service repair manual

1. 023-00040E 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
023-00040E
Serial Number 1001 and Up
February 2001
Mega 400-V

2. Table of Contents
Page 1
1TABLE OF CONTENTS
Return to Master Table of Contents
Safety
Wheel Loader Safety .......................................................................... S0103010K
Specifications
Specifications for Mega 400-V............................................................ S0203060K
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 ........................................................................................... S0602150K
Rear Axle............................................................................................ S0602160K
Air-Conditioner.................................................................................... S0605050K
Transmission and Torque Converter (ZF) .......................................... S0607070K
Transmission Error Codes (ZF) .......................................................... S0607900C
Hydraulics
Accumulator...........................................................................................S0703000
Cylinders................................................................................................S0705010
Fan Drive Hydraulic Motor (Haldex) ................................................... S0707100K

3. Table of Contents
Page 2
Main Pump (Denison T6DMY Series)................................................. S0708460K
Steering and Brake Pump (Denison T67DB Siries)............................ S0708470K
Brake Pedal Valve .............................................................................. S0709230K
Main Control Valve (Toshiba) ............................................................. S0709455K
Pilot Control Valve .............................................................................. S0709475K
Flow Amplifier (Danfoss)..................................................................... S0709665K
Power Steering Unit............................................................................ S0709730K
Unloader Valve ................................................................................... S0709850K
Hydraulic Schematic (Mega 400-V).................................................... S0793050K
Electrical System
Electrical System ................................................................................ S0802180K
Electrical Schematic (Mega 400-V) .................................................... S0893050K
Attachments

4. S0607070K
Page 50
Transmission and Torque Converter (ZF)
Return to Master Table of Contents
TRANSMISSION DISASSEMBLY
1. Fasten transmission on an appropriate
support stand.
2. Disassemble complete shift control,
remove pressure lines and duct plate.
CONVERTER-INPUT
1. Separate torque converter from
transmission, using lifting device.
Figure 71
Figure 72
Figure 73

5. S0607070K
Page 51
Transmission and Torque Converter (ZF)
Return to Master Table of Contents
2. Loosen screw connection.
3. Separate bearing cover from converter
bell, using three jacking screws.
4. Pull oil feed flange out of converter bell,
using special device (S).
5. Remove converter safety valve (composed
of ball, spring and disk.).
6. Separate converter bell from gearbox
housing, using lifting device and pry bar.
Figure 74
Figure 75
Figure 76
Figure 77

6. S0607070K
Page 52
Transmission and Torque Converter (ZF)
Return to Master Table of Contents
7. Remove shim.
8. Remove rectangular ring (Figure 79).
9. Press drive shaft out of spur gear bearing.
Remove released inner bearing race and
spur gear.
10. If necessary, drive outer bearing race out
of housing bores.
11. Press inner bearing race from drive shaft.
Figure 78
Figure 79
Figure 80
Figure 81

7. S0607070K
Page 53
Transmission and Torque Converter (ZF)
Return to Master Table of Contents
12. Remove converter pressure valve.
DRIVE SHAFT PUMP POWER TAKE-OFF
1. Pull complete drive shaft out of gearbox
housing (pump).
2. Remove rectangular ring (Figure 84).
3. Separate spur gear from shaft and remove
snap ring (Figure 85).
Figure 82
Figure 83
Figure 84
Figure 85

8. S0607070K
Page 54
Transmission and Torque Converter (ZF)
Return to Master Table of Contents
4. Pull inner bearing race from spur gear.
5. Loosen socket head screw and remove it
along with clamping plate.
6. Pull inner bearing race and drive from
shaft.
NOTE: Support puller on end face/
drive shaft. Pay attention to
released shims.
7. Separate inner bearing race from driver.
NOTE: Pay attention to released shim.
8. Remove snap rings (3x).
Figure 86
Figure 87
Figure 88
Figure 89

9. S0607070K
Page 55
Transmission and Torque Converter (ZF)
Return to Master Table of Contents
TRANSMISSION PUMP
1. Tilt gearbox housing 180°.
2. Loosen hex. head screws and remove both
pump flanges.
3. Loosen socket head screws (M8) and
position Puller device (s).
4. Pull transmission pump out of housing
bore.
NOTE: Tapping housing face is a help
during extraction operation.
OUTPUT- LAYSHAFT ASSEMBLY
1. Loosen screw connection and remove
brake caliper.
2. Unlock and loosen hex. head screws, tap
brake disk loose and separate it from
output shaft.
Figure 90
Figure 91
Figure 92
Figure 93

10. S0607070K
Page 56
Transmission and Torque Converter (ZF)
Return to Master Table of Contents
3. Pry shaft seal out of housing bore.
4. Tilt gearbox housing.
5. Remove sealing covers (Figure 95).
6. Loosen hex. head screws.
7. Pull idler shaft by means of puller out of
housing bore.
Figure 94
Figure 95
Figure 96
Figure 97

11. S0607070K
Page 57
Transmission and Torque Converter (ZF)
Return to Master Table of Contents
8. Tilt gearbox housing 180°.
9. Loosen hex. head screws and pull bearing
cover -K1/KV out of housing bore.
10. Loosen hex. head screws and remove
bearing cover KR/K2 and K3/K4.
11. Remove rectangular rings (3 pieces/axle),
see Figure 100.
12. Remove snap ring and remove released
washers.
Figure 98
Figure 99
Figure 100
Figure 101

12. S0607070K
Page 58
Transmission and Torque Converter (ZF)
Return to Master Table of Contents
13. Support output flange against gearbox
housing, see Figure 102.
14. Loosen hex. head screws and separate
housing cover from gearbox housing,
using forcing screws and lifting device.
15. Unlock and loosen hex. head screws.
16. Remove output flange and pry shaft seal
out of housing.
17. Loosen hex. head screws and remove oil
baffle.
Figure 102
Figure 103
Figure 104
Figure 105

13. S0607070K
Page 59
Transmission and Torque Converter (ZF)
Return to Master Table of Contents
18. Remove output gear along with shaft.
19. Separate output shaft from spur gear.
20. Pull inner bearing race from output gear.
21. Remove plate.
Figure 106
Figure 107
Figure 108
Figure 109

14. S0607070K
Page 60
Transmission and Torque Converter (ZF)
Return to Master Table of Contents
22. Drive roller bearing out of housing bore
and remove it.
DISASSEMBLE CLUTCHES AND LAYSHAFT
GEAR
1. Remove clutches - K3/K4, KR/K2 and KV/
K1- by means of lifting device.
NOTE: At the removal of the clutch -
K3/K4, displace clutch - KR/K2
in direction of arrow (Figure
111).
2. Illustration on right shows clutches in
removed condition.
3. Remove layshaft gear.
Figure 110
Figure 111
Figure 112
Figure 113

15. S0607070K
Page 61
Transmission and Torque Converter (ZF)
Return to Master Table of Contents
DISASSEMBLE POWER TAKE-OFF II
1. Remove snap ring and remove shim(s).
2. Pull PTO shaft by means of internal puller
out of housing bore until outer bearing
race is released.
3. Take shaft out of housing.
4. Pull inner bearing race from shaft (Figure
117).
5. Press opposite inner bearing race from
shaft.
NOTE: Separation of shaft and gear is
not possible.
Figure 114
Figure 115
Figure 116
Figure 117

16. S0607070K
Page 62
Transmission and Torque Converter (ZF)
Return to Master Table of Contents
DISASSEMBLE CLUTCHES
Clutch - K3/K4
1. Remove three rectangular rings (Figure
118).
2. Loosen slotted nut.
NOTE: Slotted nut is secured with
Loctite.
To prevent damage of thread,
heat slotted nut prior to loosen
it (about 120°C (248°F)).
3. Pull off taped roller bearing.
4. Removed flanged disk.
Figure 118
Figure 119
Figure 120
Figure 121

17. S0607070K
Page 63
Transmission and Torque Converter (ZF)
Return to Master Table of Contents
5. Remove upper roller bearing.
6. Remove angle ring, snap ring, and thrust
ring.
7. Press spur gear K3 from plate carrier and
remove released roller bearing.
8. Remove split ring.
Figure 122
Figure 123
Figure 124
Figure 125

18. S0607070K
Page 64
Transmission and Torque Converter (ZF)
Return to Master Table of Contents
9. Remove snap ring and remove compl.
Plate pack K3.
10. Tilt clutch 180°.
11. Loosen slotted nut.
NOTE: Slotted nut is secured with
Loctite. To prevent damage of
thread, heat slotted nut prior to
loosen it (about 120°C (248°F)).
12. Pull off tapered roller bearing.
13. Pull spur gear from plate carrier.
Figure 126
Figure 127
Figure 128
Figure 129

19. S0607070K
Page 65
Transmission and Torque Converter (ZF)
Return to Master Table of Contents
14. Remove oil feed ring and pull ball bearing
from plate carrier.
15. Remove snap ring and remove compl.
plate pack - K4.
16. Preload compression spring by means of
special device (S). Remove snap ring
(Figure 132) and released components.
17. Now, separate piston from plate carrier,
using compressed air.
18. Disassemble opposite piston accordingly.
Clutch - KR/K2
1. Locate clutch by means of Special device
(s) and loosen slotted nut.
2. Loosen opposite slotted nut (Figure 133)
accordingly.
NOTE: The slotted nuts are secured
with Loctite heat prior to loosen
them.
Figure 130
Figure 131
Figure 132
Figure 133

20. S0607070K
Page 66
Transmission and Torque Converter (ZF)
Return to Master Table of Contents
3. Pull off tapered roller bearing.
4. Press spur gear K-2 from shaft.
5. Remove released shim and bush.
6. Pull off tapered roller bearing.
7. On opposite side, pull off tapered roller
bearing.
Figure 134
Figure 135
Figure 136
Figure 137

21. S0607070K
Page 67
Transmission and Torque Converter (ZF)
Return to Master Table of Contents
8. Pull spur gear KR from shaft.
9. Remove released inner bearing race,
disassemble both outer bearing races and
snap ring.
10. Remove adjusting ring.
11. Pull off tapered bearing (spur gear
bearing).
12. Disassemble plate packs KR and K2 as
well as compression springs and piston
(accordingly as at clutch K3/K4.
Figure 138
Figure 139
Figure 140
Figure 141

22. Thank you very much for
your reading. Please Click
Here. Then Get COMPLETE
MANUAL. NO WAITING
NOTE:
If there is no response to
click on the link above,
please download the PDF
document first and then
click on it.

23. S0607070K
Page 68
Transmission and Torque Converter (ZF)
Return to Master Table of Contents
Clutch - KV/K1
1. Loosen slotted nut.
2. Loosen opposite slotted nut (Figure 142)
accordingly.
NOTE: The slotted nuts are secured
with Loctite and require heating
prior to loosen them.
3. Remove tapered roller bearing.
4. Remove shim.
5. Using a suitable puller remove spur gear
K1.
6. Now, remove snap ring and drive ball
bearing from spur gear bore.
Figure 142
Figure 143
Figure 144
Figure 145

24. S0607070K
Page 69
Transmission and Torque Converter (ZF)
Return to Master Table of Contents
7. Remove both rings.
8. Using a suitable puller second ball bearing
(spur gear bearing).
9. On opposite side, pull off tapered roller
bearing.
10. Pull spur gear KV from shaft.
11. Remove released inner bearing race,
disassemble both outer bearing race and
snap ring.
Figure 146
Figure 147
Figure 148
Figure 149

25. S0607070K
Page 70
Transmission and Torque Converter (ZF)
Return to Master Table of Contents
12. Remove adjusting ring.
13. Pull off tapered roller bearing (spur gear
bearing).
14. Now, remove plate pack KV and K1 as well
as compression springs and piston
(accordingly as at clutch K3/K4.
Figure 150
Figure 151