Daewoo Doosan Mega 400-V Wheel Loader Service Repair Manual (Serial Number 3001 and Up)

Mega 400-V

Shop Manual

023-00092E

Serial Number 3001 and Up

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.

023-00092E Shop Manual

Attachments

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.

S0602230C

Front Axle (ZF - MT-L 3105)

Figure 16

Figure 17

Figure 18

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

Front Axle (ZF - MT-L 3105)

S0602230C

Figure 19

Figure 20

Figure 21

Figure 22

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.

S0602230C

Front Axle (ZF - MT-L 3105)

10.Remove sun gear shaft from planet gears.

Figure 23

Figure 24

Figure 25

Figure 26

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

Front Axle (ZF - MT-L 3105)

S0602230C

Figure 27

Figure 28

Figure 29

Figure 30

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.

S0602230C

Front Axle (ZF - MT-L 3105)

Figure 31

Figure 32

Figure 33

Figure 34

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.

Front

S0602230C

Axle (ZF - MT-L 3105)

Figure 35

Figure 36

Figure 37

Figure 38

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.

S0602230C

Front Axle (ZF - MT-L 3105)

26.Press gripping rings from pin.

Figure 39

Figure 40

Figure 41

Figure 42

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.

Front Axle (ZF - MT-L 3105)

S0602230C

Figure 43

Figure 44

Figure 45

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

set 5870 345 065

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Front Axle (ZF - MT-L 3105)

bar

Figure 46

Figure 47

Figure 48

Figure 49

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

Front Axle (ZF - MT-L 3105)

S0602230C

Figure 50

Figure 51

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.

S0602230C

Front Axle (ZF - MT-L 3105)

Figure 52

Figure 53

Figure 54

Figure 55

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.

Reference Number Description

1Shaft seal

2Brake housing

*Grease filling

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

Front Axle (ZF - MT-L 3105)

S0602230C

Figure 56

Figure 57

Figure 58

Figure 59

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

1Brake housing

2Guide ring

3Support ring

4U-ring

5U-ring

6Support ring

7Output shaft

S0602230C

Front Axle (ZF - MT-L 3105)

Figure 60

Figure 61

Figure 62

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.

Front Axle (ZF - MT-L 3105)

S0602230C

Figure 63

Figure 64

Figure 65

Figure 66

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14.Install cup springs (7 pieces each / pin).

NOTE: Pay attention to installation position of cup springs, see Figure 68.

Reference Number Description

1Pin

2Gripping rings

3Cup springs

4Support shim

5Retaining Ring

XInstallation dimension Gripping rings 10.5 +0.3 mm

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.

S0602230C

Front Axle (ZF - MT-L 3105)

Figure 67

Figure 68

Figure 69

Figure 70

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).

Front Axle (ZF - MT-L 3105)

Figure 71

Figure 72

Figure 73

Figure 74

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.

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Front Axle (ZF - MT-L 3105)

23.Grease both O-rings (see arrows) and insert them into annular grooves of ring gear.

Figure 75

Figure 76

Figure 77

Figure 78