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SM-Daewoo Doosan MEGA 200-V Wheel Loader Service Repair Shop Manual-1
SM-Daewoo Doosan MEGA 200-V Wheel Loader Service Repair Shop Manual-1
Shop Manual
023-00055AE
S/N 1001 and Up (Tier I & II)
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.
Instructions
Specifications
Specifications for Mega 200-V............................................................ S0203100C
General Maintenance
General Maintenance Procedures .........................................................S0302000
Standard Torques ..................................................................................S0309000
Upper Structure
Counterweight..................................................................................... S0403030K
Fuel Transfer Pump ...............................................................................S0405500
Hydraulic Oil Tank .............................................................................. S0406060C
Hydraulics
Hydraulic System................................................................................ S0702035K
Accumulator........................................................................................ S0703010K
Cylinders............................................................................................. S0705015K
Fan Drive Hydraulic Motor (Haldex) ................................................... S0707110C
Table of Contents
Page I
Main Pump (Parker)............................................................................ S0708510C
Brake Pedal Valve .............................................................................. S0709260C
Main Control Valve (Husco)................................................................ S0709457C
Pilot Control Valve .............................................................................. S0709478C
Priority Valve..........................................................................................S0709650
Power Steering Unit............................................................................ S0709705C
Restriction Valve................................................................................. S0709752C
Hydraulic Schematic (Mega 200-V) .................................................... S0793015C
Electrical System
Electrical System ................................................................................ S0802015C
Electrical Schematic (Mega 200-V) .................................................... S0893015C
Attachments
Table of Contents
Page II
1SAFETY
S0103010K
2WHEEL LOADER
SAFETY
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
DANGER!
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.
CAUTION!
This word is used on safety messages and safety labels and indicates potential of a hazardous
situation that, if not avoided, could result in minor or moderate injury. It may also be used to alert
against a generally unsafe practice.
WARNING!
This word is used on safety messages and safety labels and indicates potential of a hazardous
situation that, if not avoided, could result in serious injury or death. It may also be used to alert
against a highly unsafe practice.
DANGER!
This word is used on safety messages and safety labels and indicates imminent hazard of a
situation that, if not avoided, is very likely to cause death or extremely serious injury. It may also
be used to alert against equipment that may explode or detonate if handled or treated carelessly.
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 compromised.
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.
HAOA060L
Figure 6
ACCUMULATOR
The pilot control system is equipped with an accumulator. For a brief period of time after the engine has
been shut down, the accumulator will store a pressure charge that may enable hydraulic controls to be
activated. Activation of any controls may enable the selected function to operate under force of gravity.
When performing maintenance on the pilot control system, the hydraulic pressure in the system must be
released as describe in Operation and Maintenance Manual.
The accumulator is charged with high-pressure nitrogen gas, so it is extremely dangerous if it is handled in
the wrong way. Always observe the following precautions;
• Do not drill or make any holes in the accumulator or expose it any flame, fire or heat source.
• Do not weld on the accumulator, or try attaching anything to it.
• When carrying out disassembly or maintenance of the accumulator, or when disposing of the
accumulator, the charged gas must be properly released. Contact your Daewoo distributor.
• Wear safety goggles and protective gloves when working on an accumulator. Hydraulic oil under
pressure can penetrate the skin and cause serious injuries.
ENGINE VENTILATION
Engine exhaust gases can cause loss of
judgment, loss of alertness, and loss of motor
control. These gases can also cause
unconsciousness, serious injury and fatal
accidents.
Make sure of adequate ventilation before
starting engine in any enclosed area.
You should also be aware of open windows,
doors or ductwork into which exhaust may be
carried, or blown by wind, exposing others to ARO1770L
danger. Figure 11
WARNING!
Protect your eyes when breaking the Figure 12 RIGHT SIDE
glass.
ENGINE STARTING
• Walk around your machine before getting in operator’s cab. Look for evidence of leaking fluid,
loose fasteners, misaligned assemblies or any other indications of possible equipment hazard.
• All equipment covers and machinery safety guards must be in place, to protect against injury
while machine is being operated.
• Look around work site area for potential hazards, or people or property that could be at risk
while operation is in progress.
• NEVER start engine if there is any indication that maintenance or service work is in progress, or
if a warning tag is attached to controls in cab.
• A machine that has not been used recently, or is being operated in extremely cold temperatures,
could require a warm-up or maintenance service before start up.
• Check gauges and monitor displays for normal operation before starting engine. Listen for
unusual noises and remain alert for other potentially hazardous conditions at start of work cycle.
• Check tire inflation and check tires for damage or uneven wear. Perform maintenance before
operation.
• Do not short circuit the starting motor to start the engine. This is not only dangerous, but may
also damage the machine.
• When starting the engine, sound the horn as an alert.
• Start and operate the machine only while seated.
Figure 15
MOVEMENT ALARMS
If wheel loader is equipped with an audible travel movement alarm, test alarm on a daily basis. Audible
alarm should sound as soon as travel system is engaged.
Use these minimum distances as a guideline only. Depending upon voltage in line and atmospheric
conditions, strong current shocks can occur with boom or bucket as far away as 4 - 6 m (13 - 20 ft) from
power line. Very high voltage and rainy weather could further decrease that safety margin.
NOTE: Before starting any type of operation near power lines (either above ground or buried
cable-type) you should always contact power utility directly and work out a safety plan with
them.
Figure 20
PARKING MACHINE
Avoid making sudden stops, or parking machine wherever it happens to be at the end of the work day. Plan
ahead so that the wheel loader will be on firm, level ground away from traffic and away from high walls, cliff
edges and any area of potential water accumulation or runoff. If parking on inclines is unavoidable, block
wheels to prevent movement. Lower bucket or other working attachment completely to ground, or to an
overnight support saddle. There should be no possibility of unintended or accidental movement.
When parking on public roads, provide fences, signs, flags, or lights, and put up any other necessary signs
to ensure that passing traffic can see the machine clearly, and park the machine so that the machine, flags,
and fences do not obstruct traffic.
IMPORTANT
When hydraulic system maintenance or service work must be performed, be aware that
accumulators in system store fluid under pressure after system has been shut down. To release
hydraulic pressure in accumulators, operate control with engine "OFF" until accumulator
pressure is completely dissipated.
HAAD4050
Figure 22
Figure 24
Pick up any tools or hammers that are laying in the work place, wipe up any grease or oil or any other
slippery substances, and clean the area to make it possible to carry out the operation in safety. If the work
place is left untidy, you may trip or slip and suffer injury.
HDO1037L
Figure 25
USE OF LIGHTING
When checking fuel, oil, battery electrolyte, or
window washing fluid, always use lighting with
anti-explosion specifications. If such lighting
equipment is not used, there is danger of
explosion.
If work is carried out in dark places without
using lighting, it may lead to injury, so always
use proper lighting.
Even if the place is dark, never use a lighter or
flame instead of lighting. There is danger of fire. HDO1040L
There is also danger that the battery gas may Figure 26
catch fire and cause and explosion.
ARO1360L
Figure 27
If the coolant level in the coolant recovery tank is below the lower limit, add coolant.
Cooling system conditioner contains alkali. Alkali can cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth.
Allow cooling system components to cool before you drain the cooling system.
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact
the skin.
Remove the hydraulic tank filter plug only after the engine has been stopped. Make sure that the hydraulic
tank filter plug is cool before you remove it with your bare hand. Remove the hydraulic tank filter plug slowly
to relieve pressure.
Relieve all pressure in the hydraulic oil system, in the fuel system, or in the cooling system before you
disconnect any lines, fittings, or related items.
Batteries give off flammable fumes that can explode.
Do not smoke while you are checking the battery electrolyte levels.
Electrolyte is an acid. Electrolyte can cause personal injury. Do not allow electrolyte to contact the skin or
the eyes.
Always wear protective glasses when you work on batteries.
X X O
HAOA420L
Figure 30
WARNING!
Failure to obtain prompt medical assistance could result in gangrene or other serious damage to
tissue.
Figure 32
WARNING!
Improper lifting can allow load to shift and
cause personal injury or damage to the
machine
1SPECIFICATIONS FOR
MEGA 200-V
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
1 2 3 4 5 6
10
12 11
18 19
17
16 21 22
20
14 23
15
24
13 25
44
26
27
28
29
43 42 41 40 39 38 37 36 35 34 33 32 31 30
APO0010L
Figure 1 (Tier I)
1 2 3 4 5 6
10
12 11
18 19
17
16
21 22
20
15 23
14 24
13 25
44
26
27
28
29
43 42 41 40 39 38 37 36 35 34 33 32 31 30
APO0020L
Figure 2 (Tier I (Europe Low noise Kit))
(Tier II)
System Flow (Work / Steer) 176 l/min (46.5 gpm) / 85 l/min (22.5 gpm)
7.3/12.7/22/36 km/h 8.2/14.3/25/39 km/h
Travel Speed (1/2/3/4)
(4.54/7.89/13.67/22.37 mph) (5.10/8.89/15.53/24.23 mph)
Working Range
Dump Height at 45° (W/O) 2,842 mm (9' 4'') 2,850 mm (9' 4'')
* Standard Figures Include R.O.P.S. Cab, 17.5 x 25 - 12 PR Tires and Standard Bucket (1.80 m3
(2.35 yd3)).
** Option Figures Include R.O.P.S. Cab, 20.5 x 25 - 12 PR Tires and Option Bucket (1.90 m3 (2.49
yd3)).
** Option Figures Include R.O.P.S. Cab, 20.5 x 25 - 12 PR Tires and Option Bucket (1.90 m3 (2.49
yd3)).
APS0180L
Figure 3
J
O
40
C
G
B (D) E
A F
I
H
APO0160L
Figure 4
7,025 mm
Overall Length (A)
(23' 1'')
2,450 mm 2,550 mm
Overall Width (B)
(8' 0'') (8' 4'')
3,180 mm 3,260 mm
Overall Height (C)
(10' 5'') (10' 8'')
2,450 mm 2,550 mm
Bucket Width (D)
(8' 0'') (8' 4'')
2,900 mm
Wheel Base (E)
(9' 6'')
1,930 mm
Tread (F)
(6' 4'')
370 mm
Ground Clearance (G)
(1' 3'')
2,720 mm 2,730 mm
Dump Height, to tooth (H)
(8' 11'') (8' 11'')
1,000 mm 870 mm
Dump Distance, to Bucket Edge (I)
(3' 3'') (2' 10'')
20.5 x 25 - 12 PR9
Tire Size 17.5 x 25 - 12 PR (Bias)
20.5 x R25 (Radial)
A
B
E
D
b
C
APS0190L
Figure 5
Reference Reference
Dimension Dimension
Number Number
A 2,026 mm D 2,734 mm
(6' 8'') (8' 12'')
B 2,303 mm E 3,593 mm
(7' 7'') (11' 10'')
C 1,500 mm a 35°
(4' 11'') b 26°
TIPPING LOAD
Static Tipping Load with bucket in Over Front position is 8,500 kg (18,740 lb). With bucket in Fully Turned
position, Static Tipping Load is 7,400 kg (16,315 lb).
MATERIAL WEIGHT
The data below describes weight of a cubic meter (cubic yard) of many types of workload materials.
401 kg/m3
Charcoal --------------------- ---------------------
(695 lb/yd3)
449 kg/m3
Coke, foundry size --------------------- ---------------------
(756 lb/yd3)
897 kg/m3
Coal, anthracite --------------------- ---------------------
(1,512 lb/yd3)
1,522 kg/m3
Dolomite, crushed --------------------- ---------------------
(2,565 lb/yd3)
1,522 kg/m3
Earth, DRY, packed --------------------- ---------------------
(2,565 lb/yd3)
1,762 kg/m3
Earth, WET, muddy --------------------- ---------------------
(2,970 lb/yd3)
1,522 kg/m3
Limestone, crushed --------------------- ---------------------
(2,565 lb/yd3)
1,602 kg/m3
Limestone, fine --------------------- ---------------------
(2,705 lb/yd3)
1,282 kg/m3
Phosphate, rock --------------------- ---------------------
(2,160 lb/yd3)
929 kg/m3
Salt --------------------- ---------------------
(1,566 lb/yd3)
529 kg/m3
Snow, light density --------------------- ---------------------
(891 lb/yd3)
1,522 kg/m3
Sand, DRY, loose --------------------- ---------------------
(2,565 lb/yd3)
1,922 kg/m3
Sand, WET, packed --------------------- ---------------------
(3,240 lb/yd3)
1,362 kg/m3
Shale, broken --------------------- ---------------------
(2,295 lb/yd3)
529 kg/m3
Sulphur, broken --------------------- ---------------------
(1,620 lb/yd3)
IMPORTANT
Weights are approximations of estimated average volume and mass. Exposure to rain, snow or
ground water; settling or compaction due to overhead weight and chemical or industrial
processing or changes due to thermal or chemical transformations could all increase value of
weights listed in table.
1GENERAL
MAINTENANCE
PROCEDURES
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
WARNING!
Structural elements of the machine may be built from a variety of steels. These could contain
unique alloys or may have been heat treated to obtain particular strength characteristics. It is
extremely important that welding repairs on these types of steel are performed with the proper
procedures and equipment. If repairs are performed incorrectly, structural weakening or other
damage to the machine (that is not always readily visible) could be caused. Always consult
Daewoo After Sales Service before welding on integral components (loader arm, frames, car
body, track frames, turntable, attachment, etc.) of the machine. It is possible that some types of
structurally critical repairs may require Magnetic Particle or Liquid Penetrant testing, to make
sure there are no hidden cracks or damage, before the machine can be returned to service.
CAUTION!
Always perform welding procedures with the proper safety equipment on hand. Adequate
ventilation and a dry work area are absolutely essential. Keep a fire extinguisher nearby and
always wear protective clothing and the recommended type of eye protection.
IMPORTANT
Make sure that cleaning solvents will be compatible with rubber materials used in the hydraulic
system. Many petroleum based compounds can cause swelling, softening, or other deterioration
of system sealing elements, such as O-rings, caps and other seals.
Figure 1
WARNING!
Care should be exercised to avoid inhalation of vapors, exposure to skin and creating fire
hazards when using solvent type cleaners.
1. Clean all metal parts thoroughly using a suitable cleaning fluid. It is recommended that parts be
immersed in cleaning fluid and moved up and down slowly until all oils, lubricants, and/or foreign
materials are dissolved and parts are thoroughly clean.
2. For bearings that can be removed, soak them in a suitable cleaning fluid for a minute or two, then
remove bearings from cleaning fluid and strike flat against a block of wood to dislodge solidified
particles of lubricant. Immerse again in cleaning fluid to flush out particles. Repeat above operation
until bearings are thoroughly clean. To dry bearings, use moisture-free compressed air. Be careful to
direct air stream across bearing to avoid spinning bearings that are not lubricated. DO NOT SPIN
BEARINGS WHEN DRYING; bearings may be rotated slowly by hand to facilitate drying process.
3. Carefully inspect all bearing rollers, cages and cups for wear, chipping or nicks to determine
condition. Do not replace a bearing cone or cup individually without replacing mating cup or cone at
the same time. After inspection, dip bearings in light weight oil and wrap in clean lintless cloth or
paper to protect them until installation.
For those bearings that are to be inspected in place; inspect bearings for roughness of rotation,
scoring, pitting, cracked or chipped races. If any of these defects are found, replace bearings. Also
inspect defective bearing housing and/or shaft for grooved, galled or burred conditions that indicate
bearing has been turning in its housing or on its shaft.
4. It is more economical to replace oil seals, O-rings, sealing rings, gaskets and snap rings when unit is
disassembled than waiting for premature failures; refer to latest Micro Fiche and/or Parts Book for
replacement items. Be extremely careful when installing sealing members, to avoid cutting or
BEARING INSPECTION
The conditions of the bearing are vital to the smooth and efficient operation of the machinery. When any
component containing bearings is disassembled, always carefully examine the condition of the bearings
and all of its components for wear and damage.
Once the bearing is removed, clean all parts thoroughly using a suitable cleaning solution. If the bearing is
excessively dirty soak the bearing assembly in a light solution and move the bearing around until all
lubricants and or foreign materials are dissolved and the parts are thoroughly clean.
When drying bearings, moisture free compressed air can be used. Be careful not to direct the air in a
direction which will force the bearing to dry spin while not being properly lubricated.
After the bearings have been cleaned and dried, carefully inspect all bearing rollers, cages and cups for
wear, chipping or nicks. If the bearing cannot be removed and is to be inspected in place, check foe
roughness of rotation, scoring, pitting, cracked or chipped races. If any of these defects are found replace
the whole bearing assembly. NEVER replace the bearing alone without replacing the mating cup or the
cone at the same time.
After inspection lightly coat the bearing and related parts with oil and wrap in a clean lintless cloth or paper
and protect them from moisture and other foreign materials until installation.
It is also important to inspect the bearing housing and/or shaft for grooved, galled or burred conditions that
indicate that the bearing has been turning in its housing or on its shaft.
If available, use magna-flux or similar process for checking for cracks that are not visible to the naked eye.
The following illustrations will aid in identifying and diagnosing some of the bearing related problems.
NOTE: The illustrations will only show tapered roller bearings, but the principles of identifying,
diagnosing and remedying the defects are common to all styles and types of bearings.
Figure 2
Bent Cage
Cage damage due to improper handling or tool
usage.
Replace bearing.
Figure 3
Figure 4
Galling
Metal smears on roller ends due to overheat,
lubricant failure or overload.
Replace bearing - check seals and check for
proper lubrication.
Figure 5
Figure 6
Etching
Bearing surfaces appear gray or grayish black
in color with related etching away of material
usually at roller spacing.
Replace bearings - check seals and check for
proper lubrication.
Figure 7
Misalignment
Outer race misalignment due to foreign object.
Clean related parts and replace bearing. Make
sure races are properly seated.
Figure 8
Indentations
Surface depressions on race and rollers caused
by hard particles of foreign materials.
Clean all parts and housings, check seals and
replace bearings if rough or noisy.
Figure 9
Figure 10
Brinelling
Surface indentations in raceway caused by
rollers either under impact loading or vibration
while the bearing is not rotating.
Replace bearing if rough or noisy.
Figure 11
Cage Wear
Wear around outside diameter of cage and roller
pockets caused by abrasive material and
inefficient lubrication.
Replace bearings - check seals.
Figure 12
Abrasive Roller Wear
Pattern on races and rollers caused by fine
abrasives.
Clean all parts and housings, check seals and
bearings and replace if leaking, rough or noisy.
Figure 13
Figure 14
Smears
Smearing of metal due to slippage caused by
poor fitting, lubrication, overheating, overloads
or handling damage.
Replace bearings, clean related parts and check
for proper fit and lubrication.
Replace shaft if damaged.
Figure 15
Frettage
Corrosion set up by small relative movement of
parts with no lubrication.
Replace bearing. Clean all related parts. Check
seals and check for proper lubrication.
Figure 16
Stain Discoloration
Discoloration can range from light brown to
black caused by incorrect lubrication or
moisture.
if the stain can be removed by light polishing or
if no evidence of overheating is visible, the
bearing can be reused.
Check seals and other related parts for damage.
Figure 18
1STANDARD TORQUES
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
STANDARD TORQUESS0309000
MODEL SERIAL NUMBER RANGE
ALL MODELS ALL RANGES
Grade
Dia. x
Pitch (mm)
3.6 4.6 4.8 5.6 5.8 6.6 6.8 6.9 8.8 10.9 12.9
(4A) (4D) (4S) (5D) (5S) (6D) (6S) (6G) (8G) (10K) (12K)
0.15 0.16 0.25 0.22 0.31 0.28 0.43 0.48 0.50 0.75 0.90
M5 x Std.
(1.08) (1.15) (1.80) (1.59) (2.24) (2.02) (3.11) (3.47) (3.61) (5.42) (6.50)
0.28 0.30 0.45 0.40 0.55 0.47 0.77 0.85 0.90 1.25 1.50
M6 x Std.
(2.02) (2.16) (3.25) (2.89) (3.97) (3.39) (5.56) (6.14) (6.50) (9.04) (10.84)
0.43 0.46 0.70 0.63 0.83 0.78 1.20 1.30 1.40 1.95 2.35
M7 x Std.
(3.11) (3.32) (5.06) (4.55) (6.00) (5.64) (8.67) (9.40) (10.12) (14.10) (16.99)
0.70 0.75 1.10 1.00 1.40 1.25 1.90 2.10 2.20 3.10 3.80
M8 x Std.
(5.06) (5.42) (7.95) (7.23) (10.12) (9.04) (13.74) (15.18) (15.91) (22.42) (27.48)
0.73 0.80 1.20 1.00 1.50 1.35 2.10 2.30 2.40 3.35 4.10
M8 x 1
(5.28) (5.78) (8.67) (7.23) (10.84) (9.76) (15.18) (16.63) (17.35) (24.23) (29.65)
1.35 1.40 2.20 1.90 2.70 2.35 3.70 4.20 4.40 6.20 7.20
M10 x Std.
(9.76) (10.12) (15.91) (13.74) (19.52) (19.99) (26.76) (30.37) (31.18) (44.84) (52.07)
1.50 1.60 2.50 2.10 3.10 2.80 4.30 4.90 5.00 7.00 8.40
M10 x 1
(10.84) (11.57) (18.08) (15.18) (22.42) (20.25) (31.10) (35.44) (36.16) (50.63) (60.75)
2.40 2.50 3.70 3.30 4.70 4.20 6.30 7.20 7.50 10.50 12.50
M12 x Std.
(17.35) (18.08) (26.76) (23.86) (33.99) (30.37) (45.56) (52.07) (54.24) (75.94) (90.41)
2.55 2.70 4.00 3.50 5.00 4.50 6.80 7.70 8.00 11.20 13.40
M12 x 1.5
(18.44) (19.52) (28.93) (25.31) (36.16) (32.54) (49.18) (55.69) (57.86) (81.00) (96.92)
3.70 3.90 6.00 5.20 7.50 7.00 10.00 11.50 12.00 17.00 20.00
M14 x Std.
(26.76) (28.20) (13.23) (37.61) (54.24) (50.63) (72.33) (83.17) (86.79) (122.96) (144.66)
4.10 4.30 6.60 5.70 8.30 7.50 11.10 12.50 13.00 18.50 22.00
M14 x 1.5
(29.65) (31.10) (47.73) (41.22) (60.03) (54.24) (80.28) (90.41) (94.02) (11.26) (158.12)
5.60 6.00 9.00 8.00 11.50 10.50 15.50 17.90 18.50 26.00 31.00
M16 x Std.
(40.50) (43.39) (65.09) (57.86) (83.17) (75.94) (112.11) (129.47) (133.81) (188.05) (224.22)
6.20 6.50 9.70 8.60 12.50 11.30 17.00 19.50 20.00 28.00 35.50
M16 x 1.5
(44.84) (47.01) (70.16) (62.20) (90.41) (81.73) (122.96) (141.04) (144.66) (202.52) (256.77)
7.80 8.30 12.50 11.00 16.00 14.50 21.00 27.50 28.50 41.00 43.00
M18 x Std.
(56.41) (60.03) (90.41) (79.56) (115.72) (104.87) (151.89) (198.90) (206.14) (296.55) (311.01)
9.10 9.50 14.40 12.50 18.50 16.70 24.50 27.50 28.50 41.00 49.00
M18 x 1.5
(65.82) (68.71) (104.15) (90.41) (133.81) (120.79) (177.20) (198.90) (206.14) (296.55) (354.41)
11.50 12.00 18.00 16.00 22.00 19.00 31.50 35.00 36.00 51.00 60.00
M20 x Std.
(83.17) (86.79) (130.19) (115.72) (159.12) (137.42) (227.83) (253.15) (260.38) (368.88) (433.98)
12.80 13.50 20.50 18.00 25.00 22.50 35.00 39.50 41.00 58.00 68.00
M20 x 1.5
(92.58) (97.64) (148.27) (130.19) (180.82) (162.74) (253.15) (285.70) (296.55) (419.51) (491.84)
15.50 16.00 24.50 21.00 30.00 26.00 42.00 46.00 49.00 67.00 75.00
M22 x Std.
(112.11) (115.72) (177.20) (151.89) (216.99) (188.05) (303.78) (332.71) (354.41) (484.61) (542.47)
17.00 18.50 28.00 24.00 34.00 29.00 47.00 52.00 56.00 75.00 85.00
M22 x 1.5
(122.96) (133.81) (202.52) (173.59) (245.92) (209.75) (339.95) (44.76) (405.04) (542.47) (614.80)
20.50 21.50 33.00 27.00 40.00 34.00 55.00 58.00 63.00 82.00 92.00
M24 x Std.
(148.27) (155.50) (238.68) (195.29) (289.32) (245.92) (397.81) (419.51) (455.67) (593.10) (655.43)
23.00 35.00 37.00 31.00 45.00 38.00 61.00 67.00 74.00 93.00 103.00
M24 x 1.5
(166.35) (253.15) (267.62) (224.22) (325.48) (202.52) (441.21) (484.61) (535.24) (672.66) (744.99)
Recommended torque, in foot pounds, for all Standard Application Nuts and Bolts, provided:
1. All thread surfaces are clean and lubricated with SAE-30 engine oil. (See Note.)
2. Joints are rigid, that is, no gaskets or compressible materials are used.
3. When reusing nuts or bolts, use minimum torque values.
NOTE: Multiply the standard torque by:
0.65 when finished jam nuts are used.
0.70 when Molykote, white lead or similar mixtures are used as lubricants.
0.75 when parkerized bolts or nuts are used.
0.85 when cadmium plated bolts or nuts and zinc bolts w/waxed zinc nuts are used.
0.90 when hardened surfaces are used under the nut or bolt head.
NOTE: When reusing bolts and nuts in service, use minimum torque values.
GRADE 5 GRADE 8
THREAD SIZE
(3 RADIAL DASHES ON HEAD) (6 RADIAL DASHES ON HEAD)
NEWTON
FOOT POUNDS FOOT POUNDS NEWTON METER
METER
(ft lb) (ft lb) (N•m)
(N•m)
1/4" - 20 6 8 9 12
1/4" - 28 7 9 11 15
5/16" - 18 13 18 18 24
5/16" - 24 15 20 21 28
3/8" - 16 24 33 34 46
3/8" - 24 27 37 38 52
7/16" - 14 38 52 54 73
7/16" - 20 42 57 60 81
1/2" - 13 58 79 82 111
1/2" - 20 65 88 90 122
9/16" - 12 84 114 120 163
9/16" - 18 93 126 132 179
5/8" - 11 115 156 165 224
5/8" - 18 130 176 185 251
3/4" - 10 205 278 290 393
3/4" - 16 240 312 320 434
7/8" - 9 305 414 455 617
7/8" - 14 334 454 515 698
1" - 8 455 617 695 942
1" - 14 510 691 785 1064
1 1/8" - 7 610 827 990 1342
1 1/8" - 12 685 929 1110 1505
1 1/4" - 7 860 1166 1400 1898
1 1/4" - 12 955 1295 1550 2102
1 3/8" - 6 1130 1532 1830 2481
1 3/8" - 12 1290 1749 2085 2827
1 1/2" - 6 1400 2034 2430 3295
1 1/2" - 12 1690 2291 2730 3701
1 3/4" - 5 2370 3213 3810 5166
2" - 4 1/2 3550 4813 5760 7810
NOTE: If any bolts and nuts are found loose or at values less than what the chart states, it is
recommended that the loose bolt and/or nut be replaced with a new one.
1/4" 1.1 8
5/16" 2.2 16
3/8" 3.9 28
7/16" 6.2 45
1/2" 9.7 70
9/16" 13.8 100
5/8" 19.4 140
3/4" 33.2 240
7/8" 53.9 390
1" 80.2 580
1 - 1/8" 113.4 820
1 - 1/4" 160.4 1160
1 - 3/8" 210.2 1520
1 - 1/2" 279.4 2020
1 - 3/4" 347.1 2510
2 522.8 3780
TORQUE
KILOGRAM KILOGRAM
INCH POUNDS INCH POUNDS
METER METER
(in lb) (in lb)
(kg•m) (kg•m)
BOLT TORQUE
FLANGE BOLT
SIZE (*) SIZE KILOGRAM METER FOOT POUNDS
(kg•m) (ft lb)
TORQUE MULTIPLICATION
A wrench extension tool can be used to
increase the tightening force on a high capacity
nut or bolt.
For example, doubling the distance between the
bolt and the back (handle) end of the torque
wrench doubles the tightening force on the bolt.
It also halves the indicated reading on the scale
or dial of the torque wrench. To accurately
adjust or convert indicated scale or dial
readings, use the following formula:
I = A x T / A + B where:
I = Indicated force shown on the torque wrench Figure 1
scale or dial.
T = Tightening force applied to the nut or bolt (actual Torque).
A = Length of the torque wrench (between the center of the nut or bolt and the center of the handle).
B = Length of the extension.
As an example, if a 12" extension is added to a 12" torque wrench, and the indicated torque on the dial
reads "150 ft lb," the real force applied to the bolt is 300 ft lb:
NOTE: The formula assumes that there is no added deflection or "give" in the joint between the
extension and torque wrench. Readings may also be inaccurate:
• If the extension itself absorbs some of the tightening force and starts to bend or bow out.
• If an extension has to be fabricated that is not perfectly straight (for example, an extension
made to go around an obstruction, to allow access to a difficult to tighten fastener), the
materials and methods used must be solid enough to transmit full tightening torque.
CAUTION!
Disassembly, overhaul and replacement of components on the machine, installation of new or
replacement parts and/or other service-related maintenance may require the use of thread or
flange sealing assembly compound.
Use the information on this page as a general guide in selecting specific formulas that will meet
the particular requirements of individual assembly installations. Daewoo does not specifically
endorse a specific manufacturer or brand name but the following table of "Loctite" applications
is included for which cross-references to other makers’ products should also be widely
available.
IMPORTANT
Use primer "T" or "N" for all cold weather assembly of fastener adhesives, with Thread locker
sealers 222, 242/243, 262, 271, 272, or 277.
Break-away
Cure Strength
Product Application Color Removal
(in lb) of Sealer
Alone
Low strength for 6 mm (1/4") or
222 Purple Hand tools 45
smaller fasteners.
242 or Medium strength for 6 mm (1/4") and
Blue Hand tools 80
243 larger fasteners.
High strength for high grade Heat/260°C (500°F)
262 fasteners subject to shock, stress Red Remove HOT 160
and vibration. (NO solvent)
Extra high strength for fine thread Heat/260°C (500°F)
271 Red 160
fasteners up to 25 mm (1") diameter. Remove HOT
High temperature/high strength for
Heat/316°C (600°F)
272 hostile environments to 232°C Red 180
Remove HOT
(450°F).
Extra high strength for coarse thread
Heat/260°C (500°F)
277 fasteners 25 mm (1") diameter and Red 210
Remove HOT
larger.
V. "Loctite" Adhesives
S0403030K
R2
1COUNTERWEIGHT
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
COUNTERWEIGHT S0403030K
MODEL SERIAL NUMBER RANGE
Mega 200-V (Tier I & II) 1001 and Up
Mega 250-V (Tier I) 1001 thru 2000
Mega 250-V (Tier II) 2001 and Up
Mega 300-V (Tier I) 1001 thru 2000
Mega 300-V (Tier II) 2001 and Up
Mega 400-V 1001 and Up
Counterweight S0403030K
Page 1
Return to Master Table of Contents
TABLE OF CONTENTS
Specifications ................................................................................................. 3
Counterweight ................................................................................................ 3
S0403030K Counterweight
Page 2
Return to Master Table of Contents
SPECIFICATIONS
NOTE: Weight.
COUNTERWEIGHT
AJS0620L
Figure 1
NOTE: 1) Tighten bolts to the torque value list in the following table.
Counterweight S0403030K
Page 3
Return to Master Table of Contents
S0403030K Counterweight
Page 4
S0405500
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
TABLE OF CONTENTS
General Description........................................................................................ 3
Theory of Operation ................................................................................ 3
Troubleshooting .............................................................................................. 4
Replacement of Rotor and Vane .................................................................... 4
Replacement of Rear Cover ........................................................................... 5
Replacement of Armature .............................................................................. 6
Figure 1
Reference Reference
Description Description
Number Number
1 Motor 3 Inlet Hose
2 Pump 4 Outlet Hose
2-1 Pump Cover 5 Check Valve
2-2 Rotor and Vane 6 Strainer Cap
Figure 2
Check resistance at connectors "A." If reading is zero, or very close to zero, the motor is bad and must be
replaced.
On units equipped with a toggle switch, check the resistance through the toggle switch, while the switch is
in the "ON" position. If continuity is not present, the switch is bad. Be sure to check resistance through the
motor.
Figure 6
REPLACEMENT OF
REAR COVER
Brush assembly and a thermal limiter are
installed in the rear cover. If you find any
damage, replace them with new ones.
Remove the switch cover and screw (M5 x L95)
from the rear cover.
Remove cover.
At reassembly of rear cover, widen the space of
brush and insert it to the armature. Then fit the Figure 7
hole of screw in the housing.
Be careful when installing screw. The cover
screw may be attracted by the motor magnet.
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
General Description........................................................................................ 4
Parts List (M200-V) ................................................................................. 4
Parts List (M250-V) ................................................................................. 6
Specifications .......................................................................................... 8
3 2 1
SECTION B
S=1/5
5
7 SECTION A
APS0200L
Figure 1 (Tier I)
Reference Reference
Description Description
Number Number
1 Return Filter 5 Air Breather
2 Bypass Valve 6 Level Gauge
3 Spring 7 Drain Plug
4 Suction Filter
SECTION B
S=1/5
7 SECTION A
BHS0050L
Figure 2 (Tier II)
Reference
Description
Number
1 Return Filter
2 Bypass Valve
3 Spring
4 Suction Filter
5 Air Breather
6 Level Gauge
7 Drain Plug
3
2
SECTION A
S=1/2.5
7 SECTION B
S=1/5
AOS0160L
Reference Reference
Description Description
Number Number
1 Return Filter 5 Air Breather
2 Bypass Valve 6 Level Gauge
3 Spring 7 Drain Plug
SECTION A
S=1/2.5
7
SECTION B
S=1/5
BAS0120L
Figure 5 (S/N 2001 and Up)
Reference Reference
Description Description
Number Number
1 Return Filter 5 Air Breather
2 Bypass Valve 6 Level Gauge
3 Spring 7 Drain Plug
1CENTER JOINT
(ARTICULATION JOINT)
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
General Description........................................................................................ 3
Maintenance Standard ............................................................................ 4
CAUTION!
When the loader is steered, the area near
the center hinge pins becomes so narrow
that you might get caught between the
front and rear frames. Before trying to
service the loader, make sure to set the
frame lock plate.
Before moving (traveling) the loader, make
sure the frame lock plate is set to the
original position. Figure 1
DETAIL B
DETAIL A (LOWER HINGE BEARING)
APS0210L
Figure 2
S0602200C
1AXLE
(CLARK-HURTH / DANA)
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
TABLE OF CONTENTS
Introduction..................................................................................................... 4
General Description........................................................................................ 5
Outline..................................................................................................... 5
Differential (Standard) ............................................................................. 8
Differential Operation ....................................................................... 8
Self Locking Differential........................................................................... 9
Troubleshooting ............................................................................................ 10
Special Tools ................................................................................................ 13
Clark-Hurth / Dana Axle Identification .......................................................... 16
Maintenance and Lubrication ................................................................ 17
Brake Disc............................................................................................. 17
Wear Check and Replacement ...................................................... 17
Adjustment of Brake Disc Gap....................................................... 18
Safety Brake.......................................................................................... 20
Adjustment of Safety Brake............................................................ 24
Wheel Hub ............................................................................................ 26
Planetary Reduction Gears................................................................... 30
Bevel Pinion Support (Rear Axle) ......................................................... 32
Self Locking Differential......................................................................... 39
INTRODUCTION
The efficiency and continued operation of the axles depends on constant and correct maintenance, also on
efficient repair work should there be a break-down or malfunction. The instructions in this manual have
been based on a complete overhaul of a axle. However the mechanic must decide whether or not it is
necessary to dismantle the individual components when only partial repair work is required. This manual
provides a quick and sure guide, which with use of photographs and diagrams illustrating various phases of
operations, allows accurate work to take place. Therefore all information required for correct disassembly,
relative checks, and assembly of each individual component, has been provided.
NOTE: Throughout the phases of repair or maintenance, it is advisable to use proper equipment
and tools such as: trestles, supporting benches, plastic or copper hammers, appropriate
levers, extractors and specific spanners or wrenches. So that work is facilitated and
working surfaces and mechanics themselves are protected. Before disassembly, it is best
to thoroughly clean axles, removing any encrusted dirt or accumulated greases, then drain
oil through oil drain plugs.
IMPORTANT
All disassembled axles and components should be thoroughly cleaned with appropriate
products and then restored or replaced if damage, wear, cracking, or seizing have occurred. In
particular, thoroughly check the state of all moving parts (bearings, gears, crown wheel and
pinion, and shafts) and sealing parts (O-rings and oil seals), which are subject to major stress
and wear. In any case it is advisable to replace seals and O-rings every time a component is
overhauled or repaired. During assembly sealing rings must be lubricated on the sealing edge.
In case of crown wheel and pinion, replacement of one requires replacement of the other. During
assembly prescribed pre-loading and backlash of parts must be maintained.
GENERAL DESCRIPTION
OUTLINE
Front Axle
Frame-Fixed
Type
Semi-Floating
SECTION A
APS0230L
Figure 1 DRIVE AXLE ASSEMBLY (DANA AXLE)
Reference Reference
Description Description
Number Number
1 Front Axle 5 Bushing
2 Rear Axle 6 Thrust Washer
3 Axle Support (Front) 7 O-ring
4 Axle Support (Rear)
DIFFERENTIAL (STANDARD)
The differential is integral with the reduction gear.
The power from the drive shafts is transmitted through the drive pinion and the ring gear to the differential
gear case. It is then sent through the right and left side gears to the final reduction gear assembly. The
speed reduction of the power is accomplished by the drive pinion and the ring gear.
Differential Operation
While the loader travels straight, the ring gear, differential gear case, and side gears rotate together, with
the pinion gears inside the differential gear case not rotating. The power of the same speed is thus
transmitted from the right and left side gears through the axle shafts to the wheels. When the loader makes
a turn, the right and left wheels rotate at different speeds; the pinion gears in the differential gear case
rotate around their own axes according to the difference in speed between the right and left side gears.
Reference Reference
Description Description
Number Number
1 Pinion Gear 5 Spider
2 Side Gear 6 Drive Pinion
3 Axle Shaft 7 Ring Gear
4 Differential Gear Case
TROUBLESHOOTING
Problem Cause Remedy
Insufficient braking. Incorrect adjustment. Inspect disc thickness, If usable
readjust brakes.
Diff-lock inoperative. If manual, loose or not properly Inspect and correct linkage and
adjusted linkage readjust.
Oil coming out of breather Leak in internal brake system. Inspect disc thickness, and
replace if necessary.
Replace all seals in axle and
master cylinder that have made
contact with incorrect fluid, and
all brake hoses.
If incorrect fluid leaked into axle
oil, seals and O-rings in axle
must be replaced.
Noise during coast or under Damaged wheel bearings. Replace and adjust.
power the same.
Noise under power greater than Low oil level Refill oil to proper level.
during coast.
Incorrect lubricant. Change retaining rings of brake
circuit and brake pump.
Noise under coast greater than Loose pinion nut Inspect ring, pinion, and pinion
under power. bearings. If undamaged,
retighten nut.
Noise during turn (Without No- Worn spider and/or side gears. Replace.
spin).
A "Stick slip" noise when going Worn or damaged cardanshaft. Inspect and replace.
from forward to reverse.
Loose wheel. Inspect for wheel and wheel stud
damage. Replace if needed and
torque lug nuts.
SPECIAL TOOLS
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Differentials Every 1500 hours With additives for oil immersed disc brakes.
Service brake circuit Only for mineral oil use e.g. ATF Dexron II. Make sure that master
cylinder seals are suitable for mineral oil.
BRAKE DISC
Figure 1
2. Remove mounting nuts and axle housing.
NOTE: Axle housing must be removed
horizontally.
Figure 2
Figure 3
4. Assembly in reverse order of disassembly.
Figure 4
Adjustment of Brake Disc Gap
1. Turn adjusting bolts (1) counterclockwise
till it stops, then back off 3/4 revolutions
clockwise; this corresponds to a gap of
0.75 mm (0.03 in) between brake discs.
Figure 5
2. Remove brake piston (2).
Figure 6
Figure 7
4. Apply pressure with compressed air for 10
minutes each side.
NOTE: Air Pressure at 0.5 ±1 bar (7
psi).
Figure 8
Figure 9
SAFETY BRAKE
1. Apply 25 - 35 bar (360 - 510 psi) of
pressure to hydraulic circuit, then remove
axle housing.
Figure 10
2. Remove four mounting studs and
disassemble intermediate covers.
NOTE: Use care not to damage parts
when disassembling.
Figure 11
3. Unlock and remove spring applied safety
brake pistons. Check pistons and replace if
necessary.
Figure 12
4. Assembly cover in reverse order of
disassembly. Special tool T18 is required
(refer to "Special Tools" in back of this
section). Check torque of cover (refer to
standard torque charts in "General
Maintenance Procedures" section).
Figure 13
Figure 14
6. Remove brake discs, and check for wear
or damage, replace if required.
NOTE: Pay attention to direction for
reassembly.
Figure 15
7. Align lubrication holes of brake discs at
reassembly.
Figure 16
8. Remove pinion and ring gear.
NOTE: Pay attention of direction for
reassembly.
Figure 17
Figure 18
10. Assemble axle and apply 25 - 35 bar (360 -
510 psi) of pressure into hydraulic circuit.
Figure 19
Figure 20
Figure 21
2. Turn the pinion with 8 N•m (6 ft lb) torque
counterclockwise till it stops. Adjust gap
between brake discs by turning three
complete revolutions clockwise.
Figure 22
3. Set adjusting studs to unlock safety brake
at 47 mm (1.85 in), and lock counter nut
Figure 23
Figure 24
WHEEL HUB
1. Remove planetary gear cover
NOTE: Mark direction for reassembly.
Figure 25
Figure 26
2. Remove locking plate.
Figure 27
3. Use partially threaded M18 X 1,5 screws
to support puller.
Figure 28
Figure 29
5. Install outer races and taper roller
bearings. Special tool T21 is required
(refer to "Special Tools" in back of this
section).
Figure 30
6. Install seal. Special tool T23 is required
(refer to "Special Tools" in back of this
section).
Figure 31
7. Install wheel studs.
Figure 32
Figure 33
9. Install wheel hub onto axle housing.
Figure 34
10. Install gear rim on center wheel.
Figure 35
11. Special tool T19 is required (refer to
"Special Tools" in back of this section).
Figure 36
Figure 37
12. Install locking plate.
Figure 38
13. Apply Loctite #270 on locking plate bolts
(M18 X 1.5 10K), and tighten to 460 - 465
N•m (338 - 342 ft lb) torque.
Figure 39
14. Torque new bearings with seals to 30 to 40
N•m (22 - 29 ft lb).
Figure 40
Figure 41
2. Mark location of reduction gears for
reassembly. Remove locking plates.
Figure 42
3. Remove planet gears and inspect for wear
or damage, and replace as required.
Figure 43
4. Remove O-rings, retaining rings, thrust
washers, planet gears, needle bearings,
and planet gear shafts.
Figure 44
Figure 45
6. Install retaining rings and O-rings.
Figure 46
7. Line up assembly marks and install locking
plates. Apply Loctite #270 to lock plate
bolts.
Figure 47
8. Torque bolts to 315 - 320 N•m (232 - 235 ft
lb).
Figure 48
Figure 49
Figure 50
BEVEL PINION SUPPORT (REAR AXLE)
1. Remove bevel pinion support. Be careful,
and guard against damage to parts.
Figure 51
2. Special tool T15 is required (refer to
"Special Tools" in back of this section).
Figure 52
Figure 53
4. Assemble external races and taper roller
bearings, check cover measurement "A."
Figure 54
5. Determination of shim pack S1 for preload
of taper roller bearings.
NOTE: S1 = B - C + X
Figure 55
6. Value X = 0,09 - 0,11 mm (0.003 - 0.004
in) (Rear Axle)
NOTE: Value X = 0,11 - 0,14 mm
(0.004 - 0.006 in) (Front Axle)
Figure 56
Figure 57
8. Press fit bearing cups in cage. Assemble
pinion gear in cage, then press fit bearing
cone. Apply pressure to bearing at
specified load, and rotate the case to settle
bearing. A special tool T22 is required
(refer to "Special Tools" in back of this
section).
NOTE: Specified load = 49 Kn (5 ton)
NOTE: When rotating the case at the
specified load, rotate lightly by
hand. If the rotation is not
smooth, replace the bearing
and spacer, and again rotate Figure 58
lightly by hand.
9. Press fit oil seal evenly in cage.
Figure 59
Figure 60
11. Tighten nut with a torque wrench, then
check rotation torque.
NOTE: Nut Torque: 600 - 800 N•m (441
- 588 ft lb) (Rear Axle)
NOTE: Nut Torque: 500 - 700 N•m (368
- 515 ft lb) (Front Axle)
Figure 61
12. Rotation Torque: 120 - 130 N•m (88 - 96 ft
lb) (Rear Axle)
NOTE: Rotation Torque: 120 - 150 N•m
(88 - 110 ft lb) (Front Axle)
Figure 62
Figure 63
Figure 64
Figure 65
14. Remove differential carrier, then remove
bevel gear.
Figure 66
15. Remove bearing, then remove spring pin
from cross shaft,
Figure 67
NOTE: Replace fitting bolts of crown
wheel every time they are
removed.
Figure 68
Figure 69
16. Assemble in reverse order of disassembly.
Mount sun wheels and planet gears.
Figure 70
17. Insert spring pins half way up the shaft.
Figure 71
18. Use Loctite #270.
Figure 72
Figure 73
SELF LOCKING DIFFERENTIAL
1. Disassemble and check for worn or
damaged parts, and replace as necessary.
Figure 74
2. When assembling check to be sure discs
are not deformed.
Figure 75
3. .Use Loctite #270.
Figure 76
Figure 77
Figure 78
Figure 79
1PARKING BRAKE
(DANA)
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
Figure 1
Reference Reference
Description Description
Number Number
1 Parking Brake Piston 4 Parking Brake Lever
2 Service Brake Piston 5 Pinion/Ring Gear
3 Brake Disks 6 Parking Brake Spring
CAUTION!
Manually releasing of the parking brake (as an emergency measure)
If the parking brake cannot be released with the parking brake switch due to a defective pump or for any
other reason, it can be manually released by using the parking brake release bolt.
CAUTION!
Manually releasing the parking brake should not be abused. It should be limited to a disabled
machine needing to be moved to an out-of-traffic area.
Always block the wheels when the parking brake is released using the emergency release bolt.
Reference Reference
Description Description
Number Number
A Parking Brake Oil Chamber 4 Parking Brake Springs
1 Parking Brake Piston 5 Parking Brake Switch
2 Parking Brake Lever 6 Brake and Pilot Supply
3 Brake Disks Valve
Reference Reference
Description Description
Number Number
A Parking Brake Oil Chamber 4 Parking Brake Springs
1 Parking Brake Piston 5 Parking Brake Switch
2 Parking Brake Lever 6 Brake and Pilot Supply
3 Brake Disks Valve
S0605050K
1AIR CONDITIONER
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
TABLE OF CONTENTS
General Description........................................................................................ 3
Refrigerant Circulation.................................................................................... 4
Control Panel.................................................................................................. 6
Control Specifications..................................................................................... 7
Temperature Level Control and Display.......................................................... 8
Air Discharge According to Path Selection..................................................... 9
Air-conditioning System Circuit Diagram...................................................... 12
Troubleshooting ............................................................................................ 14
Weight of R134a Gas Used In Machines ..................................................... 18
Refrigerant System Repairs ......................................................................... 20
Refrigerant Safe Handling Procedures ................................................. 20
Repair and Replacement Procedure..................................................... 21
Refrigerant Recovery ............................................................................ 23
Vacuuming Refrigerant System............................................................. 23
Leakage Check ..................................................................................... 24
Refrigerant Charging............................................................................. 25
Inspecting System For Leakage............................................................ 27
GENERAL DESCRIPTION
AJS0880L
Figure 1
The heater and air conditioner are combined into one blower unit in the right control stand of operator’s
seat. If necessary, the operator can control inner temperature using the operation panel installed in the top
of the right side door.
The unit is equipped with an air filtration system
which filters out dirt and dust particles from air
being circulated into the operator’s cab. This
filter (1, Figure 2) should be cleaned out at
approximately every 500 hours and replaced
with a new one every 1000 hours.
NOTE: In the event that the unit is
being operated in a dusty
environment, cleaning and
replacement should be
performed more frequently.
WARNING!
All service and inspection of the air-
conditioning system should be performed Figure 2
with the starter switch in the "O" (OFF)
position.
REFRIGERANT CIRCULATION
4
7
3
HBOI020L
Figure 3
Reference Reference
Description Description
Number Number
1 Evaporator 5 Compressor
2 Expansion Valve 6 Blower Fan
3 Condenser 7 Receiver Dryer
4 Condenser Fan
• Refrigerant (R134a) is compressed to approximately 15 kg/cm2 (213 psi) within the compressor.
• The compressed refrigerant flows into the condenser at high temperature (approximately 80°C
(176°F)).
• The refrigerant in the condenser is cooled to approximately 60° by the condenser fan. At this
time the refrigerant changes from the gas to the liquid state, even though the temperature has
only been reduced 20°C (68°F). (From 80° - 60°C (176° - 140°F)).
• The refrigerant in its liquid form is injected into the evaporator through the expansion valve. At
this time the pressure is reduced by approximately 2 kg/cm2 (28 psi) and the temperature is also
reduced. As a result, the refrigerant absorbs the heat from the air surrounding the evaporator
creating a cooling effect and changes from the gas to the liquid state.
• The refrigerant once again flows into the compressor in the gaseous state and the process is
repeated.
WARNING!
Refrigerant gas is pressurized and sealed in the air-conditioning system. Special
precautions are required for the proper recharging or release of refrigerant. Release of
refrigerant into the atmosphere is strictly regulated by law. Make sure that you are in
compliance with all mandated federal, state and municipality requirements, before starting
any service or repair of the air conditioner. Refrigerant gas used in the system must meet
or exceed specifications for R134a refrigerant, or any subsequently issued
environmentally-mandated standard.
CONTROL PANEL
OFF A/C
HDA6047L
Figure 4
DISPLAY
TEMPERATURE
SENSOR
LOW SPEED RELAY
HDA6048L
Figure 5
CONTROL SPECIFICATIONS
50%
MAX HOT
0%
HDA6049L
Figure 6
LOW RELAY
HDA6050L
Figure 7
COMP OFF
1.5 C 4.0 C
HDA6051L
Figure 8
AJS0540L
Figure 9
Reference Reference
Description Description
Number Number
1 Select Switch 3-2 Rear Vent (L)
2 Front Vent 4 Heater Core
2-1 Front Vent (R) 5 Evaporator Core
2-2 Front Vent (L) 6 Air Filter
3 Rear Vent 7 Blower Motor
3-1 Rear Vent (R)
Foot
4 5
1
6
7
3-1
3-2
2
AJS0551L
Figure 10
Reference Reference
Description Description
Number Number
1 Select Switch 4 Heater Core
2 Foot Vent 5 Evaporator Core
3 Rear Vent 6 Air Filter
3-1 Rear Vent (R) 7 Blower Motor
3-2 Rear Vent (L)
Defroster
4 5
6
7
3-1
3-2
2
AJS0561L
Figure 11
Reference Reference
Description Description
Number Number
1 Select Switch 4 Heater Core
2 Defroster Vent 5 Evaporator Core
3 Rear Vent 6 Air Filter
3-1 Rear Vent (R) 7 Blower Motor
3-2 Rear Vent (L)
Figure 12
Reference Reference
Description Description
Number Number
1 Battery 14 A/C Control Panel
2 Battery Relay 15 A/C Unit
3 Fusible Link 15-1 Blower Motor
4 Circuit Breaker 15-2 Resister
5 Fuse Box 15-3 High Speed Relay
6 Headlight Switch 15-4 Mid Speed Relay
7 Condenser Fan Relay 15-5 Low Speed Relay
8 Condenser Fan Motor 15-6 Recirculate / Fresh Air
9 Compressor Relay Control Actuator
10 Foot / Defrost Control 15-7 Vent Actuator
Actuator 15-8 Temperature Control
11 Receiver Drier Actuator
12 Diode 15-9 Temperature Sensor
(Evaporator)
13 Compressor
TROUBLESHOOTING
Refrigerant Pressure Check
Figure 13
WARNING!
Always wear protective glasses and gloves when handling refrigerant. If refrigerant comes in
contact with the skin or eyes, immediately flush with clean, running water and consult a
physician.
Select a clean and well-ventilated area to work.
The refrigerant container is under high pressure and should be stored below 40°C (104°F). Be
careful not to drop the container from a high location
The contents are under high pressure and should not be used with compressed air or near an
open flame.
UNION NUT
TORQUE WRENCH
CORRECT WRONG
WRONG
WRONG
CORRECT
O - RING POSITION
HDA6066L
Figure 14
The following procedures should be observed for safe handling of refrigerant during vacuum and charging
process.
1. Use an approved recovery / charging device which can safely perform vacuum and charge work
simultaneously.
2. The new refrigerant has improved cooling characteristics than the old type and care should be used
not to overcharge the system.
3. Do not over tighten connections when working on refrigerant system.
4. The new refrigerant system standards require new tools, equipment and parts. DO NOT attempt to
use equipment use in servicing the old refrigerant system.
5. The new refrigerant oil (PAG type) has a high moisture absorption characteristic. When the
refrigerant system vacuum seal has been broken, immediately plug up all openings to prevent
moisture from entering into the system.
6. When joining unions which use O-ring seals, lightly coat O-rings with refrigerant oil. Be careful not to
drip oil on the threads of the nut.
7. Be certain the O-rings are seated properly on the refrigerant line lip. Always use new O-rings when
reassembling parts. Do not reuse old O-rings.
8. Use a vacuum pump to evacuate refrigerant system of air.
9. When charging the refrigerant system with the engine running, do not open the high pressure valve
on the manifold gauge as the reverse flow of high pressure refrigerant will rupture the hose.
10. When releasing the high pressure hose after completing the charging process, quickly disconnect the
hose to minimize refrigerant released to the air.
RECOVER REFRIGERANT
RUN SYSTEM
REFRIGERANT RECOVERY
Reference
Description 2 3
Number
1 To Compressor 1 4
2 Low Pressure Side
3 High Pressure Side
4 From Receiver
5 Refrigerant Recovery Tank
3. When the manifold gauge dial falls below 3.5 kg/cm2 (50 psi), slowly open the low pressure valve.
4. Open both the high and low pressure valves slowly until the manifold gauge dials indicates 0 kg/cm2
(0 psi).
Reference 2 3
Description
Number 1 4
1 To Compressor
2 Low Pressure Side
3 High Pressure Side
4 From Receiver
5 Vacuum Pump
1. Vacuuming Procedure. 5
HDA6068L
NOTE: When the A/C system has been Figure 17
exposed to the air, it must be
vacuumed out. Perform vacuum
process for 30 minutes for
complete moisture and air
evacuation.
A. Attach the manifold gauges and vacuum pump to the refrigerant system as shown.
B. Turn on the vacuum pump and open both valves.
C. When the low pressure gauge shows approximately 710 mmHg, close both valves and turn off
vacuum pump.
Reference
Description
Number
1 Handle
2 Hose Connection
3 Mounting Disk
LEAKAGE CHECK
NOTE: Perform the leakage check after completing vacuuming process.
1. After attaching the manifold gauge, open the high side valve.
2. Charge system until the low side gauge dial indicates a pressure of 1 kg/cm2 (14 psi) and close the
high side valve.
Reference
Description
Number
Refrigerant Leak
1
Detection Device
WARNING!
For accurate refrigerant leak
detection, perform leak detection
procedure in a well-ventilated area.
REFRIGERANT CHARGING
1. Perform the vacuuming procedure, vacuum holding and leaking tests as described in the proceeding
headings.
NOTE: First charge the refrigerant system with 100 g (3.5 ounces) of refrigerant with the engine
off. Then using the manifold gauges as a guide fully charge the system with the engine
running.
When exchanging refrigerant containers, press the manifold gauge low side valve to
eliminate air from the charging hose.
Reference
Description 2 3
Number
1 To Compressor 1 4
2 Low Pressure Side
3 High Pressure Side
4 From Receiver
5 Refrigerant Supply
Container
3. If refrigerant does not flow freely into system, try starting engine first before operating air conditioner.
• Temperature control switch setting: Maximum Cooling
• Blower Speed Setting: Hi (3 step)
• Engine Speed: 1,300 - 1,500 rpm
WARNING!
When charging refrigerant system with the engine running;
• Always keep refrigerant supply container in the upright position.
• Never open the high side pressure valve.
4. Open the manifold gauge low side valve and charge system to standard capacity.
NOTE: These standards are for outside temperatures between 30° - 35°C (86° - 95°F). The gauge
readings may vary for extreme temperature conditions.
WARNING!
• When outside temperature is low, warm the refrigerant supply container with
warm water not exceeding 40°C (104°F). Do not allow water to come in contact
with the charging adapter valve handle.
• When outside temperature is high, cool off refrigerant supply container and
condenser to aid the refrigerant charging process.
Reference
Description
Number
1 Pressure
2 High Pressure
3 Low Pressure
4 Compressor Stop
Inspection Procedure
1. High pressure side.
Compressor outlet →condenser inlet →receiver dryer inlet →air conditioner unit inlet
2. Low pressure side.
Compressor inlet →air conditioner unit outlet
3. Compressor.
Compressor shaft area, bolt hole area and magnetic clutch area.
4. Receiver dryer.
Pressure switch and plug area.
5. Connection valve area.
Inspect all valve areas.
Verify all valves are capped to prevent leaking.
Check for foreign material inside of valve cap.
6. Interior of air conditioner unit.
After stopping engine, insert detector probe into drain hose. (Leave inserted for 10 seconds
minimum.)
NOTE: When inspecting leakage from the air conditioner unit, perform the inspection in a well-
ventilated area.
1TRANSMISSION AND
TORQUE CONVERTER
(ZF 4WG-160)
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
Figure 1
Reference Reference
Description Description
Number Number
1 Engine 8 Parking Brake
2 Torque Converter 9 Front Axle Housing
3 Transmission 10 Reduction Gearing
4 Front Drive Shaft 11 Service Brake
5 Final Drive Shaft 12 Rear Differential
6 Rear Drive Shaft 13 Rear Axle Housing
7 Front Differential
TRANSMISSION CONTROL
Transmission control, See “Schedule of Measuring Points and Connection 4WG-160” on page 9., Electro-
hydraulic unit on page -10 and “Oil Circuit Diagram 4WG - 160 Forward 1st Speed” on page 11.
The transmission pump, necessary for the oil supply of the converter, and for the transmission control, is
input-side mounted from outside, together with stator shaft and oil supply flange, on the transmission. The
drive is realized by the pump-wheel flange of the converter.
The feed rate of the pump is Q = 80 lpm at nEngine = 2000 min-1.
This pump is sucking the oil through the coarse filter out of the oil sump and delivers it through the ZF-Fine
filter - the filters is fitted externally from the transmission - to the main system pressure valve.
ZF-Fine filter
Filtration ratio according to ISO 4572: β30 ≥ 75 β15 = 25 β10 = 5.0
Filter surface at least: 3.700 cm2
Dust capacity according to ISO 4572 at least: 17g
The six clutches of the transmission are selected via the 6 proportional valves P1 to P6.
The proportional valve (pressure regulator unit) is composed of pressure regulator (e.g. Y1), booster valve
oscillation damper.
The pilot pressure of 9.0 bar (130.54 psi) for the control of the follow-on slides is created by the reducing
valve. The pressure oil (16 + 2 bar (230+ 29 psi)) is directed via the follow-on slide to the corresponding
clutch.
By the direct proportional selection with separated pressure modulation for each clutch, the pressure to the
clutches, taking part in the gear change, will be controlled. In this way, a hydraulic intersection of the
clutches to be engaged and disengaged is achieved. This is loading to fast shifting without traction force
interruption.
At the shifting, the following criteria will be considered:
- Speed of engine, turbine, central gear train and output.
- Transmission temperature.
- Shifting mode (up-, down-, reverse shifting and speed engagement out of Neutral).
- Load level (full and part load, traction, overrun inclusive consideration of load cycles during the
shifting).
Marking on the
No. Denomination of the Position Connection
Valve Block
Measuring Points for Pressure Oil and Temperature
51 Converter Inlet - Opening pressure 9 bar (130 psi) M10 x 1 H
52 Converter Exit - Opening pressure 3.5 bar (51 psi) M14 x 1.5
53 Clutch Forward 16+2 bar (230 - 260 psi) KV M10 x 1 B
55 Clutch Reverse 16 +2 bar (230 +29 psi) KR M10 x 1 E
56 Clutch 16 +2 bar (230 +29 psi) K1 M10 x 1 D
57 Clutch 16 +2 bar (230 +29 psi) K2 M10 x 1 A
58 Clutch 16 +2 bar (230 +29 psi) K3 M10 x 1 C
60 Clutch 16 +2 bar (230 +29 psi) K4 M10 x 1 F
63 Converter Exit
M14 x 1.5
Temperature 100° C, Short-time 120° C
65 System Pressure 16 +2 bar (230 +29 psi) K4 M10 x 1 K
Measuring points for Delivery Rates
15 Connection to the Heat Exchanger 1 5/16'' - 12UNF-2B
16 Connection from the Heat Exchanger 1 5/16'' - 12UNF-2B
Inductive Transmitters and Speed Sensor
21 Inductive Transmitter n Turbine M18 x 1.5
34 Speed Sensor n Output and Speedometer -------
47 Inductive Transmitter n Central Gear Train M18 x 1.5
48 Inductive Transmitter n Engine M18 x 1.5
Connections
49 Plug Connection on the Hydraulic Control Unit
68 Pilot Pressure (Option) M16 x 1.5 J
69 System Pressure (Option) M16 x 1.5 G
Reference
Positions
Number
WT Heat Changer
WGV Converter Back Pressure Valve 3.5 bar (51 psi)
WSV Converter Relief Valve 9 bar (131 psi)
HDV System Pressure Valve 16 + 2 bar (232 + 29 psi)
RV-9 Pressure Reducing Valve 9 bar (131 psi)
NFS Follow-on Slide
D Oscillation Damper
B Orifice
P1 Proportional Valve - Clutch K4
P2 Proportional Valve - Clutch KR
P3 Proportional Valve - Clutch K1
P4 Proportional Valve - Clutch K3
P5 Proportional Valve - Clutch KV
P6 Proportional Valve - Clutch K2
Y1 -Y6 Pressure Regulator
TEMP Temperature Sensor
Figure 3
21
13
10
18
19
14 17
20
8
15
1
16
9 3
11 4
12 5
6
2
AJS0191L
Figure 5
Reference Reference
Description Description
Number Number
1 T/M Controller 12 T/M Cutoff Pressure Switch
2 T/M Control Valve 13 Downshift Switch
3 T/M Oil Temperature Sensor 14 Safety Starter Switch
4 Engine Pick-Up Sensor 15 Fuse Box
5 Central Gear Pick-up Sensor 16 Parking Brake Switch
6 Turbine Pick-up Sensor 17 Control Unit
7 Output Speed Sensor 18 Starter Controller
8 Shift Lever Switch 19 LIS Switch (Option)
9 Auto Select Switch 20 LIS Solenoid Valve
10 Display 21 Speedometer
11 T/M Cutoff Switch
AJS0200L
Figure 6
TRANSMISSION CONTROL VALVE
1. The transmission control valve contains a
temperature sensor and proportional
solenoid valves (Y1-Y6) that direct
pressurized fluid to various clutches that
generates a speed with control the shift
gears.
2. Specification of the proportional solenoid
valve.
• Resistance: 19 ohm ±1.9 ohm at
20°C. AJS0210L
Figure 7
• Pressure: 0.8 kg/cm2 → 8.3 kg/cm2
(11 - 118 psi)
3. The contained temperature sensor detects
the temperature of the control valve and
transmits the electrical signal to the TCU,
and serves TCU determines gears to
change.
• Neutral: At temperature less than -
30°C
• 1st or 2nd gear: At temperature less
than -10°C
• Normal Operation: At temperature
greater than -10°C
D C B A
(AD5) PINK
X2
(AD4) YELLOW
(VP) RED
(AD7) VIOLET
D C B A
(AD1) BLUE
X1
(AD2) GREEN
(AD3) BLACK
AJS0290L
Figure 15
6. Switch Connection
ED1 VP
AD1 B1
AD2 B2
AD3 B3
AD4 V
AD5 R
AD6 AS
AD7 KD
Figure 16 AJS0300L
A
3. Automatic shifting takes place between
gears.
B
• Forward: 2nd - 3rd - 4th
• Reverse: 2nd - 3rd
HLB2007L
4. When the switch is in the '0(Manual)' Figure 17
position, the shifting is returned to the
manual mode and the control signal shifts
the transmission to gear selected by the
operator.
DISPLAY
NOTE: See "Transmission Error Codes
(ZF)" shop manual section.
AJS0311L
Figure 18
The transmission proportioning solenoid valves are shown here as (Y1 thru Y6, Figure 18).
Neutral
AJS0320L
Figure 19
When all transmission solenoid valves are de-energized (OFF) the transmission is in "NEUTRAL."
AJS0330L
Figure 20
Transmission solenoid valves (Y3 and Y5, Figure 20) are energized when in forward first gear.
AJS0340L
Figure 21
Transmission solenoid valves (Y5 and Y6, Figure 21) are energized when in forward second gear.
AJS0350L
Figure 22
Transmission solenoid valves (Y4 and Y5, Figure 22) are energized when in forward third gear.
AJS0360L
Figure 23
Transmission solenoid valves (Y2 and Y4, Figure 23) are energized when in forward fourth gear.
AJS0370L
Figure 24
Transmission solenoid valves (Y1 and Y3, Figure 24) are energized when in reverse first gear.
AJS0380L
Figure 25
Transmission solenoid valves (Y1 and Y6, Figure 25) are energized when in reverse second gear.
AJS0390L
Figure 26
Transmission solenoid valves (Y1 and Y4, Figure 26) are energized when in reverse third gear.
Overview
1. There are two downshift switches down
Figure 27, and it is possible for operators
to select one of them according to the
condition.
2. If the downshift switch is depressed during
the machine moving, downshifting takes
place automatically. As a result, fast
digging and moving is possible. But at the
manual mode the kick down can only be
activated.
AJS0400L
3. If a change or traveling direction takes Figure 27
place or the downshift switch is depressed
a second time, downshifting is released
automatically.
AJS0410L
Figure 28
AJS0420L
Figure 30
When the auto selector switch (Figure 30) is in the "I" position, the '29' terminal of transmission controller is
energized. This allows the transmission to automatically upshift and downshift gears depending on the
load and on the engine speed.
If either downshift switch (Figure 27) is activated, a pulse signal is sent to the '22' terminal of transmission
controller. This signal shifts the transmission to the next lowest gear.
Automatic
Downshift Switch "Activated"
Gear Selection
Fourth Gear Downshift to Third Gear
Third Gear Downshift to Second Gear
Second Gear Downshift to First Gear
First Gear Remains in First Gear
When either downshift (Figure 27) is depressed a second time, the transmission pulse signal of the '22' is
interrupted and the transmission returns to normal operation.
NOTE: The fourth to the third gear changes without any rpm change when the downshift switch is
pressed.
NOTE: The third to the second gear, and the third to the first gear, changes occur when the rpm is
reduced 200 - 300 rpm from current setting.
CAUTION!
When the machine is traveling or working in the place of inclination, the transmission cutoff
switch (Figure 31) must be placed in position 'O' for the purse of using engine braking and the
normal braking function at the same time.
AJS0430L
Figure 32
Figure 33
Figure 34
Reference Reference
Description Description
Number Number
1 Lifting Lugs 6 Model Identification Plate
2 Diaphragms - Direct Mounting 7 Attachment Possibility for Oil
3 Transmission Suspension Level Tube with Oil Dipstick
Threads M20 (Converter-side)
4 Output Flange - Converter Side 8 Attachment Possibility for
Emergency Steering Pump
5 Oil Drain Plug With Magnetic
Insert M38 x 1.5 9 Converter
Figure 35
Reference Reference
Description Description
Number Number
1 Diaphragms - Direct Mounting 7 Exchange Filter (Fine Filter)
2 Converter 8 Output Flange - Rear
3 Converter Bell Housing 9 Oil Drain Plug With Magnetic
4 Breather Insert M38 x 1.5
5 Transmission Case Cover 10 Output Flange - Converter Side
6 Filter Head 11 Transmission Case
Figure 36
Reference Reference
Description Description
Number Number
1 Lifting Lugs 7 Port - Return Line From Parking
2 Power Take-off; Coaxial; Brake (Option)
Engine-Dependent 8 Exchange Filter (Fine Filter)
3 Electro-Hydraulic Control 9 Filter Head With Connection for
4 Oil Level Tube With Oil Dipstick Filter Restriction Switch
5 Transmission Suspension 10 Port-System Pressure to
Threads M20 Parking Brake Valve (Option)
6 Output Flange - Rear
Figure 37
Figure 38
Figure 39
Coupling K1
Figure 40
Figure 41
Figure 42
Figure 43
Figure 44
Figure 45
Figure 46
Figure 49
Figure 50
Figure 51
Figure 52
IMPORTANT
Different versions in relation to the position of the cable harness are possible.
In this connection, pay attention to the Specifications of the Vehicle Manufacturer.
Figure 53
Figure 54
DISASSEMBLY
1. Figure 55, shows complete control unit.
Figure 55
Figure 56
3. Loosen socket head screws.
4. Remove duct plate, 1st gasket,
intermediate plate and 2nd gasket from
valve housing.
(S) Box spanner (Torx TX-27) - 5873 042
002
Figure 57
5. Remove retaining clip.
Figure 58
6. Loosen socket head screws.
7. Remove cover from housing and cable
harness.
(S) Box spanner (Torx TX-27) - 5873 042
002
Figure 59
Figure 60
10. Loosen socket head screws.
11. Remove fixing plate and pressure
regulators (3x).
(S) Box spanner (Torx TX-27) - 5873 042
002
Figure 61
12. Loosen two socket head screws and locate
housing provisionally, using adjusting
screws. (Housing is under spring preload).
Loosen remaining socket and screws.
(S) Box spanner (Torx TX-27) - 5873 042
002
(S) Adjusting screws - 5870 204 036
Figure 62
13. Remove housing from valve housing by
loosening adjusting screws uniformly.
(S) Adjusting screws - 5870 204 036
Figure 63
Figure 64
Figure 65
REASSEMBLY
NOTE: Check all components for
damage and replace if
necessary. Before installation,
check free travel of all moving
parts in housing. Spools can be
exchanged individually. Oil
components before reassembly
according to ZF-List of
lubricants TE-ML 03.
Insert diaphragms with concave
side facing up until contact is
obtained. Figure 66
Reference
Description
Number
1 Vibration Damper (3x
Spool and
Compression Spring)
2 Follow On Site (3x
Spool and
Compression Spring)
3 Pressure Reducing
Valve (1x Spool and Figure 67
Compression Spring)
Figure 68
3. Install two adjusting screws.
4. Assemble gasket (1, Figure 69) and
housing cover (Figure 69). Position
housing cover uniformly, using adjusting
screws, until contact is obtained and
remove cylindrical pins (assembly aid)
again (Figure 69).
NOTE: Pay attention to different
housing covers.
5. Install recess Ø 15.0 mm (0.5906 in) (2,
Figure 69), facing spring of pressure
reducing valve. Figure 69
(S) Adjusting screws - 5870 204 036
Figure 71
7. Install pressure regulators and attach
using fixing plates and socket head
screws.
NOTE: Install fixing plate, with claw
showing downward. Pay
attention to radial installation
position of pressure regulators,
see Figure 72.
NOTE: Torque limit 0.56 kg•m (4 ft lb).
(S) Box spanner (Torx TX-27) - 5873 042
002
Figure 72
Reference
Description
Number
1 Main Pressure Valve
(1x Spool and
Compression Spring.)
2 Follow On Slide (3x
Spool and
Compression Spring)
Figure 73
3 Vibration Damper (3x
Spool and
Compression Spring)
Figure 76
K. Install female connector against
shoulder, with groove facing guide
nose of cover.
L. Install gaskets (Figure 77) and fasten
cover using socket head screws.
NOTE: Torque limit 0.56 kg•m (4 ft lb).
(S) Box spanner (Torx TX-27) - 5873 042
002
Figure 77
M. Install female connector using
retaining clamp, see Figure 78.
N. Install opposite cover.
Figure 78
Figure 79
9. Intermediate plate - version with screens:
A. Insert screens (6x) flash -mounted
into bore of intermediate plate, see
Figure 80.
NOTE: Pay attention to installation
position- screens are facing up
(facing duct plate).
Figure 80
B. Mount intermediate plate, with
screens with screens facing up.
Figure 81
C. Mount gasket II.
Figure 82
Figure 83
E. Install new O-rings on screw plugs
(8x) and install.
NOTE: Torque limit 0.61 kg•m (4.4 ft
lb).
NOTE: The installation of hydraulic
control unit is described in
following section, See
“Attaching Duct Plate” on page
119. and “Attaching Hydraulic
Control Unit” on page 119.
Figure 84
Figure 85
2. Remove oil filter from filter head.
(S) Belt spanner - 5870 105 005
Figure 86
3. Loosen hex. head screws and remove filter
head from duct plate.
Figure 87
Figure 88
2. Remove both gaskets and intermediate
plate.
(S) Adjusting screws - 5870 204 031
Figure 89
3. Loosen socket head screws and hex. nuts
and remove duct plate from gearbox
housing.
4. Remove flat gasket.
(S) Adjusting screws - 5870 204 031
Figure 90
Remove and Dismantle Converter Safety
Valve
1. Pull converter safety valve out of housing
bore.
Figure 91
Reference
Description
Number
1 Converter safety valve
(compl.)
(S) Assembly aid - 5870
345 084
Figure 92
3. Preload compression spring carefully,
remove cylindrical pin (Figure 93) and
components (Figure 94).
Figure 93
Figure 94
Engine Connection - Converter
1. Remove lock plate and loosen hex. head
screws.
2. Remove disk and pry input flange from
shaft.
Figure 95
Figure 96
4. ,Using lifting device remove cover with
converter from transmission.
(S) Set of eye bolts - 5870 204 002
Figure 97
5. Press input shaft, reap. converter out of
the cover (ball bearing).
Figure 98
6. Squeeze retaining ring out and remove
ball bearing.
(S) Set of internal pliers - 5870 900 013
Figure 99
Figure 100
8. Loosen hex. head screws and remove
input shaft from the membrane.
Figure 101
9. Remove inductive transmitter (n Engine).
Figure 102
10. Loosen hex. head screws and remove
converter housing.
Figure 103
Figure 104
2. Apply separating device (S) on the splines
run out of the stator shaft and pull pump
(compl.) out of the housing bores, using
two-leg puller.
(S) Separating device - 5870 300 024
(S) Two-leg puller - 5870 970 004
Figure 105
3. Remove transmission pump from stator.
4. Remove cam plate from pump.
NOTE: If traces of wear are seen in the
pump housing or the cam disk,
the complete pump has to be
replaced.
5. Fit cam disk again and attach it using
grooved pins (2x).
Figure 106
6. Loosen hex. head screws and remove oil
feed housing.
7. Remove flat gasket.
Figure 107
Figure 108
2. Figure 109, shows the special tool
required for dismantling converter
pressure valve.
Reference
Description
Number
1 Converter Pressure
Valve (Compl.)
(S) Assembly Aid - 5870
345 084
Figure 109
3. Preload compression spring carefully,
drive roll pin out and remove components.
(S) Assembly aid - 5870 345 084
Figure 110
4. Loosen hex. head screws, remove cover
and flat gasket.
Figure 111
Figure 112
4. Remove speed sensor and both inductive
transmitters (Figure 113).
Figure 113
5. Loosen hex. nuts and remove the two
covers (Figure 114).
6. Loosen screw connection.
Figure 114
7. Drive both cylindrical pins (Figure 115) out.
Figure 115
Figure 116
9. Figure 117, shows the installation position
of the single clutches and of the input and
output.
Reference
Description
Number
KV Clutch - Forward
KR Clutch - Reverse
K1 Clutch - 1st Speed
K2 Clutch - 2nd Speed
K3 Clutch - 3rd Speed
K4 Clutch - 4th Speed Figure 117
AN Input
AB Output
NOTE: The following Figures describe the common removal of all clutches. For this purpose, the
housing cover, combined with special tool (Handles 5870 260 010) is necessary. The
removal of single clutches without help of the housing cover and the handles is extremely
difficult because of the installation conditions. Besides, there is the danger of injuries.
NOTE: Before the common removal of the clutches, the output shaft must be removed, see Figure
118.
10. Loosen socket head screws and remove
output shaft and both oil baffle plates.
Figure 118
Figure 119
13. Remove housing cover along with clutches
from gearbox housing, using lifting device.
(S) Handle (6 pieces needed) - 5870 260
010
Figure 120
14. Fasten housing cover on assembly car.
Figure 121
15. Tilt housing cover 180°.
16. Remove handles.
(S) Handle (6 pieces needed) - 5870 260
010
Figure 122
Figure 123
18. Remove clutch K1, at the same time, lift
clutch K4.
Figure 124
19. Lift clutch K3 out of the housing cover.
Figure 125
20. Remove clutch K4, at the same time lift
input slightly.
Figure 126
Figure 127
22. Remove outer bearing race and pull output
shaft (power take off) out of the housing
bore.
Figure 128
23. Squeeze rectangular ring (Figure 129) out
and remove ball bearing from shaft.
Figure 129
Figure 130
Figure 132
5. Squeeze snap ring out and remove plate
pack.
Figure 133
6. Preload compression spring, squeeze
retaining ring out and remove components.
(S) Assembly aid - 5870 345 086
(S) Set of external pliers - 5870 900 015
Figure 134
Figure 135
8. Remove both O-rings.
Figure 136
9. Squeeze inner retaining ring (shaft) out.
(S) Set of external pliers - 5870 900 015
Figure 137
10. Locate idler gear using separating device
(Figure 138) and press it from the shaft
(Figure 139).
11. Remove released needle bearing.
(S) Separating device - 5870 300 028
Figure 138
Figure 140
Dismantle Clutch K1. K2 and K3
NOTE: The following Figures show the
disassembly of the clutch K3
1. The disassembly of the clutches K1 and
K2 is analogous. Squeeze rectangular ring
(Figure 141) out.
Figure 141
2. Pull tapered roller bearing from the shaft.
3. Remove opposite tapered roller bearing
accordingly, see Figure 141 and Figure
142.
(S) Grab sleeve - 5873 001 057
(S) Grab sleeve (K3 - on output side) -
5873 001 058
(S) Basic set - 5873 001 000
Figure 142
Figure 143
5. Remove idler gear.
Figure 144
6. Remove both needle bearings and axial
bearing (compl.).
Figure 145
7. Squeeze snap ring out and remove plate
pack.
Figure 146
Figure 147
9. Press piston out of the plate carrier, using
compressed air.
Figure 148
10. Pry plate carrier from the shaft.
(S) Pry bar - 5870 345 065
Figure 149
Dismantle Clutch K4
1. Squeeze rectangular ring out and pull
tapered roller bearing from the shaft.
2. Remove opposite tapered roller bearing.
(S) Grab sleeve - 5873 001 057
(S) Basic set - 5873 001 000
Figure 150
Figure 151
4. Squeeze snap ring out and remove plate
pack.
Figure 152
5. Preload compression spring, squeeze
retaining ring out and remove components.
6. Remove piston.
NOTE: The separation of shaft and
gear is not possible (shrink fit).
(S) Assembly aid - 5870 345 085
Figure 153
Dismantle Input Shaft
1. If necessary, press turbine shaft out of the
input shaft.
NOTE: The turbine shaft is axially fixed
using a snap ring which will be
destroyed at the pressing out.
Figure 154
Figure 155
Figure 157
Figure 158
5. Locate both pressure pipes using special
device.
(S) Tension bar - 5870 654 030
Figure 159
Figure 161
11. Install new O-ring on screw plug and install
it.
NOTE: Torque limit (M30x1,5) 5.20
kg•m (38 ft lb).
Figure 162
Figure 163
13. Insert both oil pipes (Figure 164) into the
housing cover, tilt housing cover 180° and
roll in oil pipes into the housing bores.
NOTE: The pipe end must be situated
slightly below the housing plane
face.
(S) Rolling tool - 5870 600 005
Figure 164
14. Install studs 27x (M8x25) according to the
Figure 165.
NOTE: Torque limit (M8) 1 kg•m (7 ft
lb).
Figure 165
15. Insert set screws (2x) into the housing
bores (Figure 166).
Figure 166
Figure 167
Preassemble Plate Carrier
NOTE: Figure 167 thru Figure 170.
1. Check function of the drain valve.
NOTE: Ball may not seize, if necessary
clean using compressed air.
2. Insert both O-rings (Figure 168) into the
recesses of the piston and oil them.
NOTE: Make sure that O-rings are not
twisted.
3. Assemble piston until contact is obtained.
Figure 168
NOTE: Pay attention to the installation
position, see Figure.
4. Install compression spring along with
spring cup (2x).
Figure 169
Figure 170
Figure 171
Reference Reference
Description Description
Number Number
1 Plate Carrier 5 Outer Plates - Coated
2 Piston On Both Sides
3 Outer Plate - One- 6 Snap Ring (Optional,
sided Coated S = 2.10 - 4.20 mm
(0.0827 - 0.1654 in))
4 Inner Plates
7 End Shim
NOTE: Install outer plate 3 with the uncoated side facing the piston, reap. the end shim.
1. Install on the end shim side two outer and inner plates each.
NOTE: Effective number of friction surfaces = 18.
Figure 172
4. Mount end shim and squeeze snap ring
(e.g. s = 3.0 mm (0.1181 in)).
Figure 173
5. Press end shim on with about 10 kg (22 lb)
and measure Dimension I from the end
face/plate carrier to the end shim.
Dimension I e.g. 7.250 mm (0.2854 in)
(S) Digital depth gauge - 5870 200 072
Figure 174
Figure 175
EXAMPLE:
Dimension I 7.250 mm (0.2854 in)
Dimension II - 4.750 mm (0.1870 in)
Difference = Plate clearance 2.50 mm (0.0984 in)
NOTE: In case of deviations from the required plate clearance, correct using corresponding snap
ring (s = 2.10 - 4.20 mm (0.0827 - 0.1654 in)
7. Remove plate pack, oil and install it again.
8. Install idler gear until all inner plates are
accommodated.
NOTE: This step makes the later
assembling of the idler gear
easier.
9. Remove idler gear again.
Figure 176
10. Install stud (Figure 177).
NOTE: Use Loctite #243.
NOTE: Torque limit (M10) 1.73 kg•m
(13 ft lb).
Figure 177
Figure 178
12. Assemble needle bearing.
Figure 179
13. Press idler gear against shoulder.
NOTE: Support it on the inner bearing
race.
Figure 180
14. Attach idler gear axially using retaining
ring.
NOTE: At clutch KR there is no recess
in the shaft - assemble retaining
ring until contact on the inner
bearing race is obtained.
(S) Set of internal pliers - 5870 900 013
Figure 181
Figure 182
Figure 183
16. Press tapered roller bearing against
shoulder.
17. Install opposite tapered roller bearing.
Figure 184
18. Check function of clutch using compressed
air.
NOTE: At correctly installed
components, the closing, reap.
opening of the clutch is clearly
audible.
Figure 185
Figure 187
3. Check function of the drain valve.
NOTE: Bail may not seize, if necessary
clean using compressed air.
4. Insert both O-rings (Figure 188) into the
piston recesses and oil them.
NOTE: Make sure that O-rings are not
twisted.
Figure 188
5. Install piston until contact is obtained.
NOTE: Pay attention to the installation
position, see Figure.
Figure 189
Figure 190
7. Preload compression spring and attach it
using retaining ring.
(S) Assembly aid (K2 and K3) - 5870 345
085
(S) Assembly aid (K1) - 5870 345 086
Figure 191
Plate Pack K1, K2, and K3
NOTE: Stacking of clutch plates K1, K2
and K3 is identical. Figure 192,
shows the installation position
of the components.
Reference
Description
Number
1 Plate Carrier
2 Piston
3 Outer Plate - One-
sided Coated
4 Inner Plates
5 Outer Plates Coated
on Both Sides Figure 192
6 Snap Ring (Optional,
s = 2.10 - 4.20 mm
(0.0827 - 0.1654 in)
7 End Shim
NOTE: Install outer plate 3 with the uncoated side facing the piston. Install two outer and inner
plates each on the end shim side. Effective number of the friction surfaces = 14.
Figure 193
10. Fit end shim and squeeze snap ring (e.g.
3.0 mm (0.1181 in)) in.
Figure 194
11. Press end shim on with about 10 kg (22
lb), and measure Dimension I from the end
face/plate carrier to the end shim.
Dimension I e.g. 8.20 mm (0.3228 in)
(S) Digital depth gauge - 5870 200 072
Figure 195
Figure 196
EXAMPLE:
Dimension I 8.20 mm (0.3228 in)
Dimension II - 6.0 mm (0.2362 in)
Difference = Plate clearance 2.20 mm (0.0866 in)
NOTE: In case of deviations from the required plate clearance, correct using corresponding snap
ring (s = 2.10 - 4.20 mm (0.0827 - 0.1654 in).
13. Remove plate pack, oil and install it again.
14. Assemble running disk (1, Figure 197) (50
x 70 x 4), axial needle cage (2) and axial
washer (3) (50 x 70 x 1).
NOTE: Install running disk 1 with the
chamfer facing the axial needle
cage.
Figure 197
15. Assemble both needle bearings.
Figure 198
Figure 199
17. Assemble axial washer 3 (50 x 70 x 1),
axial needle cage 2 and running disk 1 (50
x 70 x 4).
NOTE: Install running disk 1 with the
chamfer facing the axial needle
cage.
NOTE: Only if the running disk is
overlapping with the shaft
collar, the accommodation of all
the inner plates is ensured.
Figure 200
18. Press tapered roller bearing against
shoulder.
Figure 201
19. Press tapered roller bearing against
shoulder.
Figure 202
Figure 203
Reassemble Clutch K4
1. Cool shaft (about -80°C (-112°F)), heat
gear (about +120°C (+248°F)) and
assemble it until contact is obtained.
Figure 204
2. Locate gear axially using retaining ring.
(S) Set of external pliers - 5870 900 015
Figure 205
3. Install stud (Figure 206).
NOTE: Use Loctite (Type No. 243).
NOTE: Torque limit (M10) 1.73 kg•m
(13 ft lb).
Figure 206
Figure 207
6. Install piston until contact is obtained.
NOTE: Pay attention to the installation
position, see Figure.
Figure 208
7. Install compression spring and spring cup
(2x), preload and attach using retaining
ring.
(S) Assembly aid - 5870 345 085
Figure 209
Reference
Description
Number
1 Plate Carrier
2 Piston
3 Outer Plate - One-
sided Coated
4 Inner Plates
5 Outer Plates - On Figure 210
Both Sides Coated
6 Snap Ring (Optional,
s = 2.10 - 4.2 mm
(0.0827 - 0.1654 in))
7 End Shim
Figure 211
3. Fit end shim and squeeze retaining ring
(e.g. s = 3.0 mm (0.1181 in)).
Figure 212
Figure 213
5. Press end shim against snap ring (upward)
until contact is obtained and determine
Dimension II.
Dimension II e.g. 6.0 mm (0.2362 in)
(S) Digital depth gauge - 5870 200 072
Figure 214
EXAMPLE:
Dimension I 7.20 mm (0.2835 in)
Dimension II 6.00 mm (0.2362 in)
Difference = Plate clearance 120.00 mm (4.7244 in)
NOTE: In case of deviations from the required plate clearance, correct using corresponding snap
ring (s = 2.10 - 4.20 mm (0.0827 - 0.1654 in)).
6. Install idler gear until all inner plates are
accommodated.
NOTE: This step makes the later
assembling of the idler gear
easier.
7. Remove idler gear again.
Figure 215
Figure 216
9. Assemble both needle bearings.
Figure 217
10. Assemble idler gear.
Figure 218
11. Assemble axial washer (3, Figure 219) (50
x 70 x 1) needle cage (2) and running disk
(1) (50 x 70 x 4).
NOTE: Install running disk 1 with the
chamfer facing the needle cage.
Figure 219
Figure 220
13. Attach plate carrier axially using retaining
ring.
(S) Set of external pliers - 5870 900 015
(S) Handle - 5870 260 010
Figure 221
14. Press tapered roller bearing against
shoulder.
15. Install opposite tapered roller bearing.
Figure 222
16. Check function of the clutch using
compressed air.
NOTE: With correctly installed
components, the closing, reap.
opening of the clutch is clearly
audible.
Figure 223
Figure 224
2. Attach gear axially using retaining ring.
(S) Set of external pliers - 5870 900 015
Figure 225
3. Squeeze snap ring into the recess of the
turbine shaft.
Figure 226
4. Install turbine shaft until the snap ring
snaps into the recess of the input shaft -
turbine shaft is axially fixed.
Figure 227
Figure 228
6. Install ball bearing.
7. Squeeze rectangular ring (Figure 229) in
and hook it in.
Figure 229
8. Insert output shaft into the housing bore
until contact is obtained.
Figure 230
Figure 231
2. Insert clutch KR, input shaft and clutch KV
together into housing cover.
Figure 232
3. Install clutch K4.
Figure 233
Figure 234
5. Position clutch K1.
Figure 235
6. Insert clutch K2.
Figure 236
7. Figure 237, shows the installation position
of the single clutches in the housing cover.
Figure 237
Figure 238
9. Squeeze rectangular rings (7 pieces, see
Figure 239) in and hook them in.
10. Grease rectangular rings and align them
centrically.
Figure 239
11. Tilt housing cover 180°.
12. Mount eye bolts, see Figure 240.
(S) 2x Eye bolt M20 - 0636 804 003
(S) lx Eye bolt M16 - 0636 804 001
(S) Puller device - 5870 000 017
Figure 240
13. Install adjusting screws (S).
14. Position housing cover using lifting device
carefully on the gearbox housing until
contact is obtained, reap. position the
clutches in the gearbox housing.
NOTE: Pay attention to the overlapping
of the oil pipes with the bores in
the housing cover.
(S) Lifting chain - 5870 281 047
(S) Adjusting screws - 5870 204 007
Figure 241
Figure 242
16. Remove housing cover from gearbox
housing, using lifting device.
(S) Lifting chain - 5870 281 047
Figure 243
Output
1. Assemble sheet and press both inner
bearing races against shoulder until
contact is obtained.
Figure 244
2. Insert outer bearing race (Figure 245) into
the housing bore until contact is obtained.
Figure 245
Figure 246
4. Insert output shaft.
Figure 247
5. Fasten both sheets using socket head
screws (4x).
NOTE: Insert socket head screws with
Loctite (Type No. 243).
NOTE: Torque limit (M8/8.8) 2.35 kg•m
(17 ft lb).
Figure 248
6. Squeeze rectangular rings (6x) into the
recesses of the clutch shafts and hook
them in.
7. Grease rectangular rings and align them
centrically.
Figure 249
Figure 250
9. Cover mounting face with sealing
compound Loctite #574.
10. Install adjusting screws (S) and position
housing cover carefully against gearbox
housing until contact is obtained, using
lifting device.
NOTE: Pay attention to the overlapping
of the oil pipe with the bores in
the housing cover.
(S) Adjusting screws - 5870 204 007
(S) Lifting chain - 5870 281 047
Figure 251
11. Install both cylindrical pins.
Figure 252
12. Fasten housing cover using hex. head
screws.
NOTE: Torque limit (M10/8.8) 4.69
kg•m (34 ft lb).
NOTE: Pay attention to the position of
the fixing plate, see Figure 253.
Figure 253
Figure 254
14. Heat the output flange (Max. 90°C
(194°F)), assemble it and attach it using
washer and hex. head screws.
NOTE: Wet contact area of washer with
sealing compound Loctite (Type
No. 574).
NOTE: Torque limit (M8/10.9) 3.47
kg•m (25 ft lb).
Figure 255
15. Attach hex. head screws using lock plate.
16. Install output flange on the converter side
accordingly (Figure 254 thru Figure 256).
(S) Driver - 5870 057 011
(S) Handle - 5870 260 002
Figure 256
Converter Pressure Valve
NOTE: Figure 257, shows the
components of the converter
pressure valve.
Reference
Description
Number
1 Piston
2 Compression Spring
3 Valve Insert
4 Roll Pin
Figure 257
Figure 258
2. Insert pre-assembled converter pressure
valve into the housing bore.
Figure 259
Oil Feed Housing - Transmission Pump
1. Install two adjusting screws (Figure 260)
and mount flat gasket.
(S) Adjusting screws - 5870 204 011
Figure 260
2. Mount oil feed housing and attach it
provisionally using washers and hex. head
screws.
NOTE: Screw the hex. head screws in
only until contact is obtained do
not tighten.
Figure 261
Figure 262
4. Install O-ring (Figure 263) and oil it.
Figure 263
5. Install transmission pump (compl.) until
contact is obtained.
NOTE: Pay attention to the overlapping
of the bores.
Figure 264
6. Install new O-rings on socket head screws
(Figure 265).
NOTE: Grease O-Rings.
Figure 265
Figure 266
8. Attach oil feed housing finally using hex.
head screws (mount flat washers).
NOTE: Torque limit 2.55 kg•m (18 ft lb).
NOTE: Pay attention to the installation
position of the fixing plate, see
Figure 268.
Figure 267
Figure 268
9. Install flat gasket and cover. Secure into
place using hex. head screws.
NOTE: Torque limit (M8/8.8) 2.35 kg•m
(17 ft lb).
Figure 269
Reference
Description
Number
1 Plate
2 Ball
3 Compression Spring
4 Valve Insert
5 Valve Sleeve
6 Cylindrical Pin Figure 270
Figure 271
3. Insert converter safety valve (compl.) into
the housing bore until contact is obtained.
Figure 272
Figure 273
2. Install gasket, place duct plate against
shoulder and fasten it using socket head
screws and hex. nuts (mount flat washers).
NOTE: Torque limit 2.55 kg•m (18 ft lb).
Figure 274
Attaching Hydraulic Control Unit
1. Install two adjusting screws.
2. Mount gasket (1, Figure 276), intermediate
plate (2) and gasket (3).
NOTE: Pay attention to the installation
position of the different gaskets,
see Figure 276.
(S) Adjusting screws - 5870 204 031
Figure 275
Figure 277
Figure 278
2. Fasten intermediate plate and filter head
using hex. head screws (mount flat
washers).
NOTE: Torque limit 2.55 kg•m (18 ft lb).
Figure 279
3. Oil gasket and tighten exchange filter
handtight.
Figure 280
4. If necessary, install warning switch
(according to the version).
Figure 281
Figure 282
6. Fasten the two covers (Figure 283) using
hex. nuts (mount flat washers) on the
housing.
NOTE: Torque limit 2.55 kg•m (18 ft lb).
Figure 283
7. Mount oil level tube.
8. Install screw plug (Figure 284).
NOTE: Install new gaskets.
NOTE: Torque limit (M8/8.8) 2.35 kg•m
(17 ft lb).
NOTE: Torque limit (screw plug
M26x1,5) 8.16 kg•m (59 ft lb).
Figure 284
Speed Sensor and Inductive Transmitter
1. Grease O-ring, install speed sensor
(Figure 285) and fasten it using socket
head screw.
NOTE: Torque limit (M8/8.8) 2.35 kg•m
(17 ft lb).
Reference
Description
Number
34 Speed - Output and
Speedometer
Figure 285
Reference
Description
Number
48 Speed - Engine
47 Speed - Central Gear
Train
21 Speed - Turbine
Figure 287
1TRANSMISSION ERROR
CODES (ZF)
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
Introduction..................................................................................................... 4
Abbreviations.................................................................................................. 4
Display............................................................................................................ 4
Description of Fault Codes ...................................................................... 5
Display During Operation ............................................................................... 6
Definition of Operating Modes........................................................................ 8
Normal .................................................................................................... 8
Substitute Clutch Control ........................................................................ 8
Limp-home .............................................................................................. 8
Transmission shut Down ......................................................................... 8
TCU Shut Down ...................................................................................... 8
Clutch Pack and Solenoid Valve
Cross-reference Table .................................................................................... 9
Table of Fault Codes..................................................................................... 10
Table of Fault Codes - ERGO-Control .......................................................... 32
Measurement of Resistance at Actuator/sensors and Cable ....................... 35
Actuator................................................................................................. 35
Cable..................................................................................................... 35
ABBREVIATIONS
Throughout this section the following abbreviations are used to indicate various conditions.
Abbreviations
ABS Anti Blocking System
ADM (1 - 6) Ausgeschaltet Digital Minus
(Switched Off Digital Minus)
AFP Automatic Filling Parameter
Adjustment
CAN Controller Area Network
LIS (1 and 2) Load Isolation System
(Solenoids 1 and 2)
O.C. Open Circuit
OP-Mode OPeration Mode
S.C. Short Circuit
TCU Transmission Control Unit
VPS (1 and 2) Variable Power Supply
DISPLAY h f e d
left
character
right
character
Reference Description a b c g
Letter
(special symbols a-h) HBOE630L
a, f Automatic Range (Upshifting
and Downshifting) Figure 1
b, c, d, e Preselected Gear
g EST-37 has detected an
error and is flashing.
h This character will not be
used at the EST-37.
LIMP-HOME
The detected failure in the system has strong limitations to transmission control. TCU can engage only one
gear in each direction. In some cases only one direction will be possible.
TCU will shift the transmission into neutral at the first occurrence of the failure. First, the operator must shift
the gear selector into neutral position.
If output speed is less than a threshold for neutral to gear and the operator shifts the gear selector into
forward or reverse, the TCU will select the limp-home gear.
If output speed is less than a threshold for reversal speed and TCU has changed into the limp-home gear
and the operator selects a shuttle shift, TCU will shift immediately into the limp-home gear of the selected
direction.
If output speed is greater than the threshold, TCU will shift the transmission into neutral. The operator has
to slow down the vehicle and must shift the gear selector into neutral position.
Mega 300-V
Mega 400-V
Mega 500-V
Clutch Pack
Mega 130
Mega 160
4WG-100
4WG-130
4WG-190
4WG-210
4WG-260
4WG-260
4WG-310
K1 Y3 Y3 Y3 Y3 Y3 Y3 Y3
K2 Y6 Y6 Y6 Y6 Y6 Y6 Y6
K3 Y4 Y4 Y4 Y4 Y4 Y4 Y4
K4 Y1 Y1 Y1 Y1 Y2 Y2 Y2
KR Y2 Y2 Y2 Y2 Y1 Y1 Y1
KV Y5 Y5 Y5 Y5 Y5 Y5 Y5
Fault Meaning of the Fault Code Reaction of the Possible Steps to Remarks
Code (Possible reason for fault TCU Repair
(hex) detection.)
11 Logical error at gear range TCU shifts Check cables from Failure cannot be
signal. transmission to TCU to shift lever. detected in systems
neutral. with DW2/DW3 shift
TCU detected a wrong signal Check signal
lever.
combination for gear range. OP-Mode: combinations of shift
transmission shut lever positions for Fault is taken back if
• Cable from shift lever to TCU
down. gear range. TCU detects a valid
is broken.
signal for position.
• Cable is defective and is
contacted to battery voltage or
vehicle ground.
• Shift lever is defective.
12 Logical error at direction TCU shifts Check cables from Fault is taken back if
select signal. transmission to TCU to shift lever. TCU detects a valid
neutral. signal for direction at
TCU detected a wrong signal Check signal
shift lever.
combination for direction. OP-Mode: combinations of shift
transmission shut lever positions
• Cable from shift lever to TCU
down. F-N-R.
is broken.
• Cable is defective and is
contacted to battery voltage or
vehicle ground.
• Shift lever is defective.
17 ** S.C. to ground at Solenoid Customer specific. Check cable from 1) See
LIS1 (Function No. 1). TCU to Solenoid “Measurement of
LIS1 (Function No. Resistance at
TCU detected a wrong
1) device. Actuator/sensors
voltage at output pin, that
looks like a S.C. to vehicle Check connectors and Cable” on page
ground. from Solenoid LIS1 35.
(Function No. 1) to
• Cable is defective and is
TCU.
contacted to vehicle ground.
Check resistance of
• Solenoid LIS1 (Function No.
Solenoid LIS1
• 1) device has an internal
(Function No. 1)
defect.
device.
• Connector pin is contacted
to vehicle ground.
* Only Mega 400-III PLUS
** Only Series "V"
Gray shaded boxes are error codes for other applications. They are only given for general reference purposes.
• Connector has no
connection to TCU.
98 * O.C. at LIS2 solenoid valve. No reaction. Check the cable from If fault code 95 and
TCU to the valve. 98 are both being
The measured resistance OP-Mode: normal.
displayed for about
value of the valve is out of Check the
one second each,
limit. connectors from
see combined fault
valve to TCU.
• Cable/connector resistance code.
and has no contact to TCU. Check the valve
resistance.
• Valve has an internal defect.
B1 Slippage at clutch K1. TCU shifts to neutral. Check pressure at ---------------
clutch K1.
TCU calculates a differential OP-Mode: limp
speed at closed clutch K1. If home. Check main
this calculated value is out of pressure in system.
If failure at another
range, TCU interprets this as
clutch is pending. Check sensor gap at
slipping clutch.
internal speed
TCU shifts to neutral.
• Low pressure at clutch K1. sensor.
OP-Mode: TCU shut
• Low main pressure. Check sensor gap at
down.
output speed sensor.
• Wrong signal at internal
speed sensor. Check signal at
internal speed
• Wrong signal at output
sensor.
speed sensor.
Check signal at
• Sensor gap is incorrect.
output speed sensor.
• Clutch is defective.
Replace clutch.
* Only Mega 400-III PLUS
** Only Series "V"
Gray shaded boxes are error codes for other applications. They are only given for general reference purposes.
F2 Configuration lost.
F3 Application error.
Figure 2
CABLE
UBat
open circuit:
R12 ≈ R1P ≈ R1C ≈ R2P ≈ R2C ≈ ∞
P (power supply)
HBOE650I
Figure 3
1HYDRAULIC SYSTEM
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
HYDRAULIC SYSTEMS0702035K
MODEL SERIAL NUMBER RANGE
Mega 200-V (Tier I & II) 1001 and Up
WARNING!
Do not shut off the engine while the machine is running. If the engine stalls while the machine is
running, the brake pedal becomes hard to reduce braking force.
SERVICE BRAKE
GENERAL DESCRIPTION (BRAKE LINE)
10
7 8
1
5
9
3
11
4
6
BHS0040L
Figure 1
Reference Reference
Description Description
Number Number
1 Brake Pedal and Brake 7 Front Axle
Pedal Valve 8 Rear Axle
2 Brake Pump 9 Low Pressure Warning
3 Pilot Filter Switch
4 Brake and Pilot Supply 10 Transmission Cut-off Switch
Valve 11 Low Pressure Switch for
5 Accumulator Parking Brake
6 Oil Tank
Reference Reference
Description Description
Number Number
A Brake Valve 5 Accumulators
1 Brake Pedal 6 Oil Tank
2 Brake Pump 7 Front Axle
3 Filter 8 Rear Axle
4 Brake and Pilot Supply
Valve
Reference Reference
Description Description
Number Number
A Brake Valve 5 Accumulators
1 Brake Pedal 6 Oil Tank
2 Brake Pump 7 Front Axle
3 Filter 8 Rear Axle
4 Brake and Pilot Supply
Valve
Reference Reference
Description Description
Number Number
A Brake Valve 5 Accumulators
1 Brake Pedal 6 Oil Tank
2 Brake Pump 7 Front Axle
3 Filter 8 Rear Axle
4 Brake and Pilot Supply
Valve
1ACCUMULATOR
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
ACCUMULATOR S0703010K
MODEL SERIAL NUMBER RANGE
Mega 200-V (Tier I & II) 1001 and Up
Mega 250-V (Tier II) 2001 and Up
Solar 55 0001 and Up
Solar 55-V Plus 1001 and Up
Solar 75-V 1001 and Up
Solar 140W-V 1001 and Up
Solar 160W-V 1001 and Up
Solar 180W-V 1001 and Up
Solar 210W-V 1001 and Up
Solar 225LC-V 1001 and Up
Solar 255LC-V 1001 and Up
Solar 300LC-V 1001 and Up
Solar 300LL 1001 and Up
Solar 340LC-V 1001 and Up
Solar 420LC-V 1001 and Up
Solar 470LC-V 1001 and Up
Accumulator S0703010K
Page 1
TABLE OF CONTENTS
General Description........................................................................................ 3
Specifications .......................................................................................... 4
S0703010K Accumulator
Page 2
GENERAL DESCRIPTION
The accumulator is a gas-charged storage
device designed to hold a reserve quantity of 1
hydraulic fluid under pressure. Accumulators are
used in hydraulic circuits in much the same way 2
that condensers (or capacitors) are used to
collect, store and maintain electrical charge in a
circuit.
In a hydraulic circuit, minor variations or lags in
pump output that might otherwise cause
unsteady or irregular operation are made up
from the supply of pressurized oil in the 3
accumulator.
Reference
Description
Number
1 Screw Plug
2 Steel Pressure Vessel
4
3 Diaphragm ARS1790L
4 Fluid Valve Figure 1
Accumulators are solidly constructed to resist the high operating pressures of the fluids they contain. There
are only three main moving parts: a plug at the top allows pre-charging or expelling gas from the
compressible, pre-charged upper chamber; a valve assembly at the bottom of the accumulator for passing
hydraulic fluid in and out, and an elastic diaphragm to separate the two chambers. The flexible diaphragm
changes shape to conform to the changing pressures and volumes of the two fluids in the upper and lower
chambers.
There are six possible positions the diaphragm
can be in and they are as follows: Pressure Fluid Nitrogen
Accumulator S0703010K
Page 3
NOTE: Pre-charge pressure is referred to as the "P1" pressure. The accumulator manufacturer’s
"P1" rated pressure should be stamped or marked on the accumulator’s rating plate.
Annual checks of actual pre-charge pressure should be made by tapping a hydraulic
pressure gauge (and 3-way adapter coupling) into the valve on the bottom of the
accumulator. When hydraulic fluid is pushed out the lower valve opening by the pressure
of the gas charge on the other side of the diaphragm - and there is no counter-pressure
from system oil - the valve button on the bottom of the diaphragm eventually seals off the
lower oil passage. Just after the needle on the gauge reaches its highest point (when there
is 0 bar (0 psi) resistance from hydraulic system pressure) pressure on the gauge will drop
sharply to zero, as the accumulator is completely emptied of oil and the diaphragm button
closes.
Record the highest gauge reading and compare to the "P1" rated pre-charge pressure on the
accumulator manufacturer’s data label. Repeat this test at least once a year to verify proper
functioning of the accumulator.
3. As hydraulic system pressure overcomes accumulator pre-charge pressure, the flexible diaphragm
begins to retract upward.
4. When system oil is at highest working pressure and the accumulator fills to maximum reserve
capacity, the flexible diaphragm is pushed up into the top of the upper chamber.
The highest working pressure is sometimes referred to as the "P3" pressure and can also be
referenced on the manufacturer’s data label on the exterior of the accumulator.
5. If system oil pressure begins to fall off or is momentarily checked or interrupted, the energy stored on
the other side of the diaphragm, in the form of compressed gas, pushes oil back out of the lower
chamber, maintaining oil pressure of the circuit.
6. With minimal system pressure, an equilibrium point may be reached in which accumulator pre-charge
pressure and hydraulic system oil pressure achieve a rough balance. In this condition a minimal
amount of oil is stored in the accumulator.
SPECIFICATIONS
Charge
Model Serial Number System Volume
Pressure
Mega 200-V (Tier I 30 kg/cm² 750 cc
S/N 1001 and Up Brake System
& II) (427 psi) (45.77 in3)
Mega 200-V (Tier I 15 kg/cm² 320 cc
S/N 1001 and Up Pilot
& II) (213 psi) (19.53 in3)
30 kg/cm² 750 cc
Mega 250-V (Tier I) S/N 1001 thru 2000 Brake System
(427 psi) (45.77 in3)
15 kg/cm² 320 cc
Mega 250-V (Tier I) S/N 1001 thru 2000 Pilot
(213 psi) (19.53 in3)
30 kg/cm² 750 cc
Mega 250-V (Tier II) S/N 2001 and Up Brake System
(427 psi) (45.77 in3)
15 kg/cm² 320 cc
Mega 250-V (Tier II) S/N 2001 and Up Pilot
(213 psi) (19.53 in3)
10 kg/cm2 320 cc
Solar 55-V S/N 0001 and Up Pilot
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
Solar 55-V Plus S/N 1001 and Up Pilot
(140 psi) (19.53 in3)
S0703010K Accumulator
Page 4
Charge
Model Serial Number System Volume
Pressure
10 kg/cm2 320 cc
Solar 75-V S/N 1001 and Up Pilot
(140 psi) (19.53 in3)
Solar 140W-V 30 kg/cm² 750 cc
S/N 1000 and Up Brake System
/160W-V (427 psi) (45.77 in3)
Solar 140W-V 15 kg/cm² 320 cc
S/N 1000 and Up Pilot
/160W-V (213 psi) (19.53 in3)
Solar 140W-V 8 kg/cm² 750 cc
S/N 1000 and Up Transmission
/160W-V (114 psi) (45.77 in3)
30 kg/cm² 750 cc
Solar 180W-V S/N 1001 and Up Brake System
(427 psi) (45.77 in3)
15 kg/cm² 320 cc
Solar 180W-V S/N 1001 and Up Pilot
(213 psi) (19.53 in3)
8 kg/cm² 750 cc
Solar 180W-V S/N 1001 and Up Transmission
(114 psi) (45.77 in3)
30 kg/cm² 750 cc
Solar 210W-V S/N 0001 and Up Brake System
(427 psi) (45.77 in3)
15 kg/cm² 320 cc
Solar 210W-V S/N 0001 and Up Pilot
(213 psi) (19.53 in3)
8 kg/cm² 750 cc
Solar 210W-V S/N 0001 and Up Transmission
(114 psi) (45.77 in3)
10 kg/cm² 750 cc
Solar 225LC-V S/N 1001 and Up Pilot / Travel
(142 psi) (45.77 in3)
10 kg/cm² 320 cc
Solar 255LC-V S/N 1001 thru 1002 Pilot / Travel
(142 psi)) (19.53 in3)
10 kg/cm² 750 cc
Solar 255LC-V S/N 1003 and Up Pilot / Travel
(142 psi) (45.77 in3)
10 kg/cm² 320 cc
Solar 300LC-V S/N 1001 thru 1099 Pilot / Travel
(142 psi) (19.53 in3)
10 kg/cm² 750 cc
Solar 300LC-V S/N 1100 and Up Pilot / Travel
(142 psi) (45.77 in3)
10 kg/cm² 750 cc
Solar 300LL S/N 1100 and Up Pilot / Travel
(142 psi)) (45.77 in3)
10 kg/cm² 320 cc
Solar 340LC-V S/N 1001 thru 1059 Pilot / Travel
(142 psi) (19.53 in3)
10 kg/cm² 750 cc
Solar 340LC-V S/N 1060 and Up Pilot / Travel
(142 psi)) (45.77 in3)
10 kg/cm² 320 cc
Solar 420LC-V S/N 1001 thru 1029 Pilot / Travel
(142 psi) (19.53 in3)
10 kg/cm² 750 cc
Solar 420LC-V S/N 1030 and Up Pilot / Travel
(142 psi)) (45.77 in3)
10 kg/cm² 320 cc
Solar 470LC-V S/N 1001 thru 1049 Pilot / Travel
(142 psi) (19.53 in3)
Accumulator S0703010K
Page 5
Charge
Model Serial Number System Volume
Pressure
10 kg/cm² 750 cc
Solar 470LC-V S/N 1050 and Up Pilot / Travel
(142 psi)) (45.77 in3)
S0703010K Accumulator
Page 6
S0705015K
1CYLINDERS
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
CYLINDERS S0705015K
MODEL SERIAL NUMBER RANGE
Mega 200-V (Tier I & II) 1001 and Up
Cylinders S0705015K
Page 1
TABLE OF CONTENTS
General Description........................................................................................ 3
Theory of Operation ................................................................................ 4
Parts List ................................................................................................. 6
Troubleshooting, Testing and Adjustment..................................................... 12
Disassembly ................................................................................................. 16
Cleaning and Inspection (Wear Limits and Tolerances) ............................... 18
Reassembly.................................................................................................. 19
S0705015K Cylinders
Page 2
GENERAL DESCRIPTION
The machine contains boom cylinders, buckets cylinders and steering cylinders. Each cylinder contains a
cylinder tube, piston rod, piston, and cylinder head. See Figure 1. The piston is held to piston rod by a nut.
A dust seal protects the U-ring and oil seal from dirt and also prevents oil from leaking out of the cylinder.
Figure 1
Reference Reference
Description Description
Number Number
1 Retaining Ring 10 Seal O-ring
2 Dust Seal 11 Piston
3 U-Ring 12 Spring
4 Seat O-ring 13 Cylinder Tube
5 Port (A) 14 O-ring, Backup Ring
6 Cushion Plate 15 Bushing
7 Wear Ring 16 Cylinder Head
8 Piston Nut 17 Bolt
9 Port (B) 18 Piston Rod
Cylinders S0705015K
Page 3
THEORY OF OPERATION
Reference
Description
Number
1 Piston
2 Oil Path A
3 Oil Path B
F1 = P x πB2
4
Reference
Description
Number
1 Cylinder Inside Diameter - B
2 Oil Path A
3 Oil Path B
4 Rod Diameter
F2 = P x π(B2-R2)
4
Q1 = S x π(B2)
4
Figure 4
Q2 = S x π(B2-R2)
4
Q1 > Q2
S0705015K Cylinders
Page 4
Cylinders S0705015K
Page 5
PARTS LIST
29
23
25 24
20
19
22
26
27
14
28
16
15
17
18
11
12
13
7
21 6
9 5
8
10
29
BAS0170L
Figure 5
S0705015K Cylinders
Page 6
Reference Reference
Description Description
Number Number
1 Tube Assembly 16 Wear Ring
2 Steel Bush 17 Dust Ring
3 Rod Assembly 18 O-ring
4 Steel Bush 19 Piston Nut
5 Rod Cover 20 Lock Ring
6 Du-bush 21 Socket Hex Bolt
7 Retaining Ring 22 Pipe Assembly
8 U-packing 23 O-ring
9 Backup Ring 24 Spring Washer
10 Dust wiper 25 Hex Bolt
11 O-ring 26 Pipe Clamp
12 Backup Ring 27 Spring Washer
13 O-ring 28 Hex Bolt
14 Piston 29 Grease Nipple
15 Glyd Ring Seal Kit
Cylinders S0705015K
Page 7
Lift Hydraulic Cylinder
33 2
22
23
21
30 24
32
29
30
31
26 25
27
28
19
18
13
15
14
17 7
20 10
12 11
6
5
8 4
7
9
BAS0180L
Figure 6
S0705015K Cylinders
Page 8
Reference Reference
Description Description
Number Number
1 Tube Assembly 18 Piston Nut
2 Steel Bush 19 Lock Ring
3 Rod Assembly 20 Socket Hex Bolt
4 Rod Cover 21 Pipe Assembly
5 Du-bush 22 O-ring
6 Retaining Ring 23 Spring Washer
7 U-packing 24 Hex Bolt
8 Backup Ring 25 Pipe Assembly-r
9 Dust wiper 26 O-ring
10 O-ring 27 Spring Washer
11 Backup Ring 28 Socket Hex Bolt
12 O-ring 29 Pipe Clamp
13 Piston 30 Spring Washer
14 Glyd Ring 31 Hex Bolt
15 Wear Ring 32 Hex Bolt
16 Dust Ring 33 Grease Nipple
17 O-ring Seal Kit
Cylinders S0705015K
Page 9
Steering Hydraulic Cylinder
27
27
23
24
26
1
25
21
22
20
19
14
16
15
18 17
10
11
6
12
13
5
7
8
9
27
BAS0190L
Figure 7
S0705015K Cylinders
Page 10
Reference Reference
Description Description
Number Number
1 Tube Assembly 15 Glyd Ring
2 Steel Bush 16 Wear Ring
3 Rod Assembly 17 Dust Ring
4 Steel Bush 18 O-ring
5 Rod Cover 19 Piston Nut
6 Du-bush 20 Lock Ring
7 U-packing 21 Cushion Plunger
8 Backup Ring 22 Stop Ring
9 Dust wiper 23 Check Valve
10 O-ring 24 Spring
11 Backup Ring 25 Plug
12 O-ring 26 O-ring
13 Washer 27 Grease Nipple
14 Piston Seal Kit
Cylinders S0705015K
Page 11
TROUBLESHOOTING, TESTING AND ADJUSTMENT
Problem Possible Cause Remedy
Oil leaking between cylinder Foreign material in U-ring (3). Remove foreign material.
head (16) and piston rod (18). Scratches in U-ring (3). Replace U-ring (3).
(Index nos. refer to Figure 1)
Damage to U-ring (3). Replace U-ring (3).
Foreign material in dust seal (2). Remove foreign material.
Scratches to dust seal (2). Replace dust seal.
Damage to dust seal (2). Replace dust seal.
Foreign material in seal O-ring Remove foreign material.
(4).
Scratches in seal O-ring (4). Replace O-ring (4).
Damage to seal O-ring (4). Replace O-ring (4).
Scratches on sealing surface of If scratches are not deep, hone
piston rod (18). with an oil stone and lubricate. If
scratches are deep, replace
piston rod (18).
Deep scratches on inner surface Replace Bushing.
of bushing (15).
Oil leaking between cylinder Damage to O-rings (14). Replace O-rings (14).
head (16) and cylinder tube (13).
Oil leaking from welded area of Damage to welded area. Replace cylinder tube (13).
cylinder tube (13).
S0705015K Cylinders
Page 12
Problem Cause Remedy
Oil leaking between cylinder Foreign material in U-ring (3, Remove foreign material.
head (16) and piston rod (18). Figure 1)
(Index nos. refer to Figure 1). Scratches in U-ring (3, Figure 1). Replace U-ring (3).
Damage to U-ring (3, Figure 1). Replace U-ring (3).
Foreign material in dust seal (2, Remove foreign material.
Figure 1).
Scratches in dust seal (2, Figure Replace dust seal (2).
1).
Damage to dust seal (2, Figure Replace dust seal (2).
1).
Foreign material in seal O-ring Remove foreign material.
(4, Figure 1).
Scratches in seal O-ring (4, Replace O-ring (4).
Figure 1).
Damage to seal O-ring (4, Replace O-ring (4).
Figure 1).
Scratch on sealing surface of If scratches are not deep, hone
piston rod (18, Figure 1). with an oil stone and lubricate. If
scratches are deep, replace
piston rod (18).
Deep scratches on inner surface Replace bushing.
of bushing (15, Figure 1).
Oil leaking between cylinder Damage to O-rings (14, Figure Replace O-rings (14).
head (16) and cylinder tube (13). 1).
Oil leaking from welded area of Damage to welded area. Replace cylinder tube (13).
cylinder tube (13).
Cylinder drops from pull of Light scratches on sealing Hone out scratches with oil
gravity. surface of cylinder tube (13, stone.
Figure 1).
Deep scratches on sealing Replace cylinder tube (13).
surface of cylinder tube (13,
Figure 1).
Deep scratches on sealing Replace O-rings (10).
surface of piston O-rings (10,
Figure 1).
Foreign material in U-ring (3, Remove foreign material.
Figure 1).
Scratches in U-ring (3, Figure 1). Replace U-ring (3).
Cylinders S0705015K
Page 13
Problem Cause Remedy
Slow bucket and boom Reduced oil flow due to dirty Disassemble and clean parts.
movements. filter or dirty intake line.
Air drawn into circuit through Tighten intake connections.
loose connections.
Reservoir oil level too low. Fill reservoir to correct level.
Relief valve pressure setting Adjust relief valve pressure.
incorrect.
Damaged pump shaft or pump Replace damaged parts.
drive sleeve.
Pump worn or damaged Replace worn or damaged
internally. parts.
Relief valve sticking. Disassemble and inspect
cartridge. Clean or replace
cartridge.
Air in pressure line. Perform cylinder bleeding
procedure to remove air. Tighten
or replace pressure line.
Damaged pipe or hose. Replace pipe or hose.
Worn cylinder seals. Replace worn parts.
Low pressure, shown by weak Reduced oil flow due to dirty Disassemble and clean parts.
upward movement of boom and filter or dirty intake line.
bucket. Reservoir oil level too low. Fill reservoir to correct level.
Relief valve pressure setting Adjust relief valve pressure.
incorrect.
Pump worn or damaged Replace worn or damaged
internally. parts.
Relief valve sticking. Disassemble and inspect
cartridge. Clean or replace
cartridge.
Worn cylinder seals. Replace worn parts.
Low pump output due to dirty Remove and clean pump
discharge pipes. discharge pipes.
Relief valve spring is weak. Replace worn parts.
Relief valve poppet worn.
Cylinder drops when control Worn plunger in control valve. Replace plunger.
valve is in neutral. Stuck overload relief valve due Replace worn parts.
to worn seat surface.
Loose pipes or joints. Tighten parts.
Worn piston seal on hydraulic Replace seal.
cylinder.
Vibration or excessive noise. Excessive resistance in pump Inspect intake line and clean or
intake line. replace as necessary.
Air being drawn into intake line. Inspect pipe joints and tighten.
Chattering relief valve. Change oil, replace valve.
S0705015K Cylinders
Page 14
Problem Cause Remedy
Air bubbles in oil. Wrong type of operating oil. Drain and fill with proper type of
oil.
Oil level too low. Raise to proper level.
Air trapped in system. Perform cylinder bleeding
procedure to remove air.
Frequent rubber hose damage. System pressure too high. Adjust relief valve pressure.
Hoses breaking due to contact Restrain hoses to prevent
with another machine parts. contact.
Cylinders S0705015K
Page 15
DISASSEMBLY
NOTE: Keep on hand a container large enough to hold all of the oil in cylinder being repaired.
When cylinder rod and head are removed, oil will run out of cylinder.
1. Use an allen wrench to remove bolts that
hold cylinder head to cylinder tube. See
Figure 8.
Figure 8
2. Support cylinder rod with a lifting sling.
See Figure 9. Slide cylinder rod out of
cylinder tube. Rotate cylinder rod slightly
as it is being pulled from cylinder tube.
This will make it easier to pull rod out of
tube.
Figure 9
3. Set cylinder rod assembly in a repair
fixture and secure rod in place. See Figure
10. Use a power wrench and socket to
remove nut that holds piston on rod.
Figure 10
S0705015K Cylinders
Page 16
4. Remove piston nut (1, Figure 11), piston
assembly (2), cushion flange (3), and
cylinder head assembly (4).
Reference
Description
Number
1 Piston Nut
2 Piston Assembly
3 Cushion Flange
4 Cylinder Head
Assembly
Figure 11
5. Do not remove slipper seal, backup ring,
and back ring from piston. If these three
items are not scratched or damaged. See
Figure 12. Once these 3 items are
removed from piston, they must be
replaced. They cannot be reused. Exercise
caution when removing slipper seal to
prevent damage to piston O-ring groove.
Remove wear rings from piston.
Figure 12
6. When disassembling cylinder head do not
remove slipper seal, backup ring, back
ring, or dust seal unless items are
scratched or damaged. If seals are
removed from head, they must be
replaced. They cannot be reused. Remove
snap ring, (1, Figure 13). Use a
screwdriver to remove dust seal (2) from
head.
Reference
Description
Number
1 Snap Ring
Figure 13
2 Dust Seal
Cylinders S0705015K
Page 17
7. Use caution to prevent damage to any
parts of U-packing (1, Figure 14). Remove
U-packing (1). Remove O-ring (2), and ring
(3).
Reference
Description
Number
1 U-Packing
2 O-Ring
3 Ring
Figure 14
S0705015K Cylinders
Page 18
REASSEMBLY
NOTE: Check cylinder head grooves
for U-packing and dust seal. If
edges of grooves are sharp or
have burns, use an oil stone to
smooth surface. See Figure 15.
Figure 15
1. Apply grease to inner part of cylinder head
and to U-packing groove. See Figure 16.
Figure 16
2. Install split backup ring into its groove by
compressing ring. See Figure 17. Make
sure that ends of ring do not overlap.
NOTE: The U-packing can be installed
by hand or by using a seal
installing jig. The jig should be
made of copper, aluminum, or
plastic. If a jig is used, be sure
that jig does not have sharp
edges that could damage U-
packing.
Figure 17
Cylinders S0705015K
Page 19
3. Insert one side of U-packing in its groove.
See Figure 18.
Figure 18
4. Carefully push down on other side of U-
packing until entire U-packing is seated in
its groove. See Figure 19.
Figure 19
5. Check to be sure that U-packing and
backup ring are correctly installed by
pushing with your hand on inner diameter
of U-packing. See Figure 20.
NOTE: There are 2 backup rings used
on outside of cylinder head.
One backup ring is continuous.
The other backup ring is open,
split by an angled cut.
Figure 20
6. Use grease or an adhesive to hold split
backup ring (1, Figure 21) in place. Install
split backup ring (1) in groove closets to
flange on cylinder head.
Reference
Description
Number
1 Split Backup Ring
2 Continuous Backup
Ring
Figure 21
S0705015K Cylinders
Page 20
7. Place continuous backup ring in warm
water. See Figure 22. Water temperature
should be 30 - 50°C (86 - 122°F). Leave
ring in water for 2 - 3 minutes. Slide
continuous backup ring (2, Figure 21) over
cylinder head and into its groove.
Figure 22
8. Install an O-ring over each of backup rings.
See Figure 23.
Figure 23
9. Use a seal installing jig to install dust seal
into cylinder head. See Figure 24. Install
snap ring.
Figure 24
Cylinders S0705015K
Page 21
10. On piston, check corners of grooves that
piston rings will be mounted in. See Figure
25. If any burrs, roughness, or sharp
edges (1) are present, use an oil stone to
smooth roughened areas and dull sharp
edges.
Figure 25
11. Apply grease or hydraulic oil to corner of
piston at position A. See Figure 26.
Figure 26
12. Insert one end of backup ring into its
groove. See Figure 27. Use your hand to
slide other end of ring into groove.
Figure 27
13. Use warm water to expand slipper seal.
See Figure 28. This will make seal easier
to install. Set slipper seal in 60 -100
degree C (140 - 212 degree F) water for 5
minutes or longer.
Figure 28
S0705015K Cylinders
Page 22
14. Insert one end of slipper seal, (1, Figure
29) into its groove. Use your hand to slide
other end of slipper seal into groove.
WARNING!
Before piston is inserted into
cylinder tube, make sure that slipper
seal is no longer expanded. If seal is
still expanded, it could catch on
threaded portion of cylinder tube. An
expanded seal could also jam inside Figure 29
cylinder tube.
Reference
Description
Number
1 Backup Ring
2 Slipper Seal
Figure 30
Cylinders S0705015K
Page 23
16. Install wear ring (1, Figure 31) on piston.
Figure 31
17. Set cylinder rod (1, Figure 32) into a repair
fixture (2). Securely clamp rod to fixture.
Exercise caution to prevent nicks or
scratches to chrome plated areas of rod.
chrome plated area is oil sealing surface of
rod.
Reference
Description
Number
1 Cylinder Rod
2 Repair Fixture
Figure 32
18. Slide cylinder head assembly (1, Figure
33) onto cylinder rod (2). Use caution to
prevent threads on rod from damaging
seal inside cylinder head.
Reference
Description
Number
1 Cylinder Head
2 Cylinder Rod
Figure 33
S0705015K Cylinders
Page 24
19. Install cushion flange (1, Figure 34) on
cylinder rod (2). Slide piston assembly (3)
onto cylinder rod (2).
Reference
Description
Number
1 Cushion Flange
2 Cylinder Rod
3 Piston Assembly
Figure 34
20. Install piston nut (1, Figure 35) and tighten
it with an impact wrench. Then use a
torque wrench to tighten nut (1) to
specified torque.
After nut has been tightened, check to see
that cushion flange moves.
Figure 35
21. Slide rod assembly into cylinder tube.
Align punch mark (1, Figure 36) with port
(2) in cylinder tube. This will align hole (3)
in cylinder head with port (2).
Reference
Description
Number
1 Punch Mark
2 Port
3 Hole
Figure 36
Cylinders S0705015K
Page 25
22. Install bolts in cylinder head and tighten
them to torque specified in bolt torque
chart. See Figure 37. Double check to
make sure that hole in cylinder head is
align with port in cylinder tube.
NOTE: After rebuilding a cylinder, or
after loosening a cylinder
hydraulic line, air must be bled
from hydraulic system. To bleed
air from system, first extend
and retract a cylinder (or pair of
cylinders) about 5 times at low
engine rpm. Stop cylinder about Figure 37
100 mm (4 in) short of full
extension and full retraction.
Then fully extend and retract
cylinder about 5 times, also at
low engine rpm.
S0705015K Cylinders
Page 26
S0707110C
1FAN DRIVE
HYDRAULIC MOTOR
(HALDEX)
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
General Description........................................................................................ 4
Theory of Operation ................................................................................ 4
Mega 200-V ..................................................................................... 4
Mega 250-V ..................................................................................... 6
Parts List ................................................................................................. 8
Specifications .......................................................................................... 9
Troubleshooting, Testing and Adjustment..................................................... 10
Tools Required ............................................................................................. 10
Disassembly ................................................................................................. 11
Inspect Parts for Wear.................................................................................. 14
General Information...................................................................................... 15
Reverse Shaft Rotation of Pump .................................................................. 15
Reassembly.................................................................................................. 16
Mega 200-V
65bar
(PFO1/4) (PFO3/8) (PFO3/8) (PFO3/8)
(PFO3/8) A1 LPWS P1 P2 A2
A3 TP1
(PFO3/8)
C3-1 C3-2
BRAKE & PILOT FILTER
ø1.2 C2 C3-3
10 micron TP2
(PFO1/4)
(1) 2 PILOT
28kgf/cm
C4 (PFO3/8)
60kgf/cm
2 C6
FO SAFETY
Fan motor-(4) (PFO1/2)
(3)
14ccr 41ccr 44ccr C1 C3-4 PA
(PFO3/8)
Fan-(5) FI 120kgf/cm
2
(PFO1/2)
LPWS 45bar
(7) C5
0.75" Fan motor C7
PK
2 (PFO1/4)
M 150kgf/cm
(PFO1/2)
16ccr A4 T1 T2
(PFO3/8) (PFO1/4)
90bar (PFO3/8)
(6)
APS0410L
Figure 1 FAN DRIVE SYSTEM SCHEMATIC
Reference Reference
Description Description
Number Number
1 Pump (Brake, Pilot, Fan Drive) 4 Fan Motor
2 Supply Valve 5 Fan
(Brake, Pilot, Fan motor) 6 Relief Valve
3 Sequence Valve 7 Oil Cooler
The main components of the fan drive system are pump (1), motor (4), brake / pilot / fan motor supply valve
(2), fan (5) and oil cooler (7). Oil is drawn from tank through pump (1) and brake / pilot filter, to the brake
valve and accumulators, at the same time to the sequence valve (3) of brake / pilot / fan motor supply valve
(2). In case that the pressure of brake circuit rise up to 120 kg/cm2 (1,710 psi), the sequence valve (3)
allows oil to flow fan motor (4). From fan motor (4), oil flows through oil cooler (7) and to the tank.
Fan drive pump (common as brake and pilot pump) is a fixed displacement, gear pump. The pump is
attached to the end of steering pump and common suction port as steer pump.
FAN RPM
rpm and above 1,620 rpm, the relief valve on the
fan drive pump opens to dump excess flow back
1,300
to hydraulic tank and thus the fan motor speed const
will constantly be 1,300 rpm. At low idle engine
speed (between 975 and 1,620 rpm), the fan
speed will be approximately between 750 and
750
1,300 rpm.
Fan speed can be changed by adjusting the
relief valve on the fan drive pump.
970 1,620 2,350
E/G RPM AJS0790L
Figure 2
AOS0190L
Figure 3 FAN DRIVE SYSTEM SCHEMATIC
Reference Reference
Description Description
Number Number
1 Pump (Brake, Pilot, Fan Drive) 4 Fan Motor
2 Supply Valve 5 Fan
(Brake, Pilot, Fan motor) 6 Relief Valve
3 Sequence Valve 7 Oil Cooler
The main components of the fan drive system are pump (1), motor (4), brake / pilot / fan motor supply valve
(2), fan (5) and oil cooler (7). Oil is drawn from tank through pump (1) and brake / pilot filter, to the brake
valve and accumulators, at the same time to the sequence valve (3) of brake / pilot / fan motor supply valve
(2). In case that the pressure of brake circuit rise up to 120 kg/cm2 (1,710 psi), the sequence valve (3)
allows oil to flow fan motor (4). From fan motor (4), oil flows through oil cooler (7) and to the tank.
Fan drive pump (common as brake and pilot pump) is a fixed displacement, vane pump. The pump is
attached to the end of steering pump and common suction port as steer pump.
FAN RPM
rpm and above 1,650 rpm, the relief valve on the
fan drive pump opens to dump excess flow back
1,400
to hydraulic tank and thus the fan motor speed const
will constantly be 1,400 rpm. At low idle engine
speed (between 970 and 1,650 rpm), the fan
speed will be approximately between 830 and
830
1,400 rpm.
Fan speed can be changed by adjusting the
relief valve on the fan drive pump.
970 1,650 2,350
E/G RPM BAS0050L
Figure 4
2
3
4
5
7
1 6
7
5
10
9
8
4
3
2
13
14
12
16
AJS0780L
Figure 5
Reference Reference
Description Description
Number Number
1 Front Bearing 9 Drive Gear
2 Backup Ring 10 Coupling
3 Seal 11 Cover
4 Bearing Block 12 Bolt
5 O-ring 13 Plug
6 Gear Housing 14 Spring
7 Dowel Pin 15 Ball
8 Idler Gear 16 Relief Valve Cartridge
Specification
Item
Mega 200-V Mega 250-V
Fan Motor Displacement 16 cc (0.97 in3) 23 cc (1.40 in3)
Relief Valve Setting 90 ±5 kg/cm2 (1,305 ±70 psi) 105 ±5 kg/cm2 (1,522 ±70 psi)
∆ p/1 turn
16.5 kg/cm2 (235 psi) 16.5 kg/cm2 (235 psi)
Maker (Model) HALDEX (WM9A1-16C) HALDEX (WM9A1-23C)
Fan Fan Size ∅ 660.4 mm (26 in) ∅ 712 mm (28 in)
Type Sucker, plastic -7 driven by hydraulic motor
Fan rpm 1,300 rpm @ 90 ±5 kg/cm2 1,400 rpm @ 105 ±5 kg/cm2
(at motor relief ∆ p) (1,305 ±70 psi)) (1,522 ±70 psi))
Fan Drive Pump 14 cc 19.8 cc
(0.85 in3) (1.20 in3)
Pump will not pump oil. Reservoir low or empty. Fill reservoir to proper level.
Suction line p[lugged or to small. clean line and check for proper
size.
Oil heating. Oil supply low. Fill reservoir to proper level.
TOOLS REQUIRED
Metric Socket Set
Internal Snap Ring Pliers
Shaft Seal Sleeve
Torque Wrench - 50 kg•m (100 ft lb) capacity
Figure 6
5. Clamp mounting flange in a protected jaw
vise with pump shaft facing down.
6. Loosen four metric hex head bolts.
7. Remove pump from vise and place on
clean work bench, remove four hex head
bolts and spacers if applicable.
Figure 7
8. Lift and remove end cover.
Figure 8
Figure 9
10. Remove rear bearing block from drive and
idler shafts.
Figure 10
11. Remove idler shaft from bearing block.
Figure 11
12. Remove drive shaft from mounting flange.
There is no need to protect shaft seal
since it will be replaced as a new item.
Figure 12
Figure 13
14. Turn mounting flange over, with shaft seal
up, and remove retaining ring with proper
snap ring pliers.
Figure 14
15. Remove oil seal from mounting flange, be
careful not to mar or scratch seal bore.
16. Remove dowel pins from gear housing. Do
not lose pins.
Figure 15
17. Remove seals from both bearing blocks
and discard.
Figure 16
Figure 18
5. Inspect bearing blocks for excessive wear
or scoring on surfaces which are in contact
with gears. Also inspect bearings for
excessive wear or scoring.
6. Inspect area inside gear housing. It is
normal for surface inside gear housing to
show a clean "wipe" on inside surface on
intake side. There should not be excessive
wear or deep scratches and gouges.
Figure 19
Figure 21
3. Place front and back bearing blocks on a
clean surface with E-seal grooves facing
up. Apply a light coating of petroleum jelly
in grooves. Also coat E-seal and backup
with petroleum jelly, this will help keep
seals in place during reassembly.
Figure 22
Figure 24
8. Install seal sleeve over drive shaft and
carefully slide drive shaft through shaft
seal. Remove seal sleeve from shaft.
9. Install idler gear shaft in remaining position
in bearing block. Apply a light coat of clean
oil to face of drive and idler gears.
Figure 25
Figure 26
12. To install O-rings in gear housing, apply a
light coating of petroleum jelly in grooves
on both sides of gear housing. Also coat
new O-rings and install them in grooves.
Figure 27
13. Gently slide gear housing over rear
bearing block assembly, slide housing
down until housing engages dowel pins.
Press firmly in place with hands, do not
force or use any tool. Check to make sure
intake port in housing is on same side as
open end of E-seal and that marked lines
on mounting flange and gear housing are
in alignment.
14. The surface of rear bearing block should
be slightly below face of gear housing. If
bearing block sits higher then rear face of
gear housing then E-seal or O-ring have Figure 28
shifted out of groove. If this is the case,
remove gear housing and check for proper
seal installation.
Figure 29
16. Install four spacers, if applicable, and hex
head bolts through bolt holes in end cover,
hand tighten.
Figure 30
17. Place mounting flange of pump back in
protected jawed vise and alternately
torque bolts to torque specifications in
torque chart on page 8. All torque figures
are for "dry torque" bolts.
18. Remove pump from vise.
19. Place a small amount of clean oil in inlet of
pump and rotate drive shaft away from
inlet one revolution. If drive shaft binds,
disassemble pump and check for
assembly problems, then reassemble
pump.
Figure 31
1MAIN PUMP
(PARKER)
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
General Description........................................................................................ 3
Principals of Working .............................................................................. 3
Parts List ................................................................................................. 4
Figure 1
Standard
Figure 2
APS0500L
Figure 3
1BRAKE PEDAL
VALVE
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
General Description........................................................................................ 3
Theory of Operation ................................................................................ 3
Specification............................................................................................ 4
Brake System ................................................................................................. 5
Brake and pilot supply valve.................................................................... 5
Brake, pilot and fan motor supply valve................................................... 6
Brake, Pilot and Fan Motor Supply Valve ....................................................... 7
Standard.................................................................................................. 7
Specifications .......................................................................................... 8
Option...................................................................................................... 9
Specifications ........................................................................................ 10
AJS0720L
Figure 1
4
1 5
P2 T2 P1 T1
3
6
BR BR BL
BL
2 BR2 BR1
P2 T2 P1 T1
AJS0740L
Figure 2
Reference Reference
Description Description
Number Number
1 Primary Control Spool 4 Upper Spring
2 Secondary Control Spool 5 Main Control Spring
3 Lower Spring 6 Working Element
SPECIFICATION
Item Specification
(6)
(2)
BR1 BR2
L.H Brake valve REAR AXLE
OPENS 25 B
T/M DISCONNECT
45B
P1 T1 P2 T2
0.5 BAR (5)
(8)
(9)
1.5 BAR (12)
R.H Brake pedal
* TUV Only
40B 40B 40B
TANK
C1 C2
ULTP (13)
(PFO1/4)
(15) C3
(10) P
(PFO1/2)
C10
BRAKE/PILOT 10 micron 60B
PUMP C4 PARK PKWS
10 cm3 /rev (PFO3/8)
C11 (14) (PFO1/4)
STEER PUMP
41 cm3 /rev
C6 (11)
H.P FILTER C9 45bar
LOADER PUMP
44 cm3 /rev C5 to PILOT 20 l/min
(PFO3/8)
at 28 bar
28B
PUMP C7
C8
TP
T1 (PFO1/4)
A4 15B T3 T2
BRAKE & PILOT SUPPLY VALVE 0.32L
APS0240L
Figure 3 Brake Hydraulic Circuit (Tier I)
(3) (4)
(7)
(6)
(9)
CLOSES 3 B
STOP
(2)
FRONT AXLE
BR1 BR2
L.H Brake valve REAR AXLE
OPENS 25 B
T/M DISCONNECT
(1)
(5) 45B
P1 T1 P2 T2
(8)
(12)
0.5 BAR R.H Brake pedal
∅1.2 C2 C3-3
TANK TP2 (PFO3/8)
(PFO1/4)
to PILOT
2
FO 28kgf/cm
(PFO1/2) C4
2 C6
C1 60kgf/cm SAFETY
120kgf/cm2
FI C3-4 PA
(PFO3/8)
(PFO1/2)
Fan motor(Opt.) C7 PARK
0.75" LPWS 45bar
OIL COOLER 100 L/MIN C5
(10) 90bar M PK
150kgf/cm2
10 micron 16ccr (PFO1/2) (PFO1/4)
BRAKE/PILOT
BRAKE & PILOT & FAN MOTOR A4 (PFO3/8)
T1
(PFO3/8)
T2
PUMP 40B (PFO1/4)
(14)
14 cm3 /rev SUPPLY V/V(Opt.) 0.7L * TUV Only (13)
STEER PUMP 0.5"
41 cm3 /rev
(15)
LOADER PUMP
44 cm3 /rev
APS0250L
Figure 4 Brake Hydraulic Circuit
Reference Reference
Description Description
Number Number
1 Rear Axle 9 Brake Valve
2 Transmission Cutoff Switch 10 Pilot Pump
3 Front Axle 11 Pilot Supply Line
4 Brake 12 Low Pressure Warning Switch
5 Brake Pedal 13 Parking Brake Valve
6 Stop Light Switch 14 Low Pressure Warning Switch
7 Parking Brake 15 Brake and Pilot Filter
8 Accumulators: Brake
STANDARD
PA
C7
C6 T3
C2
7 6
2 4 5
P2 T1 C9
1
PK
A3
A2
UL LP C4
C5
A1
A4 TP
C8
P NO.
P1 C3 LOT NO.
2 8 9 3 7 6
C1
T2
C11
PI
C10
APS0260L
Figure 5 Brake and Pilot Supply Valve
Reference Reference
Description Description
Number Number
1 Body (79*127*180) 6 Solenoid Valve (C8,C9)
2 Check Valve (C1,C2) 7 Coil (C8,C9)
3 Check Valve (C3,C4,C5) 8 Priority Valve (C10)
4 Unloading Valve (C6) 9 Reducing Valve (C11)
5 Relief Valve (C7)
C1 C2
UL
C10 C3 C4
P PA
C11
C6
C9 PK
C5
PI
C8
C7
T1 TP
A4 T3 T2
APS0270L
Figure 6 Hydraulic Circuit
SPECIFICATIONS
Item Specifications
C11 60 ±2 kg/cm2
(850 ±28 psi)
P, T1 PF 1/2 O-ring
UL, TP, T2, T3 PF 1/4 O-ring
Port Size
LP. PK ∅ 30 PF 1/4 BSP
All other ports PF 3/8 O-ring
A1
PI
C7
A3
1 8 6 5
3
4
P1
LP
T1 C4
3
TP1
C2
C3-3
TP2
VDL 24 VDC
KOREA CORPORATION
7
C1
C3-1
FO
VDL 24 VDC
KOREA CORPORATION
C6
C3-4
PA
FI
C5
P2
M A4
T2
C3-2
A2 PK
APS0280L
Figure 7 Low Noise Kit (Brake and Fan Motor Supply Valve)
Reference Reference
Description Description
Number Number
1 Body (200*127*79) 5 Solenoid (C4, C5)
2 Sequence (C1) 6 Coil (C4,C5)
3 Reducing (C2) 7 Reducing (C6)
4 Check (C3) 8 Relief (C7)
C3-1 C3-2
ø1.2 C2 C3-3
TP2 PI
28
FO kgf/cm 2 C4
60 kgf/cm 2 C6
SAFETY
2 C3-4
120 kgf/cm
PA
C1
FI
C7 C5 PK
M 150 kgf/cm 2
A4 T1 T2
APS0290L
Figure 8 Hydraulic Circuit
SPECIFICATIONS
Item Specifications
S0709457C
R1
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
TABLE OF CONTENTS
General Description........................................................................................ 3
Specifications ................................................................................................. 5
Operation........................................................................................................ 6
Neutral..................................................................................................... 6
Bucket/option Spool Operation................................................................ 6
Boom Spool Operation............................................................................ 7
Boom Float....................................................................................... 7
Relief Valve ............................................................................................. 7
Main Relief Valve ............................................................................. 7
Port Relief Valve............................................................................... 7
Operation (Main Relief Valve) ................................................................. 8
Operation in Inoperative State ......................................................... 8
Operation (A) ................................................................................... 8
Operation (B) ................................................................................... 8
Operation (Port Relief Valve)................................................................... 9
In the Inoperative State.................................................................... 9
Operation (A) ................................................................................... 9
Operation (B) ................................................................................... 9
Operation (C) ................................................................................. 10
Sucking Operation ......................................................................... 10
GENERAL DESCRIPTION
The main control valve controls the operation of the bucket, boom, and option cylinders. The bucket spool
has priority over the boom spool.
Pump output flows to port P on the main control valve. See Figure 1. Maximum pressure is prevented from
exceeding the desired level by the main relief valve (1). See hydraulic schematic (Figure 2). When all
spools on the main control valve are in the neutral position (when the pilot valve is not being operated), oil
passes through port P, the bucket spool, the boom spool, the option spool, and passes out T, the tank port.
Oil that passes out the tank port passes through a filter and returns to tank.
Two overload relief valve (2) are installed in the bucket circuit to protect circuit components in the event of
abnormally high pressure. One valve works as a relief valve while the other valve works as an
anticavitation valve to provide additional oil flow to the opposite side of the bucket cylinders.
Boom spool has two important roles in loader work at the floating position. One is that it is possible to lower
the boom by its weight without oil supply from the pump, and that, at the same time, the oil from the pump
makes it possible to combine with the bucket crowd at the max. height of bucket through the bucket line.
Another is that boom and bucket are positioned at the level as the cylinder ports A and B are open as a
leveling function of ground. There is a suction check valve (3) in the boom power port. When the boom is
dropped suddenly by its weight, the cylinder bottom has a cavitation with a lack of oil supply. The check
valve supplements oil to prevent the cavitation.
3A 3B
a3 b3
2A 2B
a2 b2
1A 1B
a1 b1
P
R (1) 9/16 - 18 UNF O-ring Ports (ai, a2, a3)
APS0300L
Figure 1
(1)
a2 a1 a3
P b2 b1 b3
195 BAR
R (2-SPOOL,STD.)
CONTROL V/V
BUCKET
230 B
BUCKET CYL. 1A
BOOM
(3)
(LOWER/FLOAT)
2B
OPTION
230 B
OPTION DEVICE(INC. PIPING)
3B
3A
(3-SPOOL, OPTION)
APS0310L
Figure 2 Control valve hydraulic circuit
Reference Reference
Description Description
Number Number
a3 Option Valve Port 3B Option Cylinder Port
b2 Bucket Crowd Valve Port (to Option Cylinder Tube)
a1 Boom Down Valve Port / 1B Bucket Dump Port
Float Valve Port (to Bucket Cylinder Rod)
b3 Option Valve Port 2A Boom Up Port
(to Boom Cylinder Tube)
a2 Bucket Dump Valve Port
P Pump Port
b1 Boom Up Valve Port
R Tank Port
1A Bucket Crowd Port
(to Bucket Cylinder Tube) 3A Option Cylinder Port
(to Option Cylinder Rod)
(1) Main Relief Valve
(2) Overload Relief Valve
2B Boom Lower Port /
Float Valve Port (3) Anticavitation Check Valve
(to Boom Cylinder Rod)
SPECIFICATIONS
OPERATION
NEUTRAL
When the spools of the bucket section and the boom section are in neutral, both the cylinder ports A (rod
side) and B (tail side) are closed by the spools.
The pressure oil which has reached the control valve flows through the inlet section, past the neutral oil
passages in the bucket section and the boom section to the outlet section from which it is directed to the
low-pressure oil passage and leaves the control valve through the exhaust port of the inlet section.
Reference Reference
Description Description
Number Number
1 Load Check 4 Tank Passage
2 Port A1 5 Center By-pass Passage
3 Port B1
When the bucket spool moves in the direction indicated by the arrow
The neutral oil passage is closed by the spool and the pressure oil pushes open the load check valve to
flow to the cylinder port (A1) from which it is directed into the bucket cylinder rod side.
The oil discharged from the bucket cylinder tail side flows through the cylinder port (B1) to the low pressure
oil passage.
Boom Float
Reference Reference
Description Description
Number Number
1 Port A2 4 Center By-pass Passage
2 Port B2 5 Tank Passage
3 Tank Passage
When the control lever is further pushed down from the “Down” position to the “Float” position, the boom
spool moves as indicated in the illustration.
Due to this motion the neutral passage is opened. The pressure oil flows as if in neutral position. The
cylinder ports (A2) and (B2) are connected to the low-pressure oil passage. As a result, the booms float
over the ground surface according to its irregularities. The oil discharged from the boom cylinder rod side is
sent to the tail side and the oil forced out from its tail side is sent to the rod side respectively through the
low-pressure oil passage in the control valve.
RELIEF VALVE
Operation (C)
The pressures across the relief valve poppet (3)
loses balance. Due to pressure differential, the
relief valve poppet moves so that the pressure
oil at the cylinder port (HP) flows directly to the
low-pressure oil passage (LP).
S0709478C
R1
1PILOT CONTROL
VALVE
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
TABLE OF CONTENTS
General Description........................................................................................ 3
Pilot Valve Operation............................................................................... 3
Standard.................................................................................................. 4
Option...................................................................................................... 6
Pilot System ................................................................................................... 8
Mega 200-V............................................................................................. 9
Mega 250-V........................................................................................... 10
GENERAL DESCRIPTION
When no force is applied to the lever (1, Figure 1), the return spring (4) positions the lever at the
"NEUTRAL" position. When the lever is moved, plunger (5) is moved, which pushes down the return spring
(4). At the same time, spool (2) is moved by spring (3). When spool (2) moves down, a groove (6) in the
spool opens the pilot pressure line to the line that the lever controls. This allows the pilot pressure to flow to
the boom or bucket control valve, where the pilot pressure operates the control valve. When the lever is
completely moved in one direction, the solenoid (7) energizes the electromagnet (8) and holds the lever in
the fully moved position.
STANDARD
33
29 34
32 30
25
31
27
20
26
28 24
17 23
16
22
15
21
19
9 18
5 12
4 13
8
11
7
22
6
3 20
2
1 35
42
41 40 39 38 36 37 38 39
BAS0130L
Figure 1
Reference Reference
Description Description
Number Number
1 Body 22 Plate
2 O-ring 23 Washer
3 Plug 24 Nut
4 Spring 25 Plug
5 Spring Seat 26 Nut
6 Spool 27 Set Screw
7 Spring Seat 28 Nut
8 Spring 29 Nut
9 Stopper 30 Connector
10 Plug 31 Nut
11 Rod Seal 32 Boot
12 O-ring 33 Handle Assembly
13 Push Rod 34 Spring Pin
14 Plate 35 Plug
15 Rod Stopper 36 Housing
16 Du-bushing 37 Holder Rear
17 Rod 38 Terminal
18 Magnet 39 Seal Wire
19 Plate 40 Housing
20 Joint Assembly 41 Holder Rear
21 Joint Assembly 42 Clip Band
OPTION
4
5
11
10
8
12
13
14
15
16
15
17
BAS0200S
Figure 2
Reference Reference
Description Description
Number Number
1 Main Handle Assembly 10 Main Handle U Joint
2 Handle Nut 11 7mm Cable Clamp
3 Handle Mounting Plate 12 Plunger
4 Button Red 13 Plunger
5 Button Grey 14 Capsule Assembly
6 Auxiliary Handle Assembly 15 Capsule Assembly
7 Boot 16 Capsule Assembly
8 Mounting Cap Screws 17 Block
9 Cable Assembly
PILOT SYSTEM
The pilot system uses low pressure oil to operate the main control valves. The main components of the
pilot system are pump (1), pressure reducing valve (3), accumulator (4), pilot cutoff valve (5) and pilot
valves (6 and 7).
With the engine running, oil flows from hydraulic tank to pilot pump (1) The oil flows from the pump through
pressure reducing valve (3) to pilot cutoff valve (5). The pressure reducing valve maintains pilot system
pressure at 28 kg/cm2 (450 psi).
From the pilot cutoff valve the oil flows into the pilot control valves. Pilot valve (6) is a closed center valve.
The oil cannot flow through the valve when it is in the HOLD position because it is a closed center valve.
When the control lever is moved to the DUMP position, oil flows through oil lines to the ends of the bucket
spool of main control valve (8). This causes the main control valve spool to move. Movement of the spool
opens passages for attachment pressure oil to flow to the rod end of the bucket cylinder (9).
Spool movement also opens a passage for return oil from the head end of the bucket cylinder to flow back
to hydraulic tank. Attachment pressure oil acts on the rod end of the bucket cylinder and, because the head
end of the cylinder is now vented to tank, the bucket will dump.
When the control lever is moved to the CROWD position, oil flows through oil lines to the ends of the bucket
spool of main control valve (8). This causes the main control valve spool to move in the opposite direction.
Movement of the spool in this direction opens passages for pressure oil to flow to the head end of the tilt
cylinder. Spool movement also opens a passage for return oil from the rod end of the tilt cylinder to flow
back to the hydraulic tank. Attachment pressure oil acts on head end of the tilt cylinder and because the
rod end of the cylinder is now vented to tank, the bucket will crowd.
MEGA 200-V
OPT. OPT.
DUMP CROWD AUTO RETURN RAISE LOWER
TO DIG
T
P
2 4 3 1 5 6
(3) (4)
0.5 BAR
* TUV Only
40B 40B 40B
LPWS A1 P1 P2 A2 A3
1.5 BAR (PFO1/4) (PFO3/8) (PFO3/8) (PFO3/8) (PFO3/8) (PFO3/8)
C1 C2
ULTP Horn Kick-down
(PFO1/4)
(6)
C3
P
OIL TANK (PFO1/2)
C10
DUMP CROWD AUTO RETURN RAISE LOWER
60B
TO DIG
C4 PARK D.C D.R D.F
(PFO3/8)
C11
C6 PKWS
C9 (PFO1/4)
T
C5 PILOT P 2 4 3 1
(PFO3/8)
OIL COOLER (5)
100 L/MIN
28B
C7 TP
T1 C8
(1) (PFO1/4)
3
41 cm/rev (2)
P1 P3 200 l/min at 6.9 B at 2,400 rpm
3
44 cm/rev 1.25 1.25"
C1 TPM 320 l/min max
<
0.25"
200 BAR
W22D5F6-25
EF (8)
0.75 (2-SPOOL,STD.)
R2
(9) Æ140xÆ75x490
BUCHET CYLINDER BUCKET
1.5
230 B
HT
<
<
C2 C3 0.75
(DUMP) (CROWD)
C R1
1B
0.75" 2.5 B
1.25
1.5 BOOM RAISE
(10) KICK-OUT
1A
RESTRICTION VALVE
BOOM
(LOWER/PLOT)
STEERING LINE
Æ120xÆ70X780 2B
EF CF
BOOM CYLINDER (RAISE) 2A
LS
OPTION
OPTION DEVI CE
230 B
P 3B
APS0320L
Figure 3
Reference Reference
Description Description
Number Number
1 Pilot Pump 6 Pilot Valve (Mono, STD.)
2 Brake and Pilot Filer 7 Pilot Valve (Two-lever, OPT.)
3 Pressure Reducing Valve 8 Main Control Valve
4 Accumulator: Pilot 9 Bucket Cylinder
5 Pilot Cutoff Valve 10 Boom Cylinder
MEGA 250-V
UNLOADER VALVE
STEERING LINE
PRIORITY VALVE
AOS0580L
Figure 4
Reference Reference
Description Description
Number Number
1 Pilot Pump 6 Pilot Valve (Mono, STD.)
2 Brake and Pilot Filer 7 Pilot Valve (Two-lever, OPT.)
3 Pressure Reducing Valve 8 Main Control Valve
4 Accumulator: Pilot 9 Bucket Cylinder
5 Pilot Cutoff Valve 10 Boom Cylinder
S0709650
R1
1PRIORITY VALVE
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
TABLE OF CONTENTS
General Description........................................................................................ 3
Theory of Operation ................................................................................ 3
Parts List ................................................................................................. 5
Specifications .......................................................................................... 6
Special Tools .................................................................................................. 6
Disassembly ................................................................................................... 6
Cleaning and Inspection (Wear Limits and Tolerances) ................................. 8
Reassembly.................................................................................................... 9
GENERAL DESCRIPTION
THEORY OF OPERATION
Figure 1
Oil output from the steering pump flows through the priority valve to both the loader supply line and to the
steering circuit. During operation of the steering wheel, the priority valve shifts and supplies pump flow only
to the steering circuit. This results in smooth operation of the steering circuit.
At rest, the spool (1, Figure 2) maintains an open path between inlet port P and steering outlet port CF.
Port EF is kept closed by the force from spring (2). The spool (1) contains a drilled passage. The passage
is open to port CF and is also open to both ends of the spool. At the neutral position of the steering unit, oil
from port P flows through port CF and into the drilled passage in the spool. At this time, oil flowing out of
CF is blocked at the control spool of the steering unit. This raises the pressure in port CF. At this time, port
LS is open to the chamber on the far right side of the priority valve. Port LS is not open to the chamber on
the far left side of the valve. As oil flows through the drilled passage in the spool, pressure builds on the left
side of the spool but pressure is low on the right side of the spool because oil can drain into port LS. When
oil pressure on the left side of the spool rises above the force of spring (2, Figure 2), the spool (1) shifts the
right. This allows pump flow at port P to flow out both ports CF and EF. Now both the loader supply line and
the steering supply line are charged with flow from the steering pump. Whenever the steering wheel is
turned, the spool in the steering unit directs some oil flow back to port LS. This equalizes the oil pressure
on both ends of the spool (1). The spring now shifts the spool to the left. This closes off the passage from
port P to port EF. This makes all steering pump flow now available only to the steering circuit from port CF.
Figure 2
Reference Reference
Description Description
Number Number
1. Spool CF Steering Supply Port
2. Spring ED Loader Supply Port
P Pressure Port LS Pilot Port
PARTS LIST
Figure 3
Reference Reference
Description Description
Number Number
1 Plug 5 Spring
2 O-ring 6 Plug
3 Spool 7 Orifice
4 Housing
SPECIFICATIONS
SPECIAL TOOLS
1. The following tools are necessary to repair
the priority valve. See Figure 4.
Open end wrench - 27 mm
Slip joint pliers
Nylon rod
Allen wrenches - 5 mm, 8 mm and 10 mm
Figure 4
DISASSEMBLY
1. Use open end wrench to loosen PP plug.
See Figure 5. Remove O-ring.
Figure 5
Figure 6
3. Remove spring. See Figure 7.
Figure 7
4. Use a nylon rod to push spool out of bore.
See Figure 8.
Figure 8
5. Use an 8 mm allen wrench to remove plug
from pressure relief valve. See Figure 9
Figure 9
Figure 10
7. Hold pressure relief valve with a pliers and
use a 5 mm allen wrench to remove set
screw. See Figure 11.
Figure 11
8. The pressure relief valve is composed of a
valve housing, valve needle, spring and
set screw. See Figure 12.
Figure 12
REASSEMBLY
NOTE: The relief valve pressure can be changed by changing springs. The following table
displays the characteristics of the three springs available. See Figure 13.
Figure 13
1. Figure 14, shows PP plug and spool.
Figure 14
Figure 15
3. Install spool into bore. See Figure 16. Use
a nylon rod to position spool in neutral
position.
Figure 16
4. Install spring and LS plug into bore. See
Figure 17. Use a new O-ring on plug.
Figure 17
5. Use a 27 mm wrench to tighten PP plug
and LS plug to 6 kg•m (44 ft lb). See
Figure 18.
Figure 18
Figure 19
7. Install plug into pressure relief valve bore.
Tighten plug to 5 kg•m (36 ft lb). See
Figure 20.
Figure 20
S0709705C
1POWER STEERING
UNIT
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
TABLE OF CONTENTS
General Description........................................................................................ 3
Power Steering System........................................................................... 3
Gerotor Operation ................................................................................... 6
Cushion Valve Operation......................................................................... 7
Parts List ................................................................................................. 8
Specifications .......................................................................................... 9
Special Tools ................................................................................................ 10
Troubleshooting, Testing and Adjustment..................................................... 12
Disassembly ................................................................................................. 13
Cleaning and Inspection............................................................................... 17
Reassembly.................................................................................................. 18
Installation .................................................................................................... 29
GENERAL DESCRIPTION
POWER STEERING SYSTEM
Reference
Description
Number
1 Bearing
2 Centering Springs
3 Sleeve
4 Center Pin
5 Check Valve
6 Gerotor
7 End Cap
8 Spool
9 Drive Shaft
10 Housing
Mega 200-V
P1 P3
1.25 1.25"
1.5 BAR C1 TPM
<
0.25"
100 L/MIN
EF L R
0.75
OIL TANK
R2
1.5
HT 175 BAR
(1)
<
<
(5) C2 C3 0.75
3
14 cm/rev C R1 T LS
0.75" 1.25 P
1.5 2.5 B
3
41 cm/rev RESTRICTION VALVE
LS
3
44 cm/rev 230 BAR 230 BAR
(6) <
EMR. STEER
CHECK V/V
5Bar EF CF
∅70x ∅35x396
EMR. STEER (3)
PRESSURE SENCER
LS
< <
VKLU2B
(4)
10ccr (2)
Reference Reference
Description Description
Number Number
1 Steering Unit 4 Cushion Valve
2 Priority Valve 5 Steer Pump
3 Steering Cylinder 6 Supply Line to Main Control
Valve
Mega250-V
AOS0590L
Figure 3 Steering Circuit
Reference Reference
Description Description
Number Number
1 Steering Unit 4 Cushion Valve
2 Priority Valve 5 Steer Pump
3 Steering Cylinder 6 Supply Line to Main Control
Valve
Neutral Operation
With the steering wheel in the neutral position (wheels turned neither right nor left), the spool (2, Figure 4)
and sleeve (1) are stationary at the position where the center pin (6) becomes centered in the spool space
by the centering springs (3). Oil flow through the load sensing line (LS), port L, port R, and port T are
bypassed to the tank line and the oil supply (P) is blocked by the directional spool in the steering unit (1,
Figure 3). Even if an external force is applied to the steering cylinder, the steering unit is protected because
the oil path is blocked by the directional spool.
Reference
Description
Number
1 Sleeve
2 Spool
3 Centering Spring
4 Spool
5 Sleeve
6 Center Pin
7 Drive shaft
Figure 4
Right Turn
The spool (2, Figure 4) is engaged with the spline of the steering shaft. When the steering wheel is turned
to the right, the spool turns. The sleeve (1) is connected to the spool (2) by centering springs (3). When
spool turns, the sleeve turns. The sleeve turning angle is about 10° less than the spool turning angle. This
allows the longitudinal slots in the spool to align with the ports in the sleeve. Oil from port P on the steering
unit (1, Figure 3) travels through the control spool and is directed to port R which directs the oil to the
steering cylinders (3, Figure 3). The amount of flow metered to port R is controlled by the amount of
steering wheel rotation. Excess oil flow through port P that is not metered to port R, is directed by the spool
to port T and is then directed through the il cooler and into the tank.
Left Turn
The spool (2, Figure 4) is engaged with the spline of the steering shaft. When the steering wheel is
connected to the spool (2) by centering springs (3). When the spool turns, the sleeve turns. The sleeve
turning angle is about 10° less than the spool turning angle. This allows the longitudinal slots in the spool
to align with the ports in the sleeve. When the steering wheel is turned to the left, oil from port P on the
steering unit (1, Figure 3) is directed through the control spool in the steering unit, out port L and into the
steering cylinders (3, Figure 3). The amount of oil flow metered to port L is controlled by the amount of
steering wheel rotation. Excess oil flow through port P that is not metered to port L, is directed by the spool
to port T and is then directed through the oil cooler and into the tank.
GEROTOR OPERATION
If the engine or pump is not operating, the steering unit (1, Figure 3) works as a manual pump when the
steering wheel is turned. The gerotor will work when the input torque to the steering wheel is less than 12
kg•m (87 ft lb). If the necessary input torque is greater than this, the gerotor will not function. When the
steering wheel is turned, the gerotor creates a vacuum that draws oil from port T. See Figure 3. The
gerotor pumps this oil through the control spool and into the steering cylinders. Return oil flows back to the
spool and is used to lubricate the steering unit (1, Figure 3). The return oil then flows back into the tank line
and is recirculated back to the gerotor and the steering cylinders.
Function
The cushion valve absorbs any excessive peak pressure that my be generated during initial movement of
the steering wheel or during a change in steering direction. The cushion valve also prevents excessive high
pressure and shock that can result from steering load inertia.
Working Principle
If a high pressure oil is fed back to the port R, it pushes the spring (3) and opens the poppet (2). This
operation directs the high pressure oil to port L through the center hole in spool (12) and the check valve
poppet in port L part. At the same time, oil reaches the pressure room of the plug through orifice (8). This
operation closes the passage from port R to port L. This releases the pressure and prevents machine
shock by intercepting oil. If a low pressure oil flows, the cushion operation is not necessary. It is due to the
speed of closing spool (12) is faster than the speed of opening poppet (2), therefore, the cushion valve
does not work.
Figure 5
PARTS LIST
An exploded view of the steering unit is shown in Figure 6.
Figure 6
Reference Reference
Description Description
Number Number
1 Seal Ring 16 Spacer - 25 mm (If
2 Housing equipped)
3 Spool 17 Spacer Bushing (If
equipped)
4 Sleeve
18 O-ring 80.5 x 1.5 mm
5 Ball
19 Middle Plate
6 Threaded Bushing
20 Distributor Plate
7 O-ring
21 Rotor
8 Backing Ring (If equipped)
22 O-ring - 79.92 x 1.78 mm
9 Thrust Washers
23 Cylinder Gear
10 Thrust Bearing
24 End Cover
11 Spacer Ring
25 Washer
12 Cross Pin
26 Roll Pin 2.5 x 32 mm
13 Neutral Springs
27 Bolt
14 Shaft
15 Spacer - 13.8 mm (If
equipped)
SPECIFICATIONS
Specification
Steering Unit
Mega 200-V Mega 250-V
Type Load Sensing, Dynamic Signal, Nonreaction
Gerotor
Displacement 630 cc/rev (38.44 in3/rev)
Rated Flow 80 liter/min (21.12 U.S. gal) 63 liter/min (16.63 U.S. gal)
SPECIAL TOOLS
The tools necessary for steering unit repair are illustrated below.
1. Stabilizing base. See Figure 7.
Figure 7
2. O-ring assembly tool. See Figure 8
Figure 8
3. Seal driver. See Figure 9.
Figure 9
Figure 10
DISASSEMBLY
It is very important to keep the inside of the steering unit clean. Make sure that the outside of the steering
unit is clean before opening the unit. Use a wire brush and solvent to clean the entire unit.
1. Remove steering column from steering
unit. Bolt steering unit to stabilizing base.
Bolt base to work bench.
2. Remove bolts from steering unit end cover.
See Figure 11.
Figure 11
3. Remove end cover from unit. See Figure
12
Figure 12
4. Lift cylinder gear off unit. See Figure 13.
Remove two O-rings.
Figure 13
Figure 14
6. Remove shaft from housing. See Figure
15.
Figure 15
7. Remove distributor plate from housing.
See Figure 16.
Figure 16
8. Remove O-ring from top of middle plate.
See Figure 17.
Figure 17
Figure 18
10. Remove O-ring from housing. See Figure
19.
Figure 19
11. Unscrew threaded bushing and remove it.
See Figure 20.
Figure 20
12. Remove cross pin. See Figure 21.
Figure 21
Figure 22
14. Pull sleeve and spool out of housing. See
Figure 23.
Figure 23
15. Remove thrust bearing and thrust washers
from sleeve. See Figure 24. Remove
spacer ring. Be sure to remove spacer
ring. It can stick in sleeve.
Figure 24
16. Carefully slide control spool out of sleeve.
See Figure 25.
Figure 25
Figure 26
18. Remove dust seal from housing. See
Figure 27. Remove O-ring and backup ring
from inside housing.
Figure 27
19. Figure 28, shows all parts removed from
steering unit. Clean all parts before
assembly. Use only new O-rings and
seals.
Figure 28
REASSEMBLY
NOTE: Use bolt torque chart that follows to tighten bolts as steering unit is assembled.
Figure 29
Figure 30
2. Position springs so that amount of spring
protruding out of spool is equal on both
sides. See Figure 31.
Figure 31
Figure 32
Figure 33
4. Center springs in sleeve. See Figure 34.
Figure 34
Figure 35
6. Rotate seal ring. See Figure 36. It must
rotate freely without resistance.
Figure 36
7. Turn sleeve 180°. Install cross pin into
sleeve and spool. See Figure 37.
Figure 37
Figure 38
Reference
Description
Number
1 Thrust Washer
2 Thrust Bearing
3 Thrust Washer
4 Spool
5 Sleeve
Figure 39
9. Oil O-ring and backup ring and then install
them on an O-ring assembly tool. See
Figure 40.
Figure 40
Figure 41
11. Use assembly tool to install O-ring and
backup ring into bore. See Figure 42.
Figure 42
12. Unbolt housing from stabilizing base. Hold
housing in a horizontal position. See
Figure 43. Insert sleeve and spool into
bore.
Figure 43
Figure 44
14. Bolt housing back into stabilizing base.
See Figure 45.
Figure 45
15. Insert ball into hole. See Figure 46.
Figure 46
Figure 47
17. Lubricate O-ring with 20 weight mineral
oil and install it in groove. See Figure 48.
Figure 48
18. Install middle plate onto housing. See
Figure 49. Be sure to properly align plate
holes with holes in housing.
Figure 49
19. Lubricate O-ring with 20 weight mineral oil
and install it in groove. See Figure 50.
Figure 50
Figure 51
21. Install shaft into bore of housing. See
Figure 52. Position slot in shaft to engage
cross pin.
Figure 52
22. Position rotor so that cross pin is between
two teeth as shown by position of
screwdriver. See Figure 53.
Figure 53
Figure 54
24. Use a bolt to align holes in cylinder gear
with bolt holes in housing. See Figure 55.
Figure 55
25. Install spacer bushing. See Figure 56.
Remove bolt that was installed in previous
step (If equipped.).
OSPL 630:1 = 3.8 mm (0.1496 in) (15,
Figure 6)
OSPL 800 (16, Figure 6)
OSPL 1000 (16, Figure 6)
NOTE: Refer to parts manual for our
unit to determine if these parts
are installed.
Figure 56
Figure 57
27. Install end cover. See Figure 58.
Figure 58
28. Install a washer and roll pin into hole
shown in Figure 59.
Figure 59
29. Install six remaining bolts and tighten
them. See Figure 60. Cross tighten bolts
and roll pin to 48 Nm (35 ft lb).
Figure 60
Figure 61
31. Use a seal driver and a plastic hammer to
install dust seal. See Figure 62.
Figure 62
32. Install plastic plugs to prevent dirt from
entering steering unit. See Figure 63.
Figure 63
Figure 64
INSTALLATION
The following table shows torque specifications for hydraulic fittings used to install steering unit.
Maximum
Tightening Torque
kg•m (ft lb)
Type of 1/4 RG 1/2 RG
Screw Fitting 1/4 BSP.F 1/2 BSP.F
7/16-20UNF
R 1/4 R 1/2
G l/4 G 1/2
Cutting Edge 4 (29) 10 (72)
Copper Washer 2 (15) 3 (22)
Aluminum Washer 3 (22) 8 (58)
O-ring 2 (15)
S0709752C
1RESTRICTION VALVE
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
RESTRICTION VALVES0709752C
MODEL SERIAL NUMBER RANGE
Mega 200-V (Tier I & II) 1001 and Up
TABLE OF CONTENTS
General Description........................................................................................ 3
Theory of Operation ................................................................................ 3
Unloader Cartridge Identification ............................................................ 4
Specifications .......................................................................................... 5
GENERAL DESCRIPTION
THEORY OF OPERATION
The restriction valve is made up of four bypass check valve C1, C2, C3, and C4.
Output from the steering pump passes through the priority valve that is part of the steering cylinder. See
the hydraulic schematic. (Figure 1). This flow then passes out of the steering cylinder and enters the
restriction valve at port EF. This allows output from the steering pump to join flow from the main pump to
supply the boom, bucket, and option control valves.
Pump
Brake/Pilot Pump (to Brake & Pilot V/V) to TANK
3
14 cm/rev
Steer Pump
3
41 cm/rev
Loader Pump P1 P3
3
44 cm/rev 1.25 1.25"
(to Control V/V)
C1 TPM
0.25"
EF
0.75
R2
1.5
HT
C2 C3 0.75
C R1
0.75" 2.5 B
1.25
1.5 (from Control V/V)
RESTRICTION VALVE
to Steer Line
EF CF
LS
P
Priority V/V
APS0340L
Figure 1 UNLOADING CIRCUIT
P3
R1
7 6 4 1 3
2
C1
HT
R3
EF
TPM
C R2 P1
APS0350L
Reference
Description Remark
Number
1 Body 99x125x140
2 Sub Block 63x99x129
3 Check Valve C1
4 Check Valve C2,3
5 Wrench Bolt M12x1.75x60L
6 O-ring
7 Plug Bolt R3
SPECIFICATIONS
Item Specification
Maximum Rated Pressure 210 bar
(3,050 psi)
Rated Flow Ports to P1, P3 210 lpm
(55.48 gpm)
Rated Flow Ports to EF 100 lpm
(26.42 gpm)
Rated Flow Ports to R 300 lpm
(79.25 gpm)
C1 2 ±0.2 Bar
(29 ±3 psi)
Setting Pressure Cracking Pressure
C2, 3 0.7 - 2 Bar
(10 - 29 psi)
R, R2, R3 1-1/4" SAE Flange Port (M12, 1.75)
P1 1" SAE Flange Port (M10, 1.5)
Port Size HT, EF, C 3/4" PF O-ring
TPM 1/4" PF O-ring
R3 1/4" PF O-ring (Supplied Plugged)
S0793015C
1HYDRAULIC
SCHEMATIC
(MEGA 200-V)
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
TABLE OF CONTENTS
General Description........................................................................................ 3
Mega 200-V (Standard).................................................................................. 4
Mega 200-V (Option)...................................................................................... 6
GENERAL DESCRIPTION
Schematic(s) presented in this section are laid out on facing pages.
An overlapping edge has been taken into consideration so that a photocopy can be made and pasted
together to make a complete schematic.
Figure 1
Hydraulic Schematic(Standard)
CLOSES 3 B
STOP
* TUV Only
FRONT AXLE
BR1 BR2
L.H Brake valve
OPENS 25 B
T/M DISCONNECT
45B
P1 T1 P2 T2
LPWS A1 P1 P2 A2 A3
1.5 BAR (PFO1/4) (PFO3/8) (PFO3/8) (PFO3/8) (PFO3/8) (PFO3/8)
C1 C2
ULTP
(PFO1/4)
C3
P
TANK (PFO1/2)
C10
60B
C4 PAR
(PFO3/8)
C11
C6 PKW
C9 (PFO1/4)
C5 PILO
(PFO3/8)
STEER PUMP
3
41 cm/rev
H.P FILTER
LOADER PUMP P1 P3 200 l/min at 6.9 B at 2,4
3
44 cm/rev 1.25 1.25"
C1 TPM 320 l/min max
<
0.25"
EF
PUMP 0.75
L R
EMERG.STEER R2
CHECK V/V 1.5
HT
<
<
C2 C3 0.75
5Bar
C R1
EMERG.STEER 0.75" 2.5 B
1.25
1.5
PRESS/ S/W
STEER UNIT
RESTRCITION VALVE 175 BAR
T LS
P
VALVE BLOCK
LS
EF CF
10ccr <
- M
LS
P CUSHION V/V
PRIORITY V/V < <
* ELECTRIC EMERGENCY STEERING
Figure 2
* OPTIONAL EQUIPMENT
* JOYSTICK VALVE Kick-down Horn
(3-SP. OPT.)
OPT. OPT.
DUMP CROWD AUTO RETURN RAISE LOWER
TO DIG
R2
REAR AXLE
OPENS 25 B T
T/M DISCONNECT
P
45B
2 4 3 1 5 6
P2 T2
40B 40B
0.7L 0.7L
2 A2 A3
3/8) (PFO3/8) (PFO3/8)
PKWS
C9 (PFO1/4)
T
5 PILOT P 2 4 3 1
(PFO3/8)
TP
C8 (PFO1/4)
4 15B T3 T2
0.32L
(2-SPOOL,STD.)
CONTROL V/V
R
BUCKET
230 B
(DUMP) (CROWD)
1B
ø140 x ø75 x 490
BUCKET CYL. 1A
STEER UNIT
BOOM
LS
(LOWER/FLOAT)
VALVE BLOCK ø120 x ø70 X 780 2B
OPTION
230 B
OPTION DEVICE(INC. PIPING)
3B
STEERING CYL.
3A
(3-SPOOL, OPTION)
CUSHION V/V
LOG FORK SYSTEM
MEGA 200-V
APS0430L
Hydraulic Schematic(Option)
CLOSES 3 B
STOP
FRONT AXLE
BR1 BR2
L.H Brake valve
OPENS 25 B
T/M DISCONNECT
45B
P1 T1 P2 T2
C3-1 C3-2
Æ1.2 C2 C3-3
TANK TP2
(PFO1/4)
2
FO 28kgf/cm
(PFO1/2)
2 C6
C1 60kgf/cm SAF
120kgf/cm2
FI C3-4
(PFO1/2)
Fan motor(Opt.) C7
0.75"
OIL COOLER 100 L/MIN
70bar M 150kgf/cm2
10 micron 16ccr (PFO1/2)
BRAKE/PILOT
BRAKE & PILOT & FAN MOTOR A4 (PFO3/8)
T1
(PFO3/8)
T2
PUMP 40B (PFO1/4)
14 cm3/rev SUPPLY V/V(Opt.) 0.7L * TUV Only
0.25"
EF
PUMP 0.75
L R
EMERG.STEER R2
CHECK V/V 1.5
HT
<
<
C2 C3 0.75
5Bar
C R1
EMERG.STEER 0.75" 2.5 B
1.25
1.5
PRESS/ S/W
STEER UNIT
RESTRCITION VALVE 175 BAR
T LS
P
VALVE BLOCK
LS
EF CF
10ccr <
- M
LS
P CUSHION V/V
PRIORITY V/V < <
* ELECTRIC EMERGENCY STEERING
Figure 3
* OPTIONAL EQUIPMENT
* JOYSTICK VALVE Kick-down Horn
(3-SP. OPT.)
OPT. OPT.
DUMP CROWD AUTO RETURN RAISE LOWER
TO DIG
BR2
REAR AXLE
OPENS 25 B T
T/M DISCONNECT
P
45B
2 4 3 1 5 6
P2 T2
40B 15B
C3-4 PA
(PFO3/8)
T
PARK
P 2 4 3 1
LPWS 45bar
C5
PK
(PFO1/4)
A4 (PFO3/8)
T1
(PFO3/8)
T2
40B (PFO1/4)
(2-SPOOL,STD.)
CONTROL V/V
R
BUCKET
230 B
(DUMP) (CROWD)
1B
Æ140xÆ75x490
BUCKET CYL. 1A
STEER UNIT
BOOM
LS
(LOWER/FLOAT)
VALVE BLOCK Æ120xÆ70X780 2B
OPTION
230 B
OPTION DEVICE(INC. PIPING)
3B
STEERING CYL.
3A
(3-SPOOL, OPTION)
CUSHION V/V
MEGA 200-V
APS0440L
1ELECTRICAL SYSTEM
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
Overview ........................................................................................................ 4
Electric Wire Color ........................................................................... 4
Electric Supply System .................................................................................. 5
Engine Starting Circuit ................................................................................... 7
Operation During Start Process .............................................................. 7
Operation After Start Process (Mega 200-V) .......................................... 9
Operation After Start Process (Mega (250-V)....................................... 10
Engine Preheating System........................................................................... 11
Mega 200-V / 250-V (Tier I) .................................................................. 11
Mega 200-V / 250-V (Tier II) ................................................................. 14
Engine Stop System..................................................................................... 17
Operation In Engine Running Mode...................................................... 17
Operation In Engine Stop Mode............................................................ 20
Charging System.......................................................................................... 22
Monitoring System ....................................................................................... 23
Instrument Panel ................................................................................... 24
Function Check ..................................................................................... 25
Monitoring System Schematic .............................................................. 26
Mega 200-V ................................................................................... 26
Mega 250-V ................................................................................... 28
Operation .............................................................................................. 30
Instruments .................................................................................... 30
Pilot Lights ..................................................................................... 32
Initial Operation.............................................................................. 33
Control Unit Operation ................................................................... 34
Characteristic of Operation ............................................................ 35
Windshield Wiper ......................................................................................... 36
Front windshield wiper .......................................................................... 36
Front Windshield Wiper Circuit....................................................... 36
Rear Windshield wiper .......................................................................... 37
NOTE: 0.85G: Nominal sectional area of wire core less insulator = 0.85 mm2 (0.03 in2).
6
3
8
4 2
AJS0010L
Figure 1 ELECTRICAL POWER CIRCUIT DIAGRAM
Reference Reference
Description Description
Number Number
1 Battery 5 Starter Switch
2 Battery Relay 6 Fuse Box
3 Fusible Link 7 Alternator
4 Circuit Breaker 8 Diode
Reference Reference
Description Description
Number Number
1 Battery 8 Starter Relay
2 Battery Relay 9 Starter
3 Fusible Link 10 Alternator
4 Circuit Breaker 11 Transmission Selector Switch
5 Starter Switch 12 Diode
6 Fuse Box 13 Transmission Controller
7 Starter Controller 14 Safety Starter Relay
BAS0090L
Figure 3 OPERATION OF START CIRCUIT (2) - IMMEDIATELY AFTER START
Reference Reference
Description Description
Number Number
1 Battery 8 Starter Relay
2 Battery Relay 9 Starter
3 Fusible Link 10 Alternator
4 Circuit Breaker 11 Transmission Selector Switch
5 Starter Switch 12 Diode
6 Fuse Box 13 Transmission Controller
7 Starter Controller 14 Safety Starter Relay
AJS0030L
Figure 4 OPERATION OF START CIRCUIT (2) - IMMEDIATELY AFTER START
Reference Reference
Description Description
Number Number
1 Battery 8 Starter Relay
2 Battery Relay 9 Starter
3 Fusible Link 10 Alternator
4 Circuit Breaker 11 Transmission Selector Switch
5 Starter Switch 12 Diode
6 Fuse Box 13 Transmission Controller
7 Starter Controller 14 Safety Starter Relay
12 5
2
13
7
13
8 1
10
11
AJS0040L
Reference Reference
Description Description
Number Number
1 Battery 8 Preheat Relay
2 Battery Relay 9 Glow Plug
3 Fusible Link 10 Thermal Switch
4 Circuit Breaker 11 Alternator
5 Starter Switch 12 Instrument Panel
6 Fuse Box 13 Diode
7 Preheat Controller
Reference
Description
Number
1 Terminal B
2 Fuse
3 Amperage Marked
4 Terminal H
5 Terminal C
Figure 6
12 5
2
13
8 1
10
11
BAS0100L
Reference Reference
Description Description
Number Number
1 Battery 7 Preheat Controller
2 Battery Relay 8 Preheat Relay
3 Fusible Link 9 Air Heater
4 Circuit Breaker 10 Thermal Switch
5 Starter Switch 11 Alternator
6 Fuse Box 12 Instrument Panel
4 Terminal C 4
2
5 Terminal D
BAS0160L
Figure 8
AJS0050L
Figure 9 ENGINE STOP CIRCUIT - RUNNING MODE
Reference Reference
Description Description
Number Number
1 Battery 4 Fuse Box
2 Fusible Link 5 Engine Stop Relay
3 Starter Switch 6 Engine Stop Motor
AJS0060L
Figure 10
5
6
4
2
AJS0070L
Reference Reference
Description Description
Number Number
1 Battery 4 Fuse Box
2 Fusible Link 5 Engine Stop Relay
3 Starter Switch 6 Engine Stop Motor
AJS0080L
Figure 12
AJS0090L
Reference Reference
Description Description
Number Number
1 Battery 5 Starter Switch
2 Battery Relay 6 Fuse Box
3 Fusible Link 7 Alternator
4 Circuit Breaker 8 Diode
2
19 3
18
4
1
17 5
16 6
15
7
8
13 14 12 11 10 9
AOS0910L
Figure 14
Reference Reference
Description Description
Number Number
1 Instrument Panel 10 Engine Coolant Temperature
2 Battery Switch
3 Alternator 11 Engine Oil Pressure Switch
4 Speed Sensor 12 Hazard Warning Light Switch
5 Coolant Temperature Sensor 13 Turn Signal Light Switch
6 Fuel Sensor 14 High Beam Switch
7 Transmission Oil Temperature 15 Working Light Switch
Sensor 16 Brake Oil Pressure Switch
8 Preheat Controller 17 Parking Brake Pressure Switch
9 Air Cleaner Indicator 18 Emergency Steering Switch
19 Control unit
The monitoring system displays various data and warning signals onto the instrument panel by processing
information gathered from various sensors throughout the equipment.
9 10 11 12 13 14 15 16 17
8 18
7 19
4 1 3 2 5 6
(CN1) (CN2)
AOS0920L
Figure 15
FUNCTION CHECK
When the starter switch is turned to the “ON” position, all displays, switch lights, and warning lights except
the turn and hazard warning light, high beam indicator, working light indicator, and emergency steering
indicator will be lit for two seconds and the warning buzzer will sound. Any lights that do not turn "ON"
during the function check should be replaced.
Mega 200-V
BAS0080L
Figure 16
AOS0930L
Figure 17
Instruments
Sensor Specification
Function Display Input
Input Specification
Terminal
10 Km/h- 905 Hz
20 Km/h- 1811 Hz
M200-V 30 Km/h- 2716 Hz
40 Km/h- 3622 Hz
*ƒ = 90.55 V [Hz]
CN1-4 10 Km/h- 704 Hz
Speedometer
CN1-5 20 Km/h- 1407 Hz
M250-V 30 Km/h- 2111 Hz
40 Km/h- 2814 Hz
*ƒ = 70.36 V [Hz]
ƒ : Frequency of T/M Controller
v : Speed [km/h]
500 rpm - 90 Hz
1000 rpm - 179 Hz
1500 rpm - 268 Hz
2000 rpm - 358 Hz
2500 rpm - 447 Hz
Tachometer CN1-3
3000 rpm - 537 Hz
*ƒ = 0.179 N [Hz]
ƒ : Frequency of alternator "P"
terminal
N : Engine rpm
ALTERNATOR “P”
Hour Meter CN1-2
Terminal voltage (24V)
0012.eps
Input
Symbol Description Operation Remarks
Terminal
Preheat CN2-1 Light turns "ON" when
preheat process is
completed. (Approximately
HAOA630L
19 seconds from start.)
Air Cleaner CN2-2 Light turns "ON" when air
cleaner is clogged
HAOA660L
Work Light CN2-9 Light turns "ON" when Light off when the engine is
work light is operated. started.
(Terminal input is to 24 V)
Initial Operation
Input
Item Output (Operation and initial setting mode)
(Terminal)
Initial Operation CN 1-1 • All warning lights are turned "ON" and turned "OFF"
after 2 seconds. (Except for turn signal indicator, high
beam indicator, working light indicator and transmission
cutoff indicator and emergency steering indicator.
• Warning buzzer is activated and turned off after 2
seconds.
• Monitoring system displays present conditions.
5
2
1
6
7 8
Reference Reference
Description Description
Number Number
1 Instrument Panel 8 Alternator
2 Starter Switch 9 Engine Oil Pressure Switch
3 Forward Lever Switch 10 Coolant Temperature
4 Reverse Lever Switch Switch
5 Fuse Box 11 Brake Oil Pressure Switch
6 Control Unit 12 Parking Brake Pressure
Switch
7 Warning Buzzer
13 Alarm Relay
Input Output
All warning lights are
turned "ON" and turned
1 When the starter switch is “ON”
"OFF" after 2 - 2.5
seconds.
Charging light turns
is below 12±1 V
When “R” terminal voltage of "ON" L5
2
alternator Charging light turns
is above 12±1 V
"OFF" L5
Warning buzzer sounds
Engine oil pressure switch is “ON”
after 8±1 seconds.
Warning buzzer sounds
Coolant temperature switch is “ON”
immediately
When “R” terminal voltage of
3 Warning buzzer sounds
alternator is above 12±1 V Brake oil pressure switch is “ON”
immediately
Forward or Reverse lever switch is “ON”
Warning buzzer sounds
and Parking brake pressure switch is
immediately
“ON”
Figure 19
3
2
6 5
5
4
AJS0170L
Reference Reference
Description Description
Number Number
1 Fuse Box 4 Washer Tank
2 Wiper/washer Switch 5 Diode
3 Wiper Motor 6 Diode
3
2
6 5
5
4
AJS0160L
Reference Reference
Description Description
Number Number
1 Fuse Box 4 Washer Tank
2 Wiper/washer Switch 5 Diode
3 Wiper Motor 6 Diode
27
28
19 21
20
23 26
25
2
7
8 3
12 10 11 13
6
18
4
24
14 16 15
5
BAS0150L
Figure 22 LIGHT CIRCUIT
The lighting system is consists of the headlight, the position light, the turn signal light, the hazard light, the
stop light, the license plate light, the working light, the rotating beacon light (option) and the switches,
which is used to turn "ON" the lights.
1. When the headlight switch (3) is in the first step, through the fuse box 1 (1) to the "2," "6" terminal of
headlight switch (3), the following lights will be alight.
A. The front combination light (L) (12) and rear combination light (L) through the fuse box 2 (23).
B. The front combination light (R) (13) and rear combination light (R) through the fuse box 2 (23).
C. The illumination lights through the "9" terminal of all kind of rocker switches include the
headlight switch (3), the front working light switch (19), the rear working light (21) and the
hazard switch (6).
D. The license plate light (16).
2. When the headlight switch (3) is in the second step, the current flows through the fuse box 1 (1), to
the "2," "3" terminal of headlight switch (3) and to the "86," "85" terminal of headlight relay (8), and the
"30," "87" terminal of headlight relay (8) is connected. As a result, through the fuse box 1 (1) to the
"30," "87" terminal of headlight relay (8), the voltage is applied to the "56" terminal of combination
switch (R) (4).
A. At this time if the combination switch (4) is in the "0" position, the current flows to the "56b"
terminal and it allow the low light, which is in the headlight (L) (10) and the headlight (R) (11), to
be alight.
B. Also if the combination switch (4) is in the "▼ " position, the current flows to the "56a" terminal
and it allow the high light, which is in the headlight (L) (10) and the headlight (R) (11), to be
alight. At the same time the current flows to the "CN2-7" terminal of instrument panel (17) and
the headlight indicator L7 will be alight.
C. And if the combination switch (4) is in the "▲ " position, the current flows to the "56b" terminal
and it allows the low light, which is in the headlight (L) (10) and the headlight (R) (11), to be
alight.
At the same time another current flows from the fuse box 1 (1) to the "15/1," "56b" terminal of
combination switch (4) and the high light, which is in the headlight (L) (10) and the headlight (R)
22
28 29
23
20 19 21
24 27
18 18
17
1
26
2
7
8 3
12 10 11 13
6
18
4
25
14 16 15
5
AJS0180L
The lighting system is consists of the headlight, the position light, the turn signal light, the hazard light, the
stop light, the license plate light, the working light, the rotating beacon light (option) and the switches,
which is used to turn "ON" the lights.
1. When the headlight switch (3) is in the first step, through the fuse box 1 (1) to the "2," "6" terminal of
headlight switch (3), the following lights will be alight.
A. The front combination light (L) (12) and rear combination light (L) through the fuse box 2 (23).
B. The front combination light (R) (13) and rear combination light (R) through the fuse box 2 (23).
C. The illumination lights through the "9" terminal of all kind of rocker switches include the
headlight switch (3), the front working light switch (19), the rear working light (21) and the
hazard switch (6).
D. The license plate light (16).
2. When the headlight switch (3) is in the second step, the current flows through the fuse box 1 (1), to
the "2," "3" terminal of headlight switch (3) and to the "86," "85" terminal of headlight relay (8), and the
"30," "87" terminal of headlight relay (8) is connected. As a result, through the fuse box 1 (1) to the
"30," "87" terminal of headlight relay (8), the voltage is applied to the "56" terminal of combination
switch (R) (4).
A. At this time if the combination switch (4) is in the "0" position, the current flows to the "56b"
terminal and it allow the low light, which is in the headlight (L) (10) and the headlight (R) (11), to
be alight.
B. Also if the combination switch (4) is in the "▼ " position, the current flows to the "56a" terminal
and it allow the high light, which is in the headlight (L) (10) and the headlight (R) (11), to be
alight. At the same time the current flows to the "CN2-7" terminal of instrument panel (17) and
the headlight indicator L7 will be alight.
C. And if the combination switch (4) is in the "▲ " position, the current flows to the "56b" terminal
and it allows the low light, which is in the headlight (L) (10) and the headlight (R) (11), to be
alight.
3
5
6
1
8
4
AJS0460L
Figure 24 EMERGENCY STEERING SYSTEM BLOCK DIAGRAM
Reference Reference
Description Description
Number Number
1 Fuse Box 5 Emergency Steering Pump
2 Emergency Steering Switch 6 Emergency Steering Indicator
3 Emergency Steering Timer 7 Transmission Controller
4 Emergency Steering Pressure 8 Battery
Switch
When the speed of the vehicle exceeds 5 km/h and the secondary steering pressure is less than 10 kg/cm2
(140 psi), an electrically powered hydraulic pump will be operated for a time limited 60 seconds and thus
the emergency steering is possible. This system includes the electrically powered hydraulic pump, which is
controlled by the emergency steering timer (3). The emergency steering timer (3) obtains signals from the
emergency steering pressure switch (4) and the transmission controller (7). When the emergency steering
is activated, the emergency steering indicator (6) light turns "ON."
Reference
Description
Number 4
5
1 Emergency Steering Timer
2 Emergency Steering 1
Pressure Switch
3 Transmission Controller 2
4 Emergency Steering Pump
5 Starter Switch
3
AJS0470L
Figure 26 EMERGENCY STEERING TIMER
CIRCUIT
AJS0480L
AJO0011L
WARNING
Make sure that no persons are near the machine when testing the function of the emergency
steering system, there is a risk that someone may be crushed between the front and the rear
frame.
6 7
11
5
8
1 10
9 3
AJS0490L
Figure 29 EMERGENCY STEERING SYSTEM CIRCUIT
Reference Reference
Description Description
Number Number
1 Fuse Box 6 Emergency Steering Indicator
2 Emergency Steering Switch 7 Fusible Link
3 Emergency Steering Timer 8 Diode
4 Emergency Steering Pressure 9 Transmission Controller
Switch 10 Headlight Switch
5 Emergency Steering Pump 11 Battery
ELECTRIC CIRCUIT
7 4
8
1
10 11
AJS0500L
Reference Reference
Description Description
Number Number
1 Fuse Box 7 Return to Dig Magnetic
2 Float Kick-out Switch (Option) 8 Raise Proximity Switch
3 Raise / Float Relay 9 Float Proximity Switch (Option)
4 Return to Dig Relay 10 Return to Dig Proximity Switch
5 Raise Magnetic 11 Diode
6 Float Magnetic
Proximity Switch
• Operating Distance: 10±1 mm OPERATION INDICATOR
MAIN POWER
CIRCUIT
AJS0510L
Figure 32
1ELECTRICAL
SCHEMATIC
(MEGA 200-V)
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
General Description........................................................................................ 3
Mega 200-V (Tier I) ........................................................................................ 4
Mega 200-V (Tier II) ....................................................................................... 6
Figure 1
0.85WR
0 85RW
CN2-17
0.85WR
0.85WL
0.7bar (65.27441-7007)
CN2 AMP MIC 17P 0.85YB 0.85B WATER TEMP SWITCH
0.85B 0.5LB 3W
GAUGE PANEL ASS'Y 103˚C (66.27435-6008)
1.25RB 0.5LB
(539-00028) 0.85YL 0.85B
BRAKE OIL PRESS SW 0.85RW 0.85RW
BRAKE OIL FILTER SW 0.85B 0.85GR 65bar (2549-9093 )
(2471-9054) 2RL 2RL
0.85Lg 0.85B PARK BRAKE PRESS SW 0.85BR 0.85BR 0.85RY
45bar (549-00039)
0.85WL
FLOAT KICK-OUT ASS'Y (OPTION) STD 0.85RB
0.85RB 0.85RB
FLOAT KICK-OUT SW OPT (FLOAT KICK-OUT)
0.85WR
(FLOAT KICK-OUT) (2549-9098 )
(16) 1 0.85R
+ 0.85RB +(2190-2036D22) 0.85R 0.85RY
4 HORN RELAY
1 RAISE FRONT FRONT
O 0.85W (2544-9033 )
5 MAGNET RAISE RELAY COMBI LAMP(L) HEAD LAMP(L) HEAD LAMP(R) COMBI LAMP(R) 0.
0.85RY 87a
- 0.85B 7 (2544-9033 ) (2534-1138A) (2534-1141 ) (2534-1141 ) (2534-1151A)
FLOAT (14)
2 87a 30
MAGNET 21W 10W 75/70W 75/70W 10W 21W 87
PROXIMITY SW 0.5B 10 9 0.5WR 0.85B 5 30 0.85RB
(4549-1148) 87
85 86 0.
0.85LY
+ 0.85RB 0.85RB
0.5B
(turn sig)
(turn sig)
(position)
(position)
0
0.85RW
0.85RW
0.85WR
0.85WR
0.85WR
0.85WL
0.85RW
0.85WL
0.85GL
0.85GR
0.85BR
0.5BrW
O 0.85RY 0.85RY
(high)
(high)
(low)
(low)
0.85R
0.85R
0.5GR
0.85B
0.85B
0.85G
0.5GL
0.5GL
0.5R
2RL
HORN SWITCH 2
- 0.85B
RETURN TO DIG 0.5LB 0.5BrY
MAGNET RETURN TO DIG RELAY 0.85RB
1 3
(2544-9033) (5)
(RETURN TO DIG) 3 0.85G 87a (ON JOYSTICK)-L
6 DISPLAY ILL RELAY
+ 0.85RB 0.85B 30 0.85RB 0.5GR 0.85GR
(2544-9033 )
87
O 0.85WG 87a 0.85GL 0.85GL
- 0.85B 85 86 0.85RB 30 0.5BY
0.85RW
0.5B 87
0.85R 0.85R
(15)
PROXIMITY SW 85 86 0.5WR
0.85WG 0.85WR
(4549-1148)x2
0.85GW 0.85GY
0.5B 0.85RY 0.5LB
0.5WR 0.85BR
0.5BrW 0.5BrW 0.85WR
WIPER MOTOR
(position)
(position)
(back up)
(back up)
(turn sig)
0.85GW
(stop)
(stop)
(stop)
(stop)
0.85GR
0.85WR
0.85RY
0.85RY
0.85GL
SAFETY START
0.85WL
0.85GW
0.85GW
(4538-9017 )
RELAY BACK UP RELAY 0.85B 0.85B
(2544-9033) H 0.85RY
(2544-9033 )
0.5BrW 87a 87a L 0.85YB
30 0.5RL 0.85RL 30 C A B D F E E F D B A C
87 87 0.85RY S 0.85Y 87a
LO
0.5Gr 85 86 85 86 0.5RL HI 87
0.5RL 0.5P 21W 21W 10W 12W 12W 12W 12W 10W 21W 21W 0.85LB
M STOP
5W
REAR COMBI LAMP (LH) REAR COMBI LAMP (RH) 0.5L 86
LICENCE LAMP - RUN B 0.85L
(2534-1159B ) (2534-1139A ) (2534-1158B )
DISPLAY
0.5Gr 52 5 0.5P (4539-6036 ) 0.85GW 0.85GW E
0.85GY 0.85B
30 0.85RL 2-4 1-4 0.5BY 5bar
8 BACK BUZZER STOP LAMP SW PARKING BRAKE SW
0.5L 4
14 0.85WG 2-1 2-3 0.85B (2516-1124 ) (2549-9098)
53
0.85GR + +(2190-2036D16)
57 0.85B - 1
(ZF 0750 133 022) 5 5
11 0.85WL 0.5B
7 0.85Or
15 0.85GW 2 1 0.85RL DOWN SHIFT SW
0.85R 12 18 0.85BrL 4 3 0.85B 0.85V 0.85WL 0.85WL 0.5WR 9 10
+ VPS1 7 0.85R 13 23 0.85RW 4 2
0.85G
Figure 2
0.5LR 0.5LR
0.85WR
FUSIBLE LINK
1.25LR
0.85LB
0.85WL
1.25R 5W
0.85R
3W
2LR
2RL
(2527-1023A)
3W 3W 1.25WG
1.25WR
0.85BY
0.5LB 0.5LB 0.5RW
0.5LR
0.85RW 0.85RG 2LR CIRCUIT BREAKER 2R
(2527-9004) 60R
2RL 2RL 0.5RW C
EMG STEERING (OPT) ACC B A
0.85RY 0.85LB 1.25LR 8W 8W
0.5LB B
0.85WL 0.85WL 0.85RG
1.25RG 0.85RG R2 BR 1.25Br 1.25BrW 1.25BrW BR
0.85WR 0.85WR 0.85WR R1
(1) 1.25B E
0.85RY 0.85GY STARTER 1.25BrW
1.25WG
0.5RW
0.5BW
0.5BG
LAMP SWITCH
0.5LB
(2544-9033 ) (2544-9033 )
2LR
0.5WR 6 0.85B - + - +
0.5B 0.5B 10 9 (2523-9002)
0.85WR
0.85WR
0.85BR
0.5B 1.25RW
HORN SWITCH 2
BATTERY
0.5LB 0.5BrY HAZARD SWITCH 1 3 5
SW TURN SIGNAL HEAD LAMP 0.85Br (2506-1104)x2
1 3 (2549-9138 )
N PREHEAT RELAY
(5) (6) +(2190-2036D2) TML
0.85BR
0.85YB
0.85LR
MEGA 200-V
APS0420L
Figure 3
BHS0070L
MACHINE MODEL:
SERIAL NUMBER:
MANUAL NUMBER:
SHOP MANUAL SECTION NUMBER:
PROPOSED DESCRIPTION OF CORRECTION AND/OR SUGGESTION:
Use additional paper if needed. Please include copy of current manual pages for reference. Attach any photos or
illustrations. If digital photos are available, e-mail them to Bill.Bernhardt@dhiac.com (If possible, use 1024 x 768
resolution.).
HAS THIS BEEN DISCUSSED WITH A DAEWOO SERVICE REPRESENTATIVE: YES NO
IF YES - WHO:
(It is advised to discuss this with a Daewoo service representative to ensure that the above correction is appropriate
and valid.)
Mail to:
Daewoo Heavy Industries America Corporation
2905 Shawnee Industrial Way
Suwanee, GA 30024
Attention: Publications