Getting a Daewoo Mega 400-III Plus wheel loader back to full lift, steering and drive is the outcome this 532-page shop manual PDF (OEM 4023-7130E) is built around. Hydraulics take up roughly a third of the book, working through the Vickers 35VQ main pump, steering and brake pump, Danfoss flow amplifier, Rexroth brake pedal valve, accumulator and cylinders before ending on a full hydraulic schematic. The ZF transmission, torque converter and Graziano axles claim even more, and an electrical schematic with fault code tables lets you trace a dead circuit to the wire. Set K3 clutch plate clearance at 2.2 to 2.4 mm, and confirm the engine speed input reads between its 0.45 V and 7.00 V thresholds before you condemn the sensor. Guess a clearance and you pay for a second teardown. Bookmarked sections and a searchable text layer take you straight to the figure, and your loader is cycling material again.
What's Inside This Daewoo Mega 400-III Plus Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety | 7-28 | Wheel Loader Safety |
| Specifications | 29-44 | Specifications for Mega 400-III PLUS |
| General Maintenance | 45-72 | General Maintenance Procedures, Standard Torques |
| Upper Structure | 73-74 | |
| Lower Structure and Chassis | 75-76 | |
| Front Axle | 79-118 | General Description, Parking Brake, Limited Slip Differential, Front Planetary Gear Set, Scheduled Maintenance |
| Rear Axle | 119-150 | General Description, Rear Axle Differential, Rear Axle Planetary Gear Set, Scheduled Maintenance, Lubricant Specifications, General Disassembly and Reassembly Instructions |
| Air-Conditioner | 151-168 | Refrigerant Circulation, Air-Conditioning System Circuit Diagram, Troubleshooting, Refrigerant Recovery, Leakage Check, Refrigerant Charging |
| Transmission and Torque Converter | 169-306 | Drive Train Description, Transmission, Transmission Faults Codes, Definition of Operation Modes, Table of Fault Codes, Measurement of Resistance at Actuator/Sensors and Cable |
| Hydraulics | 307-492 | Hydraulic System, Accumulator, Cylinders, Main Pump, Steering and Brake Pump, Brake Pedal Valve, Flow Amplifier, Power Steering Unit |
| Electrical System | 493-530 | Electrical System Procedures |
| Attachments | 531-532 |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Standard Metric Fasteners Torque | 0.15 kg m to 103.00 kg m | p. 63 |
| Standard U.S. Fasteners Torque (Grade 5) | 6 ft. lbs. to 3550 ft. lbs. | p. 65 |
| Engine speed input voltage threshold (high) | 7.00 V | p. 179 |
| Engine speed input voltage threshold (low) | 0.45 V | p. 179 |
| Plate clearance - K3 | 2.2 - 2.4 mm | p. 248 |
| Inner plate thickness (optional) | 2.0 - 4.0 mm | p. 247 |
| Bearing cover hex. head screw torque limit (M10/8.8) | 4.69 kg•m (33.93 ft lbs) | p. 285 |
| Bolt hex. head screw torque limit (M10/8.8) | 4.69 kg•m (33.93 ft lbs) | p. 285 |
| Pump flange/pump hex. head screw torque limit (M12/8.8) | 8.06 kg•m (58.27 ft lbs) | p. 288 |
| Pump flange (power take off) hex. head screw torque limit (M14/8.8) | 12.75 kg•m (92.20 ft lbs) | p. 288 |
| Continuous backup ring water temperature | 30 - 50°C (86 - 122°F) | p. 348 |
| Continuous backup ring soak time | 2 - 3 minutes | p. 348 |
Daewoo Mega 400-III Plus Common Problems This Manual Covers
Daewoo Mega 400-III Plus loader hydraulic cylinder leaks oil, drops, moves slowly or vibrates with air bubbles
Check the cylinder against the hydraulic cylinder troubleshooting chart for oil leaks, drops, slow movement and air bubbles before you pull it off the machine. If you reseal it, soak the continuous backup ring in 30 - 50°C (86 - 122°F) water for 2 - 3 minutes following page 348, then install it while it is still warm.
Manual Section: Hydraulic Cylinder TroubleshootingVickers 35VQ main pump not delivering fluid, running hot, noisy or losing fluid
Inspect the 35VQ main pump using the checks for no delivery, overheating, noise and fluid loss before you condemn it. Replace the hydraulic oil filter with a 10 micron (absolute) element, per page 388. On reassembly, torque the 35VQ hex head screws to 3.78 kg•m (100 in lbs) and the bolts to 68.04 ±4.54 kg•m (150 ±10 ft lbs), following page 367.
Manual Section: Main Pump (Vickers 35VQ) Troubleshooting p. 367Transmission fault code for engine speed or turbine speed input signal error
Measure the engine speed input voltage and compare it with the 0.45 V low and 7.00 V high thresholds on page 179. Check the turbine speed input against the same 0.45 V and 7.00 V limits on page 180.
Manual Section: Transmission Fault Codes p. 179Transmission throwing clutch error fault codes with clutch pack plate clearance out of range
Measure K3 plate clearance against 2.2 - 2.4 mm following page 248, and K2 clearance against 2.8 - 3.0 mm on page 256. Check inner plates against 3.5 mm and outer plates against 2.5 mm. Optional inner plates range from 2.0 to 4.0 mm, per page 247. Torque the K3-side slotted nut to 56.08 kg•m (405.66 ft lbs), page 255.
Manual Section: Transmission Fault Codes p. 248Transmission setting power supply fault codes while the battery is not charging
Check the battery charging circuit using the electrical system troubleshooting steps before you start on the transmission. Trace the transmission supply wiring on the wiring diagram at page 525. Look up the power supply fault code in the error code reference, then clear it and verify it does not come back with the engine running.
Manual Section: Transmission Fault CodesPower steering heavy, not tracking straight, noisy or leaking at the steering unit
Check the power steering unit against the troubleshooting chart for heavy feel, poor straight-line tracking, noise and leaks before replacing it. On the Mega 400-III PLUS, test flow amplifier control pressure against 10.50 kg/sq cm (149.35 psi). Then verify maximum oil flow to steering of 125.0 l/min (33.0 U.S. gpm), following page 413.
Manual Section: Power Steering Unit Troubleshooting p. 413Frequently Asked Questions
What do the ZF transmission error codes on a Daewoo Mega 400-III PLUS mean?
The transmission fault codes are identified by a first number indicating the type of signal error. For example, a '1 Hex' indicates a Digital Input Signal error, '3 Hex' indicates a Speed Signal error, and 'B Hex' indicates a Transmission Fault or Clutch Error. Detailed descriptions of these codes are provided in the 'Description of Fault Codes' table. p. 175
How to test the TCU power supply on a Daewoo Mega 400-III PLUS?
To test the TCU power supply, check the cables and connectors to sensors supplied from pin AU1. The power supply at pin AU1 should be approximately 5V. If the voltage is higher than 6V, it indicates a short circuit to battery voltage (Fault Code D1), and if it is less than 4V, it indicates a short circuit to ground (Fault Code D2). p. 191
What are the replacement specifications for ZF transmission clutch packs on the Daewoo Mega 400-III Plus?
For clutch K3, the active number of friction surfaces is 14, using 1 outer plate (one sided coated), 7 outer plates (2.5 mm), 3 inner plates (3.5 mm), 3 inner plates (3.0 mm), and 1 optional inner plate (2.0 - 4.0 mm). For clutch K4, the active number of friction surfaces is 12, using 1 outer plate (one sided coated), 6 outer plates (2.5 mm), 4 outer plates (3.5 mm), 1 inner plate (3.0 mm), and 1 optional inner plate (2.0 - 4.0 mm). p. 247
What is the torque for the main pump cover bolts on the Vickers 35VQ series pump in a Daewoo Mega 400-III Plus?
The torque for the main pump cover bolts depends on the model: 20VQ and 25VQ require 31.75 ±2.27 kg•m (70 ±5 ft lbs), 35VQ requires 68.04 ±4.54 kg•m (150 ±10 ft lbs), and 45VQ requires 120.20 ±4.54 kg•m (265 ±10 ft lbs). p. 367
What is the correct nitrogen pre-charge pressure for the accumulator on a Mega 400-III PLUS?
The nitrogen pre-charge pressure for the accumulator on a Mega 400-III PLUS is 30 kg/cm² (427 psi). p. 330
Is this Daewoo Mega 400-III Plus manual a download or a disc?
All 532 pages arrive as one searchable PDF at checkout. Read it at the desk, then take the phone out to the machine.
Is this Daewoo Mega 400-III Plus Shop Manual printable?
Yes. Many buyers print one chapter at a time for their own shop and keep the rest on a tablet.
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