................... S0103020K
Specifications
Specifications for Mega 400-V............................................................ S0203065K
General Maintenance
General Maintenance Procedures.........................................................S0302000
Standard Torques..................................................................................S0309000
Upper Structure
Counterweight..................................................................................... S0403030K
Fuel Transfer Pump...............................................................................S0405500
Hydraulic Oil Tank .............................................................................. S0406030K
Lower Structure and Chassis
Center Joint (Articulation Joint)........................................................... S0502010K
Engine and Drive Train
Front Axle (ZF - MT-L 3105)............................................................... S0602230C
Rear Axle (ZF - MT-L 3095)................................................................ S0602240C
Air Conditioner.................................................................................... S0605050K
Transmission and Torque Converter (ZF 4WG-260).......................... S0607070K
Transmission Error Codes (ZF) .......................................................... S0607900C
Hydraulics
Accumulator...........................................................................................S0703000
Cylinders................................................................................................S0705010
Fan Drive Hydraulic Motor (Haldex) ................................................... S0707100K
Main Pump (Denison T6DMY Series)................................................. S0708460K

3. Table of Contents
Page 2
Steering and Brake Pump (Denison T67DB Series)........................... S0708470K
Brake Pedal Valve .............................................................................. S0709231K
Main Control Valve (Toshiba) ............................................................. S0709455K
Pilot Control Valve ............................................................................ S07094755K
Flow Amplifier (Danfoss)..................................................................... S0709665K
Power Steering Unit............................................................................ S0709730K
Unloader Valve ................................................................................... S0709851K
Hydraulic Schematic (Mega 400-V).................................................... S0793050K
Electrical System
Electrical System ................................................................................ S0802185K
Electrical Schematic (Mega 400-V) .................................................... S0893050K
Attachments

4. S0602230C
Page 30
Front Axle (ZF - MT-L 3105)
ZF - MULTITRAC RIGID AXLE MT-L 3095
DISASSEMBLY OF OUTPUT AND BRAKE
1. Fasten axle on assembly truck.
(S) Assembly truck 5870 350 000
(S) Holding fixtures 5870 350 077
(S) Clamps 5870 350 075
2. Remove drain plugs (3x, Figure 17 and
Figure 18) and drain oil from axle casing.
Figure 16
Figure 17
Figure 18

5. S0602230C
Page 31
Front Axle (ZF - MT-L 3105)
3. Remove cover from output shaft.
(S) Pry bar set 5870 345 065
4. Remove slotted pin using striker (S) from
bore in slotted nut.
(S) Striker 5870 650 001
5. Remove slotted nut.
(S) Socket spanner
(S) Centering bracket
6. Secure output using lifting tackle (S) and
remove hexagon screws.
(S) Lifting bracket 5870 281 043
Figure 19
Figure 20
Figure 21
Figure 22

6. S0602230C
Page 32
Front Axle (ZF - MT-L 3105)
7. Separate complete output from axle
casing.
NOTE: Pay attention to released O-ring
(see arrow).
8. Remove stub shaft from sun gear shaft.
NOTE: Pay attention too possibly
released shim(s).
9. Remove shim(s) from sun gear shaft.
10. Remove sun gear shaft from planet gears.
Figure 23
Figure 24
Figure 25
Figure 26

7. S0602230C
Page 33
Front Axle (ZF - MT-L 3105)
11. Lift planet carrier from brake housing.
(S) Internal extractor 5870 300 019
12. Remove retaining ring.
(S) Set of external pliers 5870 900 015
13. Remove planet gear and remove released
inner bearing race.
(S) Three-armed puller 5873 971 002
14. Remove inner bearing race.
(S) Gripping insert 5873 001 020
(S) Basic set 5873 001 000
Figure 27
Figure 28
Figure 29
Figure 30

8. S0602230C
Page 34
Front Axle (ZF - MT-L 3105)
15. Separate ring gear from brake housing
using two-armed puller (S).
(S) Two-armed puller 5870 970 007
16. Remove O-rings (see arrows) from annular
grooves of ring gear.
17. Remove O-ring (see arrow) from recess of
brake housing.
18. Remove disk pack from brake housing.
Figure 31
Figure 32
Figure 33
Figure 34

9. S0602230C
Page 35
Front Axle (ZF - MT-L 3105)
19. Install slotted pins (6x) in support shim
until they are flush mounted.
20. Remove retaining ring.
(S) Set of external pliers 5870 900 016
21. Remove piston from brake housing using
compressed air.
22. Remove support shim from piston using
automatic piston adjusting.
Figure 35
Figure 36
Figure 37
Figure 38

10. S0602230C
Page 36
Front Axle (ZF - MT-L 3105)
23. Remove slotted pins (6x) from support
shim.
24. Preload cup springs using a press and
remove retaining ring.
(S) Assembly pliers 5870 900 051
(S) Assembly fixture 5870 345 096
25. Remove pin from support shim and
remove released cup springs.
26. Press gripping rings from pin.
Figure 39
Figure 40
Figure 41
Figure 42

11. S0602230C
Page 37
Front Axle (ZF - MT-L 3105)
27. Lift piston from brake housing.
(S) Adjusting device 5870 400 001
28. Remove guide ring, support rings and
U-rings from annular grooves of brake
housing.
NOTE: See Figure 45, for installation
position of single parts.
Reference
Number
Description
1 Brake housing
2 Guide ring
3 Support ring
4 U-ring
5 U-ring
6 Support ring
7 Output shaft
Figure 43
Figure 44
Figure 45

12. S0602230C
Page 38
Front Axle (ZF - MT-L 3105)
29. Remove brake housing using two-armed
puller (S) from output shaft and remove
released inner bearing race.
(S) Two-armed puller 5870 970 007
(S) Clamping bracket 5870 654 034
(S) Press bush 5870 506 140
30. Lift brake housing with lifting tackle (S)
from output shaft.
(S) Lifting chain 5870 281 047
(S) Eyebolts 5870 204 071
31. If necessary drive both outer bearing races
from bearing bores in brake housing.
32. Press shaft seal out of brake housing.
(S) Pry bar set 5870 345 065
Figure 46
Figure 47
Figure 48
Figure 49

13. S0602230C
Page 39
Front Axle (ZF - MT-L 3105)
33. Remove inner bearing race from output
shaft.
(S) Rapid grip 5873 014 011
(S) Basic set 5873 004 001
34. Remove bearing sheet from output shaft.
(S) Pry bar set 5870 345 065
Figure 50
Figure 51

14. S0602230C
Page 40
Front Axle (ZF - MT-L 3105)
REASSEMBLY OF OUTPUT AND BRAKE
1. Insert wheel bolt into output shaft until
seated.
(S) Wheel bolt puller - basic set 5870 610
010
(S) Insert (7/8" - 14 UNF) 5870 610 011
2. Assemble bearing sheet (shaft seal / Part
2).
3. Press bearing sheet over collar of output
shaft.
(S) Pressure ring 5870 506 141
NOTE: The exact installation position
of bearing sheet will be
obtained by using specified
pressure ring.
4. Heat roller bearing and install it until
seated.
NOTE: After cooling down bearing. it
has to be installed
subsequently.
Figure 52
Figure 53
Figure 54
Figure 55

15. S0602230C
Page 41
Front Axle (ZF - MT-L 3105)
5. Press both outer bearing races into brake
housing until seated.
6. Install shaft seal with sealing lip showing to
oil chamber, see Figure 58.
(S) Driver 5870 051 052
NOTE: The exact installation position
of shaft seal will be obtained by
using specified driver (S).
NOTE: Just before installation, wet
outer diameter of shaft seal with
mineral spirits.
NOTE: Fill space between sealing and
dust lips with grease.
7. Install preassembled brake housing using
lifting tackle (S) over output shaft until
seated.
(S) Lifting chain 5870 281 047
(S) Eyebolts 5870 204 071
Reference
Number
Description
1 Shaft seal
2 Brake housing
* Grease filling
Figure 56
Figure 57
Figure 58
Figure 59

16. S0602230C
Page 42
Front Axle (ZF - MT-L 3105)
8. Heat roller bearing and install it until
seated.
9. Insert support and U-rings into annular
grooves of brake housing.
NOTE: Pay attention to installation
position, see Figure 62.
Reference
Number
Description
1 Brake housing
2 Guide ring
3 Support ring
4 U-ring
5 U-ring
6 Support ring
7 Output shaft
Figure 60
Figure 61
Figure 62

17. S0602230C
Page 43
Front Axle (ZF - MT-L 3105)
10. Clean annular groove of brake housing
with mineral spirits.
Then insert guide ring into annular groove
(also see Figure 62) and secure with
Loctite #415 at its extremities.
NOTE: Guide ring must have contact
on whole circumference.
NOTE: Upon installation orifice of
guide ring must show upwards
(12 o'clock).
11. Insert piston into brake housing and install
it cautiously until seated.
NOTE: Apply sufficiently oil on sliding
surface of piston or support
rings, U-rings and guide ring
(use W-10 oils).
12. Insert pins into assembly fixture (S) until
seated.
(S) Assembly fixture 5870 345 096
13. Press gripping rings (4x, see arrows) onto
pins until seated on assembly fixture (S).
NOTE: The exact installation
dimension (see Figure 68) of
gripping rings is obtained when
using specified assembly
fixture.
NOTE: Observe installation position,
install gripping rings with
orifices offset by 180° to each
other.
Figure 63
Figure 64
Figure 65
Figure 66

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19. S0602230C
Page 44
Front Axle (ZF - MT-L 3105)
14. Install cup springs (7 pieces each / pin).
NOTE: Pay attention to installation
position of cup springs, see
Figure 68.
15. Insert preassembled pins into support
shim and secure using retaining ring.4
(S) Assembly pliers 5870 900 051
NOTE: Pay attention to clearance of
cup springs.
16. Insert preassembled support shim into
piston.
Reference
Number
Description
1 Pin
2 Gripping rings
3 Cup springs
4 Support shim
5 Retaining Ring
X Installation dimension
Gripping rings 10.5
+0.3
mm
Figure 67
Figure 68
Figure 69
Figure 70

20. S0602230C
Page 45
Front Axle (ZF - MT-L 3105)
17. Install support shim using retaining ring.
18. Drive slotted pins (6x) into bores of
support shim to lock retaining ring.
(S) Drive mandrel 5870 705 011
NOTE: Pay attention to installation
position, see Figure 73.
19. Drive stop bolt into planet carrier until
seated.
Then wet spline with anticorrosive Weicon
Anti Size (ZF Part Number: 0671 196 001)
(see arrow).
Reference
Number
Description
1 Brake housing
2 Retaining Ring
3 Slotted pin
4 Support shim
5 Piston
X Installation dimension
4.0 - 0.5 mm
Figure 71
Figure 72
Figure 73
Figure 74

21. S0602230C
Page 46
Front Axle (ZF - MT-L 3105)
20. Insert planet carrier into spline of output
shaft until seated.
21. Install outer and inner clutch disks
alternately starting with an outer clutch
disk.
NOTE: Oil clutch disks according to ZF
List of Lubricants TE-ML 05.
22. Insert O-ring (see arrow) into recess of
brake housing.
23. Grease both O-rings (see arrows) and
insert them into annular grooves of ring
gear.
Figure 75
Figure 76
Figure 77
Figure 78