08 Transmiss Install

Return to Master Table of Contents
S0607070K
5TRANSMISSION AND
TORQUE CONVERTER
(ZF)
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
TRANSMISSION AND TORQUE CONVERTER (ZF)S0607070K

MODEL SERIAL NUMBER RANGE
Mega 400-V 1001 and Up
Copyright 2000 Daewoo

December 2000
Transmission and Torque Converter (ZF) S0607070K

Page 1
TABLE OF CONTENTS
Drive Train Description ................................................................................... 5

Transmission and Torque Converter............................................................... 6
Powershift Transmission.......................................................................... 7
Transmission Control............................................................................... 7
Schedule of Measuring Points and Connection 4 WG-260 ..................... 8
Oil Circuit Diagram 4WG - 260 Forward 1st Speed .............................. 11
Transmission Electric Components .............................................................. 13
TCU (Transmission Control Unit) .......................................................... 14
Transmission Control Valve ................................................................... 14
Transmission Oil Temperature Sensor .................................................. 15
Engine Pick-Up Sensor ......................................................................... 15
Central Gear Pick-Up Sensor................................................................ 15
Turbine Pick-Up Sensor......................................................................... 16
Output Speed Sensor............................................................................ 16
Shift Lever Switch (DW-3) ..................................................................... 16
Auto Select Switch ................................................................................ 18
Display .................................................................................................. 18
Transmission Electrical Circuits.................................................................... 19
T/M Controller Circuit ............................................................................ 19
Travelling Circuits .................................................................................. 20
Neutral ........................................................................................... 20
Forward First Gear ......................................................................... 21
Forward Second Gear.................................................................... 22
Forward Third Gear........................................................................ 23
Forward Fourth Gear ..................................................................... 24
Reverse First Gear......................................................................... 25
Reverse Second Gear.................................................................... 26
Reverse Third Gear........................................................................ 27
Downshift .............................................................................................. 28
Overview ........................................................................................ 28
S0607070K Transmission and Torque Converter (ZF)

Page 2
Kick Down: Forward Second Gear to Forward First Gear

(Auto Selector Switch "O"- Manual Mode) ..................................... 29
Downshift (Auto Selector Switch "I" - Auto Mode).......................... 30
Transmission Cut Off ............................................................................. 31
LIS (Load Isolation System) - Option .................................................... 32
Installation View ........................................................................................... 34
Inner Section ......................................................................................... 34
Front View ............................................................................................. 36
Side View .............................................................................................. 37
Rear View.............................................................................................. 38
Hydraulic Control Unit (HSG-94) .................................................................. 39
Disassembly.......................................................................................... 40
Reassembly .......................................................................................... 43
Transmission Disassembly ........................................................................... 50
Converter-Input ..................................................................................... 50
Drive Shaft Pump Power Take-off ......................................................... 53
Transmission Pump ............................................................................... 55
Output- Layshaft Assembly ................................................................... 55
Disassemble Clutches and Layshaft Gear ............................................ 60
Disassemble Power Take-off II .............................................................. 61
Disassemble Clutches........................................................................... 62
Clutch - K3/K4................................................................................ 62
Clutch - KR/K2 ............................................................................... 65
Clutch - KV/K1 ............................................................................... 68
Transmission Reassembly............................................................................ 71
Power Take-off II.................................................................................... 71
Clutch K3/K4 ......................................................................................... 73
Clutch K3 ....................................................................................... 73
General Instructions for Plate Installation ...................................... 75
Clutch - K4 ..................................................................................... 80
Clutch KR/K2......................................................................................... 84
Clutch - KV/K1....................................................................................... 92
Install Multi-disk Clutches, Layshaft Gear and Output Gear ............... 100

Page 3
Install Filter.......................................................................................... 115

Hydraulic Pump................................................................................... 115
Drive Shaft (Power Take-off Pump) ..................................................... 117
Input - Converter ................................................................................. 121
Converter ............................................................................................ 126
Mount Hydraulic Control Unit (HSG-94).............................................. 127
Inductive Transmitter and Speed Sensor ............................................ 130
Setting Inductive Transmitter ............................................................... 132
Speed Sensor (Hall Sensor) N Output And Speedometer .................. 134

Page 4
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 front differential input 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).
Figure 1
Reference Reference
Description Description
Number Number
1 Engine 8 Parking Brake
2 Torque Converter 9 Front Axle Housing
3 Transmission 10 Reduction Gearing
4 Front Drive Shaft 11 Service Brake
5 Final Drive Shaft 12 Rear Differential
6 Rear Drive Shaft 13 Rear Axle Housing
7 Front Differential

Page 5
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 elector-hydraulic control valve that is mounted on transmission. Moving
gear select lever in cab, 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 400-V

Model 4WG 260 (Full Auto)
Type 3-Element, 1-Stage, Single-phase,
E/G mounted with flexible plate
Oil Cooler Water-cooled (multi-plate) and Air-cooled
Torque Converter Charging Pump 115 l/min at 2,000 rpm
Hydraulic Pump P.T.O 1:1
T/C Size ∅ 370 mm
Stall Ratio 2,985
Safety Relief 11 Bar (160 psi)
Type Full Power Shift, Counter shaft
Speeds 4 Forward / 3 Reverse
Ratio F : 3.73 / 2.206 / 1.969 / 0.624
Transmission R : 3.73 / 2.206 / 0.969
Power Shift Control 16 ~ 18 bar (232 ~ 261 psi)
Pressure
Shift Control Electric Shift with Proportional Valve
Oil Capacity 50 l (13.2 U.S. gal)
Dry Weight 750 kg (1,653 lbs)
Front 8.5 C Mechanics
Output Flange
Rear 7 C Mechanics

Page 6
POWERSHIFT TRANSMISSION
The multi-speed reversing transmission in countershaft design is power shiftable by hydraulically actuated
multi-disk 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 multi-disk 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 as well as the specifications of the closed clutches in the single speeds, see
“Schedule of Measuring Points and Connection 4 WG-260” on page 8 and “Oil Circuit Diagram 4WG - 260
Forward 1st Speed” on page 11.
TRANSMISSION CONTROL
Transmission control, see “Schedule of Measuring Points and Connection 4 WG-260” on page 8, Electro-
hydraulic unit on page -10 and “Oil Circuit Diagram 4WG - 260 Forward 1st Speed” on page 11.
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 9.0 bar (130.54 psi) for the actuation of the follow-on slides is created by the
pressure reducing valve. The pressure oil (16 - 18 bar (230 - 260 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 shiftings 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).

Page 7
The main pressure valve is limiting the max. control pressure to 16 - 18 bar (230 - 260 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 hydro-dynamic
principle.
To avoid cavitation, the converter must be always completely filled with oil.
This is achieved by a converter pressure back-up valve, rear-mounted to the converter, with an opening
pressure of at least 5 bar (73 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-260” on page 8 and “Oil Circuit Diagram 4WG - 260 Forward 1st Speed” on
page 11.
SCHEDULE OF MEASURING POINTS AND CONNECTION 4 WG-260

The marked positions (e. g. 53) correspond with the positions on the “Oil Circuit Diagram 4WG - 260
Forward 1st Speed” on page 11.
The measurements have to be carried out at hot transmission (about 80° - 90°C).
Marking on the
No. Denomination of the Position Connection
Valve Block
Measuring Points for Pressure Oil and Temperature
51 In front of the converter - Opening pressure 11 bar (160 M10 x 1 H
psi)
52 Behind the converter - Opening pressure 5 bar (73 psi) M14 x 1.5
53 Clutch Forward 16 - 18 bar (230 - 260 psi) KV M10 x 1 B
55 Clutch Reverse 16 - 18 bar (230 - 260 psi) KR M10 x 1 E
56 Clutch Reverse 16 - 18 bar (230 - 260 psi) K1 M10 x 1 D
57 Clutch Reverse 16 - 18 bar (230 - 260 psi) K2 M10 x 1 A
58 Clutch Reverse 16 - 18 bar (230 - 260 psi) K3 M10 x 1 C
60 Clutch Reverse 16 - 18 bar (230 - 260 psi) K4 M10 x 1 F
63 Behind the Converter
M14 x 1.5
Temperature 100°C, Short-time 120°C
65 System Pressure 16 - 18 bar (230 - 260 psi) K4 M10 x 1 K
10 Breather M10 x 1
15 Connection to the Heat Exchanger -------
16 Connection from the Heat Exchanger -------
28 To the Filter M42 x 2
29 From the Filter M42 x 2
30 From the Filter Bypass M42 x 2
36 Oil Filter Plug M42 x 2
49 Plug Connection on the Electrohydraulic Control Unit
68 System Pressure (Option) M16 x 1.5 G

Page 8
Marking on the
No. Denomination of the Position Connection
Valve Block
69 Control System (Option) M16 x 1.5 J
Inductive Transmitters and Speed Sensor
5 Inductive Transmitter n Turbine M18 x 1.5
9 Inductive Transmitter n Central Gear Train M18 x 1.5
13 Speed Sensor n Output and Speedometer -------
14 Inductive Transmitter n Engine M18 x 1.5

Page 9
Figure 2

Page 10
OIL CIRCUIT DIAGRAM 4WG - 260 FORWARD 1ST SPEED

The marked positions (e. g. 53) correspond with the positions on “Schedule of Measuring Points and
Connection 4 WG-260” on page 8
Reference
Positions
Number
WT Heat Changer
WGV Converter Back Pressure Valve 5 bar (73 psi)
WSV Converter Safety Valve 11 bar (160 psi)
HDV Main Pressure Valve 16 - 18 bar (230 - 260 psi)
RV-9 Pressure Reducing Valve 9 bar (130 pai)
NFS Follow-on Slide
D Vibration Damper
B Orifice
P1 Proportional Valve - Clutch KR
P2 Proportional Valve - Clutch K4
P5 Proportional Valve - Clutch KV
Y1 -Y6 Pressure Regulator
TEMP Temperature Sensor
Figure 3

Page 11
P1 P2 P3 P4 P5 P6
ZF-FINE FILTER
FILTER GRADE ACCORDING ISO 4572:
β30>75 β15=25 β10=5.0
DUST CAPACITY ACCORDING ISO 4572:
min. 17g
2
FILTER SURFACE cm
WT 2 x 6,700 = 13,400
(SCOPE OF SUPPLY
CUSTOMER) TRANSMISSION PUMP
LEGEND: p = 16+2 bar
= MAIN PRESSURE Qp= 115 l/min-1at
n = ENGINE 2000 min-1
= REGULATED MAIN PRESSURE
BYPASS-
= PILOT PRESSURE COARSE FILTER
VALVE
= CONVERTER INPUT PRESSURE ∆p=1.5bar MESH WIDTH µm : 450
= CONVERTER OUTPUT PRESSURE FILTER SURFACE cm2 1000
= LUBRICATION
= RETURN INTO THE SUMP
AJS0870L
Figure 4

Page 12
TRANSMISSION ELECTRIC COMPONENTS
21
13
10
18
19
14 17
20
8
15
1
16
3
9
2
11
12 4
6 7
5
AJS0190L
Figure 5
Reference Reference
Number Number
1 T/M Controller 12 T/M Cut-off Pressure Switch
2 T/M Control Valve 13 Downshift Switch
3 T/M Oil Temperature Sensor 14 Safety Starter Switch
4 Engine Pick-Up Sensor 15 Fuse Box
5 Central Gear Pick-up Sensor 16 Parking Brake Switch
6 Turbine Pick-up Sensor 17 Control Unit
7 Output Speed Sensor 18 Starter Controller
8 Shift Lever Switch 19 LIS Switch (Option)
9 Auto Select Switch 20 LIS Solenoid Valve
10 Display 21 Speedometer
11 T/M Cut-off Switch

Page 13
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 ohm ± 1.9 ohm at
20°C. AJS0210L
Figure 7
• Pressure : 0.8 kgf/cm2 → 8.3 kgf/cm2
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

Page 14
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 Ohm ± 30 Ohm ( at 60°C)
81.2 Ohm ± 10 Ohm ( at 90°C)
AJS0220L
36.5 Ohm ± 3.5 Ohm ( at 120°C)
Figure 8
18.7 Ohm ± 2.1 Ohm ( at 150°C)
ENGINE PICK-UP 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 (22.13 ft
lbs)
• Gap: 0.5 - 0.8 mm (0.0197 - 0.0315
in.)
AJS0230L
• Output : 4 Pulse/Rev.
Figure 9
CENTRAL GEAR PICK-UP SENSOR

1. Detect a revolution of central gear array
2. Specification
• Resistance : 1050Ω ± 10% ( at
20°C)
• Fasten torque : 3.06 kg•m (22.13 ft
lbs)
• Gap : 0.5 - 0.8 mm (0.0197 - 0.0315
in.)
AJS0240L
Figure 10

Page 15
TURBINE PICK-UP SENSOR

1. Detect a revolution of gear array in turbine
side.
2. Specification
• Resistance : 1050Ω ± 10% ( at 20°C)
• Fasten torque : 3.06 kg•m (22.13 ft
lbs)
• Gap : 0.5 - 0.8 mm (0.0197 - 0.0315
in.)
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
(16.96 ft lbs)
1.5 40
• Gap : 1.0 - 1.5 mm (0.0394 - 0.0591 AJS0260L
in.)
Figure 12
SHIFT LEVER SWITCH (DW-3)

1. Forward, Reverse and Shift
• F : Forward F
• N : Neutral
• R : Reverse
N KD
• 1, 2, 3, 4 : Shift Step
* Forward shift range : 1 ~ 4 SHIFT SWITCH
* Reverse shift range : 1 ~ 3 LEVER LOCK KEY
R (N/D)
2. Kick-Down (Down Shift) Switch
AJS0270L
• KD : Kick-Down Switch
Figure 13
3. Lever Lock Key
• N : Neutral (The lever is not moved.)
• D : Driving (The lever is released.)

Page 16
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

Page 17
AUTO SELECT SWITCH

1. This is an auto/manual select switch.
2. When the switch is in the 'I(Auto)' position,
the gear shifting will take place
automatically to be selected by the
operator, according to the load and to the
vehicle speed. A
A
3. Automatic shifting takes place between
gears.
B
• Forward : 2nd - 3rd - 4th
• Reverse : 2nd - 3rd
HLB2007L
4. When the switch is in the '0(Manual)' Figure 17
position, the shifting is returned to the
manual mode and the control signal shifts
the transmission to gear selected by the
operator.
DISPLAY
NOTE: See "Transmission Error Codes
(ZF)" shop manual section.

Page 18
TRANSMISSION ELECTRICAL CIRCUITS

T/M CONTROLLER CIRCUIT
AJS0310L
Figure 18
The transmission proportioning solenoid valves are shown here as (Y1 thru Y6, Figure 18).

Page 19
TRAVELLING CIRCUITS
Neutral
AJS0320L
Figure 19
When all transmission solenoid valves are de-energized (OFF) the transmission is in "NEUTRAL."

Page 20
Forward First Gear
AJS0330L
Figure 20
Transmission solenoid valves (Y3 and Y5, Figure 20) are energized when in forward first gear.

Page 21
Forward Second Gear
AJS0340L
Figure 21
Transmission solenoid valves (Y5 and Y6, Figure 21) are energized when in forward second gear.

Page 22
Forward Third Gear
AJS0350L
Figure 22
Transmission solenoid valves (Y4 and Y5, Figure 22) are energized when in forward third gear.

Page 23
Forward Fourth Gear
AJS0360L
Figure 23
Transmission solenoid valves (Y2 and Y4, Figure 23) are energized when in forward fourth gear.

Page 24
Reverse First Gear
AJS0370L
Figure 24
Transmission solenoid valves (Y1 and Y3, Figure 24) are energized when in reverse first gear.

Page 25
Reverse Second Gear
AJS0380L
Figure 25
Transmission solenoid valves (Y1 and Y6, Figure 25) are energized when in reverse second gear.

Page 26
Reverse Third Gear
AJS0390L
Figure 26
Transmission solenoid valves (Y1 and Y4, Figure 26) are energized when in reverse third gear.

Page 27
DOWNSHIFT
Overview
1. There are two downshift switches down
Figure 27, and it is possible for operators
to select one of them according to the
condition.
2. If the downshift switch is depressed during
the machine moving, downshifting takes
place automatically. As a result, fast
digging and moving is possible. But at the
manual mode the kick down can only be
activated.
AJS0400L
3. If a change or travelling direction takes Figure 27
place or the downshift switch is depressed
a second time, downshifting is released
automatically.

Page 28
Kick Down: Forward Second Gear to Forward First Gear

(Auto Selector Switch "O"- Manual Mode)
AJS0410L
Figure 28
With the auto selector switch (Figure 29) is in

the "O" and the forward second gear is selected,
if either downshift switch (Figure 27) 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 A
forward first gear. When either switch (Figure
A
27) is selected a second time, the transmission

pulse signal of the '22' terminal is interrupted
and solenoid valve, Y5 and Y6, are energized
B
and the transmission returns to the forward
second gear.
HLB2007L
Figure 29

Page 29
Downshift (Auto Selector Switch "I" - Auto Mode)
AJS0420L
Figure 30
When the auto selector switch (Figure 30) is in the "I" position, the '29' terminal of transmission controller is
energized. This allows the transmission to automatically upshift and downshift gears depending on the
load and on the engine speed.
If either downshift switch (Figure 27) is activated, a pulse signal is sent to the '22' terminal of transmission
controller. This signal shifts the transmission to the next lowest gear.
Automatic
Downshift Switch "Activated"
Gear Selection
Fourth Gear Downshift to Third Gear
Third Gear Downshift to Second Gear
Second Gear Downshift to First Gear
First Gear Remains in First Gear
When either downshift (Figure 27) is depressed a second time, the transmission pulse signal of the '22' is
interrupted and the transmission returns to normal operation.
NOTE: The fourth to the third gear changes without any RPM change when the downshift switch
is pressed.
NOTE: The third to the second gear, and the third to the first gear, changes occur when the RPM
is reduced 200 - 300 RPM from current setting.

Page 30
TRANSMISSION CUT OFF

When the brake pedal is depressed while
transmission cutoff switch (Figure 31) is in the "I
" position, the transmission cut-off pressure
switch turns "ON" and current is supplied to the
'66' terminal of the transmission controller.
All current being supplied to the transmission
0
solenoid valves (Y1 thru Y6) is cut off and the
transmission is in "NEUTRAL."
I
NOTE: To protect transmission,
transmission cutoff switch does
not function in third and fourth HA3O2018
gears. Figure 31
CAUTION!
When the machine is travelling or working in the place of inclination, the transmission cut-off
switch (Figure 31) must be placed in position 'O' for the purse of using engine braking and the
normal braking function at the same time.
AJS0430L
Figure 32

Page 31
LIS (LOAD ISOLATION SYSTEM) - OPTION

Excessive bucket pitching is drastically reduced
and good floatation 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 8.0 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 6.0 km/h (3.73 mph) the LIS solenoids HA0O2026
valves (14) are de-energized and the LIS Figure 33
system is "OFF."
NOTE: If the LIS switch is in the 'O' position, regardless of the vehicle speed the LIS solenoid
valves (14) de-energized and the LIS system is not operating.
AJS0440L
Figure 34

Page 32

Page 33
INSTALLATION VIEW
INNER SECTION
Figure 35

Page 34
Reference Reference
Number Number
1 Engine Connection - Direct 8 Clutch K1
Mounting 9 Clutch K2
2 Converter 10 Clutch K3
3 Breather 11 Output - Front Axle
4 Drive 12 Output - Rear Axle
5 Electro-hydraulic Shift 13 Layshaft
Control
14 Clutch K4
6 1st Power Take Off
15 Clutch Kr
7 Converter Charge and
16 Clutch Kv
Control Pressure Pump

Page 35
FRONT VIEW
Figure 36
Reference Reference
Number Number
1 Lifting Lugs 7 Coarse Filter
2 Breather 8 Oil Drain Plug
3 Electrohydraulic Shift Control 9 Attachment Possibility for Oil
4 Diaphragms - Direct Mounting Filter Tube with Oil Dipstick
(Converter-side)
5 Converter
10 Oil Filler Tube with Oil Dipstick
6 Output Flange (Converter-side)
(Rear-side)

Page 36
SIDE VIEW
Figure 37
Reference Reference
Number Number
1 Diaphragms for Direct Mounting 7 Output Flange (Rear -side)
2 Converter 8 Oil Filler Tube with Oil Dipstick
(Rear-side)
3 Converter Bell
9 Cover
4 Lifting Lug
10 Gearbox Housing
5 Breather
11 Output Flange (Converter-side)
6 Electrohydraulic Shift Control
12 Transmission Suspension M20

Page 37
REAR VIEW
Figure 38
Reference Reference
Number Number
1 1st Power Take-off 9 Attachment Possibility for
2 Pressure Line Clutch KV Emergency Steering Pump
3 2nd Power Take-off 10 Oil Filter Tube With Oil Dipstick
4 Lifting Lug 11 Model Identification Plate
5 Pressure Oil Line Clutch K1 12 Output Flange (Rear-side)
6 Pressure Oil Line Clutch K4 13 Lubricating Oil Line "S2" Clutch
K4 / K3
7 Pressure Oil Line Clutch K3
14 Pressure Oil Line Clutch KR
8 Lubricatiing Oil Line "S1" Clutch
KR / K2 15 Pressure Oil Line Clutch K2

Page 38

08 Transmiss Install

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

08 Transmiss Install

Uploaded by

Copyright:

Available Formats

Return to Master Table of Contents

TRANSMISSION AND TORQUE CONVERTER (ZF)S0607070K

Copyright 2000 Daewoo

Transmission and Torque Converter (ZF) S0607070K

Drive Train Description ................................................................................... 5

S0607070K Transmission and Torque Converter (ZF)

Kick Down: Forward Second Gear to Forward First Gear

Transmission and Torque Converter (ZF) S0607070K

Install Filter.......................................................................................... 115

S0607070K Transmission and Torque Converter (ZF)

DRIVE TRAIN DESCRIPTION

Transmission and Torque Converter (ZF) S0607070K

TRANSMISSION AND TORQUE CONVERTER

Item Mega 400-V

S0607070K Transmission and Torque Converter (ZF)

Transmission and Torque Converter (ZF) S0607070K

SCHEDULE OF MEASURING POINTS AND CONNECTION 4 WG-260

S0607070K Transmission and Torque Converter (ZF)

Transmission and Torque Converter (ZF) S0607070K

S0607070K Transmission and Torque Converter (ZF)

OIL CIRCUIT DIAGRAM 4WG - 260 FORWARD 1ST SPEED

Transmission and Torque Converter (ZF) S0607070K

S0607070K Transmission and Torque Converter (ZF)

TRANSMISSION ELECTRIC COMPONENTS

Transmission and Torque Converter (ZF) S0607070K

TCU (TRANSMISSION CONTROL UNIT)

S0607070K Transmission and Torque Converter (ZF)

TRANSMISSION OIL TEMPERATURE

ENGINE PICK-UP SENSOR

CENTRAL GEAR PICK-UP SENSOR

Transmission and Torque Converter (ZF) S0607070K

TURBINE PICK-UP SENSOR

OUTPUT SPEED SENSOR

SHIFT LEVER SWITCH (DW-3)

S0607070K Transmission and Torque Converter (ZF)

GEAR FORWARD REVERSE NEUTRAL KICK

Transmission and Torque Converter (ZF) S0607070K

AUTO SELECT SWITCH

S0607070K Transmission and Torque Converter (ZF)

TRANSMISSION ELECTRICAL CIRCUITS

Transmission and Torque Converter (ZF) S0607070K

S0607070K Transmission and Torque Converter (ZF)

Forward First Gear

Transmission and Torque Converter (ZF) S0607070K

Forward Second Gear

S0607070K Transmission and Torque Converter (ZF)

Forward Third Gear

Transmission and Torque Converter (ZF) S0607070K

Forward Fourth Gear

S0607070K Transmission and Torque Converter (ZF)

Reverse First Gear

Transmission and Torque Converter (ZF) S0607070K

Reverse Second Gear

S0607070K Transmission and Torque Converter (ZF)

Reverse Third Gear

Transmission and Torque Converter (ZF) S0607070K

S0607070K Transmission and Torque Converter (ZF)

Kick Down: Forward Second Gear to Forward First Gear

With the auto selector switch (Figure 29) is in

27) is selected a second time, the transmission

Transmission and Torque Converter (ZF) S0607070K

Downshift (Auto Selector Switch "I" - Auto Mode)

S0607070K Transmission and Torque Converter (ZF)

TRANSMISSION CUT OFF