Shop Manual M300V 100954

Mega 300-V
Shop Manual
023-00041AE
Serial Number 1001 thru 3000
(Tier I & II)
DOOSAN reserves the right to improve our products in a continuing process to provide the best possible
product to the market place. These improvements can be implemented at any time with no obligation to
change materials on previously sold products. It is recommended that consumers periodically contact their
distributors for recent documentation on purchased equipment.
This documentation may include attachments and optional equipment that is not available in your
machine’s package. Please call your distributor for additional items that you may require.
Illustrations used throughout this manual are used only as a representation of the actual piece of
equipment, and may vary from the actual item.
023-00041AE Shop Manual

Pub.No. 023-00041AE
(Tier I & II)(Tier I & II)
Mega 300-V
Product Label
Instructions
Trim Out The Label Along

The Lines And Insert Into
Pocket On The Binder Spine
Pub. No. 023-00041AE

1TABLE OF CONTENTS
Publication Request for Proposed Revision
Safety
Wheel Loader Safety .......................................................................... S0103010K
Specifications
Specifications for Mega 300-V............................................................ S0203080K
General Maintenance
General Maintenance Procedures .........................................................S0302000
Standard Torques ..................................................................................S0309000
Upper Structure
Counterweight..................................................................................... S0403030K
Fuel Transfer Pump ...............................................................................S0405500
Hydraulic Oil Tank .............................................................................. S0406050K
Lower Structure and Chassis

Center Joint (Articulation Joint)........................................................... S0502030K
Engine and Drive Train

Front Axle (Volvo SLA 15/W).............................................................. S0602180K
Rear Axle (Volvo SLA 12/W) .............................................................. S0602190K
Parking Brake Caliper (Volvo) ...............................................................S0603000
Air Conditioner .................................................................................... S0605050K
Transmission and Torque Converter (ZF 4WG-210) .......................... S0607090K
Transmission Error Codes (ZF) .......................................................... S0607900C
Hydraulics
Accumulator...........................................................................................S0703000
Table of Contents
Page 1
Cylinders............................................................................................. S0705005K
Cylinders................................................................................................S0705010
Fan Drive Hydraulic Motor (Haldex) ................................................... S0707100K
Main Pump (Denison) ......................................................................... S0708485K
Brake Pedal Valve .............................................................................. S0709250K
Main Control Valve (Toshiba) ............................................................. S0709456K
Pilot Control Valve .............................................................................. S0709477K
Priority Valve (Danfoss) ...................................................................... S0709651K
Power Steering Unit............................................................................ S0709730K
Restriction Valve................................................................................. S0709751K
Hydraulic Schematic (Mega 300-V) .................................................... S0793070K
Electrical System
Electrical System ................................................................................ S0802200K
Electrical Schematic (Mega 300-V) .................................................... S0893070K
Attachments
Table of Contents
Page 2
1PUBLICATION REQUEST FOR
PROPOSED REVISION
In DOOSAN's continuing effort to provide the best customer satisfaction, we invite you to help us improve
the manuals that you work with on a daily basis. This form is provided to give you a means of feedback to
the publication department.
COMPANY NAME: DATE:

STREET ADDRESS: TELEPHONE:
CITY: FAX:
STATE / PROVINCE:
COUNTRY:
NAME:
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 [email protected] (If possible, use 1024 x 768
resolution.).
HAS THIS BEEN DISCUSSED WITH A DOOSAN SERVICE REPRESENTATIVE: YES NO
IF YES - WHO:
(It is advised to discuss this with a DOOSAN service representative to ensure that the above correction is
appropriate and valid.)
Mail to:
DOOSAN Infracore America Corporation
2905 Shawnee Industrial Way
Suwanee, GA 30024
Attention: Publications
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 are in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
WHEEL LOADER SAFETYS0103010K

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 thru 3000
Mega 250-V (Tier II) 4001 and Up
Mega 300-V 3001 and Up
Copyright DOOSAN 2004

March 2004
Wheel Loader Safety S0103010K

Page 1
TABLE OF CONTENTS
To the Operator of a DOOSAN Daewoo Wheel Loader ................................. 3

General Safety Essentials .............................................................................. 6
Location of Safety Labels ............................................................................... 6
Unauthorized Modifications ............................................................................ 6
General Hazard Information ........................................................................... 7
Before Starting Engine ................................................................................. 15
Machine Operation ....................................................................................... 18
Maintenance................................................................................................. 25
Battery.......................................................................................................... 33
Towing .......................................................................................................... 35
Shipping and Transportation ........................................................................ 36
S0103010K Wheel Loader Safety

Page 2
TO THE OPERATOR OF A DOOSAN DAEWOO WHEEL
LOADER
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.

Page 3
WARNING!
Improper operation and maintenance of this machine can be hazardous and could result in
serious injury or death.
Operator and maintenance personnel should read this manual thoroughly before beginning
operation or maintenance.
Keep this manual in the storage compartment to the rear of the operator's seat, and have all
personnel involved in working on the machine periodically read the manual.
Some actions involved in operation and maintenance of the machine can cause a serious
accident, if they are not done in a manner described in this manual.
The procedures and precautions given in this manual apply only to intended uses of the
machine.
If you use your machine for any unintended uses that are not specifically prohibited, you must
be sure that it is safe for any others. In no event should you or others engage in prohibited uses
or actions as described in this manual.
DOOSAN delivers machines that comply with all applicable regulations and standards of the
country to which it has been shipped. If this machine has been purchased in another country or
purchased from someone in another country, it may lack certain safety devices and
specifications that are necessary for use in your country. If there is any question about whether
your product complies with the applicable standards and regulations of your country, consult
DOOSAN or your DOOSAN distributor before operating the machine.

Page 4
SAFETY ALERT SYMBOL
Be Prepared - Get to Know All Operating and Safety Instructions
This is the Safety Alert Symbol. Wherever it appears - in this manual or on safety signs on the
machine - you must be alert to potential for personal injury or accidents. Always observe safety
precautions and follow recommended procedures.
LEARN SIGNAL WORDS USED WITH SAFETY ALERT SYMBOL

The words "CAUTION," "WARNING," and "DANGER" used throughout this manual and on decals on the
machine indicate degree of risk of hazards or unsafe practices. All three degrees of risk indicate that safety
is involved. Observe precautions indicated whenever you see the Safety Alert "Triangle," no matter which
signal word appears next to the "Exclamation Point" symbol.
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 an 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.
Safety precautions are described in SAFETY from page 6 on.

DOOSAN cannot predict every circumstance that might involve a potential hazard in operation and
maintenance. Therefore the safety messages in this manual and on the machine may not include all
possible safety precautions. If any procedures or actions not specifically recommended or allowed in this
manual are used, you must be sure that you and others can do such procedures and actions safely and
without damaging the machine. If you are unsure about the safety of some procedures, contact a
DOOSAN distributor.

Page 5
GENERAL SAFETY ESSENTIALS
ACCESSORY APPLICATIONS
This wheel loader has been designed primarily for moving earth with a bucket. For use as a grapple or for
other object handling, contact DOOSAN. Lifting-work applications are permitted in approved lift
configuration, to rated capacity only, with no side-loading (unless prohibited by local regulation). Do not use
machine for activities for which it was not intended. Do not use bucket for lifting work, unless lift slings are
used in approved configuration.
LOCATION OF SAFETY LABELS

Location of safety labels (decals) can vary from unit to unit. Refer to appropriate Operation and
Maintenance Manual, and Parts Manual for your unit.
There are several specific warning signs on this machine. The exact location of hazards and the
description of the hazards are reviewed in the appropriate Operation and Maintenance Manual.
Please become familiarized with all warning signs.
Make sure that all of the warning signs are legible. Clean the warning signs or replace the warning signs if
you cannot read the words. Replace the illustrations if the illustrations are not visible. When you clean the
warning signs, use a cloth, water and soap. Do not use solvent, gasoline, or other harsh chemicals to clean
the safety signs. Solvents, gasoline, or other harsh chemicals could loosen the adhesive that secures the
warning sign. Loose adhesive will allow the warning sign to fall off.
Replace any safety sign that is damaged, or missing. If a safety sign is attached to a part that is replaced,
install a safety sign on the replacement part.
UNAUTHORIZED MODIFICATIONS
Any modification made without authorization or written approval from DOOSAN 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 DOOSAN 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.

Page 6
GENERAL HAZARD INFORMATION
SAFETY RULES
Only trained and authorized personnel can operate and maintain the machine.
Follow all safety rules, precautions and instructions when operating or performing maintenance on the
machine.
Do not operate the machine if you are not feeling well, if you are taking medication that makes you feel
sleepy, if you have been drinking, or if you are suffering from emotional problems. These problems will
interfere with your sense of judgement in emergencies and may cause accidents.
When working with another operator or with a person on work site traffic duty, be sure that all personnel
know the nature of the work and understand all hand signals that are to be used.
Always observe strictly any other rules related to safety.
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.

Page 7
INSIDE OPERATOR'S COMPARTMENT
When entering the operator's compartment, always remove all mud and oil from the soles of your shoes. If
you operate the accelerator and brake pedals with mud or oil stuck to your shoes, your foot may slip and
this may cause a serious accident.
Clean grease and dirt from pedals and controls. This contributes to safe operation. Cleaning also provides
an opportunity to inspect equipment. Minor damage can be repaired or corrected before major problems
result.
Keep cabin floor and consoles free of tools and personal items.
After using the ashtray, make sure that any matches or cigarettes are properly extinguished, and be sure to
close the ashtray. If the ashtray is left open, there is danger of fire.
Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire.
Do not leave lighters laying around the operator's compartment. If the temperature inside the operator's
compartment becomes high, there is danger that the lighter may explode.
Do not use cellular telephones inside the operator's compartment when driving or operating the machine.
There is danger that this may lead to an unexpected accident.
Never bring any dangerous objects such as flammable or explosive items into the operator's cabin.
To ensure safety, do not use the radio or music headphones when operating the machine. There is danger
that this may lead to a serious accident.
When operating the machine, do not put your hands or head out of the window.
When standing up from the operator's seat, always place transmission neutral lock lever in the "LOCK"
position and set pilot cutoff switch to "O" (OFF) position. If you accidentally touch the work equipment
levers when they are not locked, the machine may suddenly move and cause serous injury or damage.
When leaving the machine, lower the work equipment completely to the ground, set transmission neutral
lock lever in the "LOCK" position, set pilot cutoff switch to "O" (OFF) position, "APPLY" parking brake, and
shut down engine. Use the key to lock all the equipment. Always remove the key and take it with you.
CLOTHING AND PERSONAL PROTECTIVE

ITEMS
Contain long hair, and avoid loose clothing and
jewelry. They can catch on controls or in
protruding parts and cause serious injury or
death.
Do not wear oily clothes. They are highly
flammable.
Full eye protection, a hard hat, safety shoes and
gloves may be required at the work site.
HAOA020L
While working on the machine, never use
Figure 1
inadequate tools. They could break or slip,
causing injury, or they may not adequately
perform intended functions.

Page 8
BREATHING MASKS, EAR PROTECTION MAY BE REQUIRED
Do not forget that some risks to your health may not be immediately apparent. Exhaust gases and noise
pollution may not be visible, but these hazards can cause disabling or permanent injuries.
NOTE: The equivalent continuous A-weighted sound pressure level at the workstation for this
machine is given in the operation manual.
Measurement is obtained on a dynamic machine following the procedures and cabin
conditions as described in ISO 6396.
NOTE: The guaranteed sound power level emitted by the machinery for this machine is given in
the operation manual.
Measurement is obtained on a dynamic machine with the procedures as described in
2000/14/EC.
VIBRATION LEVEL INFORMATION

Hands/Arms: The weighted root mean square acceleration to which the hands/arms are subjected, is less
than 2.5 m/s2.
Whole body: The weighted root mean square acceleration to which the whole body is subjected, is less
than 0.5 m/s2.
Measurements are obtained on a representative machine, using measuring procedures as described in the
following standard: ISO 2631/1. ISO 5349, and SAE J1166.
ASBESTOS DUST HAZARD PREVENTION

Asbestos dust can be HAZARDOUS to your
health if it is inhaled. Materials containing
asbestos fiber can be present on work site.
Breathing air that contains asbestos fiber can
ultimately cause serious or fatal lung damage.
To prevent lung damage from asbestos fiber,
observe following precautions:
• Use a respirator that is approved for
use in an asbestos-laden
atmosphere. ARO1770L
• Never use compressed air for Figure 2
cleaning.
• Use water for cleaning to keep down
the dust.
• Work on the machine or component
with the wind at your back whenever
possible.
• Always observe any rules and
regulations related to the work site
and working environment.

Page 9
MOUNTING AND DISMOUNTING
Before getting on or off the machine, if there is
any oil, grease, or mud on the handrails, steps,
or track shoes, wipe it off immediately. Always
keep these parts clean. Repair any damage and
tighten any loose bolts.
Never get on or off a moving machine. In
particular, never get on or off a moving machine.
These actions may lead to serious injury.
When getting on or off the machine, always face
the machine, and maintain a three-point contact HA3O1003
(both feet and one hand or one foot and both Figure 3
hands) with the handholds and steps to ensure
that you support yourself securely.
Never hold any control levers when getting on or
off the machine.
Never get up from operator's seat or leave
operator's station and dismount machine if
engine is running.
FUEL, OIL AND HYDRAULIC FLUID FIRE

HAZARDS
Fuel, oil and antifreeze will catch fire if it is
brought close to a flame. Fuel is particularly
flammable and can be hazardous.
Always strictly observe the following.
Add fuel, oil, antifreeze and hydraulic fluid to the
machine only in a well ventilated area. The
machine must be parked with controls, lights
and switches turned "OFF." The engine must be
"OFF" and any flames, glowing embers,
auxiliary heating units or spark causing
equipment must be doused, turned "OFF" and/
or kept well clear of the machine.
Static electricity can produce dangerous sparks
at the fuel filling nozzle. In very cold, dry Figure 4
weather or other conditions that could produce a
static discharge, keep the tip of the fuel nozzle
in constant contact with the neck of the fuel
filling nozzle, to provide a ground.
Keep fuel and other fluid reservoir caps tight
and do not start the engine until caps have been
secured.

Page 10
PRECAUTIONS WHEN HANDLING FLUIDS
AT HIGH TEMPERATURE
Immediately after operations are stopped, the
coolant, engine oil, and hydraulic oil are at high
temperature and the radiator and hydraulic tank
are still under pressure. Attempting to remove
the cap, drain the oil or coolant, or replace the
filters may lead to serious burns. Always wait for
the temperature to go down, and follow the
specified procedures when carrying out these
operations.
HAOA050L
Figure 5
To prevent hot coolant from spurting out, shut
down engine, wait for the coolant to cool, then
loosen the cap slowly to relieve the pressure.
To prevent hot oil from spurting out, shut down
engine, wait for the oil to cool, then loosen the
cap slowly to relieve the pressure.
HAOA060L
Figure 6
INJURY FROM WORK EQUIPMENT
Do not enter or put your hand, arm or any other
part of your body between movable parts, such
as between the work equipment and cylinders,
or between the machine and work equipment.
If the control levers are operated, the clearance
between the machine and the work equipment
will change and this may lead to serious
damage or personal injury.
If going between movable parts is necessary,
always position and secure the work equipment HDO1010L
so that it cannot move. Figure 7

Page 11
FIRE EXTINGUISHER AND FIRST AID KIT
As a precaution if any injury or fire should occur,
always do the following.
• Be sure that fire extinguishers have
been provided and read the labels to
ensure that you know now to use
them. It is recommended that an
appropriately sized (2.27 kg [5 lb] or
larger) multipurpose "A/B/C" fire
extinguisher be mounted in the
cabin. Check and service the fire HDO1009L
extinguisher at regular intervals and
Figure 8
make sure that all work site crew
members are adequately trained in
its use.
• Provide a first aid kit in the storage compartment and keep another at the work site. Check the
kit periodically and make any additions if necessary.
• Know what to do in case of injury from fire.
• Keep emergency numbers for doctor, ambulance service, hospital and fire department near
your telephone.
If the machine catches fire, it may lead to serious personal injury or death. If a fire occurs during operation,
escape from the machine as follows:
• Turn the starter switch "OFF" and shut down engine.
• If there is time, use the fire extinguisher to extinguish as much of the fire as possible.
• Use the handrails and steps to escape from the machine.
The above is the basic method for escaping from the machine, but changing the method may be necessary
according to the conditions, so carry out practice drills at the work site.
PROTECTION FROM FALLING OR FLYING

OBJECTS
On work sites where there is danger that falling
objects or flying objects may hit the operator's
cabin select a guard to match the operating
conditions to protect the operator.
Work in mines, tunnels, deep pits or on loose or
wet surfaces could produce danger of falling
rock, roll over or hazardous flying objects.
Additional protection for operator's cabin could
be required in form of a FOPS/Falling Object
HAOA110L
Protective Structure and/or ROPS/Roll Over
Protective Structure reinforcement system. Figure 9

Page 12
Any reinforcement system that is installed on
machine must pass safety and certification
standards and carry appropriate labeling and
rating information. For example, most often
added type of reinforcement system, FOPS,
must meet or exceed Society of Automotive
Engineers standard SAE J1356, "Performance
Criteria for Falling Object Guards for Wheel
loaders."
Never attempt to alter or modify any type of
protective structure reinforcement system, by
drilling holes, welding or remounting or HAOA100L
relocating fasteners. Any serious impact or Figure 10
damage to system requires a complete integrity
reevaluation. Reinstallation, recertification and/
or replacement of system may be necessary.
INSTALL ADDITIONAL SAFETY EQUIPMENT IF CONDITIONS REQUIRE

Laminate glass protection for the front, side or rear windows may also be recommended depending upon
particular site conditions.
Contact your DOOSAN distributor for available safety guards and/or recommendations if there is any
danger of getting hit by objects that could strike the operator's cabin. Make sure that all other work site
crew members are kept well away from wheel loader and safe from potential hazards.
MAINTAIN STANDARD SAFETY EQUIPMENT IN GOOD CONDITION

Machinery guards and body panel covers must be in place at all times. Keep well clear of rotating parts.
Pinch point hazards such as cooling fan and alternator drive belts could catch hair, jewelry or oversize or
very loose clothing.
Safety labels must be replaced if they are damaged or become unreadable. Information on labels gives
work crew members an important safety reminder. Part numbers for each decal and required mounting
locations are shown on pages 1-2 through 1-4 of this section.

Page 13
ATTACHMENT PRECAUTIONS
Options kits are available through your dealer. Contact DOOSAN for information on available one-way
(single-acting) and two-way (double-acting) piping / valving / auxiliary control kits. Because DOOSAN
cannot anticipate, identify or test all attachments that owners may wish to install on their machines, please
contact DOOSAN for authorization and approval of attachments, and their compatibility with options kits.
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 DOOSAN 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

Page 14
BEFORE STARTING ENGINE
WORK SITE PRECAUTIONS
Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous.
Check the terrain and condition of the ground at the work site, and determine the best and safest method
of operation.
Make the ground surface as hard and horizontal as possible before carrying out operations. If there is a lot
of dust and sand on the work site, spray water before starting operations.
If you need to operate on a street, protect
pedestrians and cars by designating a person
for work site traffic duty or by erecting fences
and posting "No Entry" signs around the work
site.
Erect fences, post "No Entry" signs, and take
other steps to prevent people from coming close
to or entering the work site. If people come
close to a moving machine, they may be hit or
caught by the machine, and this may lead to
serious personal injury or death.
Water lines, gas lines, phone lines and high
Figure 12
voltage electrical lines may be buried under the
work site. Contact each utility and identify their
locations. Be careful not to damage or cut any of
these lines.
NEVER be in water that is in excess of the permissible water depth. Refer to "Operation Manual."
Any type of object in the vicinity of the boom could represent a potential hazard, or cause the operator to
react suddenly and cause an accident. Use a spotter or signal person working near bridges, phone lines,
work site scaffolds, or other obstructions.
Minimum levels of insurance coverage, work permits or certification, physical barriers around the work site
or restricted hours of operation may be mandated by governing authorities. There may also be regulations,
guidelines, standards or restrictions on equipment that may have to be followed for local requirements.
There may also be regulations related to performing certain kinds of work. If there is any question about
whether your machine and work site complies with the applicable standards and regulations contact your
local authorities and agencies.
Avoid entering soft ground. It will be difficult for the machine to escape.
Avoid operating your machine to close to the edge of cliffs, overhangs, and deep ditches. The ground may
be weak in such areas. If the ground should collapse, the machine could fall or tip over and this could result
in serious injury or death.
Remember that the soil after heavy rain, blasting or after earthquakes, is weakened in these areas.
Earth laid on the ground and the soil near ditches is loose. It can collapse under the weight of vibration of
your machine and cause your machine to tip over.
Install the head guard (FOPS) if working in areas where there is danger of falling rocks.

Page 15
CHECKS BEFORE STARTING ENGINE
Every day before starting the engine for the first time, carry out the following checks. If these checks are
not carried out properly, there is danger of serious injury.
• Completely remove all wood chips, leaves, grass, paper and other flammable materials
accumulated in the engine compartment and around the battery. They could cause a fire.
Remove any dirt from the window glass, mirrors, handrails, and steps.
• Do not leave tools or spare parts laying around in the operator's compartment. The vibration of
the machine when traveling or during operations may cause them to fall and damage or break
the control levers or switches. They may also get caught in the gap of the control levers and
cause the work equipment to malfunction or move dangerously. This may lead to unexpected
accidents.
• Check the coolant level, fuel level, and hydraulic tank oil level, and check for clogged air cleaner
and damage to the electrical wiring.
• Adjust the operator's seat to a position where it is easy to operate the machine, and check the
seat belt and mounts for damage and wear.
• Check the operation of the gauges and the angle of the mirrors, and check that the safety lever
is in "LOCKED" position.
• If any abnormalities are found in the above checks, carry out repairs immediately.
ENGINE STARTING
• Walk around your machine before getting in operator's cabin. 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 cabin.
• 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.

Page 16
BEFORE OPERATING MACHINE
If checks are not carried out properly after starting the engine, it may result in a delay in discovering
abnormalities in the machine, and this may lead to personal injury or damage to the machine.
Carry out the checks in an open area where there are no obstructions. Do not let anyone near the machine
when carrying out the checks.
• Check the operating condition of the equipment, and the actuation of the bucket, boom, and
travel systems.
• Check the machine for any abnormal noise, vibration, heat, smell, or abnormality with the
gauges. Check also for leakage of air, oil, and fuel.
• If any abnormality is found, repair the problem immediately. If the machine is used without
repairing the problems, it may lead to unexpected injury or failure.
• Clear all personnel from directly around machine and from the area.
• Clear all obstacles from the machine's path. Beware of hazards.
• Be sure that all windows are clean. Secure the doors and the windows in the open position or in
the shut position.
• Adjust the rear view mirrors for best visibility close to the machine. Make sure that the horn, the
travel alarm (if equipped), and all other warning devices are working properly.
• Fasten the seat belt securely.
• Warm up the engine and hydraulic oil before operating machine.
• Before moving the machine, check the position of undercarriage. The normal travel position is
with idler wheels to the front under the cabin and the drive sprockets to the rear. When the
undercarriage is in the reversed position, the travel controls must be operated in opposite
directions.

Page 17
MACHINE OPERATION
IMPORTANT
If you need more information or have any questions or concerns about safe operating
procedures or working the wheel loader correctly in a particular application or in the specific
conditions of your individual operating environment, please consult your local DOOSAN
representative.
OPERATE WHILE SEATED AT OPERATOR'S

STATION ONLY
Never reach in through a window to work a
control. Do not try to operate wheel loader
unless you're in command position - seated at
controls. You should stay alert and focused on
your work at all times. Do not twist out of seat if
job activity behind you (or to the side) requires
your attention.
Use a spotter or signal person if you cannot see
clearly and something is happening behind you.
HAOA151L
Replace damaged safety labels and lost or Figure 13
damaged operator's manuals.
Do not let anyone operate machine unless
they've been fully and completely trained, in
safety and in operation of the machine.
SEAT BELTS MUST BE USED AT ALL TIMES

Whenever engine is running, operator must be
seated at the control station with seat belt
properly engaged.
Figure 14
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.

Page 18
TRAVEL PRECAUTIONS
When traveling, wheel loader always keeps lights on; make sure that you are in compliance with all state
and local regulations concerning warning flags and signs.
Never turn the starter switch to the "O" (OFF) position when traveling. It is dangerous if the engine stops
when the machine is traveling. It will be impossible to operate the steering unless the unit is equipped with
an emergency steering system.
Pilot control valve lever (joystick) should not be operated while traveling.
Lower work equipment so that it is 400 mm (16 in) above ground.
Never travel over obstacles or slopes that will cause machine to tilt severely. Travel around any slope or
obstacle that causes 10° tilt, or more.
Do not operate the steering suddenly. The work equipment may hit the ground and cause the machine to
lose its balance, and this may damage the machine or structures in the area.
When traveling on rough ground, travel at low speed, and avoid sudden changes in direction.
Always keep to the permissible water depth.
When traveling over bridges or structures on private land, check first that the bridge or structure can
withstand the weight of the machine. When traveling on public roads, check with the local authorities and
follow their instructions.
SLOPING TERRAIN REQUIRES CAUTION

Dig evenly around work site whenever possible,
trying to gradually level any existing slope. If it's
TURBO-II
not possible to level area or avoid working on a

)
slope, reducing size and cycling rate workload is m(16''
recommended. 400 m
TURBO-II
On sloping surfaces, use caution when

positioning wheel loader before starting a work
cycle. Stay alert for unstable situations to avoid
getting into them. For example, you should 400 m
m(16
always avoid working bucket over downhill side '')
AHO0970L
of machine when parked perpendicular to slope.
Avoid full extensions of bucket in a downhill Figure 15
direction. Lifting bucket too high, too close to
machine, while wheel loader is turned uphill can
also be hazardous.

Page 19
AVOID HIGH VOLTAGE CABLES
Serious injury or death can result from contact
or proximity to high voltage electric lines. The
bucket does not have to make physical contact
with power lines for current to be transmitted.
Use a spotter and hand signals to stay away
from power lines not clearly visible to operator.
Voltage Minimum Safe Distance

6.6 kV 3 m (9' 10")
33.0 kV 4 m (13' 1")
66.0 kV 5 m (16' 5") Figure 16
154.0 kV 8 m (26' 3")
275.0 kV 10 m (32' 10")
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.
BEFORE STARTING TO DIG, CONTACT AUTHORITIES

Below ground hazards also include natural gas lines, water mains, tunnels and buried foundations. Know
what's underneath work site before starting to dig.
BE AWARE OF HEIGHT OBSTACLES

Any type of object in vicinity of boom could represent a potential hazard, or cause operator to react
suddenly and cause an accident. Use a spotter or signal person working near bridges, phone lines, work
site scaffolds, or other obstructions.
USE CARE ON LOOSE SUPPORT

Working heavy loads over loose, soft ground or uneven, broken terrain can cause dangerous side load
conditions and possible tipover and injury. Travel without a load or balanced load may also be hazardous.
If temperatures are changing, be cautious of dark and wet patches when working or traveling over frozen
ground. Stay away from ditches, overhangs and all other weak support surfaces. Halt work and install
support mats or blocking if work is required in an area of poor support.

Page 20
USE SOLID SUPPORT BLOCKING
Never rely on lift jacks or other inadequate
supports when work is being done. Block
wheels fore and aft to prevent any movement.
DIGGING BENEATH OVERHANGS

Digging beneath an overhang is dangerous.
Overhang could collapse on top of operator and
cause serious injury or death. Go on to another
digging area before steep overhangs are
formed. Know height and reach limits of wheel HDO1042L
loader and plan ahead while working. Park Figure 17
wheel loader away from overhangs before work
shut down.
DIGGING BENEATH WHEEL LOADER

Digging beneath wheel loader is dangerous. Earth beneath could collapse. This could cause wheel loader
to tip, which could cause serious injury or death to operator. Working around deep pits, trenching or along
high walls may require support blocks, especially after heavy rainfalls or during spring thaws.
STAY ALERT FOR PEOPLE MOVING

THROUGH WORK AREA
When loading a truck you should always know
where the driver is.
Avoid loading over the cabin of a truck even if
the driver is in a safe spot. Someone else could
have gone inside, for any number of reasons.
Avoid working where unseen passersby might
be.
Slow down work cycle and use slower travel
speeds in congested or populated areas. Use a HAOA171L
commonly understood signal so that other Figure 18
members of work crew can warn operator to
slow or halt work in an impending hazardous
situation.
BE AWARE OF AND CONFORM TO LOCAL REGULATIONS

Minimum levels of insurance coverage, work permits or certification, physical barriers around work site or
restricted hours of operation may be mandated by governing authorities. There may also be guidelines,
standards or restrictions on equipment that may be used to perform certain kinds of work. Check and
follow all local requirements, which may also be related to below ground hazards and power lines.

Page 21
NEVER USE ETHER STARTING AIDS
An electric grid type manifold heater is used for
cold starting. Glowing heater element can cause
ether or other starting fluid to detonate, causing
injury.
Figure 19
OBSERVE GENERAL SAFETY RULES

Only trained and authorized personnel, with a good knowledge and awareness of safe procedures, may be
allowed to operate or perform maintenance or service on wheel loader.
All personnel at work site must be aware of assigned individual responsibilities and tasks. Communication
and hand signals used must be understood by everyone.
Terrain and soil conditions at work site, approaching traffic, weather related hazards and any above or
below ground obstacles or hazards must be observed and monitored by all work crew members.
TAKE TIME TO PROVIDE GOOD VISIBILITY

Be careful not to go close to the edge of a cliff by mistake.
Use the machine only for its main purpose. Using it for other purposes will cause failures.
To ensure an ample view, do as follows:
• When working in dark areas, attach working lights and front lights to the machine. If necessary,
set up lighting at the work site.
• Stop operations when the visibility is poor, such as in fog, mist, snow, and rain. Wait for the
visibility to improve to a level which causes no problems for the operation.
• Keep dirt and dust off of windows and off lens surfaces of work lights. Stop working if lights,
windows or mirrors need cleaning or adjustment.
To avoid hitting the work equipment, always do the following:
• When working in tunnels, on bridges, under electric wires, or when parking the machine or
carrying out other operations in places with limited height, be extremely careful not to hit the
bucket or other parts.
• To prevent collisions, operate the machine at a safe speed when working in confined spaces,
indoors, or in crowded areas.
• Do not pass the bucket over the heads of workers or over the operator's compartment of dump
truck.

Page 22
KEEP "PINCH POINT" AREAS CLEAR - USE
CAUTION IN REVERSE
Use a signal person in high traffic areas and
whenever operator's view is not clear, such as
when traveling in reverse.
Anyone standing near wheels, or working
assemblies of the attachment, is at risk of being
caught between moving parts of machine.
Never allow anyone to ride on any part of
machine or attachment, including any part of
operator's cabin. HAOA191L
Figure 20
OPERATE CAREFULLY ON SNOW AND ICE AND IN VERY COLD TEMPERATURES

In icy cold weather avoid sudden travel movements and stay away from even very slight slopes. Machine
could skid off to one side very easily.
Snow accumulation could hide or obscure potential hazards. Use care while operating or while using
machine to clear snow.
Warming up engine for a short period may be necessary, to avoid operating with sluggish or reduced
working capacity. Jolting shocks and impact loads caused by bumping or bottoming boom or attachment
are more likely to cause severe stress in very cold temperatures. Reducing work cycle rate and work load
may be necessary.
When the temperature rises, frozen road surfaces become soft, so the machine travel becomes unstable.
In cold weather, do not touch metal surfaces with your bare hands. If you touch a metal surface in
extremely cold weather, your skin may freeze to the metal surface.
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 must 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.

Page 23
SHUTDOWN CONTROL FUNCTIONS
After bucket has been lowered to overnight storage position, move all switches and controls to "OFF"
position. Pull parking brake knob to "APPLIED" position. This will apply parking brake. Move pilot cutoff
switch to "LOCK" position. This will disable pilot control valve lever (joystick). Move key in starter switch to
"OFF" position, and remove key from switch.
Engage all lock-down security equipment that may have been installed on machine.
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.
NEVER LET ANYONE RIDE ON

ATTACHMENT
Never let anyone ride on any work attachment,
such as the bucket, crusher, grapple, or
clamshell (grab bucket). There is a danger of the
person falling and suffering serious injury.
HAAD4050
Figure 21

Page 24
MAINTENANCE
USE WARNING TAG DURING SERVICE
Alert others that service or maintenance is
being performed and tag operator's cabin
controls - and other machine areas if required -
with a warning notice.
Warning tags for controls are available from WARNING
DOOSAN distributors; see Figure 22.
CLEAN BEFORE INSPECTION OR

MAINTENANCE
HAOC920L
Clean the machine before carrying out
inspection and maintenance. This prevents dirt Figure 22
from getting into the machine and also ensures
safety during maintenance.
If inspection and maintenance are carried out when the machine is dirty, it will become more difficult to
locate the problems, and also there is danger that you may get dirt or mud in your eyes or that you may slip
and injure yourself.
When washing the machine, do the following:
• Wear shoes with nonslip soles to prevent yourself from slipping and falling on wet places.
• Wear safety glasses and protective clothing when washing the machine with high-pressure
steam.
• Take action to prevent touching high-pressure water and cutting your skin or having mud fly into
your eyes.
• Do not spray water directly on electrical components (sensors, connector) (1, Figure 23). If
water gets into the electrical system, there is danger that it will cause defective operation and
malfunction.
Figure 23
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.

Page 25
PROPER TOOLS
Use only tools suited to the task. Using
damaged, low qualify, faulty, or makeshift tools
could cause personal injury. There is danger
that pieces from, chisels with crushed heads, or
hammers, may get into your eyes and cause
blindness.
HDO1037L
Figure 24
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 an
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 25
catch fire and cause and explosion.
FIRE PREVENTION AND EXPLOSION PREVENTION

All fuels, most lubricants and some coolant mixtures are flammable. Leaking fuel or fuel that is spilled onto
hot surfaces or onto electrical components can cause a fire.
Store all fuels and all lubricants in properly marked containers and away from all unauthorized persons.
Store oily rags and other flammable material in a protective container.
Do not smoke while you refuel the machine or while you are in a refueling area.
Do not smoke in battery charging areas or in areas the contain flammable material.
Clean all electrical connections and tighten all electrical connections. Check the electrical wires daily for
wires that are loose of frayed. Tighten all lose electrical wires before you operate the machine. Repair all
frayed electrical wires before you operate the machine.
Remove all flammable materials before they accumulate on the machine.
Do not weld on pipes or on tubes that contain flammable fluids. Do not flame cut on pipes or on tubes that
contain flammable fluids. Before you weld on pipes or on tubes or before you flame cut on pipes or on
tubes, clean the pipes or tubes thoroughly with a nonflammable solvent.

Page 26
BURN PREVENTION
When checking the radiator coolant level, shut down engine, let the engine and radiator cool down, then
check the coolant recovery tank. If the coolant level in the coolant recovery tank is near the upper limit,
there is enough coolant in the radiator.
Loosen the radiator cap gradually to release the internal pressure before removing the radiator cap.
ARO1360L
Figure 26
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.

Page 27
WELDING REPAIRS
When carrying out welding repairs, carry out the welding in a properly equipped place. The welding must
be performed by a qualified worker. During welding operations, there is the danger of, generation of gas,
fire, or electric shock, so never let an unqualified worker do welding.
The qualified welder must do the following:
• To prevent explosion of the battery, disconnect the battery terminals and remove batteries.
• To prevent generation of gas, remove the paint from the location of the weld.
• If hydraulic equipment, piping or places close to them are heated, a flammable gas or mist will
be generated and there is danger of it catching fire. To avoid this, never subject these places to
heat.
• Do not weld on pipes or on tubes that contain flammable fluids. Do not flame cut on pipes or on
tubes that contain flammable fluids. Before you weld on pipes or on tubes or before you flame
cut on pipes or on tubes, clean the pipes or tubes thoroughly with a nonflammable solvent.
• If heat is applied directly to rubber hoses or piping under pressure, they may suddenly break so
cover them with a fireproof covering.
• Wear protective clothing.
• Make sure there is good ventilation.
• Remove all flammable objects and provide a fire extinguisher.
PRECAUTIONS FOR REMOVAL,

INSTALLATION, AND STORAGE OF
ATTACHMENTS
Before starting removal and installation of
attachments, decide the team leader.
Do not allow anyone except the authorized
workers close to the machine or attachment.
Place attachments that have been removed
from the machine in a safe place so that they do
not fall. Put up a fence around the attachments
and take other measures to prevent HDO1041L
unauthorized persons from entering. Figure 27

Page 28
PRECAUTIONS WHEN WORKING ON
MACHINE
When carrying out maintenance operations on
the machine, keep the area around your feet
clean and tidy to prevent you from falling.
Always do the following:
• Do not spill oil or grease.
• Do not leave tools laying about.
• Watch your step when walking.
Never jump down from the machine. When ARO1380L
getting on or off the machine, use the steps and Figure 28
handrails, and maintain a three-point contact
(both feet and one hand or both hands and one
foot) to support yourself securely.
If the job requires it, wear protective clothing.
To prevent injury from slipping or falling, when
working on the hood or covers, never use any
part except the inspection passage fitted with
nonslip pads.
LOCK INSPECTION COVERS

When carrying out maintenance with the inspection cover open, lock the cover securely in position with the
lock bar.
If maintenance work is carried out with the inspection cover open but not locked, there is danger that it may
suddenly close and cause injury if there is a gust of wind.
CRUSHING PREVENTION AND CUTTING PREVENTION

You should always have at least two people working together if the engine must be run during service. One
person needs to remain in the operator's seat, ready to work the controls or stop the machine and shut off
the engine.
Unless you are instructed otherwise, never attempt adjustments while the machine is moving or while the
engine is running.
Stay clear of all rotating parts and moving parts.
Keep objects away from moving fan blades. The fan blades will throw objects and the fan blades can cut
objects.
Do not use a wire rope cable that is kinked or flayed. Wear gloves when you handle a wire rope cable.
When you strike a retainer pin, the retainer pin might fly out. The loose retainer pin can injure personnel.
Make sure that the area is clear of people when you strike a retainer pin. To avoid injury to your eyes, wear
protective glasses when you strike a retainer pin.
DO NOT RUN ENGINE IF REPAIRS OR WORK ARE BEING PERFORMED ALONE

You should always have at least two people working together if engine must be run during service. One
person needs to remain in operator's seat, ready to work controls or stop machine and shut "OFF" engine.

Page 29
ALWAYS USE ADEQUATE EQUIPMENT SUPPORTS AND BLOCKING
Do not allow weight or equipment loads to remain suspended. Lower everything to ground before leaving
operator's seat. Do not use hollow, cracked or unsteady, wobbling weight supports. Do not work under any
equipment supported solely by a lift jack.
DO NOT WORK ON HOT ENGINES OR HOT COOLING OR HYDRAULIC SYSTEMS

Wait for engine to cool off after normal operation. Park wheel loader on firm, level ground and lower all
equipment before shutting down and switching "OFF" controls. When engine lube oil, gearbox lubricant or
other fluids require change, wait for fluid temperatures to decrease to a moderate level before removing
drain plugs.
NOTE: Oil will drain more quickly and completely if it is warm. Do not drain fluids at temperatures
exceeding 95°C (203°F), however do not allow full cool down.
HYDRAULIC CYLINDER SEALS REQUIRE PERIODIC REPLACEMENT

Check cylinder drift rate at regular intervals. Overhaul seal kits are available through DOOSAN.
HIGH-PRESSURE HYDRAULIC LINES CAN STORE A GREAT DEAL OF ENERGY

Exposed hydraulic hoses on arm or boom could react with explosive force if struck by a falling rock,
overhead obstacle or other work site hazard. Extra safety guards may be required. NEVER allow hoses to
be hit, bent or interfered with during operation.

Page 30
PRECAUTIONS WITH HIGH-PRESSURE LINE, TUBES AND HOSES
When inspecting or replacing high-pressure piping or hoses, check that the pressure has been released
from the circuit. Failure to release the pressure may lead to serious injury. Always do the following:
• Wear protective glasses and leather gloves.
• Fluid leaks from hydraulic hoses or pressurized components can be difficult to see but
pressurized oil has enough force to pierce the skin and cause serious injury. Always use a piece
of wood or cardboard to check for suspected hydraulic leaks. Never use your hands or expose
your fingers.
• Do not bend high-pressure lines. Do not strike high-pressure lines. Do not install lines, tubes or
hoses that are bent or damaged.
• Make sure that all clamps, guards and heat shields are installed correctly to prevent vibration,
rubbing against other parts, and excessive heat during operation.
– If any of the following conditions are found, replace the part.
– Damage or leakage from hose end.
– Wear, damage, cutting of covering, or exposure of strengthening wire layer.
– Cover portion is swollen in places.
– There is twisting or crushing at movable parts of hose.
– Foreign material is embedded in the covering.
– Hose end is deformed.
NOTE: Refer to "Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 CEN)"
in Operation and Maintenance Manual, for additional European regulations.
X X O
HAOA420L
Figure 29
OBTAIN IMMEDIATE MEDICAL ATTENTION IF PRESSURIZED OIL PIERCES SKIN.
WARNING!
Failure to obtain prompt medical assistance could result in gangrene or other serious damage to
tissue.

Page 31
USE CORRECT REPLACEMENT FASTENERS TIGHTENED TO PROPER TORQUE
Refer to "General Maintenance" section of Shop Manual for information on tightening torques and
recommended assembly compounds and always use correct part.
Poor or incorrect fastener connections can dangerously weaken assemblies.
SAFETY CRITICAL PARTS MUST BE REPLACED PERIODICALLY

Replace following fire related components as soon as they begin to show any sign of wear, or at regular
periodic intervals, whether or not deterioration is visible:
• Fuel system flexible hoses, the tank overflow drain hose and the fuel fill cap.
• Hydraulic system hoses, especially the pump outlet lines and front and rear pump branch
hoses.
• Keep mounting brackets and hose and cable routing straps tight. Hose routing should have
gradual bends.
DISPOSE OF ALL PETROLEUM BASED OILS

AND FLUIDS PROPERLY
Physical contact with used motor oil may pose a
X
health risk. Wipe oil from your hands promptly
and wash off any remaining residue.
Used motor oil is an environmental contaminant
and may only be disposed of at approved
collection facilities. To prevent pollution of the
environment, always do the following:
• Never dump waste oil in a sewer
system, rivers, etc. HAOA470L
• Always put oil drained from your Figure 30

machine in containers. Never drain
oil directly onto the ground.
• Obey appropriate laws and
regulations when disposing of
harmful materials such as oil, fuel,
solvent, filters, and batteries.
CHECK TIRE PRESSURE AND CONDITION

Maintain tire pressure but do not overinflate. Inspect tires and wheels daily. When inflating tires, follow
procedures in Maintenance Section, which include using an extension to allow you to avoid standing in
front of or over a tire. Do not change a tire unless you have both experience and proper equipment.

Page 32
BATTERY
BATTERY HAZARD PREVENTION
Battery electrolyte contains diluted sulfuric acid and batteries generate hydrogen gas. Hydrogen gas is
highly explosive, and mistakes in handling them can cause serious injury or fire. To prevent problems,
always do the following:
• Do not smoke or bring any flame near the battery.
• When working with batteries, ALWAYS wear safety glasses and rubber gloves.
• If you spill battery electrolyte on yourself or your clothes, immediately flush the area with water.
• If battery electrolyte gets into your eyes, flush them immediately with large quantities of water
and see a doctor at once.
• If you accidentally drink battery electrolyte, drink a large quantity of water or milk, raw egg or
vegetable oil. Call a doctor or poison prevention center immediately.
• When cleaning the top surface of the battery, wipe it with a clean, damp cloth. Never use
gasoline, thinner, or any other organic solvent or detergent.
• Tighten the battery caps securely.
• Explosive battery gas can be set off by sparks from incidental contact or static discharge. Turn
"OFF" all switches and engine when working on batteries. Keep battery terminals tight. Contact
between a loose terminal and post can create an explosive spark.
• If the battery electrolyte is frozen, do not charge the battery or start the engine with power from
another source. There is danger that the battery may catch fire.
• When charging the battery or starting with power from another source, let the battery electrolyte
melt and check that there is no leakage of battery electrolyte before starting the operation.
• Always remove the battery from the machine before charging.
Figure 31
DISCONNECT BATTERIES BEFORE ELECTRICAL SERVICE OR ELECTRICAL WELDING

Remove cable to negative terminal first when disconnecting cable. Connect positive terminal cables first
when installing a battery.

Page 33
USE LOW HEAT PORTABLE LIGHTING
Hot surfaces on trouble lights or portable work lights can set off fuel or battery explosive gases.
BOOST STARTING OR CHARGING ENGINE

BATTERIES
If any mistake is made in the method of
connecting the booster cables, it may cause an
explosion or fire. Always do the following:
• Turn off all electrical equipment
before connecting leads to the
battery. This includes electrical
switches on the battery charger or
boost starting equipment.
• When boost starting from another HAOA310L
machine or vehicle do not allow the Figure 32
two machines to touch. Wear safety
glasses or goggles while required
battery connections are made.
• 24 volt battery units consisting of two series connected twelve volt batteries have a cable
connecting one positive terminal on one of the 12 volt batteries to a negative terminal on the
other battery. Booster or charger cable connections must be made between the nonseries
connected positive terminals and between the negative terminal of the booster battery and the
metal frame of the machine being boosted or charged. Refer to the procedure and illustration in
Operation and Maintenance Manual.
• Connect positive cable first when installing cables and disconnect the negative cable first when
removing them. The final cable connection, at the metal frame of the machine being charged or
boost started, must be as far away from the batteries as possible.

Page 34
TOWING
PRECAUTIONS WHEN TOWING
If any mistake is made in the method of selecting or inspecting the towing wire or in the method of towing,
it may lead to serious personal injury. Always do the following:
• Always use the method of towing given in this Operation and Maintenance Manual. Do not use
any other method.
• Use leather gloves when handling the wire rope.
• When carrying out the preparation work for towing with two or more workers, determine the
signals to use and follow these signals correctly.
• If the engine on the problem machine will not start or there is a failure in the brake system.
always contact your DOOSAN distributor.
• Never go between the towing machine and the towed machine during the towing operation.
• It is dangerous to carry out towing on slopes, so select a place where the slope is gradual. If
there is no place where the slope is gradual, carry out operations to reduce the angle of the
slope before starting the towing operation.
• When towing a problem machine, always use a wire rope with a sufficient towing capacity.
• Do not use a frayed, kinked rope or a rope with any loss of diameter.

Page 35
SHIPPING AND TRANSPORTATION
OBEY STATE AND LOCAL OVER-THE-ROAD REGULATIONS
Check state and local restrictions regarding weight, width and length of a load before making any other
preparation for transport.
Hauling vehicle, trailer and load must all be in compliance with local regulations governing intended
shipping route.
Partial disassembly or tear-down of wheel loader may be necessary to meet travel restrictions or particular
conditions at work site.
Refer to the section "Transportation" section of operation manual.
SUMMARY OF SAFETY PRECAUTIONS FOR

LIFTING
WARNING!
Improper lifting can allow load to shift and
cause personal injury or damage to the
machine
To make safe lifts, the following items must be

evaluated by operator and work site crew.
Figure 33
• Condition of ground support.
• Wheel loader configuration and
attachments.
• Weight, lifting height and lifting
radius.
• Safe rigging of load.
• Proper handling of suspended load.
Tag lines on opposite sides of load can be very
helpful in keeping a suspended load secure, if
they are anchored safely to control points on
ground.

Page 36
1SPECIFICATIONS
S0203080K
1SPECIFICATIONS FOR
MEGA 300-V
CAUTION!
SPECIFICATIONS FOR MEGA 300-VS0203080K


November 2002
Specifications for Mega 300-V S0203080K

Page 1
S0203080K Specifications for Mega 300-V
Page 2
TABLE OF CONTENTS
Component Locations .................................................................................... 4

General Specifications ................................................................................... 7
Engine Performance Curves .......................................................................... 8
Working Range and Dimensions.................................................................. 12
Working Capacities ...................................................................................... 15
Bucket Capacity .................................................................................... 15
Tipping Load ......................................................................................... 15
Material Weight ............................................................................................ 15
Approximate Weight of Workload Materials .......................................... 15

Page 3
COMPONENT LOCATIONS
Figure 1 identifies the location of major machine components.
1 2 3 4 5 6
7
8
9
11 10
20
18
17 22
19
21
15 16 24
14 23
13
12 25
26
44
27
28
35 29
38 34 30
43 42 41 39 40 37 36 33 32 31
AMS0200L
Figure 1

Page 4
Reference Reference
Description Description
Number Number
1 Bucket Tooth 23 Cac Cooler
2 Bucket 24 Radiator
3 Air Conditioner Condenser 25 Grille
4 Rear Wheel Cover 26 Fan
5 Battery Box 27 Fuel Tank
6 Rear Light 28 Engine Oil Fill Cap
7 Counterweight 29 Engine Oil Filter
8 Fan Motor 30 Engine Oil Level Dipstick
9 Towing Pin 31 Rear Axle Pivot
10 Tool Box / Fuel Pump 32 Rear Axle
11 Oil Tank 33 Drive Shaft (Rear)
12 Tilt Lever 34 Transmission
13 Front Wheel Cover 35 Transmission Oil Filter
14 Bucket Cylinder 36 Drive Shaft (Center)
15 Headlight Support 37 Center Pin
16 Ladder 38 Steering Wheel Cylinder
17 Work Light 39 Boom Cylinder
18 Operator's Cabin 40 Drive Shaft (Front)
19 Air Cleaner 41 Parking Brake
20 Precleaner 42 Front Axle
21 Engine 43 Loader Arm
22 Muffler 44 Link

Page 5
Page 6
GENERAL SPECIFICATIONS
MEGA 300-V
Item Specification
Serial Number 1001 thru 2000 2001 and Up
Standard Bucket Capacity 2.90 m3 3
(3.80 yd )
Vehicle Weight 17,300 kg (38,150 lb)
Engine
Type DOOSAN DE12TIS DOOSAN DE08TIS
Rated power (SAE J 1995 gross) 235 ps @ 2,100 rpm 212 ps @ 2,100 rpm
(232 hp @ 2,100 rpm) (209 hp @ 2,100 rpm)
Max. Torque (SAE J 1995 gross) 110 kg•m / 1,200 rpm 92 kg•m / 1,300 rpm
(796 ft lb @ 1,200 rpm) (666 ft lb @ 1,300 rpm)
Transmission
Full Automatic Power -Shift Full Automatic Power Shift
Speeds 4 Forward, 3 Reverse
Brake Systems
Service Brakes 4 Wheel, Wet Multi Disks, Dual Pedal
Parking Brake Dry Disk on Front Axle
Performance
Travel Speed (1 / 2 / 3 / 4) 7.6 (4.7) / 13.5 (8.4) / 24.0 (14.9) / 36.5 (22.7) km/h
(MPH)
Steering Angle + 40°
Min. Tire Turning Radius (Out- 5,470 mm (17' 11")
Tire Center)
Max Tractive Effort 16,400 kg (36,156 lb)
Max. Breakout Force 18,500 kg (40,790 lb)
Bucket Rise Time 5.4 Seconds
Bucket Dump Time 1.5 Seconds
Bucket Descent Time 4.0 Seconds
Maximum Gradeability 58% (30°)
Working Range
Dump Height at 45° (w/o teeth) 2,962 mm (9' 8")
Dump Reach at 45° (w/o teeth) 1,152 mm (3' 9")
Max Dump Angle at Fully Raised 47°
Max Tilt Angle at Carry 47°
Travel Dimension
Overall Length 8,085 mm (26' 6")
Overall Width 2,920 mm (9' 7")
Overall Height 3,470 mm (11' 5")
Wheel Base 3,200 mm (10' 6")
Tread 2,150 mm (7' 0")
Ground Clearance 470 mm (1' 6")

Page 7
ENGINE PERFORMANCE CURVES
AMS0210L
Figure 2 (S/N 1001 thru 2000)

Page 8
Engine Type DE12TIS
Rated Power 235 ps @ 2,100 rpm
(232 hp @ 2,100 rpm)
Maximum Torque 110 kg•m @ 1,200 rpm
(795 ft lb @ 1,200 rpm)
Fuel Consumption 160 g / ps.h
Performance Standard SAE J 1995 gross
NOTE: Barometric Pressure: 760 mm (30") Mercury

Temperature: 20°C (68°F)
W/O Cooling Fan: Driven by hydraulic fan motor
Alternator: 24 V, 50 amp
Exhaust System: Complete, attached
Air Cleaner; Installed

Page 9
BIS0240L
Figure 3 (S/N 2001 and Up)

Page 10
Serial Number 2001 and Up
Engine Type DE08TIS
Rated Power 212 ps @ 2,200 rpm
(209 hp @ 2,200 rpm)
Maximum Torque 92 kg•m @ 1,300 rpm
(666 ft lb @ 1,300 rpm)
Fuel Consumption 160 g / ps.h
Performance Standard SAE J 1995 gross
NOTE: Barometric Pressure: 760 mm (30") Mercury

Temperature: 20°C (68°F)
W/O Cooling Fan: Driven by hydraulic fan motor
Alternator: 24 V, 50 amp
Exhaust System: Complete, attached
Air Cleaner; Installed

Page 11
WORKING RANGE AND DIMENSIONS
Figure 4, illustrates exterior machine dimensions and working range of machine when it is equipped with a
standard bucket.
C
H
B (D) E
A F
I
K
H
AMO0370L
Figure 4

Page 12
Category Dimension
Overall Length (A) 8,085 mm (26' 6")
Overall Width (B) 2,920 mm (9' 7")
Overall Height (C) 3,470 mm (11' 5")
Bucket Width (D) 2,920 mm (9' 7")
Wheel Base (E) 3,200 mm (10' 6")

Tread (F) 2,150 mm (7' 0")
Ground Clearance (G) 470 mm (1' 6")
Dump Height, to tooth (H) 2,780 mm (9' 1")

Dump Distance, to Bucket Edge (I) 1,152 mm (3' 9")
Dump Height to Bucket Pivot (K) 4,000 mm (13' 1")
Max. Dump Angle at Fully Raised (a) 47°
Max. Tilt Angle at Carry (b) 47°
Tire Size 23.5-25-16 PR(L3)

Page 13
Figure 5, illustrate working range when machine is equipped with optional Pallet.
F E
A
a
B
b
D
AMS0220L
Figure 5
Reference Reference
Dimension Dimension
Number Number
A 1519.5 mm (4' 11") E 1,800 mm (5' 11")
B 1873.5 mm (6' 2") F 798 mm (2' 7")
C 3749.5 mm (12' 3") a 36.4°
D 8834.5 mm (28' 12") b 34.7°

Page 14
WORKING CAPACITIES
BUCKET CAPACITY
Standard toothed bucket has a capacity of 2.9 m3 (3.8 yd3). An optional bucket equipped with a cutting
edge and no teeth has a capacity of 2.9 m3 (3.8 yd3).
TIPPING LOAD
Static Tipping Load with bucket in Over Front position is 13,500 kg (28,890 lb). With bucket in Fully Turned
position, Static Tipping Load is 11,100 kg (24,480 lb).
MATERIAL WEIGHT
The data below describes weight of a cubic meter (cubic yard) of many types of workload materials.
APPROXIMATE WEIGHT OF WORKLOAD MATERIALS
LOW WEIGHT OR MEDIUM WEIGHT OR HIGH WEIGHT OR

DENSITY DENSITY DENSITY
MATERIAL 1,100 KG/M3 1,600 KG/M3 2,000 KG/M3
(1,850 LB/YD3), OR (2,700 LB/YD3), OR (3,370 LB/YD3), OR
LESS LESS LESS
401 kg/m3
Charcoal --------------------- ---------------------
(695 lb/yd3)
Coke, blast furnace 433 kg/m3

--------------------- ---------------------
size (729 lb/yd3)
449 kg/m3
Coke, foundry size --------------------- ---------------------
(756 lb/yd3)
Coal, bituminous slack, 801 kg/m3

--------------------- ---------------------
piled (1,350 lb/yd3)
Coal, bituminous r. of 881 kg/m3

--------------------- ---------------------
m., piled (1,485 lb/yd3)
897 kg/m3
Coal, anthracite --------------------- ---------------------
(1,512 lb/yd3)
Clay, DRY, in broken 1,009 kg/m3

--------------------- ---------------------
lumps (1,701 lb/yd3)
Clay, DAMP, natural 1,746 kg/m3

--------------------- ---------------------
bed (2,943 lb/yd3)

Page 15
LESS LESS LESS
Cement, Portland, DRY 1,506 kg/m3

--------------------- ---------------------
granular (2,583 lb/yd3)
Cement, Portland, DRY 1,362 kg/m3

--------------------- ---------------------
clinkers (2,295 lb/yd3)
1,522 kg/m3
Dolomite, crushed --------------------- ---------------------
(2,565 lb/yd3)
Earth, loamy, DRY, 1,202 kg/m3

--------------------- ---------------------
loose (2,025 lb/yd3)
1,522 kg/m3
Earth, DRY, packed --------------------- ---------------------
(2,565 lb/yd3)
1,762 kg/m3
Earth, WET, muddy --------------------- ---------------------
(2,970 lb/yd3)
Gypsum, calcined, 961 kg/m3

--------------------- ---------------------
(heated, powder) (1,620 lb/yd3)
Gypsum, crushed to 3 1,522 kg/m3

--------------------- ---------------------
inch size (2,565 lb/yd3)
Gravel, DRY, packed 1,810 kg/m3

--------------------- ---------------------
fragments (3,051 lb/yd3)
Gravel, WET, packed 1,922 kg/m3

--------------------- ---------------------
fragments (3,240 lb/yd3)
Limestone, graded 1,282 kg/m3

--------------------- ---------------------
above 2 (2,160 lb/yd3)
Limestone, graded 1,362 kg/m3

--------------------- ---------------------
1-1/2 or 2 (2,295 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)

Page 16
LESS LESS LESS
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.

Page 17
Page 18
1GENERAL MAINTENANCE
S0302000
R1
1GENERAL
MAINTENANCE
PROCEDURES
CAUTION!
GENERAL MAINTENANCE PROCEDURESS0302000

ALL MODELS ALL RANGES

May 2002
General Maintenance Procedures S0302000

Page 1
TABLE OF CONTENTS
Welding Precautions and Guidelines ............................................................. 3

Hydraulic System - General Precautions ....................................................... 4
Maintenance Service and Repair Procedure ................................................. 5
General Precautions ............................................................................... 5
Hydraulic System Cleanliness and Oil Leaks................................................. 6
Maintenance Precautions for Hydraulic System Service ........................ 6
Oil Leakage Precautions ......................................................................... 6
Cleaning and Inspection................................................................................. 7
General Guidelines ................................................................................. 7
Bearing inspection .................................................................................. 8
S0302000 General Maintenance Procedures

Page 2
WELDING PRECAUTIONS AND GUIDELINES
IMPORTANT
To avoid accidents, personal injury and the possibility of causing damage to the machine or to
components, welding must only be performed by properly trained and qualified personnel, who
possess the correct certification (when required) for the specific welding fabrication or
specialized repair being performed.
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
DOOSAN 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.

Page 3
CAUTION!
Observe the following safety precautions:
1. Use extra caution and adequate safety shielding when welding near fuel and oil tanks,
batteries, hydraulic piping lines or other fire hazards.
2. Never weld when the engine is running. Battery cables must be disconnected before the
welding procedure is started.
3. Never weld on a wet or damp surface. The presence of moisture causes hydrogen
embrittlement and structural weakening of the weld.
4. If welding procedures are being performed near cylinder rods, operator's cabin window
areas or any other assemblies that could be damaged by weld spatters, use adequate
shielding protection in front of the assembly.
5. During equipment setup, always attach ground cables directly to the area or component
being welded to prevent arcing through bearings, bushings, or spacers.
6. Always use correct welding rods for the type of weld being performed and observe
recommended precautions and time constraints. AWS Class E7018 welding rods for low
alloy to medium carbon steel must be used within two hours after removal from a freshly
opened container. Class E11018G welding rods for T-1 and other higher strength steel must
be used within 1/2 hour.
HYDRAULIC SYSTEM - GENERAL PRECAUTIONS

Always maintain oil level in the system at recommended levels. Assemblies that operate under heavy
loads, at high speed, with extremely precise dimensional tolerances between moving parts - pistons and
cylinders, or shoes and swash plates, for example - can be severely damaged if oil supply runs dry.
Assemblies can be run dry and damaged severely in a very short time when piping or hoses are
disconnected to repair leaks and/or replace damaged components. Hoses that are inadvertently switched
during disassembly (inlet for outlet and vice versa), air introduced into the system or assemblies that are
low on oil due to neglect or careless maintenance, could all produce sufficient fluid loss to cause damage.
When starting the engine (particularly after long layoff or storage intervals), make sure that all hydraulic
controls and operating circuits are in neutral, or "OFF." That will prevent pumps or other components that
may be temporarily oil starved from being run under a load.
Replacement of any hydraulic system component could require thorough cleaning, flushing, and some
amount of prefilling with fresh, clean oil if the protective seal on replacement parts has obviously been
broken or if seal integrity may have been compromised. When protective seals are removed before
installation and reassembly, inspect all replacement parts carefully, before they are installed. If the
replacement part is bone dry (with no trace of factory prelube) or has been contaminated by dirt or by
questionable oils, flushing and prefilling with clean hydraulic fluid is recommended.
Vibration, irregular or difficult movement or unusual noise from any part of the hydraulic system could be
an indication of air in the system (and many other types of problems). As a general precaution (and to help
minimize the risk of potential long-term damage), allow the engine to run at no-load idle speed immediately
after initial start-up. Hydraulic fluid will circulate, releasing any air that may have been trapped in the
system before load demands are imposed.
A daily walk-around prestart equipment safety inspection, including a quick visual scan for any exterior
evidence of leaking hydraulic fluid, can help extend the service life of system components.

Page 4
IMPORTANT
Hydraulic system operating conditions (repetitive cycling, heavy work loads, fluid circulating
under high-pressure) make it extremely critical that dust, grit or any other type of contamination
be kept out of the system. Observe fluid and filter change maintenance interval
recommendations and always preclean any exterior surface of the system before it is exposed to
air. For example, the reservoir fill cap and neck area, hoses that have to be disassembled, and
the covers and external surfaces of filter canisters should all be cleaned before disassembly.
MAINTENANCE SERVICE AND REPAIR PROCEDURE

GENERAL PRECAUTIONS
Fluid level and condition should always be checked whenever any other type of maintenance service or
repair is being performed.
NOTE: If the unit is being used in an extreme temperature environment (in subfreezing climates or
in high temperature, high humidity tropical conditions), frequent purging of moisture
condensation from the hydraulic reservoir drain tap must be a regular and frequent part of
the operating routine. In more moderate, temperate climates, draining reservoir sediment
and moisture may not be required more than once or twice every few months.
Inspect drained oil and used filters for signs of abnormal coloring or visible fluid contamination at every oil
change. Abrasive grit or dust particles will cause discoloration and darkening of the fluid. Visible
accumulations of dirt or grit could be an indication that filters are overloaded (and will require more
frequent replacement) or that disintegrating bearings or other component failures in the hydraulic circuit
may be imminent or have already occurred. Open the drain plugs on the main pump casings and check
and compare drain oil in the pumps. Look for evidence of grit or metallic particles.
Vibration or unusual noise during operation could be an indication of air leaking into the circuit (Refer to the
appropriate Troubleshooting section for component or unit for procedures.), or it may be evidence of a
defective pump. The gear type pilot pump could be defective, causing low pilot pressure, or a main pump
broken shoe or piston could be responsible.
NOTE: If equipped, indicated operating pressure, as shown on the multidisplay digital gauge on
the Instrument Panel ("F-Pump" and "R-Pump") will be reduced as a result of a
mechanical problem inside the pump. However, pressure loss could also be due to
cavitation or air leakage, or other faults in the hydraulic system.
Check the exterior case drain oil in the main pumps. If no metallic particles are found, make sure there is
no air in the system. Unbolt and remove the tank return drain line from the top part of the swing motor, both
travel motors and each main pump. If there is air in any one of the drain lines, carefully prefill the assembly
before bolting together the drain line piping connections. Run the system at low rpm.

Page 5
HYDRAULIC SYSTEM CLEANLINESS AND OIL LEAKS
MAINTENANCE PRECAUTIONS FOR HYDRAULIC SYSTEM SERVICE
Whenever maintenance, repairs or any other type of troubleshooting or service is being performed, it's
important to remember that the hydraulic system - including both the interior and exterior surfaces of
assemblies, and every drop of operating fluid - must be protected from contamination.
Dust and other foreign contaminants are major contributors to premature wear in hydraulic circuits. The
narrow tolerances, rapidly moving parts and high operating pressures of the system require that fluid be
kept as clean as possible. The performance and dependability of the machine (and the service lift of
individual components) can be noticeably reduced if proper precautions are not observed:
• Use a safe, noncombustible, evaporative type, low residue solvent and thoroughly clean exterior
surfaces of assemblies before any part of the circuit is opened up or disassembled.
NOTE: It's just as important to clean the cap and reservoir top before routine fluid changes or
quick checks as it is before major repairs. (Accumulated dirt attracts moisture, oil and
other fluids - and more dirt.)
• Keep dismantled parts covered during disassembly. Use clean caps, plugs or tape to protect the
disconnected openings of flanges, manifolds and piping.
• Do not allow cleaning solvents or other fluids to mix with the oil in the system. Use clean oil to
flush any traces of solvent or other residue before reassembly.
• If metal or rubber fragments are found in the system, flush and replace all fluid in the system
and troubleshoot the circuit to identify the source of contamination.
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.
OIL LEAKAGE PRECAUTIONS

Oil that is visibly seeping from joints or seals should always serve as a "red flag" alarm.
Leaks must alert the machine operator and maintenance crew that air, water and dirt have an open, free
passageway through which to enter the circuit. Harsh, corrosive salt air, freezing and thawing condensation
cycles and working environments that are full of fine dust are especially hazardous. Clogging of valve
spools or external piping (especially pilot circuit piping) can gradually diminish or very suddenly put a
complete stop to normal hydraulic function. You can prevent having to make these types of repairs by
following recommended assembly procedures:
1. Use new O-rings and oil seals whenever hydraulic assemblies are rebuilt.
2. Prepare joint surfaces before assembly by checking alignment and flatness. Clean and repair
corrosion or any other damage.
3. Follow bolt torque recommendations and all other assembly requirements.

Page 6
NOTE: Grease lip seals before
assembly.
Figure 1
CLEANING AND INSPECTION

GENERAL GUIDELINES
All parts must be clean to permit an effective inspection. During assembly, it is very important that no dirt or
foreign material enters unit being assembled. Even minute particles can cause malfunction of close fitting
parts such as thrust bearing, matched parts, etc.
WARNING!
Care must 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 retaining 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

Page 7
scratching. Curling under of any seal lip will seriously impair its efficiency. Apply a thin coat of Loctite
#120 to outer diameter, of metal casing, on oil seals to assure an oil tight fit into retainer. Use extreme
care not to get Loctite on lips of oil seals. If this happens, that portion of the seal will become brittle
and allow leakage.
When replacing lip type seals, make sure spring loaded side is towards oil to be sealed.
5. If available, use magna-flux or similar process for checking for cracks that are not visible to the eye.
Examine teeth on all gears carefully for wear, pitting, chipping, nicks, cracks or scores. Replace all
gears showing cracks or spots where case hardening has worn through. Small nicks may be removed
with suitable hone. Inspect shafts and quills to make certain they have not been sprung, bent, or
splines twisted, and that shafts are true.
NOTE: Spline wear is not considered detrimental except where it affects tightness of splined
parts.
Inspect thrust washers for distortion, scores, burs, and wear. Replace thrust washer if defective or
worn.
6. Inspect bores and bearing surfaces of cast parts and machined surfaces for scratches, wear, grooves
and dirt. Remove any scratches and burrs with crocus cloth. Remove foreign material. Replace any
parts that are deeply grooved or scratched which would affect their operation.
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.

Page 8
Normal Bearing
Smooth even surfaces with no discoloration or
marks.
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

Page 9
Abrasive Step Wear
Pattern on roller ends caused by fine abrasives.
Clean all parts and housings, check all parts
and housings, check seals and bearings and
replace if leaking, rough or noisy.
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

Page 10
Fatigue Spalling
Flaking of surface metal resulting from fatigue.
Replace bearing - clean all related parts.
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

Page 11
Cracked Inner Race
Race cracked due to improper fit, cocking or
poor bearing seat.
Replace all parts and housings, check seals and
bearings and replace if leaking.
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

Page 12
Heat Discoloration
Heat discoloration can range from faint yellow to
dark blue resulting from overload or incorrect
lubrication.
Excessive heat can cause softening of races or
rollers.
To check for loss of temper on races or rollers, a
simple file test may be made. A file drawn over a
tempered part will grab and cut metal, whereas
a file drawn over a hard part will glide readily
with no metal cutting.
Figure 17
Replace bearing if over heating damage is
indicated. Check seals and other related parts
for damage.
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

Page 13
Page 14
S0309000
R1
1STANDARD TORQUES
CAUTION!
STANDARD TORQUESS0309000
ALL MODELS ALL RANGES

May 2002
Standard Torques S0309000

Page 1
TABLE OF CONTENTS
Torque Values for Standard Metric Fasteners ................................................ 3

Torque Values for Standard U.S. Fasteners ................................................... 4
Type 8 Phosphate Coated Hardware ............................................................. 6
Torque Values for Hose Clamps ..................................................................... 7
Torque Values for Split Flanges...................................................................... 8
Torque Wrench Extension Tools..................................................................... 9
Torque Multiplication ............................................................................... 9
Other Uses for Torque Wrench Extension Tools ................................... 10
Tightening Torque Specifications (Metric) ............................................. 10
S0309000 Standard Torques

Page 2
TORQUE VALUES FOR STANDARD METRIC
FASTENERS
NOTE: The units for the torque values are kg•m (ft lb).
Grade
Dia. x Pitc
h (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)

Page 3
TORQUE VALUES FOR STANDARD U.S. FASTENERS
S.A.E. BOLT HEAD
TYPE DESCRIPTION
GRADE MARKING
WILL HAVE NO MARKINGS IN THE CENTER OF THE

HEAD.
1 1 OR 2
Low or Medium Carbon Steel Not Heat Treated.
WILL HAVE THREE RADIAL LINES.

5 5
Quenched and Tempered Medium Carbon Steel.
WILL HAVE 6 RADIAL LINES.

8 8
Quenched and Tempered Special Carbon or Alloy Steel.
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.

Page 4
The following General Torque Values must be used in all cases where SPECIAL TORQUE VALUES are
not given.
NOTE: TORQUE VALUES LISTED THROUGHOUT THIS MANUAL ARE LUBRICATED

(WET) THREADS; VALUES MUST BE INCREASED 1/3 FOR NONLUBRICATED
(DRY) THREADS.
HEAT TREATED MATERIAL GRADE 5 AND GRADE 8
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) (Nm)
(Nm)
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.

Page 5
TYPE 8 PHOSPHATE COATED HARDWARE
This chart provides tightening torque for general purpose applications using original equipment standard
hardware as listed in the Parts Manual for the machine involved. DO NOT SUBSTITUTE. In most cases,
original equipment standard hardware is defined as Type 8, coarse thread bolts and nuts and thru
hardened flat washers (Rockwell "C" 38 - 45), all phosphate coated and assembled without supplemental
lubrication (as received) condition.
The torques shown below also apply to the following:
1. Phosphate coated bolts used in tapped holes in steel or gray iron.
2. Phosphate coated bolts used with phosphate coated prevailing torque nuts (nuts with distorted
threads or plastic inserts).
3. Phosphate coated bolts used with copper plated weld nuts.
Markings on bolt heads or nuts indicate material grade ONLY and are NOT to be used to determine
required torque.
STANDARD TORQUE ±10%

NOMINAL THREAD
DIAMETER
KILOGRAM METER FOOT POUNDS
(kg•m) (ft lb)
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

Page 6
TORQUE VALUES FOR HOSE CLAMPS
The following chart provides the tightening torques for hose clamps used in all rubber applications
(radiator, air cleaner, operating lever boots, hydraulic system, etc.).
TORQUE
RADIATOR, AIR CLEANER,

HYDRAULIC SYSTEM
BOOTS, ETC.
CLAMP TYPE AND SIZE
KILOGRAM KILOGRAM
INCH POUNDS INCH POUNDS
METER METER
(in lb) (in lb)
(kg•m) (kg•m)
"T" Bolt (Any Diameter) 0.68 - 0.72 59 - 63 ------- ------
Worm Drive - Under 0.2 - 0.3 20 - 30 0.5 - 0.6 40 - 50

44 mm (1-3/4 in) Open
Diameter
Worm Drive - Over 44 mm 0.5 - 0.6 40 - 50 ------- ------

(1-3/4 in) Open Diameter
Worm Drive - All 0.6 - 0.7 50 - 60 0.5 - 0.6 40 - 50

"Ultra-Tite"

Page 7
TORQUE VALUES FOR SPLIT FLANGES
The following chart provides the tightening torques for split flange connections used in hydraulic systems.
Split flanges and fitting shoulders should fit squarely. Install all bolts, finger tight and then torque evenly.
NOTE: Over torquing bolts will damage the flanges and/or bolts, which may cause leakage.
BOLT TORQUE
FLANGE BOLT
SIZE (*) SIZE KILOGRAM METER FOOT POUNDS
(kg•m) (ft lb)
1/2" 5/16" 2.1 - 2.5 15 - 18

3/4" 3/8" 3.0 - 3.7 22 - 27
1" 3/8" 3.7 - 4.8 27 - 35
1 - 1/4" 7/16" 4.8 - 6.2 35 - 45
1 - 1/2" 1/2" 6.4 - 8.0 46 - 58
2" 1/2" 7.6 - 9.0 55 - 65
2 - 1/2" 1/2" 10.9 - 12.6 79 - 91
3" 5/8" 19.1 - 20.7 138 - 150
3 - 1/2" 5/8" 16.2 - 18.4 117 - 133
(*) - Inside diameter of flange on end of hydraulic tube or hose fitting.

NOTE: Values stated in chart are for Standard Pressure Series (Code 61) Split Flanges.

Page 8
TORQUE WRENCH EXTENSION TOOLS
Very large diameter, high grade fasteners (nuts, bolts, cap screws, etc.) require a great deal of turning force
to achieve recommended tightening torque values.
Common problems that could occur as a result are:
• Recommended torque exceeds the measuring capacity of the torque wrench.
• Specialized sockets do not fit the adapter on the front end (nose) of the torque wrench.
• Generating adequate force on the back end (handle) of the wrench is difficult or impossible.
• Restricted access or an obstruction may make use of the torque wrench impossible.
• A unique application requires fabrication of an adapter or other special extension.
Most standard torque wrenches can be adapted to suit any one of the proceeding needs or situations, if
the right extension tool is used or fabricated.
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:
AxT 12 x 300 3600

I= = = = 150
A+B 12 + 12 24
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.

Page 9
OTHER USES FOR TORQUE WRENCH EXTENSION TOOLS
Torque wrench extensions are sometimes made up for reasons other than increasing leverage on a
fastener.
For example, a torque wrench and extension can be used to measure adjustment "tightness" of a linkage
or assembly. Specially fabricated extensions can be used to make very precise checks of the force
required to engage or disengage a clutch mechanism, release a spring-applied brake assembly, or "take
up" free play in most any movable linkage.
Once the value of the adjustment force is established, repeated checks at regular intervals can help to
monitor and maintain peak operating efficiency. These types of adjustment checks are especially useful if
physical measurements of linkage travel are difficult to make or will not provide the needed degree of
precision and accuracy.
To allow the assembly or mechanism to accept a torque wrench, welding a nut or other adapter on the end
of a linkage shaft or other leverage point will allow turning the shaft or assembly manually.
TIGHTENING TORQUE SPECIFICATIONS (METRIC)

(For coated threads, prelubricated assemblies.)
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. DOOSAN 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.

Page 10
I. "Loctite" Fastener Adhesives
Breakaway Cure
Product Application Color Removal Strength (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.
II. "Loctite" Pipe Thread Sealant
Product Application Color Removal Required Setup

"No-filler/nonclog" formula for high-pressure 4 Hours (or 1/2 hour
545 hydraulic systems. Over application will not Purple Hand tools with Locquic "T"
restrict or foul system components. Primer)
4 Hours (or 1/2 hour
Solvent resistant, higher viscosity tapered
656 White Hand tools with Locquic "T"
thread sealer.
Primer)
III. "Loctite" gasket/flange sealer
Product Application Color Notes

Gasket eliminator specifically made for Use Locquic "N" primer for fast
518 aluminum flanges/surfaces. For hydraulic Red (1/2 - 4 hours) setup. Unprimed
systems to 34,475 kPa (5,000 psi). setup 4 - 24 hours.
Low-pressure/wide-gap gasket eliminator Use Locquic "N" primer for faster
504 compound. Fills gaps to 0.0012 mm (0.030"), Orange (1/2 - 4 hours) setup. Unprimed
cures to rigid seal. setup 4 - 24 hours.
General purpose, fast setup, flexible-cure Use Locquic "N" primer for faster
515 gasket eliminator. For nonrigid assemblies Purple (1/4 - 2 hours) setup. Unprimed
subject to shock, vibration or deflection. setup 1 - 12 hours.

Page 11
IV. "Loctite" retaining compounds

For bushings, sleeves, press-fit bearings, Use Locquic "N" primer for
609 splines and collars. For gaps to 0.0002 mm Green increased bond strength and all
(0.005"), temperatures to 121°C (250°F). cold temperature applications.
620 For high temperatures to 232°C (450°F). Green Same as 609, above.
For high strength bonds and tight clearance
680 Green Same as 609, above.
gaps, to 0.00008 mm (0.002").
V. "Loctite" Adhesives

Black Max instant adhesive for shock and May take 120 hours to reach full
380 Black
vibration-resistant bonds. cure strength.
454 Adhesive for porous surfaces. Clear Full strength in 24 hours.
Increased strength (+50%), shock and
480 Black Full strength in 24 hours.
vibration-resistant.

Page 12
1UPPER STRUCTURE
S0403030K
R3
1COUNTERWEIGHT
CAUTION!
COUNTERWEIGHT S0403030K

July 2004
Counterweight S0403030K
Page 1
TABLE OF CONTENTS
Specifications ................................................................................................. 3
Counterweight ................................................................................................ 3
S0403030K Counterweight
Page 2
SPECIFICATIONS
NOTE: Weight.
Model Weight Serial Number Range

Mega 200-V 622 kg (1,370 lb) S/N 1001 and Up
Mega 250-V 992 kg (2,190 lb) S/N 1001 thru 2000
Mega 250-V 1,100 kg (2,430 lb) S/N 2001 and Up
Mega 300-V 1,100 kg (2,430 lb) S/N 1001 thru 2000
Mega 300-V 1,100 kg (2,430 lb) S/N 2001 thru 3000
COUNTERWEIGHT
AJS0620L
Figure 1
NOTE: 1) Tighten bolts to the torque value list in the following table.
Mega 200-V 115 kg•m (830 ft lb)

Mega 250-V 115 kg•m (830 ft lb)
Mega 300-V 250 kg•m (1,800 ft lb)
Mega 400-V 250 kg•m (1,800 ft lb)
Counterweight S0403030K
Page 3
S0403030K Counterweight
Page 4
S0405500
1FUEL TRANSFER PUMP
CAUTION!
FUEL TRANSFER PUMPS0405500

Mega 130 0001 and Up
Mega 200-III 1001 and Up
Mega 200-V (Tier I and II) 1001 and Up
Mega 400-III PLUS 1001 and Up
Mega 500-V 1001 thru 2000
Solar 130LC-V 0001 and Up
Solar 130W-V 0001 and Up
Models continued on back of cover.

January 2004
Fuel Transfer Pump S0405500

Page 1
Solar 220LL 1001 and Up
Solar 220N-V 1001 and Up
Solar 225NLC-V 1001 and Up
Solar 55W-V PLUS 1001 and Up
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
S0405500 Fuel Transfer Pump

Page 2
GENERAL DESCRIPTION
THEORY OF OPERATION
Figure 1
Reference Reference
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
The fuel pump consists of a motor, pump,

switch, and hose assembly.
Figure 2

Page 3
TROUBLESHOOTING
On some pumps the ON-OFF switch is installed separately at a remote location.
A thermal limiter, built into the motor, will automatically shut off power if motor is overheating to protect it
from being damaged.
NOTE: OPEN TEMP: 150 ±5°C (302 ±41°F). After circuit is automatically shut off due to
overheating the pump will stop running. When temperature drops below 143°C (289°F) the
circuit will reactivate allowing the pump to restart.
Figure 3 WITH TOGGLE SWITCH Figure 4 WITHOUT TOGGLE SWITCH
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.
REPLACEMENT OF ROTOR AND VANE

If dirt or other foreign materials enter the pump
during operation, it can become lodged between
the rotor and/or vanes and generate heat which
can cause the pump damage.
Remove the pump cover and check the rotor
and vane. If any pump parts or components
become lost, damaged or inoperable,
immediately replace them with new ones.
Figure 5 WITHOUT TOGGLE SWITCH

Page 4
Insert vane, with the circled edge of vane facing
in the counterclockwise direction. (Detail A)
Insert a new O-ring during reassembly of the
pump cover.
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
the brush and insert it to the armature. Then fit Figure 7
the hole of screw in the housing.
Be careful when installing the screw. The cover
screw may be attracted by the motor magnet.

Page 5
REPLACEMENT OF
ARMATURE
You can replace only the armature in case the
motor was damaged by a short circuit.
Remove the switch cover and rear cover, than
remove the armature from the housing.
Remove the pump cover and remove the rotor
and vane.
Insert a new armature into the housing.
Figure 8
Refer to “Replacement of Rear Cover” on page
5, for installation of the rear cover.
Fit the rotor into the shaft flute of the armature.
Insert vane to the rotor being careful of the
direction. Refer to “Replacement of Rotor and
Vane” on page 4.

Page 6
S0406050K
1HYDRAULIC OIL TANK
CAUTION!
HYDRAULIC OIL TANKS0406050K


May 2001
Hydraulic Oil Tank S0406050K

Page 1
TABLE OF CONTENTS
Parts List ................................................................................................. 3
Specifications .......................................................................................... 4
S0406050K Hydraulic Oil Tank

Page 2
GENERAL DESCRIPTION
PARTS LIST
SECTION A
SECTION B
AMS0230L
Figure 1
Reference Reference
Number Number
1 Return Filter 5 Air Breather
2 Bypass Valve 6 Level Gauge
3 Spring 7 Drain Plug
4 Suction Filter
Hydraulic Oil Tank S0406050K

Page 3
SPECIFICATIONS
Mega 300-V
Type Pressurized Sealing
Capacity (System) 210 liters (55 U.S. gal.)
Air breather
Open Pressure 0.40 kg/cm2 (5.7 psi)
Vacuum pressure 0.035 kg/cm2 (0.5 psi) at 900 liters (238 U.S. gal.)/min
Return Filter
Filtration rating 10 μ
Pressure drop 0.2 kg/cm2 (3 psi) at 600 liters (159 U.S. gal.)
Suction Filter 177 μ
S0406050K Hydraulic Oil Tank

Page 4
1LOWER STRUCTURE AND CHASSIS
S0502030K
1CENTER JOINT
(ARTICULATION JOINT)
CAUTION!
CENTER JOINT (ARTICULATION JOINT)S0502030K


July 2004
Center Joint (Articulation Joint) S0502030K

Page 1
TABLE OF CONTENTS
Maintenance Standard ............................................................................ 4
S0502030K Center Joint (Articulation Joint)

Page 2
GENERAL DESCRIPTION
The loader frame is an articulated type: the front frame is joined to the rear frame with two hinge pins
around which the loader pivots for steering.
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

Page 3
MAINTENANCE STANDARD
DETAIL B
DETAIL A
AMS0600L
Figure 2

Page 4
Unit: mm
No. Check item Criteria Remedy
1 Clearance between upper Standard Tolerance Standard Clearance
hinge pin and rear frame size clearance limit
66.7 -0.040 +0.060 0.070 - -
-0.076 +0.030 0.136
2 Clearance between upper 66.7 -0.040 +0.060 0.070 - -
hinge pin and spacer -0.076 +0.030 0.136
(small)
3 Clearance between upper 66.7 -0.040 0 0.055 - -
hinge pin and bearing -0.076 -0.015 0.076
4 Clearance between upper 66.7 -0.040 +0.060 0.055 - -
hinge pin and spacer -0.076 +0.030 0.076
(large)
5 Clearance between rear 78 +0.060 -0.036 0.066 - -
frame and spacer (large) +0.030 -0.090 0.15
Replace
6 Clearance between front 122.3 -0.048 -0.037 -0.011 - -
frame and upper hinge -0.088 -0.062 -0.125
bearing
7 Clearance between lower 66.7 -0.020 +0.046 0.020 - -
hinge pin and rear frame -0.076 0 0.122
8 Clearance between lower 66.7 -0.020 0 0.035 - -
hinge pin and bearing -0.076 -0.015 0.076
9 Clearance between front 122.3 -0.048 -0.037 -0.11 - -
frame and lower hinge -0.088 -0.062 -0.125
bearing
11 Height of upper hinge 28.5 +0 - - 0 0
spacer (small) -0.1
12 Height of upper hinge 55.5 +0 - - 0 0
spacer (large) -0.1
13 Shim thickness for upper 0.5 - 1.04 - - - -
hinge and retainer (front
frame)
14 Shim thickness for upper 2.24 - - - - -
hinge and retainer (rear 3.55
frame)
15 Tightening torque of When adjusting with shim: 4 ±0.2 kg•m
upper hinge retainer
mounting bolt Final value: 13 ±1.0 kg•m
Tightening torque of When adjusting with shim: 4 ±0.2 kg•m
16 upper hinge retainer Final value: 13 ±1.0 kg•m
mounting bolt Retighten
17 Tightening torque of 13 ±1.0 kg•m
upper hinge pin mounting
bolt
18 Tightening torque of lower 13 ±1.0 kg•m
hinge pin mounting bolt

Page 5
Page 6
1ENGINE AND DRIVE TRAIN
S0602180K
1FRONT AXLE
(VOLVO SLA 15/W)
CAUTION!
FRONT AXLE (VOLVO SLA 15/W)S0602180K


May 2001
Front Axle (Volvo SLA 15/W) S0602180K

Page 1
TABLE OF CONTENTS
Outline..................................................................................................... 5
Drive Axle................................................................................................ 5
Axle Mount ....................................................................................... 5
Differential (Standard) ............................................................................. 8
Differential Operation ....................................................................... 8
Limited Slip Differential Cross Section (Option) ............................... 8
Parking Brake Operation ......................................................................... 9
Parts List ............................................................................................... 11
Front Axle Housing ........................................................................ 11
Front Axle Differential..................................................................... 12
Front Planetary Gear Set ............................................................... 14
Parking Brake................................................................................. 16
Scheduled Maintenance............................................................................... 20
After First 250 Hours ............................................................................. 20
Every 150 hours .................................................................................... 20
Every 1,500 Hours ................................................................................ 21
Lubricant Specifications ........................................................................ 21
General Disassembly and Reassembly Instructions .................................... 22
General Instructions .............................................................................. 22
Assembling Leakproof Components ..................................................... 23
Axle Disassembly ......................................................................................... 23
Drain Oil ................................................................................................ 23
Final Drive ............................................................................................. 24
Differential Assembly............................................................................. 28
Overhauling Super Max Trac Assembly ................................................ 31
Checking Clearance on Assembled Disk Packs.................................... 31
Axle Reassembly.......................................................................................... 32
Determining Thickness of Adjustment Shims........................................ 32
Inner Oil Recirculation Piping................................................................ 33
S0602180K Front Axle (Volvo SLA 15/W)

Page 2
Axial Position of Bevel Pinion ................................................................ 34
Adjusting Backlash................................................................................ 35
Adjusting Tooth Contact ........................................................................ 36
Correct Pattern............................................................................... 36
Increase Pinion Distance ............................................................... 36
Decrease Pinion Distance.............................................................. 37
Securing Differential to Axle Housing.................................................... 39
Final Drive ............................................................................................. 40
Determining Space Available to Form Brake Disk Pack........................ 42
Parking Brake (S/N 1001 thru 2000) ............................................................ 44
Disassembly.......................................................................................... 45
Reassembly .......................................................................................... 45
Adjustment ............................................................................................ 45
Parking Brake (S/N 2001 and Up) ................................................................ 46

Page 3
Page 4
GENERAL DESCRIPTION
OUTLINE
Front Axle
Frame-Fixed,
Type
Semifloating
Serial Number 1001 thru 2000 2001 and Up
Overall Reduction Ratio 24.685
STD. Max. Trac (Locking Ration: 30%)
Differential type
OPT. Super Max Trac (Limited Slip: 45%)
Max Static Load 35,700 kg (78,710 lb)
Max Output Torque 11,800 kg•m (85,350 ft lb)
Type Multi Wet Disk
Brake Torque 2,532 kg•m @ 80 Bar 2,362 kg•m @ 80 Bar
(18,314 ft lb @ 1,160 psi) (17,084 ft lb @ 1,160 psi)
Type C-CLAMP SAHR SAHR CALIPER DISK BRAKE
Torque 306 kg•m (2,213 ft lb) 342 kg•m (2,474 ft lb)
Parking Brake
Release Press. 70 - 140 Bar 102 - 230 Bar
(1,015 - 2,030 psi)) (1,479 - 3,336 psi)
Drive Flange 7C
DRIVE AXLE
The drive axle consists of the differential, final reduction gear assembly, wet type hydraulic disk brake unit,
and axle shafts to which wheels are attached.
The power from the drive unit is transmitted through the drive shafts to the front and rear drive axles. The
power is then transmitted to the differential where it is divided into the right and left axle shafts to the final
reduction gear assembly on each shaft end thus driving the wheels.
The wet type hydraulic disk brake unit is installed in front of the final reduction gear assembly and serves
as a service brake.
Axle Mount
The front axle is bolted directly to the front frame.
The rear axle is supported by the trunnion method in which axle supports are installed across the rear axle
and bolted to the rear frame. Consequently, the rear axle is cradled up and down around the center line of
the differential according to the ground condition the loader travels. The trunnion-mounted drive axle helps
improve operator comfort because loaders with a trunnion-mounted drive axle jolt less than those with the
conventional cradle-supported drive axle, when they travel on bad ground conditions.

Page 5
SECTION A
AJS0641L
Figure 1 DRIVE AXLE ASSEMBLY

Page 6
Reference Reference
Number Number
1 Front Axle 6 Bushing
2 Rear Axle 7 Thrust Plate
3 Axle Support (Front) 8 Thrust Cap
4 Axle Support (Rear) 9 Thrust Washer
5 Packing
NOTE: 1) 28 kg•m (200 ft lb) Threaded area: Loctite #262.

NOTE: 2) 140 kg•m (1010 ft lb).
NOTE: 3) 170 kg•m (1230 ft lb).
NOTE: 4) Inner surface: Grease (Assemble with chamfered surface toward axle.)
NOTE: 5) Assemble with lip pointing outward.
NOTE: 6) Assemble with groove pointing toward plate (7).
NOTE: 7) Apply grease and assemble.

Page 7
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.
Figure 2 DIFFERENTIAL GEAR OPERATION
Reference Reference
Number Number
1 Pinion Gear 5 Spider
2 Side Gear 6 Drive Pinion
3 Axle Shaft 7 Ring Gear
4 Differential Gear Case
Limited Slip Differential Cross Section (Option)

Figure 3, shows a cross-sectional view of the parts contained in the limited slip differential.

Page 8
Reference
Description
Number
1 Ring Gear
2 Bevel Pinion
3 Cross
4 Upper Thrust Ring
5 Outer Disk
6 Inner Disk
7 Cover
8 Clutch Disk
9 Side Gear
10 Lower Thrust Ring
Figure 3
PARKING BRAKE OPERATION

A disk type parking brake is attached to the input shaft on the front axle. This brake is spring applied and
hydraulically released. When the parking brake switch in the operator's cabin is moved to the brake release
position, the parking brake solenoid valve opens and directs fluid from the brake pump to the brake cylinder
(6, Figure 7).
Parking brake release pressure is 70 - 140 Bar (1,015 - 2,030 psi) S/N 1001 thru 2000, 102 - 230 Bar
(1,479 - 3,336 psi) S/N 2001 and up (max). The brake cylinder retracts the brake set spring (14) and
releases the brake.
If the electrical supply to the parking brake is solenoid valve is interrupted, or if the engine is shut off, the
parking brake is automatically applied.
As a safety feature, the transmission forward/reverse gear selector must be in the neutral position and the
parking brake switch must be in the "ON" position, to start the engine.
When the parking brake switch is ON, a warning light turns ON. If either forward/reverse is selected on the
transmission while the parking brake switch is on, a buzzer will sound.

Page 9
Page 10
PARTS LIST
Front Axle Housing
Figure 4
Reference Reference
Number Number
1 Housing; Front 9 O-ring
2 Plug; Magnetic 10 Tube Assembly
3 O-ring 11 Bolt
4 Plug; Drain 12 O-ring
5 O-ring 13 Tube Assembly - RH
6 Breather; Air 14 Tube Assembly - LH
7 - 15 Bolt
8 -

Page 11
Front Axle Differential
Figure 5

Page 12
Reference Reference
Number Number
1 Carrier Assembly 21 Spider
2 Carrier; Front 22 Washer; Thrust
3 Cap 23 Washer; Thrust
4 Bolt 24 Flange Assembly
5 Case Assembly 25 Flange
6 Case - LH 26 Cover
7 Case - RH 27 Holder
8 Bolt 28 Nut
9 Washer; Plain 29 Bolt
10 Set; Bevel 30 Shim T = 0.1 mm
11 Pinion; Bevel Shim T = 0.3 mm
12 Gear; Bevel Ring Shim T = 0.5 mm
13 Nut Shim T = 1.0 mm
14 Bearing 31 Shim T = 0.1 mm
15 Bearing Shim T = 0.3 mm
16 Bearing Shim T = 0.5 mm
17 Pump 32 Pin; Spring
18 Seal; Oil 33 Bolt
19 Gear; Side 34 Washer; Plain
20 Pinion; Differential 35 Pin; Split

Page 13
Front Planetary Gear Set
Figure 6

Page 14
Reference Reference
Number Number
1 Drum Assembly-hub 27 Bolt
2 Drum; Hub 28 Bolt
3 Pin; Planetary 29 Ring; Retaining
4 Gear; Planetary 30 Ring; Retaining
5 Spacer 31 Plate; Lock
6 Bearing; Needle 32 Plate
7 Washer; Thrust 33 Stud; Wheel
8 Washer; Thrust 34 Nut; Wheel
9 Plug 35 Washer; Thrust
10 O-ring 36 Drum
11 Shaft; Bevel Gear 37 Disk; Brake
12 Hub; Wheel 38 Spacer
13 Spindle Assembly-LH 39 Spring; Return
Spindle Assembly-RH 40 Cover
14 Spindle-LH 41 Rod; Push
Spindle-RH 42 Plate
15 Seal 43 Piston
16 Spacer 44 O-ring
19 Bolt 45 O-ring
20 Cover 46 Bearing D140x195x291
21 Gear; Sun 47 Bearing
22 Gear; Ring 48 Seal; Oil
23 Support 49 O-ring
24 Ring; Retaining 50 O-ring
25 Nut; Adjusting 51 Disk
26 Breather 52 Plug
NOTE: No. of Brake Disks (Front): 4 EA

(Rear): 4 EA

Page 15
Parking Brake

Page 16
Reference Reference
Number Number
1 Rod; End 18 Body; Cylinder
2 Nut; Hex 19 Guide; Ring
3 Rod 20 Rod; Packing
4 Sleeve 21 Dust; Wiper
5 Nut; Hex 22 Spring
6 Cover 23 Flange
7 Cover; Tie Rod 24 Nut; Stopper
8 Pin 25 Caliper; Clamp
9 Tie Rod 26 Bolt; Hex
10 Pin 27 Washer; Spring
11 Plate; Wa 28 Disk; Brake
12 Dust; Wiper 29 Bolt; Hex
13 Rod; Packing 30 Washer; Spring
14 Guide; Ring 31 Bolt; Hex
15 Stud 32 Washer; Spring
16 Nut; Hex 33 Pin; Split
17 Washer; Spring 34 Cylinder Kit

Page 17

Page 18
Reference Reference
Number Number
1 Bracket 16 Pin
2 Bolt 17 Nut
3 Disk 18 Cover
4 Bolt 19 O-ring
5 Spring Washer 20 Bolt
6 Brake Caliper 21 Breather
7 body 22 Cap
8 Pad 23 Bolt
9 Shuttle 24 Nut
10 Ring 25 Split Pin
11 Wagnet 26 Ring
12 Piston 27 Seal
13 Ring 28 Ring
14 Plate Ring 29 O-ring
15 Lock Plate

Page 19
SCHEDULED MAINTENANCE
Figure 9
AFTER FIRST 250 HOURS

Replace oil in axle assembly as follows:
1. Differential Unit.
• Remove fill plug (1) and drain oil from drain plug (2).
• Replace drain plug (2) and refill through plug (1) until oil if overflowing.
2. Side Final Drives.
• Position plug (3) at bottom, remove plug and drain oil.
• Refill by rotating hub 90o (so "OIL LEVEL" writing is horizontal) and add oil until it overflows,
replace plug (3).
EVERY 150 HOURS

Check oil in axle assembly as follows:
• With axle positioned horizontal, remove fill plug (1) and check oil level. Oil level should reach
edge of fill plug seat. Add oil as required.

Page 20
• Check oil by rotating hub 90o (so "OIL LEVEL" writing is horizontal), remove plug (3) and check
oil. Oil should edge of fill plug seat. Add oil as required, replace plug (3).
EVERY 1,500 HOURS

• Remove fill plug (1) and drain oil from drain plug (2)
replace plug (3).
LUBRICANT SPECIFICATIONS
For differential and final drive units:
• Oil specification: MOBIL INFILREX 33
80W90
• Corresponding to: SAE 90 or SAE 80W90 rating
NOTE: DOOSAN recommends oils with LIMITED-SLIP (LS) additives to prevent noise when
brakes are actuated.

Page 21
GENERAL DISASSEMBLY AND REASSEMBLY
INSTRUCTIONS
WARNING!
Never use gasoline, solvents, or other flammable fluids to clean components. Only use
approved commercial solvents that are nonflammable and nontoxic.
IMPORTANT
Use only genuine DOOSAN spare parts to warrant proper operations and prevent
interchangeability problems.
GENERAL INSTRUCTIONS
1. Thoroughly clean and dry axle before disassembly.
2. All components must be thoroughly cleaned and dried before reassembly. Dirt, chips, and foreign
material may cause failures.
3. All ducts and castings must be thoroughly cleaned and dried to remove dirt, chips, and foreign
material to prevent damage after reassembly.
4. Reassembly must be done in a clean shop, and must be as dust free as possible.
5. Make sure tools and equipment are at hand.
6. When reassembling DOOSAN strongly recommends to replace the following parts with new.
• Seal Rings.
• O-rings.
• Gaskets.
• Threaded rings with notched collar.
• Any component damaged during disassembly.
7. When mounting heat fitted components, make sure of their proper position and direction of assembly,
after they have cooled.
8. To heat bearings, use proper heating plates, piping, or suitable ovens.
NOTE: Never heat parts by using a torch. Oil bath, heated by a torch, maybe used to warm
components.
9. Lubricate all sections concerned when reassembling shafts, bearings, etc.
10. Lubricate O-rings before installing them in relevant seats to prevent kinking during assembly, such a
position would impair proper sealing.
11. Replace gears only in matched sets to make sure of proper tooth mating.

Page 22
ASSEMBLING LEAKPROOF COMPONENTS
1. Use of proper sealing compounds is recommended when assembling matched parts to be sealed
against fluid leakage (oil or water), and no sealing gasket is used.
2. Best results are reached, with said compounds, when matching surfaces are thoroughly cleaned,
degreased, and dried before spreading a uniform coat over contact area.
3. DOOSAN suggests to use the following compounds:
• Loctite Plastic Gasket
• Rhodorsil CAF 1
• Silastic 732 RTV
AXLE DISASSEMBLY
Figure 10
DRAIN OIL

Page 23
FINAL DRIVE
Figure 11

Page 24
WARNING!
Lift and handle all heavy components by using proper equipment. Make sure that assemblies or
components are lifted and held with the use of proper slings and hooks. Use specific lifting
eyes. Always make sure that people are out of the way when lifting.
1. Remove six cover mounting screws (1), then remove final drive cover (2).
NOTE: Cover (2) is provided with three threaded holes for puller screws.
2. Remove O-ring (3).
3. Using a puller screw, remove axle shaft backing plate (4).
4. Provide suitable support for side gear carrier (6), then remove screws (5) fixing side gear carrier to
wheel hub (7), and pry side gear carrier (6) to separate from wheel hub (7).
5. Pull side gear carrier (6) out of wheel hub.
6. Remove lock ring (9) retaining sun gear (10), and remove sun gear from wheel shaft (14).
7. Remove disk carrier hub (11) along with thrust washer (12) resting against wheel hub sleeve.
8. Remove solid and lined brake disks (13).
9. Remove wheel shaft (14).
10. Remove lock ring (15) securing lock (16), then remove ring nut (17).

Page 25
Figure 12
Spring Retainer Installed

A Spring Retainer
17 Ring Nut
18 Pressure Plate
19 Return Spring
NOTE: Install a spring retainer (A), secured thru three threaded holes of disk pressure plate (18),
to compress return spring (19) and allow removal of ring nut (17).
11. Unlock and remove ring nut (17) from sleeve (27).
12. Remove pressure plate (18) along with brake return spring retainer (A).
13. Provide suitable support for wheel hub (7) and pull ring gear unit (21) and support (22) from hub.
14. Remove six rods (24) in seats on ring gear support (22).
15. Using a screwdriver, pry off lock ring (23) from ring gear (21).
16. Disassemble ring gear support (22) from ring gear (21).
NOTE: Should replacement of outer wheel bearing (25) inner race be mandatory, old part can be
removed by a proper puller, or by a remover that can be inserted in specific holes of ring
gear support (22).
17. Remove brake return spring retainer (A) and disassemble return spring (19), retaining cup (20), and
pressure plate (18).

Page 26
18. Using compressed air thru brake oil ducting, remove brake actuating piston (26) from wheel hub
sleeve (27).
19. Remove and replace with new two O-rings (28 and 29) in seats on brake actuating piston.
20. Remove complete wheel hub (7).
22. Pry off seal (30) from wheel hub (7), and remove inner race with roller cage of inner wheel bearing
(31).
23. Using a proper remover, push out outer races of inner and outer wheel bearings (25 and 30) from
wheel hub (7).
NOTE: Should sleeve (27) be damaged, it can be removed by undoing relevant screws (32). At
reassembly, smear proper sealing compound on axle case joining flange, then tighten
screws. Torque to 900 ±45 Nm (91.8 ±4.6 kg•m / 663.8 ±30 ft lb).
24. Mark side gear pins (33), various components and seats (34) for identification of original position at
reassembly.
25. Arrange side gear carrier (6) on wooden blocks and push out pins (33) with proper remover.
26. Pick up all needle rollers (35).
NOTE: It is important to keep matched needle rollers (35) and thrust washers (36) with relevant
pin (33), this is consequent to predetermined assembly tolerance limits.
27. Remove side gears (37) and relevant thrust washers (38).
NOTE: No gear can be removed before having released all of them.

Page 27
DIFFERENTIAL ASSEMBLY
Figure 13
1. Release and remove six screw (1) that secure outer recirculation piping (2) and three seals (3).
2. Check wear condition of components and repair or replace as required.
3. Unlock and remove screws (4) retaining differential assembly, then remove differential assembly from
axle case.

Page 28
Figure 14
4. Hammer out spring pins (2) locking slotted rings (3).

5. Mark caps (4) to match parts at reassembly.
6. Remove screws (5), caps (4), and slotted rings (3).
7. Remove differential case assembly from support (11).
8. Straighten locking notches on pinion nut collar (6), position reaction tool on drive flange to unlock nut
(6), release pinion nut, remove drive flange (9) from pinion shank along with washer (8).
9. Pry seal (10) from drive flange.

Page 29
10. Remove bevel pinion (7) from differential support (11), hammer pinion shank with a proper removal
tool.
NOTE: Be careful not to damage threads on pinion (7).
11. Pick up inner race of pinion shank bearing (13).
12. Remove outer races of outer and inner pinion bearings (13 and 14) from differential support (11), pick
up shims (15).
NOTE: Be careful not to loose shims (15) for pinion axial position adjustment, store in a safe place
for reassembly.
13. Remove spacer (16) with shims (17) for bearing preload adjustment, using a proper puller remove
inner race of pinion under head bearing (14).
NOTE: Be careful not to loose shims for bearing preload adjustment, store in a safe place for
reassembly.
14. Mark differential half cases (18 and 19) for reference at reassembly, then remove screws (19a) and
separate half cases (18 and 19).
15. Make a visual and dimensional check of wear on sun gears (21), side gears (20), thrust washers (22
and 23), friction disks (22a), backing disks (22), and spider (24).
16. Using a proper puller, remove bearings (25) from half cases (18 and 19).
17. Clamp ring gear (26) in a vise fitted with soft caps, then remove screws (27) securing ring gear (26) to
half case (18).
18. Fit inner races of differential bearings (25) on half cases (18 and 19)
NOTE: This operation must be carried out by heating equipment or use a proper installer.
19. Mount bevel ring gear (26) on half case (18), secure with screws (27).
NOTE: Torque to 900 ±45 Nm (91.8 ±4.6 kg•m / 663.8 ±30 ft lb).
20. Position differential components in their proper seats.

Page 30
OVERHAULING SUPER MAX TRAC
ASSEMBLY
1. Select backing disks (22) to reach, as
assembling is completed, prescribed
clearance of 0.05 - 0.10 mm (0.0020 -
0.0039") all around both disk packs.
NOTE: When packing friction and
backing disk, pay particular
care to position of first disk
(22a), it is molybdenum plated
on one side only. Disk (22a) is
in contact with sun gear (21),
and molybdenum plated side Figure 15
must face backing disk (22).
2. Join half cases (18 and 19) matching
reference marks made at disassembly.
3. Mount and secure case halves (18 and 19)
with screws (19a).
NOTE: Torque to 220 ±11 Nm
(22.4 ±1.12 kg•m /
162.3 ±8 ft lb).
CHECKING CLEARANCE ON ASSEMBLED DISK PACKS

1. Check must be carried out all around at
points placed at 120o to one another on
both disk packs to prevent mileacting
recording of values due to spider and sun
gear play.
NOTE: Should recorded clearance not
be as specified, disk packs
must be reformed to prescribed
value of 0.05 - 0.10 mm (0.0020
- 0.0039").
Figure 16

Page 31
AXLE REASSEMBLY
DETERMINING THICKNESS OF ADJUSTMENT SHIMS
Figure 17
1. Some dimensions must be recorded before starting reassembly of bevel pinion to determine
thickness of spacer to be fitted between inner (under head) pinion bearing and backing of relevant
seat in differential support.
2. Record dimension from ring gear axis to seat inner (under head) pinion bearing (that will be identified
as "A").
• Example: "A" = 290.6 mm.
3. A number "X" prefix by symbol " ±" is marked on bevel pinion face. This value is expressed in tenth of
millimeter, indicates deviation from theoretical distance from pinion under head to ring gear axis.
• Example: +1 = +0.1 mm.
4. Consequently, the true distance (identified as "B") will be: B = 321.7 ±deviation.
• Example: B = 231.7 + 0.1 = 231.8 mm.
5. Measure thickness of pinion head bearing and identify as "D."
• Example: "D" = 54.85 mm.
6. Compute thickness of shim "S" for proper axial position of bevel pinion: S = A - (B + D).
• Example: S = 290.6 - (231.8 + 54.85) = 3.95 mm.
7. Increase by 0.05 mm the computed thickness value to compensate subsequent bearing preload.
Round off to nearest tenth of millimeter to computed thickness value.
• Example: 4.02 rounded off = 4 mm.
3.88 rounded off = 3.9 mm.

Page 32
INNER OIL RECIRCULATION PIPING
Figure 18
1. Remove pipes (A and B), remove seals (C) from axle housing.
2. Check wear condition of pipes (A and B), replace with new if required.
3. Replace seals (C) with new.

Page 33
Figure 19
AXIAL POSITION OF BEVEL PINION

1. Press fit inner race of inner (under head) bearing (14) on pinion by using heating equipment or use of
proper installer.
2. Position shim (15), see "Determining Thickness of Adjustment Shims," in its seat and press fit outer
races of inner (under head) and outer bearings (13 and 14) of pinion.

Page 34
3. Fit impeller (16) on pinion along with shims (17) for bearing preload adjustment, then mount inner
race of pinion outer bearing (13).
NOTE: To facilitate proper preload computation, it is advisable to mount as many shims as
required to warrant a pinion end play and not a preload (that could be excessive) on
bearings.
4. Fit drive flange (9) on pinion (7), position specific reaction tool and tighten nut (6). Remove reaction
tool.
NOTE: Torque from 570 - 630 Nm (58 - 64 kg•m / 419 - 463 ft lb).
5. Check pinion end play using a dial gauge, then disassemble and change shims to eliminate all end
play and reach intended preload.
6. Reassembly components, check that proper preload of bearing corresponding to a revolving torque
(no seal installed).
NOTE: Revolving torque of 2 - 4 Nm (0.2 - 0.4 kg•m / 1.5 - 3.0 ft lb).
7. As the prescribed preload of bearings has been reached, remove drive flange (9) and fit lip seal (10)
into its proper seat.
8. Remount drive flange (9) and tighten to specified torque.
NOTE: Torque from 570 - 630 Nm (58 - 64 kg•m / 419 - 463 ft lb).
9. Position differential assembly with ring gear on support (11), insert ring nut (3), and temporarily adjust
back lash.
10. Mount caps (4), being careful not to invert position, secure support to differential with screws (5).
NOTE: Torque to 880 - 920 Nm (90 - 94 kg•m / 650 - 680 ft lb).
11. Check differential end play with a dial gauge.
12. Screw in a ring nut to have a notch aligned against slot of lockplate, and actuate opposite nut up to
eliminate end play.
NOTE: When end play is eliminated, set bearing preload by screwing in ring nut one more notch.
ADJUSTING BACKLASH
1. Position a dial gauge perpendicular to ring
gear (26) tooth, with pinion steady check
backlash.
• Standard backlash of bevel gear set:
0.30 - 0.41 mm (0.0118 - 0.0161").
• To obtain backlash within specified
range, rotate both ring nuts (3),
displacing them same number of
notches.
• Moving toward ring gear to pinion, if
backlash is too LARGE. Figure 20
• Moving away ring gear to pinion, if

backlash is too SMALL.

Page 35
ADJUSTING TOOTH CONTACT
1. Coat face of 7 or 8 teeth of bevel gear
lightly with red lead. Hold bevel gear by
hand to act as a brake, rotate pinion gear
forward and backward, then inspect
pattern left on teeth.
Correct Pattern
Drive Side.
Figure 21
Neutral Side.
Figure 22
Increase Pinion Distance
Drive Side.
Figure 23
Neutral Side.
Figure 24

Page 36
Decrease Pinion Distance
Drive Side.
Figure 25
Neutral Side.
Figure 26
NOTE: When adjusting bevel gear, do not change preload of bearing. Adjust by rotating both ring
nuts the same number of notches.
2. Fit spring pins (2) to lock differential ring nuts.
3. Make two lock notches on pinion nut collar (6).

Page 37
Page 38
SECURING DIFFERENTIAL TO AXLE HOUSING
Figure 27
1. Thoroughly clean mating surfaces, apply sealing compound and mount differential assembly on axle
housing, and secure with screws (4).
NOTE: Torque to 330 ±16.5 Nm (33.7 ±1.69 kg•m / 243.4 ±12.2 ft lb).
2. Install outer oil recirculation piping (2) with new seals (3), and secure with six screws (1).

Page 39
FINAL DRIVE
Figure 28
1. Reinstall wheel hub (7), first fit outer races of wheel inner and outer bearings (25 and 31), making
sure they rest against seats.

Page 40
2. Position inner race with roller cage of wheel inner side bearing (31) before fitting lip seal (31).
3. Install O-ring (8).
4. Install wheel inner bearing (31) into sleeve (27).
NOTE: Support wheel hub (7) during assembly stage to prevent damage to seal.
5. Lubricate seals (28 and 29) on piston (26), then insert at travel end on wheel hub sleeve (27).
6. Using heating equipment or proper installer, fit inner race of wheel outer bearing (25) on ring gear
support (22), then mount support (22) in ring gear (21) and secure with lock ring (23).
7. Mount ring gear (21) and support (22) unit onto sleeve (27).
8. Fit six rods (24) into seats on ring gear support (22).
9. Install spring retainer and compress spring (19) with retaining cup (20) onto pressure plate (18).
10. Mount pressure plate and spring assembly onto ring gear support (22).
11. Hand screw ring nut (17) onto wheel hub sleeve (27).
12. With a wrench, tighten ring nut (17) to the prescribed preload for wheel bearings and corresponding
to a revolving torque, checking alignment of lock plates (16).
NOTE: Revolving Torque: 15 - 30 Nm (1.5 - 3.1 kg•m / 11.1 - 22.1 ft lb).
NOTE: To prevent recording wrong torque values, it is advisable to seat bearing properly before
checking, by revolving wheel hub repeatedly.
13. Remove spring retainer compressing brake actuator return spring.
14. Insert lock plates (16) securing ring nut and install lock ring (15).
15. Arrange three side gear gears (37) in proper seats of side gear carrier (6).
NOTE: Two rows of needle rollers of same selection class must be used for replacement in each
single side gear pin.
16. Insert outer thrust washers (36), apply grease to pin lower portion (head end) and position the first
row of needle rollers, insert spacer and apply grease to upper portion of pin, then position second row
of needle rollers (35).
17. Position outer thrust washers (38) of side gear on side gear carrier and align holes.
18. Insert and force fit complete pins (33).
NOTE: Avoid any bump or knock that could cause rollers to fall.
19. Insert wheel shaft (14).
20. Insert thrust washer (39).
21. Mount disk carrier hub (11) onto wheel shaft (14).
22. Mount brake disks, alternating solid disks and lined disks. (See "Determining Space Available to
Form Brake Disk Pack").
NOTE: Insert a solid disk (outer teeth) facing pressure plate (12).
23. Insert sun gear (10) and secure with lock ring (9).
24. Mount side gear carrier (6) on side gear unit and secure onto wheel hub (7) with screws (5).
NOTE: Torque to: 70 ±3.5 Nm (7.1 ±0.4 kg•m / 51.6 ±2.6 ft lb).
25. Force fit wheel shaft backing plate (4).
26. Mount O-ring seal (3) on edge.

Page 41
27. Rotate and align pins (33) to allow mounting of cover (2), which also acts as a pin lock to prevent their
rotation.
28. Fit side final drive cover (2).
29. Apply sealing compound to screws (1) and secure cover (2).
DETERMINING SPACE AVAILABLE TO

FORM BRAKE DISK PACK
1. Record depth from seating surface of side
gear carrier on wheel hub to outer edge of
ring gear, identify value as "A."
2. Record depth from ring gear outer edge to
brake pressure plate, identify value as "B."
3. Subtract value "B" from value "A" and
identify as value "D."
• Example: A - B = D.
Figure 29
4. Record depth from disk reaction face to
outer edge of side gear carrier, identify
value as "C."
5. Add value "C" to value "D" to provide
space available to form brake disk pack.
• Example: C + D = X
Figure 30

Page 42
6. To form disk packs, compute thickness of
disk pack (solid disks + lined disks), it is
necessary to subtract clearance of 1 mm
(0.0394") for each brake disk plus the total
thickness of the lined disks from space
available for remaining clearance with solid
disks (outer teeth) of proper thickness with
a tolerance of ±0.25 mm (0.0098").
Figure 31

Page 43
PARKING BRAKE (S/N 1001 THRU 2000)
Figure 32

Page 44
DISASSEMBLY
1. Unlock right and left counternuts (1) of adjustment sleeve (2).
2. Remove nuts (3) retaining hydraulic cylinder (5) to bracket (4), then undo sleeve (2) and remove
cylinder (5).
3. Undo two screws (7) securing caliper to support, then remove brake caliper assembly (6).
4. Undo eight screws (8) and remove brake disk (9) from drive flange.
5. Remove split pin (10) from stem (14), unscrew spring reaction nut (11), then remove thrust washer
(13) and spring (12).
NOTE: In case of leaks, remove stem (14) to replace seals (15) seated in cylinder body (5).
REASSEMBLY
1. Reassembly hydraulic cylinder (5).
2. Mount brake disk (9) on drive flange and lock eight screws (8).
NOTE: Torque from 62 - 68 Nm (6.3 - 6.9 kg•m / 45 - 50 ft lb).
3. Mount caliper assembly (6) to support and lock two screws (7).
NOTE: Torque from 185 - 205 Nm (18.9 - 20.9 kg•m / 136.3 - 151.2 ft lb).
4. Mount hydraulic cylinder (5) on support (4) with lock washer and two nuts (3).
NOTE: Torque from 43 - 48.7 Nm (4.4 - 5.0 kg•m / 31.7 - 35.9 ft lb).
5. Connect linkage thru adjustment sleeve (2).
ADJUSTMENT
1. Apply pressure to cylinder (5) of 70 - 140 bar (1,015 - 2,030 psi), checking that stem (14) is at travel
end (about 65 mm {2.56"} of spring compression.
2. Actuate sleeve (2) to adjust disk (9) to pad clearance up to 0.25 mm (0.009") reach on each side.
NOTE: For fine adjustment of clearance on each side of pads it is necessary to undo counternut
(16) and actuate screw (17).
3. Release pressure and check that stem (14) return travel is about 40 mm (1.58").
4. Restore pressure and check that clearance and travel remain unchanged (repeating many times).
5. Lock counternuts (1 and 16) of pad adjustment screws (17) and sleeve (2).

Page 45
PARKING BRAKE (S/N 2001 AND UP)
NOTE: Refer to "Parking Brake (S0603000)" for S/N 2001 and Up.

Page 46
S0602190K
1REAR AXLE
(VOLVO SLA 12/W)
CAUTION!
REAR AXLE (VOLVO SLA 12/W)S0602190K


November 2002
Rear Axle (Volvo SLA 12/W) S0602190K

Page 1
TABLE OF CONTENTS
Outline..................................................................................................... 5
Drive Axle................................................................................................ 5
Axle Mount ....................................................................................... 5
Differential (Standard) ............................................................................. 8
Differential Operation ....................................................................... 8
Limited Slip Differential Cross Section (Option) ............................... 8
Parts List ............................................................................................... 11
Rear Axle Housing ......................................................................... 11
Rear Axle Differential ..................................................................... 12
Rear Axle Planetary Gear Set ....................................................... 14
Scheduled Maintenance............................................................................... 16
After First 250 Hours ............................................................................. 16
Every 150 hours .................................................................................... 17
Every 1,500 Hours ................................................................................ 17
Lubricant Specifications ........................................................................ 17
General Disassembly and Reassembly Instructions .................................... 18
General Instructions .............................................................................. 18
Assembling Leakproof Components ..................................................... 19
Axle Disassembly ......................................................................................... 19
Drain Oil ................................................................................................ 19
Final Drive ............................................................................................. 20
Overhauling Super Max Trac Assembly ................................................ 28
Checking Clearance on Assembled Disk Packs.................................... 28
Axle Reassembly.......................................................................................... 29
Determining Thickness of Adjustment Shims........................................ 29
Axial Position of Bevel Pinion ................................................................ 30
Adjusting Backlash................................................................................ 31
S0602190K Rear Axle (Volvo SLA 12/W)

Page 2
Adjusting Tooth Contact ........................................................................ 32
Correct Pattern............................................................................... 32
Increase Pinion Distance ............................................................... 32
Decrease Pinion Distance.............................................................. 33
Securing Differential to Axle Housing.................................................... 35
Final Drive ............................................................................................. 36
Determining Space Available to Form Brake Disk Pack........................ 38

Page 3
Page 4
GENERAL DESCRIPTION
OUTLINE
Rear Axle
Type Trunnion Mounting, Semifloating
Overall Reduction Ratio 24.685
STD. Max. Trac (Locking Ration: 30%)
Differential type
OPT. Super Max Trac (Limited Slip: 45%)
Max Static Load 28,500 kg (62,830 lb)
Max Output Torque 8,790 kg•m (63,580 ft lb)
Type Multi Wet Disk
Brake Torque 2,362 kg•m @ 80 Bar
(17,084 ft lb @ 1,160 psi)
Drive Flange 7C
DRIVE AXLE
The drive axle consists of the differential, final reduction gear assembly, wet type hydraulic disk brake unit,
and axle shafts to which wheels are attached.
The power from the drive unit is transmitted through the drive shafts to the front and rear drive axles. The
power is then transmitted to the differential where it is divided into the right and left axle shafts to the final
reduction gear assembly on each shaft end, thus driving the wheels.
The wet type hydraulic disk brake unit is installed in front of the final reduction gear assembly and serves
as a service brake.
Axle Mount
The front axle is bolted directly to the front frame.
The rear axle is supported by the trunnion method in which axle supports are installed across the rear axle
and bolted to the rear frame. Consequently, the rear axle is cradled up and down around the center line of
the differential according to the ground condition the loader travels. The trunnion-mounted drive axle helps
improve operator comfort because loaders with a trunnion-mounted drive axle jolt less than those with the
conventional cradle-supported drive axle, when they travel on bad ground conditions.

Page 5
SECTION A
AJS0641L
Figure 1 DRIVE AXLE ASSEMBLY

Page 6
Reference Reference
Number Number
1 Front Axle 6 Bushing
2 Rear Axle 7 Thrust Plate
3 Axle Support (Front) 8 Thrust Cap
4 Axle Support (Rear) 9 Thrust Washer
5 Packing
NOTE: 1) 28 kg•m (200 ft-lb) Threaded area: Loctite #262.

NOTE: 2) 140 kg•m (1010 ft lb).
NOTE: 3) 170 kg•m (1230 ft lb).
NOTE: 4) Inner surface: Grease (Assemble with chamfered surface toward axle.)
NOTE: 5) Assemble with lip pointing outward.
NOTE: 6) Assemble with groove pointing toward plate (7).
NOTE: 7) Apply grease and assemble.

Page 7
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.
Figure 2 DIFFERENTIAL GEAR OPERATION
Reference Reference
Number Number
1 Pinion Gear 5 Spider
2 Side Gear 6 Drive Pinion
3 Axle Shaft 7 Ring Gear
4 Differential Gear Case
Limited Slip Differential Cross Section (Option)

Figure 3, shows a cross-sectional view of the parts contained in the limited slip differential.

Page 8
Reference
Description
Number
1 Ring Gear
2 Bevel Pinion
3 Cross
4 Upper Thrust Ring
5 Outer Disk
6 Inner Disk
7 Cover
8 Clutch Disk
9 Side Gear
10 Lower Thrust Ring
Figure 3

Page 9
Page 10
PARTS LIST
Rear Axle Housing
Figure 4
Reference Reference
Number Number
1 Housing; Rear 4 Plug; Drain M27x2
2 Plug; Magnetic 5 O-ring
3 O-ring 6 Breather; Air

Page 11
Rear Axle Differential
Figure 5

Page 12
Reference Reference
Number Number
1 Carrier Assembly 28 Flange
2 Carrier; Rear 29 Cover
3 Cap 31 Holder
4 Bolt 32 Nut
6 Case Assembly 33 Bearing
7 Case-LH 34 Nut
8 Case-RH 36 Bolt
9 Bolt 37 Shim T = 0.1 mm
10 Washer; Plain Shim T = 0.3 mm
11 Set; Bevel Shim T = 0.5 mm
12 Pinion; Bevel Shim T = 1.0 mm
13 Gear; Bevel Ring 38 Spacer T = 20.500 mm
14 Nut Spacer T = 20.525 mm
15 Bearing Spacer T = 20.550 mm
16 Bearing Spacer T = 20.575 mm
17 Bearing 39 Shim T = 0.1 mm
18 Beam; Cross Shim T = 0.3 mm
20 Seal; Oil Shim T = 0.5 mm
21 Gear; Side 40 Washer
22 Pinion; Differential 41 Pin
23 Spider 42 Pin; Spring
24 Washer; Thrust 43 Pin; Split
25 Washer; Thrust 44 Bolt
26 Screw 45 Washer; Plain
27 Flange Assembly 46 Pin; Split

Page 13
Rear Axle Planetary Gear Set
Figure 6

Page 14
Reference Reference
Number Number
1 Drum Assembly - Hub. 27 Bolt
2 Drum; Hub 28 Bolt
3 Pin; Planetary 29 Ring; Retaining
4 Gear; Planetary 30 Ring; Retaining C
5 Spacer 31 Plate; Lock
6 Bearing; Needle 32 Plate
7 Washer; Thrust 33 Stud; Wheel
8 Washer; Thrust 34 Nut; Wheel
9 Plug 35 Washer; Thrust
10 O-ring 36 Drum
11 Shaft 37 Disk; Brake
12 Hub; Wheel 38 Spring; Return
13 Spindle Assembly-LH 39 Cover
Spindle Assembly-RH 40 Rod; Push
14 Spindle-LH 41 Plate
Spindle-RH 42 Piston
15 Seal 43 O-ring
16 Spacer 44 O-ring
19 Bolt 45 Bearing
20 Cover 46 Bearing; Tapper Roller
21 Gear; Sun 47 Seal; Oil
22 Gear; Ring 48 O-ring
23 Support 49 O-ring
24 Ring; Retaining 50 Disk
25 Nut; Adjusting 51 Plug
26 Breather; Oil
NOTE: No. of Brake Disks (Front): 4 EA

(Rear): 4 EA

Page 15
SCHEDULED MAINTENANCE
Figure 7
AFTER FIRST 250 HOURS

replace plug (3).

Page 16
EVERY 150 HOURS
Check oil in axle assembly as follows:
• With axle positioned horizontal, remove fill plug (1) and check oil level. Oil level should reach
edge of fill plug seat. Add oil as required.
• Check oil by rotating hub 90o (so "OIL LEVEL" writing is horizontal), remove plug (3) and check
oil. Oil should edge of fill plug seat. Add oil as required, replace plug (3).
EVERY 1,500 HOURS

replace plug (3).
LUBRICANT SPECIFICATIONS
For differential and final drive units:
• Oil specification: MOBIL INFILREX 33
80W90
• Corresponding to: SAE 90 or SAE 80W90 rating
NOTE: DOOSAN recommends oils with LIMITED-SLIP (LS) additives to prevent noise when
brakes are actuated.

Page 17
GENERAL DISASSEMBLY AND REASSEMBLY
INSTRUCTIONS
WARNING!
Never use gasoline, solvents, or other flammable fluids to clean components. Only use approved
commercial solvents that are nonflammable and nontoxic.
IMPORTANT
Use only genuine DOOSAN spare parts to warrant proper operations and prevent
interchangeability problems.
GENERAL INSTRUCTIONS
1. Thoroughly clean and dry axle before disassembly.
2. All components must be thoroughly cleaned and dried before reassembly. Dirt, chips, and foreign
material may cause failures.
3. All ducts and castings must be thoroughly cleaned and dried to remove dirt, chips, and foreign
material to prevent damage after reassembly.
4. Reassembly must be done in a clean shop, and must be as dust free as possible.
5. Make sure tools and equipment are at hand.
6. When reassembling DOOSAN strongly recommends to replace the following parts with new.
• Seal Rings.
• O-rings.
• Gaskets.
• Threaded rings with notched collar.
• Any component damaged during disassembly.
7. When mounting heat fitted components, make sure of their proper position and direction of assembly,
after they have cooled.
8. To heat bearings, use proper heating plates, piping, or suitable ovens.
NOTE: Never heat parts by using a torch. Oil bath, heated by a torch, maybe used to warm
components.
9. Lubricate all sections concerned when reassembling shafts, bearings, etc.
10. Lubricate O-rings before installing them in relevant seats to prevent kinking during assembly, such a
position would impair proper sealing.
11. Replace gears only in matched sets to make sure of proper tooth mating.

Page 18
ASSEMBLING LEAKPROOF COMPONENTS
1. Use of proper sealing compounds is recommended when assembling matched parts to be sealed
against fluid leakage (oil or water), and no sealing gasket is used.
2. Best results are reached, with said compounds, when matching surfaces are thoroughly cleaned,
degreased, and dried before spreading a uniform coat over contact area.
3. DOOSAN suggests to use the following compounds:
• Loctite Plastic Gasket
• Rhodorsil CAF 1
• Silastic 732 RTV
AXLE DISASSEMBLY
Figure 8
DRAIN OIL

Page 19
FINAL DRIVE
Figure 9

Page 20
WARNING!
Lift and handle all heavy components by using proper equipment. Make sure that assemblies or
components are lifted and held with the use of proper slings and hooks. Use specific lifting
eyes. Always make sure that people are out of the way when lifting.
1. Remove six cover mounting screws (1), then remove final drive cover (2).
NOTE: Cover (2) is provided with three threaded holes for puller screws.
3. Using a puller screw, remove axle shaft backing plate (4).
4. Provide suitable support for side gear carrier (6), then remove screws (5) fixing side gear carrier to
wheel hub (7), and pry side gear carrier (6) to separate from wheel hub (7).
5. Pull side gear carrier (6) out of wheel hub.
6. Remove lock ring (9) retaining sun gear (10), and remove sun gear from wheel shaft (14).
7. Remove disk carrier hub (11) along with thrust washer (12) resting against wheel hub sleeve.
8. Remove solid and lined brake disks (13).
9. Remove wheel shaft (14).
10. Remove lock ring (15) securing lock (16), then remove ring nut (17).

Page 21
Figure 10
Spring Retainer Installed

A Spring Retainer
17 Ring Nut
18 Pressure Plate
19 Return Spring
NOTE: Install a spring retainer (A), secured thru three threaded holes of disk pressure plate (18),
to compress return spring (19) and allow removal of ring nut (17).
11. Unlock and remove ring nut (17) from sleeve (27).
12. Remove pressure plate (18) along with brake return spring retainer (A).
13. Provide suitable support for wheel hub (7) and pull ring gear unit (21) and support (22) from hub.
14. Remove six rods (24) in seats on ring gear support (22).
15. Using a screwdriver, pry off lock ring (23) from ring gear (21).
16. Disassemble ring gear support (22) from ring gear (21).
NOTE: Should replacement of outer wheel bearing (25) inner race be mandatory, old part can be
removed by a proper puller, or by a remover that can be inserted in specific holes of ring
gear support (22).
17. Remove brake return spring retainer (A) and disassemble return spring (19), retaining cup (20), and
pressure plate (18).

Page 22
18. Using compressed air thru brake oil ducting, remove brake actuating piston (26) from wheel hub
sleeve (27).
19. Remove and replace with new two O-rings (28 and 29) in seats on brake actuating piston.
20. Remove complete wheel hub (7)
22. Pry off seal (30) from wheel hub (7), and remove inner race with roller cage of inner wheel bearing
(31).
23. Using a proper remover, push out outer races of inner and outer wheel bearings (25 and 30) from
wheel hub (7).
NOTE: Should sleeve (27) be damaged, it can be removed by undoing relevant screws (32). At
reassembly, smear proper sealing compound on axle case joining flange, then tighten
screws. Torque to 900 ±45 Nm (91.8 ±4.6 kg•m / 663.8 ±30 ft lb).
24. Mark side gear pins (33), various components and seats (34) for identification of original position at
reassembly.
25. Arrange side gear carrier (6) on wooden blocks and push out pins (33) with proper remover.
26. Pick up all needle rollers (35).
NOTE: It is important to keep matched needle rollers (35) and thrust washers (36) with relevant
pin (33), this is consequent to predetermined assembly tolerance limits.
27. Remove side gears (37) and relevant thrust washers (38).
NOTE: No gear can be removed before having released all of them.

Page 23
Page 24
Figure 11
1. Remove screws (1) retaining differential assembly, then remove differential assembly from axle case.

Page 25
Figure 12
2. Hammer out spring pins (2) locking slotted rings (3).

3. Mark caps (4) to match parts at reassembly.
4. Remove screws (5), caps (4), and slotted rings (3).
5. Remove differential case assembly from support (11).
6. Straighten locking notches on pinion nut collar (6), position reaction tool on drive flange to unlock nut
(6), release pinion nut, remove drive flange (9) from pinion shank along with washer (8).
7. Pry seal (10) from drive flange.

Page 26
8. Remove bevel pinion (7) from differential support (11), hammer pinion shank with a proper removal
tool.
NOTE: Be careful not to damage threads on pinion (7).
9. Pick up inner race of pinion shank bearing (13).
10. Remove outer races of outer and inner pinion bearings (13 and 14) from differential support (11), pick
up shims (15).
NOTE: Be careful not to loose shims (15) for pinion axial position adjustment, store in a safe place
for reassembly.
11. Remove spacer (16) with shims (17) for bearing preload adjustment, using a proper puller remove
inner race of pinion under head bearing (14).
NOTE: Be careful not to loose shims for bearing preload adjustment, store in a safe place for
reassembly.
12. Mark differential half cases (18 and 19) for reference at reassembly, then remove screws (19a) and
separate half cases (18 and 19).
13. Make a visual and dimensional check of wear on sun gears (21), side gears (20), thrust washers (22
and 23), friction disks (22a), backing disks (22), and spider (24).
14. Using a proper puller, remove bearings (25) from half cases (18 and 19).
15. Clamp ring gear (26) in a vise fitted with soft caps, then remove screws (27) securing ring gear (26) to
half case (18).
16. Fit inner races of differential bearings (25) on half cases (18 and 19).
NOTE: This operation must be carried out by heating equipment or use a proper installer.
17. Mount bevel ring gear (26) on half case (18), secure with screws (27).
NOTE: Torque to 480 ±24 Nm (48.9 ±2.5 kg•m / 354 ±17.7 ft lb).
18. Position differential components in their proper seats.

Page 27
OVERHAULING SUPER MAX TRAC
ASSEMBLY
1. Select backing disks (22) to reach, as
assembling is completed, prescribed
clearance of 0.05 - 0.10 mm (0.0020 -
0.0039") all around both disk packs.
NOTE: When packing friction and
backing disk, pay particular
care to position of first disk
(22a), it is molybdenum plated
on one side only. Disk (22a) is
in contact with sun gear (21),
and molybdenum plated side Figure 13
must face backing disk (22).
2. Join half cases (18 and 19) matching
reference marks made at disassembly.
3. Mount and secure case halves (18 and 19)
with screws (19a).
NOTE: Torque to 120 ±6 Nm
(12.2 ±0.61 kg•m /
88.5 ±4.4 ft lb).
CHECKING CLEARANCE ON ASSEMBLED

DISK PACKS
1. Check must be carried out all around at
points placed at 120o to one another on
both disk packs to prevent mileacting
recording of values due to spider and sun
gear play.
NOTE: Should recorded clearance not
be as specified, disk packs
must be reformed to prescribed
value of 0.05 - 0.10 mm (0.0020
- 0.0039"). Figure 14

Page 28
AXLE REASSEMBLY
DETERMINING THICKNESS OF ADJUSTMENT SHIMS
Figure 15
1. Some dimensions must be recorded before starting reassembly of bevel pinion to determine
thickness of spacer to be fitted between inner (under head) pinion bearing and backing of relevant
seat in differential support.
2. Record dimension from ring gear axis to seat inner (under head) pinion bearing (that will be identified
as "A").
• Example: "A" = 266.1 mm.
3. A number "X" prefix by symbol " ±" is marked on bevel pinion face. This value is expressed in tenth of
millimeter, indicates deviation from theoretical distance from pinion under head to ring gear axis.
• Example: +1 = +0.1 mm.
4. Consequently, the true distance (identified as "B") will be: B = 208 ±deviation.
• Example: B = 208 + 0.1 = 208.1 mm.
5. Measure thickness of pinion head bearing and identify as "D."
• Example: "D" = 54.15 mm.
6. Compute thickness of shim "S" for proper axial position of bevel pinion: S = A - (B + D).
• Example: S = 266.1 - (208.1 + 54.15) = 3.85 mm.
7. Increase by 0.05 mm the computed thickness value to compensate subsequent bearing preload.
Round off to nearest tenth of millimeter to computed thickness value.
• Example: 4.02 rounded off = 4 mm.
3.88 rounded off = 3.9 mm.

Page 29
Figure 16
AXIAL POSITION OF BEVEL PINION

1. Press fit inner race of inner (under head) bearing (14) on pinion by using heating equipment or use of
proper installer.
2. Position shim (15), see "Determining Thickness of Adjustment Shims," in its seat and press fit outer
races of inner (under head) and outer bearings (13 and 14) of pinion.

Page 30
3. Fit spacer (16) on pinion along with shims (17) for bearing preload adjustment, then mount inner race
of pinion outer bearing (13).
NOTE: To facilitate proper preload computation, it is advisable to mount as many shims as
required to warrant a pinion end play and not a preload (that could be excessive) on
bearings.
4. Fit drive flange (9) on pinion (7), position specific reaction tool and tighten nut (6). Remove reaction
tool.
5. Check pinion end play using a dial gauge, then disassemble and change shims to eliminate all end
play and reach intended preload.
6. Reassembly components, check that proper preload of bearing corresponding to a revolving torque
(no seal installed).
NOTE: Revolving torque of 2.0 - 4.0 Nm (0.2 - 0.4 kg•m / 1.5 - 3.0 ft lb).
7. As the prescribed preload of bearings has been reached, remove drive flange (9) and fit lip seal (10)
into its proper seat.
8. Remount drive flange (9) and tighten to specified torque.
9. Position differential assembly with ring gear on support (11), insert ring nut (3), and temporarily adjust
back lash.
10. Mount caps (4), being careful not to invert position, secure support to differential with screws (5).
11. Check differential end play with a dial gauge.
12. Screw in a ring nut to have a notch aligned against slot of lockplate, and actuate opposite nut up to
eliminate end play.
NOTE: When end play is eliminated, set bearing preload by screwing in ring nut one more notch.
ADJUSTING BACKLASH
1. Position a dial gauge perpendicular to ring
gear (26) tooth, with pinion steady check
backlash.
• Standard backlash of bevel gear set:
0.15 - 0.20 mm (0.0059 - 0.0079").
• To obtain backlash within specified
range, rotate both ring nuts (3),
displacing them same number of
notches.
• Moving toward ring gear to pinion, if
backlash is too LARGE. Figure 17
• Moving away ring gear to pinion, if

backlash is too SMALL.

Page 31
ADJUSTING TOOTH CONTACT
1. Coat face of 7 or 8 teeth of bevel gear
lightly with red lead. Hold bevel gear by
hand to act as a brake, rotate pinion gear
forward and backward, then inspect
pattern left on teeth.
Correct Pattern
Drive Side.
Figure 18
Neutral Side.
Figure 19
Increase Pinion Distance
Drive Side.
Figure 20
Neutral Side.
Figure 21

Page 32
Decrease Pinion Distance
Drive Side.
Figure 22
Neutral Side.
Figure 23
NOTE: When adjusting bevel gear, do not change preload of bearing. Adjust by rotating both ring
nuts the same number of notches.
2. Fit spring pins (2) to lock differential ring nuts.
3. Make two lock notches on pinion nut collar (6).

Page 33
Page 34
SECURING DIFFERENTIAL TO AXLE HOUSING
Figure 24
1. Thoroughly clean mating surfaces, apply sealing compound and mount differential assembly on axle
housing, and secure with screws (1).
NOTE: Torque to 330 ±16.5 Nm (33.7 ±1.69 kg•m / 243.4 ±12.2 ft lb)

Page 35
FINAL DRIVE
Figure 25
1. Reinstall wheel hub (7), first fit outer races of wheel inner and outer bearings (25 and 31), making
sure they rest against seats.

Page 36
2. Position inner race with roller cage of wheel inner side bearing (31) before fitting lip seal (31).
3. Install O-ring (8).
4. Install wheel inner bearing (31) into sleeve (27).
NOTE: Support wheel hub (7) during assembly stage to prevent damage to seal.
5. Lubricate seals (28 and 29) on piston (26), then insert at travel end on wheel hub sleeve (27).
6. Using heating equipment or proper installer, fit inner race of wheel outer bearing (25) on ring gear
support (22), then mount support (22) in ring gear (21) and secure with lock ring (23).
7. Mount ring gear (21) and support (22) unit onto sleeve (27).
8. Fit six rods (24) into seats on ring gear support (22).
9. Install spring retainer and compress spring (19) with retaining cup (20) onto pressure plate (18).
10. Mount pressure plate and spring assembly onto ring gear support (22).
11. Hand screw ring nut (17) onto wheel hub sleeve (27).
12. With a wrench, tighten ring nut (17) to the prescribed preload for wheel bearings and corresponding
to a revolving torque, checking alignment of lock plates (16).
NOTE: Revolving Torque: 15 - 30 Nm (1.5 - 3.1 kg•m / 11.1 - 22.1 ft lb).
NOTE: To prevent recording wrong torque values, it is advisable to seat bearing properly before
checking, by revolving wheel hub repeatedly.
13. Remove spring retainer compressing brake actuator return spring.
14. Insert lock plates (16) securing ring nut and install lock ring (15).
15. Arrange three side gear gears (37) in proper seats of side gear carrier (6).
NOTE: Two rows of needle rollers of same selection class must be used for replacement in each
single side gear pin.
16. Insert outer thrust washers (36), apply grease to pin lower portion (head end) and position the first
row of needle rollers, insert spacer and apply grease to upper portion of pin, then position second row
of needle rollers (35).
17. Position outer thrust washers (38) of side gear on side gear carrier and align holes.
18. Insert and force fit complete pins (33).
NOTE: Avoid any bump or knock that could cause rollers to fall.
19. Insert wheel shaft (14).
20. Insert thrust washer (39).
21. Mount disk carrier hub (11) onto wheel shaft (14).
22. Mount brake disks, alternating solid disks and lined disks. (See "Determining Space Available to
Form Brake Disk Pack").
NOTE: Insert a solid disk (outer teeth) facing pressure plate (12).
23. Insert sun gear (10) and secure with lock ring (9).
24. Mount side gear carrier (6) on side gear unit and secure onto wheel hub (7) with screws (5).
25. Force fit wheel shaft backing plate (4).
26. Mount O-ring seal (3) on edge.

Page 37
27. Rotate and align pins (33) to allow mounting of cover (2), which also acts as a pin lock to prevent their
rotation.
28. Fit side final drive cover (2).
29. Apply sealing compound to screws (1) and secure cover (2).
DETERMINING SPACE AVAILABLE TO

FORM BRAKE DISK PACK
1. Record depth from seating surface of side
gear carrier on wheel hub to outer edge of
ring gear, identify value as "A."
2. Record depth from ring gear outer edge to
brake pressure plate, identify value as "B."
3. Subtract value "B" from value "A" and
identify as value "D."
• Example: A - B = D
Figure 26
4. Record depth from disk reaction face to
outer edge of side gear carrier, identify
value as "C."
5. Add value "C" to value "D" to provide
space available to form brake disk pack.
• Example: C + D = X
Figure 27
6. To form disk packs, compute thickness of
disk pack (solid disks + lined disks), it is
necessary to subtract clearance of 1 mm
(0.0394") for each brake disk plus the total
thickness of the lined disks from space
available for remaining clearance with solid
disks (outer teeth) of proper thickness with
a tolerance of ±0.25 mm (0.0098").
Figure 28

Page 38
S0603000
R1
1PARKING BRAKE
CALIPER (VOLVO)
CAUTION!
PARKING BRAKE CALIPER (VOLVO)S0603000

Mega 200-III 1026 thru 1040, 1055 thru 1060, 1071 and Up
Mega 250-III 1037 thru 1051, 1067 thru 1086, 1132 and Up

August 2002
Parking Brake Caliper (Volvo) S0603000

Page 1
TABLE OF CONTENTS
Operation ................................................................................................ 3
Parking Brake Applied............................................................................. 4
Parking Brake Released.......................................................................... 4
Parts List ................................................................................................. 5
Special Tools and Materials............................................................................ 5
Lubricants and Sealants ......................................................................... 5
Troubleshooting, Testing and Adjustment....................................................... 6
Parking Brake System............................................................................. 6
Checking and Adjusting Parking Brake ................................................... 6
Measuring Pad Thickness ....................................................................... 6
Measuring Disk / Pad Clearance............................................................. 6
Measuring Procedure.............................................................................. 7
Adjustment .............................................................................................. 7
Releasing the Parking Brake in Emergency Case .................................. 8
Disassembly ................................................................................................... 9
General ................................................................................................... 9
Changing Brake Pads ............................................................................. 9
Work Sequence During Change of Brake Pads ...................................... 9
Cleaning and Inspection (Wear Limits and Tolerances) ............................... 11
Reassembly.................................................................................................. 13
S0603000 Parking Brake Caliper (Volvo)

Page 2
GENERAL DESCRIPTION
OPERATION
1. Parking brake is a dry disk caliper type and is installed on the front axle.
2. The force of the spring stack (3) inside the brake chamber is used to apply the brake mechanically; it
is released by hydraulic pressure.
3. If the park brake system pressure drops below the pressure required to compress the actuator spring,
the spring force will apply the parking brake even if the park brake switch is in the "OFF" position.
4. The pad and disk wear is compensated by a mechanical adjustment device.
5. Disk (1) is installed to the front axle input flange and rotates together with the input shaft.
Figure 1
Reference Reference
Number Number
1 Parking Brake Disk 3 Disk Spring Stack
2 Caliper

Page 3
PARKING BRAKE APPLIED
When the operator pushes the parking brake
switch to the "ON" position the solenoid valve is
de-energized and the hydraulic pressure from
the accumulator is cut off by the solenoid valve.
At the same time, the oil from brake chamber (8)
is drained to the hydraulic tank. Therefore, disk
spring stack (5) together with adjuster screw (6),
push rod (3) and pad (2) to move towards the
brake disk. Then brake pads (2) are pushed
against the disk and the parking brake is
applied.
Figure 2
PARKING BRAKE RELEASED
When the operator pushes the parking brake
switch to the off position the solenoid valve is
energized and the solenoid valve closes the
return port to tank and opens the port to the
accumulator.
At the same time, the oil from the accumulator
flows to the caliper oil chamber (8). The
hydraulic pressure overcomes the force of
spring stack (5) and pushes piston (4) together
with adjuster screw (6), push rod (3) and pad (2)
until stopped by thrust ring (9). Therefore the
parking brake is kept released.
Figure 3

Page 4
PARTS LIST
Figure 4
Reference Reference
Number Number
1 Caliper 5 Disk Spring Stack
2 Pad 6 Adjuster Screw
3 Push. Rod 7 Guide Pins
4 Piston 8 Oil Chamber
SPECIAL TOOLS AND MATERIALS

LUBRICANTS AND SEALANTS
Fuchs Renocal FN 745

Page 5
TROUBLESHOOTING, TESTING AND ADJUSTMENT
PARKING BRAKE SYSTEM
1. Upon initial installation the parking brake
has to be bled using bleed screw (2).
2. The tightening torque of bleed screw (2):
12+4 Nm. (9+3 ft lb).
Figure 5
CHECKING AND ADJUSTING PARKING BRAKE

• Measurement condition.
• Hydraulic pressure: Maximum set pressure.
Item Standard Value Permissible Value

Thickness of Pad 5.0 mm (0.1969 in) 2.0 mm (0.0787 in)
WARNING!
Block the tires securely.
MEASURING PAD THICKNESS

1. Turn the starter switch to the "ON" position. (Ensure the brake system is fully charged.)
2. Push the parking brake switch "OFF" to release the parking brake.
3. Measure the thickness of each pad (2).
A. When the starter switch is turned to "OFF," the parking brake is applied automatically.
B. Measure two pads.
C. If the thickness is not within the permissible value, both pads must be replaced as or set.
D. For details of pad replacement, see DISASSEMBLY AND ASSEMBLY.
MEASURING DISK / PAD CLEARANCE
Item Standard Value Permissible Value

Clearance Between Disk and 0.25 - 0.50 mm 1.0 mm
Pad (a + b) (0.0098 - 0.0197 in) (0.0394 in)

Page 6
MEASURING PROCEDURE
1. Push the parking brake switch "OFF" to
release parking brake.
2. Insert the thickness gauge between disk
(1) and pad (2), then measure the
clearance on both sides of the disk.
NOTE: The clearance value mentioned
above indicates the total value
of both sides (a + b).
Figure 6
ADJUSTMENT
NOTE: Upon initial installation and as a result of pad and disk wear, the brake must be adjusted
according to the following steps.
1. Turn the starter switch "ON," then push the parking brake switch "OFF" to release the parking brake.
* When the starter switch is turned to "OFF," the parking brake is applied automatically, so be careful
not to turn it "OFF."
2. Remove sheet cover (12, Figure 7).
3. Loosen lock nut (11, Figure 7), wrench size 24 mm.
4. Release disk spring stack (5, Figure 7) by screwing adjuster screw (7) clockwise with an allen wrench
until pads (3 and 4) contact the disk.
5. Turn adjuster screw (7, Figure 7) counterclockwise until the desired gap is reached.
Item Standard Value

Clearance 0.25 - 0.50 mm
Between Disk (0.0098 - 0.0197 in)
and Pad (a + b)
6. Secure adjuster screw (7, Figure 7) by tightening lock nut (11) with a tightening torque of 150+10 Nm
(111+7 ft lb).
NOTE: When replacing the pads always replace both pads as a set.
NOTE: After adjusting, measure the parking brake performance again and check that it is within
specification.

Page 7
Reference
Description
Number
1. Caliper
3, 4 Brake Pad
5 Spring Stack
6 Piston
7 Adjuster Screw
8 Push Rod
9 Thrust Ring
10 Oil Chamber
11 Lock Nut
12 Sheet Cover
RELEASING THE PARKING BRAKE IN Figure 7

EMERGENCY CASE
NOTE: If the parking brake does not
function due to a failure in the
electrical or hydraulic systems,
it can be manually released as
follows.
1. Remove sheet cover (12, Figure 7).
2. Loosen lock nut (11, Figure 7), wrench
size 24 mm.
3. Turn adjuster screw (7, Figure 7)
counterclockwise until the parking brake is
released using an allen wrench 8 mm.

Page 8
DISASSEMBLY
GENERAL
1. For safe braking characteristics, it is vital that the brake is kept in good working order. The brake
should therefore be checked at regular service intervals and worn parts must be replaced.
2. The rubber parts must be replaced after 2 years or when damaged.
3. Only original spare parts of the brake manufacturer may be used.
4. Repair and service work on the brake may only be carried out by trained personnel.
5. The brake design avoids the use of special tools; i.e. for repair and service work only standard tools
are necessary. The brake must be adjusted during the service intervals or if the vehicle looses grade
holding ability.
NOTE: If, during an emergency brake application, the vehicle is decelerated by the parking brake
only, the brake disk and the brake pads have to be inspected for damage.
CHANGING BRAKE PADS

1. Brake pads must be changed when the remaining lining thickness is 2.0 mm (0.0787 in) or when
brake linings are burned or glazed. Pads specified by the vehicle or brake manufacturer must be used
exclusively.
2. Guide surfaces or guide parts for the brake pads must be cleaned. Solvents containing mineral oil or
sharp edged tools must not be used.
3. The protection boot for the push rod must be checked to make sure it is in perfect condition.
4. Upon changing the brake pads the disk, too, has to be inspected with regard to wear.
5. If the brake is equipped with magnets, those have to be cleaned before the new pads are fitted.
WORK SEQUENCE DURING CHANGE OF BRAKE PADS

1. Remove sheet cover (20, Figure 11) respectively rubber cap (23).
2. Loosen lock nut (11, Figure 11), wrench size 24 mm.
3. Release the force of the disk spring stack by turning adjuster screw (7, Figure 11) counterclockwise,
using an allen key 8 mm. Alternative; Apply hydraulic pressure on the brake and turn the adjuster
screw counterclockwise.
4. Remove split pin (17, Figure 11) and unscrew castle nut (16), wrench size 24 mm.
5. Pull guide pin (2, Figure 11) out of the brake until brake pads (3 and 4) can be removed.
CAUTION!
The brake caliper (1, Figure 11) may rotate around the other guide pin.
6. Insert new brake pads (3 and 4, Figure 11) and push guide pin (2) back into position. Screw castle
nut (11) on the guide pin and secure with split pin (17) following work sequence according to Figure
25.
7. Adjust the brake.

Page 9
8. Close the brake with sheet cover (20, Figure 11) respectively rubber cap (23) following Figure 27 or
Figure 28.
Figure 8
Figure 9

Page 10
CLEANING AND INSPECTION (WEAR LIMITS AND
TOLERANCES)
For general cleaning and inspection procedures, refer to "General Maintenance Procedures" section.
Figure 10

Page 11
No Check Item Criteria Remedy
Wear of Brake Standard Size Tolerance Repair Limit
1 Pads (Thickness of 5.0 mm Replace
Friction Material) -- 2.0 mm (0.0787 in)
(0.1969 in)
Face Run Out of 0.050 mm
2 -- 0.150 mm (0.0059 in)
Disk (0.0020 in)
Thickness of plate
must be under
+0 Rebuild
Wear of Disk 11.50 mm
12.70 mm (0.4528 in)
3 (Thickness of Disk -0.10 mm
(0.50 in)
Plate) (0.0039 in) Less than
11.50 mm Replace
(0.4528 in)
Clearance
Between Pad and 0.3750 mm ±0.1250 mm 1.0 mm
4 Adjust
Disk (Total of Both (0.0148 in) (0.0049 in) (0.0394 in)
Sides)
Tightening Torque 14.2 - 15.7 kg•m
5
of Bolt (103 - 114 ft lb)
6
Tightening Torque 14 - 16 kg•m
7 Tighten
8
Tightening Torque 3 - 4 kg•m
9

Page 12
REASSEMBLY
Using Figure 11 to Figure 29 with the work sequences and notes, the assembly instruction shows in steps
the complete assembly of the brake. If the application of grease is required, FUCHS RENOCAL FN 745
has to be used for normal use (-50°C up to +120°C). For special use greases with a wider temperature
range contact your supplier. The disk brake is dismantled in reverse sequence.
Figure 11, shows the individual parts of a brake design with a protection device against dirt consisting of a
cover made of sheet material, an O-ring and the screws (22). Figure 12, shows a brake design with a
rubber cap as protection.
Figure 11
Figure 12
Reference Reference
Number Number
1 Brake Caliper 13 Sealing Ring
2 Guide Bolt 14 Securing Ring
3 and 4 Brake Pad 15 Protection Boot
5 Disk Spring Stack 16 Castle Nut
6 Piston 17 Split Pin
7 Adjuster Screw 20 Sheet Cover
8 Push Rod 21 O-ring
9 Thrust Ring 22 Screw
11 Lock Nut 23 Rubber Boot
12 Sealing Ring

Page 13
1. Insert sealing ring (12, Figure 13) into the
groove of brake caliper (1).
NOTE: The sealing ring has to be
mounted with the sealing lip
pointing towards the oil
chamber.
2. Grease the groove.
Figure 13
3. Insert sealing ring (13, Figure 14) in the
NOTE: The sealing ring has to be
mounted with the sealing lip
pointing towards the oil
chamber. see Figure 8
4. Grease the groove.
Figure 14
5. Push rod (8, Figure 15) has to be
assembled with piston (6) thus the groove.
See arrow is outside the piston.
Figure 15
6. Press piston (6, Figure 16) which is
assembled with push rod (8) into the brake
caliper.
NOTE: Grease the piston, because it
slides easier through sealing
ring (12) see Figure 13.
Figure 16

Page 14
7. Insert disk spring stack (5, Figure 17)
completely into piston (6). Do not change
the disk springs within the stack.
NOTE: The orientation of the installed
disk spring stack with 5 disk
springs has to be in accordance
with Figure 18. The orientation
of the installed spring stack with
6 disk spring has to be
according to Figure 19. The
installation or replacement of
the disk spring stack is only
allowed as a complete Figure 17
assembly.
8. Grease disk spring stack.
Figure 18
Figure 19

Page 15
9. Grease thrust ring (9, Figure 20) and
assemble it according to Figure 8; it has to
center the disk spring stack.
Figure 20
10. Insert sealing ring (14, Figure 21) in the
groove. See arrow of brake caliper (1).
Figure 21
11. Press protection boot (15, Figure 22) using
an assembly tool into its seat (see arrow)
in brake caliper (1). Push the bead of
protection boot (15) into the groove of
push rod (8).
NOTE: The rubber part must not be
destroyed and seat in caliper
has to be greased before
assembly.
Figure 22
12. Screw adjuster screw (7, Figure 23) using
an allen wrench 8 mm into piston (6).
Figure 23

Page 16
13. Screw lock nut (11, Figure 24), wrench
size 24 mm, on adjuster screw (7) until it
touches piston.
NOTE: The lock nut is tightened to a
tightening torque of 150 ±10
Nm (110 ±7 ft lb) after the
brake is installed in the vehicle
and the gap is adjusted.
Figure 24
14. The brake caliper is assembled with
bracket (not shown in Figure 25) using two
guide pins. Install first guide pin (2, Figure
25) by pushing it through guide hole in
brake caliper (1) and bracket from
actuation side (See Figure 25) Insert brake
pads (3 and 4). Assemble all the above
parts by pushing the second guide pin
through the guide hole in the caliper and
bracket and the abutment and guide
recesses of the brake pads. Install castle
nuts (16), wrench size 24 mm, tightening
torque 20 Nm (15 ft lb). Secure both castle
Figure 25
nuts with split pin (17).
15. Screw bleeder valve (18, Figure 26) into
threaded hole. See arrow in brake caliper
(1), wrench size 11 mm.
NOTE: The tightening torque for the
bleeder is 12 + 4 Nm (9 +
3 ft lb).
16. Fit dust cap (19, Figure 26) on bleeder
valve (18) after brake is bled.
Figure 26

Page 17
17. After brake is adjusted. brake caliper is
protected at operation side with a cover
against dirt. According to brake type, it can
be a cover from sheet material Figure 27
or a rubber cap Figure 28.
18. Insert O-ring (21, Figure 27) on its seat in
sheet cover (20) (See arrow and Figure
11).
19. Assemble sheet cover with screw (22,
Figure 27), wrench size 1.0 mm.
Figure 27
20. Fasten rubber cap (23, Figure 28) in
Figure 28
21. To avoid noise produced by rattling brake
pads, the pads are kept by magnets (25,
Figure 29) in their abutment areas of the
push rod and the brake caliper reaction
side. For installation see the following work
sequence.
22. Press magnet with the friction ring (See
arrow) in its seat in push rod (8, Figure
29).
23. Press magnet with the friction ring (26,
Figure 29) (See arrow, in its seat at the
brake caliper reaction side).
Figure 29
24. Insert O-ring (24, Figure 29) in the groove.
See arrow of push rod (8).
NOTE: The magnets must not be
damaged upon installation.
When installed the magnets are
not to jut out of the push rod or
the pad abutment area of the
brake caliper reaction side.

Page 18
S0605050K
1AIR CONDITIONER
CAUTION!
AIR CONDITIONER S0605050K

Mega 500-V 1001 thru 2000

December 2002
Air Conditioner S0605050K

Page 1
TABLE OF CONTENTS
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 ..................................................... 17
Refrigerant System Repairs ......................................................................... 19
Refrigerant Safe Handling Procedures ................................................. 19
Repair and Replacement Procedure..................................................... 20
Refrigerant Recovery ............................................................................ 22
Vacuuming Refrigerant System............................................................. 22
Leakage Check ..................................................................................... 24
Refrigerant Charging............................................................................. 24
Inspecting System for Leakage............................................................. 26
S0605050K Air Conditioner

Page 2
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 cabin. This
filter (1, Figure 2) must be cleaned out at 1
approximately every 500 hours and replaced
with a new one every 1,000 hours.
NOTE: In the event that the unit is
being operated in a dusty
environment, cleaning and
replacement must be
performed more frequently.
WARNING!
AJS0530L
All service and inspection of the
air-conditioning system must be Figure 2
performed with the starter switch in the
"O" (OFF) position.
NOTE: Refer to appropriate operation

and maintenance manual for
latest service intervals.

Page 3
REFRIGERANT CIRCULATION
4
7
3
HBOI020L
Figure 3
Reference Reference
Number Number
1 Evaporator 5 Compressor
2 Expansion Valve 6 Blower Fan
3 Condenser 7 Receiver Dryer
4 Condenser Fan

Page 4
Shading Temperature Refrigerant State
High High-pressure Gas
High High-pressure Liquid
Low Low-pressure Liquid
High High-pressure Gas/Liquid
Low Low-pressure Gas
• 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 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.

Page 5
CONTROL PANEL
OFF A/C
LO MID HI COOL WARM
HDA6047L
Figure 4
INPUT CONTROL OUTPUT

PANEL
DISPLAY
TEMPERATURE
SENSOR
LOW SPEED RELAY
OFF SW MID SPEED RELAY BLOWER

MOTOR
A / C SW
VENT SW HIGH SPEED RELAY
DEF. SW
HEAT SW A/C TEMP. CONTROL
ACTUATOR MIX DOOR
FRE SW CONTROL
REC SW PANEL VENT ACTUATOR VENT CONTROL
LOW SW
MID SW DEF. ACTUATOR FOOT / DEF.
HI SW
COOL SW INTAKE RECYCLE/FRESH
ACTUATOR AIR CONTROL
WARM SW
TEMPERATURE COMP. RELAY COMPRESSOR
CONTROL ACTUATOR
CONDENSER CONDENSER
FAN RELAY FAN
HDA6048L
Figure 5

Page 6
CONTROL SPECIFICATIONS
Control Item Control Switch Control Specifications

Temperature "COOL" Switch
MAX COOL
Control
"WARM" Switch 100%
50%
MAX HOT
0%
HDA6049L
Figure 6
Temperature control switch consists of a 24 step

variable selector. The display uses 7, Green / Red
two-color LED's to display the selected temperature.
Blower Fan "OFF" Switch
Speed Control
"LOW" Switch
"MID" Switch
HI RELAY
"HI" Switch
MID RELAY
LOW RELAY
OFF LOW MID HI
HDA6050L
Figure 7
Compressor Temperature Sensor

Control
COMP ON
COMP OFF
1.5 C 4.0 C
HDA6051L
Figure 8

Page 7
TEMPERATURE LEVEL CONTROL AND DISPLAY
Position
Step LED 1 LED 2 LED 3 LED 4 LED 5 LED 6 LED 7 Sensor Remark
Voltage
0 Green Green Green Green Green Green Green 4.50 V ±0.2 MAX. COOL
1 Green Green Green Green Green Green Green 4.33 V ±0.2
2 Green Green Green Green Green Green Green 4.15 V ±0.2
3 Red Green Green Green Green Green Green 3.98 V ±0.2
6 Red Red Green Green Green Green Green 3.46 V ±0.2
9 Red Red Red Green Green Green Green 2.93 V ±0.2
12 Red Red Red Red Green Green Green 2.41 V ±0.2
15 Red Red Red Red Red Green Green 1.89 V ±0.2
18 Red Red Red Red Red Red Green 1.37 V ±0.2
21 Red Red Red Red Red Red Red 0.85 V ±0.2
22 Red Red Red Red Red Red Red 0.67 V ±0.2
23 Red Red Red Red Red Red Red 0.50 V ±0.2 MAX. HOT

Page 8
AIR DISCHARGE ACCORDING TO PATH SELECTION
Vent
AJS0540L
Figure 9
Reference Reference
Number Number
1 Selector 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)

Page 9
Foot
4 5
1
6
7
3-1
3-2
2
AJS0551L
Figure 10
Reference Reference
Number Number
1 Selector 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)

Page 10
Defroster
4 5
6
7
3-1
3-2
2
AJS0561L
Figure 11
Reference Reference
Number Number
1 Selector 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)

Page 11
AIR-CONDITIONING SYSTEM CIRCUIT DIAGRAM
Figure 12

Page 12
Reference Reference
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

Page 13
TROUBLESHOOTING
Refrigerant Pressure Check
Figure 13
1. Open all doors and windows.

2. Install manifold gauge set.
3. Start engine and maintain engine speed at 1,800 - 2,000 rpm.
4. Check high / low-pressure of refrigerant.
High-pressure: 8 - 10 kg/cm2 (114 - 142 psi)

1
Low-pressure: Approximately 1 kg/cm2 (14 psi)
Possible Cause: Low Refrigerant Level
Step Inspection Item Remedy
Reassemble using correct
Yes
1 Check for traces of refrigerant oil. tightening torque.
No Go to next step.
Using a leak detection device or soapy water Yes Repair leaking component.
2 check for refrigerant leakage at all major No Recharge system to correct
components and joints. pressure.
High-pressure: Over 23 kg/cm2 (327 psi)

2
Low-pressure: Approximately 2.5 - 3 kg/cm2 (36 - 43 psi)
Possible Cause: Overcharge, Frost on condenser
Check for condenser pin damage or Yes Clean, repair or replace condenser.
1
contamination. No Refrigerant overcharge.

Page 14
High-pressure: Approximately 20 - 25 kg/cm2 (284 - 356 psi)
3
Low-pressure: Approximately 2.5 - 3.5 kg/cm2 (36 - 50 psi)
Possible Cause: Air in system.
1. Recover any remaining refrigerant.
2. Vacuum out system.
3. Recharge system.
NOTE: If the system has been exposed to the air for a long period of time, replace the receiver
dryer.
4 High-pressure: Over 6 kg/cm2 (85 psi)

Low-pressure: Approximately 760 mmHg (Negative Pressure)
Possible Cause: Refrigerant does not circulate
1. Connect manifold gauge and start engine.
2. Turn on air conditioner. Moisture in system, replace
Yes
receiver dryer.
3. Set blower switch to HIGH position.
4. Turn air conditioner "OFF" and wait 10
1 minutes.
Contaminated system, replace
5. Recheck high / low-pressure readings. expansion valve.
No
High-pressure: 13 - 19 kg/cm2 (185 - 270 psi) (Replace evaporator core
assembly.)
Low-pressure: 1.5 - 3.3 kg/cm2 (21 - 47 psi)
5 High-pressure: Over 6 - 18 kg/cm2 (85 - 256 psi)

Low-pressure: 500 mmHg (Negative Pressure) - Dial indicator needle unstable.
Possible Cause: Moisture in system has iced up the expansion valve.
NOTE: When the absorbed moisture freezes the pressure readings may look normal. Careful
readings must be made to determine whether pressure is in normal range.
1. Recover any remaining refrigerant.
2. Vacuum out system.
3. Recharge system.
NOTE: If the system has been exposed to the air for a long period of time, replace the receiver
dryer.

Page 15
High-pressure: Over 22 - 23 kg/cm2 (313 - 327 psi)
6
Low-pressure: 2.5 kg/cm2 (36 psi)
Possible Cause: Refrigerant pressure problem due to defective expansion valve or temperature sensor.
Inspect whether the temperature sensor is Yes Replace expansion valve.
1
installed properly. No Exchange duct sensor.
High-pressure: Over 7 - 11 kg/cm2 (100 - 156 psi)

7
Low-pressure: 4 - 6 kg/cm2 (57 - 85 psi)
Possible Cause: Low refrigerant pressure due to poor compressor compression
Inspect and replace compressor if necessary.

Page 16
WEIGHT OF R134A GAS USED IN MACHINES
Model Weight of Gas

Mega 130 850 ±20 grams (30 ±0.7 oz)
Mega 160 850 ±20 grams (30 ±0.7 oz)
Mega 200-III 850 ±20 grams (30 ±0.7 oz)
Mega 200-V 850 ±20 grams (30 ±0.7 oz)
Mega 250-III 850 ±20 grams (30 ±0.7 oz)
Mega 250-V (Tier I) 850 ±20 grams (30 ±0.7 oz)
Mega 250-V (Tier II) 850 ±20 grams (30 ±0.7 oz)
Mega 300-III 950 ±20 grams (33 ±0.7 oz)
Mega 300-V (Tier I) 850 ±20 grams (30 ±0.7 oz)
Mega 300-V (Tier II) 850 ±20 grams (30 ±0.7 oz)
Mega 300-V 850 ±20 grams (30 ±0.7 oz)
Mega 400-III 950 ±20 grams (33 ±0.7 oz)
Mega 400-III PLUS 850 ±20 grams (30 ±0.7 oz)
Mega 400-V 850 ±20 grams (30 ±0.7 oz)
Mega 500-V 850 ±20 grams (30 ±0.7 oz)
Solar 130-III 950 ±20 grams (33 ±0.7 oz)
Solar 130LC-V 850 ±20 grams (30 ±0.7 oz)
Solar 130W-III 950 ±20 grams (33 ±0.7 oz)
Solar 130W-V 850 ±20 grams (30 ±0.7 oz)
Solar 140W-V 850 ±20 grams (30 ±0.7 oz)
Solar 160W-V 850 ±20 grams (30 ±0.7 oz)
Solar 180W-V 850 ±20 grams (30 ±0.7 oz)
Solar 200W-V 850 ±20 grams (30 ±0.7 oz)
Solar 210W-V 850 ±20 grams (30 ±0.7 oz)
Solar 220LC-III 950 ±20 grams (33 ±0.7 oz)
Solar 220LL 850 ±20 grams (30 ±0.7 oz)
Solar 225NLC-V 850 ±20 grams (30 ±0.7 oz)
Solar 225LL 850 ±20 grams (30 ±0.7 oz.)

Page 17
Model Weight of Gas
Solar 290LL 850 ±20 grams (30 ±0.7 oz)
Solar 300LL 850 ±20 grams (30 ±0.7 oz)
Solar 55 750 ±20 grams (26 ±0.7 oz)
Solar 55-V PLUS 750 ±20 grams (26 ±0.7 oz)
Solar 55W-V PLUS 750 ±20 grams (26 ±0.7 oz)
Solar 75-V 750 ±20 grams (26 ±0.7 oz)

Page 18
REFRIGERANT SYSTEM REPAIRS
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 must 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.
REFRIGERANT SAFE HANDLING PROCEDURES
UNION NUT
TORQUE WRENCH
CORRECT WRONG
WRONG
WRONG
CORRECT
O - RING POSITION
CAP & PLUG CORRECT WRONG WRONG
HDA6066L
Figure 14
The following procedures must 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 must 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.

Page 19
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.
REPAIR AND REPLACEMENT PROCEDURE

1. Work Procedure.
A. Before repairing or replacing any refrigerant components first, return all refrigerant oil to the
compressor and perform recovery procedures.
2. Operating Condition.
A. Run engine at maximum engine speed.
B. Select "HI" blower fan speed and select A/C switch to "ON."
C. Set the temperature control switch for maximum cooling and leave running for approximately 20
minutes.
NOTE: The manifold gauge dial pointer can vary depending on the outdoor temperatures.

Page 20
INSTALL REPAIR TOOL
RECOVER REFRIGERANT
REPAIR / REPLACE DEFECTIVE PARTS
VACUUM SYSTEM (OVER 5 MINUTES)
CHECK SYSTEM FOR AIR LEAKAGE REPAIR
VACUUM SYSTEM (OVER 20 MINUTES)
CHARGE SYSTEM (APPROXIMATELY 100 g)
CHECK SYSTEM FOR REFRIGERANT LEAKAGE
CHARGE SYSTEM TO PROPER LEVEL

(Standard Capacity less Initial Charge)
CHECK SYSTEM FOR REFRIGERANT LEAKAGE
CHECK FOR PROPER REFRIGERANT LEVEL
RUN SYSTEM
RECOVER REFRIGERANT IN CHARGING HOSE
REMOVE REPAIR TOOLS

HDA6067L
Figure 15

Page 21
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
1. Attach the manifold gauges and the

refrigerant recovery unit to the refrigerant 5
lines as shown. HDA6067L
Figure 16
NOTE: Be careful not to switch the
connections for the low and
high-pressure valves.
2. Open the high-pressure valve slowly to release the refrigerant to the recovery unit.
NOTE: Open the valve slowly, while checking to see that refrigerant is not leaking out.
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).
VACUUMING REFRIGERANT SYSTEM
Reference 2 3
Description
Number 1 4
1 To Compressor
2 Low-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.

Page 22
2. Check system for vacuum leak.
Allow system to sit for 10 minutes and
check whether the system is holding the
pressure. If the pressure has dropped, it
must be repaired before proceeding to the
next step.
3. Vacuuming Procedure.
If the system is holding the pressure and it
has not changed for 10 minutes, vacuum
out the system for an additional 20
minutes.
Figure 18
A. Turn on the vacuum pump and slowly
open both valves.
B. Allow vacuum pump to run for
additional 20 minutes until the
low-pressure gauge dial reads
approximately 750 mmHg.
C. Close both valves and stop the
vacuum pump.
4. Installation of Refrigerant Container.
Reference
Description
Number
1 Handle
2 Hose Connection
3 Mounting Disk
A. Before mounting valve on the

container, make sure the handle is in
the counterclockwise most position,
with the puncture pin retracted and
the mounting disk is in the raised Figure 19
position.
B. Attach the manifold gauge center
hose to the valve assembly.
C. Turn the disk in the clockwise direction and securely mount valve onto refrigerant container.
D. Turn the valve handle in the clockwise direction and puncture the container seal with the pin.
E. Once the can has been punctured, turn the handle in the counterclockwise direction so the
refrigerant can flow into the manifold gauge center hose. At this time, do not open the low and
high-pressure valves of the manifold gauge.
F. Press the manifold gauge low side valve to eliminate the trapped air in the hose.

Page 23
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.
3. Using a refrigerant leak detector or soapy
water check each joint for leakage.
Reference
Description
Number
Refrigerant Leak
1
Detection Device
4. If a leak is detected, check for O-ring

damage or correct tightening torque and
replace or repair as necessary.
5. If no leaks are detected, proceed with the
charging process. Figure 20
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
4 From Receiver
5 Refrigerant Supply
Container
2. Charge the system by opening the manifold 5

gauge low side valve. HDA6072L
Figure 21
Initial charge amount: 100 g (3.5 ounces).

Page 24
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.
Gauge Dial Standard Reading
High Side Gauge 13 - 20 kg/cm2

(185 - 285 psi)
Low Side Gauge 1.5 - 3.5 kg/cm2

(21 - 50 psi)
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.
5. Close low-pressure side valve.

6. Shut off engine and close refrigerant supply container adapter valve. Disconnect manifold gauge
hoses from vehicle.

Page 25
INSPECTING SYSTEM FOR LEAKAGE
After completing charging procedures, clean all
joints and connections with a clean dry cloth.
Using a refrigerant leak detecting device or
soapy water, inspect system for leaks starting
from the high-pressure side.
NOTE: When the refrigerant circulation
has been stopped the
high-pressure will start to
decrease and the low-pressure
will start to increase until they
are equalized. Starting the
inspection from the high side
will result in a accurate test. Figure 22
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.

Page 26
S0607090K
R1
1TRANSMISSION AND
TORQUE CONVERTER
(ZF 4WG-210)
CAUTION!
TRANSMISSION AND TORQUE CONVERTER (ZF 4WG-210)S0607090K


April 2004
Transmission and Torque Converter S0607090K

(ZF 4WG-210) Page 1
TABLE OF CONTENTS
Drive Train Description ................................................................................... 6

Transmission and Torque Converter............................................................... 8
Powershift Transmission.......................................................................... 9
Transmission Control............................................................................... 9
Schedule of Measuring Points and Connection 4 WG-210................... 11
Oil Circuit Diagram 4WG-210 Forward 1st Speed ................................ 13
Transmission Electrical Components ........................................................... 16
TCU (Transmission Control Unit) .......................................................... 17
Transmission Control Valve ................................................................... 18
Transmission Oil Temperature Sensor .................................................. 18
Engine Pickup Sensor........................................................................... 19
Central Gear Pickup Sensor ................................................................. 19
Turbine Pickup Sensor .......................................................................... 19
Output Speed Sensor............................................................................ 20
Shift Lever Switch (DW-3) ..................................................................... 20
Auto Selector Switch ............................................................................. 22
Display .................................................................................................. 22
Transmission Faults Codes .......................................................................... 23
Fault Display.......................................................................................... 23
CAN - Message..................................................................................... 23
Description of Fault Codes.................................................................... 23
Abbreviations ........................................................................................ 24
Definition of Operation Modes............................................................... 24
Normal ........................................................................................... 24
Substitute Clutch Control ............................................................... 24
Limp-home ..................................................................................... 24
Transmission Shut Down ............................................................... 24
TCU Shut Down ............................................................................. 24
Table of Fault Codes ............................................................................. 25
Measurement of Resistance at Actuator/sensors and Cable ................ 25
S0607090K Transmission and Torque Converter

Page 2 (ZF 4WG-210)
Actuator.......................................................................................... 25
Cable.............................................................................................. 25
Transmission Electrical Circuits.................................................................... 26
Transmission Controller Circuit ............................................................. 26
Traveling Circuits ................................................................................... 28
Neutral ........................................................................................... 28
Forward First Gear ......................................................................... 29
Forward Second Gear.................................................................... 30
Forward Third Gear........................................................................ 31
Forward Fourth Gear ..................................................................... 32
Reverse First Gear......................................................................... 33
Reverse Second Gear.................................................................... 34
Reverse Third Gear........................................................................ 35
Kick-down.............................................................................................. 36
Overview ........................................................................................ 36
Kick-down: Forward Second Gear to Forward First Gear
(Auto Selector Switch "O"- Manual Mode) ..................................... 38
Kick-down (Auto Selector Switch "I" - Auto Mode) ......................... 40
Transmission Cutoff............................................................................... 41
LIS (Load Isolation System) - Option .................................................... 43
Installation View (S/N 1001 thru 2000)......................................................... 46
Inner Section ......................................................................................... 46
Front View ............................................................................................. 47
Front View with Disk Brake ................................................................... 48
Side View .............................................................................................. 49
Side View with Disk Brake..................................................................... 50
Rear View.............................................................................................. 51
Rear View with Disk Brake .................................................................... 52
Installation View (S/N 2001 thru 3000, 3001 and Up) .................................. 53
Inner Section ......................................................................................... 53
Front View ............................................................................................. 54
Front View with Disk Brake ................................................................... 55
Side View .............................................................................................. 56

(ZF 4WG-210) Page 3
Side View with Disk Brake..................................................................... 57
Rear View.............................................................................................. 58
Rear View with Disk Brake .................................................................... 59
Special Tools ................................................................................................ 60
Gearshift System................................................................................... 60
Engine Connection................................................................................ 62
Pressure Oil Pump ................................................................................ 63
Gearbox Housing .................................................................................. 64
Input ...................................................................................................... 66
Coupling ................................................................................................ 67
Output ................................................................................................... 73
Power Take-off ...................................................................................... 74
Hydraulic Control Unit (HSG-94) .................................................................. 75
Disassembly.......................................................................................... 77
Reassembly .......................................................................................... 80
Transmission Disassembly ........................................................................... 86
Hydraulic Control Unit (HSG-94) and Duct plate................................... 86
Engine Connection - Converter............................................................. 87
Hydraulic Pump..................................................................................... 89
Converter Back Pressure Valve ............................................................ 90
Remove Output, Input and Clutches ..................................................... 91
Disassemble Clutch - KV and KR ......................................................... 96
Disassemble Clutch - K1, K2 and K3 .................................................... 99
Disassemble Clutch - K4..................................................................... 101
Disassemble Drive Shaft ..................................................................... 102
Transmission Reassembly.......................................................................... 104
Install Oil Tube..................................................................................... 104
Reassemble Clutch - KV and KR ........................................................ 106
Reassemble Clutch - K1, K2 and K3................................................... 112
Reassemble Clutch - K4 ..................................................................... 119
Preassemble Drive Shaft .................................................................... 126
Preassemble and Install Output .......................................................... 127
Install Preassembled Drive Shaft and Clutches .................................. 129

Page 4 (ZF 4WG-210)
Install Pump Shaft (Power Take-off) .................................................... 132
Install Output Flanges ......................................................................... 134
Converter Back Pressure Valve .......................................................... 135
Oil Feed Housing - Transmission Pump .............................................. 135
Engine Connection - Converter........................................................... 137
Converter Safety Valve........................................................................ 140
Mount Duct Plate and Hydraulic Control Unit...................................... 140
Install Plugs and Oil Level Tube .......................................................... 141
Speed Sensor and Inductive Transmitters .......................................... 142

(ZF 4WG-210) Page 5
DRIVE TRAIN DESCRIPTION
Figure 1, shows layout of drive train assemblies. The engine (1, Figure 1) drives a torque converter (2),
which drives a power shift transmission (3). Two output shafts extend out of the transmission. Each output
shaft has a drive shaft attached to it. Front drive shaft (4) drives a final drive shaft (6) that drives the front
differential (7).
A parking brake (8, Figure 1) is mounted on the transmission output shaft. The front differential is enclosed
in the front axle housing (9). Each end of the front axle housing contains reduction gearing (10). Each end
of the front axle housing also contains a service brake (11). Rear drive shaft (5) drives the rear differential
(12). The rear differential is enclosed in the rear axle housing (13). Each end of the rear axle housing
contains reduction gearing (10). Each end of the rear axle housing also contains a service brake (11).
10 11 10 11
9
8
2 3
4 6
13
12 5
BZS0050L
Figure 1

Page 6 (ZF 4WG-210)
Reference Reference
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

(ZF 4WG-210) Page 7
TRANSMISSION AND TORQUE CONVERTER
The machine contains a powershift transmission that has four forward speeds and three speeds in reverse.
Gear changes are made by an electrohydraulic control valve that is mounted on transmission. Moving gear
select lever in cabin, generates an electrical signal that is transmitted to the control valve. The control valve
contains proportional valves that direct pressurized fluid to various clutches that control the forward and
reverse gears.
Item Mega 300-V

Serial Number 1001 thru 2000 2001 thru 3000, 3001 and Up
Model 4WG 210 (Full Auto)
Type 3-Element, 1-Stage, Single-phase,
E/G mounted with flexible plate
Oil Cooler Water-cooled (multiplate) and Air-cooled
Torque Charging Pump 105 liters/min (28 U.S. gal.) @ 2,000 rpm
Converter Hydraulic Pump
1:1
PTO
T/C Size ø 340 mm (13.39 in)
Stall Ratio 2,813 3.06
Safety Relief 11 Bar (160 psi)
Type Full Power Shift, Counter shaft
Speeds 4 Forward / 3 Reverse
Ratio F: 3.745 / 2.089 / 1.072 / 0.636 F: 4.152 / 2.089 / 1.072 / 0.636
Transmission R: 3.551 / 1.981 / 1.017 R: 3.937 / 1.981 / 1.017
Power Shift Control
16 - 18 Bar (230 - 260 psi)
Pressure
Shift Control Electric Shift with Proportional Valve
Oil Capacity 38 liters (10 U.S. gal)
Dry Weight 470 kg (1,036 lb)
Output Front 7C Mechanics
Flange Rear 7C Mechanics

Page 8 (ZF 4WG-210)
POWERSHIFT TRANSMISSION
The multispeed reversing transmission in countershaft design is power shiftable by hydraulically actuated
multidisk clutches.
All gears are constantly meshing and carried on antifriction bearings.
The gear wheels, bearings and clutches are cooled and lubricated with oil.
The 4-speed reversing transmission is equipped with 6 multidisk clutches.
At the shifting, the actual plate pack is compressed by a piston, movable in axial direction, which is
pressurized by pressure oil.
A compression spring takes over the pushing back of the piston, thus the release of the plate pack. As to
the layout of the transmission and the specifications of the closed clutches in the single speeds, See
“Schedule of Measuring Points and Connection 4 WG-210” on page -11. and “Oil Circuit Diagram
4WG-210 Forward 1st Speed” on page 13.
TRANSMISSION CONTROL
Transmission control, See “Schedule of Measuring Points and Connection 4 WG-210” on page -11.,
Electrohydraulic unit on page -12 and “Oil Circuit Diagram 4WG-210 Forward 1st Speed” on page 13.
The transmission pump, necessary for the oil supply of the converter, and for the transmission control, is
sitting in the transmission on the engine dependent input shaft.
The feed rate of the pump is Q = 105 l/min at nEngine = 2000 min-1.
This pump is sucking the oil via the coarse filter out of the oil sump and delivers it via the ZF fine filter - the
filters is fitted externally from the transmission - to the main pressure valve.
ZF fine filter
Filtration ratio according to ISO 4572: β30 ≥ 75 β15 = 25 β10 = 5.0
Filter surface at least: 2 x 6,700 cm2 = 13,400 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. Y6). follow-on slide
and vibration damper.
The control pressure of 9 bar (130 psi) for the actuation of the follow-on slides is created by the pressure
reducing valve. The pressure oil [16 +2 bar (230 +30 psi)] is directed via the follow-on slide to the
respective clutch.
Due to the direct proportional selection with separated pressure modulation for each clutch, the pressure
to the clutches, which are engaged in the gear change, will be controlled. In this way, a hydraulic
intersection of the clutches to be engaged and disengaged becomes possible. This is creating
spontaneous shifts 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 condition (full and part load, traction, overrun inclusive consideration of load cycles during
the shifting).

(ZF 4WG-210) Page 9
The main pressure valve is limiting the max. control pressure to 16 +2 bar (230 +30 psi) and releases the
main stream to the converter and lubricating circuit.
In the inlet to the converter, a converter safety valve is installed which protects the converter from high
internal pressure (opening pressure 11 bar (160 psi)).
Within the converter, the oil serves to transmit the power according to the well-known hydrodynamic
principle.
To avoid cavitation, the converter must be always completely filled with oil.
This is achieved by a converter pressure backup valve, rear mounted to the converter, with an opening
pressure of at least 5 bar (70 psi).
The oil, escaping out of the converter, is directed to a heat exchanger.
From the heat exchanger, the oil is directed to the transmission and there to the lubricating oil circuit, so
that all lubricating points are supplied with cooled oil.
The allocation of the pressure regulators to the single speeds can be seen on the “Schedule of Measuring
Points and Connection 4 WG-210” on page 11 and “Oil Circuit Diagram 4WG-210 Forward 1st Speed” on
page 13.

Page 10 (ZF 4WG-210)
SCHEDULE OF MEASURING POINTS AND CONNECTION 4 WG-210
The marked positions (e.g. 53) correspond with the positions on the “Oil Circuit Diagram 4WG-210
Forward 1st Speed” on page 13.
The measurements have to be carried out at hot transmission (about 80° - 95°C).
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 (50 psi) M14 x 1.5
53 Clutch Forward 16 +2 bar (230 +30 psi) KV M10 x 1 B
55 Clutch Reverse 16 +2 bar (230 +30 psi) KR M10 x 1 E
56 Clutch Reverse 16 +2 bar (230 +30 psi) K1 M10 x 1 D
57 Clutch Reverse 16 +2 bar (230 +30 psi) K2 M10 x 1 A
58 Clutch Reverse 16 +2 bar (230 +30 psi) K3 M10 x 1 C
60 Clutch Reverse 16 +2 bar (230 +30 psi) K4 M10 x 1 F
63 Converter Exit Temperature 100°C, Short-time
M14 x 1.5
120°C
65 System Pressure 16 +2 bar (230 +30 psi) M10 x 1 K
Measuring Points for Delivery Rates
15 Connection to the Heat Exchanger 1 5/16"-12 UNF-2B
16 Connection from the Heat Exchanger 1 5/16"-12 UNF-2B
Inductive Transmitter 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

(ZF 4WG-210) Page 11
Figure 2

OIL CIRCUIT DIAGRAM 4WG-210 FORWARD 1ST SPEED
The marked positions (e.g. 53) correspond with the positions on “Schedule of Measuring Points and
Connection 4 WG-210” on page 11.
Reference
Positions
Number
WT Heat Changer
WGV Converter Back Pressure Valve 3.50 bar (50 psi)
WSV Converter Relief Valve 9 bar (130 psi)
HDV System Pressure Valve 16 +2 bar (230 +30 psi)
RV-9 Pressure Reducing Valve 9 bar (130 psi)
NFS Follow-on Slide
D Oscillation Damper
B Orifice
P1 Proportional Valve - Clutch K4
P2 Proportional Valve - Clutch KR
P5 Proportional Valve - Clutch KV
Y1 - Y6 Pressure Regulator
TEMP Temperature Sensor
Figure 3

LEGEND:
= System Pressure
= Controlled Clutch Pressure
= Pilot Pressure
= Converter Inlet Pressure

= Converter Exit Pressure
= Lubrication
= Return Flow Into The Sump
AMS1110L
Figure 4

TRANSMISSION ELECTRICAL COMPONENTS
AMS0870L
Figure 5

Reference Reference
Number Number
1 Transmission Controller 11 Transmission Cutoff Switch
2 Transmission Control Valve 12 Transmission Cutoff Pressure
3 Transmission Oil Temperature Switch
Sensor 13 Downshift Switch
4 Engine Pickup Sensor 14 Safety Starter Switch
5 Central Gear Pickup Sensor 15 Fuse Box
6 Turbine Pickup Sensor 16 Parking Brake Switch
7 Output Speed Sensor 17 Control Unit
8 Shift Lever Switch 18 Starter Controller
9 Auto Selector Switch 19 Speedometer
10 Display
TCU (TRANSMISSION CONTROL UNIT)

1. Sending a control signal transmitted from
the shift lever to the control valve,
generates a speed.
2. At the auto mode, transmits the appreciate
signals to the control valves according to
the load and engine rpm.
3. Detecting a fault, controls various clutches.
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 ±1.9 ohm at 20°C
AJS0210L
• Pressure: 0.8 - 8.3 kg/cm2 Figure 7
(11.4 - 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
TRANSMISSION OIL TEMPERATURE

SENSOR
1. Detecting a oil temperature of transmission
and send a control signal to transmission
oil temperature gauge.
2. Specification
• Resistance
216 ±30 Ohm (at 60°C)
81.2 ±10 Ohm (at 90°C)
AJS0220L
36.5 ±3.5 Ohm (at 120°C) Figure 8
18.7 ±2.1 Ohm (at 150°C)

ENGINE PICKUP SENSOR
1. Detect a revolution of gear array in engine
side.
2. Specification
• Resistance: 1050Ω ± 10% (at 20°C)
• Fasten torque: 3.06 kg•m (22 ft lb)
• Gap: 0.5 + 0.3 mm
(0.0197 +0.0118 in)
• Output: 4 Pulse/Rev. AJS0230L
Figure 9
CENTRAL GEAR PICKUP SENSOR
1. Detect a revolution of central gear array
2. Specification
• Resistance: 1050Ω ±10% (at 20°C)
• Gap: 0.5 + 0.3 mm
(0.0197 +0.0118 in)
• Output: 91 Pulse/Rev.
AJS0240L
Figure 10
TURBINE PICKUP SENSOR
1. Detect a revolution of gear array in turbine
side.
2. Specification
• Resistance: 1050Ω ± 10% (at 20°C)
• Gap: 0.5 + 0.3 mm
(0.0197 +0.0118 in)
• Output: 59 Pulse/Rev. AJS0250L
Figure 11

OUTPUT SPEED SENSOR
3(+)
1. Detect a revolution of gear array in
transmission output side. 2(SIG)
1(-)
2. Specification
• Voltage Supply: 20 V - 32 V
• Operation Frequency: 2 Hz - 5 KHz
• Fasten torque (M8): 2.35 kg•m
(17 ft lb)
1.5 40
• Gap: 0.5 + 0.3 mm AJS0260L
(0.0197 +0.0118 in)
Figure 12
• Output: 60 Pulse/Rev.
SHIFT LEVER SWITCH (DW-3)

1. Forward, Reverse and Shift F
• F: Forward
• N: Neutral
N KD
• R: Reverse
• 1,2,3,4: Shift Step SHIFT SWITCH
* Forward shift range: 1 - 4 LEVER LOCK KEY
R (N/D)
* Reverse shift range: 1 - 3
AJS0270L
2. Kick-down (Down Shift) Switch Figure 13
• KD: Kick-down Switch
3. Lever Lock Key
• N: Neutral (The lever is not moved.)
• D: Driving (The lever is released.)
4. Switch Circuit
B A AD3 (B3)
1 2 G B AD2 (B2)
1 2 L X1
C AD1 (B1)
1 2 V
D AD7 (KD)
R A ED1 (+/VP)
2 Gr
1 D AD6 (N)
3 2
1
3 Y B AD4 (F) X2
2
1
3 P C AD5 (R)
AJS0280L
Figure 14

5. Terminal Position and Color
TERMINAL COLOR
(AD6) GREY
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
GEAR FORWARD REVERSE NEUTRAL KICK

TERMINAL 1 2 3 4 1 2 3 4 1 2 3 4 DOWN
ED1 VP
AD1 B1
AD2 B2
AD3 B3
AD4 V
AD5 R
AD6 AS
AD7 KD
AJS0300L
Figure 16

AUTO SELECTOR SWITCH
1. This is an auto/manual selector switch.
2. When the switch is in the "I" - (Auto)
position, the gear shifting will take place
automatically to be selected by the A
operator, according to the load and to the
A
vehicle speed.
3. Automatic shifting takes place between
gears.
B
• Forward: 2nd - 3rd - 4th
HLB2007L
• Reverse: 2nd - 3rd Figure 17
4. When the switch is in the "0" - (Manual)
position, the shifting is returned to the
manual mode and the control signal shifts
the transmission to gear selected by the
operator.
DISPLAY
Fault codes are given in a separate section "Transmission Faults Codes."

TRANSMISSION FAULTS CODES
The transmission has a monitoring system that indicates when a malfunction is occurring.
FAULT DISPLAY left right

h f e d character character
If a fault is detected, the display shows a
spanner symbol (g) for a fault. The display
shows the fault code, if the gear selector is in S
neutral.
T
If more than one fault is detected, each fault O
code is shown for about 1 second.
P
CAN - MESSAGE
a b c g
The TCU sends the fault code of a detected fault (special symbols a-h) HBOE630L
in the specified CAN - message, while the fault
is active. Figure 18
If more than one fault is detected, the fault code

scrolls.
DESCRIPTION OF FAULT CODES
First Number Meaning of Number

1 Hex Digital Input Signal
2 Hex Analog Input Signal
3 Hex Speed Signal
4 Hex Can Signal Error
7 Hex Analog Current Output Signal
9 Hex Digital Output Signal
A Hex Digital Output Signal
B Hex Transmission Fault, Clutch Error
C Hex Logical Fault
D Hex Power Supply
E Hex High Speed Signal
F Hex General Fault

ABBREVIATIONS
Throughout this section the following abbreviations are used to indicate various conditions.
Abbreviations
O.C. Open Circuit
S.C. Short Circuit
OP-Mode OPeration Mode
TCU Transmission Control Unit
ABS Anti Blocking System
ASR Anti Slipping Regulation
EEC Electronic Engine Controller
PTO Power Take Off
CCO Clutch Cut Off
DEFINITION OF OPERATION MODES
Normal
There is no failure detected in transmission system or failure has no or slight effects on transmission
control. TCU will work without or in special cases with little limitations. (see following table)
Substitute Clutch Control

TCU cannot change gears or direction under control of normal clutch modulation. TCU uses substitute
strategy for clutch control. All modulations are only time controlled. (Comparable with EST 25)
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.
Transmission Shut Down

TCU has detected a severe failure that disables control of the transmission. TCU will shut off the solenoid
valves for the clutches and also the common power supply (VPS1). Transmission shifts to Neutral. The
park brake will operate normally, also the other functions which use ADM 1 to ADM 8. The operator has to
slow down the vehicle. The transmission will stay in neutral.
TCU Shut Down

TCU has detected a severe failure that disables control of system. TCU will shut off all solenoid valves and
also both common power supplies (VPS1, VPS2). The park brake will engage, also all functions are
disabled which use ADM 1 to ADM 8. The transmission will stay in neutral.

TABLE OF FAULT CODES
Fault codes are given in a separate section "Transmission Faults Codes."
MEASUREMENT OF RESISTANCE AT ACTUATOR/SENSORS AND CABLE
Actuator
open circuit:R12 ≈ R1G ≈ R2G ≈ ∞
1
short cut to ground:R12 ≈ R;R1G ≈ 0, R2G ≈ R or
R1G ≈ R, R2G ≈ 0(for S.C. to ground, G is
R
connected to vehicle ground)
short cut to battery:R12 ≈ R;R1G ≈ 0, R2G ≈ R or
R1G ≈ R, R2G ≈ 0(for S.C. to battery, G is 2
G
connected to battery voltage).
HBOE640I
Figure 19
Cable
UBat
open circuit:
R12 ≈ R1P ≈ R1C ≈ R2P ≈ R2C ≈ ∞
P (power supply)
short cut to ground: TCU

Actuator /
R12 ≈ 0;R1C ≈ R2C ≈ 0,R1P ≈ R2P ≈ ∞
1 2
Sensor
short cut to battery: C (chassis)
R12 ≈ 0,R1C ≈ R2C ≈ ∞,R1P ≈ R2P ≈ 0

Gnd
HBOE650I
Figure 20

TRANSMISSION ELECTRICAL CIRCUITS
TRANSMISSION CONTROLLER CIRCUIT
AMS0880L
Figure 21

Reference Reference
Number Number
1 Transmission Controller 9 Down Shift Switch
2 Transmission Selector Switch 10 Safety Start Relay
3 Transmission Control Valve 11 Output Speed Sensor
4 Fuse Box 12 Speed Pickup
6 Transmission Cutoff Selector 16 Parking Brake Switch
Switch 17 Control Unit
7 Transmission Cutoff Pressure 18 Starter Controller
Switch
8 Display
The transmission proportioning solenoid valves are shown here as (Y1 thru Y6, Figure 21).

TRAVELING CIRCUITS
Neutral
AMS0890L
Figure 22
Reference Reference
Number Number
1 Transmission Controller 10 Safety Start Relay
2 Transmission Selector Switch 11 Output Speed Sensor
3 Transmission Control Valve 12 Speed Pickup
4 Fuse Box 15 Speedometer
5 Auto Selector Switch 16 Parking Brake Switch
8 Display 17 Control Unit
9 Down Shift Switch 18 Starter Controller
When all transmission solenoid valves are de-energized (OFF) the transmission is in "NEUTRAL."

Forward First Gear
AMS0900L
Figure 23
Reference Reference
Number Number
Transmission solenoid valves (Y3 and Y5, Figure 23) are energized when in forward first gear.

Forward Second Gear
AMS0910L
Figure 24
Reference Reference
Number Number
Transmission solenoid valves (Y5 and Y6, Figure 24) are energized when in forward second gear.

Forward Third Gear
AMS0920L
Figure 25
Reference Reference
Number Number
Transmission solenoid valves (Y4 and Y5, Figure 25) are energized when in forward third gear.

Forward Fourth Gear
AMS0930L
Figure 26
Reference Reference
Number Number
Transmission solenoid valves (Y2 and Y4, Figure 26) are energized when in forward fourth gear.

Reverse First Gear
AMS0940L
Figure 27
Reference Reference
Number Number
Transmission solenoid valves (Y2 and Y3, Figure 27) are energized when in reverse first gear.

Reverse Second Gear
AMS0950L
Figure 28
Reference Reference
Number Number
Transmission solenoid valves (Y2 and Y6, Figure 28) are energized when in reverse second gear.

Reverse Third Gear
AMS0960L
Figure 29
Reference Reference
Number Number
Transmission solenoid valves (Y2 and Y4, Figure 29) are energized when in reverse third gear.

KICK-DOWN
Overview
1. There are two kick-down switches shown
Figure 30, and it is possible for operators
to select either one of them according to
the condition.
2. If the kick-down switch is depressed while
the machine moving, downshifting takes
place automatically.
As a result, faster digging and moving is
possible. When in the manual mode the
kick-down can only be activated. AJS0400L
Figure 30
3. If a change in travel direction takes place
or the downshift switch is depressed a
second time, the kick-down function is
automatically released.

Kick-down: Forward Second Gear to Forward First Gear
(Auto Selector Switch "O"- Manual Mode)
AMS1070L
Figure 31
Reference Reference
Number Number
1 Transmission Controller 7 Transmission Cutoff Pressure
2 Transmission Selector Switch Switch
3 Transmission Control Switch 8 Display
4 Fuse Box 9 Down Shift Switch
5 Auto Selector Switch 11 Output Speed Sensor
6 Transmission Cutoff Selector 12 Speed Pickup
Switch 15 Speedometer
16 Parking Brake Switch

With the auto selector switch (Figure 32) is in
the "O" and the forward second gear is selected,
if either downshift switch (Figure 30) is
activated, a pulse is sent to the "22"
transmission controller. This signal energizes
solenoid valves, (Y3 and Y5), which shifts the
transmission to the forward first gear. When
A
A
either switch (Figure 30) is selected a second
time, the transmission pulse signal of the "22"
terminal is interrupted and solenoid valve, Y5 B
and Y6, are energized and the transmission
returns to the forward second gear.
HLB2007L
Figure 32

Kick-down (Auto Selector Switch "I" - Auto Mode)
AMS1080L
Figure 33
Reference Reference
Number Number
1 Transmission Controller 7 Transmission Cutoff Pressure
2 Transmission Selector Switch Switch
3 Transmission Control Switch 8 Display
4 Fuse Box 9 Down Shift Switch
5 Auto Selector Switch 11 Output Speed Sensor
6 Transmission Cutoff Selector 12 Speed Pickup
Switch 15 Speedometer
16 Parking Brake Switch

When the auto selector switch (Figure 33) 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 kick-down switch (Figure 30) 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 kick-down switch (Figure 30) 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.
TRANSMISSION CUTOFF
When the brake pedal is depressed while
transmission cutoff switch (Figure 34) is in the
"I" position, the transmission cutoff pressure
switch turns "ON" and current is supplied to the
"66" terminal of the transmission controller.
All current being supplied to the transmission
O
solenoid valves (Y1 thru Y6) is cutoff and the
transmission is in "NEUTRAL."
I
NOTE: To protect transmission,
transmission cutoff switch does
not function in third and fourth HA3O2018
gears. Figure 34
CAUTION!
When the machine is traveling or working in the place of inclination, the transmission cutoff
switch (Figure 34) must be placed in position 'O' for the purse of using engine braking and the
normal braking function at the same time.

AMS0980L
Figure 35
Reference Reference
Number Number
1 Transmission Controller 9 Down Shift Switch
2 Transmission Selector Switch 10 Safety Start Relay
3 Transmission Control Switch 11 Output Speed Sensor
4 Fuse Box 12 Speed Pickup
6 Transmission Cutoff Selector 16 Parking Brake Switch
Switch 17 Control Unit
7 Transmission Cutoff Pressure 18 Starter Controller
Switch
8 Display

LIS (LOAD ISOLATION SYSTEM) - OPTION
Excessive bucket pitching is drastically reduced
and good flotation is maintained for minimum
operator fatigue and maximum productivity.
LIS is useful for sites where frequent cycles of
loading and carry are needed or rough terrain.
O
When the LIS switch is "I" and the vehicle speed
is above 8 km/h (4.97 MPH), the LIS solenoids
valves (14) are energized and the LIS system is I
"ON."
When the LIS switch is "I" and the vehicle speed
is below 6 km/h (3.73 MPH) the LIS solenoids HA0O2026
valves (14) are de-energized and the LIS Figure 36
system is "OFF."
NOTE: If the LIS switch is in the "O" position, despite the vehicle speed the LIS solenoid valves
(14) de-energized and the LIS system is not operating.

AMS0970L
Figure 37
Reference Reference
Number Number
1 Transmission Controller 11 Output Speed Sensor
2 Shift Lever Switch 12 Speed Pickup (3)
4 Fuse Box 1 13 LIS (Load Isolation System)
5 Auto Selector Switch Switch (Option)
8 Display 14 LIS Solenoid Valve
9 Down Shift Switch 15 Speedometer
10 Safety Start Relay 16 Parking Brake Switch
19 Fuse Box 2

INSTALLATION VIEW (S/N 1001 THRU 2000)
INNER SECTION
Figure 38
Reference Reference
Number Number
1 Clutch Shaft "KR" 9 Transmission Pump
2 Power Take-off; Coaxial; 10 Input Flange - Input
Engine-dependent Through Universal Shaft
3 Clutch Shaft "KV" 11 Converter
4 Clutch Shaft "K2" 12 Input Transmitter for Engine
5 Clutch Shaft "K3" Speed
6 Output Flange - Rear 13 Clutch Shaft "K4"
7 Output Flange - Converter 14 Converter Relief Valve
Side 15 Clutch Shaft "K1"
8 Output Shaft

FRONT VIEW
Figure 39
Reference Reference
Number Number
1 Lifting Lugs 5 Oil Drain Plug with Magnetic
2 Drive Flange - Input Through Insert M38x1.5
Universal Shaft 6 output Flange - Converter Side
3 Transmission Suspension 7 Attachment Possibility for
Bores M20 Emergency
4 Model Identification Plate 8 Attachment Possibility for
Emergency Steering Pump

FRONT VIEW WITH DISK BRAKE
Figure 40
Reference Reference
Number Number
1 Lifting Lugs 5 Model Identification Plate
2 Drive Flange - Input Through 6 output Flange - Converter Side
Universal Shaft 7 Oil Drain Plug with Magnetic
3 Transmission Suspension Insert M38x1.5
Bores M20 8 Attachment Possibility for Oil
4 Attachment Possibility for Filter Pipe with Oil Dipstick
Emergency Steering Pump (Converter Side)

SIDE VIEW
Figure 41
Reference Reference
Number Number
1 Drive Flange - Input Through 7 Box Filter (Fine Filter)
Universal Shaft 8 Oil Fill Pipe with Oil Dipstick
2 Cover 9 Output Flange - Rear
3 Converter Bell Housing 10 Oil Drain Plug with Magnetic
4 Breather Insert M38x1.5
5 Transmission - Case Cover 11 Output Flange - Converter Side
6 Filter Head with Alarm Switch 12 Transmission Case

SIDE VIEW WITH DISK BRAKE
Figure 42
Reference Reference
Number Number
1 Drive Flange - Input Through 7 Box Filter (Fine Filter)
Universal Shaft 8 Disk Brake (Parking Brake)
2 Cover 9 Output Flange with Disk Brake -
3 Converter Bell Housing Rear
4 Breather 10 Oil Drain Plug with Magnetic
5 Transmission - Case Cover Insert M38x1.5
6 Filter Head with Alarm Switch 11 Output Flange - Converter Side
12 Transmission Case

REAR VIEW
Figure 43
Reference Reference
Number Number
1 Lifting Lugs 7 Output Flange - Rear
2 Power Take-off; Coaxial; 8 Box Filter (Fine Filter)
Engine-dependent 9 Filter Head with Connection for
3 Electrohydraulic Control Alarm Switch
4 Port-return Line M26x1.5 10 Port-system Pressure M16x1.5
(Option-e.g. from Parking Brake) ((Option-e.g. to Parking Brake
5 Oil Filter Pipe with Oil Dipstick Valve)
6 Transmission Suspension Bores
M20

REAR VIEW WITH DISK BRAKE
Figure 44
Reference Reference
Number Number
1 Lifting Lugs 7 Attachment Possibility for Oil Fill
2 Power Take-off; Coaxial; Pipe with Oil Dipstick (Rear)
Engine-dependent 8 X Filter (Fine Filter)
3 Electrohydraulic Control 9 Filter Head with Connection for
4 Port Return Line M26x1.5 Alarm Switch
(Option, e.g. from Parking 10 Port-system Pressure M16x1.5
Brake) ((Option-e.g. to Parking Brake
5 Disk Brake Valve)
M20

INSTALLATION VIEW (S/N 2001 THRU 3000, 3001 AND
UP)
INNER SECTION
Figure 45
Reference Reference
Number Number
1 Clutch Shaft "KR" 9 Transmission Pump
2 Power Take-off; Coaxial; 10 Flexible Plate
Engine-dependent 11 Converter
3 Clutch Shaft "KV" 12 Input Transmitter for Engine
4 Clutch Shaft "K2" Speed
5 Clutch Shaft "K3" 13 Clutch Shaft "K4"
6 Output Flange - Rear 14 Converter Relief Valve
7 Output Flange - Converter 15 Clutch Shaft "K1"
Side
8 Output Shaft

FRONT VIEW
Figure 46
Reference Reference
Number Number
1 Lifting Lugs 6 Output Flange - Converter Side
2 Flexible Plate 7 Oil Drain Plug with Magnetic
4 Attachment Possibility for Fill Pipe with Oil Dipstick
Emergency Steering Pump 9 Oil Fill Pipe with Oil Dipstick
5 Model Identification Plate

FRONT VIEW WITH DISK BRAKE
Figure 47
Reference Reference
Number Number
1 Lifting Lugs 6 output Flange - Converter Side
2 Flexible Plate 7 Oil Drain Plug with Magnetic
4 Attachment Possibility for Fill Pipe with Oil Dipstick
Emergency Steering Pump (Converter Side)
5 Model Identification Plate

SIDE VIEW
Figure 48
Reference Reference
Number Number
1 Flexible Plate 7 Box Filter (Fine Filter)
2 Converter 8 Oil Fill Pipe with Oil Dipstick
3 Converter Bell Housing 9 Output Flange - Rear
5 Transmission - Case Cover Insert M38x1.5
6 Filter Head with Alarm Switch 11 Output Flange - Converter Side

SIDE VIEW WITH DISK BRAKE
Figure 49
Reference Reference
Number Number
1 Flexible Plate 8 Disk Brake (Parking Brake)
2 Converter 9 Output Flange with Disk Brake -
3 Converter Bell Housing Rear
Insert M38x1.5
5 Transmission - Case Cover
11 Output Flange - Converter Side
6 Filter Head with Alarm Switch
7 Box Filter (Fine Filter)

REAR VIEW
Figure 50
Reference Reference
Number Number
1 Lifting Lugs 7 Output Flange - Rear
2 Power Take-off; Coaxial; 8 Box Filter (Fine Filter)
Engine-dependent 9 Filter Head with Connection for
3 Electrohydraulic Control Alarm Switch
4 Port-return Line M26x1.5 10 Port-system Pressure M16x1.5
(Option-e.g. from Parking Brake) ((Option-e.g. to Parking Brake
5 Oil Fill Pipe with Oil Dipstick Valve)
M20

REAR VIEW WITH DISK BRAKE
Figure 51
Reference Reference
Number Number
1 Lifting Lugs 6 Attachment Possibility for Oil Fill
2 Power Take-off; Coaxial; Pipe with Oil Dipstick (Rear)
Engine-dependent 7 Output Flange with Disk Brake
3 Electrohydraulic Control (Rear)
4 Port Return Line M26x1.5 8 X Filter (Fine Filter)
(Option, e.g. from Parking 9 Filter Head with Connection for
Brake) Alarm Switch
5 Transmission Suspension Bores 10 Port-system Pressure M16x1.5
M20 (Option-e.g. to Parking Brake
Valve)

SPECIAL TOOLS
GEARSHIFT SYSTEM
Figure 52

Figure 53

ENGINE CONNECTION
Figure 54

PRESSURE OIL PUMP
Figure 55

GEARBOX HOUSING
Figure 56

Figure 57

INPUT
Figure 58

COUPLING
Figure 59

Figure 60

Figure 61

Figure 62

Figure 63

Figure 64

OUTPUT
Figure 65

POWER TAKE-OFF
Figure 66

HYDRAULIC CONTROL UNIT (HSG-94)
Figure 67, shows a sectional view of the HSG-94.
IMPORTANT
Different versions in relation to the position of cable harness are possible.
In this connection, pay attention to the Specifications of the Vehicle Manufacturer.
Figure 67

Section A - A
Figure 68
Section B - B
Figure 69

DISASSEMBLY
1. Figure 70, shows complete control unit.
Figure 70
2. Mark the installation position of different
covers, the housing and the cable harness
with the valve housing.
Figure 71
3. Loosen socket head screws.
4. Separate duct plate, 1st gasket,
intermediate plate and 2nd gasket from the
valve housing.
(S) Box spanner (Torx TX-27) - 5873 042
002
Figure 72
5. Remove retaining clip.
Figure 73

7. Separate cover from housing and cable
harness.
(S) Box spanner (Torx TX - 27) - 5873 042
002
Figure 74
8. Disassemble opposite cover.
9. Disconnect pressure regulator and remove
cable harness.
Figure 75
10. Loosen socket head screws, remove fixing
plate and pressure regulators (3x).
002
Figure 76
11. Loosen two socket head screws and locate
housing provisionally, using adjusting
screws. (Housing is spring loaded). Then
loosen remaining socket and screws.
002
(S) Adjusting screws - 5870 204 036
Figure 77

12. Separate housing from valve housing by
loosening adjusting screws uniformly.
Figure 78
13. Remove components (Figure 79).
14. Remove opposite pressure regulators,
housing and components accordingly
(Figure 80).
Figure 79
Figure 80

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 upward until contact
is obtained. Figure 81
NOTE: Installation position, see

arrows.
1. Figure 82, shows the following
components:
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 82
Compression Spring)
2. Install components according to Figure 82.

NOTE: Preload compression spring of
the follow on slides and locate
spool provisionally using
cylindrical pins Ø 5.0 mm
(0.1969 in) (assembly aid), See
Figure 83.
Figure 83

3. Install two adjusting screws.
4. Assemble gasket (1, Figure 84) and
housing cover (Figure 84). Position
housing cover uniformly, using adjusting
screws, until contact is obtained and
remove cylindrical pins (assembly aid)
again (Figure 85).
NOTE: Pay attention to different
housing covers.
NOTE: Install recess Ø 15.0 mm
(0.5906 in) (2, Figure 84),
facing spring of pressure Figure 84
reducing valve.
Figure 85
5. Fasten housing cover using socket head
screws.
NOTE: Torque limit 0.56 kg•m (4 ft lb).
002
Figure 86

6. Install pressure regulators and secure
using fixing plates and socket head
screws.
NOTE: Install fixing plate, with claw
facing downward. Pay attention
to radial installation position of
pressure regulators, see Figure
87.
002
Figure 87
7. Preassemble opposite side.
A. Figure 88, shows the following
components:
Reference
Description
Number
1 Main Pressure Valve
(1x Spool and
Compression Spring.)
2 Follow On Slide (3x
Spool and
Compression Spring)
Figure 88
3 Vibration Damper (3x
Spool and
Compression Spring)
B. Install components according to

Figure 88.
C. Preload compression springs of the
follow on slides and locate spool
provisionally using cylindrical pins Ø
5 mm (0.1969 in) (assembly aid).
See arrows.
D. Install two adjusting screws.
E. Assemble gasket (1, Figure 89) and
housing cover, and position them
uniformly against shoulder, using
adjusting screws. Figure 89
housing covers, install the
recess Ø 19 mm (0.7480 in) (2,
Figure 89), facing the main
pressure valve.
F. Fasten housing cover using socket head screws.

G. Remove cylindrical pins (assembly aid) again.
(S) Box spanner (Torx TX-27) - 5873 042 002
H. Install pressure regulators and
secure using fixing plates and socket
head screws.
NOTE: Install fixing plates, with claw
facing downward.
Pay attention to radial
installation position of pressure
regulators, see Figure 90.
(S) Box spanner (Torx TX-27) - 5873
042 002
Figure 90
I. Introduce cable harness and connect
pressure regulators (6x).
NOTE: Pay attention to installation
position of cable harness, see
also markings (Figure 71).
Figure 91
J. Introduce female connector against
shoulder, with groove facing guide
nose of cover.
K. Install gaskets (Figure 92) and fasten
cover using socket head screws.
042 002
Figure 92

L. Secure female connector using
retaining clamp, see Figure 93.
M. Install opposite cover.
Figure 93
N. Install two adjusting screws and
mount gasket I.
gaskets, see Figure 94 and
Figure 97.
Figure 94
8. Intermediate plate-version with screens:
A. Insert screens (6x) flash -mounted
into bore of intermediate plate, see
Figure 95.
position- screens are facing
upward (facing duct plate).
Figure 95
B. Mount intermediate plate, with
screens with screens facing upward.
Figure 96

C. Mount gasket II.
Figure 97
D. Mount duct plate and fasten it
uniformly using socket head screws.
042 002
Figure 98
E. Equip screw plugs (8x) with new
O-rings and install them.
NOTE: The installation of hydraulic
control unit is described in
following section, “Mount Duct
Plate and Hydraulic Control
Unit” on page 140.
Figure 99

TRANSMISSION DISASSEMBLY
1. Fasten transmission on the assembly car.
(S) Assembly car - 5870 350 000
(S) Strips - 5870 350 063
(S) Support - 5870 350 090
Figure 100
HYDRAULIC CONTROL UNIT (HSG-94) AND
DUCT PLATE
1. Loosen two socket head screws and install
adjusting screws.
2. Loosen remaining socket head screws and
separate valve housing from duct plate.
(S) Adjusting screws (M6) - 5870 204 063
002
Figure 101
3. Remove both gaskets and intermediate
plate.
4. Loosen socket head screws and hex nuts
(Figure 102) and separate duct plate from
gearbox housing. Remove gasket.
004
Figure 102

5. Pull converter safety valve out of housing
bore.
Figure 103
ENGINE CONNECTION - CONVERTER
1. Remove lock plate and loosen hex head
screws.
2. Remove disk and pry drive flange off shaft.
Figure 104
3. Loosen screw connection.
NOTE: Mark radial installation position
of housing cover.
Figure 105
4. Separate converter, along with cover from
the transmission, using lifting device.
(S) Set of eyebolts - 5870 204 002
Figure 106

5. Press drive shaft resp. converter out of the
cover (ball bearing).
Figure 107
6. Squeeze retaining ring out and remove
ball bearing.
(S) Set of internal pliers - 5870 900 013
Figure 108
7. Loosen hex head screws and separate
diaphragm from the converter.
Figure 109
8. Loosen hex head screws and separate
drive shaft from the diaphragm.
Figure 110

9. Remove inductive transmitter (n Engine).
Figure 111
10. Loosen hex head screws and remove
converter bell.
Figure 112
HYDRAULIC PUMP
Figure 113
2. Apply separate device (S) on the gear
teeth run out of the stator shaft and pull
(compl.) using two-armed puller carefully
out of the housing bores.
(S) Separating device - 5870 300 024
(S) Two-armed puller - 5870 970 004
Figure 114

3. Separate hydraulic pump from stator shaft.
4. Separate control disk from pump.
NOTE: If traces due to running-in must
be encountered in the pump
housing or on the control disk,
the complete pump has to be
replaced.
5. Lay on control disk again and secure it
using grooved pins (2x).
Figure 115
6. Loosen socket head screws and the two
hex head screws and remove oil feed
housing.
Remove gasket.
(S) Box spanner (Torx, TX-40) - 5873 023
004
Figure 116
CONVERTER BACK PRESSURE VALVE
1. Preload compression spring and remove
lock plate.
2. Remove released components.
Figure 117
3. Loosen hex head screws. Remove cover
and gasket.
Figure 118

REMOVE OUTPUT, INPUT AND CLUTCHES
1. Remove lock plate, loosen hex head
screws and pry converter-side output
flange off the shaft.
2. Pry shaft seal out of the housing bore.
3. Tilt transmission 180° and remove
rear-side output flange accordingly.
(S) Pry bar - 5870 345 065
Figure 119
4. Remove speed sensor and both inductive
transmitters (Arrows).
Figure 120
5. Loosen hex nuts and remove both covers
(Arrows).
6. Loosen screw connection (housing/
housing cover).
Figure 121
7. Drive both cylindrical pins out (Arrows).
NOTE: The following figures show the
common removal of all
clutches.
8. The removal of single clutches without use
of the special tool (Handles - 5870 260
010) due to the installation conditions is
extremely difficult.
NOTE: Besides there is the danger of
injuries.
Figure 122

9. Locate all clutches using handles (S) in the
housing cover.
10. Install eyebolts and hang in the lifting
device.
(S) Handles (6 pieces needed) - 5870 260
010
(S) Eyebolt 2x (M20) - 0636 804 003
(S) Eyebolt 1x (M16) - 0636 804 001
(S) Puller device - 5870 000 017
(S) Lifting chain - 5870 281 047
Figure 123
11. Separate housing cover along with
clutches from the gearbox housing using
lifting device.
Figure 124
12. Fasten housing cover on the assembly car.
(S) Assembly car - 5870 350 000
(S) Clamping bracket - 5870 350 089
Figure 125
13. Loosen socket head screws and remove
output shaft and the two oil collecting
plates.
Figure 126

14. Remove tapered roller bearing.
15. Remove opposite tapered roller bearing
accordingly.
(S) Grab sleeve - 5873 002 038
(S) Basic set - 5873 002 001
Figure 127
16. Tilt gearbox housing 180°.
17. Figure 128, shows the arrangement of the
single clutches and the input in the
housing cover.
Reference
Description
Number
AN Input
KV Clutch - Forward
KR Clutch - Reverse
K1 Clutch - 1st Speed
K2 Clutch - 2nd Speed Figure 128
K3 Clutch - 3rd Speed
K4 Clutch - 4th Speed
18. Remove handles (S) (Figure 129).

(S) Handles - 5870 260 010
Figure 129

19. Lift Clutch-K4 a bit using pry bars and
remove Clutch-K1.
Figure 130
20. Remove Clutch-K2.
Figure 131
21. Remove Clutch-K3.
Figure 132
22. Lift Clutch - KV and KR using pry bars and
remove Clutch - K4.
(S) Pry bar - 5870 345 065
Figure 133

23. Lift Clutch - KV and Clutch - KR and input
together out of the housing cover.
24. Remove outer bearing races out of the
housing bores.
IMPORTANT
If contrary to the ZF recommendation
the tapered roller bearing of the
clutches and of the input and output
will not be replaced, the allocation
(inner bearing races to outer bearing Figure 134
races) must at least be maintained.
Mark inner bearing races and outer
bearing races accordingly to each
other.
25. Tilt housing cover 90°.

26. Squeeze retaining ring out and separate
pump shaft from housing cover.
Figure 135
27. Squeeze rectangular ring out (Arrow) and
press ball bearing from the shaft.
Figure 136

DISASSEMBLE CLUTCH - KV AND KR
1. Squeeze rectangular ring out (Arrow).
disassembly of Clutch - KV. The
disassembly of Clutch - KR is
similar.
Figure 137
2. Pull tapered roller bearing from the shaft.
accordingly.
(S) Grab sleeve - 5873 001 057
(S) Grab sleeve - 5873 001 059
(S) Basic set - 5873 001 000
Figure 138
4. Squeeze retaining ring out.
Figure 139
5. Separate plate carrier from the shaft.
(S) Three0leg puller - 5870 970 003
Figure 140

plate pack.
Figure 141
7. Preload compression spring, squeeze
retaining ring out and remove components.
(S) Assembly aid - 5870 345 088
Figure 142
8. Lift piston using compressed air out of the
cylinder bore and remove it.
Figure 143
9. Remove both O-rings (Arrows).
Figure 144

10. Lift idler gear a bit using pry bars (Figure
145).
11. Apply puller and separate idler gear from
the clutch shaft (Figure 146).
Figure 145
ball bearing.
NOTE: The disassembly of Clutch - KR
has to be carried out
accordingly.
Figure 146
Figure 147

DISASSEMBLE CLUTCH - K1, K2 AND K3
disassembly of Clutch - K3. The
disassembly of the Clutches -
K1 and K2 is similar.
1. Squeeze rectangular ring out. Pull tapered
roller bearing from the shaft.
2. Remove the opposite tapered roller
bearing accordingly.
(S) Grab sleeve (Bearing 33800) - 5873
001 059
Figure 148
(S) Grab sleeve (Bearing 33800) - 5873
002 038
(S) Basic set - 5873 001 000
(S) Basic set - 5873 002 001
3. Remove running disk, axial needle cage
and axial washer.
Figure 149
4. Remove idler gear.
Figure 150

5. Remove needle bearings and the axial
bearing (compl.).
Figure 151
plate pack.
Figure 152
7. Preload cup-spring pack and squeeze
retaining ring out. Remove released
components.
(S) Assembly aid - 5870 345 088
Figure 153
8. Squeeze retaining ring (S) into the groove
of the plate carrier.
9. Apply puller on the retaining ring and pull
plate carrier from the clutch shaft.
(S) Puller - 5870 970 004
(S) Retaining ring - 0630 502 053
Figure 154

Page 100 (ZF 4WG-210)
DISASSEMBLE CLUTCH - K4
1. Squeeze rectangular ring out (Arrow).
Figure 155
2. Pull tapered roller bearing from the shaft.
accordingly.
(S) Grab sleeve - 5873 001 057
(S) Grab sleeve - 5873 001 059
(S) Basic set - 5873 001 000
Figure 156
4. Squeeze retaining ring out and separate
plate carrier from the shaft.
(S) Three-armed puller - 5870 971 003
Figure 157
plate pack.
Figure 158

(ZF 4WG-210) Page 101
6. Preload cup-spring pack and squeeze
retaining ring out.
7. Remove released components. Remove
piston.
(S) Assembly aid - 5870 345 088
Figure 159
8. Lift piston using compressed air out of the
cylinder bore and remove it.
Figure 160
9. Take off the idler gear and remove
released components.
NOTE: The separation of shaft and
gear is not possible (shrink fit).
Figure 161
DISASSEMBLE DRIVE SHAFT
1. Squeeze rectangular ring out.
2. Remove tapered roller bearing. Remove
opposite tapered roller bearing
accordingly.
(S) Grab sleeve - 5873 002 045
(S) Basic set - 5873 002 001
(S) Basic set - 5873 002 006
Figure 162

Page 102 (ZF 4WG-210)
3. If necessary, press turbine shaft out of the
drive shaft.
NOTE: The turbine shaft is axially fixed
with a retaining ring which will
be destroyed at the pressing
out.
Figure 163

(ZF 4WG-210) Page 103
TRANSMISSION REASSEMBLY
INSTALL OIL TUBE
IMPORTANT
To ensure the correct installation of
the oil tubes, the use of the indicated
special tool (S) is imperative.
1. Insert suction pipe (1), pressure pipes (2)

and pressure pipe lubrication (3) into the
housing bores.
2. Fasten suction and pressure pipes using
socket head screws.
NOTE: Torque limit (M8/8.8) 2.35 kg•m
(17 ft lb)
Figure 164
3. Tilt housing 180°.
4. Roll suction and pressure pipes (Arrows)
into the housing bores, using special tool.
IMPORTANT
The pipe end must be maximally
plane with the housing face. If
necessary, equalize projection of
pipe.
Figure 165
(S) Rolling tool - 5870 600 003
(S) Rolling tool - 5870 600 005
(S) Rolling tool - 5870 600 007

Page 104 (ZF 4WG-210)
5. Insert O-rings (2x/pipe) into the annular
grooves of the two oil tubes and oil them.
Figure 166
6. Assemble both oil tubes (Arrows) until
contact is obtained.
7. Equip screw plug with new O-ring and
install it.
NOTE: Torque limit 14.28 kg•m
(103 ft lb).
Figure 167
8. Insert both oil tubes (Arrows) into the
housing cover, tilt housing cover 180° and
roll oil tubes into the housing bores.
(S) Rolling tool - 5870 600 008
IMPORTANT
The pipe end must be maximally
plane with the housing face. If
necessary, equalize projection of
pipe.
Figure 168

(ZF 4WG-210) Page 105
9. Mount studs (M8 x 25).
NOTE: Torque limit (studs) 0.92 kg•m
(7 ft lb).
NOTE: Wet screw thread with Loctite
#262.
10. Equip plugs (Arrows) with new O-ring and
install them.
NOTE: Torque limit (M16x1.5) 4.08
kg•m (30 ft lb).
kg•m (37 ft lb). Figure 169
kg•m (39 ft lb).
11. Insert sealing cover, with the recess facing
upward.
NOTE: Wet contact face with Loctite
#262.
Figure 170
REASSEMBLE CLUTCH - KV AND KR
reassembly of the Clutch - KV.
The reassembly of the Clutch -
KR has to be carried out
accordingly.
1. Preassemble Plate Carrier (Figure 171
thru Figure 174).
A. Check function of the purge valve.
NOTE: Ball must not stick, if necessary,
clean with compressed air.
Figure 171
B. Insert both O-rings (Arrows) scroll
free into the grooves of the piston
and oil.

Page 106 (ZF 4WG-210)
C. Introduce piston until contact is
obtained.
position, see Figure 172.
Figure 172
D. Install disk, compression spring and
guide ring.
Figure 173
E. Preload compression spring and
secure it using retaining ring.
(S) Assembly aid - 5870 345 088
Figure 174

(ZF 4WG-210) Page 107
F. Plate pack- KV, KR
Figure 175, shows the installation
position of components.
NOTE: The plate arrangement resp.
stacking of clutch - KV and KR
is identical.
Reference
Description
Number
1 Plate Carrier
2 Piston
3 Outer Plate - One Sided
Coated (1 Piece)
4 Inner Plates (10 Pieces)
5 Outer Plate - Coated on Figure 175
Both Sides (10 Pieces)
6 Retaining Ring [optional
s = 2.1 - 4.2 mm
(0.0827 - 0.1654 in)]
7 End Shim
NOTE: Effective number of friction

surface = 20.
IMPORTANT
Install outer plate (3) with the
uncoated side facing the piston.
• Adjust Plate Clearance = 2.7 +0.2 mm

(0.1654 +0.0079 in).
NOTE: For the adjustment of the plate
clearance are retaining rings of
different thickness available. To
ensure a faultless measuring
result, install plates for the
moment without oil.
2. Introduce plate pack accordingly to Figure
175.
Figure 176

Page 108 (ZF 4WG-210)
3. Lay on the end shim and squeeze the
retaining ring in (e.g. s = 2.55 mm
(0.10 in)).
Figure 177
4. Press on end shim with about 100 N (10
kg), apply dial indicator and set it at zero
(Figure 178).
Figure 178
5. Press on the end shim, using screwdriver
against retaining ring until contact is
obtained (upward) and read plate
clearance on the dial indicator (Figure
179).
NOTE: In case of a deviation from the
required plate clearance,
correct with corresponding
retaining ring (s = 2.1 - 4.2 mm
(0.08 - 0.17 in)).
6. After the adjustment of the plate clearance
has been carried out, remove the plate
pack, oil plates and install it again. Figure 179
(S) Magnetic stand - 5870 200 055

(S) Dial indicator 5870 200 057
IMPORTANT
Use oil according to the list of
lubricants TE-ML 03.

(ZF 4WG-210) Page 109
7. Introduce idler gear until all inner plates
are accommodated.
NOTE: This step makes the later
assembly of the idler gear
easier.
8. Remove the idler gear again.
Figure 180
9. Mount stud (Arrow).
#241.
NOTE: Torque limit (M10) 1.73 kg•m
(13 ft lb).
Figure 181
10. Insert ball bearing until contact is obtained
and secure using retaining ring.
Figure 182
11. Assemble needle bearing.
Figure 183

Page 110 (ZF 4WG-210)
12. Press idler gear against shoulder.
NOTE: Support it on the inner bearing
race.
Figure 184
13. Heat inner diameter of plate carrier (about
120°C).
(S) Hot-air blower 220V - 5870 221 500
(S) Hot-air blower 110V - 5870 221 501
Figure 185
14. Assemble preassembled plate carrier until
Figure 186
15. Locate plate carrier axially using retaining
ring.
Figure 187

(ZF 4WG-210) Page 111
16. Check function of clutch using compressed
air.
NOTE: At correctly installed
components, the closing resp.
opening of the clutch is clearly
audible.
Figure 188
17. Press tapered roller bearing against
shoulder.
18. Install opposite tapered roller bearing
accordingly.
Figure 189
19. Squeeze rectangular rings in (Arrows) and
let them snap in.
Figure 190
REASSEMBLE CLUTCH - K1, K2 AND K3
1. The following figures show the reassembly
of Clutch-K3. The reassembly of the
Clutches-K1 and K2 has to be carried out
accordingly.
2. Install stud (Arrow).
#241.
(13 ft lb).
Figure 191

Page 112 (ZF 4WG-210)
3. Heat inner diameter of plate carrier (Figure
192) and assemble plate carrier until
contact is obtained (Figure 193).
(S) Hot-air blower 220V - 5870 221 500
(S) Hot-air blower 110V - 5870 221 501
Figure 192
Figure 193
4. Check function of the purge valve.
NOTE: Ball must not stick, if necessary
5. Insert both O-rings (Arrows) scroll free into
the grooves of the piston and oil.
Figure 194
6. Introduce piston until contact is obtained.
Figure 195

(ZF 4WG-210) Page 113
7. Lay on cup-spring pack and guide ring.
NOTE: Pay attention to the stacking of
the cup springs, see page -115.
Figure 196
8. Preload cup-spring pack and secure it
using retaining ring.
(S) Assembly aid - 5870 345 088
Figure 197

Page 114 (ZF 4WG-210)
A. Plate pack- K1
IMPORTANT
The plate arrangement of Clutch-K1is
not identical with Clutch-K2 and K3.
In this connection see Figure 198.
Reference
Description
Number
1 Plate Carrier
2 Piston
3 Outer Plate - One Sided Figure 198
Coated (1 Piece)
5 Outer Plate - Coated on
6 Retaining Ring (Optional
s = 2.1 - 4.2 mm
(0.08 - 0.17 in))
7 End Shim

surface = 18.
• Adjust plate clearance = 2.4+0.2 mm
(0.05 +0.01 in)

(ZF 4WG-210) Page 115
B. Plate pack- K2 and K3
Reference
Description
Number
1 Plate Carrier
2 Piston
Coated (1 Piece)
s = 2.1 - 4.2 mm
(0.08 - 0.17 in))
7 End Shim

surface = 14. Figure 199
• Adjust plate clearance = 1.8 +0.2 mm
(0.07 +0.01 in)
IMPORTANT
9. Introduce plate pack according to Figure

198 and Figure 199.
clearance are retaining rings
with different thickness
available. To ensure a faultless
measuring result, install the
plates for the moment without
oil.
Figure 200

Page 116 (ZF 4WG-210)
10. Lay on the end shim and squeeze
retaining ring in (e.g. s = 3.1 mm (0.12 in)).
Figure 201
11. Press on the end shim with about 100 N
(10 kg), apply dial indicator and set it at
zero (Figure 202).
12. Push the end shim using screwdriver
203).
retaining ring (s= 2.1 - 4.2 mm
(0.08 - 0.17 in)). Figure 202

has been carried out, remove the plate
pack, oil plates and install it again.
IMPORTANT

(S) Dial indicator - 5870 200 057
Figure 203

(ZF 4WG-210) Page 117
14. Assemble running disk (1) (55 x 78 x 5),
axial needle cage (2) and axial washer (3)
(55 x 78 x 1).
NOTE: Install running disk (1), with the
chamber facing the axial needle
cage.
Figure 204
15. Assemble both needle bearing.
Figure 205
are accommodated.
Figure 206
17. Assemble axial washer (3) (55 x 78 x),
axial needle cage (2) and running disk (1)
(55 x 78 x 5).
chamber facing the axle needle
cage.
IMPORTANT
Only if the running disk is overlapping
with the shaft collar is ensured that all
inner plates are accommodated. Figure 207

Page 118 (ZF 4WG-210)
shoulder.
Press opposite tapered roller bearing
against shoulder.
Figure 208
19. Check function of the clutch using
compressed air.
audible.
Figure 209
20. Squeeze rectangular ring in (Arrow) and
let it snap in. Install opposite rectangular
ring accordingly.
21. Tilt clutch into horizontal position and
install spur gear K4 until all inner plates
are accommodated.
Figure 210
REASSEMBLE CLUTCH - K4
1. Cool shaft (about -80°C) and assemble it
until contact is obtained.
Figure 211

(ZF 4WG-210) Page 119
2. Secure gear axially using retaining ring.
(S) set of external pliers - 5870 900 015
Figure 212
3. Install stud (Arrow).
#241.
(13 ft lb).
Figure 213
4. Check function of the purge valve.
NOTE: Ball must not stick, if necessary
5. Insert both O-rings (Arrows) scroll free into
the grooves of the piston and oil them.
Figure 214
6. Introduce piston until contact is obtained.
Figure 215

Page 120 (ZF 4WG-210)
7. Install cup-spring pack and guide ring.
NOTE: Pay attention to the stacking of
the cup springs, see Figure
218.
Figure 216
8. Preload cup-spring pack and secure it
using retaining ring.
(S) Assembly aid - 5870 345 088
Figure 217

(ZF 4WG-210) Page 121
9. Plate pack - K4
Figure 218, shows the installation position
of components.
Reference
Description
Number
1 Plate Carrier
2 Piston
Coated (1 Piece)
s = 2.1 - 4.2 mm
(0.08 - 0.17 in)) Figure 218
7 End Shim

surface = 10.
• Adjust plate clearance = 1.2+0.2 mm
(0.05 +0.01 in)
IMPORTANT
10. Introduce plate pack according to Figure

218.
clearance are retaining rings
with different thickness
available. To ensure a faultless
measuring result, install the
plates for the moment without
oil.
Figure 219

Page 122 (ZF 4WG-210)
11. Lay on end shim and squeeze retaining
ring in (e.g. s = 3.4 mm (0.13 in)).
Figure 220
12. Press on the end shim with about 100 N
(10 kg), apply dial indicator and set it at
zero (Figure 221).
13. Push the end shim using screwdriver
223).
retaining ring. (s = 2.1 -
4.2 mm) (0.08 - 0.17 in). Figure 221

has been carried out, remove plate pack,
oil plates and install it again.
IMPORTANT

(S) Dial indicator - 5870 200 057
Figure 222

(ZF 4WG-210) Page 123
are accommodated.
NOTE: This step makes the later
assembling of the idler gear
easier.
16. Remove idler gear again.
Figure 223
17. Assemble both axial washer and needle
cage.
NOTE: Upper and lower axial washer
have the same thickness
(55 x 78 x 1).
Figure 224
18. Assemble both needle bearings.
Figure 225
19. Assemble idler gear.
Figure 226

Page 124 (ZF 4WG-210)
20. Assemble axial washer (3) (55 x 78 x 1),
needle cage (2) and running disk (1)
(55 x 78 x 5).
chamber facing the needle
cage.
Figure 227
21. Heat inner diameter of the plate carrier
(about 120°C). Assemble preassembled
plate carrier until all inner plates are
accommodated.
CAUTION!
Use safety gloves.
Figure 228
22. Secure plate carrier axially using retaining
ring.
(S) Set of external pliers - 5870 900 015
Figure 229
23. Check function of the clutch by means if
compressed air.
audible.
Figure 230

(ZF 4WG-210) Page 125
shoulder. Install opposite tapered roller
bearing.
Figure 231
let it snap in. Install opposite rectangular
ring.
Figure 232
PREASSEMBLE DRIVE SHAFT
1. Cool drive shaft (about -80°C). heat the
gear (about +120°C) and assemble it until
Figure 233
2. Secure gear axially using retaining ring.
Figure 234

Page 126 (ZF 4WG-210)
3. Squeeze retaining ring into the groove of
the turbine shaft.
Figure 235
4. Introduce turbine shaft until the retaining
ring snaps into the groove of the drive
shaft - turbine shaft is axially secured.
Figure 236
shoulder. Squeeze rectangular ring into
the groove of the drive shaft and let it snap
in.
6. Install opposite tapered roller bearing.
Figure 237
PREASSEMBLE AND INSTALL OUTPUT
1. Lay on screening plate.
Figure 238

(ZF 4WG-210) Page 127
2. Heat tapered roller bearing and assemble
it until contact is obtained.
3. Install opposite tapered roller bearing
accordingly.
Figure 239
4. Insert all outer bearing races into the
bearing bores of the housing. Install O-ring
(Arrows).
NOTE: At the use of already run
bearings, pay attention to the
allocation of the outer bearing
races.
Reference
Description
Number
AN Input
KV Clutch - Forward
KR Clutch - Reverse
Figure 240
K2 Clutch - 2nd Speed
AB Output
5. Lay on screening plate.
Figure 241

Page 128 (ZF 4WG-210)
6. Insert preassembled output shaft.
NOTE: Secure screening plates using
socket head screws.
(17 ft lb).
Figure 242
INSTALL PREASSEMBLED DRIVE SHAFT
AND CLUTCHES
1. Insert all outer bearing races into the
bearing bores of the housing cover.
NOTE: At the reuse of already run
bearings, pay attention to the
allocation of the outer bearing
races.
Reference
Description
Number
AN Input
KV Clutch - Forward
KR Clutch - Reverse
K2 Clutch - 2nd Speed
AB Output
Figure 243
2. Insert Clutch - KR, drive shaft and Clutch -
KV together into the housing cover.
IMPORTANT
Before the installation of the clutches
and the drive shaft, grease
rectangular rings and align them
centrally.
Figure 244

(ZF 4WG-210) Page 129
3. Lift drive gear and position Clutch-K4.
Figure 245
4. Install Clutch-K3.
Figure 246
5. Position Clutch-K2.
Figure 247
6. Lift Clutch - K4 and position Clutch-K1.
Figure 248

Page 130 (ZF 4WG-210)
7. Figure 249, shows the installation position
of single clutches in the housing cover.
8. Grease rectangular rings (Arrows) and
align them centrally.
Figure 249
9. Secure all clutches using handles (S).
(S) Handle (6 pieces needed) - 5870 260
010
Figure 250
10. Tilt housing cover 180°C.
11. Install eyebolts (Arrows).
(S) Eyebolt 2x (M20) - 0636 804 003
(S) Eyebolt 1x (M16) - 0636 804 001
(S) Puller device - 5870 000 017
Figure 251
12. Grease O-rings of the two oil tubes (see
also Figure 166). Wet mounting face with
sealing compound Loctite #574.
13. Position preassembled housing cover
using lifting device carefully on the
gearbox housing until contact is obtained
(Figure 252).
NOTE: Pay attention to the overlapping
of the oil tubes with the bores in
the housing cover.
(S) Lifting chain - 5870 281 047
Figure 252

(ZF 4WG-210) Page 131
14. Remove handles (S) again.
Figure 253
15. Install both cylindrical pins centrally to the
housing face.
Figure 254
16. 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
fixing plates, see Arrow.
Figure 255
INSTALL PUMP SHAFT (POWER TAKE-OFF)
1. Install ball bearing.
let it snap in.
Figure 256

Page 132 (ZF 4WG-210)
3. Grease rectangular ring, align it centrally
and introduce pump shaft until contact is
obtained.
Figure 257
4. Secure pump shaft using retaining ring.
Figure 258
5. Insert O-ring (Arrow) into the annular
groove of the oil feed covers.
Figure 259
6. Fasten both covers (Arrows) using hex
nuts (use plain washers).
Figure 260

(ZF 4WG-210) Page 133
INSTALL OUTPUT FLANGES
1. Install shaft seal with the sealing lip facing
the oil chamber.
NOTE: At the use of the prescribed
driver, the exact installation
position is obtained. Wet
rubber0coated outer diameter
with mineral spirits. Grease
sealing lip.
(S) Driver - 5870 048 213
Figure 261
2. Assemble output flange.
3. Insert O-ring (Arrow) into the gap of drive
flange and shaft.
Figure 262
4. Fasten output flange using disk and hex,
head screws.
kg•m (34 ft lb).
Figure 263
5. Secure hex head screws using lock plate.
(S) Driver 5870 057 009
(S) Handle 5870 260 002
6. Install converter-side output flange
accordingly.
Figure 264

Page 134 (ZF 4WG-210)
CONVERTER BACK PRESSURE VALVE
1. Figure 265, shows the components of the
converter back pressure valve.
Reference
Description
Number
1 Piston
2 Compression Spring
3 Pressure Plate
4 Lock Plate
NOTE: Install pressure plate with the

spigot (∅6 mm (0.24 in)) facing Figure 265
the lock plate.
2. Introduce components according to Figure
265, preload and secure using lock plate.
3. Equip plug (Arrow) with new O-ring and
install it.
NOTE: Torque limit (M14 x 1.5) 2.55
kg•m (18 ft lb).
Figure 266
OIL FEED HOUSING - TRANSMISSION PUMP
1. Install two adjusting screws (Arrows) and
lay on gasket.
Figure 267

(ZF 4WG-210) Page 135
2. Lay on oil feed housing and secure it
provisionally using socket head screws.
NOTE: Screw socket head screws only
in until contact is obtained - do
not tighten.
Figure 268
3. Install two adjusting screws and introduce
stator shaft until contract is obtained.
NOTE: Pay attention to the overlapping
of the bores.
Figure 269
4. Insert O-ring (Arrow) into the annular
groove and oil it.
Figure 270
5. Introduce transmission pump (compl.) and
put it using socket head screws (for the
moment without O-rings) evenly against
shoulder.
6. Remove socket head screws again.
Figure 271

Page 136 (ZF 4WG-210)
7. Equip socket head screws with new
O-rings (Arrow).
NOTE: Grease O-rings.
Figure 272
8. Fasten transmission pump using socket
head screws.
Figure 273
9. Fasten oil feed housing using socket head
screws and hex head screws (2 pieces).
NOTE: Torque limit (Socket head
screws) 2.35 kg•m (17 ft lb).
NOTE: Torque limit (Hex head screws)
4.69 kg•m (34 ft lb).
NOTE: Pay attention to the position of
fixing plate, see Arrow.
(S) Box spanner (Torx, TX-40) - 5870 042
004
Figure 274
ENGINE CONNECTION - CONVERTER
1. Fasten converter bell using hex head
screws.
kg•m (50 ft lb).
Figure 275

(ZF 4WG-210) Page 137
2. Screw drive shaft and diaphragm together.
kg•m (85 ft lb).
Figure 276
3. Fasten diaphragm using hex head screws
on the converter.
kg•m (85 ft lb).
NOTE: Insert hex head screws with
Loctite #262.
Figure 277
4. Introduce converter until contact is
obtained.
NOTE: Pulse disk of the converter
must be positioned centrally to
the bore of the inductive
transmitter, see Figure 279.
Only in this way will be ensured
that the converter is perfectly
introduced.
Figure 278
Figure 279

Page 138 (ZF 4WG-210)
5. Insert ball bearing until contact is obtained
and secure it using retaining ring.
Figure 280
6. Assemble housing cover.
7. Install drive flange, lay on disk and pull
cover using hex head screws evenly
against shoulder.
kg•m (25 ft lb).
NOTE: Pay attention to the radial
installation position of cover,
see Figure 281.
Figure 281
8. Secure hex head screws using lock plate.
(S) Driver - 5870 057 010
(S) Handle - 5870 260 002
Figure 282
9. Fasten cover using hex head screws and
nuts on the converter bell.
kg•m (34 ft lb).
Figure 283

(ZF 4WG-210) Page 139
10. Mount gasket and fasten cover using hex
head screws.
(17 ft lb).
Figure 284
CONVERTER SAFETY VALVE
1. Insert converter safety valve (compl.) into
the housing bore.
Figure 285
MOUNT DUCT PLATE AND HYDRAULIC
CONTROL UNIT
1. Install components according to the Figure
286.
(17 ft lb) (Hex nuts and socket
head screws).
position of different gaskets,
see Figure 286.
Reference
Description
Number
1 Gasket
2 Duct Plate Figure 286
3 Gasket
4 Intermediate Plate
5 Gasket

004

Page 140 (ZF 4WG-210)
2. Equip screw plug (Arrow) with new O-ring
and install it.
kg•m (22 ft lb).
Figure 287
3. Fasten hydraulic control unit (HSG-94)
using socket head screws.
(7 ft lb).
002
Figure 288
INSTALL PLUGS AND OIL LEVEL TUBE
1. Equip both plugs (Arrows) with new
O-rings and install them.
kg•m (37 ft lb).
kg•m (59 ft lb).
Figure 289

(ZF 4WG-210) Page 141
2. Install oil level tube (Arrow).
NOTE: Mount new gasket.
NOTE: Torque limit (M8/109) 3.47 kg•m
(25 ft lb).
Figure 290
3. Install cover plate (1, Figure 291).
NOTE: Install new gasket.
(17 ft lb).
4. Equip screw plug (2, Figure 291) with new
O-ring and install it.
kg•m (103 ft lb).
Figure 291
SPEED SENSOR AND INDUCTIVE
TRANSMITTERS
1. The Figure 292 and Figure 293 show the
installation position of single inductive
transmitters and the speed sensor.
Reference
Description
Number
34 Speed Sensor
N-Output and
Speedometer
21 Inductive Transmitter
N-Turbine Figure 292
N-Central Gear Train
N-Engine

Page 142 (ZF 4WG-210)
2. Grease O-rings and install speed sensor
and inductive transmitters.
NOTE: Torque limit 2.35 kg•m (17 ft lb)
(Socket head screw / Speed
sensor).
NOTE: Torque limit 3.06 kg•m (22 ft lb)
(Inductive transmitter).
Figure 293
3. Install breather (Arrow).
Figure 294

(ZF 4WG-210) Page 143
Page 144 (ZF 4WG-210)
S0607900C
R3
1TRANSMISSION ERROR
CODES (ZF)
CAUTION!
TRANSMISSION ERROR CODES (ZF)S0607900C

Mega 500-V 1001 thru 2000

June 2004
Transmission Error Codes (ZF) S0607900C

Page 1
TABLE OF CONTENTS
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
S0607900C Transmission Error Codes (ZF)

Page 2
Page 3
INTRODUCTION
The "WG" series of ZF Transmissions use an electronic control system called "ZF Ergopower."
The Ergo System (for short) allows the transmission to function either in a manual powershift mode, or in a
fully automatic mode.
An LCD display (Figure 1) is in the cabin. This display gives the machine operator a continuos status of the
operating condition of the system. It displays normal operational codes, and fault codes.
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
If a fault is detected, the display shows a

spanner symbol (g) for a fault. The display
shows the fault code, if the gear selector is in
S
neutral position. T
O
If more than one fault is detected, each fault
code is shown for about 1 second. P
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.

Page 4
DESCRIPTION OF FAULT CODES
The first number of the error code is the category that it is grouped into. They are as follows for the first
number.
First Number Meaning of Number

1 Hex Digital Input Signal
2 Hex Analog Input Signal
3 Hex Speed Signal
4 Hex CAN Signal Error
9 Hex Digital Output Signal
A Hex Digital Output Signal
B Hex Transmission Fault, Clutch Error
C Hex Logical Fault
D Hex Power Supply
E Hex High Speed Signal
F Hex General Fault

Page 5
DISPLAY DURING OPERATION
Symbol Meaning Remarks

1F, 1R Actual gear and direction. ---------------
2F, 2R Left digit shows actual gear.
3F, 3R Right digit shows actual direction.
4F
5F
6F
LF, LR Limp home gear.
F or R, no gear Clutch Cut Off. ---------------
F or R flashing Only 6WG. ---------------
Direction F or R selected while
turbine speed is too high.
CAUTION: Gear will engage if
turbine speed drops.
NN Not neutral, waiting for neutral after Go engage a gear, first move shift selector to
power up or a severe fault. neutral position and again to F or R position.
** Oil temperature too low, no gear Warm up engine / transmission.
available.
*N Oil temperature low, only one gear Warm up engine / transmission.
available.
1 bar (special Manual mode 1. gear. ---------------
symbol)
2 bars Manual mode 2. gear. ---------------
4 bars and 2 Automatic mode. ---------------
arrows
Bars flashing 6 WG: converter lockup clutch Difference of engine and turbine speed above
open. a certain limit and lockup clutch not activated.
4 WG: Downshift mode active.
Spanner At least one fault active. Select neutral to get fault code displayed.
Fault code See fault code list (See page 10). ---------------
WS Warning sump temperature. Changes between actual gear/direction while
driving, in neutral only displayed if no fault is
detected (spanner).
WR Warning retarder temperature. Changes between actual gear/direction while
detected (spanner).
WT Warning torque converter temperature. Changes between actual gear/direction while
detected (spanner)

Page 6
Symbol Meaning Remarks
WE Warning high engine speed. Changes between actual gear/direction while
detected (spanner).
PN Direction F or R selected while Transmission in neutral until parking brake is
parking brake engaged. released.
CAUTION: Vehicle starts to move after
release of parking brake.
F or R flashing Direction F or R selected while ---------------
turbine speed is to high.
CAUTION: Gear will engage if
turbine speed drops.
EE flashing No communication with display. Checked wiring from TCU to display.

Page 7
DEFINITION OF OPERATING MODES
NORMAL
There is no failure detected in transmission system or failure has no or slight effects on transmission
control. TCU will work without or in special cases with little limitations. (See “Table of Fault Codes” on page
10.)
SUBSTITUTE CLUTCH CONTROL

TCU cannot change gears or direction under control of normal clutch modulation. TCU uses substitute
strategy for clutch control. All modulations are only time controlled. (Comparable with EST 25.)
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.
TRANSMISSION SHUT DOWN

TCU has detected a severe failure that disables control of the transmission.
TCU will shut off the solenoid valves for the clutches and also the common power supply (VPS1).
Transmission shifts to Neutral. The park brake will operate normally, also the other functions which use
ADM 1 to ADM 6.
The operator has to slow down the vehicle. The transmission will stay in neutral.
TCU SHUT DOWN

TCU has detected a severe failure that disables control of system.
TCU will shut off all solenoid valves and also both common power supplies (VPS1, VPS2). The park brake
will engage, also all functions are disabled which use ADM 1 to ADM 6.
The transmission will stay in neutral.
NOTE: VPS2: is the LIS (option power supply).

Page 8
CLUTCH PACK AND SOLENOID VALVE
CROSS-REFERENCE TABLE
Throughout the fault codes, references are made to various clutch packs within the transmission. These
clutch pack references are indicated as K1, K2, etc.
Clutch pack charge pressure is controlled by proportional valves that contain a solenoid valve.
The following chart identifies which solenoid valve corresponds to each clutch pack.
Solenoid Valve (Proportioning Valve) Number
Mega 400-III PLUS

Mega 250-V
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

Page 9
TABLE OF FAULT CODES
The fault codes shown in this table are a complete list of codes that are common to more than one version
of the transmission. Some of the versions are 4WG (four speed) and 6WG (six speed).
NOTE: This fault code list is valid for the ZF Software Versions V 53.x to V58.0
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.
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
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.

Page 10
(hex) detection.)
18 ** S.C. to battery voltage at Customer specific. Check cable from 1)
See
Solenoid LIS1 (Function No. TCU to Solenoid “Measurement of
1). LIS1 (Function No. Resistance at
voltage at output pin, that Check connectors and Cable” on page
looks like a S.C. to battery from Solenoid LIS1 35.
voltage. (Function No. 1) to
TCU.
contacted to battery voltage. Check resistance of
Solenoid LIS1
(Function No. 1)
1) device has an internal
device.
defect.
to battery voltage.
19 ** O.C. at Solenoid LIS1 Customer specific. Check cable from 1)See
(Function No. 1). TCU to Solenoid “Measurement of
looks like a O.C. for this output Check connectors and Cable” on page
pin. from Solenoid LIS1 35.
(Function No. 1)
• Cable is defective and has
device to TCU.
no connection to TCU.
Check resistance of
Solenoid LIS1
(Function No. 1)
defect.
device.
• Connector has no
connection to TCU.
1A ** S.C. to ground at Solenoid Customer specific. Check cable from 1)
See
LIS2 (Function No. 2). TCU to Solenoid “Measurement of
looks like a S.C. to vehicle Check connectors and Cable” on page
ground. from Solenoid LIS2 35.
(Function No. 2)
device to TCU.
Check resistance of
Solenoid LIS2
(Function No. 2)
defect.
device.
to vehicle ground.
** Only Series "V"

Page 11
(hex) detection.)
1B ** S.C. to battery voltage at Customer specific. Check cable from 1)
See
Solenoid LIS2 (Function No. TCU to Solenoid “Measurement of
2). LIS2 (Function No. Resistance at
voltage at output pin, that Check connectors and Cable” on page
looks like a S.C. to battery from Solenoid LIS2 35.
voltage. (Function No. 2)
device to TCU.
contacted to battery voltage. Check resistance of
Solenoid LIS2
(Function No. 2)
device.
defect.
to battery voltage.
1C ** O.C. at Solenoid LIS2 Customer specific. Check cable from 1)See
(Function No. 2). TCU to Solenoid “Measurement of
looks like a O.C. for this output Check connectors and Cable” on page
pin. from Solenoid LIS2 35.
(Function No. 2)
device to TCU.
no connection to TCU.
Check resistance of
Solenoid LIS2
(Function No. 2)
defect.
device.
connection to TCU.
25 S.C. to battery voltage or O.C. No reaction. Check cable from ---------------
at transmission sump TCU to sensor.
TCU uses default
temperature sensor input.
temperature. Check connectors.
The measured voltage is too
Op-Mode: normal. Check temperature
high:
sensor.
contacted to battery voltage.
• Cable has no connection to
TCU.
• Temperature sensor has an
internal defect.
to battery voltage or is broken.
** Only Series "V"

Page 12
(hex) detection.)
26 S.C. to ground at transmission No reaction. Check cable from ---------------
sump temperature sensor TCU to sensor.
TCU uses default
input.
temperature. Check connectors.
The measured voltage is too
Op-Mode: normal. Check temperature
low:
sensor.
• Temperature sensor has an
internal defect.
to vehicle ground.
31 S.C. to battery voltage or O.C. Op-Mode: substitute Check cable from ---------------
at engine speed input. clutch control. TCU to sensor.
TCU measures a voltage Check connectors.
higher than 7.00 V at speed
Check speed sensor.
input pin.
TCU.
• Speed sensor has an
internal defect.
to battery voltage or has no
contact.
32 S.C. to ground at engine Op-Mode: substitute Check cable from ---------------
speed input. clutch control. TCU to sensor.
TCU measures a voltage less Check connectors.
than 0.45V at speed input pin.
Check speed sensor.
• Cable / connector is
defective and is contacted to
vehicle ground.
internal defect.
** Only Series "V"

Page 13
(hex) detection.)
33 Logical error at engine speed Op-Mode: substitute Check cable from This fault is reset
input. clutch control. TCU to sensor. after power up of
TCU.
TCU measures a engine Check connectors.
speed over a threshold and
Check speed sensor.
the next moment the
measured speed is zero. Check sensor gap.
defective and has bad
contact.
internal defect.
• Sensor gap is incorrect.
at turbine speed input. clutch control. TCU to sensor.
TCU measures a voltage If a failure is existing Check connectors.
higher than 7.00 V at speed at output speed.
Check speed sensor.
input pin.
TCU shifts to neutral.
Op-Mode: limp
home.
TCU.
internal defect.
contact.
35 S.C. to ground at turbine Op-Mode: substitute Check cable from ---------------
TCU measures a voltage less If a failure is existing Check connectors.
than 0.45V at speed input pin. at output speed.
Check speed sensor.
• Cable / connector is TCU shifts to neutral.
Op-Mode: limp
vehicle ground.
home.
internal defect.
** Only Series "V"

Page 14
(hex) detection.)
36 Logical error at turbine speed Op-Mode: substitute Check cable from This fault is reset
TCU.
TCU measures a turbine If a failure is existing Check connectors.
speed over a threshold and at at output speed.
Check speed sensor.
the next moment the
Op-Mode: limp
home.
contact.
internal defect.
at internal speed input. clutch control. TCU to sensor.
TCU measures a voltage Check connectors.
higher than 7.00 V at speed
Check speed sensor.
input pin.
TCU.
internal defect.
contact.
38 S.C. to ground at internal Op-Mode: substitute Check cable from ---------------
TCU measures a voltage less Check connectors.
than 0.45V at speed input pin.
Check speed sensor.
vehicle ground.
internal defect.
** Only Series "V"

Page 15
(hex) detection.)
39 Logical error at internal speed Op-Mode: substitute Check cable from This fault is reset
TCU.
TCU measures a internal Check connectors.
speed over a threshold and at
Check speed sensor.
the next moment the
contact.
internal defect.
3A S.C. to battery voltage or O.C. Special mode for Check cable from ---------------
at output speed input. gear selection. TCU to sensor.
TCU measures a voltage Op-Mode: substitute Check connectors.
higher than 12.5 V at speed clutch control.
Check speed sensor.
input pin.
If a failure is existing
• Cable is defective and is at turbine speed.
Op-Mode: limp
TCU.
home.
internal defect.
contact.
3B S.C. to ground at output Special mode for Check cable from ---------------
speed input. gear selection. TCU to sensor.
TCU measures a voltage less Op-Mode: substitute Check connectors.
than 1.00V at speed input pin. clutch control.
Check speed sensor.
• Cable / connector is If a failure is existing
defective and is contacted to at turbine speed.
vehicle ground.
Op-Mode: limp
internal defect.
home.
** Only Series "V"

Page 16
(hex) detection.)
3C Logical error at output speed Special mode for Check cable from This fault is reset
input. gear selection. TCU to sensor. after power up of
TCU.
TCU measures a output Op-Mode: substitute Check connectors.
speed over a threshold and at clutch control.
Check speed sensor.
the next moment the
If a failure is existing
at turbine speed.
contact. Op-Mode: limp
home.
internal defect.
3E Output speed zero doesn't fit Special mode for Check sensor signal This fault is reset
to other speed signals. gear selection. of output speed after power up of
sensor. TCU.
If transmission is not neutral Op-Mode: substitute
and the shifting has finished. clutch control. Check sensor gap of
output speed sensor.
TCU measures output speed If a failure is existing
zero and turbine speed or at turbine speed. Check cable from
internal speed not equal to TCU to sensor.
zero.
Op-Mode: limp
home.
internal defect.
71 S.C. to battery voltage at TCU shifts to neutral. Check cable from 1)
See
clutch K1. TCU to gearbox. “Measurement of
Op-Mode: limp
The measured resistance home. Check connectors Resistance at
value of valve is out of limit, from TCU to Actuator/sensors
If failure at another and Cable” on page
voltage at K1 valve is too high. gearbox.
clutch is pending. 35.
• Cable / connector is Check regulator
defective and has contact to resistance. 1)
battery voltage. Op-Mode: TCU shut
down. Check internal wire
• Cable / connector is harness of gearbox.
defective and has contact to
another regulator output of
TCU.
• Regulator has an internal
defect.
** Only Series "V"

Page 17
(hex) detection.)
72 S.C. to ground at clutch K1. TCU shifts to neutral. Check cable from 1)
See
TCU to gearbox. “Measurement of
The measured resistance Op-Mode: limp
value of valve is out of limit, home. Check connectors Resistance at
voltage at K1 valve is too low. from gearbox to Actuator/sensors
TCU.
• Cable / connector is clutch is pending. 35.
defective and has contact to Check regulator
vehicle ground. resistance. 1)
Op-Mode: TCU shut
• Regulator has an internal Check internal wire
down.
defect. harness of gearbox.
73 O.C. at clutch K1. TCU shifts to neutral. Check cable from 1) See
value of valve is out of limit. home. Check connectors Resistance at
from gearbox to Actuator/sensors
• Cable / connector is If failure at another and Cable” on page
TCU.
defective and has no contact clutch is pending. 35.
to TCU. Check regulator
• Regulator has an internal resistance. 1)
Op-Mode: TCU shut
defect. Check internal wire
down.
harness of gearbox.
74 S.C. to battery voltage at TCU shifts to neutral. Check cable from 1)See
Op-Mode: limp
value of valve is out of limit, from gearbox to Actuator/sensors
voltage at K2 valve is too high. TCU.
TCU.
defect.
75 S.C. to ground at clutch K2. TCU shifts to neutral. Check cable from 1) See
TCU.
Op-Mode: TCU shut
down.
** Only Series "V"

Page 18
(hex) detection.)
76 O.C. at clutch K2. TCU shifts to neutral. Check cable from 1)
See
TCU.
Op-Mode: TCU shut
down.
harness of gearbox.
77 S.C. to battery voltage at TCU shifts to neutral. Check cable from 1) See
Op-Mode: limp
TCU.
defect.
78 S.C. to ground at clutch K3. TCU shifts to neutral. Check cable from 1) See
TCU.
Op-Mode: TCU shut
down.
TCU.
Op-Mode: TCU shut
down.
harness of gearbox.
** Only Series "V"

Page 19
(hex) detection.)
7D S.C. to ground at engine Engine derating will Check cable from 1)
See
derating device. be on until TCU TCU to engine “Measurement of
power down even if derating device. Resistance at
fault vanishes (loose Actuator/sensors
contacted to vehicle ground. Check connectors
connection). and Cable” on page
from engine derating
• Engine derating device has 35. (Only Mega
Op-Mode: normal. device to TCU.
an internal defect. 500-V)
• Connector pin is contacted Check resistance 1)
to vehicle ground. of engine derating
device.
7E S.C. to battery voltage at No reaction. Check cable from Only Mega 500-V
engine derating device. TCU to engine
Op-Mode: normal.
derating device.
defective and is contacted to Check connectors
battery voltage. from backup alarm
device to TCU.
• Engine derating device has
an internal defect. Check resistance 1)
of backup alarm
device.
7F O.C. at engine derating No reaction. Check cable from 1)
See
device. TCU to engine “Measurement of
Op-Mode: normal.
derating device. Resistance at
voltage at output pin, that Check connectors Actuator/sensors
looks like a O.C. for this output from engine derating and Cable” on page
pin. device to TCU. 35. (Only Mega
500-V)
• Cable is defective and has Check resistance 1)
no connection to TCU. of engine derating
• Engine derating device has device.
an internal defect.
connection to TCU.
Op-Mode: limp
TCU.
defect.
** Only Series "V"

Page 20
(hex) detection.)
82 S.C. to ground at clutch K4. TCU shifts to neutral. Check cable from 1)
See
TCU.
Op-Mode: TCU shut
down.
TCU.
Op-Mode: TCU shut
down.
harness of gearbox.
84 S.C. to battery voltage at TCU shifts to neutral. Check cable from 1)See
clutch KV. TCU to gearbox. “Measurement of
Op-Mode: limp
voltage at KV valve is too TCU.
high.
Check regulator
• Cable / connector is resistance. 1)
defective and has contact to Op-Mode: TCU shut
battery voltage. down. Check internal wire
harness of gearbox.
TCU.
defect.
85 S.C. to ground at clutch KV. TCU shifts to neutral. Check cable from 1)
See
voltage at KV valve is too low. from gearbox to Actuator/sensors
TCU.
Op-Mode: TCU shut
down.
** Only Series "V"

Page 21
(hex) detection.)
86 O.C. at clutch KV. TCU shifts to neutral. Check cable from 1)
See
TCU.
Op-Mode: TCU shut
down.
harness of gearbox.
clutch KR. TCU to gearbox. “Measurement of
Op-Mode: limp
voltage at KR valve is too TCU.
high.
Check regulator
• Cable / connector is resistance. 1)
defective and has contact to Op-Mode: TCU shut
battery voltage. down. Check internal wire
harness of gearbox.
TCU.
defect.
88 S.C. to ground at clutch KR. TCU shifts to neutral. Check cable from 1) See
voltage at KR valve is too low. from gearbox to Actuator/sensors
TCU.
Op-Mode: TCU shut
down.
89 O.C. at clutch KR. TCU shifts to neutral. Check cable from 1)
See
TCU.
Op-Mode: TCU shut
down.
harness of gearbox.
** Only Series "V"

Page 22
(hex) detection.)
91 ** S.C. to ground at relay reverse Backup alarm will be Check cable from 1)
See
warning alarm. on until TCU power TCU to backup “Measurement of
down even if fault alarm device. Resistance at
vanishes (loose Actuator/sensors
voltage at output pin, that Check connectors
connection). and Cable” on page
looks like a S.C. to vehicle from backup alarm
ground. Op-Mode: normal. device to TCU. 35.
• Cable is defective and is Check resistance 1)

contacted to vehicle ground. of backup alarm
• Backup alarm device has an device.
internal defect.
to vehicle ground.
92 ** S.C. to battery voltage at relay No reaction. Check cable from 1)
See
reverse warning alarm. TCU to backup “Measurement of
Op-Mode: normal.
alarm device. Resistance at
looks like a S.C. to battery from backup alarm and Cable” on page
voltage. device to TCU. 35.

contacted to battery voltage. of backup alarm
internal defect.
to battery voltage.
93 ** O.C. at relay reverse warning No reaction. Check cable from 1)
See
alarm. TCU to backup “Measurement of
Op-Mode: normal.
alarm device. Resistance at
looks like a O.C. for this output from backup alarm and Cable” on page
pin. device to TCU. 35.
• Cable is defective and has Check resistance 1)

no connection to TCU. of backup alarm
internal defect.
connection to TCU.
** Only Series "V"

Page 23
(hex) detection.)
94 ** S.C. to ground at relay starter No reaction. Check cable from 1)
See
interlock. TCU to starter “Measurement of
Op-Mode: normal.
interlock relay. Resistance at
looks like a S.C. to vehicle from starter interlock and Cable” on page
ground. relay to TCU. 35.

contacted to vehicle ground. of starter interlock
• Starter interlock relay has an relay.
internal defect.
to vehicle ground.
95 * O.C. at LIS1 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 is defective code.
and has no contact to TCU. Check the valve
resistance.
• Valve has an internal defect.
95 ** S.C. to battery voltage at relay No reaction. Check cable from 1)
See
starter interlock. TCU to starter “Measurement of
Op-Mode: normal.
looks like a S.C. to battery from starter interlock and Cable” on page
voltage. relay to TCU. 35.

contacted to battery voltage. of starter interlock
• Starter interlock relay has an relay.
internal defect.
to battery voltage.
95 * S.C. battery voltage or ground No reaction. Check the cable from ---------------
98 * at LIS1 solenoid valve or LIS2 TCU to the valve.
Op-Mode: normal.
solenoid valve.
Each Check the connector.
fault • Cable is defective and is
Check the valve.
code contacted to vehicle ground or
shown vehicle ground.
for about
one
TCU.
second.
to battery voltage or is broken.
to vehicle ground.
** Only Series "V"

Page 24
(hex) detection.)
96 ** O.C. at relay starter interlock. No reaction. Check cable from 1)
See
TCU to starter “Measurement of
TCU detected a wrong Op-Mode: normal.
looks like a O.C. for this output Check connectors Actuator/sensors
pin. from starter interlock and Cable” on page
relay to TCU. 35.
no connection to TCU. Check resistance 1)
• Starter interlock relay has an of starter interlock
internal defect. relay.
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.
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
• Low-pressure at clutch K1. sensor.
Op-Mode: TCU shut
• Low main pressure. Check sensor gap at
down.
• Wrong signal at internal
speed sensor. Check signal at
internal speed
• Wrong signal at output
sensor.
speed sensor.
Check signal at
• Clutch is defective.
Replace clutch.
** Only Series "V"

Page 25
(hex) detection.)
clutch K2.
slipping clutch.
internal speed
Op-Mode: TCU shut
down.
internal speed
sensor.
speed sensor.
Check signal at
Replace clutch.
clutch K3.
slipping clutch.
internal speed
Op-Mode: TCU shut
down.
internal speed
sensor.
speed sensor.
Check signal at
Replace clutch.
** Only Series "V"

Page 26
(hex) detection.)
clutch K4.
slipping clutch.
internal speed
Op-Mode: TCU shut
down.
turbine speed
sensor.
speed sensor.
Check signal at
• Wrong signal at turbine
internal speed
speed sensor.
sensor.
Check signal at
• Clutch is defective. turbine speed
sensor.
Replace clutch.
B5 Slippage at clutch KV. TCU shifts to neutral. Check pressure at ---------------
clutch KV.
speed at closed clutch KV. If home. Check main
slipping clutch.
internal speed
• Low-pressure at clutch KV. sensor.
Op-Mode: TCU shut
down.
turbine speed
sensor.
speed sensor.
Check signal at
internal speed
speed sensor.
sensor.
Check signal at
sensor.
Replace clutch.
** Only Series "V"

Page 27
(hex) detection.)
B6 Slippage at clutch KR. TCU shifts to neutral. Check pressure at ---------------
clutch KR.
speed at closed clutch KR. If home. Check main
slipping clutch.
internal speed
• Low-pressure at clutch KR. sensor.
Op-Mode: TCU shut
down.
turbine speed
sensor.
speed sensor.
Check signal at
internal speed
speed sensor.
sensor.
Check signal at
sensor.
Replace clutch.
B7 Overtemp sump. No reaction. Cool down machine. ---------------
TCU measured a temperature Op-Mode: normal. Check oil level.
in oil sump that is over
Check temperature
allowed threshold.
sensor.
BA Mega 400-V and
Mega 500-VTII
Differential pressure oil filter No reaction. Check oil filter. 1) See
TCU measured a voltage at Op-Mode: normal. Check the cable from “Measurement of
differential pressure switch TCU to the Resistance at
out of the allowable range. differential pressure Actuator/sensors
switch. and Cable” on page
• Oil filter is dirty. 35.
Check differential
• Cable or connectors are
pressure switch
defect and are contacted to
(measure
battery voltage.
resistance1).
vehicle ground.
• Differential pressure switch
is defective.
D1 S.C. to battery voltage at See fault codes No. Check cables and Fault codes No. 21 to
power supply for sensors. 21 - 2C. connectors to No. 2C may be a
sensors, which are reaction of this fault.
TCU measures more than 6V
supplied from AU1.
at the pin AU1 (5V sensor
supply). Check the power
supply at the pin AU1
(must be
approximately 5V).
** Only Series "V"

Page 28
(hex) detection.)
D2 S.C. to ground at power See fault codes No. Check cables and Fault codes No. 21 to
supply for sensors. 21 - 2C. connectors to No. 2C may be a
sensors, which are reaction of this fault.
TCU measures less than 4V
supplied from AU1.
at the pin AU1 (5V sensor
supply). Check the power
supply at the pin AU1
(must be
approximately 5V).
D3 Low power at battery. Shift to neutral. Check power supply ---------------
battery.
Measured voltage at power Op-Mode: TCU shut
supply is lower than 18 V. down. Check cables from
batteries to TCU.
Check connectors
from batteries to
TCU.
D4 High power at battery. Shift to neutral. Check power supply ---------------
battery.
Measured voltage at power Op-Mode: TCU shut
supply is higher than 32 V. down. Check cables from
batteries to TCU.
Check connectors
from batteries to
TCU.
D5 Error at switch 1 for valve Shift to neutral. Check fuse. ---------------
power supply VPS1.
Op-Mode: TCU shut Check cables from
TCU switched on VPS1 and down. gearbox to TCU.
measured VPS1 is off or TCU
Check connectors
switched off VPS1 and
from gearbox to
measured VPS1 is still on.
TCU.
Replace TCU.
battery voltage.
vehicle ground.
• Permanent power supply
KL30 missing.
• TCU has an internal defect.
** Only Series "V"

Page 29
(hex) detection.)
D6 Error at switch 2 for valve Shift to neutral. Check fuse. ---------------
power supply VPS2.
Op-Mode: TCU shut Check cables from
TCU switched on VPS2 and down. gearbox to TCU.
measured VPS2 is off or TCU
Check connectors
switched off VPS2 and
from gearbox to
measured VPS2 is still on.
TCU.
Replace TCU.
battery voltage.
vehicle ground.
• Permanent power supply
KL30 missing.
• TCU has an internal defect.
E3 S.C. to battery voltage at No reaction. Check the cable from ---------------
display output. TCU to the display.
Op-Mode: normal.
TCU sends data to the display Check the
and measures always a high connectors at the
voltage level on the connector. display.
• Cable or connectors are Change display.
defective and are contacted to
battery voltage.
• Display has an internal
defect.
E4 S.C. to ground at display No reaction. Check the cable from ---------------
output. TCU to the display.
Op-Mode: normal.
TCU sends data to the display Check the
and measures always a high connectors at the
voltage level on the connector. display.
• Cable or connectors are Change display.
defective and are contacted to
vehicle ground.
• Display has an internal
defect.
F1 General EEPROM fault. Transmission stay Replace TCU. Often shown
neutral. together with fault
TCU cannot read nonvolatile
code F2.
memory. Op-Mode: TCU shut
down.
• TCU is defective.
** Only Series "V"

Page 30
(hex) detection.)
F2 Configuration lost. Transmission stay Reprogram the ---------------
neutral. correct configuration
TCU has lost the correct
for the vehicle (e.g.
configuration and can't control Op-Mode: TCU shut
with cluster
the transmission. down.
controller,...).
• Interference during saving
data on nonvolatile memory.
• TCU is brand new or from
another vehicle.
F3 Application error. Transmission stay Replace TCU! This fault occurs only
neutral. if an test engineer
Something of this application
did something wrong
is wrong. Op-Mode: TCU shut
in the application of
down.
the vehicle.
F5 ** Clutch failure. Transmission stay Check clutch. TCU shows also the
neutral. affected clutch on
AFP was not able to adjust
the Display.
clutch filling parameters. Op-Mode: TCU shut
down.
• One of the AFP-Values is out
of limit.
F6 ** Clutch Adjustment Data lost. No reaction. Execute AFP. ---------------
TCU was not able to read Default values = 0 for
correct clutch adjustment AFP offsets used.
parameters.
Op-Mode: normal.
• Interference during saving
data on nonvolatile memory.
• TCU is brand new.
** Only Series "V"

Page 31
TABLE OF FAULT CODES - ERGO-CONTROL
Error Code
Meaning of Error Code Remarks
Number
11 Logical error at gear range signal.
12 Logical error at direction select signal.
21 Short circuit to battery voltage at clutch cutoff input.
22 Short circuit to ground or open circuit at clutch cutoff input.
23 Short circuit to battery voltage at load sensor input. Not used.

24 Short circuit to ground or open circuit at load sensor input. Not used.
25 Short circuit to battery voltage or open circuit at temperature sensor

input.
26 Short circuit to ground at temperature sensor input.
31 Short circuit to battery voltage at engine speed input.
32 Short circuit to ground or open circuit at engine speed input.
33 Logical error at engine speed input.
34 Short circuit to battery voltage at turbine speed input.
35 Short circuit to ground or open circuit at turbine speed input.
36 Logical error at turbine speed input.
37 Short circuit to battery voltage at internal speed input.
38 Short circuit to ground or open circuit at internal speed input.
39 Logical error at internal speed input.
3A Short circuit to battery voltage at output speed input.
3B Short circuit to ground or open circuit at output speed input.
3C Logical error at output speed input.
71 Short circuit to battery voltage at clutch K1.
72 Short circuit to ground at clutch K1.

73 Open circuit at clutch K1.


Page 32
Error Code
Number
7A Short circuit to battery voltage at converter clutch. Not used.
7B Short circuit to ground at converter clutch. Not used.
7C Open circuit at converter clutch. Not used
81 Short circuit battery voltage at clutch K4.
84 Short circuit to battery voltage at clutch KV.
85 Short circuit to ground at clutch KV.
86 Open circuit at clutch KV.
87 Short circuit to battery voltage at clutch KR.
88 Short circuit to ground at clutch KR.

89 Open circuit at clutch KR.
91 Short circuit battery voltage at relay reverse warning alarm.
92 Short circuit to ground at relay reverse warning alarm.
93 Open circuit at relay reverse warning alarm.
94 Short circuit to battery voltage at relay starter interlock.

95 Short circuit to ground at relay starter interlock.
96 Open circuit at relay starter interlock.
97 Short circuit to battery voltage at park brake solenoid.

98 Short circuit ground at park brake solenoid.
99 Open circuit at park brake solenoid.
B1 Slippage at clutch K1.


Page 33
Error Code
Number
B5 Slippage at clutch KV.
B6 Slippage at clutch KR.

BA Differential pressure oil filter.
D1 Short circuit to battery voltage at power supply for sensors.
D2 Short circuit to ground at power supply for sensors.
D3 Low power at battery.
D4 High power at battery.

D5 Error at switch 1 for valve power supply.
D6 Error at switch 2 for valve power supply.
E1 Short circuit to battery at speedometer output. Not used.
E2 Short circuit to ground or open circuit at speedometer output. Not used.
E3 Short circuit to battery voltage at display output. Not used.
E4 Short circuit to ground or open circuit at display output. Not used.
E5 Error at communication on CAN.
F1 General EEPROM fault.

F2 Configuration lost.
F3 Application error.

Page 34
MEASUREMENT OF RESISTANCE AT ACTUATOR/
SENSORS AND CABLE
ACTUATOR
Open circuit:R12 ≈ R1G ≈ R2G ≈ ∞
1
Short cut to ground:R12 ≈ R;R1G ≈ 0, R2G ≈ R or
R1G ≈ R, R2G ≈ 0(for S.C. to ground, G is
R
connected to vehicle ground)
Short cut to battery:R12 ≈ R;R1G ≈ 0, R2G ≈ R or
R1G ≈ R, R2G ≈ 0(for S.C. to battery, G is 2
G
connected to battery voltage.
HBOE640I
Figure 2
CABLE
UBat
open circuit:
R12 ≈ R1P ≈ R1C ≈ R2P ≈ R2C ≈ ∞
P (power supply)
short cut to ground: TCU

Actuator /
R12 ≈ 0;R1C ≈ R2C ≈ 0,R1P ≈ R2P ≈ ∞
1 2
Sensor
short cut to battery: C (chassis)
R12 ≈ 0,R1C ≈ R2C ≈ ∞,R1P ≈ R2P ≈ 0

Gnd
HBOE650I
Figure 3

Page 35
Page 36
1HYDRAULICS
S0703000
R3
1ACCUMULATOR
CAUTION!
ACCUMULATOR S0703000
Mega 500-V 1001 thru 2000

June 2002
Accumulator S0703000
Page 1
Solar 220N-V 1001 and Up
TABLE OF CONTENTS
Specifications .......................................................................................... 4
Accumulator Charging.................................................................................... 7
Charging the Accumulator with Nitrogen................................................. 7
S0703000 Accumulator
Page 2
GENERAL DESCRIPTION
The accumulator is a gas charged storage
device designed to hold a reserve quantity of
hydraulic fluid under pressure. Accumulators are
used in hydraulic circuits in much the same way
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
accumulator.
Reference
Description
Number
1 Screw Plug
2 Sealing Ring
3 Diaphragm
4 Fluid Valve
5 Steel Pressure Vessel 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 valve
assembly at the top allows adding or expelling gas from the compressible, precharged 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:
1. With no gas charge in the upper chamber
0 bar (0 psi, empty) and no oil in the
bottom 0 bar (0 psi, dry) the elastic
diaphragm hangs loosely.
2. When the prepressure charge of gas
(usually nitrogen) is introduced through the
valve at the top of the accumulator, the
diaphragm expands to maximum size. The
valve button in the center of the diaphragm
pushes into the fluid opening in the bottom
chamber, sealing off the lower valve. If the
pressure of the gas charge exceeds
system oil pressure, no fluid enters the
accumulator. The button also keeps the
diaphragm from protruding into the lower
valve opening.
Figure 2
Page 3
NOTE: Precharge pressure is referred to as the "P1" pressure. The accumulator manufacturer's
"P1" rated pressure must be stamped or marked on the accumulator's rating plate. Annual
checks of actual precharge pressure must 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 precharge 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 precharge 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 precharge
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
15 kg/cm2 320 cc
Mega 130 S/N 0001 - 1003 Pilot
(210 psi) (19.53 in3)
9 kg/cm2 500 cc
Mega 130 S/N 0001 and Up Brake System
(130 psi) (30.51 in3)
8 kg/cm2 500 cc
Mega 160 S/N 0001 - 1020 Brake System
(115 psi) (30.51 in3)
15 kg/cm2 320 cc
Mega 160 S/N 0001 - 1020 Pilot
(210 psi) (19.53 in3)
30 kg/cm2 750 cc
Mega 160 S/N 1021 and Up Brake System
(430 psi) (45.77 in3)
15 kg/cm2 320 cc
Mega 200-III S/N 1001 - 1386 Brake System
(210 psi) (19.53 in3)
15 kg/cm2 320 cc
Mega 200-III S/N 1001 - 1386 Pilot
(210 psi) (19.53 in3)
40 kg/cm2 750 cc
Mega 200-III S/N 1387 and Up Brake System
(570 psi) (45.77 in3)
Page 4
Charge
Pressure
15 kg/cm2 320 cc
Mega 200-V S/N 1001 and Up Brake System
(210 psi) (19.53 in3)
Brake / Pilot 30 kg/cm2 750 cc
Mega 250-III S/N 1001 and Up
System (430 psi) (45.77 in3)
Mega 250-V S/N 1001 and Up
System (210 psi) (19.53 in3)
30 kg/cm2 750 cc
(430 psi) (45.77 in3)
15 kg/cm2 320 cc
Mega 300-V S/N 1001 and Up Pilot
(210 psi) (19.53 in3)
Mega 400-III S/N 1001 and Up Brake System
Mega 400-III S/N 1001 and Up Pilot
Mega 400-III PLUS S/N 1001 and Up
System (430 psi) (45.77 in3)
30 kg/cm2 750 cc
(430 psi) (45.77 in3)
15 kg/cm2 320 cc
Mega 400-V S/N 1001 and Up Pilot
(210 psi) (19.53 in3)
S/N 1001 thru 30 kg/cm2 750 cc
Mega 500-V Brake System
2000 (430 psi) (45.77 in3)
S/N 1001 thru 15 kg/cm2 320 cc
Mega 500-V Pilot
2000 (210 psi) (19.53 in3)
10 kg/cm2 320 cc
Solar 130LC-V S/N 0001 and Up Pilot / Travel
(140 psi) (19.53 in3)
30 kg/cm2 750 cc
Solar 130W-V S/N 0001 and Up Brake System
(430 psi) (45.77 in3)
10 kg/cm2 320 cc
Solar 130W-V S/N 0001 and Up Pilot
(140 psi) (19.53 in3)
8 kg/cm2 750 cc
Solar 130W-V S/N 0001 and Up Transmission
(115 psi) (45.77 in3)
10 kg/cm2 320 cc
(140 psi) (19.53 in3)
30 kg/cm2 750 cc
(430 psi) (45.77 in3)
10 kg/cm2 320 cc
(140 psi) (19.53 in3)
8 kg/cm2 750 cc
(115 psi) (45.77 in3)
30 kg/cm2 750 cc
(430 psi) (45.77 in3)
10 kg/cm2 320 cc
(140 psi) (19.53 in3)
Page 5
Charge
Pressure
8 kg/cm2 750 cc
(115 psi) (45.77 in3)
10 kg/cm2 320 cc
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
Solar 220LL S/N 1001 and Up Pilot / Travel
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
Solar 220N-V S/N 1001 and Up
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
Solar 290LL S/N 1001 and Up Pilot / Travel
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
Solar 450-V S/N 1001 and Up Pilot / Travel
(140 psi) (19.53 in3)
Page 6
ACCUMULATOR CHARGING
WARNING!
In the event of a diaphragm or upper valve failure, or any type of accident or handling fault, the
upper chamber of the accumulator could at some point require repressurization. Depending
upon the specific procedures and safety precautions recommended for the type and model
accumulator that has been installed on your machine, a specialized adapter and/or filling tool
may be required to perform the procedure. Consult your dealer or DOOSAN After Sales Service
for more information and follow recommended procedures carefully. All accumulators may
contain gas held under high-pressure. Careless handling or improper disassembly could release
explosive stored energy, resulting in an accident or injury.
NOTE: Some machines use 320 cc (19.53 in3) Bosch Accumulators with a nitrogen precharge
(P1) pressure of 15 kg/cm2 (213 psi). Always verify precharge pressure by checking the
manufacturer's data label on the exterior of the accumulator.
CHARGING THE ACCUMULATOR WITH NITROGEN

1. Remove the protective cap (10, Figure 3) and the protective plug (11) from the accumulator (6).
Figure 3
Page 7
Reference Reference
Number Number
1 Nitrogen Cylinder Fitting 7 Cylinder to Accumulator
2 Hose, 3 Meters (10 ft) Long Adapter
3 Check Valve 8 Nitrogen Bleeder Valve
4 Pressure Gauge 9 Nut O-ring
5 Sealing Nut 10 Protective Cap
6 Accumulator 11 Protective Plug
12 Sealing Ring
2. Clean area around seal ring (12).

3. Thread the sealing nut (5, Figure 3) of adapter (7) onto accumulator. Tighten adapter securely. Close
nitrogen bleeder vale (8).
4. Thread nitrogen cylinder fittings (1, Figure 3) onto nitrogen cylinder.
5. Open valve on nitrogen cylinder and charge accumulator to a appropriate pressure (P1). Close valve
on nitrogen cylinder.
NOTE: Wait 2 or 3 minutes for nitrogen to warm to ambient temperature. This will stabilize
pressure.
6. Slowly open nitrogen bleeder valve (8). Open valve (8) until gauge (4) reading is equal to primary
pressure. Close bleeder valve.
7. Unscrew adapter (7, Figure 3) from accumulator (6).
8. Thread protective plug (11, Figure 3) into accumulator. Tighten to 3 kg•m (22 ft lb).
9. Check for nitrogen leaks around protective plug (11, Figure 3). Coat area around protective plug (11)
with soapy water. If soap bubbles form, retighten protective plug (11).
10. Install protective cap (10, Figure 3) on accumulator.
WARNING!
Accumulator store nitrogen under high-pressure. Before replacing an accumulator, install
an adapter (7) with a bleeder valve (8) on the accumulator. Slowly and carefully bleed off all
nitrogen before removing the accumulator from the hydraulic system.
NOTE: After an accumulator has been installed, or after an accumulator has been recharged with
(P1) after the first week of operation. Check for a pressure drop due to leaks. If no
pressure drop is found after the first week, check again after 3 more weeks. If no pressure
drop is found after 3 weeks, check after one year.
Page 8
S0705005K
1CYLINDERS
CAUTION!
CYLINDERS S0705005K
Mega 250-V (Tier II) 2001 and 4000

November 2002
Cylinders S0705005K
Page 1
TABLE OF CONTENTS
Parts List ................................................................................................. 6
Troubleshooting, Testing and Adjustment..................................................... 12
Disassembly ................................................................................................. 16
Reassembly.................................................................................................. 19
S0705005K Cylinders
Page 2
Cylinders S0705005K
Page 3
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
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
S0705005K Cylinders
Page 4
THEORY OF OPERATION
1. Piston
2. Oil Path A
3. Oil Path B
Cylinder piston rods are extended or retracted

by oil flow to back side of cylinder (shown as "oil
path A") or to front of the cylinder ("oil path B").
The cylinder rod is extended as oil flow is
pumped through the circuit to the back side of
the piston. The force (F1) of the piston stroke
can be expressed by the formula below, where
P = circuit oil pressure and the inside diameter
of the cylinder is expressed by B (Figure 1).
Figure 1
F1 = P x πB2
4
(P: Pressure, π = 3.14, B: Cylinder Inside Diameter)
1. Cylinder Inside Diameter - B

2. Oil Path A
3. Oil Path B
4. Rod Diameter
When the cylinder rod is retracted, oil flow

through the circuit from the pump to the front
side of the cylinder generates a force (F2) that Figure 2
can be expressed by the formula in which the
diameter of the piston rod is expressed by R,
and the other two terms are the same as in the
preceding expression.
F2 = P x π(B2-R2)
4
Because the volume of oil needed to lengthen

the cylinder rod (Q1) is greater than the volume
of oil required to retract the cylinder rod, it takes
more time to decrease cylinder stroke length
than it does to lengthen it.
Q1 = S x π(B2)
4
Figure 3
Q2 = S x π(B2-R2)
4
Q1 > Q2
Cylinders S0705005K
Page 5
PARTS LIST
Bucket Hydraulic Cylinder
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 4
S0705005K Cylinders
Page 6
Reference Reference
Number Number
1 Tube Assembly 16 Wear Ring
2 Steel Bushing 17 Dust Ring
3 Rod Assembly 18 O-ring
4 Steel Bushing 19 Piston Nut
5 Rod Cover 20 Lock Ring
6 DU-bushing 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 Fitting Seal Kit
15 Glyd Ring
Cylinders S0705005K
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 5
S0705005K Cylinders
Page 8
Reference Reference
Number Number
1 Tube Assembly 18 Piston Nut
2 Steel Bushing 19 Lock Ring
3 Rod Assembly 20 Socket Hex Bolt
4 Rod Cover 21 Pipe Assembly
5 DU-bushing 22 O-ring
6 Retaining Ring 23 Spring Washer
7 U-packing 24 Hex Bolt
8 Backup Ring 25 Pipe Assembly
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 Fitting Seal Kit
17 O-ring
Cylinders S0705005K
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 6
S0705005K Cylinders
Page 10
Reference Reference
Number Number
1 Tube Assembly 15 Glyd Ring
2 Steel Bushing 16 Wear Ring
3 Rod Assembly 17 Dust Ring
4 Steel Bushing 18 O-ring
5 Rod Cover 19 Piston Nut
6 DU-bushing 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 Fitting Seal Kit
14 Piston
Cylinders S0705005K
Page 11
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).
S0705005K Cylinders
Page 12
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).
(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
piston rod (18).
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).
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).
Nylon wear rings (7, Figure 1) Replace nylon wear rings (7).
twisted.
scratched.
have other damage.
Cylinders S0705005K
Page 13
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.
incorrect.
internally. parts.
cartridge.
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.
S0705005K Cylinders
Page 14
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 S0705005K
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.
NOTE: Dispose of drained fluids according to local regulations.
1. Use an allen wrench to remove bolts that
hold cylinder head to cylinder tube. See
Figure 7.
Figure 7
2. Support cylinder rod with a lifting sling.
See Figure 8. 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 8
3. Set cylinder rod assembly in a repair
fixture and secure rod in place. See Figure
9. Use a power wrench and socket to
remove nut that holds piston on rod.
Figure 9
S0705005K Cylinders
Page 16
4. Remove piston nut (1, Figure 10), 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 10
5. Do not remove slipper seal, backup ring,
and back ring from piston. If these three
items are not scratched or damaged. See
Figure 11. 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 11
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
retaining ring, (1, Figure 12). Use a
screwdriver to remove dust seal (2) from
head.
Reference
Description
Number
1 Retaining Ring
Figure 12
2 Dust Seal
Cylinders S0705005K
Page 17
7. Use caution to prevent damage to any
parts of U-packing (1, Figure 13). Remove
U-packing (1). Remove O-ring (2), and ring
(3).
Reference
Description
Number
1 U-Packing
2 O-ring
3 Ring
Figure 13

TOLERANCES)
S0705005K 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 14.
Figure 14
1. Apply grease to inner part of cylinder head
and to U-packing groove. See Figure 15.
Figure 15
2. Install split backup ring into its groove by
compressing ring. See Figure 16. 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 must 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 16
Cylinders S0705005K
Page 19
3. Insert one side of U-packing in its groove.
See Figure 17.
Figure 17
4. Carefully push down on other side of
U-packing until entire U-packing is seated
in its groove. See Figure 18.
Figure 18
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 19.
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 19
6. Use grease or an adhesive to hold split
backup ring (1, Figure 20) 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 20
S0705005K Cylinders
Page 20
7. Place continuous backup ring in warm
water. See Figure 21. Water temperature
must be 30 - 50°C (86 - 122°F). Leave ring
in water for 2 - 3 minutes. Slide continuous
backup ring (2, Figure 20) over cylinder
head and into its groove.
Figure 21
8. Install an O-ring over each of backup rings.
See Figure 22.
Figure 22
9. Use a seal installing jig to install dust seal
into cylinder head. See Figure 23. Install
retaining ring.
Figure 23
Cylinders S0705005K
Page 21
10. On piston, check corners of grooves that
piston rings will be mounted in. See Figure
24. If any burrs, roughness, or sharp
edges (1) are present, use an oil stone to
smooth roughened areas and dull sharp
edges.
Figure 24
11. Apply grease or hydraulic oil to corner of
piston at position A. See Figure 25.
Figure 25
12. Insert one end of backup ring into its
groove. See Figure 26. Use your hand to
slide other end of ring into groove.
Figure 26
13. Use warm water to expand slipper seal.
See Figure 27. This will make seal easier
to install. Set slipper seal in 60 -100° C
(140 - 212° F) water for 5 minutes or
longer.
Figure 27
S0705005K Cylinders
Page 22
14. Insert one end of slipper seal, (1, Figure
28) 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 28
cylinder tube.
15. Install two backup rings, (1, Figure 29).

One ring fits on either side of slipper seal
(2).
Reference
Description
Number
1 Backup Ring
2 Slipper Seal
Figure 29
Cylinders S0705005K
Page 23
16. Install wear ring (1, Figure 30) on piston.
Figure 30
17. Set cylinder rod (1, Figure 31) 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 31
18. Slide cylinder head assembly (1, Figure
32) 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 32
S0705005K Cylinders
Page 24
19. Install cushion flange (1, Figure 33) 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 33
20. Install piston nut (1, Figure 34) 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 34
21. Slide rod assembly into cylinder tube.
Align punch mark (1, Figure 35) 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 35
Cylinders S0705005K
Page 25
22. Install bolts in cylinder head and tighten
them to torque specified in bolt torque
chart. See Figure 36. 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 36
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.
S0705005K Cylinders
Page 26
S0705010
1CYLINDERS
CAUTION!
CYLINDERS S0705010
Mega 300-V (Tier I) 1001 and 2000
Mega 500-V 1001 thru 2000

June 2002
Cylinders S0705010
Page 1
TABLE OF CONTENTS
Parts List ................................................................................................. 5
Troubleshooting, Testing and Adjustment....................................................... 7
Disassembly ................................................................................................. 11
Reassembly.................................................................................................. 14
S0705010 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
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 S0705010
Page 3
THEORY OF OPERATION
Reference
Description
Number
1 Piston
2 Oil Path A
3 Oil Path B
Cylinder piston rods are extended or retracted

by oil flow to back side of cylinder (shown as "oil
path A") or to front of cylinder ("oil path B").
The cylinder rod is extended as oil flow is
pumped through the circuit to the back side of
the piston. The force (F1) of the piston stroke
can be expressed by the formula below, where
P = circuit oil pressure and the inside diameter
Figure 2
of the cylinder is expressed by B (Figure 2).
F1 = P x πB2
4
(P: Pressure, π = 3.14, B: Cylinder Inside Diameter)
Reference
Description
Number
1 Cylinder Inside Diameter - B
2 Oil Path A
3 Oil Path B
4 Rod Diameter
When the cylinder rod is retracted, oil flow Figure 3

through the circuit from the pump to the front
side of the cylinder generates a force (F2) that
can be expressed by the formula in which the
diameter of the piston rod is expressed by R,
and the other two terms are the same as in the
preceding expression.
F2 = P x π(B2-R2)
4
Because the volume of oil needed to lengthen

the cylinder rod (Q1) is greater than the volume
of oil required to retract the cylinder rod, it takes
more time to decrease cylinder stroke length
than it does to lengthen it.
Q1 = S x π(B2)
4
Figure 4
Q2 = S x π(B2-R2)
4
Q1 > Q2
S0705010 Cylinders
Page 4
PARTS LIST
Lift Cylinder
Figure 5
Reference Reference
Number Number
1 Cylinder Tube 11 Piston Ring
2 Cylinder Rod 12 U-ring
3 Cylinder Head 13 U-ring Holder
4 Bushing 14 Stopper
5 Retaining Ring 15 U-nut
6 Packing Header 16 Lock Washer
7 U-ring 17 Pin Bushing
8 Wiper Ring 18 Pin Bushing
9 Retaining Ring 19 Grease Flitting
10 Piston 20 O-ring
Cylinders S0705010
Page 5
Bucket Cylinder
Figure 6
Reference Reference
Number Number
1 Cylinder Tube 12 U-ring Holder
2 Cylinder Rod 13 U-ring Holder
3 Cylinder Head 14 Stopper
4 Bushing 15 Castle Nut
5 Retaining Ring 16 Shim
6 Packing Header 17 Dividing Pin
7 U-ring 18 Lock Washer
8 Wiper Ring 19 Pin Bushing
9 Piston 20 O-ring
10 Piston Ring 21 O-ring
11 U-ring 22 Plug
S0705010 Cylinders
Page 6
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.
(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
piston rod (18).
of bushing (15).
Oil leaking between cylinder Damage to O-rings (14). Replace O-rings (14).
head (16) and cylinder tube (13).
cylinder tube (13).
Cylinders S0705010
Page 7
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).
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).
(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
piston rod (18).
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).
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).
twisted.
scratched.
have other damage.
S0705010 Cylinders
Page 8
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.
incorrect.
Damaged pump shaft or pump Replace damaged parts.
drive sleeve.
internally. parts.
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.
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.
incorrect.
internally. parts.
cartridge.
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.
Cylinders S0705010
Page 9
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.
S0705010 Cylinders
Page 10
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.
NOTE: Dispose of drained fluids according to local regulations.
1. Use an allen wrench to remove bolts that
hold cylinder head to cylinder tube. See
Figure 7.
Figure 7
2. Support cylinder rod with a lifting sling.
See Figure 8. 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 8
3. Set cylinder rod assembly in a repair
fixture and secure rod in place. See Figure
9. Use a power wrench and socket to
remove nut that holds piston on rod.
Figure 9
Cylinders S0705010
Page 11
4. Remove piston nut (1, Figure 10), 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 10
5. Do not remove slipper seal, backup ring,
and back ring from piston. If these three
items are not scratched or damaged. See
Figure 11. 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 11
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
retaining ring, (1, Figure 12). Use a
screwdriver to remove dust seal (2) from
head.
Reference
Description
Number
1 Retaining Ring
Figure 12
2 Dust Seal
S0705010 Cylinders
Page 12
7. Use caution to prevent damage to any
parts of U-packing (1, Figure 13). Remove
U-packing (1). Remove O-ring (2), and ring
(3).
Reference
Description
Number
1 U-Packing
2 O-ring
3 Ring
Figure 13

TOLERANCES)
Cylinders S0705010
Page 13
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 14.
Figure 14
1. Apply grease to inner part of cylinder head
and to U-packing groove. See Figure 15.
Figure 15
2. Install split backup ring into its groove by
compressing ring. See Figure 16. 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 must 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 16
S0705010 Cylinders
Page 14
3. Insert one side of U-packing in its groove.
See Figure 17.
Figure 17
4. Carefully push down on other side of
U-packing until entire U-packing is seated
in its groove. See Figure 18.
Figure 18
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 19.
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 19
6. Use grease or an adhesive to hold split
backup ring (1, Figure 20) 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 20
Cylinders S0705010
Page 15
7. Place continuous backup ring in warm
water. See Figure 21. Water temperature
must be 30 - 50°C (86 - 122°F). Leave ring
in water for 2 - 3 minutes. Slide continuous
backup ring (2, Figure 20) over cylinder
head and into its groove.
Figure 21
8. Install an O-ring over each of backup rings.
See Figure 22.
Figure 22
9. Use a seal installing jig to install dust seal
into cylinder head. See Figure 23. Install
retaining ring.
Figure 23
S0705010 Cylinders
Page 16
10. On piston, check corners of grooves that
piston rings will be mounted in. See Figure
24. If any burrs, roughness, or sharp
edges (1) are present, use an oil stone to
smooth roughened areas and dull sharp
edges.
Figure 24
11. Apply grease or hydraulic oil to corner of
piston at position A. See Figure 25.
Figure 25
12. Insert one end of backup ring into its
groove. See Figure 26. Use your hand to
slide other end of ring into groove.
Figure 26
13. Use warm water to expand slipper seal.
See Figure 27. This will make seal easier
to install. Set slipper seal in 60 - 100° C
(140 - 212° F) water for 5 minutes or
longer.
Figure 27
Cylinders S0705010
Page 17
14. Insert one end of slipper seal, (1, Figure
28) 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 28
cylinder tube.
15. Install two backup rings, (1, Figure 29).

One ring fits on either side of slipper seal
(2).
Reference
Description
Number
1 Backup Ring
2 Slipper Seal
Figure 29
S0705010 Cylinders
Page 18
16. Install wear ring (1, Figure 30) on piston.
Figure 30
17. Set cylinder rod (1, Figure 31) 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 31
18. Slide cylinder head assembly (1, Figure
32) 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 32
Cylinders S0705010
Page 19
19. Install cushion flange (1, Figure 33) 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 33
20. Install piston nut (1, Figure 34) 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 34
21. Slide rod assembly into cylinder tube.
Align punch mark (1, Figure 35) 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 35
S0705010 Cylinders
Page 20
22. Install bolts in cylinder head and tighten
them to torque specified in bolt torque
chart. See Figure 36. 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 36
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.
Cylinders S0705010
Page 21
S0705010 Cylinders
Page 22
S0707100K
R1
1FAN DRIVE
HYDRAULIC MOTOR
(HALDEX)
CAUTION!
FAN DRIVE HYDRAULIC MOTOR (HALDEX)S0707100K


June 2002
Fan Drive Hydraulic Motor (Haldex) S0707100K

Page 1
TABLE OF CONTENTS
Parts List ................................................................................................. 5
Specifications .......................................................................................... 6
S0707100K Fan Drive Hydraulic Motor (Haldex)

Page 2
GENERAL DESCRIPTION
THEORY OF OPERATION
AJS0770L
Figure 1 Fan Drive System Schematic
Reference Reference
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.

Page 3
On the fan drive motor, at engine speed of 1,620
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

Page 4
PARTS LIST
2
3
4
5
7
1 6
7
5
10
9
8
4
3
2
13
14
12
16
AJS0780L
Figure 3
Reference Reference
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

Page 5
SPECIFICATIONS
Specification
Item
S/N 1001 thru 3000 S/N 3001 and Up
Fan Motor Displacement 31.0 cc (1.89 in3) 23.0 cc (1.40 in3)
Relief Valve Setting 70 ± 5 kg/cm2 (996 ±70 psi) 115 ± 5 kg/cm2 (1,636 ±70 psi)
Δ p/1 turn
16.5 kg/cm2 (235 psi) 16.5 kg/cm2 (235 psi)
Maker (Model) HALDEX (WM9A1-31...) HALDEX (WM9A1-31...)
Fan Fan Size ∅812 (32") ∅812 (32")
Type Sucker, plastic -8 driven by Sucker, plastic -8 driven by
hydraulic motor hydraulic motor
Fan rpm 1,300 rpm @ 70 ± 5 kg/cm2 1,300 rpm @ 115 ± 5 kg/cm2
(at motor relief Δ p) (996 ±70 psi)) (1,636 ±70 psi))
Fan Drive Pump 24.9 cc 24.9 cc
(1.52 cu. in) (1.52 cu. in)

Page 6
S0708485K
R1
1MAIN PUMP
(DENISON)
CAUTION!
MAIN PUMP (DENISON)S0708485K


December 2002
Main Pump (Denison) S0708485K

Page 1
TABLE OF CONTENTS
General ................................................................................................... 4
Description .............................................................................................. 4
Parts List ................................................................................................. 8
Specifications ........................................................................................ 10
Special Tools ................................................................................................ 11
Seal Driver ............................................................................................ 11
Protective Cone..................................................................................... 11
Troubleshooting ............................................................................................ 12
Overhaul....................................................................................................... 14
General ................................................................................................. 14
Changing Rotation ................................................................................ 15
Changing Cartridges ............................................................................. 16
Changing Port Locations....................................................................... 16
Changing Shaft or Shaft Seal................................................................ 17
Disassembly of Pump ........................................................................... 18
End Cap ......................................................................................... 18
Shaft End ....................................................................................... 19
Shaft............................................................................................... 19
Reassembly of Pump ............................................................................ 19
Shaft End ....................................................................................... 19
Center Housing and "D" Unitized Cartridge (P1) ........................... 20
"C" Unitized Cartridge (P2) and End Cap ...................................... 20
Unitized Pumping Cartridges ......................................................... 21
Disassembly of "C" Cartridge................................................................ 22
Reassembly of "C" Cartridge ................................................................ 23
Disassembly of "D" Cartridge................................................................ 24
Reassembly of "D" Cartridge ................................................................ 25
Installation .................................................................................................... 26
S0708485K Main Pump (Denison)

Page 2
Mounting ............................................................................................... 26
Piping .................................................................................................... 26
Fluids..................................................................................................... 27
Type ............................................................................................... 27
Antiwear Additives ......................................................................... 27
Non Petroleum Base or Fire Resistant Fluids ................................ 27
Operating Temperature .................................................................. 27
Pump inlet Conditions .................................................................... 28
Start-up Procedures ..................................................................................... 29
Prestart Check ...................................................................................... 29
Priming .................................................................................................. 29

Page 3
GENERAL DESCRIPTION
GENERAL
This manual covers installation, operation, maintenance and overhaul instructions for the Denison T6DC
series vane type double pumps.
DESCRIPTION
Figure 1
The Denison T6DC vane pumps are efficient, compact units designed for continuous duty up to 210 bar
(3,040 psi) and 2500 rpm and intermittent duty up to 245 bar (3,550 psi).
Ten basic cartridge sizes are offered for the "D" section worth a rated delivery of 57, 59, 95, 106, 117, 12,
144, 159, 170 and 189 l/min @ 1,200 rpm @ 7 bar (100psi). and thirteen basic cartridge sizes are offered
for the "C" section with a rated delivery of 11, 19, 23, 30, 38, 44, 44, 53, 64, 76, 83, 95, 106 and 130 l/min
@1,200 RPM @ 7 bar (100 psi). Any "D" cartridge may be used with any "C" cartridge which allows for 130
characteristics are given for each cartridge size in table I on (See page 6).
The T6OC vane pumps consist of sox basic components: (a) end cap, (7) "C" section unitized cartridge
consisting of; rotor, vanes, vane holdout pins, cam ring, bearing, port plate, and pressure plate, (c) center
housing, (d) "D" section unitized cartridge consisting of; rotor, vanes, vane holdout pins, cam ring, port
plate, pressure plate, (e) shaft and bearing and (f) mounting cap.
The T6DC vane pump features the use of unitized pumping Cartridge for both the "D" and "C" pump
section. The unitized cartridge assemblies are pretested and provide for ease of disassembly and
assembly in the event it becomes necessary or desirable to make repairs, overhaul or revise the flow
delivery.

Page 4
THEORY OF OPERATION
The pumping operation of this unit (each cartridge) is obtained by providing a fixed interior cam surface
and a rotating inner member (rotor) containing vanes which are held in contact with the inner cam surface.
As the rotor is rotated by the drive shaft, the vanes are urged outward against the outward sloping cam
surface, forming a cavity at the inlet ports of the port plates. Atmospheric pressure and suction created by
the expanding cavity between the rotating vanes fill the inlet cavity with fluid.
As the rotation continues and the vanes that had previously moved outward and now have fluid trapped
between them and the port plates, follow the inward slope of the cam which decreases the cavity
containing the trapped fluid and discharge the fluid at system pressure thru the pressure port openings in
the port plates.
The rotating portion of the unitized cartridges feature the use of pressure actuated vanes which are urged
against the cam ring by pins in the bottom of each rotors vane slot. Initial force to bring the vanes in contact
with the cam ring contour during start up is provided by centrifugal force. When pumping operation starts
and pressure is established, fluid under pressure fills the pin cavity thru the feed holes. The feed holes
open to the pressure port twice every revolution. All other times they are closed off by the port plate. This
pressure under the pin provides the force necessary to keep the vanes in contact with the cam contour.
NOTE: When operating the pump at the maximum outlet pressure, the pump shaft rotation should
not be allowed to fall below 600 RPM in order to maintain proper vane to cam ring contact.
The inlet or suction flow for both the "D" cartridge and "C" cartridge feeds through a common 76.2 mm
(3.0 in) port in the center housing, through the large ports of each port plate for each cartridge and through
the center hole in the suction zone of each cam ring.
To determine the performance characteristics of a given model, refer to table I on (See page 6):

Page 5
Table I. Operating Characteristics - Typical (24 cSt)
Pressure Volumetric Flow Q (l/min) & n=1,500 RPM Input power P (kW) & n=1,500 RPM
Series
Port displacemnet.Vp p=0bar p=140bar p=240bar p=7bar p=140bar p=240bar
014 47.6 ml/rev 74.4 62.1 55.9 2.5 18.0 30.6
020 66.0 ml/rev 99.0 89.7 83.5 2.8 24.4 41.7
024 79.5 ml/rev 119.3 110.0 103.8 3.0 29.6 49.8
028 89.7 ml/rev 134.5 125.2 119.0 3.2 32.7 55.9
031 98.3 ml/rev 147.4 138.1 131.9 3.3 35.7 61.0
P1
035 111.0 ml/rev 166.5 157.2 151.0 3.5 40.1 68.7
038 120.3 ml/rev 180.4 171.1 164.9 3.7 43.3 74.2
042*** 136.0 ml/rev 204.0 194.7 188.5 4.0 48.7 83.7
045*** 145.7 ml/rev 218.5 209.2 203.0 4.1 52.1 89.5
050*** 158.0 ml/rev 237.0 227.7 224.0** 4.4 57.0 85.0**
003 10.8 ml/rev 16.2 11.2 7.7 1.3 5.3 8.4
005 17.2 ml/rev 25.8 20.8 17.3 1.4 7.5 12.2
006 21.3ml/rev 31.9 26.9 23.4 1.5 8.9 14.7
008 26.4 ml/rev 39.6 34.6 31.1 1.6 10.7 17.7
010 34.1 ml/rev 51.1 46.1 42.6 1.7 13.4 22.3
012 37.1 ml/rev 55.6 50.6 47.1 1.7 14.4 24.1
P2 014 46.0 ml/rev 69.0 64.0 60.5 1.9 17.6 29.5
017 58.3 ml/rev 87.4 82.4 78.9 2.1 21.9 36.9
020 63.8 ml/rev 95.7 90.7 87.2 2.2 23.8 40.2
022 70.3 ml/rev 105.4 100.4 96.9 2.3 26.1 44.1
025* 79.3 ml/rev 18.9 113.9 110.4 2.5 29.2 49.5
028* 88.8 ml/rev 133.2 128.2 124.7** 2.8 32.7 48.5**
031* 100.0 ml/rev 150.0 145.0 151.5** 2.8 36.5 54.4**
* 025 - 028 - 031= 2,500 RPM max.
** 028 - 031 - 050 = 210 bar max. int.
*** 042 - 045 - 050 = 2,200 RPM max.
Port connection can be furnished with metric threads.

Page 6
Page 7
PARTS LIST
Figure 2

Page 8
Deference Deference
Number Number
1 End Cap 25 Ring; Backup
2 Seal; Section 26 Pin; Dowel
3 Seal; Section 27 Housing
4 Ring; Backup 28 Pin; Dowel
5 Seal; Section 29 Pin; Dowel
6 Rotor 30 Port Plate; Rear
7 Bushing 31 Pin
8 Screw 32 Cam Ring
9 Washer; Lock 33 Vane
10 Port Plate; Rear 34 Pin; Dowel
11 Cam Ring 35 Port Plate; Press
12 Vane 36 Bolt
13 Seal; Section 37 Coupling
14 Seal; Section 38 O-ring
15 Pin 39 Bolt
16 Seal; Section 40 Pump; Gear
17 Ring; Retaining 41 Bolt
18 Bearing; Ball 42 Bolt
19 Seal; Section 43 Cartridge Kit (P1)
20 Shaft 44 Cartridge Kit (P2)
21 Ring; Section 45 Seal Kit
22 Cap; Mounting 46 Shaft & Bearing Kit
23 Port Plate; Press 47 Port Plate Kit (C)
24 Rotor 48 Port Plate Kit (D)

Page 9
SPECIFICATIONS
Item Specification
Engine DE12TIS DE08TIS
Pump Main Pump Steering Pilot Pump Main Pump Steering Pilot Pump
Pump Pump
Model T67CCA-B25-B22-B06-3R32 T67CCAY-B20-B22-B06-3R32
Number
Type Vane Vane Vane Vane Vane Vane
Displacement 79.5 cc 70.3 cc 19.6 cc 63.8 cc 70.3 cc 19.6 cc
(4.85 in3) (4.29 in3) (1.20 in3) (3.89 in3) (4.29 in3) (1.20 in3)
* Maximum 167 l/min 148 l/min 41 l/min 134 l/min 148 l/min 41 l/min
Flow Rate (44.1 gpm) (39.1 gpm) (10.8 gpm) (35.4 gpm) (39.1 gpm) (10.8 gpm)
Pump 200 kg/cm2 185 kg/cm2 120 kg/cm2 200 kg/cm2 185 kg/cm2 120 kg/cm2
Pressure (2,840 psi) (2,631 psi) (1,707 psi) (2,840 psi) (2,631 psi) (1,707 psi)
Weight 43.50 kg (96 lb)
(* at rated rpm)

Page 10
SPECIAL TOOLS
Special tools will help to properly install the shaft seal. A shaft seal driver of propel size must be used to
install the shaft seal. A protective cone must be used over the shaft end to prevent damage to the shaft
seal when installing the shaft.
The remainder of the pump disassembly and assembly can be accomplished with normal repair shop tools
and good repair practices. Refer to Figure 3 and Figure 4 for proper configuration and dimensions for the
seal driver and protective cone.
SEAL DRIVER
NOTE: 1. Remove all burrs and break
sharp edges. 0.25/0.31R.
2. Length "A" to heat treated to
HRC 50-55.
3. Length "A" to have a 1.5-3S
full length, with a smooth
intersection between
chamber and dia "B."
4. Grease O.D. of length "A"
before installing shaft seal
Figure 3
onto tool to prevent damage
to the seal. Material SCM4
(HRC = 27-23) or equivalent.
PROTECTIVE CONE
NOTE: 1. Remove all burrs and break
sharp edges. 0.25/0.31R.
2. Teflon preferred, alternate
SCM4 treated after
machining to HRC 40-45.
3. Install protective cone over
shaft extension and grease
O.D. to prevent damage to
shaft seal.
4. Length "A" to have a 1.5 - 3S
Figure 4
full length, with a smooth
intersection between
chamber and dia. "B."

Page 11
TROUBLESHOOTING
The internal parts of this pump are lubricated by the operating fluid, therefore, preventative maintenance is
limited to keeping the fluid in the system clean. The system filters must be replaced frequently and if a
suction strainer is used it must not be allowed to become restricted. When possible, dirt should not be
allowed to accumulate on the pump or around the shaft seal. All fittings and bolts must be tight.
NOTE: It is especially important that the suction or inlet piping and fittings be tight and in good
repair to prevent air from being drawn into the system.
In the event the pump does not perform properly or a malfunction occurs, refer to the "Trouble Shooting
Chart" before proceeding with an overhaul.
Trouble Possible Cause Possible Remedy

External Leakage. Seal failure. Replace seal.
Damaged casting. Replace casting.
Damaged or defective seal between Replace seal.
housing and mounting cap.
Leakage at Fittings. Cracked or damaged flange or fittings. Replace flange or fittings.
Damaged or defective flange threads or Replace flange. Use shorter
screws too long. screws.
Damaged or defective O-ring seal. Replace O-ring seal.
Burr on mating surfaces. Remove burr.
Loss in pump RPM Power source too small for pump being Provide larger power source.
under load. used.
Pump not delivering Pump does not prime. Bleed air from system.
oil Wrong direction on shaft rotation. Reverse direction of shaft.
Covert pump to reverse direction
of rotation. (Check rotation arrows
on identification. plate and cam
ring.)
Tank fluid level too low. Add fluid and check level to be
certain suction line is submerged.
Fluid inlet line or suction strainer clogged Clean strainer of all foreign
or undersized. material. Provide proper size
strainer (should have a capacity
equal to 2 x pump volume in flow).
Air leak in suction line. Tighten and seal connection.
Replace seals.
Fluid viscosity too heavy to pick up prime. Use lighter viscosity fluid.
Broken pump shaft or internal parts. Replace damaged parts per
overhaul instructions.

Page 12
Trouble Possible Cause Possible Remedy
Pump not Relief valve setting too low. Reset relief valve.
developing pressure Relief valve sticking open. Check for defective or
malfunctioning valve.
Vane hold out pins not loading vanes. Disassemble and check pins for
burrs or damage: Check for
foreign material.
Free recirculation of fluid to tank being Check directional control valve for
allowed. open center or neutral position.
Check for open bypass valve.
Noisy or erratic Air leak at pump inlet or suction lines. Check for air leaks by pouring
operation system fluid around joints and
listen for change in sound level.
Tighten as required.
Housing and mounting cap separation. Check bolts for proper torque.
Restricted or clogged inlet line or strainer. Provide larger inlet line or strainer.
Clean strainer.
Excessive pump RPM (cavitation). Provide power source that does
not exceed maximum pump RPM
recommendations for existing
inlet conditions.
Worn vanes, cam ring or port plates. Disassemble per overhaul
instructions and replace worn
parts.
Worn vane holdout pins. Disassemble per overhaul
instructions. Replace pins if worn.
Worn bearings. Disassemble and replace.
Seal failure Excessive inlet pressure Decrease inlet pressure. Inlet
pressure must not exceed 2.5 bar
(35 psi).

Page 13
OVERHAUL
Figure 5
GENERAL
The instructions in this section cover complete disassembly, inspection and reassembly of the Denison
T6DC series vane type double pumps.
Also, in this section is information for changing port location, changing cartridges, changing relation and
changing the shaft and shaft seal.

Page 14
CHANGING ROTATION
These instructions detail the procedure to change direction of rotation of a pump.
1. Drain all fluid from the pump and thoroughly clean exterior surface.
2. Secure the pump in a vise with the shaft extended down. Clamp the vise on the mounting cap, not on
the housing.
3. Remove the seven screws (1, Figure 5) from the end cap (2). Remove the end cap by pulling
outward. Remove the O-ring (3) from the end cap.
4. Remove the "C" cartridge (4) from the end cap and lay on a clean surface. Refer to -- during cartridge
directional change.
5. Before performing work on the "C" cartridge, note when viewing the pressure plate, a right-hand
(CW) pump will have the directional arrow on the cam ring pointing (CW). For left-hand (CCW) pump
rotation the arrow on the cam ring will point (CCW).
6. Remove the two screws from the "C" cartridge (4a, Figure 5) and remove the port plate (4c). Remove
and invert the cam ring (4e).
7. Note that dowel pins (4j and 4d) are not inserted in the same holes for (CCW) as for (CW) operation.
The arrow on the cam ring (4e) must point in the direction the pump is intended to run.
8. Install the cam ring on the pressure plate over the rotor. Install the port plate (4c) and secure with two
screws through the cam ring and into the pressure plate.
9. Remove the four screws (15) and separator the center housing (5) from the mounting cap (14). It may
be necessary to use a gear puller to remove the "D" cartridge (6) by hooking the arms under the cam
ring. Care must be taken not to damage the cam ring or mounting cap.
10. Before performing work on the "D" cartridge refer to Figure 5 and notice the difference in assembly of
the right-hand and left-hand units.
11. Remove the four screws (6a, Figure 5) and lock washers (6b). Remove the port plate (6d). Invert the
cam ring (6f).
NOTE: The arrow on the cam ring must indicate the same direction as the arrow on the pressure
plate next to the dowel pin hole.
12. Install the cam ring on the pressure plate over the rotor. Install the port plate and secure with four
screws and lock washers through the cam ring and into the pressure plate. Tighten with a screw
diver.
13. Install "D" cartridge in center housing making sure the drive lock pin in the port place seats in the hole
in the center housing.
14. Lubricate the "D" cartridge O-rings and place mounting cap and shaft assembly over front cartridge.
Make sure the shaft passes thru the "D" rotor. Rotate shaft back and forth to make sure the splines in
the rotor engage.
15. Orient pressure port in the desired direction and line up the screw holes. Draw the mounting cap
down onto the center housing by alternately tightening two screws in diagonally opposed holes.
16. Install the other two screws and torque all four to 18.7 kg•m (135 ft lb).
17. Install the "C" cartridge in the center housing over the shaft making sure the drive lock pin in the port
plate seats in the hope in the center the housing.
18. Lubricate "C" cartridge pressure plate O-rings and place end cap over pressure plate. Orient port to
proper direction and make sure the screw holes line up.
19. Draw the end cap onto the center housing by alternately lightening two screws in opposite holes.
20. Install the other five screws and torque all seven to 6.2 kg•m (45 ft lb).

Page 15
CHANGING CARTRIDGES
When changing cartridges the following instructions must be observed.
1. Drain all fluid from pump and thoroughly clean exterior surface.
2. Secure unit in a vise with the shaft extended down. Clamp the vise on the mounting cap, not on the
housing.
3. Remove the seven screws (1, Figure 5) and end cap (2) and cartridge. Note position of pressure port
in reference to the suction port. Remove the seat (3) from cap.
4. Remove the "C" cartridge assembly (P2) from end cap. It may be necessary to use a gear puller with
its arms hooked under the cam ring. It may also be removed by prying up against the cam ring. Care
must be taken not to damage the cam ring or cap.
5. Remove the four screws (15) and separate the center housing (5) from the mounting cap (14). Items
6 thru 14 will be removed as a unit. It may be necessary to use a gear puller to remove the "D"
cartridge (6) by hooking the arms under the cam ring. Care must be taken not to damage the cam
ring or the mounting cap.
6. Place the center housing (5) with large open end up and install the "D" cartridge in the housing. Make
sure the pin (6c, Figure 5) enters drilled hole in housing.
7. Install the mounting cap (14) with the attached shaft assembly by inserting the shaft through the
cartridge assembly. Rotate the shaft to engage the spline in the rotor.
NOTE: Position the P1 outlet port and the inlet port in the housing to the required position by
turning the mounting cap.
8. Install the four screws and alternately tighter two to draw down mounting cap. Torque all four to 78.7
kg•m (570 ft lb).
9. Install the "C" cartridge in the small end of the housing. Make certain the pin in the per plate enters
the drilled hole in housing.
10. Install seal (3) on end cap. Apply hydraulic fluid on all the seals to assist in assembly. Install end cap
(2) over the cartridge and rotate until the P2 outlet is in the desired position.
11. Install the seven screws and alternately tighten two to draw down end cap. Torque all seven to 6.20
kg•m (45 ft lb).
CHANGING PORT LOCATIONS

These instructions detail the procedure to change the port locations.
1. Drain the fluid from the pump and thoroughly clean the exterior surface.
2. Secure the pump in a vise with the shaft extended down. Clamp the vise on the mounting cap, not on
the housing.
3. Remove the seven screws that secure the end cap (2). Remove the end cap and the "C" cartridge
assembly from the center housing.
4. Separate the end cap from the cartridge assembly and install the cartridge back into the center
housing. It may be removed by use of a gear puller with the arms hooked under the cam ring or by
prying up against the cam ring. Care must be taken not to damage the ring.
5. Replace the O-ring (3) on the end cap. Lubricate all O-rings after installation. Position the end cap in
the desired position and secure with seven screws. Torque to 6.22 kg•m (45 ft lb).
6. Remove the four screws that secure the mounting cap to the housing and pull the mounting cap and
"D" cartridge from the center housing. Remove the "D" cartridge from the mounting cap.

Page 16
7. Replace the cartridge in the center housing. Make certain the pin in the port plate enters the drilled
hole In the housing.
8. Install new O-ring (13) in mounting cap and position cap in the desired position. Install four screws
and torque to 18.7 kg•m (135 ft lb).
9. Fill the pump with hydraulic fluid.
CHANGING SHAFT OR SHAFT SEAL

When necessary to change the shaft seal or shaft the following steps must be observed.
1. Drain the unit of hydraulic fluid.
2. Remove the four screws (15, Figure 5) and separate the center housing from the mounting cap. Items
6 thru 14 will be removed as a unit. Remove the cartridge assembly from the mounting cap.
3. Remove the O-ring (13) from the cap. Remove retaining ring (7) and press or drive the shaft
assembly from the cap. Use a soft faced hammer and gently tap the end of the shaft. If shaft seal is
not to be changed, use the protective cone (Figure 4) when driving out the shaft. Remove the seal if it
is to be changed.
4. To assemble a new shaft assembly use the following procedure. Install retaining ring (10, Figure 5) In
groove nearest drive end of shaft by passing ring over the internal serration. Do not install it over the
drive end of the shaft as this may damage the seal surface next to the groove.
5. Install the ball bearing (9) by pressing on the inner bearing race until seated against ring (10). Install
retaining ring (8). Make sure both rings are fully seated in grooves.
6. Use seal driver (Figure 3) and press shaft seal into the mounting cap. Grease seal lips.
NOTE: The open face of seal must be toward installation tool. If a sealant is not furnished on the
O.D. of the seal apply a light coat of approved sealing compound to the O.D. of the seal.
Extreme care must be taken to avoid depositing any of the sealing compound on the seal
element or the shaft.
7. Install protective nose cone (Figure 4) over external drive end of shaft subassembly and then by
pressing on the outer race of the ball bearing, press the shaft into the mounting cap.
CAUTION!
Do not press on end of shaft.
8. Install retaining ring (7) to hold shaft in place. Make sure ring is fully seated In groove.
9. Place cartridge in housing. Install O-ring in mounting cap and insert shaft assembly down through the
"D" cartridge engaging the matching serrations.
CAUTION!
Take special care the splines of the shaft and rotor engage smoothly. If necessary rotate the
shaft slightly to obtain n smooth engagement.
10. Locate P1 port in proper position and secure mounting cap to housing with four screws. Torque to
18.7 kg•m (135 ft lb).

Page 17
DISASSEMBLY OF PUMP
Figure 6
Sometimes a malfunction in the small section of the pump, "C" cartridge (P2), can be corrected without
removing the pump from the power source. To service the large section, "D" cartridge, (P1) the complete
pump must be removed.
1. Drain all fluid from the pump and thoroughly clean the exterior surface.
2. Prepare a clean, lint free surface on which to lay the internal parts for inspection and repair.
3. Inspect all internal parts for scratches, nicks and excessive wear. Slight imperfections may be
removed with a fine India stone.
4. All parts must be cleaned with a suitable solvent and dried with clean, dry compressed air. Protect
parts from dirt and rust until time of assembly with a film of clean hydraulic fluid.
5. During assembly all lapped and ground surfaces must be lubricated with clean hydraulic fluid. Use
extreme care not to damage these surfaces.
Secure the pump in a vise or other suitable holding fixture with the shaft (11) extended down.
Note position of two outlet ports (P1 & P2) with reference to the inlet port in the center housing (5) before
removing any screws so that the two outlet ports may be returned to their original position at reassembly.
Discard all seals as they are removed.
End Cap
1. Remove the seven screws (1) from the end cap (2). Remove the end cap by pulling outward. Remove
the rubber seal (3) from the end cap.
2. Remove the "C" unitized cartridge (4) from the end cap (2) and lay aside on a clean surface for
disassembly and inspection later. See Figure 5 for cartridge disassembly and assembly instructions.

Page 18
Shaft End
1. Remove the four screws (15) and separate the center housing (5) from the mounting cap (14). Items
(6 through 14) will be removed as a unit. Remove cartridge from mounting cap with puller or by
carefully prying against cam ring and mounting cap. Be careful not to damage the cam ring or
mounting cap. Lay the cartridge aside for inspection later. See Figure 5 for cartridge disassembly and
assembly instructions.
2. Remove the rubber seal (13) from the mounting cap, Remove retaining ring (7) and press the shaft
and hearing assembly (items 8, 9, 10 and 11) from the mounting cap. Remove shaft seal (12) from
the mounting cap.
Shaft
1. Examine the ball bearing (9) for wear before removing it from the shaft. Apply a little pressure to the
outer race and relate the bearing to check the balls and race for wear or cracks and check for
looseness. Remove the bearing from the shaft if a replacement is needed. Inspect the outside
diameter of the shaft at the point of contacts with bearing in the "C" cartridge and the sealing surface
for the shaft seal. Do not remove the bearing from the shaft if both are reusable.
Omit the next procedure if not required.
2. Remove retaining ring (8) and press bearing (9) from the shaft (11). Remove retaining ring (10).
NOTE: See Figure 7 for critical areas on the shaft.
WARNING!
Retaining ring (10) must be removed by passing over the bearing surface of the shaft and never
over the shaft seal surface. A damaged seal surface will cause the shaft seal to leak.
REASSEMBLY OF PUMP
Immerse the seals and bearing in clean hydraulic fluid to make the reassembly easier and to provide initial
lubrication.
Shaft End
1. Place the mounting cap (14) on a clean surface with the large open end facing up. Use a shaft seal
driver (See Figure 3) and install the shaft seal (12) in the cap (14). Make certain the open side of the
seal is toward the inside of the mounting cap. The shaft seal driver wilt prevent damage to the seal
during installation.

Page 19
2. Install retaining ring (10) in the groove on
the shaft between the bearing surface and
the seal surface. Do not allow the retaining
ring to touch the seal surface on the shaft.
Press bearing (9) over the same end of the
shaft and install retaining ring (8). See
Figure 7. Be sure retaining rings (8 and
10) are fully seated in grooves.
3. Apply lubricating fluid to the inside of the
shaft seal (12) and install the shaft
assembly (8, 9, 10 and 11) in the mounting
cap (14).
Figure 7
4. Install retaining ring (7) in the mounting
cap (14) and against the bearing (9) to
held the shaft assembly in place. Make
certain retaining ring (7) is fully seated in
the groove.
5. Install seal (13) on the pilot of the
mounting cap (14).
Center Housing and "D" Unitized Cartridge (P1)

1. Place the center housing (5) on a clean flat surface with the large open end up and install the "D"
unitized cartridge assembly (6) in the housing. Make certain that Driv-Lok pin (Figure 5, Item 6c)
enters the drilled hole in the housing.
2. Apply lubricating fluid to the two seals on the cartridge (6) and seal (13) on the mounting cap (14).
This fluid will lessen the chance of damaging the seals when installing the mounting cap.
3. Install the mounting cap (14) with the attached shaft assembly by inserting the shaft through the
cartridge assembly and into the center housing (5). Rotate the shaft to engage the spline in the rotor.
NOTE: Position the P1 outlet port in the mounting cap (14) and the inlet port in the center housing
(5) in required position by turning the mounting cap.
4. Install tIne four screws (15) and alternately lighten two opposed screws to draw down cap. Torque all
four screws to 18.7 kg•m (135 ft lb).
"C" Unitized Cartridge (P2) and End Cap

1. Install the "C" unitized cartridge assembly (4) in the small end of the center housing (5). Make certain
that the Driv-Lok pin (Figure 5, Item 4b) enters the drilled hole in the housing.
2. Install rubber seal (3) on end cap (2) (Figure 6).
3. Apply lubricating fluid to the two seals on the cartridge (4) and to seal (3) on the end cap (2).
4. Install end cap (2) over the exposed end of cartridge (4) arid rotate until the P2 outlet is in the desired
position.
5. Install the seven screws (1) and alternately tighten two opposed screws to draw down cap. Torque all
seven screws to 5.2 kg•m (38 ft lb).

Page 20
Unitized Pumping Cartridges
The unitized pumping cartridges used in the T6DC series pump function in the same manner, however,
due to the cartridge arrangement when installed in the pump, different assembly procedures must be
followed for each cartridge.
It is recommended that a complete preassembled and pretested unitized cartridge be used when it
becomes necessary to perform changes or overhaul in the field. In the extent it is desired to change or
overhaul a unitized cartridge, the service man must be aware of the different assembly procedures
required of the two cartridges.
Refer to Figure 8 and observe the general line up of components and the position of port plates and
pressure plates of each unitized cartridge.
Before performing work on the "C" cartridge (P2), refer to Figure 5 and observe the location of the dowel
pins in the port plate, pressure plate and cam ring. When viewing this cartridge from the port plate end, a
right-hand and (CW) assembly will have the directional arrow on the cam ring pointing right-hand (CW),
For a left-hand (CCW) assembly the arrow will be pointing left-hand (CCW).
Before performing work on the "D" cartridge (P1), refer to Figure 5. When viewing this cartridge from the
port plate end, a right-hand (CW) assembly will have the directional arrow on the cam ring pointing
left-hand (CCW). For a left-hand (CCW) assembly the arrow will be pointing right-hand (CW).
To insure proper pump operation, it is imperative that the following procedure be used when performing a
cartridge overhaul.
Figure 8

Page 21
DISASSEMBLY OF "C" CARTRIDGE
Figure 9
1. Remove the two screws (4a) and the port plate (4c). The Driv-Lok pin (4b) is pressed into the port
plate and should not be removed unless damaged and replacement is required.
2. Remove dowel pin (4d) cam ring (4e) and dowel pin (4j).
3. Remove the vanes (4f), and the pins (4g) from the rotor.
4. Remove the seals (4m and 4n) and backup ring (4q) from the pressure plate.
Wash all the metal parts in cleaning solvent and dry thoroughly. Discard the rubber seals. Place all the
parts on a clean lint free surface and inspect for wear marks, nicks and burrs. Light scoring on the wear

Page 22
surfaces of the port plate and pressure plate may be removed by lapping. The vanes must move freely in
the rotor slots and not bind or have excessive play. The edges of the vanes and the rotor slots may be
stoned with a fine India stone to remove all burrs. Inspect the cam ring for excessive wear (ripples or
washboard marks on the contour). Replace a badly worn or defective cam ring and any parts that cannot
be reconditioned.
All metal parts that have been lapped or stoned, must be washed again in clean solvent and dried before
they are assembled.
Make certain that all internal passages in the port plate, pressure plate, rotor, and vanes are open and
clean.
REASSEMBLY OF "C" CARTRIDGE

The "C" cartridge is made up using the same parts regardless of the direction of rotation. Refer to Figure 9
and observe that screws (4a) and dowel pins (4d and 4j) are not inserted in the same holes for left-hand
(CCW) as for right-hand (CW) operation. The arrow on the cam ring (4e) must point in the direction that the
pump is intended to run.
1. Place the pressure plate (4k) on a clean flat surface with the wear face up and apply clean hydraulic
fluid to the face.
NOTE: Again, Check the rotation of the pump where this cartridge will be used.
2. Insert dowel pin (4j) in the pressure plate using the hole nearest the arrow that indicates the desired
rotation.
3. Center the rotor assembly (4h) on the pressure plate with the splined side of the rotor up.
4. Insert one vane holdout pin (4g) in each vane slot in the rotor assembly. The holdout pins must move
freely and be inserted against the bottom of the hole.
5. Install the vanes (4f) in the rotor with the flat side of the vane toward the center of the rotor.
6. Place the cam ring (4e) over the dowel pin (4j). The arrow on the cam ring must indicate the same
directions as the arrow which is closer to dowel pin (4j) in the pressure plate (4k).
7. Install dowel pin (4d) in the cam ring. If the Driv-Lok pin (4b) was removed from the port plate (4c), it
must be replaced.
8. If removed, press the Driv-Lok pin (4b) into the hole provided in the back of the port plate (4c)
(grooved end first).
9. Pour clean hydraulic fluid over the cam ring and rotor assembly and install the port plate assembly
(4c) over the dowel pin (4d). The port plate must be positioned to allow the two screws (4a) to pass
through the cam ring and enter the pressure plate.
10. Insert the two screws (4a) and tighten. Install seals (4m and 4n) and backup ring (4q) on the pressure
plate.
NOTE: Contoured side of the backup ring must face seal.

Page 23
DISASSEMBLY OF "D" CARTRIDGE
Figure 10
1. Remove the four screws (6a), lock washers (6b) and the port plate (6d). The Driv-Lok pin (6c) is
pressed into the port plate and should not be removed unless damaged and replacement is required.
2. Remove dowel pin (6e), cam ring (6f) and dowel pin (6k).
3. Remove the vanes (6g), and the pins (6h) from the rotor (6j).
4. Remove the seals (6n and 6p) and backup plate (6q) from the pressure palate (6m).
Wash all the metal parts in cleaning solvent and duty thoroughly. Discard the rubber seals.

Page 24
Place all the parts on a clean lint free surface and inspect for wear marks, nicks and burrs, Light scoring on
the wear surfaces of the port plates may be removed by tapping. The vanes must move freely in the rotor
slots and not bind or have excessive play. The edge of the vanes and the rotor slots may be stoned with a
fine India stone to remove all burrs. Inspect the cam ring for excessive wear (ripples or washboard marks
on the contour). Replace a badly worn or defective cam ring and any parts that cannot be reconditioned.
All metal parts that have been lapped or stoned must be washed again in clean solvent and dried before
they are assembled.
Make certain that all internal passages in the port plate, rotor and vanes are open and clean.
REASSEMBLY OF "D" CARTRIDGE

1. Place pressure plate (6m) on a clean bench with the wear face up and apply clean hydraulic fluid.
Install dowel pin (6k) in pressure plate in the hole nearest the arrow that indicates the desired
rotation.
2. Center the rotor (6j) on the pressure plate with the splined side of the rotor up.
3. Insert one vane pin (6h) in each vane slot in the rotor. The pins must move freely and be inserted
against the bottom of the hole.
4. Install the vanes (6g) in the rotor with the flat side of the vane toward the center of the rotor.
5. Install the cam ring (6f) over the dowel pin (6k) with the arrow pointing in the direction that the pump
is intended to run. Install dowel pin (6e) in cam ring.
NOTE: The arrow on the cam ring must indicate the same direction as the stamped arrow on the
pressure plate.
6. If removed, press the Driv-Lok pin (6c) into the back of the port plate (6d) (Grooved End First).
7. Pour clean hydraulic fluid over the cam ring and motor and install the port plate (6d) over the dowel
pin (6k) so the pin is in the hole nearest the arrow that indicates the desired rotation.
8. Insert the four screws (6a) and lock washers (6b) through the port plate (6d), cam ring (61) and into
the pressure plate (6m) and tighten with a screwdriver. Install seals (6n and 6p) and backup ring (6q)
on the pressure plate.
NOTE: The contoured side of the backup ring must face the seal.

Page 25
INSTALLATION
MOUNTING
This pump may be mounted In any position, however it is recommended that a horizontal position be used
whenever possible. The Inlet port and the outlet port of the "D" section (shaft end) (P1) allows four relative
positions In 90° interval: The Inlet port and the outlet port of the "C" section (cap end) (P2) allows eight
relative positions in 45° intervals. If so desired, the porting relationship between the inlet and the "D"
section outlet may be changed by removing the four bolts securing the mounting cap to the center housing
and rotating the mounting cap relative to the center housing to the desired porting arrangements. When
replacing the four bolts they be torque to the recommended value 18.7 kg•m (135 ft lb).
The porting relationship between the inlet and the "C" section outlet may be changed by following the
procedure in the section "Changing Port Location."
The mounting hub and mounting bolt hole location conform to SAE-C, 2 bolt standard in both the spline
and key shaft options. For proper operation, the pump shaft must be in alignment with the power source
shaft and must be checked with a dial Indicator. The mounting pad or adapter into which the pump pilots
must be concentric with the power source shaft within 0.15 mm (0.0059 in) TIR. The shaft concentricities
are particularly important if the pump shaft Is rigidly connected to the power source without a flexible
coupling or a coupling that allows only for minor misalignment.
PIPING
All fluid lines, either pipe, tubing or flexible hose must be of adequate size and strength to assure free flow
to and from the pump.
NOTE: Do not use galvanized pipe.
Galvanized coating may flake off after continued use. The inlet line must be of proper size to prevent
restriction of the fluid flow to the pump. Excessive inlet restrictions will prevent proper operation and may
cause damage due to cavitation. The inlet piping must be sized to meet or exceed the minimum inlet
requirements as outlined in below table II.
Table II - Inlet Pressure, Minimum - as measured at pump inlet flange with petroleum base fluids. Multiply
absolute pressures by multiplier shown in TABLE IV to find inlet pressures for Fire Resistant Fluids.
Speed Gauge Pressure Absolute Pressure

PSIG Bar in. Hg. mm Hg. PSIA Bar
1200 -3 -0.20 (-)6 (-)152 8.0 0.55
1500 -3 -0.20 (-)6 (-)152 9.0 0.62
1800 -3 -0.20 (-)6 (-)152 10.5 0.72
2500 +4.2a +0.28a +8.4a 212a 18.7a 1.29a
Except for pumps with 045 cam ring which are rated as follows at their 2,500 RPM max.
2500 +4.7 +0.32 +0.64 +16.2 19.2 1.32
If rigid pipe or tubing is used, the workmanship must be accurate in order to eliminate strain on the pump
housing, mounting cap or end cap or the fluid connectors. Sharp bend, elbows or reducers In the lines
must be eliminated or minimized whenever possible. All system piping must be cleaned with solvent or
equivalent cleaning agent before connecting to the pump.

Page 26
FLUIDS
Type
It is recommended that the fluid used in the T6DC pump have a petroleum base and contain agents which
provide oxidation inhibition and anti-rust, antifoam and de-aerating properties.
Antiwear Additives
It is strongly recommended that fluid used contain the necessary additives to secure high antiwear
characteristics. Comparative operating pressures and speed limits for antiwear and nonantiwear fluids are
shown in below table III.
Table III - Operating Specifications
Fluid Type Denison T6DC Continuous T6DC Intermittent

Fluid spec. Speed Pressur Pressure Speed Pressur Pressure
RPM e PSI Bar RPM e PSI Bar
Antiwear petroleum HF-0 2,500 3,000/ 207/241 2,500 3,000/ 241/276
base 3,500 4,000
HF-2 2,500 2,500 172 2,500 3,000 207
Non antiwear HF-1 1,800 2,500 172 2,500 3,000 207
petroleum base
Water-in-oil HF-3 1,800 2,000 138 1,800 2,500 172
emulsions
Water Glycols HF-4 1,800 2,000 138 1,800 2,500 172
Synthetic fluids HF-5 1,800 2,500 172 1,800 3,000 207
Non Petroleum Base or Fire Resistant Fluids

When it is necessary to use these types of fluids, the T6DC pump can be used. To determine performance
characteristics or ratings for a particular fluid, a Denison Sales Representative must be consulted.
Operating Temperature
For the most efficient pump operation, refer to below table IV.
Table IV - Operating Temperature
Fluid Type Denison Max. temp. Max. System Pressure Suction Pressure
Spec. °F °C PSI Bar Multiplier
Antiwear petroleum base HF-0 210 100 3500/ 241/276 1.0
fluids for severe duty 4000
Antiwear petroleum base HF-2 210 100 3000 207 1.0
fluids
Non antiwear petroleum HF-1 210 100 3000 207 1.0
base fluids
Water-in-oil invert HF-3 120 49 2500 172 1.25
emulsions
Water glycols HF-4 120 49 2500 172 1.25
synthetic fluids (Phosphate HF-5 160 71 3000 207 1.35
ester & others)

Page 27
Pump inlet Conditions
During pump operation, the inlet conditions must be sufficient to provide filling without cavitation. The use
of an improper grade of oil, improper or restrictive inlet piping may result in an inlet vacuum in excess of
recommendations and will reduc.e the pump service life or may cause damage to the pump parts. An inlet
pressure of 0.07 - 0.7 bar (1 - 10 psi) is desirable. During high speed operation, it is particularly important
to provide proper inlet pressures. If a pressurized or boosted inlet system is used, the inlet pressure must
not exceed 2.5 bar (36 psi) except for pumps with S-5 seals. These must not exceed 3.5 bar (50 psi) inlet
pressure. Refer to table II on (See page 26) for minimum inlet requirements.
NOTE: When an inlet strainer is used, it should have a minimum capacity equal to twice the flow
output of the pump.

Page 28
START-UP PROCEDURES
PRESTART CHECK
Before initial starting of the pump, the following checks must be made.
1. Check the rotation of the power source to be sure the pump will rotate in the direction indicated by the
arrow on the pump identification tag.
2. Check inlet and discharge to be sure all connections are tight and connected properly.
3. Check all mounting bolts and flanges to be sure they are tight and properly aligned.
4. When possible the rotating element or pump shaft must be rotated by hand to assume that it rotates
freely.
PRIMING
If the pump is installed with a positive head on the inlet, priming will be instantaneous upon start up. It is
recommended that a minimum pump shaft speed of 600 RPM be obtained for priming, however, this speed
will vary with different inlet and outlet conditions. When a pressure relief valve is used at the outlet, it must
be backed off to the minimum setting. When possible, an air bleed off must be provided in the circuit to
facilitate purging the system of air. When it is not possible or practical to provide a positive head at the
pump inlet or the installation is such that a suction lift results, the following procedure is recommended.
1. Manually fill the pump housing with fluid.
2. Start relation in a jogging manner until a prime is picked up.
3. Bleed off air that may become trapped in the pump.
To prevent possible damage to the internal parts, the pump should never be started dry or without internal
lubrication.
If the pump does not prime properly or pressure cannot be obtained within 15 seconds it must be shut
down and condition corrected.

Page 29
Page 30
S0709250K
R1
1BRAKE PEDAL VALVE
CAUTION!
BRAKE PEDAL VALVES0709250K


March 2004
Brake Pedal Valve S0709250K

Page 1
TABLE OF CONTENTS
Specification............................................................................................ 4
Brake System (S/N 1001 thru 2000) .............................................................. 5
Brake System (S/N 2001 thru 3000,
3001 and Up).................................................................................................. 6
Brake, Pilot and Fan Motor Supply Valve ....................................................... 8
S/N 1001 thru 3000 ................................................................................. 8
S/N 3001 and Up..................................................................................... 9
Hydraulic Circuit ........................................................................................... 10
S/N 1001 thru 2000 ............................................................................... 10
S/N 2001 thru 3000, 3001 and Up ........................................................ 10
Specifications ............................................................................................... 11
S/N 1001 thru 2000 ............................................................................... 11
S/N 2001 thru 3000, S/N 3001 and Up ................................................. 11
S0709250K Brake Pedal Valve

Page 2
GENERAL DESCRIPTION
THEORY OF OPERATION
The brake pedal valve is attached to, and operated by, the brake pedal. See Figure 1. The valve contains
two spools. See Figure 2. One spool ports fluid to the brake pistons in the front axle, and the other spool
ports fluid to the brake pistons in the rear axle. Maximum system operating pressure is 60 ±5 bars
(870 ±73 psi). If something in one of the circuits should fail, the other circuit will continue to operate.
AJS0720L
Figure 1

Page 3
When the brake pedal is depressed, force is applied to the working element (6, Figure 2). This force is
transferred to the primary control spool (1) and the secondary control spool (2) by the main control spring
(5). This causes the control spool lands to close the path from the supply ports (P1 and P2) to the tank
ports (T1 and T2). Simultaneously, the spool then open a path from the brake circuit ports (Br1 and Br2) to
the supply ports (P1 and P2). Drilled passages in the control spools (1 and 2) allow fluid pressure in the
ports P1 and P2 to act against the main control spring (5). This allows the brake pressure in both circuits to
rise proportionally to the force applied to the brake pedal.
As the force applied to the brake pedal becomes constant, the control spools (1 and 2) move into a
balanced position and hold the braking pressure constant.
When force is removed from the brake pedal, this removes force from the control spring. The return springs
(3 and 4) now move the control spools (1 and 2) to the upward. The spools open a path from the brake
circuit ports (Br1 and Br2) to the tank ports (T1 and T2) and this releases the pressure from the brake
circuits.
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
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
Braking Pressure 60 ±3 kg/cm2 (835 ±43 psi)
Pedal Force 21 ±2 kg (46 ±4.4 lb)
Operating Angle 18 ±2°

Page 4
BRAKE SYSTEM (S/N 1001 THRU 2000)
Multiple wet disk brakes for stopping vehicle movement are contained in the axle-end planetary gear sets.
A brake pump (10, Figure 3) supplies pressurized fluid to the brake hydraulic system. Force on the brake
pedal (5) moves two spools in the brake valve (9). The spools are proportional. The farther the brake pedal
is pushed, the greater the amount of fluid that passes through each spool. One spool ports fluid to brake
pistons in the front axle (3). The other spool ports fluid to brake pistons in the rear axle (1). Pressure on the
brake pistons applies pressure to the brake disks, and this stops axle shaft and wheel rotation.
The brake hydraulic system also contains three accumulators (8). The accumulators hold a volume of
pressurized fluid large enough to allow the brakes to be applied nine times with full pressure, after the
engine has been turned off.
The brake hydraulic system includes a pressure operated transmission cutoff switch (2, Figure 3). Pressing
the brake pedal (5) will open cutoff switch (2). When the transmission cutoff switch in the operator's cabin is
selected, this will cutoff current to a solenoid operated hydraulic valve in the transmission. This prevents
operation of the forward clutch in the transmission. This prevents the transmission from driving the wheels
forward when the brake pedal is pressed.
AMS0321L
Figure 3 BRAKE HYDRAULIC CIRCUIT
Reference Reference
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

Page 5
BRAKE SYSTEM (S/N 2001 THRU 3000,
3001 AND UP)
Multiple wet disk brakes for stopping vehicle movement are contained in the axle-end planetary gear sets.
A brake pump (10, Figure 3) supplies pressurized fluid to the brake hydraulic system. Force on the brake
pedal (5) moves two spools in the brake valve (9). The spools are proportional. The farther the brake pedal
is pushed, the greater the amount of fluid that passes through each spool. One spool ports fluid to brake
pistons in the front axle (3). The other spool ports fluid to brake pistons in the rear axle (1). Pressure on the
brake pistons applies pressure to the brake disks, and this stops axle shaft and wheel rotation.
The brake hydraulic system also contains three accumulators (8). The accumulators hold a volume of
pressurized fluid large enough to allow the brakes to be applied nine times with full pressure, after the
engine has been turned off.
The brake hydraulic system includes a pressure operated transmission cutoff switch (2, Figure 4). Pressing
the brake pedal (5) will open cutoff switch (2). When the transmission cutoff switch in the operator's cabin is
selected, this will cutoff current to a solenoid operated hydraulic valve in the transmission. This prevents
operation of the forward clutch in the transmission. This prevents the transmission from driving the wheels
forward when the brake pedal is pressed.
BIS0180L
Figure 4 BRAKE HYDRAULIC CIRCUIT

Page 6
Reference Reference
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

Page 7
BRAKE, PILOT AND FAN MOTOR SUPPLY VALVE
This valve controls oil flow to the brake pedal valve for braking, to the pilot controller for operation of bucket
and boom and to the fan motor.
S/N 1001 THRU 3000
AJS0750L
Figure 5 VALVE CARTRIDGE IDENTIFICATION AND PILOT LOCATION
Reference Reference
Number Number
1 Body (200*120*79) 4 Check (C3)
2 Sequence (C1) 5 Solenoid (C4,5)
3 Reducing (C2) 6 Coil (C4,5)

Page 8
S/N 3001 AND UP
TP1 PA
PART NO.
C3-1 A1 A1-1 LOT NO.
A4
P1
PL
3 6
C3-4
TP2
LP
PK
KOREA CORPORATION
VDL 24 VDC
C2 FO
T1
KOREA CORPORATION
VDL 24 VDC
C4
C1 C6
C5
P2 A3
7 2
4
1 4
T2
C3-2 A2 A2-2
M FI C3-3
BYS0050L
Figure 6 VALVE CARTRIDGE IDENTIFICATION AND PILOT LOCATION
Reference Reference
Number Number
1 Body (200*120*79) 5 Solenoid (C4,5)
2 Sequence (C1) 6 Coil (C4,5)
3 Reducing (C2) 7 Relief Valve
4 Check (C3)

Page 9
HYDRAULIC CIRCUIT
S/N 1001 THRU 2000
AJS0760L
Figure 7 HYDRAULIC CIRCUIT
S/N 2001 THRU 3000, 3001 AND UP
BIS0190L
Figure 8 HYDRAULIC CIRCUIT

Page 10
SPECIFICATIONS
S/N 1001 THRU 2000
Item Specifications
Max. Operating Pressure 210.0 kg/cm2 (3,000 psi)
Max. Flow 53.0 lpm (14 gpm)
System Pressure 120.0 kg/cm2 (1,710 psi)
System Flow 20 lpm (5.28 gpm)
Setting Pressure C1 120 ±2 kg/cm2 @53 lpm
(1,710 ±28 psi @ 14 gpm)
C2 28 ±2 kg/cm2 @ 20 lpm
(398 ±28 psi @ 5.28 gpm)
C3 Cracking Pressure 2.40 kg/cm2 (34.1 psi)
Port Size FO, F1, M PF 1/2 O-ring
TP1, TP2, LPWS, LKWS PF 1/4 O-ring
All other ports PF 3/8 O-ring
S/N 2001 THRU 3000, S/N 3001 AND UP
Item Specifications
Max. Operating Pressure 210.0 kg/cm2 (3,000 psi)
Max. Flow 53.0 l/min (14 gpm)
System Pressure 120.0 kg/cm2 (1,710 psi)
System Flow 20 l/min (5.28 gpm)
Setting Pressure C1 120 ±2 kg/cm2 @53 l/min
(1,710 ±28 psi @ 14 gpm)
C2 28 ±2 kg/cm2 @ 20 l/min
(398 ±28 psi @ 5.28 gpm)
C3 Cracking Pressure 2.40 kg/cm2 (34.1 psi)
C6 150 ±2 kg/cm2 @ 40 l/min
(2,134 ±28 psi @ 10.57 gpm)
Port Size FO, F1, M PF 1/2 O-ring
TP1, TP2, LPWS, LKWS PF 1/4 O-ring
All other ports PF 3/8 O-ring

Page 11
Page 12
S0709456K
1MAIN CONTROL VALVE

(TOSHIBA)
CAUTION!
MAIN CONTROL VALVE (TOSHIBA)S0709456K


November 2001
Main Control Valve (Toshiba) S0709456K

Page 1
TABLE OF CONTENTS
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
S0709456K Main Control Valve (Toshiba)

Page 2
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.
AMS0330L
Figure 1

Page 3
AJS0660L
Figure 2 CONTROL VALVE HYDRAULIC CIR-
Reference Reference
Number Number
a3 Option Valve Port B3 Option Cylinder Port
a1 Bucket Crowd Valve Port (to Option Cylinder Tube)
b2 Boom Down Valve Port B1 Bucket Dump Port
(to Bucket Cylinder Rod)
b3 Option Valve Port
A2 Boom Up Port
b1 Bucket Dump Valve Port
(to Boom Cylinder Tube)
a2 Boom Up Valve Port
P Pump Port
f Float Valve Port
R Tank Port
A1 Bucket Crowd Port
A3 Option Cylinder Port
(to Bucket Cylinder Tube)
(to Option Cylinder Rod)
(1) Main Relief Valve
(2) Overload Relief Valve
B2 Boom Lower Port
(3) Anticavitation Check Valve
(to Boom Cylinder Rod)

Page 4
SPECIFICATIONS
2-Spool (STD.) 3-Spool (OPT.)

Name WA28D4F1-51 WA28D5F2D5-52
Type Pilot Control with Float spool
Spool Diameter ∅ 28 mm (1.10 in)
Spool Arrangement Bucket - Boom Bucket - Boom - Auxiliary
Main relief pressure 200 kg/cm @ 160 liters/min
2
(2,840 psi @ 42 gpm)

Overload relief pressure 240 kg/cm2 @ 30 liters/min
(3,400 psi @ 8 gpm)

Page 5
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.
BUCKET/OPTION SPOOL OPERATION
Figure 3 OPERATION IN BUCKET/OPTION
Reference Reference
Number Number
1 Load Check 4 Tank Passage
2 Port A1 5 Center Bypass 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.

Page 6
BOOM SPOOL OPERATION
Boom Float
Figure 4 OPERATION IN BOOM FLOAT
Reference Reference
Number Number
1 Port A2 4 Center Bypass Passage
2 Port B2 5 Tank Passage
3 Tank Passage
When the control lever is pushed further 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 boom floats over
the ground surface according to the contour of the ground. 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
Main Relief Valve

The main relief valve is between the neutral oil passage and the low-pressure oil passage (return oil
passage) in the inlet section.
Port Relief Valve

The port relief valve is between the rod side cylinder port and the low-pressure oil passage (return oil
passage) in the bucket spool section.
The combination valve, used as the port relief valve, serves both as the relief valve and an anticavitation
valve.

Page 7
OPERATION (MAIN RELIEF VALVE)
Operation in Inoperative State

The pressure oil in the neutral oil passage (HP)
flows through the throttle hole (2) in the main
poppet (1) to fill the internal cavity (3). Owing to
the difference in area on which the hydraulic
pressure acts, the main poppet (1) closely seats
to the sleeve (4).
Figure 5 IN INOPERATIVE STATE

Operation (A)
When the pressure in the neutral oil passage
(HP) rises and exceeds the relief pressure
setting. the pilot poppet (5) opens. The pressure
oil flows from the pilot poppet into the
low-pressure oil passage (LP). passing between
the sleeve (4) and the housing (6).
Figure 6 OPERATION (A)

Operation (B)
As the pilot poppet (5) opens, the pressure in
the internal cavity (3) lowers to move the main
poppet (1) so that the pressure oil in the neutral
oil passage (HP) flows directly into the
low-pressure oil passage (LP).
Figure 7 OPERATION (B)

Page 8
OPERATION (PORT RELIEF VALVE)
In the Inoperative State

The pressure oil at the cylinder port (HP) flows
through the hole in the piston poppet (1) to act
from the opposite sides of the check valve
poppet (2) and relief valve poppet (3). Owing to
the difference in area on which the hydraulic
pressure acts, both poppets close to seat the
same time.
Figure 8 IN INOPERATIVE STATE

Operation (A)
When the pressure at the cylinder port (HP)
rises and exceeds the relief pressure setting,
the pilot poppet (4) opens. The pressure oil
flows from the pilot poppet into the low-pressure
oil passage (LP), passing between the check
valve poppet (2) and the housing (5).
Figure 9 OPERATION (A)

Operation (B)
As the pilot poppet (4) opens, the pressure at
the back of the piston poppet (1) lowers to move
the piston poppet (1). As a result, the hole in the
piston poppet (1) is closed so that the pressure
at the back of the relief valve poppet (3) drops
further.
Figure 10 OPERATION (B)

Page 9
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).
Figure 11 OPERATION (C)

Sucking Operation
If the pressure at the cylinder port (HP)
becomes lower than that at the low-pressure oil
passage (LP) due to the development of
cavitation, the check valve poppet (2) moves
depending upon the difference in area on which
negative pressure acts across the check valve
poppet. Consequently, oil is supplied from the
low-pressure oil passage (LP) to the cylinder
port side (HP) to eliminate the cavitation.
Figure 12 SUCKING OPERATION

Page 10
S0709477K
1PILOT CONTROL
VALVE
CAUTION!
PILOT CONTROL VALVES0709477K


December 2002
Pilot Control Valve S0709477K

Page 1
TABLE OF CONTENTS
General Description (S/N 1001 thru 2000)..................................................... 3

Pilot Valve Operation............................................................................... 3
General Description (S/N 2001 and up) ......................................................... 5
Pilot Valve Operation............................................................................... 5
Standard.................................................................................................. 6
Option...................................................................................................... 8
Pilot System ................................................................................................. 10
S0709477K Pilot Control Valve

Page 2
GENERAL DESCRIPTION (S/N 1001 THRU 2000)
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.
PILOT VALVE OPERATION

The lever handle is positioned on the right side of the operator's seat. This single lever controls the
following machine functions: raise boom, lower boom, bucket crowd, and bucket dump. The lever positions
are identified as follows:
F-Float
L-Lower
N-Neutral
R-Raise
H-Hold Position
C-Bucket Crowd
D-Bucket Dump
HR-Holds lever in Raise Mode.

Page 3
Figure 1
Reference Reference
Number Number
1 Lever 5 Plunger
2 Valve Spool 6 Spool Groove
3 Regulating Spring 7 Solenoid
4 Return Spring 8 Electromagnet

Page 4
GENERAL DESCRIPTION (S/N 2001 AND UP)
When no force is applied to the lever (33, Figure 2), 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.
PILOT VALVE OPERATION

The lever handle is positioned on the right side of the operator's seat. This single lever controls the
following machine functions: raise boom, lower boom, bucket crowd, and bucket dump. The lever positions
are identified as follows:
F-Float
L-Lower
N-Neutral
R-Raise
H-Hold Position
C-Bucket Crowd
D-Bucket Dump
HR-Holds lever in Raise Mode.

Page 5
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 2

Page 6
Reference Reference
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 Ass'y
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 Ass'y 41 Holder Rear
21 Joint Ass'y 42 Clip Band

Page 7
OPTION
4
5
11
10
8
12
13
14
15
16
15
17
BAS0200S
Figure 3

Page 8
Reference Reference
Number Number
1 Main Handle Assembly 10 Main Handle U Joint
2 Handle Nut 11 7 mm Cable Clamp
3 Handle Mounting Plate 12 Plunger
4 Button Red 13 Plunger
5 Button Grey 14 Capsule Assembly
6 Auxilliary Handle Assembly 15 Capsule Assembly
7 Boot 16 Capsule Assembly
8 Mounting Cap Screws 17 Block
9 Cable Assembly

Page 9
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 (398 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.

Page 10
AMS0340L
Figure 4
Reference Reference
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

Page 11
Page 12
S0709651K
1PRIORITY VALVE
(DANFOSS)
CAUTION!
PRIORITY VALVE (DANFOSS)S0709651K


December 2002
Priority Valve (Danfoss) S0709651K

Page 1
TABLE OF CONTENTS
Parts List ................................................................................................. 5
Specifications .......................................................................................... 6
Disassembly ................................................................................................... 6
Reassembly.................................................................................................... 9
S0709651K Priority Valve (Danfoss)

Page 2
Page 3
GENERAL DESCRIPTION
THEORY OF OPERATION
Oil output from the steering pump flows through the priority valve to both the loader 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 1) maintains an open path between inlet port P and steering output 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 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 clocked 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 in the far right side of the priority valve. Port LS is not open to the camber 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 o f 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 1), the spool (1) shifts the
right. This allows pump flow at port P to flow out both port CF and EF. Now both the loader supply line and
the steering supply line are changed with flow from the steering pump. Whenever the steering wheel is
turned, the spool on 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 1

Page 4
Reference Reference
Number Number
1 Spool CF Steering Supply Port
2 Spring ED Loader Supply Port
P Pressure Port LS Pilot Port
PARTS LIST
Figure 1
Reference Reference
Number Number
1 Plug PP 5 Spring [7 bar (100 psi)]
2 O-ring 6 Plug LS
3 Spool 13 Orifice
4 Housing

Page 5
SPECIFICATIONS
Priority Valve Specification

Control Pressure 7 kg/cm2 (100 psi)
Rated Flow 160 l/min (42 gpm)
DISASSEMBLY
1. The following tools are necessary to repair
the priority valve. See Figure 2.
Open end wrench - 27 mm
Slip joint pliers
Nylon rod
Allen wrenches - 5 mm, 8 mm, 10 mm
Figure 2
2. Use the open end wrench to loosen the PP
plug. See Figure 3.
3. Remove the O-ring.
Figure 3
4. Use the open end wrench to loosen the LS
plug. See Figure 4.
5. Remove the O-ring.
Figure 4

Page 6
6. Remove the spring. See Figure 5.
Figure 5
7. Use a nylon rod to push the spool out of
the bore. See Figure 6.
Figure 6
8. Use an 8 mm allen wrench to remove the
plug from the pressure relief valve. See
Figure 7.
Figure 7
9. Use a 10 mm allen wrench to unthread the
pressure relief valve from its bore. See
Figure 8.
Figure 8

Page 7
10. Hold the pressure relief valve with a pliers
and use a 5 mm allen wrench to remove
the set screw. See Figure 9.
Figure 9
11. The pressure relief valve is composed of a
valve housing, valve needle, spring, and
set screw. See Figure 10.
12. Clean all parts with a nonflammable,
nontoxic solvent.
13. Carefully inspect all parts. Replace all
worn or broken parts. Use only new O-
rings to assemble the valve.
14. Coat all parts with oil before assembling
them.
Figure 10

Page 8
REASSEMBLY
1. The relief valve pressure can be changed
by changing springs. The following table
displays the characteristics of the 3
springs available. See Figure 11.
Figure 11
Coil Inner Diameter

Pressure Wire Diameter (d) Spring Height (H)
(Di)
4 bar 2.5 mm 12.5 mm 50 mm
(60 psi) (0.0984") (0.492") (1.968 in)
7 bar 3.0 mm 12.5 mm 50 mm
(100 psi) (0.1181") (0.492") (1.968 in)
10 bar 3.2 mm 12.5 mm 50 mm
(145 psi) (0.1259") (0.492") (1.968 in)
2. Figure 12 shows the PP plug and the

spool.
Figure 12
3. Install the spool into the bore. See Figure
13. Use a nylon rod to position the spool in
the neutral position.
Figure 13

Page 9
4. Install the spring and the LS plug into the
bore. See Figure 14. Use a new O-ring on
the plug.
Figure 14
5. Use the 27 mm wrench to tighten the PP
plug and the LS plug to 6 kg•m (43 ft lb).
See Figure 15.
Figure 15
6. Assemble the valve needle, spring, and set
screw into the pressure relief valve
housing. See Figure 10.
7. Thread the pressure relief valve into the
body of the priority valve and tighten it.
See Figure 16.
Figure 16
8. Install the plug into the pressure relief
valve bore. Tighten the plug to 5 kg•m
(36 ft lb). See Figure 17.
Figure 17

Page 10
S0709730K
R1
1POWER STEERING
UNIT
CAUTION!
POWER STEERING UNITS0709730K

Mega 500-V 1001 thru 2000

June 2002
Power Steering Unit S0709730K

Page 1
TABLE OF CONTENTS
Power Steering System........................................................................... 3
Gerotor Operation ................................................................................... 5
Cushion Valve Operation......................................................................... 6
Parts List ................................................................................................. 8
Specifications .......................................................................................... 9
Special Tools ................................................................................................ 10
Troubleshooting, Testing and Adjustment..................................................... 12
Disassembly ................................................................................................. 13
Cleaning and Inspection............................................................................... 17
Reassembly.................................................................................................. 18
Installation .................................................................................................... 29
S0709730K Power Steering Unit

Page 2
GENERAL DESCRIPTION
POWER STEERING SYSTEM
Power Steering Unit.

The machine contains a fully hydraulic steering unit. See Figure 1. Rotating the steering wheel controls
hydraulic flow through the steering valve. Figure 2, shows the hydraulic schematic for the steering system.
The steering valve meters the volume of pump flow that is supplied to the steering cylinders
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
The steering unit contains a gerotor. This allows

the operator to steer the machine when the
engine is not running or when the steering pump
has failed. The gerotor functions as a manual
hydraulic pump that is powered by the rotation
of the steering wheel. Rotating the steering Figure 1
wheel will cause the gerotor to draw oil from the
hydraulic tank and send this oil to the steering
cylinders.
The shaft that is rotated by the steering wheel is attached to the spool (8, Figure 1) by the engagement of
a spline. The spool is surrounded by a sleeve (3). The spool and sleeve are connected by the centering
spring (2). At the steering wheel neutral position, the center pin does not contact the spool. A drive shaft
(9) extends through the spool. The upper end of the drive shaft engages the center pin (4). The lower end
of the drive shaft engages the spline in the gerotor (6).

Page 3
AJS0700L
Figure 2 STEERING CIRCUIT
Reference Reference
Number Number
1 Steering Unit 5 Valve block
2 Priority Valve 6 Steer Pump
3 Steering Cylinder 7 Supply Line to Main Control
4 Cushion Valve Valve

Page 4
Neutral Operation
With the steering wheel in the neutral position (wheels turned neither right nor left), the spool (2, Figure 3)
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 2). 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 3
Right Turn
The spool (2, Figure 3) 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 2) travels through the control spool and is directed to port R which directs the oil to the
steering cylinders (3, Figure 2). 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 3) 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 2) is directed through the control spool in the steering unit, out port L and into the
steering cylinders (3, Figure 2). 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 2) 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 2. 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 2). The return oil then flows back into the tank line
and is recirculated back to the gerotor and the steering cylinders.

Page 5
CUSHION VALVE OPERATION
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 port R, it pushes spring (3) and opens 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 4

Page 6
Page 7
PARTS LIST
An exploded view of the steering unit is shown in Figure 5.
Figure 5

Page 8
Reference Reference
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 500-V
Mega 300-V Mega 400-V
Mega 500-V (Tier II)
Type Load Sensing, Dynamic Signal, Nonreaction
Gerotor Displacement 1,000 cc/rev 200 cc/rev 315 cc/rev
(61 in3/rev) (12.2 in3/rev) (19.2 in3/rev)

Page 9
SPECIAL TOOLS
The tools necessary for steering unit repair are illustrated below.
1. Stabilizing base. See Figure 6.
Figure 6
2. O-ring assembly tool. See Figure 7.
Figure 7
3. Seal driver. See Figure 8.
Figure 8

Page 10
4. Torque wrench, 0 - 5 kg•m (0 - 35 ft lb).
See Figure 9. 13 mm socket. Ratchet
handle. 12 mm screwdriver. 6 mm
screwdriver. 2 mm screwdriver. Plastic
hammer.
Figure 9

Page 11
Steering wheel does not operate Broken or damaged oil pump. Replace pump.
smoothly Stuck or damaged relief valve. Repair or replace.
Stuck, damaged or worn out Clean, repair or replace.
steering valve.
Restricted hose or pipe. Leaking Clean, repair or replace.
or restricted hose, pipe, or
connection.
Mechanical defect in steering Repair or replace.
gear.
Steering wheel has a heavy feel. Oil level low in reservoir. Add oil.
Low oil pressure due to broken Replace pump.
or damaged oil pump.
Steering valve stuck. Clean, repair or replace.
Low oil level in steering gearbox. Inspect oil level, fill to proper
level.
Damaged bolt and nut in Replace damaged parts.
steering gearbox.
Difficult to drive in a straight line Defective spool in steering valve. Tighten lock nut.
Stuck or damaged steering valve Repair or replace.
or damaged or defective spring.
Improper fit of track line. Repair or replace.
Noise during steering Low oil level in reservoir. Add oil.
Restricted inlet pipe or filter. Clean or replace
Steering system leaking oil Worn or damaged O-ring and oil Replace worn or damaged
seal of pipe and steering valve. parts.

Page 12
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 10.
Figure 10
3. Remove end cover from unit. See Figure
11.
Figure 11
4. Lift cylinder gear off unit. See Figure 12.
Remove two O-rings.
Figure 12

Page 13
5. Remove spacer bushing and spacer from
cylinder gear (If equipped). See Figure 13.
NOTE: Refer to parts manual for our
unit to determine if these parts
are installed.
Figure 13
6. Remove shaft from housing. See Figure
14.
Figure 14
7. Remove distributor plate from housing.
See Figure 15.
Figure 15
8. Remove O-ring from top of middle plate.
See Figure 16.
Figure 16

Page 14
9. Lift middle plate off housing. See Figure
17.
Figure 17
10. Remove O-ring from housing. See Figure
18.
Figure 18
11. Unscrew threaded bushing and remove it.
See Figure 19.
Figure 19
12. Remove cross pin. See Figure 20.
Figure 20

Page 15
13. Shake ball out of housing. See Figure 21.
Figure 21
14. Pull sleeve and spool out of housing. See
Figure 22.
Figure 22
15. Remove thrust bearing and thrust washers
from sleeve. See Figure 23. Remove
spacer ring. Be sure to remove spacer
ring. It can stick in sleeve.
Figure 23
16. Carefully slide control spool out of sleeve.
See Figure 24.
Figure 24

Page 16
17. Push neutral position springs out of groove
in spool. See Figure 25.
Figure 25
18. Remove dust seal from housing. See
Figure 26. Remove O-ring and backup ring
from inside housing.
Figure 26
19. Figure 27, shows all parts removed from
steering unit. Clean all parts before
assembly. Use only new O-rings and
seals.
Figure 27
CLEANING AND INSPECTION


Page 17
REASSEMBLY
NOTE: Use bolt torque chart that follows to tighten bolts as steering unit is assembled.
Bolt Torque Chart

Bolt Size Torque Value
M10 4.8 kg•m (35 ft lb)
3/8 - 16 NC 4.8 kg•m (35 ft lb)
1. Install springs in spool slot. See Figure 28.

Springs must be positioned as shown in
Figure 29.
Figure 28
Figure 29
2. Position springs so that amount of spring
protruding out of spool is equal on both
sides. See Figure 30.
Figure 30

Page 18
3. Insert spool into sleeve. See Figure 31.
Use care so that sleeve and spool are
correctly assembled. The spring slot in
sleeve must align with spring slot in spool.
Also, one of the T shaped slots (A) in the
spool must align with one of the small
holes (B) in sleeve. See Figure 32.
Figure 31
Figure 32
4. Center springs in sleeve. See Figure 33.
Figure 33

Page 19
5. Install seal ring on sleeve. See Figure 34.
Burnish seal ring with a smooth object until
seal does not protrude past diameter of
sleeve.
Figure 34
6. Rotate seal ring. See Figure 35. It must
rotate freely without resistance.
Figure 35
7. Turn sleeve 180°. Install cross pin into
sleeve and spool. See Figure 36.
Figure 36

Page 20
8. Install two thrust washers and thrust
bearing over end of spool. See Figure 37.
The sequence of the parts installation is
shown in Figure 38.
Figure 37
Reference
Description
Number
1 Thrust Washer
2 Thrust Bearing
3 Thrust Washer
4 Spool
5 Sleeve
Figure 38
9. Oil O-ring and backup ring and then install
them on an O-ring assembly tool. See
Figure 39.
Figure 39

Page 21
10. Insert assembly tool down into bore of
steering unit. See Figure 40.
Figure 40
11. Use assembly tool to install O-ring and
backup ring into bore. See Figure 41.
Figure 41
12. Unbolt housing from stabilizing base. Hold
housing in a horizontal position. See
Figure 42. Insert sleeve and spool into
bore.
Figure 42

Page 22
13. The sleeve will push the O-ring and
backup ring into correct position. See
Figure 43.
Figure 43
14. Bolt housing back into stabilizing base.
See Figure 44.
Figure 44
15. Insert ball into hole. See Figure 45.
Figure 45

Page 23
16. Install threaded bushing into hole that ball
was placed into. See Figure 46. Lightly
tighten bushing. The top of the bushing
must be lower than the surface of housing.
Figure 46
17. Lubricate O-ring with 20 weight mineral oil
and install it in groove. See Figure 47.
Figure 47
18. Install middle plate onto housing. See
Figure 48. Be sure to properly align plate
holes with holes in housing.
Figure 48
19. Lubricate O-ring with 20 weight mineral oil
and install it in groove. See Figure 49.
Figure 49

Page 24
20. Install distributor plate. See Figure 50. Be
sure to properly align plate holes with
holes in middle plate.
Figure 50
21. Install shaft into bore of housing. See
Figure 51. Position slot in shaft to engage
cross pin.
Figure 51
22. Position rotor so that cross pin is between
two teeth as shown by position of
screwdriver. See Figure 52.
Figure 52

Page 25
23. Lubricate two O-rings with 20 weight
mineral oil and install them in grooves of
cylinder gear. Slide cylinder gear into
position on housing. See Figure 53.
Figure 53
24. Use a bolt to align holes in cylinder gear
with bolt holes in housing. See Figure 54.
Figure 54
25. Install spacer bushing. See Figure 55.
Remove bolt that was installed in previous
step (If equipped.).
OSPL 630:1 = 3.80 mm (0.1496 in) (15,
Figure 5)
OSPL 800 (16, Figure 5)
OSPL 1000 (16, Figure 5)
are installed.
Figure 55

Page 26
26. Use a screwdriver to install OSPL 800 and
1000 spacers (If equipped.). See Figure
56.
are installed.
Figure 56
27. Install end cover. See Figure 57.
Figure 57
28. Install a washer and roll pin into hole
shown in Figure 58.
Figure 58
29. Install six remaining bolts and tighten
them. See Figure 59. Cross tighten bolts
and roll pin to 48.1 Nm (35 ft lb).
Figure 59

Page 27
30. Turn steering unit over and work from
opposite side. Set dust seal in position on
housing. See Figure 60.
Figure 60
31. Use a seal driver and a plastic hammer to
install dust seal. See Figure 61.
Figure 61
32. Install plastic plugs to prevent dirt from
entering steering unit. See Figure 62.
Figure 62

Page 28
33. Figure 63, shows port identification for
steering unit.
L = Left pressure port.
R = Right pressure port
T = Tank port
P = Pressure from pump.
Figure 63
INSTALLATION
The following table shows torque specifications for hydraulic fittings used to install steering unit.
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)

Page 29
Page 30
S0709751K
R1
1RESTRICTION VALVE
CAUTION!
RESTRICTION VALVES0709751K

March 2004
Restriction Valve S0709751K

Page 1
TABLE OF CONTENTS
UNLOADING CIRCUIT (S/N 1001 thru 2000)......................................... 4
UNLOADING CIRCUIT (S/N 2001 thru 3000, 3001 and Up) .................. 5
Unloader Cartridge Identification (S/N 1001 thru 2000).......................... 6
Unloader Cartridge Identification (S/N 2001 thru 3000,
3001 and Up) .......................................................................................... 7
Specifications .......................................................................................... 8
S0709751K Restriction Valve

Page 2
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 or Figure 2). 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.

Page 3
UNLOADING CIRCUIT (S/N 1001 THRU 2000)
to OIL COOLER
to TANK
PUMP
to OIL COOLER
to CONTROL VALVE
79.5 cm3/rev
169 l/min C3
to OIL COOLER
70.3 cm/rev 148 l/min
to OIL COOLER
19.6 cm3/rev
41 l/min
C4 C5 C6 HT
(from CONTROL V/V)
UNLOADER VALVE
PRIORITY VALVE
BIS0200L
Figure 1

Page 4
UNLOADING CIRCUIT (S/N 2001 THRU 3000, 3001 AND UP)
0.75" Fan motor
23ccr 95bar
0.5"
BRAKE & PILOT & FAN SUPPLY V/V
PUMP
LOADER PUMP P1 P3 CONTROL V/V

63.8 cm/rev 3
1.1/4" 1.1/4"
134 l/min TPM
1/4"
STEER PUMP
EF
STEER "EF"
3
70.3 cm/rev, 140 l/min 1.1/4"
BRAKE/PILOT PUMP
3
19.6 cm/rev
41 l/min
R2
2"
C 1.1/2" CONTROL V/V

1" R1
HT
BLOCK VALVE
STEER "T"
STEER "P"
BYS0100L
Figure 2 Valve

Page 5
UNLOADER CARTRIDGE IDENTIFICATION (S/N 1001 THRU 2000)
AMS0530L
Figure 3 VALVE CARTRIDGE IDENTIFICATION (S/N 1001 thru 2000)
Reference
Description Remark
Number
1 Body 125×99×184
2 Sub Block 125×99×79
3 Check Valve C1
4 Floating Body HrC30 - 35
5 Poppet HrC38 - 45
6 Guide
7 Hex Nut
8 Spring
9 O-ring
10 O-ring
11 Backup Ring

Page 6
UNLOADER CARTRIDGE IDENTIFICATION (S/N 2001 THRU 3000,
3001 AND UP)
BIS0020L
Figure 4 VALVE CARTRIDGE IDENTIFICATION (S/N 2001 and Up)
Reference
Description Remark
Number
1 Body 125×99×263
2 Hex Plug
3 O-ring
4 Hex Plug
5 O-ring

Page 7
SPECIFICATIONS
Item Specification
Maximum Rated Pressure 210 bar
(3,050 psi)
Rated Flow Ports to P1 170 l/min
(45 gpm)
Rated Flow Ports to P3 320 l/min
(84 gpm)
Rated Flow Ports to R1, R2 520 l/min
(137 gpm)
Rated Flow Ports to C 100 l/min
(26 gpm)
C1 2 ±0.2 Bar
(29 ±3 psi)
Setting Pressure Cracking Pressure
C2, 3, 4 0.7 - 2 Bar
(10 - 29 psi)
R2 2" SAE Flange Port (M12, 1.75)
R1 1-1/2" SAE Flange Port (M12, 1.75)
P1, P3 1-1/4" SAE Flange Port (M12, 1.75)
Port Size HT, EF 3/4" PF O-ring
TPM 1/4" PF O-ring
R3 1/4" PF O-ring (Supplied Plugged)
C 1" PF O-ring

Page 8
S0793070K
R2
1HYDRAULIC
SCHEMATIC
(MEGA 300-V)
CAUTION!
HYDRAULIC SCHEMATIC (MEGA 300-V)S0793070K


December 2002
Hydraulic Schematic (Mega 300-V) S0793070K

Page 1
TABLE OF CONTENTS
Mega 300-V (Tier I) (S/N 1001 thru 2000) ..................................................... 4
Mega 300-V (Tier II) (S/N 2001 thru 3000) .................................................... 6
Mega 300-V (S/N 3001 and Up)..................................................................... 8
S0793070K Hydraulic Schematic (Mega 300-V)

Page 2
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

Page 3
MEGA 300-V (TIER I) (S/N 1001 THRU 2000)

Page 4
* OPTIONAL EQUIPMENT
MEGA 300-V
BIS0030L

Page 5
MEGA 300-V (TIER II) (S/N 2001 THRU 3000)

Page 6
MEGA 300-V
BIS0160L

Page 7
MEGA 300-V (S/N 3001 AND UP)
Figure 4

Page 8
MEGA 300-V
BYS0070L

Page 9
Page 10
1ELECTRICAL SYSTEM
S0802200K
R3
1ELECTRICAL SYSTEM
CAUTION!
ELECTRICAL SYSTEMS0802200K

May 2005
Electrical System S0802200K

Page 1
TABLE OF CONTENTS
Overview ........................................................................................................ 5
Electric Wire Color ........................................................................... 5
Electric Supply System .................................................................................. 6
Engine Starting Circuit ................................................................................... 8
Operation During Start Process .............................................................. 8
Operation After Start Process ............................................................... 10
Engine Preheating System (S/N 1001 thru 2000) ........................................ 12
Principle of Operation............................................................................ 12
Engine Preheating System (S/N 2001 thru 3000) ........................................ 14
Principle of Operation............................................................................ 14
Engine Stop System..................................................................................... 16
Operation In Engine Running Mode...................................................... 16
Operation In Engine Stop Mode............................................................ 18
Charging System.......................................................................................... 20
Monitoring System ....................................................................................... 21
Monitoring System (S/N 1001 thru 2000).............................................. 21
Instrument Panel (S/N 1001 thru 2000) ................................................ 22
Function Check (S/N 1001 thru 2000)................................................... 23
Monitoring System Schematic (S/N 1001 thru 2000)............................ 24
Monitoring System (S/N 2001 thru 3000).............................................. 26
Instrument Panel (S/N 2001 thru 3000) ................................................ 27
Function Check (S/N 2001 thru 3000)................................................... 28
Monitoring System Schematic (S/N 2001 thru 3000)............................ 28
Operation .............................................................................................. 30
Instruments .................................................................................... 30
Indicator Lights............................................................................... 31
Initial Operation.............................................................................. 33
Control Unit Operation ................................................................... 33
Characteristic of Operation ............................................................ 35
Windshield Wiper ......................................................................................... 36
S0802200K Electrical System

Page 2
Front Windshield Wiper ......................................................................... 36
Front Windshield Wiper Circuit....................................................... 36
Rear Windshield Wiper ......................................................................... 37
Lighting System............................................................................................ 40
Light Circuit (S/N 1001 thru 2000) ........................................................ 40
Light Circuit (S/N 2001 thru 3000) ........................................................ 44
Emergency Steering System (Option).......................................................... 48
Block Diagram ....................................................................................... 48
Emergency Steering System Components ........................................... 49
Emergency Steering Timer ............................................................ 49
Emergency Steering Pump ............................................................ 50
Emergency Steering Switch........................................................... 50
Emergency Steering System Electric Circuit ........................................ 51
Electric Detent System ................................................................................. 52
Electric Circuit ....................................................................................... 52
Boom Kick-out....................................................................................... 52
Return To Dig ........................................................................................ 53
Proximity Switch............................................................................. 53

Page 3
Page 4
OVERVIEW
The electrical system for this equipment is DC 24 volts. The rated voltage for all electric components is 24
volts with the exception of the stereo and the air-conditioning control actuator. The system contains two 12
volt batteries connected in series and a three phase AC generator with a rectifier. The electric wiring used
in the system is easily identifiable by the insulator color. The color symbols used in the electrical system
are listed in the following chart.
Electric Wire Color
Symbol Color Symbol Color

W White R Red
G Green Gr Gray
Or Orange P Pink
B Black Y Yellow
L Blue Br Brown
Lg Light green V Violet
NOTE: RW: Red wire with White stripe.

R - Base Color, W - Stripe Color.
NOTE: 0.85G: Nominal sectional area of wire core less insulator = 0.85 mm2 (0.03 in2).

Page 5
ELECTRIC SUPPLY SYSTEM
The electric power circuit supplies electric current to each electric component. It consists of a battery,
battery relay, starter switch, circuit breaker, fusible link and fuse box.
The negative terminal of the battery is grounded to the vehicle body.
Even when the starter switch is in the "OFF" position, electric current is supplied to the following
components through battery, to the fusible link, and then to the fuse box.
1. Cabin light, fuel pump switch, No. 1 terminal of DC-DC converter (back up for stereo memory)
2. "B" terminal of starter switch and No. 22 terminal of air conditioner control panel.
3. Power terminal "B" of engine stop motor.
When the starter switch is in the "PREHEAT, ON and START" positions, the current flows from the battery,
to the fusible link, to the fuse box, to the starter switch "B" terminal/starter switch "BR" terminal, to the
diode, and then to the battery relay "BR" terminal. which activates the coil of the battery relay and the
electric supply system is energized.
When the battery relay's contacts are connected, all electric devices can be operated.
While the engine is not running, the electric power for all electric devices are supplied by the battery. Once
the engine is started the power is supplied from the alternator.

Page 6
AMS0010L
Figure 1
Reference Reference
Number Number
1 Battery 5 Starter Switch
2 Battery Relay 6 Fuse Box
3 Fusible Link 7 Alternator
4 Circuit Breaker 8 Diode

Page 7
ENGINE STARTING CIRCUIT
OPERATION DURING START PROCESS
When the starter switch is turned to the start position, the safety start relay (14) is opened by the current
flow from the connected "52" and "67" terminal of the transmission controller (13) and the "S" and "E"
terminal of the starter controller (7) are connected. At this time the contacts in the starter relay (8) are
closed by the current flow from the battery (1), to the fusible link (3), to the "B" terminal of the starter switch
(5), to the "C" terminal of the starter switch (5), to the "C" terminal of the starter relay (8), to the "D" terminal
of starter relay (8), to the "S" terminal of starter controller (7), to the "E" terminal of the starter controller,
and then to the ground.
The contact point "B" and "PP" of starter relay (8) are connected, the pinion gear of the starter (9) is
pushed forward and makes contact with the ring gear of the flywheel and the internal contacts of the starter
are connected.
The current flows from the battery (1), to the "A" terminal of the battery relay (2), to the "B" terminal of the
battery relay (2), and then to the "B" terminal of the starter (9). The starter motor is rotated and the engine
is started.
The engine can be cranked only when the transmission selector switch (11) is the neutral position. If the
transmission selector switch (11) is in the forward or reverse, the current that flows the switch (11) to the
starter controller (7) opens the path to ground for the starter relay (8). This prevents the start relay (8) from
closing.

Page 8
AMS0020L
Figure 2 STARTER CIRCUIT (1) - WHILE STARTING
Reference Reference
Number Number
1 Battery 8 Starter Relay
2 Battery Relay 9 Starter
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

Page 9
OPERATION AFTER START PROCESS
Once the engine has been started, the belt driven alternator (10) generates a current. The output
generated by the alternator is a square wave pulse voltage through the "P" terminal and the frequency of
the pulse voltage is proportional to the rotation of the alternator. The starter controller (7) monitors the
frequency of the output current. Once the frequency equivalent to 500 rpm is sensed the connection
between "S" and "E" terminals and the connection between "B" and "PP" terminals are opened. As a result
the rotation of the starter (9) is stopped. Once the engine is running, the starter (9) will not operate even if
the starter switch (5) is moved to the start position, preventing possible damage to the starter (9).
AMS0030L
Figure 3 OPERATION OF START CIRCUIT (2) - IMMEDIATELY AFTER START
Reference Reference
Number Number
1 Battery 8 Starter Relay
2 Battery Relay 9 Starter
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

Page 10
Page 11
ENGINE PREHEATING SYSTEM (S/N 1001 THRU 2000)
The engine preheating system consists of a grid type resistance heater between the engine air cleaner and
intake manifold, a thermal switch that is used to monitor engine temperature, a preheat controller which
turns "ON" a grid type resistance heater and a preheat indicator.
PRINCIPLE OF OPERATION
1. When coolant temperature is lower than 10°C (50°F) (Thermal switch is "OFF.")
• With the starter switch in PREHEAT position, the signal current flows from the "R1" terminal of
starter switch to NO. 8 terminal of preheat controller. Then current from the fuse flows through
coil of preheat relay, No. 5 terminal of preheat controller, No. 6 terminal of preheat controller,
and then to ground. This current makes the preheat relay contact closed, and thus current from
battery flows to glow plug via circuit breaker and preheat relay. 3.5 seconds after starter switch
is turned to preheat position, the preheat light will turn "ON" to indicate that preheating is
finished.
2. When coolant temperature is higher than 10°C (50°F) (Thermal switch is "ON.")
• The preheat pilot is lit as soon as starter switch is turned to PREHEAT position, and the
preheating current does not flow. This means that preheating is not necessary when coolant
temperature is higher than 10°C (50°F).

Page 12
AMS0040L
Figure 4 ENGINE PREHEAT CIRCUIT (S/N 1001 thru 2000)
Reference Reference
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

Page 13
ENGINE PREHEATING SYSTEM (S/N 2001 THRU 3000)
The engine preheating system is consists of a grid type resistance heater between the engine air cleaner
and intake manifold, a thermal switch that is used to monitor engine temperature, a preheat controller
which turns "ON" a grid type resistance heater and a preheat indicator.
PRINCIPLE OF OPERATION
1. When coolant temperature is lower than 10°C (50°F) (Thermal switch is "OFF.")
• With the starter switch in PREHEAT position, the signal current flows from the "R1" terminal of
starter switch to NO. 8 terminal of preheat controller. Then current from the fuse flows through
coil of preheat relay, No. 5 terminal of preheat controller, No. 6 terminal of preheat controller,
and then to ground. This current makes the preheat relay contact closed, and thus current from
battery flows to air heater via circuit breaker and preheat relay. 19 seconds after starter switch is
turned to preheat position, the preheat light will turn "ON" to indicate that preheating is finished.
2. When coolant temperature is higher than 10°C (50°F) (Thermal switch is "ON.")
• The preheat pilot is lit as soon as starter switch is turned to PREHEAT position, and the
preheating current does not flow. This means that preheating is not necessary when coolant
temperature is higher than 10°C (50°F).

Page 14
AMS0040L
Figure 5 ENGINE PREHEAT CIRCUIT (S/N 2001 thru 3000)
Reference Reference
Number Number
1 Battery 8 Preheat Relay
2 Battery Relay 9 Air Heater
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

Page 15
ENGINE STOP SYSTEM
The engine stop circuit consists of a starter switch (3), engine stop motor (4) and engine stop relay (5).
There are two modes of operation - engine running and engine stop.
OPERATION IN ENGINE RUNNING MODE

When the starter switch (3) is turned to the "ON" position, the contact points "30" and "87" of the engine
stop relay (5) are closed due to current flowing from the battery (1), to the fusible link (2), to the "B" terminal
of the starter switch (3), to the "ACC" terminal of starter switch (3), to the "86" terminal of engine stop relay
(5) to the battery (1) and then to the ground. As a result, the engine stop motor (6) is rotated by the current
flow from the battery (1) to the fusible link (2) to the fuse box (4) to "B" terminal of the engine stop motor (6)
to the "P2" terminal of engine stop motor (6), to the "87" terminal of engine stop relay (5), to the "30"
terminal of the engine stop relay (5), to the "A" terminal of engine stop motor (6) to the "E" terminal of
engine stop motor (6), and then to the ground. The engine stop motor opens (pushes) the fuel shut off lever
of the fuel injection pump and the system is in the running mode. The engine stop motor rotates 180° and
comes to a stop due to the cam switch which shuts off the current to the motor.
AMS0050L
Figure 6 ENGINE STOP CIRCUIT - RUNNING MODE
Reference Reference
Number Number
1 Battery 4 Fuse Box
2 Fusible Link 5 Engine Stop Relay
3 Starter Switch 6 Engine Stop Motor

Page 16
When the starter switch is in the "ON" position, the internal components of the engine stop motor's cam
switch is in the position shown.
AMS0060L
Figure 7

Page 17
OPERATION IN ENGINE STOP MODE
When the starter switch (3) is in the "OFF" position, the electric current flow to the coil of the engine stop
relay (5) is shut off.
As a result, the "30" and "87a" contact point of the engine stop relay are connected and current is supplied
to the engine stop motor from the battery (1), to the fusible link (2), to the fuse box (4) to the "B" terminal of
engine stop motor (6), to the "P1" terminal of engine stop motor (6), to the "87a" terminal of engine stop
relay (5), to the "30" terminal of engine stop relay (5), to the "E" terminal of engine stop motor (6), to the
ground, and then the motor is rotated. The shut off lever of the fuel injection pump, linked to the engine
stop motor by a cable, is moved to the close (pull) position and the engine is stopped. The engine stop
motor moves 180° from the running mode position and is stopped by the internal cam switch which cuts off
the current to the motor.
AMS0070L
Figure 8 ENGINE STOP CIRCUIT - STOP MODE
Reference Reference
Number Number
1 Battery 4 Fuse Box
2 Fusible Link 5 Engine Stop Relay
3 Starter Switch 6 Engine Stop Motor

Page 18
When the starter switch is in the "OFF" position, the internal components of the engine stop motor's cam
switch is in the position shown.
AMS0080L
Figure 9

Page 19
CHARGING SYSTEM
When the starter switch (5) is turned to the "ON" position, an initial excited current flows to the field coil of
the alternator (7) through the battery relay (2) and circuit breaker (4). When the engine is started from this
condition the alternator (7) starts charging. The current flows from the "B+" terminal of alternator (7), to the
circuit breaker (4), to the battery relay (2), and to the battery (1).
The alternator also, supplies electric current to other electrical components. When the alternator (7) starts
to operate, a current flows from the "R" terminal of alternator to the diode (8) and then to the battery relay
(2) coil securing a path for the charging current to the battery (1). Thus, preventing the possibility of a high
voltage build up and possible damage to the electric system.
AMS0090L
Figure 10 CHARGING CIRCUIT
Reference Reference
Number Number
1 Battery 5 Starter Switch
2 Battery Relay 6 Fuse Box
4 Circuit Breaker 8 Diode

Page 20
MONITORING SYSTEM
MONITORING SYSTEM (S/N 1001 THRU 2000)
AMS0100L
Reference Reference
Number Number
1 Instrument Panel 11 Engine Oil Pressure Switch
2 Battery 12 Hazard Warning Light Switch
3 Alternator 13 Turn Signal Light Switch
4 Speed Sensor 14 High Beam Switch
5 Coolant Temperature Sensor 15 Work Light Switch
6 Fuel Sensor 16 Brake Oil Pressure Switch
7 Transmission Oil Temperature 17 Parking Brake Pressure Switch
Sensor 18 Emergency Steering Switch
8 Preheat Controller 19 Control unit
9 Air Cleaner Indicator 20 Brake Oil Filter Switch
10 Engine Coolant Temperature
Switch
The monitoring system displays the various data and warning signals onto the instrument panel by
processing the information gathered from the various sensors throughout the equipment.

Page 21
INSTRUMENT PANEL (S/N 1001 THRU 2000)
AMS0110L

Page 22
Reference Reference
Number Number
1 Speed Meter 11 Charging Warning Light
2 Tachometer 12 Turn and Hazard Warning
3 Hour Meter Light
4 Fuel Gauge 13 High Beam Indicator
5 Engine Coolant 14 Turn and Hazard Warning
Temperature Gauge Light
6 Transmission Oil 15 Work Light Indicator
Temperature Gauge 16 Brake Oil Pressure
7 Preheat Completion Warning Light
Indicator 17 Brake and Pilot Oil Filter
8 Air Cleaner Clogged Clogged Warning Light
Warning Light 18 Parking Brake Indicator
9 Engine Coolant 19 Emergency Steering
Temperature Warning Light Indicator
10 Engine Oil Pressure
Warning Light
FUNCTION CHECK (S/N 1001 THRU 2000)

When the starter switch is turned to the "ON" position, all displays, switch lights and warning lights except
turn and hazard warning light, high beam indicator, work light indicator and emergency steering indicator
will be turned "ON" for two seconds and the warning buzzer will sound. Any lights which do not turn "ON"
during the function check must be replaced.

Page 23
MONITORING SYSTEM SCHEMATIC (S/N 1001 THRU 2000)
AMS0120L

Page 24
Reference Reference
Number Number
1 Instrument Panel Air Cleaner Clogged
15
2 Headlight Switch Warning Light
3 Forward Lever Switch 16 Engine Oil Pressure Switch
4 Reverse Lever Switch Coolant Temperature
17
Switch
5 High Beam Switch
18 Brake Oil Pressure Switch
6 Left Turn Signal Switch
Parking Brake Pressure
7 Right Turn Signal Switch 19
Switch
8 Work Light Switch
20 Alternator
9 Emergency Steering Switch
21 Control Unit
10 Speed Sensor
22 Alarm Buzzer
Coolant Temperature
11 23 Alarm Relay
Sensor
24 Battery
12 Fuel Sensor
25 Battery Relay
Transmission Oil
13 26 Circuit Breaker
Temperature Sensor
Brake and Pilot Oil Filter 27 Fuse Box
14
Switch 28 Preheat Controller

Page 25
MONITORING SYSTEM (S/N 2001 THRU 3000)
BIS0040L
Reference Reference
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 Work 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 the various data and warning signals onto the instrument panel by
processing the information gathered from the various sensors throughout the equipment.

Page 26
INSTRUMENT PANEL (S/N 2001 THRU 3000)
BIS0050L
Reference Reference
Number Number
1 Speed Meter 10 Engine Oil Pressure
2 Tachometer Warning Light
3 Hour Meter 11 Charging Warning Light
4 Fuel Gauge 12 Turn and Hazard Warning
Light
5 Engine Coolant
Temperature Gauge 13 High Beam Indicator
6 Transmission Oil 14 Turn and Hazard Warning
Temperature Gauge Light
7 Preheat Completion 15 Work Light Indicator
Indicator 16 Brake Oil Pressure
8 Air Cleaner Clogged Warning Light
Warning Light 17 Unused Light
9 Engine Coolant 18 Parking Brake Indicator
Temperature Warning Light 19 Emergency Steering
Indicator

Page 27
FUNCTION CHECK (S/N 2001 THRU 3000)
When the starter switch is turned to the "ON" position, all displays, switch lights and warning lights except
turn and hazard warning light, high beam indicator, work light indicator and emergency steering indicator
will be turned "ON" for two seconds and the warning buzzer will sound. Any lights which do not turn "ON"
during the function check must be replaced.
MONITORING SYSTEM SCHEMATIC (S/N 2001 THRU 3000)
BIS0220L

Page 28
Reference Reference
Number Number
1 Instrument Panel 15 Engine Oil Pressure Switch
2 Headlight Switch Coolant Temperature
16
3 Forward Lever Switch Switch
4 Reverse Lever Switch 17 Brake Oil Pressure Switch
5 High Beam Switch Parking Brake Pressure
18
Switch
6 Left Turn Signal Switch
19 Alternator
7 Right Turn Signal Switch
20 Control Unit
8 Work Light Switch
21 Alarm Buzzer
9 Emergency Steering Switch
22 Alarm Relay
10 Speed Sensor
23 Battery
Coolant Temperature
11 24 Battery Relay
Sensor
12 Fuel Sensor 25 Circuit Breaker
Transmission Oil 26 Fuse Box
13
Temperature Sensor 27 Preheat Controller
Air Cleaner Clogged
14
Warning Light

Page 29
OPERATION
Instruments
Sensor Specification
Function Display Input
Input Specification
Terminal
10 km/h- 852 Hz
20 km/h- 1704 Hz
30 km/h- 2556 Hz
CN1-4 40 km/h- 3408 Hz
Speedometer
CN1-5 *ƒ = 85.2 V [Hz]
ƒ : Frequency of T/M
Controller
v : Speed [km/h]
500 rpm - 123 Hz
1000 rpm - 246 Hz
1500 rpm - 368 Hz
2000 rpm - 491 Hz
2500 rpm - 614 Hz
Tachometer CN1-3
3000 rpm - 737 Hz
*ƒ = 0.2456 N [Hz]
ƒ: Frequency of alternator "P"
terminal
N : Engine rpm
ALTERNATOR "R"
Hour Meter CN1-2
Terminal voltage (24V)
0012.eps
EMPTY - Above 90 Ohm

Fuel Level
CN1-7 1/2 - 38 Ohm
Gauge
FULL - Below 10 Ohm

Page 30
Sensor Specification
Function Display Input
Input Specification
Terminal
50°C - Above 188.2 Ohm

67°C - 102 Ohm
Engine Coolant 105°C - 32 Ohm
Temperature CN1-6
Gauge 125°C - Below 19.8 Ohm
50°C - Above 322.8 Ohm

Transmission Oil
Temperature CN1-8 120°C - 36.5 Ohm
Gauge
150°C - Below 18.6 Ohm
Indicator Lights
Input
Symbol Description Operation Remarks
Terminal
Preheat CN2-1 Light turns "ON" when
preheat process is
completed.
HAOA639L
(Approximately 19
seconds from start.)
Air Cleaner CN2-2 Light turns "ON" when
air cleaner is clogged
HAOA660L
Coolant CN2-3 Light up when coolant

Temperature temperature increases
over 102°C.
HAOA51AL
(When terminal input is

connected)
Engine Oil CN2-4 Light turns "ON" when After starting engine, if
Pressure engine oil pressure engine oil pressure is
drops below 1.6 kg/cm2 insufficient after 8
HAOA620L
(23 psi) seconds, a warning buzzer
will sound.

Page 31
Input
Terminal
Charging CN2-5 Light turns "ON" when Under normal conditions,
not charging. will turn "ON" before
engine start-up and shut
(and "R" terminal output
off once engine is running.
HAOA610L
drops below 24V)

Left Turn and CN2-6 Light turns "ON" when
Hazard Light left turn signal or hazard
light is operated.
(Terminal input is to
24V)
Right Turn CN2-8 Light turns "ON" when
and Hazard right turn signal or
Light hazard light is operated.
24V)
High Beam CN2-7 Light turns "ON" when
high beam is operated.
HGB2008L
24V)
Work Light CN2-9 Light turns "ON" when Light turns "OFF" when the
work light is operated. engine is started.
(Terminal input is to 24
V)
Brake Oil CN2-10 Light turns "OFF" when Under normal conditions,
Pressure brake oil pressure will turn "ON" before
increases over 65 kg/ engine start-up and shut
0717B cm2 (925 psi), and light off once engine is running.
turns "ON" when brake
oil pressure drops below
60 kg/cm2 (853 psi).
(When terminal input is
connected)
Parking CN2-12 Light turns "ON" when Under any conditions, will
Brake the parking brake switch be light turns "ON" before
P is applied and parking engine start-up.
0717A
brake pressure is above
65 kg/cm2 (925 psi).
(24V is inputted to the
input terminal)
Brake Oil CN2-11 Light turns "ON" when
Filter the brake oil filter
Pressure pressure is above 5 kg/
cm2 (71 psi), light turns
"OFF" when the brake
oil filter pressure is
below 4.7 kg/cm2 (67
psi).

Page 32
Input
Terminal
Emergency CN2-13 Light turns "ON" when This is option parts.
Steering the vehicle speed is
above 5 km/h and the
AJO0450L steering pressure is
below 10 kg/cm2 (142
psi).
(When the test switch is
applied)
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, work light indicator and transmission
cutoff indicator and emergency steering indicator.
• Warning buzzer is activated and turned "OFF" after 2
seconds.
• Monitoring system displays present condition.
Control Unit Operation
Figure 17

Page 33
Reference Reference
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

Page 34
Characteristic of Operation
Input Output
All warning lights are
turned "ON" and turned
1 When the starter switch is "ON"
"OFF" after 2 - 2.5
seconds.
Battery warning light
is below 12 ±1 V
When "R" terminal voltage of turns "ON" (L5)
2
alternator Battery warning light
is above 12 ±1 V
turns "OFF" (L5)
Warning buzzer sounds
Engine oil pressure switch is "ON"
after 8 ±1 seconds.
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"
and Parking brake pressure switch is
immediately
"ON."

Page 35
WINDSHIELD WIPER
FRONT WINDSHIELD WIPER
You can control windshield wiper by operating wiper washer switch (2).
1. Low speed wiper action (1st)
Wiper acts in low speed through fuse box (1) to the 15,53 terminal of wiper switch (2) to the L,E
terminal of wiper motor (5).
2. High speed wiper action (2nd)
Wiper acts in high speed through Fuse box (1) to the 15,53b terminal of wiper switch (2) to the H,E
terminal of wiper motor (5).
3. When you turn "OFF" switch during low speed wiper action (1st) or High speed wiper action (2nd),
electric currents flow through Fuse box (1) to the B,S terminal of wiper motor (5) to the 87a,30
terminal of wiper relay (3) to the 31b,53 terminal of wiper switch (2) - L,E terminal of wiper motor (5).
Wiper acts until wiper rotates to the stop position, than the wiper stops.
4. Intermittent wiper action
Fuse box (1) to the 15,J terminal of wiper switch (2) to the 1,4 terminal of wiper timer (4) are
connected intermittently, and electric current flow into 86,85 terminal of wiper relay (3) than 87
terminal and 30 terminal are connected.
Therefore, electric current flow through fuse box (1) to the 87,30 terminal of wiper relay (3) to the
31b,53 terminal of wiper switch (2) to the L,E terminal of wiper motor (5), and wiper operates
intermittently in low speed.
Front Windshield Wiper Circuit
AMS0140L
Figure 18

Page 36
Reference Reference
Number Number
1 Fuse Box (1) 5 Wiper Motor
2 Wiper Washer Switch 6 Washer Tank
3 Wiper Relay 7 Diode
4 Wiper Timer
REAR WINDSHIELD WIPER

You can control rear windshield wiper by pressing wiper washer switch (2) in the switch panel.
1. 1st wiper action (Wiper and washer activate the same time, automatic return)
Fuse box (1), to the washer tank (4), to the 5,7 terminal of switch (20) are connected, then activates
windshield washers. Also, fuse box (1), to the B,L terminal of wiper motor (3), to the diode (5), to the
5,7 terminal of switch (2) are connected, then activates wiper.
AMS0150L
Figure 19 REAR WINDSHIELD WIPER 1ST ACTION CIRCUIT
Reference Reference
Number Number
1 Fuse Box (2) 4 Washer Tank
2 Wiper/washer Switch 5 Diode
3 Wiper Motor

Page 37
2. 2nd wiper action (Only wiper action)
Fuse box (1), to the B,L terminal of wiper motor (3), to the 4,2 terminal of switch (2) are connected,
then activates wiper.
3. When you turn "OFF" windshield wiper switch in 1st or 2nd position, electric current flows fuse box
(1), to the B,L terminal of wiper motor (3), to the 4,6 terminal of wiper switch (2), to the diode (6), to
the S,E terminal of wiper motor (3).
AMS0160L
Figure 20 REAR WINDSHIELD WIPER STOP CIRCUIT
Reference Reference
Number Number
1 Fuse Box (2) 4 Washer Tank
2 Wiper/washer Switch 5 Diode
3 Wiper Motor

Page 38
Page 39
LIGHTING SYSTEM
LIGHT CIRCUIT (S/N 1001 THRU 2000)
AMS0170L
Figure 21 LIGHT CIRCUIT (S/N 1001 thru 2000)

Page 40
Reference Reference
Number Number
1 Fuse Box 1 16 License Plate Light
2 Blinker Unit 17 Instrument Panel
3 Headlight Switch 18 Diode
4 Combination Switch 19 Front Work Light Switch
5 Shift Lever Switch 20 Front Work Light
6 Hazard Switch 21 Rear Work Light Switch
7 Stop Light Switch 22 Work Light Relay
8 Headlight Relay 23 Rear Work Light 1
9 Reverse Relay 24 Rear Work Light 2
10 Headlight (L) 25 Fuse Box 2
11 Headlight (R) 26 Starter Switch
12 Front Combination Light (L) 27 Pilot Buzzer
13 Front Combination Light (R) 28 Alarm Relay 1
14 Rear Combination Light (L) 29 Alarm Relay 2
15 Rear Combination Light (R)

Page 41
The lighting system consists of the headlight, the position light, the turn signal light, the hazard light, the
stop light, the license plate light, the work light, the rotating beacon light (option) and the switches, which
are 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 light turns "ON."
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 work light switch (19), the rear work 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 light turns "ON."
B. Also, if the combination switch (4) is in the "t " position, the current flows to the "56a" terminal
and it allow the high beam light, which is in the headlight (L) (10) and the headlight (R) (11), to
be light turns "ON." At the same time the current flows to the "CN2-7" terminal of instrument
panel (17) and the headlight indicator L7 will be light turns "ON."
C. And if the combination switch (4) is in the "s " 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 light
turns "ON."
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)
(11) will be turned "ON," and the other current flows to the "CN2-7" terminal of instrument panel
(17) and the headlight indicator will be light turns "ON."
The combination switch (4) is returned automatically.
3. When the combination switch (4) is in the "←"(or "→")position, the current flows from the fuse box
1(1), to the blinker unit (2), to the "L" (or "R") terminal through "49a" terminal of combination switch
(4), to the "C" terminal of front combination light (L) (12) and the rear combination light (L) (14) (or to
the front combination light (R) (13) and the rear combination light (R) (15)). This current makes the
turn signal light turn "ON." At the same time the current flows to the "CN2-6" terminal (or to the CN2-
8 terminal) of instrument panel and the turn signal light indicator L6(or L8) will be light turns "ON."
4. If you operates the hazard light switch (6), the current flows from to the fuse box 1(1), to the blinker
unit (2), to the "5," "1" terminal of hazard switch (6), to the diode (18), to the front combination light (L)
(12) and the front combination light (R) (13), to the "C" terminal of rear combination light (L) (14) and
rear combination light (R) (15). This current makes the turn signal light turn "ON."
At the same time through the "2," "6" terminal of hazard switch (6), the voltage is applied to the "9"
terminal and the illumination light used to symbol light will be light turns "ON." Also, the current flows
to the "CN2-6," "CN2-8" terminal of instrument panel (17) and the turn signal light indicator "L,"" "L8"
will be light turns "ON."
5. When the shift lever switch (5) is in the "R" position, the contact points "30" and "87" of the reverse
relay (9) are closed due to current flowing from the fuse box 2(23), to the shift lever switch (5), to the

Page 42
"86" terminal of reverse relay (9) and to the ground. Thus the current flows from fuse box 2(23), to the
reverse relay (9) and to the "D" terminal of rear combination light (L) (14) and rear combination light
(R) (15), and the reverse light will be light turns "ON."
6. When the brake pedal is depressed and at the same time the stop light switch (7) is turned "ON," the
current flows the from fuse box 1(1), to the stop light switch (7) and to the "F" terminal of rear
combination light (L) (14) and rear combination light (R) (15), and the stop light will be light turns
"ON."
7. When the front work light switch (19) is in the "ON" position, the current flows from the fuse box 1(1),
to the "5," "1" terminal of front work light switch (19) and to the front work light (20).
This current makes the front work lights turn "ON." At the same time the work light indicator,L9," is
turned "ON" due to the current flowing from the diode (8) to the "CN2-9" terminal of instrument panel
(17).
8. When the rear work light switch (21) is in the second step, the contact points "30" and "87" of the
work light relay (22) is closed due to the flowing current from the fuse box 1(1), to the "2" and "6"
terminal of the work light switch (21), to the "86" terminal of the work light relay (22) and to the
ground. Thus the current flows from the fuse box 1(1), to the work light relay (22) and to the rear work
light 1(23) mounted on right/left rear fender. As a result the rear work light (23) light turns "ON." At the
same time the work light indicator "L9" light turns "ON" due to the current flowing from the diode (18)
to the "CN2-9" terminal of the instrument panel.
work light relay (22) is closed due to the flowing current from the fuse box 1(1), to the "2" and "6" and
"3" terminal of the work light switch (21), the rear working (23) is operated like being described above
clause "8" and the rear work light (24) mounted on the cabin light turns "ON" at the same time.
10. When the headlight switch (3) is in the first step or in the second step while the starter switch (26) is
in the "OFF" position, the contact point "30," "87" of alarm relay 1(28) is closed due to the excited
current, which flows to the coil of alarm relay 1(28) and the pilot buzzer (27) will sound.
But when the headlight switch (3) is in the first step or in the second step while the starter switch (26)
is in the "ON" position, the contact point "3," "87" of alarm relay 2(29) is closed due to the excited
current, which flows to the coil of alarm relay 2(29). At the same time the current is not supplied to the
"30" terminal of alarm relay 1(28) and the pilot buzzer will not sound any more.

Page 43
LIGHT CIRCUIT (S/N 2001 THRU 3000)
BIS0230L
Figure 22 LIGHT CIRCUIT (S/N 2001 thru 3000)

Page 44
Reference Reference
Number Number
1 Fuse Box 1 16 License Plate Light
2 Blinker Unit 17 Instrument Panel
3 Headlight Switch 18 Diode
4 Combination Switch 19 Front Work Light Switch
5 Shift Lever Switch 20 Front Work Light
6 Hazard Switch 21 Rear Work Light Switch
7 Stop Light Switch 22 Work Light Relay
8 Headlight Relay 23 Rear Work Light 1
9 Reverse Relay 24 Rear Work Light 2
10 Headlight (L) 25 Fuse Box 2
11 Headlight (R) 26 Starter Switch
12 Front Combination Light (L) 27 Pilot Buzzer
13 Front Combination Light (R) 28 Alarm Relay 1
14 Rear Combination Light (L) 29 Alarm Relay 2
15 Rear Combination Light (R)

Page 45
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 work light, the rotating beacon light (option) and the switches, which
are 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 light turns "ON."
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 work light switch (19), the rear work 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 light turns "ON."
B. Also, if the combination switch (4) is in the "t " position, the current flows to the "56a" terminal
and it allow the high beam light, which is in the headlight (L) (10) and the headlight (R) (11), to
be light turns "ON." At the same time the current flows to the "CN2-7" terminal of instrument
panel (17) and the headlight indicator L7 will be light turns "ON."
C. And if the combination switch (4) is in the "s " 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 light
turns "ON."
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)
(11) will be turned up, and the other current flows to the "CN2-7" terminal of instrument panel
(17) and the headlight indicator will be light turns "ON."
The combination switch (4) is returned automatically.
3. When the combination switch (4) is in the "←"(or "→")position, the current flows from the fuse box
1(1), to the blinker unit (2), to the "L" (or "R") terminal through "49a" terminal of combination switch
(4), to the "C" terminal of front combination light (L) (12) and the rear combination light (L) (14) (or to
the front combination light (R) (13) and the rear combination light (R) (15)). This current makes the
turn signal light turned up. At the same time the current flows to the "CN2-6" terminal (or to the CN2-
8 terminal) of instrument panel and the turn signal light indicator L6(or L8) will be light turns "ON."
4. If you operates the hazard light switch (6), the current flows from to the fuse box 1(1), to the blinker
unit (2), to the "5," "1" terminal of hazard switch (6), to the diode (18), to the front combination light (L)
(12) and the front combination light (R) (13), to the "C" terminal of rear combination light (L) (14) and
rear combination light (R) (15). This current makes the turn signal light turned up.
At the same time through the "2," "6" terminal of hazard switch (6), the voltage is applied to the "9"
terminal and the illumination light used to symbol light will be light turns "ON." Also, the current flows
to the "CN2-6," "CN2-8" terminal of instrument panel (17) and the turn signal light indicator "L,"" "L8"
will be light turns "ON."
5. When the shift lever switch (5) is in the "R" position, the contact points "30" and "87" of the reverse
relay (9) are closed due to current flowing from the fuse box 2(23), to the shift lever switch (5), to the

Page 46
"86" terminal of reverse relay (9) and to the ground. Thus the current flows from fuse box 2(23), to the
reverse relay (9) and to the "D" terminal of rear combination light (L) (14) and rear combination light
(R) (15), and the reverse light will be light turns "ON."
6. When the brake pedal is depressed and at the same time the stop light switch (7) is turned up, the
current flows the from fuse box 1(1), to the stop light switch (7) and to the "F" terminal of rear
combination light (L) (14) and rear combination light (R) (15), and the stop light will be light turns
"ON."
7. When the front work light switch (19) is in the "ON" position, the current flows from the fuse box 1(1),
to the "5," "1" terminal of front work light switch (19) and to the front work light (20).
This current makes the front work lights turned up. At the same time the work light indicator,L9," is
turned up due to the current flowing from the diode (8) to the "CN2-9" terminal of instrument panel
(17).
8. When the rear work light switch (21) is in the first step, the current flows from the fuse box 1 (1) to the
"2" and "6" terminal of the work light switch (21). Thus the current flows from the fuse box 1 (1), to the
work light switch (21) and to the rear work light 2 (24) mounted on the cabin. As a result the rear work
light (24) light turns "ON."
work light relay (22) is closed due to the flowing current from the fuse box 1(1), to the "2" and "6" and
"3" terminal of the work light switch (21), to the "86" terminal of the work light relay (22) and to the
ground. Thus the current flows from the fuse box 1(1), to the work light relay (22) and to the rear work
light 1(23) mounted on right/left rear fender. As a result the rear work light (23) light turns "ON." At the
same time the work light indicator "L9" light turns "ON" due to the current flowing from the diode (18)
to the "CN2-9" terminal of the instrument panel. (Option)
10. When the headlight switch (3) is in the first step or in the second step while the starter switch (26) is
in the "OFF" position, the contact point "30," "87" of alarm relay 1(28) is closed due to the excited
current, which flows to the coil of alarm relay 1(28) and the pilot buzzer (27) will sound.
But when the headlight switch (3) is in the first step or in the second step while the starter switch (26)
is in the "ON" position, the contact point "3," "87" of alarm relay 2(29) is closed due to the excited
current, which flows to the coil of alarm relay 2(29). At the same time the current is not supplied to the
"30" terminal of alarm relay 1(28) and the pilot buzzer will not sound any more.

Page 47
EMERGENCY STEERING SYSTEM (OPTION)
BLOCK DIAGRAM
3
5
6
1
8
4
AJS0460L
Figure 23 EMERGENCY STEERING SYSTEM BLOCK DIAGRAM
Reference Reference
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
(142 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."

Page 48
EMERGENCY STEERING SYSTEM COMPONENTS
Emergency Steering Timer

1. Obtains signals from the emergency
pressure switch (4) and the transmission
controller (7), and play a role in operating
the emergency steering pump (5).
2. As the frequency signal of the
transmission controller is differ from each
machine, the reference frequency is 405
Hz which come under about 5 km/h. 1 2 3
3. When the starter switch is "ON," the 4 5

characteristic of operation is following.
AJS0450L
Figure 24
No. Wire size and Color
1 0.85 WL
2 0.85G
3 0.85WB
4 0.85W
5 0.85B
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 25 EMERGENCY STEERING TIMER
CIRCUIT
Input Condition Output

S0 S1 Vehicle Speed (Emergency Steering Pump)
When in the ON - OFF
"ON" position When above 5 km/h will be operated only one time and
OFF stop after 60±10 seconds.
When below 5 km/h OFF

Page 49
Emergency Steering Pump
This is an electrically powered hydraulic pump
and includes an emergency steering relay
(1,Figure 26),which is excited by the signal of 1
the emergency steering timer.
AJS0480L
Figure 26 EMERGENCY STEERING PUMP

Emergency Steering Switch
1. When the switch is in the "I" position, the
emergency steering pump and the
emergency steering indicator of the
instrument panel are activated
simultaneously. O
2. The basic usage of this switch is testing
function whether the emergency steering
system is all right or not.
I
AJO0011L
WARNING Figure 27 EMERGENCY STEERING SWITCH
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.
3. This returns automatically when not

pressed down.
NOTE: Because the emergency
steering pump consumes high
current, it's forbidden to use
continuously to avoid
discharging of battery and a
risk of overheating.

Page 50
EMERGENCY STEERING SYSTEM ELECTRIC CIRCUIT
When the control signal, which is transmitted from the "36" terminal of the transmission controller, is
inputted to the "2" terminal of the emergency steering timer (3) and the emergency steering pressure
switch (4) is "OFF," the contact points "A" and "B" of the emergency steering pump (5) is closed due to the
current flowing from the fuse box (1), to the "C" and "D" coil of the emergency steering pump (5), and to the
"4" and "5" terminal of the emergency steering timer (3).
Thus the high current flows from the battery (11) to the "A" and "B" terminal of the emergency steering
pump (5), which is operated. At the same time the emergency steering indicator light turns "ON" due to the
current flowing from the "B" terminal of the steering pump (5), to the fusible link (7) and to the emergency
steering indicator.
6 7
11
5
8
1 10
9 3
AJS0490L
Figure 28 EMERGENCY STEERING SYSTEM CIRCUIT
Reference Reference
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

Page 51
ELECTRIC DETENT SYSTEM
The electric detent system separated into boom kick-out and return to dig.
An each part consists of magnetic locking lever and proximity switch detecting the position of bucket or
boom.
ELECTRIC CIRCUIT
FLOAT KICK-OUT (OPTION)

6
2
5
11 3
9
7 4
8
1
10 11
AJS0500L
Figure 29 ELECTRIC DETENT CIRCUIT
Reference Reference
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
BOOM KICK-OUT
When the work lever (joystick) is in the "FLOAT" (or "RAISE") position, lever is locked and boom is lowered
(or lifted). When the boom is matched to setting position, lever locking is released and lever is returned to
"NEUTRAL" position automatically and boom lowering (or lifting) is stopped.
1. Boom Raise Kick-out
With the raise magnetic (5) is energized and the work lever (joystick) is held in "RAISE," then boom is
approaching to the raise proximity switch (8). When the raise proximity switch (8) and the boom are
matched, the contact points "30" and "87a" of the raise/float relay (3) is opened due to the current
flowing from the fuse box (1), to the coil of the raise relay (3) and to the "0" and "-" terminal of the
raise proximity switch (8).

Page 52
As a result the magnetic (5) is de-energized and the locked lever is returned to "NEUTRAL" position,
boom lifting is stopped.
2. Boom Float Kick-out (Option)
With the float kick-out switch shown in
Figure is in the "I" position and the float
magnetic (6) is energized and the work
lever (joystick) is held in "FLOAT," then
boom is approaching to the float proximity
O
switch (9).
When the float proximity switch (9) and the I
boom are matched, the contact points "30"
and "87a" of the raise/float relay (3) is
opened due to the current flowing from the HA0O2027
fuse box (1), to the coil of the raise/float
Figure 30
relay (3), to the terminal "5" and "1" of the
float kick-out switch (2) and to the "0" and
"-" terminal of the raise proximity switch
(9). As a result the magnetic (6) is de-
energized and the locked lever is returned
to "NEUTRAL" position, and boom
lowering is stopped.
RETURN TO DIG
After dumping, if the work lever (joystick) is in the "CROWD" position, the work lever (joystick) will be locked
and the bucket will be crowded. When the bucket is matched to setting position, the lever is returned to the
"NEUTRAL" position and bucket crowding will be stopped. After this operation, if the boom is lowered the
bucket is in parallel with ground.
With the return to dig proximity switch (10) and the bucket positioner are matched, the contact points "30"
and "87" of the return to dig relay (4) is closed due to the current flowing from fuse box (1), to the coil of the
return to dig relay (4) and to the "0" and "-" terminal of the return to dig proximity switch (10).
In this states, if the work lever (joystick) is in the "CROWD" position, the lever is locked and the bucket
positioner is approaching out of the return to dig proximity switch (10). That is, bucket is crowded. If the
bucket positioner is out of the return to dig proximity switch (10), the float magnetic (9) is de-energized.
As a result the lever is returned to "NEUTRAL" position and bucket is set to the selected digging angle.
Proximity Switch OPERATION INDICATOR
• Operating Distance: 10 ±1 mm POSITIONER

(0.3937 ±0.0394 in).
• Operation Indicator Light: Light turns
(OPERATING DISTANCE)
"ON" when the object is detected.
MAIN POWER
CIRCUIT
AJS0510L
Figure 31

Page 53
Page 54
S0893070K
1ELECTRICAL
SCHEMATIC
(MEGA 300-V)
CAUTION!
ELECTRICAL SCHEMATIC (MEGA 300-V)S0893070K


May 2001
Electrical Schematic (Mega 300-V) S0893070K

Page 1
TABLE OF CONTENTS
Mega 300-V.................................................................................................... 4
S0893070K Electrical Schematic (Mega 300-V)

Page 2
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

Page 3
MEGA 300-V
Figure 2

Page 4
MEGA 300-V
AMS0190L

Page 5
Page 6
1ATTACHMENTS

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Mega 300-V

023-00041AE Shop Manual

Trim Out The Label Along

Pub. No. 023-00041AE

Lower Structure and Chassis

Engine and Drive Train

COMPANY NAME: DATE:

WHEEL LOADER SAFETYS0103010K

Copyright DOOSAN 2004

Wheel Loader Safety S0103010K

To the Operator of a DOOSAN Daewoo Wheel Loader ................................. 3

S0103010K Wheel Loader Safety

Wheel Loader Safety S0103010K

S0103010K Wheel Loader Safety

LEARN SIGNAL WORDS USED WITH SAFETY ALERT SYMBOL

Safety precautions are described in SAFETY from page 6 on.

Wheel Loader Safety S0103010K

LOCATION OF SAFETY LABELS

S0103010K Wheel Loader Safety

Wheel Loader Safety S0103010K

CLOTHING AND PERSONAL PROTECTIVE

S0103010K Wheel Loader Safety

VIBRATION LEVEL INFORMATION

ASBESTOS DUST HAZARD PREVENTION

Wheel Loader Safety S0103010K

FUEL, OIL AND HYDRAULIC FLUID FIRE

S0103010K Wheel Loader Safety

Wheel Loader Safety S0103010K

PROTECTION FROM FALLING OR FLYING

S0103010K Wheel Loader Safety

INSTALL ADDITIONAL SAFETY EQUIPMENT IF CONDITIONS REQUIRE

MAINTAIN STANDARD SAFETY EQUIPMENT IN GOOD CONDITION

Wheel Loader Safety S0103010K

S0103010K Wheel Loader Safety

Wheel Loader Safety S0103010K

S0103010K Wheel Loader Safety

Wheel Loader Safety S0103010K

OPERATE WHILE SEATED AT OPERATOR'S

SEAT BELTS MUST BE USED AT ALL TIMES

S0103010K Wheel Loader Safety

SLOPING TERRAIN REQUIRES CAUTION

not possible to level area or avoid working on a

On sloping surfaces, use caution when

Wheel Loader Safety S0103010K

Voltage Minimum Safe Distance

Use these minimum distances as a guideline

BEFORE STARTING TO DIG, CONTACT AUTHORITIES

BE AWARE OF HEIGHT OBSTACLES

USE CARE ON LOOSE SUPPORT

S0103010K Wheel Loader Safety

DIGGING BENEATH OVERHANGS

DIGGING BENEATH WHEEL LOADER

STAY ALERT FOR PEOPLE MOVING

BE AWARE OF AND CONFORM TO LOCAL REGULATIONS

Wheel Loader Safety S0103010K

OBSERVE GENERAL SAFETY RULES

TAKE TIME TO PROVIDE GOOD VISIBILITY

S0103010K Wheel Loader Safety

OPERATE CAREFULLY ON SNOW AND ICE AND IN VERY COLD TEMPERATURES

Wheel Loader Safety S0103010K