SM-Daewoo Doosan MEGA 200-V Wheel Loader Service Repair Shop Manual-1

Mega 200-V
Shop Manual
023-00055AE
S/N 1001 and Up (Tier I & II)
Daewoo reserves the right to improve our products in a continuing process to provide the best possible
product to the market place. These improvements can be implemented at any time with no obligation to
change materials on previously sold products. It is recommended that consumers periodically contact their
distributors for recent documentation on purchased equipment.
This documentation may include attachments and optional equipment that is not available in your
machine’s package. Please call your distributor for additional items that you may require.
Illustrations used throughout this manual are used only as a representation of the actual piece of
equipment, and may vary from the actual item.
023-00055AE Shop Manual

Pub.No. 023-00055AE
S/N 1001 and Up (Tier I & II)
Mega 200-V
Product Label
Instructions
Trim Out The Label Along

The Lines And Insert Into
Pocket On The Binder Spine
Pub. No. 023-00055AE

1TABLE OF CONTENTS
Safety
Wheel Loader Safety .......................................................................... S0103010K
Specifications
Specifications for Mega 200-V............................................................ S0203100C
General Maintenance
General Maintenance Procedures .........................................................S0302000
Standard Torques ..................................................................................S0309000
Upper Structure
Counterweight..................................................................................... S0403030K
Fuel Transfer Pump ...............................................................................S0405500
Hydraulic Oil Tank .............................................................................. S0406060C
Lower Structure and Chassis

Center Joint (Articulation Joint)........................................................... S0502040C
Engine and Drive Train

Axle (Clark-Hurth / Dana) ................................................................... S0602200C
Parking Brake (DANA)........................................................................ S0603005K
Air Conditioner .................................................................................... S0605050K
Transmission and Torque Converter (ZF 4WG-160) .......................... S0607110C
Transmission Error Codes (ZF) .......................................................... S0607900C
Hydraulics
Hydraulic System................................................................................ S0702035K
Accumulator........................................................................................ S0703010K
Cylinders............................................................................................. S0705015K
Fan Drive Hydraulic Motor (Haldex) ................................................... S0707110C
Table of Contents
Page I
Main Pump (Parker)............................................................................ S0708510C
Brake Pedal Valve .............................................................................. S0709260C
Main Control Valve (Husco)................................................................ S0709457C
Pilot Control Valve .............................................................................. S0709478C
Priority Valve..........................................................................................S0709650
Power Steering Unit............................................................................ S0709705C
Restriction Valve................................................................................. S0709752C
Hydraulic Schematic (Mega 200-V) .................................................... S0793015C
Electrical System
Electrical System ................................................................................ S0802015C
Electrical Schematic (Mega 200-V) .................................................... S0893015C
Attachments
Table of Contents
Page II
1SAFETY
S0103010K
2WHEEL LOADER
SAFETY
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
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 and Up
Mega 400-V 1001 and Up
Copyright 2002 Daewoo

November 2002
Wheel Loader Safety S0103010K

Page 1
TABLE OF CONTENTS
To the Operator of a 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 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.
Daewoo 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
Daewoo or your Daewoo 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 should 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

Words "CAUTION," "WARNING," and "DANGER" used throughout this manual and on labels on machine
indicate hazards or unsafe practices. All three statements 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 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.

Daewoo 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 your unsure about the safety of some procedures, contact a DAEWOO
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 Daewoo. 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 Daewoo can create a safety hazard,
for which the machine owner must be held responsible.
For safety’s sake, replace all OEM parts with the correct authorized or genuine Daewoo part. For example,
not taking the time to replace fasteners, bolts or nuts with the correct replacement parts could lead to a
condition in which the safety of critical assemblies is dangerously compromised.

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 cab 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 cab.
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.
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.
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.

Page 9
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.
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

Page 10
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
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 cab.
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.

Page 11
PROTECTION FROM FALLING OR FLYING
OBJECTS
On work sites where there is danger that falling
objects or flying objects may hit the operator's
cab 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 cab could be
required in form of a FOPS/Falling Object
HAOA110L
Protective Structure and/or ROPS/Roll Over
Protective Structure reinforcement system. Figure 9
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 Daewoo distributor for available safety guards and/or recommendations if there is any danger
of getting hit by objects that could strike the operator’s cab. 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 12
ATTACHMENT PRECAUTIONS
Options kits are available through your dealer. Contact Daewoo for information on available one-way
(single-acting) and two-way (double-acting) piping / valving / auxiliary control kits. Because Daewoo cannot
anticipate, identify or test all attachments that owners may wish to install on their machines, please contact
Daewoo 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 Daewoo distributor.
• Wear safety goggles and protective gloves when working on an accumulator. Hydraulic oil under
pressure can penetrate the skin and cause serious injuries.
ENGINE VENTILATION
Engine exhaust gases can cause loss of
judgment, loss of alertness, and loss of motor
control. These gases can also cause
unconsciousness, serious injury and fatal
accidents.
Make sure of adequate ventilation before
starting engine in any enclosed area.
You should also be aware of open windows,
doors or ductwork into which exhaust may be
carried, or blown by wind, exposing others to ARO1770L
danger. Figure 11

Page 13
WINDOW GLASS BREAKING TOOL
This loader is equipped with a glass breaking
tool. It is on the lower right side of the cab
beside the operator’s seat. This tool can be
used in case of an emergency situation which
requires the breaking of glass to exit from the
operator’s cab. Grip the handle firmly and use
the sharp point to break the glass.
WARNING!
Protect your eyes when breaking the Figure 12 RIGHT SIDE
glass.

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 13
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 cab. Look for evidence of leaking fluid,
loose fasteners, misaligned assemblies or any other indications of possible equipment hazard.
• All equipment covers and machinery safety guards must be in place, to protect against injury
while machine is being operated.
• Look around work site area for potential hazards, or people or property that could be at risk
while operation is in progress.
• NEVER start engine if there is any indication that maintenance or service work is in progress, or
if a warning tag is attached to controls in cab.
• A machine that has not been used recently, or is being operated in extremely cold temperatures,
could require a warm-up or maintenance service before start up.
• Check gauges and monitor displays for normal operation before starting engine. Listen for
unusual noises and remain alert for other potentially hazardous conditions at start of work cycle.
• Check tire inflation and check tires for damage or uneven wear. Perform maintenance before
operation.
• Do not short circuit the starting motor to start the engine. This is not only dangerous, but may
also damage the machine.
• When starting the engine, sound the horn as an alert.
• Start and operate the machine only while seated.

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 cab 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 Daewoo
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 14
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 SHOULD BE USED AT ALL

TIMES
Whenever engine is running, operator should be
seated at the control station with seat belt
properly engaged.
Figure 15
MOVEMENT ALARMS
If wheel loader is equipped with an audible travel movement alarm, test alarm on a daily basis. Audible
alarm should sound as soon as travel system is engaged.

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 16
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") Figure 17
66.0 kV 5 m (16’ 5")
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.
Overhand 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 18
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 cab 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 19
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 20
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 should be aware of assigned individual responsibilities and tasks.
Communication and hand signals used should 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 should 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 cab. HAOA191L
Figure 21
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 should be no possibility of unintended or accidental movement.
When parking on public roads, provide fences, signs, flags, or lights, and put up any other necessary signs
to ensure that passing traffic can see the machine clearly, and park the machine so that the machine, flags,
and fences do not obstruct traffic.

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 22

Page 24
MAINTENANCE
USE WARNING TAG DURING SERVICE
Alert others that service or maintenance is
being performed and tag operator’s cab controls
- and other machine areas if required - with a
warning notice.
Warning tags for controls are available from WARNING
Daewoo distributors; see Figure 23.
CLEAN BEFORE INSPECTION OR

MAINTENANCE
HAOC920L
Clean the machine before carrying out
inspection and maintenance. This prevents dirt Figure 23
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 24). If
water gets into the electrical system, there is danger that it will cause defective operation and
malfunction.
Figure 24
Pick up any tools or hammers that are laying in the work place, wipe up any grease or oil or any other
slippery substances, and clean the area to make it possible to carry out the operation in safety. If the work
place is left untidy, you may trip or slip and suffer injury.

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 25
USE OF LIGHTING
When checking fuel, oil, battery electrolyte, or
window washing fluid, always use lighting with
anti-explosion specifications. If such lighting
equipment is not used, there is danger of
explosion.
If work is carried out in dark places without
using lighting, it may lead to injury, so always
use proper lighting.
Even if the place is dark, never use a lighter or
flame instead of lighting. There is danger of fire. HDO1040L
There is also danger that the battery gas may Figure 26
catch fire and cause and explosion.
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 27
If the coolant level in the coolant recovery tank is below the lower limit, add coolant.
Cooling system conditioner contains alkali. Alkali can cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth.
Allow cooling system components to cool before you drain the cooling system.
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact
the skin.
Remove the hydraulic tank filter plug only after the engine has been stopped. Make sure that the hydraulic
tank filter plug is cool before you remove it with your bare hand. Remove the hydraulic tank filter plug slowly
to relieve pressure.
Relieve all pressure in the hydraulic oil system, in the fuel system, or in the cooling system before you
disconnect any lines, fittings, or related items.
Batteries give off flammable fumes that can explode.
Do not smoke while you are checking the battery electrolyte levels.
Electrolyte is an acid. Electrolyte can cause personal injury. Do not allow electrolyte to contact the skin or
the eyes.
Always wear protective glasses when you work on batteries.

Page 27
WELDING REPAIRS
When carrying out welding repairs, carry out the welding in a properly equipped place. The welding should
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 28

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 29
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 Daewoo.
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.
X X O
HAOA420L
Figure 30
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 filler 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 31

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 over inflate. 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 32
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 33
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, should 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 Daewoo 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 34
• Condition of ground support.
• Wheel loader configuration and
attachments.
• Weight, lifting height and lifting
radius.
• Safe rigging of load.
• Proper handling of suspended load.
Taglines 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
S0203100C
1SPECIFICATIONS FOR
MEGA 200-V
CAUTION!
SPECIFICATIONS FOR MEGA 200-VS0203100C


December 2002
Specifications for Mega 200-V S0203100C

Page 1
S0203100C Specifications for Mega 200-V
Page 2
TABLE OF CONTENTS
Component Locations .................................................................................... 4

General Specifications ................................................................................... 8
Engine Performance Curves ........................................................................ 10
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
10
12 11
18 19
17
16 21 22
20
14 23
15
24
13 25
44
26
27
28
29
43 42 41 40 39 38 37 36 35 34 33 32 31 30
APO0010L
Figure 1 (Tier I)

Page 4
Reference Reference
Description Description
Number Number
1 Bucket Tooth 24 Radiator
2 Bucket 25 Grill
3 Air-conditioner Condenser 26 Fan
4 Rear Wheel Cover 27 Fuel Tank
5 Engine Oil Filter 28 Engine Oil Filler Pipe
6 Battery Box 29 Engine Oil Level Gauge
7 Rear Light 30 Remote Engine Oil Drain Port
8 Counterweight 31 Rear Axle Pivot
10 Towing Pin 32 Rear Axle
11 Tool Box / Fuel Pump 33 Drive Shaft (Rear)
12 Oil Tank 34 Transmission
13 Tilt Lever 35 Transmission Oil Filter
14 Bucket Cylinder 36 Center Pin
15 Front Wheel Cover 37 Steering Wheel Cylinder
16 Headlight Support 38 Drive Shaft (Center)
17 Ladder 39 Drive Shaft (Front)
18 Work Light 40 Parking Brake
19 Operator’s Cab 41 Front Axle
20 Air Cleaner 42 Boom Cylinder
21 Muffler 43 Loader Arm
22 Pre-cleaner 44 Link
23 Engine

Page 5
Figure 2 identifies the location of major machine components.
1 2 3 4 5 6
10
12 11
18 19
17
16
21 22
20
15 23
14 24
13 25
44
26
27
28
29
43 42 41 40 39 38 37 36 35 34 33 32 31 30
APO0020L
Figure 2 (Tier I (Europe Low noise Kit))
(Tier II)

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

Page 7
GENERAL SPECIFICATIONS
Mega 200-V (Tier I & II)
Specification
Item
Standard* Option**
Standard Bucket Capacity 1.8 m3 3
(2.4 yd ) 1.9 m3 (2.5 yd3)
Vehicle Weight 11,000 kg (24,251 lb) 11,200 kg (24,692 lb)
Engine
Emission Tier I Tier II
Maker X Model Daewoo DB58TI Daewoo DB58TIS
Turbo charged air to air after
Type Turbo, Intercooler
cooler
Rated:145 ps @ 2,200 rpm
140 ps @ 2,200 rpm (143 hp @ 2,200 rpm)
Horsepower (see note) (138 hp @ 2,200 rpm) Max:160 ps @ 2,000 rpm
(SAE J 1349 net) (158 hp @ 2,000 rpm)
(Gross) (SAE J1995)
57 kg•m @ 1,500 rpm 64 kg•m @ 1,600
Max. Torque (see note) (412 ft lb @ 1,500 rpm) (463 ft lb) @ 1,600 rpm
(SAE J 1349 net) (Gross) (SAE J1995)
Transmission
Type Full Automatic Power Shift
Speeds 4 Forward, 3 Reverse
Brake Systems
Service Brakes Full Hydraulic, Separate Dual Line Wet Discs
Parking Brake Spring Applied / Oil Release on Front Axle, Dry Disc
Performance
Steering Angle ±40°
Bucket Rise Time 5.0 Sec.
Bucket Lower Time 3.3 Sec.
Bucket Dump Time 1.2 Sec.
Max. Breakout Force 10,500 kg (23,150 lb)
Static Tipping Load 8,500 / 7,400 kg
(Straight / Full Turn) (18,740 / 16,315 lb)
Maximum Gradeability 30° (58%)
System Pressure (Work / Steer) 200 kg/cm (196 bar) / 175 kg/cm2 (172 bar)
2
System Flow (Work / Steer) 176 l/min (46.5 gpm) / 85 l/min (22.5 gpm)
7.3/12.7/22/36 km/h 8.2/14.3/25/39 km/h
Travel Speed (1/2/3/4)
(4.54/7.89/13.67/22.37 mph) (5.10/8.89/15.53/24.23 mph)
Working Range
Dump Height at 45° (W/O) 2,842 mm (9' 4'') 2,850 mm (9' 4'')
* Standard Figures Include R.O.P.S. Cab, 17.5 x 25 - 12 PR Tires and Standard Bucket (1.80 m3
(2.35 yd3)).
** Option Figures Include R.O.P.S. Cab, 20.5 x 25 - 12 PR Tires and Option Bucket (1.90 m3 (2.49
yd3)).

Page 8
Specification
Item
Standard* Option**
Dump Reach at 45° (W/O) 1,000 mm (3' 3'') 870 mm (2' 10'')
Max Dumping Angle 46°
Max Tilt Angle 40°
Max Tilt Angle 66°
Max Tilt Angle 45°
Bucket Hinge Height 3,748 mm (12' 4'') 3,828 mm (12' 7'')
Digging Depth (0° level) 50 mm (1.97 in)
Boom Up Speed 5.0 km/h (3.11 mph)
Travel Dimension
Overall Length (A) 7,025 mm (23' 1'')
Overall Width (B) 2,450 mm (8' 0'')
Overall Height (C) 3,180 mm (10' 5'')
Wheel Base (E) 2,900 mm (9' 6'')
Tread (F) 1,930 mm (6' 4'')
Ground Clearance (G) 370 mm (1' 3'')
Tire Size 17.5 x 25 -12 PR 20.5 x 25 - 12 PR
Turning Radius (Tire Center) 4,949 (16' 3'')
Sound Level in Cab (2000 14 / EC) LpA 75 dB(A)
External Sound Level (2000 14 / EC) LwA 104 dB(A)
Fuel Tank Capacity 260 Liter (68.7 U.S. gal.)
* Bucket
- Teeth Bucket (1.90 m3 (2.49 yd3))
- Cutting Edge Bucket (2.0 m3 (2.62 yd3))

* Pallet Fork
Option Attachments
* Emergency Steering
* Rear Full Fender
* 3rd Spool
* Europe Low Noise Kit
* Standard Figures Include R.O.P.S. Cab, 17.5 x 25 - 12 PR Tires and Standard Bucket (1.80 m3
(2.35 yd3)).
** Option Figures Include R.O.P.S. Cab, 20.5 x 25 - 12 PR Tires and Option Bucket (1.90 m3 (2.49
yd3)).
NOTE: "High torque rise"

Fuel system deliveries a control increase of fuel as the engine lugs back from rated speed.
This results in horsepower greater than rated power. The combination of increased torque
rise and maximum horsepower improves response, provides greater rimpull, more lift
force, and faster cycle times. The maximum horsepower occurs at 2000 rpm when power
is needed during the working cycle.

Page 9
ENGINE PERFORMANCE CURVES
APS0180L
Figure 3
(SAE J 1349, Net)
(SAE J 1995, Gross)

Page 10
Emission Tier I Tier II
Power (Maximum/rpm) 140 ps @ 2,200 rpm Rated:145 ps @ 2,200 rpm
(138 hp @ 2,200 rpm) (Net) (143 hp @ 2,200 rpm)
Max:160 ps @ 2,000 rpm
(158 hp @ 2,000 rpm)
(Gross) (SAE J1995)
Maximum Torque 64 kg•m @ 1,600
57 kg•m / 1,500 rpm
(463 ft lb @ 1,600 rpm)
(412 ft lb @ 1,500 rpm) (Net)
(Gross) (SAE J1995)
Fuel consumption 160 g/ps•h
(5.64 oz/hp•h)
Performance Standard KS-DIN6270
NOTE: Barometric Pressure: 760 mm (30 in) Mercury

Temperature: 20°C (68°F)
W/O Cooling Fan
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.
J
O
40
C
G
B (D) E
A F
I
H
APO0160L
Figure 4

Page 12
Dimension
Category
Standard Option
7,025 mm
Overall Length (A)
(23' 1'')
2,450 mm 2,550 mm
Overall Width (B)
(8' 0'') (8' 4'')
3,180 mm 3,260 mm
Overall Height (C)
(10' 5'') (10' 8'')
2,450 mm 2,550 mm
Bucket Width (D)
(8' 0'') (8' 4'')
2,900 mm
Wheel Base (E)
(9' 6'')
1,930 mm
Tread (F)
(6' 4'')
370 mm
Ground Clearance (G)
(1' 3'')
2,720 mm 2,730 mm
Dump Height, to tooth (H)
(8' 11'') (8' 11'')
1,000 mm 870 mm
Dump Distance, to Bucket Edge (I)
(3' 3'') (2' 10'')
Minimum Tire Turning Radius (J) 4,949 mm (16' 3'')
Bucket Angle, Raised (a) 46°

Bucket Angle (b), Lowered (at carry) 45°
Bucket Angle (b), Lowered (on ground) 38°
20.5 x 25 - 12 PR9
Tire Size 17.5 x 25 - 12 PR (Bias)
20.5 x R25 (Radial)

Page 13
Figure 5 illustrate working range when machine is equipped with optional pallet or log fork.
A
B
E
D
b
C
APS0190L
Figure 5
Reference Reference
Dimension Dimension
Number Number
A 2,026 mm D 2,734 mm
(6' 8'') (8' 12'')
B 2,303 mm E 3,593 mm
(7' 7'') (11' 10'')
C 1,500 mm a 35°
(4' 11'') b 26°

Page 14
WORKING CAPACITIES
BUCKET CAPACITY
Standard toothed bucket has a capacity of 1.8 m3 (2.4 yd3).
TIPPING LOAD
Static Tipping Load with bucket in Over Front position is 8,500 kg (18,740 lb). With bucket in Fully Turned
position, Static Tipping Load is 7,400 kg (16,315 lb).
MATERIAL WEIGHT
The data below describes weight of a cubic meter (cubic yard) of many types of workload materials.
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)
Cement, Portland, DRY 1,506 kg/m3

--------------------- ---------------------
granular (2,583 lb/yd3)

Page 15
LESS LESS LESS
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 1-1/ 1,362 kg/m3

--------------------- ---------------------
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)
929 kg/m3
Salt --------------------- ---------------------
(1,566 lb/yd3)

Page 16
LESS LESS LESS
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
Daewoo After Sales Service before welding on integral components (loader arm, frames, car
body, track frames, turntable, attachment, etc.) of the machine. It is possible that some types of
structurally critical repairs may require Magnetic Particle or Liquid Penetrant testing, to make
sure there are no hidden cracks or damage, before the machine can be returned to service.
CAUTION!
Always perform welding procedures with the proper safety equipment on hand. Adequate
ventilation and a dry work area are absolutely essential. Keep a fire extinguisher nearby and
always wear protective clothing and the recommended type of eye protection.

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 cab 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 pre-filling 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 pre-lube) or has been contaminated by dirt or by
questionable oils, flushing and pre-filling 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 pre-start 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 pre-clean any exterior surface of the system before it is exposed
to air. For example, the reservoir filler 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 sub-freezing climates
or in high temperature, high humidity tropical conditions), frequent purging of moisture
condensation from the hydraulic reservoir drain tap should 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 filter elements 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 pre-fill 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 should be exercised to avoid inhalation of vapors, exposure to skin and creating fire
hazards when using solvent type cleaners.
1. Clean all metal parts thoroughly using a suitable cleaning fluid. It is recommended that parts be
immersed in cleaning fluid and moved up and down slowly until all oils, lubricants, and/or foreign
materials are dissolved and parts are thoroughly clean.
2. For bearings that can be removed, soak them in a suitable cleaning fluid for a minute or two, then
remove bearings from cleaning fluid and strike flat against a block of wood to dislodge solidified
particles of lubricant. Immerse again in cleaning fluid to flush out particles. Repeat above operation
until bearings are thoroughly clean. To dry bearings, use moisture-free compressed air. Be careful to
direct air stream across bearing to avoid spinning bearings that are not lubricated. DO NOT SPIN
BEARINGS WHEN DRYING; bearings may be rotated slowly by hand to facilitate drying process.
3. Carefully inspect all bearing rollers, cages and cups for wear, chipping or nicks to determine
condition. Do not replace a bearing cone or cup individually without replacing mating cup or cone at
the same time. After inspection, dip bearings in light weight oil and wrap in clean lintless cloth or
paper to protect them until installation.
For those bearings that are to be inspected in place; inspect bearings for roughness of rotation,
scoring, pitting, cracked or chipped races. If any of these defects are found, replace bearings. Also
inspect defective bearing housing and/or shaft for grooved, galled or burred conditions that indicate
bearing has been turning in its housing or on its shaft.
4. It is more economical to replace oil seals, O-rings, sealing rings, gaskets and snap rings when unit is
disassembled than waiting for premature failures; refer to latest Micro Fiche and/or Parts Book for
replacement items. Be extremely careful when installing sealing members, to avoid cutting or

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
Pitch (mm)
3.6 4.6 4.8 5.6 5.8 6.6 6.8 6.9 8.8 10.9 12.9
(4A) (4D) (4S) (5D) (5S) (6D) (6S) (6G) (8G) (10K) (12K)
0.15 0.16 0.25 0.22 0.31 0.28 0.43 0.48 0.50 0.75 0.90
M5 x Std.
(1.08) (1.15) (1.80) (1.59) (2.24) (2.02) (3.11) (3.47) (3.61) (5.42) (6.50)
0.28 0.30 0.45 0.40 0.55 0.47 0.77 0.85 0.90 1.25 1.50
M6 x Std.
(2.02) (2.16) (3.25) (2.89) (3.97) (3.39) (5.56) (6.14) (6.50) (9.04) (10.84)
0.43 0.46 0.70 0.63 0.83 0.78 1.20 1.30 1.40 1.95 2.35
M7 x Std.
(3.11) (3.32) (5.06) (4.55) (6.00) (5.64) (8.67) (9.40) (10.12) (14.10) (16.99)
0.70 0.75 1.10 1.00 1.40 1.25 1.90 2.10 2.20 3.10 3.80
M8 x Std.
(5.06) (5.42) (7.95) (7.23) (10.12) (9.04) (13.74) (15.18) (15.91) (22.42) (27.48)
0.73 0.80 1.20 1.00 1.50 1.35 2.10 2.30 2.40 3.35 4.10
M8 x 1
(5.28) (5.78) (8.67) (7.23) (10.84) (9.76) (15.18) (16.63) (17.35) (24.23) (29.65)
1.35 1.40 2.20 1.90 2.70 2.35 3.70 4.20 4.40 6.20 7.20
M10 x Std.
(9.76) (10.12) (15.91) (13.74) (19.52) (19.99) (26.76) (30.37) (31.18) (44.84) (52.07)
1.50 1.60 2.50 2.10 3.10 2.80 4.30 4.90 5.00 7.00 8.40
M10 x 1
(10.84) (11.57) (18.08) (15.18) (22.42) (20.25) (31.10) (35.44) (36.16) (50.63) (60.75)
2.40 2.50 3.70 3.30 4.70 4.20 6.30 7.20 7.50 10.50 12.50
M12 x Std.
(17.35) (18.08) (26.76) (23.86) (33.99) (30.37) (45.56) (52.07) (54.24) (75.94) (90.41)
2.55 2.70 4.00 3.50 5.00 4.50 6.80 7.70 8.00 11.20 13.40
M12 x 1.5
(18.44) (19.52) (28.93) (25.31) (36.16) (32.54) (49.18) (55.69) (57.86) (81.00) (96.92)
3.70 3.90 6.00 5.20 7.50 7.00 10.00 11.50 12.00 17.00 20.00
M14 x Std.
(26.76) (28.20) (13.23) (37.61) (54.24) (50.63) (72.33) (83.17) (86.79) (122.96) (144.66)
4.10 4.30 6.60 5.70 8.30 7.50 11.10 12.50 13.00 18.50 22.00
M14 x 1.5
(29.65) (31.10) (47.73) (41.22) (60.03) (54.24) (80.28) (90.41) (94.02) (11.26) (158.12)
5.60 6.00 9.00 8.00 11.50 10.50 15.50 17.90 18.50 26.00 31.00
M16 x Std.
(40.50) (43.39) (65.09) (57.86) (83.17) (75.94) (112.11) (129.47) (133.81) (188.05) (224.22)
6.20 6.50 9.70 8.60 12.50 11.30 17.00 19.50 20.00 28.00 35.50
M16 x 1.5
(44.84) (47.01) (70.16) (62.20) (90.41) (81.73) (122.96) (141.04) (144.66) (202.52) (256.77)
7.80 8.30 12.50 11.00 16.00 14.50 21.00 27.50 28.50 41.00 43.00
M18 x Std.
(56.41) (60.03) (90.41) (79.56) (115.72) (104.87) (151.89) (198.90) (206.14) (296.55) (311.01)
9.10 9.50 14.40 12.50 18.50 16.70 24.50 27.50 28.50 41.00 49.00
M18 x 1.5
(65.82) (68.71) (104.15) (90.41) (133.81) (120.79) (177.20) (198.90) (206.14) (296.55) (354.41)
11.50 12.00 18.00 16.00 22.00 19.00 31.50 35.00 36.00 51.00 60.00
M20 x Std.
(83.17) (86.79) (130.19) (115.72) (159.12) (137.42) (227.83) (253.15) (260.38) (368.88) (433.98)
12.80 13.50 20.50 18.00 25.00 22.50 35.00 39.50 41.00 58.00 68.00
M20 x 1.5
(92.58) (97.64) (148.27) (130.19) (180.82) (162.74) (253.15) (285.70) (296.55) (419.51) (491.84)
15.50 16.00 24.50 21.00 30.00 26.00 42.00 46.00 49.00 67.00 75.00
M22 x Std.
(112.11) (115.72) (177.20) (151.89) (216.99) (188.05) (303.78) (332.71) (354.41) (484.61) (542.47)
17.00 18.50 28.00 24.00 34.00 29.00 47.00 52.00 56.00 75.00 85.00
M22 x 1.5
(122.96) (133.81) (202.52) (173.59) (245.92) (209.75) (339.95) (44.76) (405.04) (542.47) (614.80)
20.50 21.50 33.00 27.00 40.00 34.00 55.00 58.00 63.00 82.00 92.00
M24 x Std.
(148.27) (155.50) (238.68) (195.29) (289.32) (245.92) (397.81) (419.51) (455.67) (593.10) (655.43)
23.00 35.00 37.00 31.00 45.00 38.00 61.00 67.00 74.00 93.00 103.00
M24 x 1.5
(166.35) (253.15) (267.62) (224.22) (325.48) (202.52) (441.21) (484.61) (535.24) (672.66) (744.99)

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 SHOULD 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) (N•m)
(N•m)
1/4" - 20 6 8 9 12
1/4" - 28 7 9 11 15
5/16" - 18 13 18 18 24
5/16" - 24 15 20 21 28
3/8" - 16 24 33 34 46
3/8" - 24 27 37 38 52
7/16" - 14 38 52 54 73
7/16" - 20 42 57 60 81
1/2" - 13 58 79 82 111
1/2" - 20 65 88 90 122
9/16" - 12 84 114 120 163
9/16" - 18 93 126 132 179
5/8" - 11 115 156 165 224
5/8" - 18 130 176 185 251
3/4" - 10 205 278 290 393
3/4" - 16 240 312 320 434
7/8" - 9 305 414 455 617
7/8" - 14 334 454 515 698
1" - 8 455 617 695 942
1" - 14 510 691 785 1064
1 1/8" - 7 610 827 990 1342
1 1/8" - 12 685 929 1110 1505
1 1/4" - 7 860 1166 1400 1898
1 1/4" - 12 955 1295 1550 2102
1 3/8" - 6 1130 1532 1830 2481
1 3/8" - 12 1290 1749 2085 2827
1 1/2" - 6 1400 2034 2430 3295
1 1/2" - 12 1690 2291 2730 3701
1 3/4" - 5 2370 3213 3810 5166
2" - 4 1/2 3550 4813 5760 7810
NOTE: If any bolts and nuts are found loose or at values less than what the chart states, it is
recommended that the loose bolt and/or nut be replaced with a new one.

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 "Ultra- 0.6 - 0.7 50 - 60 0.5 - 0.6 40 - 50

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. Daewoo does not specifically
endorse a specific manufacturer or brand name but the following table of "Loctite" applications
is included for which cross-references to other makers’ products should also be widely
available.
IMPORTANT
Use primer "T" or "N" for all cold weather assembly of fastener adhesives, with Thread locker
sealers 222, 242/243, 262, 271, 272, or 277.

Page 10
I. "Loctite" Fastener Adhesives
Break-away
Cure Strength
Product Application Color Removal
(in lb) of Sealer
Alone
Low strength for 6 mm (1/4") or
222 Purple Hand tools 45
smaller fasteners.
242 or Medium strength for 6 mm (1/4") and
Blue Hand tools 80
243 larger fasteners.
High strength for high grade Heat/260°C (500°F)
262 fasteners subject to shock, stress Red Remove HOT 160
and vibration. (NO solvent)
Extra high strength for fine thread Heat/260°C (500°F)
271 Red 160
fasteners up to 25 mm (1") diameter. Remove HOT
High temperature/high strength for
Heat/316°C (600°F)
272 hostile environments to 232°C Red 180
Remove HOT
(450°F).
Extra high strength for coarse thread
Heat/260°C (500°F)
277 fasteners 25 mm (1") diameter and Red 210
Remove HOT
larger.
II. "Loctite" Pipe Thread Sealant
Product Application Color Removal Required Setup

"No-filler/non-clog" formula for high-
4 Hours (or 1/2 hour
pressure hydraulic systems. Over-
545 Purple Hand tools with Locquic "T"
application will not restrict or foul system
Primer)
components.
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
504 compound. Fills gaps to 0.0012 mm (0.030"), Orange faster (1/2 - 4 hours) setup.
cures to rigid seal. Unprimed setup 4 - 24 hours.
General purpose, fast setup, flexible-cure Use Locquic "N" primer for
515 gasket eliminator. For nonrigid assemblies Purple faster (1/4 - 2 hours) setup.
subject to shock, vibration or deflection. Unprimed 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
Return to Master Table of Contents
S0403030K
R2
1COUNTERWEIGHT
CAUTION!
COUNTERWEIGHT S0403030K

December 2002
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
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 400-III PLUS 1001 and Up
Mega 500-V 1001 thru 2000
Solar 75-V 1001 and Up
Solar 130LC-V 0001 and Up
Solar 130W-V 0001 and Up
Models continued on back of cover.

December 2002
Fuel Transfer Pump S0405500

Page 1
Solar 220LL 1001 and Up
Solar 220N-V 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
Fuel pump consists of 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 damage.
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 pump
during operation, it can become lodged between
the rotor and/or vanes and generate heat which
can cause 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 a 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 O-ring again at reassembly of 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
brush and insert it to the armature. Then fit the Figure 7
hole of screw in the housing.
Be careful when installing screw. The cover
screw may be attracted by the motor magnet.

Page 5
REPLACEMENT OF
ARMATURE
You can replace only the armature in case 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 rear cover.
Fit the rotor in the shaft flute of armature. Insert
vane to the rotor being careful for the direction.
Refer to “Replacement of Rotor and Vane” on
page 4.

Page 6
S0406060C
R1
1HYDRAULIC OIL TANK
CAUTION!
HYDRAULIC OIL TANKS0406060C


December 2002
Hydraulic Oil Tank S0406060C

Page 1
TABLE OF CONTENTS
Parts List (M200-V) ................................................................................. 4
Parts List (M250-V) ................................................................................. 6
Specifications .......................................................................................... 8
S0406060C Hydraulic Oil Tank

Page 2
Page 3
GENERAL DESCRIPTION
PARTS LIST (M200-V)
3 2 1
SECTION B
S=1/5
5
7 SECTION A
APS0200L
Figure 1 (Tier I)
Reference Reference
Number Number
1 Return Filter 5 Air Breather
2 Bypass Valve 6 Level Gauge
3 Spring 7 Drain Plug
4 Suction Filter

Page 4
3 2 1
SECTION B
S=1/5
7 SECTION A
BHS0050L
Figure 2 (Tier II)
Reference
Description
Number
1 Return Filter
2 Bypass Valve
3 Spring
4 Suction Filter
5 Air Breather
6 Level Gauge
7 Drain Plug

Page 5
PARTS LIST (M250-V)
3
2
SECTION A
S=1/2.5
7 SECTION B
S=1/5
AOS0160L
Figure 3 (S/N 1001 thru 2000)
Reference Reference
Number Number

Page 6
3
SECTION A
S=1/2.5
7
SECTION B
S=1/5
BAS0120L
Figure 5 (S/N 2001 and Up)
Reference Reference
Number Number

Page 7
SPECIFICATIONS
Mega 200-V Mega 250-V

Serial Number 1001 and Up 1001 thru 2000 2001 and Up
Type Pressurized Sealing
Capacity (System) 150 liters 195 liters 166 liters
(40 U.S. gal.) (51 U.S. gal.) (43.8 U.S. gal.)
Air breather
Open Pressure 0.40 kg/cm2 (5.7 psi)
Vacuum pressure 0.035 kg/cm2 @ 900 liters/min. (0.5 psi @ 238 gpm)
Return Filter
Filtration rating 10 µ
Pressure drop 2
0.2 kg/cm @ 600 liters (3 psi @ 159 gpm)
Suction Filter 177 µ −

Page 8
1LOWER STRUCTURE AND CHASSIS
S0502040C
1CENTER JOINT
(ARTICULATION JOINT)
CAUTION!
CENTER JOINT (ARTICULATION JOINT)S0502040C


December 2002
Center Joint (Articulation Joint) S0502040C

Page 1
TABLE OF CONTENTS
Maintenance Standard ............................................................................ 4
S0502040C 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 (LOWER HINGE BEARING)
(UPPER HINGE BEARING)
APS0210L
Figure 2

Page 4
Unit: mm
No. Check item Criteria Remedy
Standar Tolerance Standard Clearance
Clearance between upper d size clearance limit
1
hinge pin and rear frame -0.025 +0.039 0.025 -
45 -
-0.064 +0 0.103
Clearance between upper
-0.025 +0.050 0.050 -
2 hinge pin and spacer 45 -
-0.064 +0.025 0.114
(small)
Clearance between upper -0.025 +0 0.013 -
3 45 -
hinge pin and bearing -0.064 -0.012 0.064
Clearance between upper
-0.025 +0.050 0.050 -
4 hinge pin and spacer 45 -
-0.064 +0.025 0.114
(large)
Clearance between rear -0.046 +0.076 0.076 -
5 55 -
frame and spacer (large) 0 +0.030 0
Replace
Clearance between front
-0.043 +0 -0.025 -
6 frame and upper hinge 85 -
-0.076 -0.018 -0.076
bearing
Clearance between lower -0.025 +0.039 0.025 -
7 45 -
hinge pin and rear frame -0.064 +0 0.103
Clearance between lower -0.025 +0 0.013 -
8 45 -
hinge pin and bearing -0.064 -0.012 0.064
Clearance between front
-0.043 +0 -0.025 -
9 frame and lower hinge 85 -
-0.076 -0.018 -0.076
bearing
Height of upper hinge 20. +0
11 -0.13 - - +0 +0
spacer (small) 7
Height of upper hinge 52. +0
12 -0.13 - - +0 +0
spacer (large) 5
Shim thickness for upper
13 hinge and retainer 1.5-1.9 - - - -
(front frame)
Shim thickness for upper
14 hinge and retainer 1.5-2.6 - - - -
(rear frame)
Tightening torque of When adjusting with shim: 4 ±0.2 kg•m
15 upper hinge retainer
mounting bolt Final value: 8 ±1.0 kg•m
Tightening torque of When adjusting with shim: 4 ±0.2 kg•m
16 upper hinge retainer
mounting bolt Final value: 8 ±1.0 kg•m
Retighten
Tightening torque of
17 lower hinge pin mounting 8 ±1.0 kg•m
bolt
Shim thickness for lower
18 hinge and retainer 1.2 - 1.9 mm
(front frame)

Page 5
Page 6
1ENGINE AND DRIVE TRAIN
S0602200C
1AXLE
(CLARK-HURTH / DANA)
CAUTION!
AXLE (CLARK-HURTH / DANA)S0602200C


December 2002
Axle (Clark-Hurth / Dana) S0602200C

Page 1
TABLE OF CONTENTS
Introduction..................................................................................................... 4
Outline..................................................................................................... 5
Differential (Standard) ............................................................................. 8
Differential Operation ....................................................................... 8
Self Locking Differential........................................................................... 9
Troubleshooting ............................................................................................ 10
Special Tools ................................................................................................ 13
Clark-Hurth / Dana Axle Identification .......................................................... 16
Maintenance and Lubrication ................................................................ 17
Brake Disc............................................................................................. 17
Wear Check and Replacement ...................................................... 17
Adjustment of Brake Disc Gap....................................................... 18
Safety Brake.......................................................................................... 20
Adjustment of Safety Brake............................................................ 24
Wheel Hub ............................................................................................ 26
Planetary Reduction Gears................................................................... 30
Bevel Pinion Support (Rear Axle) ......................................................... 32
Self Locking Differential......................................................................... 39
S0602200C Axle (Clark-Hurth / Dana)

Page 2

Page 3
INTRODUCTION
The efficiency and continued operation of the axles depends on constant and correct maintenance, also on
efficient repair work should there be a break-down or malfunction. The instructions in this manual have
been based on a complete overhaul of a axle. However the mechanic must decide whether or not it is
necessary to dismantle the individual components when only partial repair work is required. This manual
provides a quick and sure guide, which with use of photographs and diagrams illustrating various phases of
operations, allows accurate work to take place. Therefore all information required for correct disassembly,
relative checks, and assembly of each individual component, has been provided.
NOTE: Throughout the phases of repair or maintenance, it is advisable to use proper equipment
and tools such as: trestles, supporting benches, plastic or copper hammers, appropriate
levers, extractors and specific spanners or wrenches. So that work is facilitated and
working surfaces and mechanics themselves are protected. Before disassembly, it is best
to thoroughly clean axles, removing any encrusted dirt or accumulated greases, then drain
oil through oil drain plugs.
IMPORTANT
All disassembled axles and components should be thoroughly cleaned with appropriate
products and then restored or replaced if damage, wear, cracking, or seizing have occurred. In
particular, thoroughly check the state of all moving parts (bearings, gears, crown wheel and
pinion, and shafts) and sealing parts (O-rings and oil seals), which are subject to major stress
and wear. In any case it is advisable to replace seals and O-rings every time a component is
overhauled or repaired. During assembly sealing rings must be lubricated on the sealing edge.
In case of crown wheel and pinion, replacement of one requires replacement of the other. During
assembly prescribed pre-loading and backlash of parts must be maintained.

Page 4
GENERAL DESCRIPTION
OUTLINE
Front Axle
Frame-Fixed
Type
Semi-Floating
Overall Reduction Ratio 22.8:1 (DANA Axle)
Standard T.P.D.Type (Locking Ratio: 35%)

Differential Type DANA Axle
Option L.S.D.Type (Locking Ratio: 50%)
Front 23,000 kg (50,700 lb)

Max. Static Load
Rear 19,000 kg (41,890 lb)
Max. Out Put Torque 6,000 kg•m (43,400 ft lb)
Type Multi Wet Disc

Brake 1,020 kg•m @ 40 bar each side
Torque DANA Axle
(7,380 ft lb @ 580 psi)
Type DANA Axle 280 kg•m (2,025 ft lb)

Parking Brake
Release Pressure DANA Axle 52 - 65 Bar (755 - 940 psi)
Drive Flange (Front / Rear) DANA Axle 6C / 6C

Page 5
SECTION A
APS0230L
Figure 1 DRIVE AXLE ASSEMBLY (DANA AXLE)

Page 6
Reference Reference
Number Number
1 Front Axle 5 Bushing
2 Rear Axle 6 Thrust Washer
3 Axle Support (Front) 7 O-ring
4 Axle Support (Rear)
NOTE: 1) 60 kg•m (430 ft lb) Threaded area: Loctite #262.

NOTE: 2) 51 kg•m (370 ft lb)
NOTE: 3) Inner surface: Grease (Assemble with chamfered surface toward axle.)
NOTE: 4) Surface: Grease
NOTE: 5) Surface: Grease

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

Page 8
SELF LOCKING DIFFERENTIAL

Structure of self-locking differential is same as conventional differential, it additionally has a multidisc brake
among right and left side gears, and differential gear box. It produces a relative motion which creates a
brake force with torque condition of both wheels. Finally, brake moment gives a locking effect to wheel with
a larger road friction coefficient to increase a torque. Locking ratio of axles is 50%.

Page 9
TROUBLESHOOTING
Problem Cause Remedy
Insufficient braking. Incorrect adjustment. Inspect disc thickness, If usable
readjust brakes.
Brake disc worn out. Inspect disc thickness, and

replace if necessary.
Incorrect brake fluid. Replace all seals in axle and

master cylinder that have made
contact with incorrect fluid, and
all brake hoses.
If incorrect fluid leaked into axle
oil, seals and O-rings in axle
must be replaced.
Loss of brake fluid. Inspect for and repair any leaks

in outside brake circuit or master
cylinder.
Overheated axle causing brake See "Overheating" problem.
fluid to vaporize (brake return
when axle cools).
Soft brake pedal Air in brake circuit. Bleed brake system.
Ineffective safety brake. Incorrect adjustment. Inspect disc thickness, If usable

readjust brakes.
Brake disc worn out. Inspect disc thickness, and


Page 10
Overheating. Oil level wrong. Drain, flush, and refill oil to

proper level
Too small of a brake gap. Readjust brakes.
Parking brake drags. Unlock brake and adjust to

correct gap.
Incorrect brake fluid in system. Replace all seals in axle and

all brake hoses.
must be replaced.
No free pedal at master cylinder. Readjust brake pedal.
Restriction in brake line Inspect for and replace any

damaged lines.
Restriction in return line of brake Inspect for and replace any

Servo system. damaged lines.
Inspect for and remove any filter,
tee’d in line, or any other source
of back pressure from return
line.
Incorrect lubricant. Change retaining rings of brake

circuit and brake pump.
Diff-lock inoperative. If manual, loose or not properly Inspect and correct linkage and
adjusted linkage readjust.
If hydraulic, problems in Inspect and correct.

hydraulic or electrical circuits of
the vehicle.
If hydraulic, problems in Rebuild cylinder.

actuating cylinder (notable
through loss of oil or increase of
oil level in axle).
If limited slip differential, worn Replace discs.

discs.

Page 11
Oil coming out of breather Leak in internal brake system. Inspect disc thickness, and
Replace all seals in axle and
all brake hoses.
must be replaced.
Leak in diff-lock actuating Rebuild cylinder.

cylinder.
No-spin indexing noise when Unequal tire pressure (left and Inflate tires to recommended
driving straight. right). pressure.
Different style, size, or brand of Change tires to same style, size,

tires between left and right side. or brand.
Noise during coast or under Damaged wheel bearings. Replace and adjust.
power the same.
Noise under power greater than Low oil level Refill oil to proper level.
during coast.
Incorrect lubricant. Change retaining rings of brake
circuit and brake pump.
Ring and pinion worn. Inspect through rear cover.

Replace and adjust.
Worn ring and pinion bearings. Inspect through rear cover.

Replace and adjust.
Worn planetary gears or Replace.

bearings.
Noise under coast greater than Loose pinion nut Inspect ring, pinion, and pinion
under power. bearings. If undamaged,
retighten nut.
Only one pinion bearing Replace and adjust.

damaged.
Noise during turn (Without No- Worn spider and/or side gears. Replace.
spin).
A "Stick slip" noise when going Worn or damaged cardanshaft. Inspect and replace.
from forward to reverse.
Loose wheel. Inspect for wheel and wheel stud
damage. Replace if needed and
torque lug nuts.
Spider pins loose in diff-carrier. Inspect through rear cover.

Replace.
Damaged or missing spider and/ Replace.

or side gear washers.

Page 12
SPECIAL TOOLS
Figure 3
Figure 4

Page 13
Figure 5

Page 14
Figure 6

Page 15
CLARK-HURTH / DANA AXLE IDENTIFICATION
Figure 7
Figure 8
Figure 9

Page 16
MAINTENANCE AND LUBRICATION
Operation Period Lubricant
Check Levels: SAE 85 W 90 API GL4 - L-2105

Differentials Monthly With additives for oil immersed disc brakes.
Planetary Reduction Every 400 hours
Oil Change: Brake-In: 250 Hours SAE 85 W 90 API GL4 - L-2105-B
Differentials Every 1500 hours With additives for oil immersed disc brakes.
Planetary Reduction Every 1500 hours

Greasing:
Under normal use Monthly Grease: Multipurpose lithium base
Under heavy duty use Weekly
Screw and bolt retorqueing Every 200 hours -----
Service brake circuit Only for mineral oil use e.g. ATF Dexron II. Make sure that master
cylinder seals are suitable for mineral oil.
BRAKE DISC
Wear Check and Replacement

1. Insert feeler gauge into oil level check hole
to check thickness of brake discs.
Minimum thickness: S = 4.5 mm (0.18
in).
Figure 1
2. Remove mounting nuts and axle housing.
NOTE: Axle housing must be removed
horizontally.
Figure 2

Page 17
3. Remove brake discs.

NOTE: If brake discs do not need to be
replaced, remove complete
pack without changing position
of discs.
Figure 3
4. Assembly in reverse order of disassembly.
Figure 4
Adjustment of Brake Disc Gap
1. Turn adjusting bolts (1) counterclockwise
till it stops, then back off 3/4 revolutions
clockwise; this corresponds to a gap of
0.75 mm (0.03 in) between brake discs.
Figure 5
2. Remove brake piston (2).
Figure 6

Page 18
3. Replace O-rings (3) and check piston (2)

for wear, scratches, and gouges.
Figure 7
4. Apply pressure with compressed air for 10
minutes each side.
NOTE: Air Pressure at 0.5 ±1 bar (7
psi).
Figure 8
Figure 9

Page 19
SAFETY BRAKE
1. Apply 25 - 35 bar (360 - 510 psi) of
pressure to hydraulic circuit, then remove
axle housing.
Figure 10
2. Remove four mounting studs and
disassemble intermediate covers.
NOTE: Use care not to damage parts
when disassembling.
Figure 11
3. Unlock and remove spring applied safety
brake pistons. Check pistons and replace if
necessary.
Figure 12
4. Assembly cover in reverse order of
disassembly. Special tool T18 is required
(refer to "Special Tools" in back of this
section). Check torque of cover (refer to
standard torque charts in "General
Maintenance Procedures" section).
Figure 13

Page 20
5. Lock safety brake piston into position.
Figure 14
6. Remove brake discs, and check for wear
or damage, replace if required.
NOTE: Pay attention to direction for
reassembly.
Figure 15
7. Align lubrication holes of brake discs at
reassembly.
Figure 16
8. Remove pinion and ring gear.
NOTE: Pay attention of direction for
reassembly.
Figure 17

Page 21
9. Remove internal lever.

NOTE: Pay attention of direction for
reassembly.
Figure 18
10. Assemble axle and apply 25 - 35 bar (360 -
510 psi) of pressure into hydraulic circuit.
Figure 19

Page 22
Figure 20

Page 23
Adjustment of Safety Brake

1. Apply 25 - 35 bar (360 - 510 psi) of
pressure in hydraulic circuit, then remove
bolt and locking plate.
Figure 21
2. Turn the pinion with 8 N•m (6 ft lb) torque
counterclockwise till it stops. Adjust gap
between brake discs by turning three
complete revolutions clockwise.
Figure 22
3. Set adjusting studs to unlock safety brake
at 47 mm (1.85 in), and lock counter nut
Figure 23

Page 24
Figure 24

Page 25
WHEEL HUB
1. Remove planetary gear cover
NOTE: Mark direction for reassembly.
Figure 25
Figure 26
2. Remove locking plate.
Figure 27
3. Use partially threaded M18 X 1,5 screws
to support puller.
Figure 28

Page 26
4. Inspect for wear or damage and replace

any parts as required.
Figure 29
5. Install outer races and taper roller
bearings. Special tool T21 is required
section).
Figure 30
6. Install seal. Special tool T23 is required
section).
Figure 31
7. Install wheel studs.
Figure 32

Page 27
8. Install wheel hub and center ring. Special

tool T20 is required (refer to "Special
Tools" in back of this section).
Figure 33
9. Install wheel hub onto axle housing.
Figure 34
10. Install gear rim on center wheel.
Figure 35
11. Special tool T19 is required (refer to
"Special Tools" in back of this section).
Figure 36

Page 28
Figure 37
12. Install locking plate.
Figure 38
13. Apply Loctite #270 on locking plate bolts
(M18 X 1.5 10K), and tighten to 460 - 465
N•m (338 - 342 ft lb) torque.
Figure 39
14. Torque new bearings with seals to 30 to 40
N•m (22 - 29 ft lb).
Figure 40

Page 29
PLANETARY REDUCTION GEARS

1. Remove cover.
Figure 41
2. Mark location of reduction gears for
reassembly. Remove locking plates.
Figure 42
3. Remove planet gears and inspect for wear
or damage, and replace as required.
Figure 43
4. Remove O-rings, retaining rings, thrust
washers, planet gears, needle bearings,
and planet gear shafts.
Figure 44

Page 30
5. Reassemble planet gear shafts, thrust

washers, needle bearings, and planet
gears.
Figure 45
6. Install retaining rings and O-rings.
Figure 46
7. Line up assembly marks and install locking
plates. Apply Loctite #270 to lock plate
bolts.
Figure 47
8. Torque bolts to 315 - 320 N•m (232 - 235 ft
lb).
Figure 48

Page 31
9. Install planetary cover making sure of

direction of installation.
Figure 49
Figure 50
BEVEL PINION SUPPORT (REAR AXLE)
1. Remove bevel pinion support. Be careful,
and guard against damage to parts.
Figure 51
2. Special tool T15 is required (refer to
"Special Tools" in back of this section).
Figure 52

Page 32
3. Using a press, remove pinion gear and

bearing cups from cage, then remove
bearings and spacer from pinion gear.
Figure 53
4. Assemble external races and taper roller
bearings, check cover measurement "A."
Figure 54
5. Determination of shim pack S1 for preload
of taper roller bearings.
NOTE: S1 = B - C + X
Figure 55
6. Value X = 0,09 - 0,11 mm (0.003 - 0.004
in) (Rear Axle)
NOTE: Value X = 0,11 - 0,14 mm
(0.004 - 0.006 in) (Front Axle)
Figure 56

Page 33
7. Press fit bearing cone onto pinion gear,

then assemble spacer and shim.
NOTE: There must be no clearance at
contact faces of any parts.
Figure 57
8. Press fit bearing cups in cage. Assemble
pinion gear in cage, then press fit bearing
cone. Apply pressure to bearing at
specified load, and rotate the case to settle
bearing. A special tool T22 is required
section).
NOTE: Specified load = 49 Kn (5 ton)
NOTE: When rotating the case at the
specified load, rotate lightly by
hand. If the rotation is not
smooth, replace the bearing
and spacer, and again rotate Figure 58
lightly by hand.
9. Press fit oil seal evenly in cage.
Figure 59

Page 34
10. Assemble with Loctite #242.
Figure 60
11. Tighten nut with a torque wrench, then
check rotation torque.
NOTE: Nut Torque: 600 - 800 N•m (441
- 588 ft lb) (Rear Axle)
NOTE: Nut Torque: 500 - 700 N•m (368
- 515 ft lb) (Front Axle)
Figure 61
12. Rotation Torque: 120 - 130 N•m (88 - 96 ft
lb) (Rear Axle)
NOTE: Rotation Torque: 120 - 150 N•m
(88 - 110 ft lb) (Front Axle)
Figure 62

Page 35
Figure 63
Figure 64

Page 36
13. Remove axle housing.
Figure 65
14. Remove differential carrier, then remove
bevel gear.
Figure 66
15. Remove bearing, then remove spring pin
from cross shaft,
Figure 67
NOTE: Replace fitting bolts of crown
wheel every time they are
removed.
Figure 68

Page 37
Figure 69
16. Assemble in reverse order of disassembly.
Mount sun wheels and planet gears.
Figure 70
17. Insert spring pins half way up the shaft.
Figure 71
18. Use Loctite #270.
Figure 72

Page 38
19. Torque M12 X 35 X 1,25-10K bolts to 135 -

138 N•m (99 - 102 ft lb).
Figure 73
SELF LOCKING DIFFERENTIAL
1. Disassemble and check for worn or
damaged parts, and replace as necessary.
Figure 74
2. When assembling check to be sure discs
are not deformed.
Figure 75
3. .Use Loctite #270.
Figure 76

Page 39
4. Torque M12 X 35 X 1,25-10K bolts to 135 -

138 N•m (99 - 102 ft lb).
Figure 77
Figure 78

Page 40
Figure 79

Page 41

Page 42
S0603005K
1PARKING BRAKE
(DANA)
CAUTION!
PARKING BRAKE (DANA)S0603005K


December 2002
Parking Brake (DANA) S0603005K

Page 1
TABLE OF CONTENTS
Front Axle Housing ......................................................................................... 3

Parking Brake ................................................................................................. 4
Front Axle Parking Brake Emergency Release ....................................... 4
Applying Parking Brake ........................................................................... 5
Releasing Parking Brake......................................................................... 6
S0603005K Parking Brake (DANA)

Page 2
FRONT AXLE HOUSING
Figure 1, shows major components of the brake system in the axle.
Figure 1
Reference Reference
Number Number
1 Parking Brake Piston 4 Parking Brake Lever
2 Service Brake Piston 5 Pinion/Ring Gear
3 Brake Disks 6 Parking Brake Spring

Page 3
PARKING BRAKE
CAUTION!
Manually releasing of the parking brake (as an emergency measure)
If the parking brake cannot be released with the parking brake switch due to a defective pump or for any
other reason, it can be manually released by using the parking brake release bolt.
CAUTION!
Manually releasing the parking brake should not be abused. It should be limited to a disabled
machine needing to be moved to an out-of-traffic area.
Always block the wheels when the parking brake is released using the emergency release bolt.
FRONT AXLE PARKING BRAKE

EMERGENCY RELEASE
1. Locate parking brake release bolt. located
on the lower section on both sides of the
housing.
2. Loosen lock nut (1, Figure 2) from
adjusting bolt (2).
3. Tighten adjusting bolt (2, Figure 2) until it
stops. This will manually release the
parking brake so that the drive shaft will be
free to turn.
NOTE: The initial setting of adjusting
bolt (2, Figure 2) is 47 mm and
should be readjusted to this
length and lock nut (1)
tightened after towing is
complete.
Figure 2

Page 4
APPLYING PARKING BRAKE
When parking brake switch (5) is set to the "I" (APPLIED) position, two solenoids on the brake and pilot
supply valve (6) are de-energized and the pressurized oil from the brake pump is blocked in the brake and
pilot supply valve (6). The pressurized oil in brake chamber (A) of the parking brake piston (1) is drained
through the brake and pilot supply valve (6) back to tank.
The parking brake piston (1) with lever (2) are shifted by springs (4) to actuate the disk brake (3).
Figure 3 APPLYING PARKING BRAKE
Reference Reference
Number Number
A Parking Brake Oil Chamber 4 Parking Brake Springs
1 Parking Brake Piston 5 Parking Brake Switch
2 Parking Brake Lever 6 Brake and Pilot Supply
3 Brake Disks Valve

Page 5
RELEASING PARKING BRAKE
When parking brake switch (5) is set to the "O" (RELEASED) position, two solenoids on the brake and pilot
supply valve (6) are energized and the pressurized oil from the brake pump is allowed to pass through the
brake and pilot supply valve (6) to brake chamber (A). The pressurized oil forces the parking brake piston
(1) to compress springs (4), allowing lever (2) to release the brake disks (3).
Figure 4 RELEASING PARKING BRAKE
Reference Reference
Number Number
A Parking Brake Oil Chamber 4 Parking Brake Springs
1 Parking Brake Piston 5 Parking Brake Switch
2 Parking Brake Lever 6 Brake and Pilot Supply
3 Brake Disks Valve

Page 6
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 ..................................................... 18
Refrigerant System Repairs ......................................................................... 20
Refrigerant Safe Handling Procedures ................................................. 20
Repair and Replacement Procedure..................................................... 21
Refrigerant Recovery ............................................................................ 23
Vacuuming Refrigerant System............................................................. 23
Leakage Check ..................................................................................... 24
Refrigerant Charging............................................................................. 25
Inspecting System For Leakage............................................................ 27
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 cab. This
filter (1, Figure 2) should be cleaned out at
approximately every 500 hours and replaced
with a new one every 1000 hours.
NOTE: In the event that the unit is
being operated in a dusty
environment, cleaning and
replacement should be
performed more frequently.
WARNING!
All service and inspection of the air-
conditioning system should be performed Figure 2
with the starter switch in the "O" (OFF)
position.
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 once again flows into the compressor in the gaseous state and the process is
repeated.
WARNING!
Refrigerant gas is pressurized and sealed in the air-conditioning system. Special
precautions are required for the proper recharging or release of refrigerant. Release of
refrigerant into the atmosphere is strictly regulated by law. Make sure that you are in
compliance with all mandated federal, state and municipality requirements, before starting
any service or repair of the air conditioner. Refrigerant gas used in the system must meet
or exceed specifications for R134a refrigerant, or any subsequently issued
environmentally-mandated standard.

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 MIX DOOR
ACTUATOR
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 Select Switch 3-2 Rear Vent (L)
2 Front Vent 4 Heater Core
2-1 Front Vent (R) 5 Evaporator Core
2-2 Front Vent (L) 6 Air Filter
3 Rear Vent 7 Blower Motor
3-1 Rear Vent (R)

Page 9
Foot
4 5
1
6
7
3-1
3-2
2
AJS0551L
Figure 10
Reference Reference
Number Number
1 Select Switch 4 Heater Core
2 Foot Vent 5 Evaporator Core
3 Rear Vent 6 Air Filter
3-1 Rear Vent (R) 7 Blower Motor
3-2 Rear Vent (L)

Page 10
Defroster
4 5
6
7
3-1
3-2
2
AJS0561L
Figure 11
Reference Reference
Number Number
1 Select Switch 4 Heater Core
2 Defroster Vent 5 Evaporator Core
3 Rear Vent 6 Air Filter
3-1 Rear Vent (R) 7 Blower Motor
3-2 Rear Vent (L)

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 - 3.0 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 should 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

Page 17
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 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 55 750 ±20 grams (26 ±0.7 oz.)
Solar 55-V PLUS 750 ±20 grams (26 ±0.7 oz.)
Solar 70-III 800 ±20 grams (28 ±0.7 oz.)
Solar 75-V 750 ±20 grams (26 ±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 290LL 850 ±20 grams (30 ±0.7 oz.)

Page 18
Model Weight of Gas

Solar 300LL 850 ±20 grams (30 ±0.7 oz.)

Page 19
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 should be stored below 40°C (104°F). Be
careful not to drop the container from a high location
The contents are under high pressure and should not be used with compressed air or near an
open flame.
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 should be observed for safe handling of refrigerant during vacuum and charging
process.
1. Use an approved recovery / charging device which can safely perform vacuum and charge work
simultaneously.
2. The new refrigerant has improved cooling characteristics than the old type and care should be used
not to overcharge the system.
3. Do not over tighten connections when working on refrigerant system.
4. The new refrigerant system standards require new tools, equipment and parts. DO NOT attempt to
use equipment use in servicing the old refrigerant system.

Page 20
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 21
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 22
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 23
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 disc 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 counter clockwise 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.
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.

Page 24
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 25
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 26
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 27

Page 28
S0607110C
1TRANSMISSION AND
TORQUE CONVERTER
(ZF 4WG-160)
CAUTION!
TRANSMISSION AND TORQUE CONVERTER (ZF 4WG-160)S0607110C


December 2002
Transmission and Torque Converter (ZF S0607110C

4WG-160) 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 4WG-160 ...................... 9
Oil Circuit Diagram 4WG - 160 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
Traveling 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
S0607110C Transmission and Torque Converter (ZF

Page 2 4WG-160)
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
Installation View ........................................................................................... 32
Inner Section ......................................................................................... 32
Front View ............................................................................................. 34
Side View .............................................................................................. 35
Rear View.............................................................................................. 36
Special Tools ................................................................................................ 37
Engine Connection................................................................................ 37
Input ...................................................................................................... 38
Gearbox Housing .................................................................................. 39
Coupling ................................................................................................ 40
Coupling K1 ................................................................................... 40
Coupling K2 ................................................................................... 41
Coupling K4 ................................................................................... 42
Coupling KV ................................................................................... 43
Coupling KR................................................................................... 44
Output ................................................................................................... 45
Gearshift System................................................................................... 46
Pressure Regulator ............................................................................... 49
Pressure Oil Pump ................................................................................ 50
Filter ...................................................................................................... 51
Oil Pipes................................................................................................ 52
Hydraulic Control Unit (HSG-94) .................................................................. 53
Disassembly.......................................................................................... 54
Reassembly .......................................................................................... 57
Powershift Transmission ............................................................................... 64
Disassembly.......................................................................................... 64
Remove Filter Unit ......................................................................... 64
Remove Hydraulic Control Unit (HGS-94)
and Duct Plate from Gearbox Housing .......................................... 65
Remove and Dismantle Converter Safety Valve ............................ 65

4WG-160) Page 3
Engine Connection - Converter...................................................... 66
Remove Transmission Pump ......................................................... 69
Converter Pressure Valve .............................................................. 70
Remove Outputs Input and Clutches ............................................. 71
Dismantle Clutch KV and KR ......................................................... 77
Dismantle Clutch K1. K2 and K3.................................................... 79
Dismantle Clutch K4 ...................................................................... 81
Dismantle Input Shaft..................................................................... 82
Reassembly .......................................................................................... 84
Mount Oil Pipes.............................................................................. 84
Plate Pack KV and KR ................................................................... 90
Reassemble Clutches K1, K2 and K3............................................ 95
Reassemble Clutch K4 ................................................................ 100
Pre-assemble Input Shaft ............................................................ 106
Install Pre-assembled Output Shaft and Clutches ....................... 108
Output .......................................................................................... 111
Converter Pressure Valve ............................................................ 114
Oil Feed Housing - Transmission Pump....................................... 115
Converter Safety Valve ................................................................ 118
Attaching Duct Plate .................................................................... 119
Attaching Hydraulic Control Unit .................................................. 119
Filter ............................................................................................. 121
Speed Sensor and Inductive Transmitter ..................................... 122

Page 4 4WG-160)
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
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

4WG-160) 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 200-V

Model 4WG-160 (Full Auto)
Type 3-Element, 1-Stage, Single-phase,
E/G mounted with flexible plate
Oil Cooler Air-cooled
Torque Converter Charging Pump 80 lpm at 2,000 rpm
Hydraulic Pump P.T.O 1:1
T/C Size ∅ 300 mm
Stall Ratio 2,91
Safety Relief 11 Bar (160 psi)
Type Full Power Shift, Counter shaft
Speeds 4 Forward / 3 Reverse
Ratio F: 3.611 / 2.024 / 1.088 / 0.619
Transmission R: 3.424 / 1.919 / 1.031
Power Shift Control 16 - 18 bar (232 - 261 psi)
Pressure
Shift Control Electric Shift with Proportional Valve
Oil Capacity 35 liters (9.3 U.S. gal)
Dry Weight 360 kg (794 lb)
Front 6 C Mechanics
Output Flange
Rear 6 C Mechanics

Page 6 4WG-160)
POWERSHIFT TRANSMISSION
The multispeed reversing transmission in layshaft design is engaged under load by hydraulically controlled
multidisc clutches.
All gears are constantly meshing and running in antifriction bearings.
The gear wheels, bearings and clutches are cooled and lubricated with oil.
The 4-speed reversing transmission is equipped with 6 multidisc clutches.
At the shifting, the corresponding plate pack is compressed by a piston, movable in axial direction, which is
pressurized by pressure oil.
A compression spring is 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 4WG-160” on page 9. and “Oil Circuit Diagram 4WG - 160 Forward 1st
Speed” on page 11.
TRANSMISSION CONTROL
Transmission control, See “Schedule of Measuring Points and Connection 4WG-160” on page 9., Electro-
hydraulic unit on page -10 and “Oil Circuit Diagram 4WG - 160 Forward 1st Speed” on page 11.
The transmission pump, necessary for the oil supply of the converter, and for the transmission control, is
input-side mounted from outside, together with stator shaft and oil supply flange, on the transmission. The
drive is realized by the pump-wheel flange of the converter.
The feed rate of the pump is Q = 80 lpm at nEngine = 2000 min-1.
This pump is sucking the oil through the coarse filter out of the oil sump and delivers it through the ZF-Fine
filter - the filters is fitted externally from the transmission - to the main system pressure valve.
ZF-Fine filter
Filtration ratio according to ISO 4572: β30 ≥ 75 β15 = 25 β10 = 5.0
Filter surface at least: 3.700 cm2
Dust capacity according to ISO 4572 at least: 17g
The six clutches of the transmission are selected via the 6 proportional valves P1 to P6.
The proportional valve (pressure regulator unit) is composed of pressure regulator (e.g. Y1), booster valve
oscillation damper.
The pilot pressure of 9.0 bar (130.54 psi) for the control of the follow-on slides is created by the reducing
valve. The pressure oil (16 + 2 bar (230+ 29 psi)) is directed via the follow-on slide to the corresponding
clutch.
By the direct proportional selection with separated pressure modulation for each clutch, the pressure to the
clutches, taking part in the gear change, will be controlled. In this way, a hydraulic intersection of the
clutches to be engaged and disengaged is achieved. This is loading to fast shifting without traction force
interruption.
At the shifting, the following criteria will be considered:
- Speed of engine, turbine, central gear train and output.
- Transmission temperature.
- Shifting mode (up-, down-, reverse shifting and speed engagement out of Neutral).
- Load level (full and part load, traction, overrun inclusive consideration of load cycles during the
shifting).

4WG-160) Page 7
The system pressure valve is limiting the max. control pressure to 16 + 2 bar (230+ 29 psi) and releases
the main stream to the converter and lubricating circuit.
Converter relief valve is installed in the counter inlet, which protects the converter against high internal
pressure (opening pressure 11 bar (160 psi).
Within the converter, the oil transmit the power transmission 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 back pressure valve, following the converter, with an opening pressure of at
least 3.5 bar (51 psi).
The oil, escaping out of the converter, is directed to a heat exchanger (oil - water resp. oil - air).
The oil is directed from the heat exchanger to the transmission and from there to the lubricating-oil circuit
so that all lubricating points are supplied with cooled oil.
In the electro-hydraulic control unit there are 6 pressure regulators installed - See “Hydraulic Control Unit
(HSG-94)” on page 53..
The allocation of the pressure regulators to the single speeds can be seen on the “Schedule of Measuring
Points and Connection 4WG-160” on page 9 and “Oil Circuit Diagram 4WG - 160 Forward 1st Speed” on
page 11.

Page 8 4WG-160)
SCHEDULE OF MEASURING POINTS AND CONNECTION 4WG-160
The marked positions (e.g. 53) correspond with the positions on the “Oil Circuit Diagram 4WG - 160
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 Converter Inlet - Opening pressure 9 bar (130 psi) M10 x 1 H
52 Converter Exit - Opening pressure 3.5 bar (51 psi) M14 x 1.5
53 Clutch Forward 16+2 bar (230 - 260 psi) KV M10 x 1 B
55 Clutch Reverse 16 +2 bar (230 +29 psi) KR M10 x 1 E
56 Clutch 16 +2 bar (230 +29 psi) K1 M10 x 1 D
57 Clutch 16 +2 bar (230 +29 psi) K2 M10 x 1 A
58 Clutch 16 +2 bar (230 +29 psi) K3 M10 x 1 C
60 Clutch 16 +2 bar (230 +29 psi) K4 M10 x 1 F
63 Converter Exit
M14 x 1.5
Temperature 100° C, Short-time 120° C
65 System Pressure 16 +2 bar (230 +29 psi) K4 M10 x 1 K
Measuring points for Delivery Rates
15 Connection to the Heat Exchanger 1 5/16'' - 12UNF-2B
16 Connection from the Heat Exchanger 1 5/16'' - 12UNF-2B
Inductive Transmitters and Speed Sensor
21 Inductive Transmitter n Turbine M18 x 1.5
34 Speed Sensor n Output and Speedometer -------
47 Inductive Transmitter n Central Gear Train M18 x 1.5
48 Inductive Transmitter n Engine M18 x 1.5
Connections
49 Plug Connection on the Hydraulic Control Unit
68 Pilot Pressure (Option) M16 x 1.5 J
69 System Pressure (Option) M16 x 1.5 G

4WG-160) Page 9
Figure 2

Page 10 4WG-160)
OIL CIRCUIT DIAGRAM 4WG - 160 FORWARD 1ST SPEED
The marked positions (e.g. 53) correspond with the positions on “Schedule of Measuring Points and
Connection 4WG-160” on page 9
Reference
Positions
Number
WT Heat Changer
WGV Converter Back Pressure Valve 3.5 bar (51 psi)
WSV Converter Relief Valve 9 bar (131 psi)
HDV System Pressure Valve 16 + 2 bar (232 + 29 psi)
RV-9 Pressure Reducing Valve 9 bar (131 psi)
NFS Follow-on Slide
D Oscillation Damper
B Orifice
P1 Proportional Valve - Clutch K4
P2 Proportional Valve - Clutch KR
P5 Proportional Valve - Clutch KV
Y1 -Y6 Pressure Regulator
TEMP Temperature Sensor
Figure 3

4WG-160) Page 11
Figure 4

Page 12 4WG-160)
TRANSMISSION ELECTRIC COMPONENTS
21
13
10
18
19
14 17
20
8
15
1
16
9 3
11 4
12 5
6
2
AJS0191L
Figure 5
Reference Reference
Number Number
1 T/M Controller 12 T/M Cutoff Pressure Switch
2 T/M Control Valve 13 Downshift Switch
3 T/M Oil Temperature Sensor 14 Safety Starter Switch
4 Engine Pick-Up Sensor 15 Fuse Box
5 Central Gear Pick-up Sensor 16 Parking Brake Switch
6 Turbine Pick-up Sensor 17 Control Unit
7 Output Speed Sensor 18 Starter Controller
8 Shift Lever Switch 19 LIS Switch (Option)
9 Auto Select Switch 20 LIS Solenoid Valve
10 Display 21 Speedometer
11 T/M Cutoff Switch

4WG-160) 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 kg/cm2 → 8.3 kg/cm2
(11 - 118 psi)
3. The contained temperature sensor detects
the temperature of the control valve and
transmits the electrical signal to the TCU,
and serves TCU determines gears to
change.
• Neutral: At temperature less than -
30°C
• 1st or 2nd gear: At temperature less
than -10°C
• Normal Operation: At temperature
greater than -10°C

Page 14 4WG-160)
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 PICK-UP SENSOR

1. Detect a revolution of gear array in engine
side.
2. Specification
• Resistance: 1050Ω ± 10% (at 20°C)
• Fasten torque: 3 kg•m (22 ft lb)
• Gap: 0.5 - 0.8 mm (0.0197 - 0.0315
in)
• Output: 4 Pulse/Rev. AJS0230L
Figure 9
CENTRAL GEAR PICK-UP SENSOR
1. Detect a revolution of central gear array
2. Specification
• Resistance: 1050Ω ±10% (at 20°C)
• Gap: 0.5 - 0.8 mm (0.0197 - 0.0315
in)
• Output: 91 Pulse/Rev.
AJS0240L
Figure 10

4WG-160) Page 15
TURBINE PICK-UP SENSOR
1. Detect a revolution of gear array in turbine
side.
2. Specification
• Resistance: 1050Ω ± 10% (at 20°C)
• Gap: 0.5 - 0.8 mm (0.0197 - 0.0315
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: 1.0 - 1.5 mm (0.0394 - 0.0591 AJS0260L
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.)

Page 16 4WG-160)
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
Figure 16 AJS0300L

4WG-160) 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 4WG-160)
TRANSMISSION ELECTRICAL CIRCUITS
T/M CONTROLLER CIRCUIT
AJS0311L
Figure 18
The transmission proportioning solenoid valves are shown here as (Y1 thru Y6, Figure 18).

4WG-160) Page 19
TRAVELING CIRCUITS
Neutral
AJS0320L
Figure 19
When all transmission solenoid valves are de-energized (OFF) the transmission is in "NEUTRAL."

Page 20 4WG-160)
Forward First Gear
AJS0330L
Figure 20
Transmission solenoid valves (Y3 and Y5, Figure 20) are energized when in forward first gear.

4WG-160) 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 4WG-160)
Forward Third Gear
AJS0350L
Figure 22
Transmission solenoid valves (Y4 and Y5, Figure 22) are energized when in forward third gear.

4WG-160) 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 4WG-160)
Reverse First Gear
AJS0370L
Figure 24
Transmission solenoid valves (Y1 and Y3, Figure 24) are energized when in reverse first gear.

4WG-160) 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 4WG-160)
Reverse Third Gear
AJS0390L
Figure 26
Transmission solenoid valves (Y1 and Y4, Figure 26) are energized when in reverse third gear.

4WG-160) 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 traveling direction takes Figure 27
place or the downshift switch is depressed
a second time, downshifting is released
automatically.

Page 28 4WG-160)
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

4WG-160) 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 4WG-160)
TRANSMISSION CUT OFF
When the brake pedal is depressed while
transmission cutoff switch (Figure 31) is in the
"I" position, the transmission cutoff 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 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 traveling or working in the place of inclination, the transmission cutoff
switch (Figure 31) must be placed in position 'O' for the purse of using engine braking and the
normal braking function at the same time.
AJS0430L
Figure 32

4WG-160) Page 31
INSTALLATION VIEW
INNER SECTION
Figure 33

Page 32 4WG-160)
Reference Reference
Number Number
1 Clutch Shaft KR 9 Transmission Pump
2 Power Take-off; Coaxial; 10 Diaphragms - Direct Mounting
Engine-Dependent 11 Converter
3 Clutch Shaft KV 12 Inductive Transmitter for
4 Clutch Shaft K2 Engine Speed
5 Clutch Shaft K5 13 Clutch Shaft K4
6 Output Flange - Rear 14 Converter Relief Valve
7 Output Flange - Converter 15 Clutch Shaft K1
Side
8 Output Shaft

4WG-160) Page 33
FRONT VIEW
Figure 34
Reference Reference
Number Number
1 Lifting Lugs 6 Model Identification Plate
2 Diaphragms - Direct Mounting 7 Attachment Possibility for Oil
3 Transmission Suspension Level Tube with Oil Dipstick
Threads M20 (Converter-side)
4 Output Flange - Converter Side 8 Attachment Possibility for
Emergency Steering Pump
5 Oil Drain Plug With Magnetic
Insert M38 x 1.5 9 Converter

Page 34 4WG-160)
SIDE VIEW
Figure 35
Reference Reference
Number Number
1 Diaphragms - Direct Mounting 7 Exchange Filter (Fine Filter)
2 Converter 8 Output Flange - Rear
3 Converter Bell Housing 9 Oil Drain Plug With Magnetic
4 Breather Insert M38 x 1.5
5 Transmission Case Cover 10 Output Flange - Converter Side
6 Filter Head 11 Transmission Case

4WG-160) Page 35
REAR VIEW
Figure 36
Reference Reference
Number Number
1 Lifting Lugs 7 Port - Return Line From Parking
2 Power Take-off; Coaxial; Brake (Option)
Engine-Dependent 8 Exchange Filter (Fine Filter)
3 Electro-Hydraulic Control 9 Filter Head With Connection for
4 Oil Level Tube With Oil Dipstick Filter Restriction Switch
5 Transmission Suspension 10 Port-System Pressure to
Threads M20 Parking Brake Valve (Option)
6 Output Flange - Rear

Page 36 4WG-160)
SPECIAL TOOLS
ENGINE CONNECTION
Figure 37

4WG-160) Page 37
INPUT
Figure 38

Page 38 4WG-160)
GEARBOX HOUSING
Figure 39

4WG-160) Page 39
COUPLING
Coupling K1
Figure 40

Page 40 4WG-160)
Coupling K2
Figure 41

4WG-160) Page 41
Coupling K4
Figure 42

Page 42 4WG-160)
Coupling KV
Figure 43

4WG-160) Page 43
Coupling KR
Figure 44

Page 44 4WG-160)
OUTPUT
Figure 45

4WG-160) Page 45
GEARSHIFT SYSTEM
Figure 46

Page 46 4WG-160)
Figure 47

4WG-160) Page 47
Figure 48

Page 48 4WG-160)
PRESSURE REGULATOR
Figure 49

4WG-160) Page 49
PRESSURE OIL PUMP
Figure 50

Page 50 4WG-160)
FILTER
Figure 51

4WG-160) Page 51
OIL PIPES
Figure 52

Page 52 4WG-160)
HYDRAULIC CONTROL UNIT (HSG-94)
Figure 53, shows a sectional view of the HSG-94.
IMPORTANT
Different versions in relation to the position of the cable harness are possible.
In this connection, pay attention to the Specifications of the Vehicle Manufacturer.
Figure 53

4WG-160) Page 53
Section A -A
Figure 54
DISASSEMBLY
1. Figure 55, shows complete control unit.
Figure 55

Page 54 4WG-160)
2. Match mark installation position of different
covers, housing and cable harness with
valve housing.
Figure 56
3. Loosen socket head screws.
4. Remove duct plate, 1st gasket,
intermediate plate and 2nd gasket from
valve housing.
(S) Box spanner (Torx TX-27) - 5873 042
002
Figure 57
5. Remove retaining clip.
Figure 58
7. Remove cover from housing and cable
harness.
002
Figure 59

4WG-160) Page 55
8. Disassemble opposite cover.
9. Disconnect pressure regulator and remove
cable harness.
Figure 60
11. Remove fixing plate and pressure
regulators (3x).
002
Figure 61
12. Loosen two socket head screws and locate
housing provisionally, using adjusting
screws. (Housing is under spring preload).
Loosen remaining socket and screws.
002
(S) Adjusting screws - 5870 204 036
Figure 62
13. Remove housing from valve housing by
loosening adjusting screws uniformly.
Figure 63

Page 56 4WG-160)
14. Remove components (Figure 64).
15. Remove opposite pressure regulators,
housing and components accordingly
(Figure 65).
Figure 64
Figure 65
REASSEMBLY
NOTE: Check all components for
damage and replace if
necessary. Before installation,
check free travel of all moving
parts in housing. Spools can be
exchanged individually. Oil
components before reassembly
according to ZF-List of
lubricants TE-ML 03.
Insert diaphragms with concave
side facing up until contact is
obtained. Figure 66
NOTE: Installation position, see

arrows.

4WG-160) Page 57
1. Figure 67, 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 67
Compression Spring)
2. Install components according to Figure 67.

NOTE: Preload compression spring of
the follow on sitie slides and
locate spool provisionally using
cylindrical pins Ø 5.0 mm
(0.1969 in) (assembly aid), See
Figure 68.
Figure 68
3. Install two adjusting screws.
4. Assemble gasket (1, Figure 69) and
housing cover (Figure 69). Position
housing cover uniformly, using adjusting
screws, until contact is obtained and
remove cylindrical pins (assembly aid)
again (Figure 69).
NOTE: Pay attention to different
housing covers.
5. Install recess Ø 15.0 mm (0.5906 in) (2,
Figure 69), facing spring of pressure
reducing valve. Figure 69

Page 58 4WG-160)
Figure 70
6. Fasten housing cover using socket head
screws.
NOTE: Torque limit 0.56 kg•m (4 ft lb).
002
Figure 71
7. Install pressure regulators and attach
using fixing plates and socket head
screws.
NOTE: Install fixing plate, with claw
showing downward. Pay
attention to radial installation
position of pressure regulators,
see Figure 72.
002
Figure 72

4WG-160) Page 59
8. Pre-assemble opposite side.
A. Figure 73, 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 73
3 Vibration Damper (3x
Spool and
Compression Spring)
B. Install components according to

Figure 73.
C. Preload compression springs of the
follow on slides and locate spool
provisionally using cylindrical pins Ø
5.0 mm (0.1969 in) (assembly aid).
See arrows.
D. Install two adjusting screws.
E. Assemble gasket (1, Figure 74) and
housing cover, and position them
uniformly against shoulder, using
adjusting screws.
housing covers, install the
recess Ø 19.0 mm (0.7480 in)
(2, Figure 74), facing the main
pressure valve.
F. Down, fasten housing cover using
socket head screws. Figure 74
G. Remove cylindrical pins (assembly
aid) again.
002

Page 60 4WG-160)
H. Install pressure regulators and attach
using fixing plates and socket head
screws.
NOTE: Install fixing plates, with claw
showing downward.
I. Pay attention to radial installation
position of pressure regulators, see
Figure 75.
NOTE: Torque limit 5.5 N.
002
Figure 75
J. Install cable harness and connect
pressure regulators (6x).
NOTE: Pay attention to installation
position of cable harness, see
also markings (Figure 56).
Figure 76
K. Install female connector against
shoulder, with groove facing guide
nose of cover.
L. Install gaskets (Figure 77) and fasten
cover using socket head screws.
002
Figure 77
M. Install female connector using
retaining clamp, see Figure 78.
N. Install opposite cover.
Figure 78

4WG-160) Page 61
O. Install two adjusting screws and
mount gasket I.
gaskets, see Figure 79 and
Figure 82.
Figure 79
9. Intermediate plate - version with screens:
A. Insert screens (6x) flash -mounted
into bore of intermediate plate, see
Figure 80.
NOTE: Pay attention to installation
position- screens are facing up
(facing duct plate).
Figure 80
B. Mount intermediate plate, with
screens with screens facing up.
Figure 81
C. Mount gasket II.
Figure 82

Page 62 4WG-160)
D. Mount duct plate and fasten it
uniformly using socket head screws.
NOTE: Torque limit 1 kg•m (7 ft lb).
002
Figure 83
E. Install new O-rings on screw plugs
(8x) and install.
NOTE: Torque limit 0.61 kg•m (4.4 ft
lb).
NOTE: The installation of hydraulic
control unit is described in
following section, See
“Attaching Duct Plate” on page
119. and “Attaching Hydraulic
Control Unit” on page 119.
Figure 84

4WG-160) Page 63
POWERSHIFT TRANSMISSION
DISASSEMBLY
Remove Filter Unit

1. Remove warning switch (Figure 85) from
filter head.
Figure 85
2. Remove oil filter from filter head.
(S) Belt spanner - 5870 105 005
Figure 86
3. Loosen hex. head screws and remove filter
head from duct plate.
Figure 87

Page 64 4WG-160)
Remove Hydraulic Control Unit (HGS-94)
and Duct Plate from Gearbox Housing
1. Loosen socket head screws, install two
adjusting screws and remove control unit
from duct plate.
Figure 88
2. Remove both gaskets and intermediate
plate.
Figure 89
3. Loosen socket head screws and hex. nuts
and remove duct plate from gearbox
housing.
4. Remove flat gasket.
Figure 90
Remove and Dismantle Converter Safety
Valve
1. Pull converter safety valve out of housing
bore.
Figure 91

4WG-160) Page 65
2. Figure 92, shows required special tool for
the dismantling of the converter safety
valve.
Reference
Description
Number
1 Converter safety valve
(compl.)
(S) Assembly aid - 5870
345 084
Figure 92
3. Preload compression spring carefully,
remove cylindrical pin (Figure 93) and
components (Figure 94).
Figure 93
Figure 94
Engine Connection - Converter
1. Remove lock plate and loosen hex. head
screws.
2. Remove disk and pry input flange from
shaft.
Figure 95

Page 66 4WG-160)
3. Loosen screw connection.
NOTE: Mark radial installation position
of the housing cover.
Figure 96
4. ,Using lifting device remove cover with
converter from transmission.
(S) Set of eye bolts - 5870 204 002
Figure 97
5. Press input shaft, reap. converter out of
the cover (ball bearing).
Figure 98
6. Squeeze retaining ring out and remove
ball bearing.
(S) Set of internal pliers - 5870 900 013
Figure 99

4WG-160) Page 67
7. Loosen hex. head screws and remove
membrane from converter.
Figure 100
input shaft from the membrane.
Figure 101
9. Remove inductive transmitter (n Engine).
Figure 102
converter housing.
Figure 103

Page 68 4WG-160)
Remove Transmission Pump
Figure 104
2. Apply separating device (S) on the splines
run out of the stator shaft and pull pump
(compl.) out of the housing bores, using
two-leg puller.
(S) Separating device - 5870 300 024
(S) Two-leg puller - 5870 970 004
Figure 105
3. Remove transmission pump from stator.
4. Remove cam plate from pump.
NOTE: If traces of wear are seen in the
pump housing or the cam disk,
the complete pump has to be
replaced.
5. Fit cam disk again and attach it using
grooved pins (2x).
Figure 106
6. Loosen hex. head screws and remove oil
feed housing.
7. Remove flat gasket.
Figure 107

4WG-160) Page 69
Converter Pressure Valve
1. Pull converter pressure valve out of
housing bore.
Figure 108
2. Figure 109, shows the special tool
required for dismantling converter
pressure valve.
Reference
Description
Number
1 Converter Pressure
Valve (Compl.)
(S) Assembly Aid - 5870
345 084
Figure 109
3. Preload compression spring carefully,
drive roll pin out and remove components.
(S) Assembly aid - 5870 345 084
Figure 110
4. Loosen hex. head screws, remove cover
and flat gasket.
Figure 111

Page 70 4WG-160)
Remove Outputs Input and Clutches
1. Remove lock plate, hex. head screws, and
pry converter side output flange from
shaft.
2. Pry shaft seal out of housing bore.
3. Tilt gearbox 180° and remove rear output
flange.
(S) Pry bar - 5870 345 065
Figure 112
4. Remove speed sensor and both inductive
transmitters (Figure 113).
Figure 113
5. Loosen hex. nuts and remove the two
covers (Figure 114).
6. Loosen screw connection.
Figure 114
7. Drive both cylindrical pins (Figure 115) out.
Figure 115

4WG-160) Page 71
8. Remove housing cover carefully from
gearbox housing, using lifting device.
(S) Lifting chain - 5870 281 047
Figure 116
9. Figure 117, shows the installation position
of the single clutches and of the input and
output.
Reference
Description
Number
KV Clutch - Forward
KR Clutch - Reverse
K1 Clutch - 1st Speed
K2 Clutch - 2nd Speed
K3 Clutch - 3rd Speed
K4 Clutch - 4th Speed Figure 117
AN Input
AB Output
NOTE: The following Figures describe the common removal of all clutches. For this purpose, the
housing cover, combined with special tool (Handles 5870 260 010) is necessary. The
removal of single clutches without help of the housing cover and the handles is extremely
difficult because of the installation conditions. Besides, there is the danger of injuries.
NOTE: Before the common removal of the clutches, the output shaft must be removed, see Figure
118.
10. Loosen socket head screws and remove
output shaft and both oil baffle plates.
Figure 118

Page 72 4WG-160)
11. Assemble housing cover carefully until
contact is obtained.
12. Attach all clutches in the housing cover,
using handles (S).
(S) Handle (6 pieces needed) - 5870 260
010
Figure 119
13. Remove housing cover along with clutches
from gearbox housing, using lifting device.
010
Figure 120
14. Fasten housing cover on assembly car.
Figure 121
15. Tilt housing cover 180°.
16. Remove handles.
010
Figure 122

4WG-160) Page 73
17. Remove clutch K2.
Figure 123
18. Remove clutch K1, at the same time, lift
clutch K4.
Figure 124
19. Lift clutch K3 out of the housing cover.
Figure 125
20. Remove clutch K4, at the same time lift
input slightly.
Figure 126

Page 74 4WG-160)
21. Remove clutches KV and KR together with
input from the housing cover.
Figure 127
22. Remove outer bearing race and pull output
shaft (power take off) out of the housing
bore.
Figure 128
23. Squeeze rectangular ring (Figure 129) out
and remove ball bearing from shaft.
Figure 129

4WG-160) Page 75
NOTE: If contrary to the
ZF-Recommendation, the
tapered roller bearings of the
clutches and of the input and
output are not replaced, the
allocation of the inner and outer
races to the single assemblies
must at least be maintained.
24. Mark inner and outer bearing races.
Figure 130

Page 76 4WG-160)
Dismantle Clutch KV and KR
NOTE: The following Figures show the
disassembly of the clutch KV.
The disassembly of the clutch
KR is analogous.
1. Squeeze rectangular ring out.
2. Pull tapered roller bearing from shaft.
3. Remove opposite tapered roller bearing.
(S) Grab sleeve - 5873 001 057
(S) Basic set - 5873 001 000
Figure 131
4. Remove plate carrier from shaft.
(S) Hammer - 5870 280 004
Figure 132
5. Squeeze snap ring out and remove plate
pack.
Figure 133
6. Preload compression spring, squeeze
retaining ring out and remove components.
(S) Assembly aid - 5870 345 086
(S) Set of external pliers - 5870 900 015
Figure 134

4WG-160) Page 77
7. Lift piston using compressed air out of the
cylinder bore and remove it.
Figure 135
8. Remove both O-rings.
Figure 136
9. Squeeze inner retaining ring (shaft) out.
Figure 137
10. Locate idler gear using separating device
(Figure 138) and press it from the shaft
(Figure 139).
11. Remove released needle bearing.
(S) Separating device - 5870 300 028
Figure 138

Page 78 4WG-160)
Figure 139
ball bearing.
NOTE: The disassembly of the clutch
KR has to be carried out.
Figure 140
Dismantle Clutch K1. K2 and K3
NOTE: The following Figures show the
disassembly of the clutch K3
1. The disassembly of the clutches K1 and
K2 is analogous. Squeeze rectangular ring
(Figure 141) out.
Figure 141
2. Pull tapered roller bearing from the shaft.
3. Remove opposite tapered roller bearing
accordingly, see Figure 141 and Figure
142.
(S) Grab sleeve - 5873 001 057
(S) Grab sleeve (K3 - on output side) -
5873 001 058
(S) Basic set - 5873 001 000
Figure 142

4WG-160) Page 79
4. Remove running disk, axial needle cage
and axial washer.
Figure 143
5. Remove idler gear.
Figure 144
6. Remove both needle bearings and axial
bearing (compl.).
Figure 145
pack.
Figure 146

Page 80 4WG-160)
(S) Assembly aid (K2 and K3) - 5870 345
085
(S) Assembly aid (K1) - 5870 345 086
Figure 147
9. Press piston out of the plate carrier, using
compressed air.
Figure 148
10. Pry plate carrier from the shaft.
(S) Pry bar - 5870 345 065
Figure 149
Dismantle Clutch K4
1. Squeeze rectangular ring out and pull
tapered roller bearing from the shaft.
2. Remove opposite tapered roller bearing.
(S) Grab sleeve - 5873 001 057
(S) Basic set - 5873 001 000
Figure 150

4WG-160) Page 81
plate carrier from the shaft.
(S) Assembly aid - 5870 345 085
Figure 151
pack.
Figure 152
6. Remove piston.
NOTE: The separation of shaft and
gear is not possible (shrink fit).
(S) Assembly aid - 5870 345 085
Figure 153
Dismantle Input Shaft
1. If necessary, press turbine shaft out of the
input shaft.
NOTE: The turbine shaft is axially fixed
using a snap ring which will be
destroyed at the pressing out.
Figure 154

Page 82 4WG-160)
2. Squeeze rectangular ring out and pull off
the tapered roller bearing.
3. Pull off the opposite tapered roller bearing.
NOTE: The separation of input shaft (1,
Figure 155) and gear (2) is not
possible (shrink fit).
(S) Grab sleeve - 5873 001 058
(S) Basic set - 5873 001 000
Figure 155

4WG-160) Page 83
REASSEMBLY
NOTE: If contrary to the ZF-Recommendation, the tapered roller bearings of the clutches and of
the input and output would are not replaced, the allocation of the inner and outer races to
the single assemblies must at least be maintained.
Mount Oil Pipes

NOTE: To ensure the correct
reassembly of the oil pipes, the
use of the specified special tool
(S) is imperative.
1. Install studs (Figure 156).
NOTE: Torque limit (M8) 1 kg•m (7 ft
lb).
NOTE: Insert studs with Loctite Crype
No. 262).
Figure 156
2. Place distance tubes over the studs.
Figure 157

Page 84 4WG-160)
3. Insert suction tube (1, Figure 158),
pressure pipe (2) and pressure pipe
lubrication (3) into the housing bores.
4. Fasten suction tube (1) and pressure pipes
(2) provisionally using socket head screw
and hex. nuts.
NOTE: Torque limit (M8/8.8) 2.35 kg•m
(17 ft lb).
Figure 158
5. Locate both pressure pipes using special
device.
(S) Tension bar - 5870 654 030
Figure 159

4WG-160) Page 85
6. Tilt housing 180°.
7. Roll in suction tubes and pressure pipes
(Figure 160) into the housing bores, using
special tool.
NOTE: Pipe end of pressure pipes
(Figure 160) must be slightly
below the housing plane face, if
necessary equalize.
(S) Rolling tool - 5870 600 003
(S) Rolling tool - 5870 600 004
(S) Rolling tool - 5870 600 005 Figure 160
(S) Rolling tool - 5870 600 006
8. Tilt housing 180°.
9. Check installation position of the two
pressure pipes and correct if necessary.
NOTE: Pipes must be located in the
Special device (S) without play
and pressure.
10. Remove special device.
(S) Tension bar - 5870 654 030
Figure 161
11. Install new O-ring on screw plug and install
it.
NOTE: Torque limit (M30x1,5) 5.20
kg•m (38 ft lb).
Figure 162

Page 86 4WG-160)
12. Insert all outer bearing races into the
housing bore.
NOTE: In the case that already run
bearings are reused, pay
attention to the allocation of the
outer bearing races, see also
Note, Page 84. Pay attention to
the corresponding markings.
Figure 163
13. Insert both oil pipes (Figure 164) into the
housing cover, tilt housing cover 180° and
roll in oil pipes into the housing bores.
NOTE: The pipe end must be situated
slightly below the housing plane
face.
(S) Rolling tool - 5870 600 005
Figure 164
14. Install studs 27x (M8x25) according to the
Figure 165.
NOTE: Torque limit (M8) 1 kg•m (7 ft
lb).
Figure 165
15. Insert set screws (2x) into the housing
bores (Figure 166).
Figure 166

4WG-160) Page 87
Reassemble Clutch KV and KR
NOTE: The following Figures describe
the reassembly of the clutch KV.
The reassembly of the clutch
KR has to be carried out.
Figure 167
Preassemble Plate Carrier
NOTE: Figure 167 thru Figure 170.
1. Check function of the drain valve.
NOTE: Ball may not seize, if necessary
clean using compressed air.
2. Insert both O-rings (Figure 168) into the
recesses of the piston and oil them.
NOTE: Make sure that O-rings are not
twisted.
3. Assemble piston until contact is obtained.
Figure 168
NOTE: Pay attention to the installation
position, see Figure.
4. Install compression spring along with
spring cup (2x).
Figure 169

Page 88 4WG-160)
5. Preload compression spring and attach it
using retaining ring.
(S) Assembly aid - 5870 345 086
Figure 170

4WG-160) Page 89
Plate Pack KV and KR
NOTE: The plate equipment, reap. stacking of clutch KV and KR is identical.
Figure 171
Reference Reference
Number Number
1 Plate Carrier 5 Outer Plates - Coated
2 Piston On Both Sides
3 Outer Plate - One- 6 Snap Ring (Optional,
sided Coated S = 2.10 - 4.20 mm
(0.0827 - 0.1654 in))
4 Inner Plates
7 End Shim
NOTE: Install outer plate 3 with the uncoated side facing the piston, reap. the end shim.
1. Install on the end shim side two outer and inner plates each.
NOTE: Effective number of friction surfaces = 18.

Page 90 4WG-160)
2. Adjust plate clearance = 2.50+0.20 mm
(0.0984+0.0079 in).
NOTE: For the adjustment of the plate
clearance there are snap rings
of different thickness available.
To ensure a faultless measuring
result, in tall plates for the
movement without oil.
3. Install plate pack according to Figure 171.
Figure 172
4. Mount end shim and squeeze snap ring
(e.g. s = 3.0 mm (0.1181 in)).
Figure 173
5. Press end shim on with about 10 kg (22 lb)
and measure Dimension I from the end
face/plate carrier to the end shim.
Dimension I e.g. 7.250 mm (0.2854 in)
(S) Digital depth gauge - 5870 200 072
Figure 174

4WG-160) Page 91
6. Press end shim against snap ring (upward)
until contact is obtained and determine
Dimension II.
Dimension II e.g. 4.750 mm (0.1870 in)
(S) Digital Depth gauge - 5870 200 072
Figure 175
EXAMPLE:
Dimension I 7.250 mm (0.2854 in)
Dimension II - 4.750 mm (0.1870 in)
Difference = Plate clearance 2.50 mm (0.0984 in)
NOTE: In case of deviations from the required plate clearance, correct using corresponding snap
ring (s = 2.10 - 4.20 mm (0.0827 - 0.1654 in)
7. Remove plate pack, oil and install it again.
8. Install idler gear until all inner plates are
accommodated.
NOTE: This step makes the later
assembling of the idler gear
easier.
9. Remove idler gear again.
Figure 176
10. Install stud (Figure 177).
NOTE: Use Loctite #243.
NOTE: Torque limit (M10) 1.73 kg•m
(13 ft lb).
Figure 177

Page 92 4WG-160)
11. Insert ball bearing until contact is obtained
and attach it using retaining ring.
Figure 178
12. Assemble needle bearing.
Figure 179
13. Press idler gear against shoulder.
NOTE: Support it on the inner bearing
race.
Figure 180
14. Attach idler gear axially using retaining
ring.
NOTE: At clutch KR there is no recess
in the shaft - assemble retaining
ring until contact on the inner
bearing race is obtained.
Figure 181

4WG-160) Page 93
15. Assemble pre-assembled plate carrier until
NOTE: Only if the plate carrier plane
face is overlapping with the
shaft collar, the accommodation
of all inner plates is ensured,
see Figure 183.
Figure 182
Figure 183
16. Press tapered roller bearing against
shoulder.
17. Install opposite tapered roller bearing.
Figure 184
18. Check function of clutch using compressed
air.
NOTE: At correctly installed
components, the closing, reap.
opening of the clutch is clearly
audible.
Figure 185

Page 94 4WG-160)
Reassemble Clutches K1, K2 and K3
NOTE: The following Figures describe
the reassembly of the clutch K3.
The reassembly of the clutches
K1 and K2 has to be carried
out.
NOTE: Use Loctite #243.
(13 ft lb).
Figure 186
2. Assemble plate carrier until contact is
obtained.
Figure 187
NOTE: Bail may not seize, if necessary
piston recesses and oil them.
twisted.
Figure 188
5. Install piston until contact is obtained.
Figure 189

4WG-160) Page 95
6. Install compression spring along with
spring cup (2x).
Figure 190
7. Preload compression spring and attach it
using retaining ring.
(S) Assembly aid (K2 and K3) - 5870 345
085
(S) Assembly aid (K1) - 5870 345 086
Figure 191
Plate Pack K1, K2, and K3
NOTE: Stacking of clutch plates K1, K2
and K3 is identical. Figure 192,
shows the installation position
of the components.
Reference
Description
Number
1 Plate Carrier
2 Piston
3 Outer Plate - One-
sided Coated
4 Inner Plates
5 Outer Plates Coated
on Both Sides Figure 192
6 Snap Ring (Optional,
s = 2.10 - 4.20 mm
(0.0827 - 0.1654 in)
7 End Shim
NOTE: Install outer plate 3 with the uncoated side facing the piston. Install two outer and inner
plates each on the end shim side. Effective number of the friction surfaces = 14.

Page 96 4WG-160)
8. Adjust plate clearance = 2.10+0.20 mm
(0.0827+0.0079 in).
NOTE: For the plate clearance
adjustment there are snap rings
result, in tall the plates for the
moment without oil.
Figure 193
10. Fit end shim and squeeze snap ring (e.g.
3.0 mm (0.1181 in)) in.
Figure 194
11. Press end shim on with about 10 kg (22
lb), and measure Dimension I from the end
Figure 195

4WG-160) Page 97
until contact is obtained, and determine
Dimension II.
Figure 196
EXAMPLE:
Dimension II - 6.0 mm (0.2362 in)
ring (s = 2.10 - 4.20 mm (0.0827 - 0.1654 in).
13. Remove plate pack, oil and install it again.
14. Assemble running disk (1, Figure 197) (50
x 70 x 4), axial needle cage (2) and axial
washer (3) (50 x 70 x 1).
NOTE: Install running disk 1 with the
chamfer facing the axial needle
cage.
Figure 197
15. Assemble both needle bearings.
Figure 198

Page 98 4WG-160)
accommodated.
Figure 199
17. Assemble axial washer 3 (50 x 70 x 1),
axial needle cage 2 and running disk 1 (50
x 70 x 4).
chamfer facing the axial needle
cage.
NOTE: Only if the running disk is
overlapping with the shaft
collar, the accommodation of all
the inner plates is ensured.
Figure 200
shoulder.
Figure 201
shoulder.
Figure 202

4WG-160) Page 99
20. Check function of the clutch using
compressed air.
NOTE: At correctly installed
audible.
Figure 203
Reassemble Clutch K4
1. Cool shaft (about -80°C (-112°F)), heat
gear (about +120°C (+248°F)) and
assemble it until contact is obtained.
Figure 204
2. Locate gear axially using retaining ring.
Figure 205
NOTE: Use Loctite (Type No. 243).
(13 ft lb).
Figure 206

Page 100 4WG-160)
NOTE: Ball may not seize, if necessary
piston recesses and oil them.
twisted.
Figure 207
6. Install piston until contact is obtained.
Figure 208
7. Install compression spring and spring cup
(2x), preload and attach using retaining
ring.
(S) Assembly aid - 5870 345 085
Figure 209

4WG-160) Page 101
Plate Pack K4
Figure 210, shows the installation position
of the components.
Reference
Description
Number
1 Plate Carrier
2 Piston
3 Outer Plate - One-
sided Coated
4 Inner Plates
5 Outer Plates - On Figure 210
Both Sides Coated
6 Snap Ring (Optional,
s = 2.10 - 4.2 mm
(0.0827 - 0.1654 in))
7 End Shim
NOTE: Install outer plate 3 with the

uncoated side facing the piston.
NOTE: Effective number of friction
surfaces = 10.
1. Adjust plate clearance = 1.20+0.20mm

(0.0472+0.0079in).
NOTE: For the plate clearance
adjustment there are snap rings
result, install the plates for the
moment without oil.
Figure 211
3. Fit end shim and squeeze retaining ring
(e.g. s = 3.0 mm (0.1181 in)).
Figure 212

Page 102 4WG-160)
4. Press end shim on with about 10 kg (22
lb)) and measure Dimension I from the end
Figure 213
until contact is obtained and determine
Dimension II.
Figure 214
EXAMPLE:
Dimension II 6.00 mm (0.2362 in)
ring (s = 2.10 - 4.20 mm (0.0827 - 0.1654 in)).
accommodated.
NOTE: This step makes the later
assembling of the idler gear
easier.
7. Remove idler gear again.
Figure 215

4WG-160) Page 103
8. Assemble both axial washers and needle
cage.
NOTE: Upper and lower axial washer
have the same thickness (50x
70x 1).
Figure 216
9. Assemble both needle bearings.
Figure 217
10. Assemble idler gear.
Figure 218
11. Assemble axial washer (3, Figure 219) (50
x 70 x 1) needle cage (2) and running disk
(1) (50 x 70 x 4).
chamfer facing the needle cage.
Figure 219

Page 104 4WG-160)
12. Assemble pre-assembled plate carrier until
all inner plates are accommodated.
Figure 220
13. Attach plate carrier axially using retaining
ring.
(S) Handle - 5870 260 010
Figure 221
shoulder.
15. Install opposite tapered roller bearing.
Figure 222
16. Check function of the clutch using
compressed air.
NOTE: With correctly installed
audible.
Figure 223

4WG-160) Page 105
Pre-assemble Input Shaft
1. Cool the input shaft (about -80°C
(-112°F)), heat gear (about +120°C
(+248°F)) and assemble it until contact is
obtained.
Figure 224
2. Attach gear axially using retaining ring.
Figure 225
3. Squeeze snap ring into the recess of the
turbine shaft.
Figure 226
4. Install turbine shaft until the snap ring
snaps into the recess of the input shaft -
turbine shaft is axially fixed.
Figure 227

Page 106 4WG-160)
5. Press both inner bearing races against
shoulder.
Figure 228
6. Install ball bearing.
7. Squeeze rectangular ring (Figure 229) in
and hook it in.
Figure 229
8. Insert output shaft into the housing bore
until contact is obtained.
Figure 230

4WG-160) Page 107
Install Pre-assembled Output Shaft and Clutches
NOTE: The following Figures describe the common installation of all clutches. For it, the housing
cover, combined with special tool (Handle 5870 260 010) is needed. The reassembly of
single clutches without housing cover and handles is extremely difficult because of the
installation conditions. Besides, there is the danger of injury.
1. Insert all outer bearing races into the
housing cover until contact is obtained.
NOTE: In the case that already run
bearings are reused, pay
attention to the allocation of the
outer bearing races, see also
Note, Page 84
Figure 231
2. Insert clutch KR, input shaft and clutch KV
together into housing cover.
Figure 232
3. Install clutch K4.
Figure 233

Page 108 4WG-160)
4. Install clutch K3.
Figure 234
5. Position clutch K1.
Figure 235
6. Insert clutch K2.
Figure 236
7. Figure 237, shows the installation position
of the single clutches in the housing cover.
Figure 237

4WG-160) Page 109
8. Locate all clutches using Handles (S).
010
Figure 238
9. Squeeze rectangular rings (7 pieces, see
Figure 239) in and hook them in.
10. Grease rectangular rings and align them
centrically.
Figure 239
11. Tilt housing cover 180°.
12. Mount eye bolts, see Figure 240.
(S) 2x Eye bolt M20 - 0636 804 003
(S) lx Eye bolt M16 - 0636 804 001
(S) Puller device - 5870 000 017
Figure 240
13. Install adjusting screws (S).
14. Position housing cover using lifting device
carefully on the gearbox housing until
contact is obtained, reap. position the
clutches in the gearbox housing.
NOTE: Pay attention to the overlapping
of the oil pipes with the bores in
the housing cover.
Figure 241

Page 110 4WG-160)
15. Remove handles.
Figure 242
16. Remove housing cover from gearbox
housing, using lifting device.
Figure 243
Output
1. Assemble sheet and press both inner
bearing races against shoulder until
Figure 244
2. Insert outer bearing race (Figure 245) into
the housing bore until contact is obtained.
Figure 245

4WG-160) Page 111
3. Position screening plate.
Figure 246
4. Insert output shaft.
Figure 247
5. Fasten both sheets using socket head
screws (4x).
NOTE: Insert socket head screws with
Loctite (Type No. 243).
(17 ft lb).
Figure 248
6. Squeeze rectangular rings (6x) into the
recesses of the clutch shafts and hook
them in.
7. Grease rectangular rings and align them
centrically.
Figure 249

Page 112 4WG-160)
annular groove of the oil pipes and grease
them.
Figure 250
9. Cover mounting face with sealing
compound Loctite #574.
10. Install adjusting screws (S) and position
housing cover carefully against gearbox
housing until contact is obtained, using
lifting device.
of the oil pipe with the bores in
the housing cover.
Figure 251
11. Install both cylindrical pins.
Figure 252
12. Fasten housing cover using hex. head
screws.
NOTE: Torque limit (M10/8.8) 4.69
kg•m (34 ft lb).
NOTE: Pay attention to the position of
the fixing plate, see Figure 253.
Figure 253

4WG-160) Page 113
13. Install shaft seal, with the sealing lip facing
the oil chamber.
NOTE: By application of the prescribed
driver, the exact installation
position is obtained. Wet rubber
coated outer diameter with
spirit. Grease sealing lip.
(S) Driver - 5870 048 057
Figure 254
14. Heat the output flange (Max. 90°C
(194°F)), assemble it and attach it using
washer and hex. head screws.
NOTE: Wet contact area of washer with
sealing compound Loctite (Type
No. 574).
kg•m (25 ft lb).
Figure 255
15. Attach hex. head screws using lock plate.
16. Install output flange on the converter side
accordingly (Figure 254 thru Figure 256).
(S) Driver - 5870 057 011
(S) Handle - 5870 260 002
Figure 256
Converter Pressure Valve
NOTE: Figure 257, shows the
components of the converter
pressure valve.
Reference
Description
Number
1 Piston
2 Compression Spring
3 Valve Insert
4 Roll Pin
Figure 257

Page 114 4WG-160)
1. Install compression spring and piston,
preload and attach them using roll pin.
(S) Assembly aid - 5870 345 084
Figure 258
2. Insert pre-assembled converter pressure
valve into the housing bore.
Figure 259
Oil Feed Housing - Transmission Pump
1. Install two adjusting screws (Figure 260)
and mount flat gasket.
Figure 260
2. Mount oil feed housing and attach it
provisionally using washers and hex. head
screws.
NOTE: Screw the hex. head screws in
only until contact is obtained do
not tighten.
Figure 261

4WG-160) Page 115
3. Install two adjusting screws and install
stator shaft until contact is obtained.
of the bores.
Figure 262
4. Install O-ring (Figure 263) and oil it.
Figure 263
5. Install transmission pump (compl.) until
of the bores.
Figure 264
6. Install new O-rings on socket head screws
(Figure 265).
NOTE: Grease O-Rings.
Figure 265

Page 116 4WG-160)
7. Fasten transmission pump using socket
head screws.
kg•m (34 ft lb).
Figure 266
8. Attach oil feed housing finally using hex.
head screws (mount flat washers).
position of the fixing plate, see
Figure 268.
Figure 267
Figure 268
9. Install flat gasket and cover. Secure into
place using hex. head screws.
(17 ft lb).
Figure 269

4WG-160) Page 117
Converter Safety Valve
1. Figure 270, shows the components of the
converter safety valve.
Reference
Description
Number
1 Plate
2 Ball
3 Compression Spring
4 Valve Insert
5 Valve Sleeve
6 Cylindrical Pin Figure 270
2. Reassemble components according to

Figure 270, preload and attach using
cylindrical pin.
(S) Assembly aid - 5870 345 084
Figure 271
3. Insert converter safety valve (compl.) into
the housing bore until contact is obtained.
Figure 272

Page 118 4WG-160)
Attaching Duct Plate
1. Install both screw plugs (Figure 273).
NOTE: Install new sealing rings.
Figure 273
2. Install gasket, place duct plate against
shoulder and fasten it using socket head
screws and hex. nuts (mount flat washers).
Figure 274
Attaching Hydraulic Control Unit
1. Install two adjusting screws.
2. Mount gasket (1, Figure 276), intermediate
plate (2) and gasket (3).
position of the different gaskets,
see Figure 276.
Figure 275

4WG-160) Page 119
Figure 276
3. Fasten complete control unit on the duct

plate, using socket head screws.
Figure 277

Page 120 4WG-160)
Filter
1. Figure 278, shows the components of the
filter unit.
NOTE: Install new O-rings (Figure
278).
Figure 278
2. Fasten intermediate plate and filter head
using hex. head screws (mount flat
washers).
Figure 279
3. Oil gasket and tighten exchange filter
handtight.
Figure 280
4. If necessary, install warning switch
(according to the version).
Figure 281

4WG-160) Page 121
5. Insert O-ring (Figure 282) into the annular
groove of the oil feed covers.
Figure 282
6. Fasten the two covers (Figure 283) using
hex. nuts (mount flat washers) on the
housing.
Figure 283
7. Mount oil level tube.
8. Install screw plug (Figure 284).
NOTE: Install new gaskets.
(17 ft lb).
NOTE: Torque limit (screw plug
M26x1,5) 8.16 kg•m (59 ft lb).
Figure 284
Speed Sensor and Inductive Transmitter
1. Grease O-ring, install speed sensor
(Figure 285) and fasten it using socket
head screw.
(17 ft lb).
Reference
Description
Number
34 Speed - Output and
Speedometer
Figure 285

Page 122 4WG-160)
2. Install new O-rings on inductive
transmitters and install.
Reference
Description
Number
48 Speed - Engine
47 Speed - Central Gear
Train
21 Speed - Turbine
3. Install breather (Figure 286).

Figure 286
4. Install gasket and cover plate (1, Figure
287).
(17 ft lb).
5. Install new O-ring on screw plug (2) and
install.
NOTE: Torque limit 14.28 kg•m (105 ft
lb).
Figure 287

4WG-160) Page 123
Page 124 4WG-160)
S0607900C
R2
1TRANSMISSION ERROR
CODES (ZF)
CAUTION!
TRANSMISSION ERROR CODES (ZF)S0607900C

Mega 400-III PLUS 1001 and Up
Mega 500-V 1001 thru 2000

December 2002
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 cab. 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
7 Hex Analog Current Output Signal
8 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

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).
WE Warning high engine speed. Changes between actual gear/direction while
detected (spanner).

Page 6
Symbol Meaning Remarks
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.
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.
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.
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
(should be
approximately 5V).
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
(should 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.
** Only Series "V"

Page 28
(hex) detection.)
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.
• Cable or connectors are
Replace TCU.
defect and are contacted to
battery voltage.
vehicle ground.
• Permanent power supply
KL30 missing.
• TCU has an internal defect.
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.
** Only Series "V"

Page 29
(hex) detection.)
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.
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.
** Only Series "V"

Page 30
(hex) detection.)
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.
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 /
1 2
R12 ≈ 0;R1C ≈ R2C ≈ 0,R1P ≈ R2P ≈ ∞ Sensor
short cut to battery: C (chassis)
R12 ≈ 0,R1C ≈ R2C ≈ ∞,R1P ≈ R2P ≈ 0

Gnd
HBOE650I
Figure 3

Page 35
Page 36
1HYDRAULICS
S0702035K
1HYDRAULIC SYSTEM
CAUTION!
HYDRAULIC SYSTEMS0702035K

December 2002
Hydraulic System S0702035K

Page 1
TABLE OF CONTENTS
Hydraulic System ........................................................................................... 3

Oil Circulation Routes ............................................................................. 3
Main Hydraulic Circuit ............................................................................. 3
Brake System ................................................................................................. 4
Service Brake ................................................................................................. 4
General Description (Brake Line)............................................................ 4
Service Brake Line........................................................................... 4
Safety System and Alarm System ................................................... 4
Service Brake Hydraulic System............................................................. 5
When Brake Pedal Is Released ....................................................... 6
When Brake Pedal Is Applied .......................................................... 7
Accumulator Operation .................................................................... 8
S0702035K Hydraulic System

Page 2
HYDRAULIC SYSTEM
The hydraulic system uses the main pump as its power source and directs oil flow with the control valve.
The hydraulic system consists of the main pump, control valve, valve controls, oil tank, and hydraulic
piping.
OIL CIRCULATION ROUTES

The hydraulic circuit of the loader consists of the main hydraulic circuit and steering hydraulic circuit.
MAIN HYDRAULIC CIRCUIT

The oil picked up from the oil tank by the main pump is directed into the priority valve where it is divided
into two portions: one for the main hydraulic circuit and the other for the steering hydraulic circuit.
The oil for the main hydraulic circuit is routed to the control valve. When the control valve is in neutral, the
oil passes through the control valve back into the oil tank. With the control valve in an operating position,
the oil flows through the oil passage chosen by the spool into the cylinder. The oil discharged from the
cylinder returns into the control valve which in turn sends the oil through the return filter into the oil tank.

Page 3
BRAKE SYSTEM
Mega 200-V
Service brake
Type Hydraulic operated, oil immersed, disk brakes.
Number of fluid lines 2 lines.
Brake valve Single brake valve.
Disk brake 4-wheels wet type disk brake.
Brake pump Rear pump of main pump unit.
Pressure setting 52~65 kg/cm2 (740~925 psi)
Alarm system Warning light and buzzer.
Safety system With accumulator.
Parking brake
Type Spring applied and hydraulically released (SAHR).
Installation Front axle.
WARNING!
Do not shut off the engine while the machine is running. If the engine stalls while the machine is
running, the brake pedal becomes hard to reduce braking force.
SERVICE BRAKE
GENERAL DESCRIPTION (BRAKE LINE)
Service Brake Line

The service brake is a 4-wheel wet type disk brake and uses the full power brake system. The hydraulic
brake system coming from the brake pedal valve has two independent lines. One for the front axle and one
for the rear axle. If one of the two lines is damaged, the other line will operate properly to brake the
machine.
Safety System and Alarm System

An accumulator is installed as a safety device for the service brake line.
If the brake pump fails to operate properly or the engine stalls, the disk brake can be actuated by the
accumulator oil pressure.
The accumulator is equipped with a pressure switch. If the accumulator oil pressure drops to 65.0 bar (940
psi), the operator will notice it immediately by way of the buzzer and the "brake oil pressure" warning light
on the instrument panel.

Page 4
SERVICE BRAKE HYDRAULIC SYSTEM
10
7 8
1
5
9
3
11
4
6
BHS0040L
Figure 1
Reference Reference
Number Number
1 Brake Pedal and Brake 7 Front Axle
Pedal Valve 8 Rear Axle
2 Brake Pump 9 Low Pressure Warning
3 Pilot Filter Switch
4 Brake and Pilot Supply 10 Transmission Cut-off Switch
Valve 11 Low Pressure Switch for
5 Accumulator Parking Brake
6 Oil Tank

Page 5
When Brake Pedal Is Released
When brake pedal (1) is released, brake pedal valve (A) returns to the neutral position. The pressurized
supply oil is blocked within the brake pedal valve (A) and is returned to the hydraulic oil tank (6). At the
same time the axle brake piston is depressurized which releases the brake disks in the axles (7 and 8).
Figure 2 BRAKE PEDAL RELEASED
Reference Reference
Number Number
A Brake Valve 5 Accumulators
1 Brake Pedal 6 Oil Tank
2 Brake Pump 7 Front Axle
3 Filter 8 Rear Axle
4 Brake and Pilot Supply
Valve

Page 6
When Brake Pedal Is Applied
When brake pedal (1) is applied, brake pedal valve (A) is actuated. The pressurized supply oil from the
brake and pilot supply valve (4) is then routed to the, front and rear axles (7 and 8), service brake pistons.
The service brake pistons then apply pressure to the brake disks, squeezing them together, causing the
unit to stop.
Figure 3 BRAKE PEDAL APPLIED
Reference Reference
Number Number
Valve

Page 7
Accumulator Operation
It is possible to produce braking force by using the hydraulic oil pressure in the accumulators, if the engine
has stalled or the brake pump fails to operate normally.
When the brake valve (A) is operated by bottoming the brake pedal (1), the pressurized oil in the
accumulators (5) is sent through the brake and pilot supply valve (4), to the brake pedal valve (A) and
activates the service brake pistons in axles (7 and 8).
The service brake pistons then apply pressure to the brake disks, squeezing them together, causing the
unit to stop.
All of the other ports of the brake valve are closed.
Figure 4 BRAKE PEDAL APPLIED WITH BRAKE PUMP NOT RUNNING
Reference Reference
Number Number
Valve

Page 8
S0703010K
1ACCUMULATOR
CAUTION!
ACCUMULATOR S0703010K
Solar 55 0001 and Up
Solar 55-V Plus 1001 and Up
Solar 75-V 1001 and Up

December 2002
Accumulator S0703010K
Page 1
TABLE OF CONTENTS
Specifications .......................................................................................... 4
S0703010K Accumulator
Page 2
GENERAL DESCRIPTION
The accumulator is a gas-charged storage
device designed to hold a reserve quantity of 1
hydraulic fluid under pressure. Accumulators are
used in hydraulic circuits in much the same way 2
that condensers (or capacitors) are used to
collect, store and maintain electrical charge in a
circuit.
In a hydraulic circuit, minor variations or lags in
pump output that might otherwise cause
unsteady or irregular operation are made up
from the supply of pressurized oil in the 3
accumulator.
Reference
Description
Number
1 Screw Plug
2 Steel Pressure Vessel
4
3 Diaphragm ARS1790L
4 Fluid Valve Figure 1
Accumulators are solidly constructed to resist the high operating pressures of the fluids they contain. There
are only three main moving parts: a plug at the top allows pre-charging or expelling gas from the
compressible, pre-charged upper chamber; a valve assembly at the bottom of the accumulator for passing
hydraulic fluid in and out, and an elastic diaphragm to separate the two chambers. The flexible diaphragm
changes shape to conform to the changing pressures and volumes of the two fluids in the upper and lower
chambers.
There are six possible positions the diaphragm
can be in and they are as follows: Pressure Fluid Nitrogen
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 pre-pressure charge of gas
(usually nitrogen) is introduced through the
port at the top of the accumulator, the 1 2 3
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
4 5 6
valve opening. ARS1800L
Figure 2
Page 3
NOTE: Pre-charge pressure is referred to as the "P1" pressure. The accumulator manufacturer’s
"P1" rated pressure should be stamped or marked on the accumulator’s rating plate.
Annual checks of actual pre-charge pressure should be made by tapping a hydraulic
pressure gauge (and 3-way adapter coupling) into the valve on the bottom of the
accumulator. When hydraulic fluid is pushed out the lower valve opening by the pressure
of the gas charge on the other side of the diaphragm - and there is no counter-pressure
from system oil - the valve button on the bottom of the diaphragm eventually seals off the
lower oil passage. Just after the needle on the gauge reaches its highest point (when there
is 0 bar (0 psi) resistance from hydraulic system pressure) pressure on the gauge will drop
sharply to zero, as the accumulator is completely emptied of oil and the diaphragm button
closes.
Record the highest gauge reading and compare to the "P1" rated pre-charge pressure on the
accumulator manufacturer’s data label. Repeat this test at least once a year to verify proper
functioning of the accumulator.
3. As hydraulic system pressure overcomes accumulator pre-charge pressure, the flexible diaphragm
begins to retract upward.
4. When system oil is at highest working pressure and the accumulator fills to maximum reserve
capacity, the flexible diaphragm is pushed up into the top of the upper chamber.
The highest working pressure is sometimes referred to as the "P3" pressure and can also be
referenced on the manufacturer’s data label on the exterior of the accumulator.
5. If system oil pressure begins to fall off or is momentarily checked or interrupted, the energy stored on
the other side of the diaphragm, in the form of compressed gas, pushes oil back out of the lower
chamber, maintaining oil pressure of the circuit.
6. With minimal system pressure, an equilibrium point may be reached in which accumulator pre-charge
pressure and hydraulic system oil pressure achieve a rough balance. In this condition a minimal
amount of oil is stored in the accumulator.
SPECIFICATIONS
Charge
Model Serial Number System Volume
Pressure
Mega 200-V (Tier I 30 kg/cm² 750 cc
S/N 1001 and Up Brake System
& II) (427 psi) (45.77 in3)
Mega 200-V (Tier I 15 kg/cm² 320 cc
S/N 1001 and Up Pilot
& II) (213 psi) (19.53 in3)
30 kg/cm² 750 cc
Mega 250-V (Tier I) S/N 1001 thru 2000 Brake System
(427 psi) (45.77 in3)
15 kg/cm² 320 cc
Mega 250-V (Tier I) S/N 1001 thru 2000 Pilot
(213 psi) (19.53 in3)
30 kg/cm² 750 cc
Mega 250-V (Tier II) S/N 2001 and Up Brake System
(427 psi) (45.77 in3)
15 kg/cm² 320 cc
Mega 250-V (Tier II) S/N 2001 and Up Pilot
(213 psi) (19.53 in3)
10 kg/cm2 320 cc
Solar 55-V S/N 0001 and Up Pilot
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
Solar 55-V Plus S/N 1001 and Up Pilot
(140 psi) (19.53 in3)
Page 4
Charge
Pressure
10 kg/cm2 320 cc
Solar 75-V S/N 1001 and Up Pilot
(140 psi) (19.53 in3)
Solar 140W-V 30 kg/cm² 750 cc
S/N 1000 and Up Brake System
/160W-V (427 psi) (45.77 in3)
S/N 1000 and Up Pilot
/160W-V (213 psi) (19.53 in3)
S/N 1000 and Up Transmission
/160W-V (114 psi) (45.77 in3)
30 kg/cm² 750 cc
Solar 180W-V S/N 1001 and Up Brake System
(427 psi) (45.77 in3)
15 kg/cm² 320 cc
Solar 180W-V S/N 1001 and Up Pilot
(213 psi) (19.53 in3)
8 kg/cm² 750 cc
Solar 180W-V S/N 1001 and Up Transmission
(114 psi) (45.77 in3)
30 kg/cm² 750 cc
Solar 210W-V S/N 0001 and Up Brake System
(427 psi) (45.77 in3)
15 kg/cm² 320 cc
Solar 210W-V S/N 0001 and Up Pilot
(213 psi) (19.53 in3)
8 kg/cm² 750 cc
Solar 210W-V S/N 0001 and Up Transmission
(114 psi) (45.77 in3)
10 kg/cm² 750 cc
Solar 225LC-V S/N 1001 and Up Pilot / Travel
(142 psi) (45.77 in3)
10 kg/cm² 320 cc
Solar 255LC-V S/N 1001 thru 1002 Pilot / Travel
(142 psi)) (19.53 in3)
10 kg/cm² 750 cc
(142 psi) (45.77 in3)
10 kg/cm² 320 cc
(142 psi) (19.53 in3)
10 kg/cm² 750 cc
(142 psi) (45.77 in3)
10 kg/cm² 750 cc
Solar 300LL S/N 1100 and Up Pilot / Travel
(142 psi)) (45.77 in3)
10 kg/cm² 320 cc
(142 psi) (19.53 in3)
10 kg/cm² 750 cc
(142 psi)) (45.77 in3)
10 kg/cm² 320 cc
(142 psi) (19.53 in3)
10 kg/cm² 750 cc
(142 psi)) (45.77 in3)
10 kg/cm² 320 cc
(142 psi) (19.53 in3)
Page 5
Charge
Pressure
10 kg/cm² 750 cc
(142 psi)) (45.77 in3)
Page 6
S0705015K
1CYLINDERS
CAUTION!
CYLINDERS S0705015K

December 2002
Cylinders S0705015K
Page 1
TABLE OF CONTENTS
Parts List ................................................................................................. 6
Troubleshooting, Testing and Adjustment..................................................... 12
Disassembly ................................................................................................. 16
Cleaning and Inspection (Wear Limits and Tolerances) ............................... 18
Reassembly.................................................................................................. 19
S0705015K Cylinders
Page 2
GENERAL DESCRIPTION
The machine contains boom cylinders, buckets cylinders and steering cylinders. Each cylinder contains a
cylinder tube, piston rod, piston, and cylinder head. See Figure 1. The piston is held to piston rod by a nut.
A dust seal protects the U-ring and oil seal from dirt and also prevents oil from leaking out of the cylinder.
Figure 1
Reference Reference
Number Number
1 Retaining Ring 10 Seal O-ring
2 Dust Seal 11 Piston
3 U-Ring 12 Spring
4 Seat O-ring 13 Cylinder Tube
5 Port (A) 14 O-ring, Backup Ring
6 Cushion Plate 15 Bushing
7 Wear Ring 16 Cylinder Head
8 Piston Nut 17 Bolt
9 Port (B) 18 Piston Rod
Cylinders S0705015K
Page 3
THEORY OF OPERATION
Reference
Description
Number
1 Piston
2 Oil Path A
3 Oil Path B
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
S0705015K Cylinders
Page 4
Cylinders S0705015K
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 5
S0705015K Cylinders
Page 6
Reference Reference
Number Number
1 Tube Assembly 16 Wear Ring
2 Steel Bush 17 Dust Ring
3 Rod Assembly 18 O-ring
4 Steel Bush 19 Piston Nut
5 Rod Cover 20 Lock Ring
6 Du-bush 21 Socket Hex Bolt
7 Retaining Ring 22 Pipe Assembly
8 U-packing 23 O-ring
9 Backup Ring 24 Spring Washer
10 Dust wiper 25 Hex Bolt
11 O-ring 26 Pipe Clamp
12 Backup Ring 27 Spring Washer
13 O-ring 28 Hex Bolt
14 Piston 29 Grease Nipple
15 Glyd Ring Seal Kit
Cylinders S0705015K
Page 7
Lift Hydraulic Cylinder
33 2
22
23
21
30 24
32
29
30
31
26 25
27
28
19
18
13
15
14
17 7
20 10
12 11
6
5
8 4
7
9
BAS0180L
Figure 6
S0705015K Cylinders
Page 8
Reference Reference
Number Number
1 Tube Assembly 18 Piston Nut
2 Steel Bush 19 Lock Ring
3 Rod Assembly 20 Socket Hex Bolt
4 Rod Cover 21 Pipe Assembly
5 Du-bush 22 O-ring
6 Retaining Ring 23 Spring Washer
7 U-packing 24 Hex Bolt
8 Backup Ring 25 Pipe Assembly-r
9 Dust wiper 26 O-ring
10 O-ring 27 Spring Washer
11 Backup Ring 28 Socket Hex Bolt
12 O-ring 29 Pipe Clamp
13 Piston 30 Spring Washer
14 Glyd Ring 31 Hex Bolt
15 Wear Ring 32 Hex Bolt
16 Dust Ring 33 Grease Nipple
17 O-ring Seal Kit
Cylinders S0705015K
Page 9
Steering Hydraulic Cylinder
27
27
23
24
26
1
25
21
22
20
19
14
16
15
18 17
10
11
6
12
13
5
7
8
9
27
BAS0190L
Figure 7
S0705015K Cylinders
Page 10
Reference Reference
Number Number
1 Tube Assembly 15 Glyd Ring
2 Steel Bush 16 Wear Ring
3 Rod Assembly 17 Dust Ring
4 Steel Bush 18 O-ring
5 Rod Cover 19 Piston Nut
6 Du-bush 20 Lock Ring
7 U-packing 21 Cushion Plunger
8 Backup Ring 22 Stop Ring
9 Dust wiper 23 Check Valve
10 O-ring 24 Spring
11 Backup Ring 25 Plug
12 O-ring 26 O-ring
13 Washer 27 Grease Nipple
14 Piston Seal Kit
Cylinders S0705015K
Page 11
TROUBLESHOOTING, TESTING AND ADJUSTMENT
Problem Possible Cause Remedy
Oil leaking between cylinder Foreign material in U-ring (3). Remove foreign material.
head (16) and piston rod (18). Scratches in U-ring (3). Replace U-ring (3).
(Index nos. refer to Figure 1)
Damage to U-ring (3). Replace U-ring (3).
Foreign material in dust seal (2). Remove foreign material.
Scratches to dust seal (2). Replace dust seal.
Damage to dust seal (2). Replace dust seal.
Foreign material in seal O-ring Remove foreign material.
(4).
Scratches in seal O-ring (4). Replace O-ring (4).
Damage to seal O-ring (4). Replace O-ring (4).
Scratches on sealing surface of If scratches are not deep, hone
piston rod (18). with an oil stone and lubricate. If
scratches are deep, replace
piston rod (18).
Deep scratches on inner surface Replace Bushing.
of bushing (15).
Oil leaking between cylinder Damage to O-rings (14). Replace O-rings (14).
head (16) and cylinder tube (13).
Oil leaking from welded area of Damage to welded area. Replace cylinder tube (13).
cylinder tube (13).
S0705015K Cylinders
Page 12
Oil leaking between cylinder Foreign material in U-ring (3, Remove foreign material.
head (16) and piston rod (18). Figure 1)
(Index nos. refer to Figure 1). Scratches in U-ring (3, Figure 1). Replace U-ring (3).
Damage to U-ring (3, Figure 1). Replace U-ring (3).
Foreign material in dust seal (2, Remove foreign material.
Figure 1).
Scratches in dust seal (2, Figure Replace dust seal (2).
1).
Damage to dust seal (2, Figure Replace dust seal (2).
1).
Foreign material in seal O-ring Remove foreign material.
(4, Figure 1).
Scratches in seal O-ring (4, Replace O-ring (4).
Figure 1).
Damage to seal O-ring (4, Replace O-ring (4).
Figure 1).
Scratch on sealing surface of If scratches are not deep, hone
piston rod (18, Figure 1). with an oil stone and lubricate. If
scratches are deep, replace
piston rod (18).
Deep scratches on inner surface Replace bushing.
of bushing (15, Figure 1).
Oil leaking between cylinder Damage to O-rings (14, Figure Replace O-rings (14).
head (16) and cylinder tube (13). 1).
Oil leaking from welded area of Damage to welded area. Replace cylinder tube (13).
cylinder tube (13).
Cylinder drops from pull of Light scratches on sealing Hone out scratches with oil
gravity. surface of cylinder tube (13, stone.
Figure 1).
Deep scratches on sealing Replace cylinder tube (13).
surface of cylinder tube (13,
Figure 1).
Deep scratches on sealing Replace O-rings (10).
surface of piston O-rings (10,
Figure 1).
Foreign material in U-ring (3, Remove foreign material.
Figure 1).
Scratches in U-ring (3, Figure 1). Replace U-ring (3).
Damage to 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 S0705015K
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.
Relief valve pressure setting Adjust relief valve pressure.
incorrect.
Pump worn or damaged Replace worn or damaged
internally. parts.
Relief valve sticking. Disassemble and inspect
cartridge. Clean or replace
cartridge.
Worn cylinder seals. Replace worn parts.
Low pump output due to dirty Remove and clean pump
discharge pipes. discharge pipes.
Relief valve spring is weak. Replace worn parts.
Relief valve poppet worn.
Cylinder drops when control Worn plunger in control valve. Replace plunger.
valve is in neutral. Stuck overload relief valve due Replace worn parts.
to worn seat surface.
Loose pipes or joints. Tighten parts.
Worn piston seal on hydraulic Replace seal.
cylinder.
Vibration or excessive noise. Excessive resistance in pump Inspect intake line and clean or
intake line. replace as necessary.
Air being drawn into intake line. Inspect pipe joints and tighten.
Chattering relief valve. Change oil, replace valve.
S0705015K Cylinders
Page 14
Air bubbles in oil. Wrong type of operating oil. Drain and fill with proper type of
oil.
Oil level too low. Raise to proper level.
Air trapped in system. Perform cylinder bleeding
procedure to remove air.
Frequent rubber hose damage. System pressure too high. Adjust relief valve pressure.
Hoses breaking due to contact Restrain hoses to prevent
with another machine parts. contact.
Cylinders S0705015K
Page 15
DISASSEMBLY
NOTE: Keep on hand a container large enough to hold all of the oil in cylinder being repaired.
When cylinder rod and head are removed, oil will run out of cylinder.
1. Use an allen wrench to remove bolts that
hold cylinder head to cylinder tube. See
Figure 8.
Figure 8
2. Support cylinder rod with a lifting sling.
See Figure 9. Slide cylinder rod out of
cylinder tube. Rotate cylinder rod slightly
as it is being pulled from cylinder tube.
This will make it easier to pull rod out of
tube.
Figure 9
3. Set cylinder rod assembly in a repair
fixture and secure rod in place. See Figure
10. Use a power wrench and socket to
remove nut that holds piston on rod.
Figure 10
S0705015K Cylinders
Page 16
4. Remove piston nut (1, Figure 11), piston
assembly (2), cushion flange (3), and
cylinder head assembly (4).
Reference
Description
Number
1 Piston Nut
2 Piston Assembly
3 Cushion Flange
4 Cylinder Head
Assembly
Figure 11
5. Do not remove slipper seal, backup ring,
and back ring from piston. If these three
items are not scratched or damaged. See
Figure 12. Once these 3 items are
removed from piston, they must be
replaced. They cannot be reused. Exercise
caution when removing slipper seal to
prevent damage to piston O-ring groove.
Remove wear rings from piston.
Figure 12
6. When disassembling cylinder head do not
remove slipper seal, backup ring, back
ring, or dust seal unless items are
scratched or damaged. If seals are
removed from head, they must be
replaced. They cannot be reused. Remove
snap ring, (1, Figure 13). Use a
screwdriver to remove dust seal (2) from
head.
Reference
Description
Number
1 Snap Ring
Figure 13
2 Dust Seal
Cylinders S0705015K
Page 17
7. Use caution to prevent damage to any
parts of U-packing (1, Figure 14). Remove
U-packing (1). Remove O-ring (2), and ring
(3).
Reference
Description
Number
1 U-Packing
2 O-Ring
3 Ring
Figure 14
CLEANING AND INSPECTION (WEAR LIMITS AND

TOLERANCES)
For general cleaning and inspection procedures, refer to "General Maintenance Procedures" section.
S0705015K Cylinders
Page 18
REASSEMBLY
NOTE: Check cylinder head grooves
for U-packing and dust seal. If
edges of grooves are sharp or
have burns, use an oil stone to
smooth surface. See Figure 15.
Figure 15
1. Apply grease to inner part of cylinder head
and to U-packing groove. See Figure 16.
Figure 16
2. Install split backup ring into its groove by
compressing ring. See Figure 17. Make
sure that ends of ring do not overlap.
NOTE: The U-packing can be installed
by hand or by using a seal
installing jig. The jig should be
made of copper, aluminum, or
plastic. If a jig is used, be sure
that jig does not have sharp
edges that could damage U-
packing.
Figure 17
Cylinders S0705015K
Page 19
3. Insert one side of U-packing in its groove.
See Figure 18.
Figure 18
4. Carefully push down on other side of U-
packing until entire U-packing is seated in
its groove. See Figure 19.
Figure 19
5. Check to be sure that U-packing and
backup ring are correctly installed by
pushing with your hand on inner diameter
of U-packing. See Figure 20.
NOTE: There are 2 backup rings used
on outside of cylinder head.
One backup ring is continuous.
The other backup ring is open,
split by an angled cut.
Figure 20
6. Use grease or an adhesive to hold split
backup ring (1, Figure 21) in place. Install
split backup ring (1) in groove closets to
flange on cylinder head.
Reference
Description
Number
1 Split Backup Ring
2 Continuous Backup
Ring
Figure 21
S0705015K Cylinders
Page 20
7. Place continuous backup ring in warm
water. See Figure 22. Water temperature
should be 30 - 50°C (86 - 122°F). Leave
ring in water for 2 - 3 minutes. Slide
continuous backup ring (2, Figure 21) over
cylinder head and into its groove.
Figure 22
8. Install an O-ring over each of backup rings.
See Figure 23.
Figure 23
9. Use a seal installing jig to install dust seal
into cylinder head. See Figure 24. Install
snap ring.
Figure 24
Cylinders S0705015K
Page 21
10. On piston, check corners of grooves that
piston rings will be mounted in. See Figure
25. If any burrs, roughness, or sharp
edges (1) are present, use an oil stone to
smooth roughened areas and dull sharp
edges.
Figure 25
11. Apply grease or hydraulic oil to corner of
piston at position A. See Figure 26.
Figure 26
12. Insert one end of backup ring into its
groove. See Figure 27. Use your hand to
slide other end of ring into groove.
Figure 27
13. Use warm water to expand slipper seal.
See Figure 28. This will make seal easier
to install. Set slipper seal in 60 -100
degree C (140 - 212 degree F) water for 5
minutes or longer.
Figure 28
S0705015K Cylinders
Page 22
14. Insert one end of slipper seal, (1, Figure
29) into its groove. Use your hand to slide
other end of slipper seal into groove.
WARNING!
Before piston is inserted into
cylinder tube, make sure that slipper
seal is no longer expanded. If seal is
still expanded, it could catch on
threaded portion of cylinder tube. An
expanded seal could also jam inside Figure 29
cylinder tube.
15. Install two backup rings, (1, Figure 30).

One ring fits on either side of slipper seal
(2).
Reference
Description
Number
1 Backup Ring
2 Slipper Seal
Figure 30
Cylinders S0705015K
Page 23
16. Install wear ring (1, Figure 31) on piston.
Figure 31
17. Set cylinder rod (1, Figure 32) into a repair
fixture (2). Securely clamp rod to fixture.
Exercise caution to prevent nicks or
scratches to chrome plated areas of rod.
chrome plated area is oil sealing surface of
rod.
Reference
Description
Number
1 Cylinder Rod
2 Repair Fixture
Figure 32
18. Slide cylinder head assembly (1, Figure
33) onto cylinder rod (2). Use caution to
prevent threads on rod from damaging
seal inside cylinder head.
Reference
Description
Number
1 Cylinder Head
2 Cylinder Rod
Figure 33
S0705015K Cylinders
Page 24
19. Install cushion flange (1, Figure 34) on
cylinder rod (2). Slide piston assembly (3)
onto cylinder rod (2).
Reference
Description
Number
1 Cushion Flange
2 Cylinder Rod
3 Piston Assembly
Figure 34
20. Install piston nut (1, Figure 35) and tighten
it with an impact wrench. Then use a
torque wrench to tighten nut (1) to
specified torque.
After nut has been tightened, check to see
that cushion flange moves.
Figure 35
21. Slide rod assembly into cylinder tube.
Align punch mark (1, Figure 36) with port
(2) in cylinder tube. This will align hole (3)
in cylinder head with port (2).
Reference
Description
Number
1 Punch Mark
2 Port
3 Hole
Figure 36
Cylinders S0705015K
Page 25
22. Install bolts in cylinder head and tighten
them to torque specified in bolt torque
chart. See Figure 37. Double check to
make sure that hole in cylinder head is
align with port in cylinder tube.
NOTE: After rebuilding a cylinder, or
after loosening a cylinder
hydraulic line, air must be bled
from hydraulic system. To bleed
air from system, first extend
and retract a cylinder (or pair of
cylinders) about 5 times at low
engine rpm. Stop cylinder about Figure 37
100 mm (4 in) short of full
extension and full retraction.
Then fully extend and retract
cylinder about 5 times, also at
low engine rpm.
S0705015K Cylinders
Page 26
S0707110C
1FAN DRIVE
HYDRAULIC MOTOR
(HALDEX)
CAUTION!
FAN DRIVE HYDRAULIC MOTOR (HALDEX)S0707110C

Mega 200-V (Tier I) 1001 and Up (Europe Low Noise Kit)
Mega 250-V (Tier I) 1001 thru 2000 (Europe Low Noise Kit)

December 2001
Fan Drive Hydraulic Motor (Haldex) S0707110C

Page 1
TABLE OF CONTENTS
Mega 200-V ..................................................................................... 4
Mega 250-V ..................................................................................... 6
Parts List ................................................................................................. 8
Specifications .......................................................................................... 9
Tools Required ............................................................................................. 10
Disassembly ................................................................................................. 11
Inspect Parts for Wear.................................................................................. 14
General Information...................................................................................... 15
Reverse Shaft Rotation of Pump .................................................................. 15
Reassembly.................................................................................................. 16
S0707110C Fan Drive Hydraulic Motor (Haldex)

Page 2
Page 3
GENERAL DESCRIPTION
THEORY OF OPERATION
Mega 200-V
65bar
(PFO1/4) (PFO3/8) (PFO3/8) (PFO3/8)
(PFO3/8) A1 LPWS P1 P2 A2
A3 TP1
(PFO3/8)
C3-1 C3-2
BRAKE & PILOT FILTER
ø1.2 C2 C3-3
10 micron TP2
(PFO1/4)
(1) 2 PILOT
28kgf/cm
C4 (PFO3/8)
60kgf/cm
2 C6
FO SAFETY
Fan motor-(4) (PFO1/2)
(3)
14ccr 41ccr 44ccr C1 C3-4 PA
(PFO3/8)
Fan-(5) FI 120kgf/cm
2
(PFO1/2)
LPWS 45bar
(7) C5
0.75" Fan motor C7
PK
2 (PFO1/4)
M 150kgf/cm
(PFO1/2)
16ccr A4 T1 T2
(PFO3/8) (PFO1/4)
90bar (PFO3/8)
0.5" BRAKE & PILOT & FAN MOTOR

SUPPLY VALVE - (2)
(6)
APS0410L
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, gear pump. The pump is
attached to the end of steering pump and common suction port as steer pump.

Page 4
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 5
Mega 250-V
BRAKE & PILOT & FAN MOTOR

SUPPLY VALVE - (2)
AOS0190L
Figure 3 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 6
On the fan drive motor, at engine speed of 1,650
FAN RPM
rpm and above 1,650 rpm, the relief valve on the
fan drive pump opens to dump excess flow back
1,400
to hydraulic tank and thus the fan motor speed const
will constantly be 1,400 rpm. At low idle engine
speed (between 970 and 1,650 rpm), the fan
speed will be approximately between 830 and
830
1,400 rpm.
Fan speed can be changed by adjusting the
relief valve on the fan drive pump.
970 1,650 2,350
E/G RPM BAS0050L
Figure 4

Page 7
PARTS LIST
2
3
4
5
7
1 6
7
5
10
9
8
4
3
2
13
14
12
16
AJS0780L
Figure 5
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 8
SPECIFICATIONS
Specification
Item
Fan Motor Displacement 16 cc (0.97 in3) 23 cc (1.40 in3)
Relief Valve Setting 90 ±5 kg/cm2 (1,305 ±70 psi) 105 ±5 kg/cm2 (1,522 ±70 psi)
∆ p/1 turn
16.5 kg/cm2 (235 psi) 16.5 kg/cm2 (235 psi)
Maker (Model) HALDEX (WM9A1-16C) HALDEX (WM9A1-23C)
Fan Fan Size ∅ 660.4 mm (26 in) ∅ 712 mm (28 in)
Type Sucker, plastic -7 driven by hydraulic motor
Fan rpm 1,300 rpm @ 90 ±5 kg/cm2 1,400 rpm @ 105 ±5 kg/cm2
(at motor relief ∆ p) (1,305 ±70 psi)) (1,522 ±70 psi))
Fan Drive Pump 14 cc 19.8 cc
(0.85 in3) (1.20 in3)

Page 9
Problem Possible Cause Remedy
Pump does note develop full System relief valve set too low or check system relief valve for
pressure. leaking proper setting
Oil viscosity too low. Change to proper viscosity oil.
Pump is worn out. Repair or replace pump.
Pump will not pump oil. Reservoir low or empty. Fill reservoir to proper level.
Suction strainer clogged. Clean suction strainer.
Noisy pump caused by Oil to thick. change to proper viscosity.

cavitation.
Oil filter plugged. Clean filters.
Suction line p[lugged or to small. clean line and check for proper
size.
Oil heating. Oil supply low. Fill reservoir to proper level.
Contaminated oil. drain reservoir and refill with

clean oil.
setting of relief valve too high or to Set to correct pressure.
low.
Oil viscosity too low. Drain reservoir and fill with proper
viscosity.
Foaming oil. Low oil level. Fill reservoir to proper level.
Air leaking into suction line. Tighten fittings, check condition of

line.
Wrong kind of oil. Drain reservoir, fill with
nonfoaming oil.
Shaft seal leaking. Worn shaft seal. Replace shaft seal.
Worn shaft in shaft area. Replace drive shaft and seal.
TOOLS REQUIRED
Metric Socket Set
Internal Snap Ring Pliers
Shaft Seal Sleeve
Torque Wrench - 50 kg•m (100 ft lb) capacity

Page 10
DISASSEMBLY
NOTE: The following general instructions also apply to multiple section gear pumps, the only extra
parts are the coupling between the drive shafts and the center distance plate which
divides the two pump sections. This repair procedure also applies to the "W" series Gear
Motors.
1. It is very important to work in a clean work area when repairing hydraulic products. Plug ports and
wash exterior of pump with a proper cleaning solvent before continuing.
2. Remove port plugs and drain oil from pump.
3. Use a permanent marker pen to mark a
line across mounting flange, gear housing
and end cover. This will assure proper
reassembly and rotation of pump.
4. Remove key from drive shaft if applicable.
Figure 6
5. Clamp mounting flange in a protected jaw
vise with pump shaft facing down.
6. Loosen four metric hex head bolts.
7. Remove pump from vise and place on
clean work bench, remove four hex head
bolts and spacers if applicable.
Figure 7
8. Lift and remove end cover.
Figure 8

Page 11
9. Carefully remove gear housing and place
on work bench. Make sure rear bearing
block remains on drive and idler shafts.
Figure 9
10. Remove rear bearing block from drive and
idler shafts.
Figure 10
11. Remove idler shaft from bearing block.
Figure 11
12. Remove drive shaft from mounting flange.
There is no need to protect shaft seal
since it will be replaced as a new item.
Figure 12

Page 12
13. Remove front bearing block.
Figure 13
14. Turn mounting flange over, with shaft seal
up, and remove retaining ring with proper
snap ring pliers.
Figure 14
15. Remove oil seal from mounting flange, be
careful not to mar or scratch seal bore.
16. Remove dowel pins from gear housing. Do
not lose pins.
Figure 15
17. Remove seals from both bearing blocks
and discard.
Figure 16

Page 13
INSPECT PARTS FOR WEAR
1. Clean and dry all parts thoroughly before
inspection. It is not necessary to inspect
seals since they will be replaced with new
items.
2. Check drive shaft spline for twisted or
broken teeth check keyed drive shaft for
broken or chipped key way. No marks or
grooves on shaft in seal area, some
discoloration of shaft is allowable.
3. Inspect both drive gear shaft and idler gear
shafts at bearing points and seal area for
rough surfaces and excessive wear.
Figure 17
4. Inspect gear face for scoring or excessive
wear. If face edge of gear teeth are sharp,
they will mill into bearing blocks. If wear
has occurred, the parts are unusable.
Figure 18
5. Inspect bearing blocks for excessive wear
or scoring on surfaces which are in contact
with gears. Also inspect bearings for
excessive wear or scoring.
6. Inspect area inside gear housing. It is
normal for surface inside gear housing to
show a clean "wipe" on inside surface on
intake side. There should not be excessive
wear or deep scratches and gouges.
Figure 19

Page 14
GENERAL INFORMATION
It is important that the relationship of the mounting flange, bearing blocks and gear housing is correct.
Failure to properly assemble this pump will result with little or no flow at rated pressure.
REVERSE SHAFT ROTATION OF PUMP

NOTE: This pump is not bi-rotational, if the staff rotation must be changed the following procedure
must be followed.
Reversing the shaft rotation of the "W" series gear pump may be accomplished by rotating, as a group, the
two bearing blocks and the gear housing 180ø in relationship to the remaining parts of the pump. This
procedure will place the pressure port on the opposite side of the pump from its original position.

Page 15
REASSEMBLY
NOTE: New seals should be installed
upon reassembly of pump or
motor. Refer to page 8 for the
necessary kit part numbers for
the W-600, W-900 and W1500
pumps and motors.
1. Install new shaft seal in mounting flange
with part number side facing outboard.
Press seal into seal bore until seal reaches
bottom of bore. Uniform pressure must be
used to prevent misalignment or damage
to seal.
Figure 20
2. Install retaining ring in groove in seal bore
of mounting flange.
Figure 21
3. Place front and back bearing blocks on a
clean surface with E-seal grooves facing
up. Apply a light coating of petroleum jelly
in grooves. Also coat E-seal and backup
with petroleum jelly, this will help keep
seals in place during reassembly.
Figure 22

Page 16
4. Place E-seals, flat side outward, into
grooves in both bearing blocks. Follow by
carefully placing backup ring, flat side
outward, in groove made by E-seal and
groove in bearing block. (Note: In the
W900 series pump, in center of backup
ring and E-seal there is a notch, make sure
that these notches line up so backup ring
will set flush with E-seal). The backup ring
in the W1500 pump is symmetrical.
5. Place mounting flange, with shaft seal side
down, on a clean flat surface.
6. Apply a light coating of petroleum jelly to Figure 23
exposed face of front bearing block.
7. Insert drive end of drive shaft through

bearing block with seal side down, and
open side of E-seal pointing to intake side
of pump.
Figure 24
8. Install seal sleeve over drive shaft and
carefully slide drive shaft through shaft
seal. Remove seal sleeve from shaft.
9. Install idler gear shaft in remaining position
in bearing block. Apply a light coat of clean
oil to face of drive and idler gears.
Figure 25

Page 17
10. Pick up rear bearing block, with seal side
up and with open end of E-seal facing
intake side of pump, place over drive and
idler gear shafts.
11. Install two dowel pins in holes in mounting
flange or two long dowel pins through gear
housing if pump is a multiple section
pump.
Figure 26
12. To install O-rings in gear housing, apply a
light coating of petroleum jelly in grooves
on both sides of gear housing. Also coat
new O-rings and install them in grooves.
Figure 27
13. Gently slide gear housing over rear
bearing block assembly, slide housing
down until housing engages dowel pins.
Press firmly in place with hands, do not
force or use any tool. Check to make sure
intake port in housing is on same side as
open end of E-seal and that marked lines
on mounting flange and gear housing are
in alignment.
14. The surface of rear bearing block should
be slightly below face of gear housing. If
bearing block sits higher then rear face of
gear housing then E-seal or O-ring have Figure 28
shifted out of groove. If this is the case,
remove gear housing and check for proper
seal installation.

Page 18
15. Install two remaining dowel pins in rear of
gear housing, if applicable, and place end
cover over back of pump.
Figure 29
16. Install four spacers, if applicable, and hex
head bolts through bolt holes in end cover,
hand tighten.
Figure 30
17. Place mounting flange of pump back in
protected jawed vise and alternately
torque bolts to torque specifications in
torque chart on page 8. All torque figures
are for "dry torque" bolts.
18. Remove pump from vise.
19. Place a small amount of clean oil in inlet of
pump and rotate drive shaft away from
inlet one revolution. If drive shaft binds,
disassemble pump and check for
assembly problems, then reassemble
pump.
Figure 31

Page 19
Page 20
S0708510C
1MAIN PUMP
(PARKER)
CAUTION!
MAIN PUMP (PARKER)S0708510C


December 2001
Main Pump (Parker) S0708510C

Page 1
TABLE OF CONTENTS
Principals of Working .............................................................................. 3
Parts List ................................................................................................. 4
S0708510C Main Pump (Parker)

Page 2
GENERAL DESCRIPTION
PRINCIPALS OF WORKING
The hydraulic pump is a triple vane pump which contains three pumping sections. The first pumping
section supplies oil for the front attachment. The second pumping section supplies oil for the steering
cylinders. Surplus oil which is not necessary for the steering function is directed into control valve to join
the first pump’s oil by the priority valve. Pilot pump oil is used for brake and pilot line operation.
Figure 1
1. First pumping section (Figure 1).
Pumping displacement: 44.0 cc/rev. (2.69 in3/rev.).

Front attachment.
2. The second pumping section (Figure 1).
Pumping volume: 41.0 cc/rev (2.50 in3/rev.).

Steering and Front attachment.
3. Pilot pumping section (Figure 1).
Pumping volume:
• Standard: 10.0 cc/rev. (0.61 in3/rev.)
• Low noise option kit: 14.0 cc/rev. (0.85 in3/rev.)

Brake and pilot line.

Page 3
PARTS LIST
Standard
Figure 2

Page 4
Reference Reference
Number Number
1 Gear 20 Coupling, Splined
2 Gear 21 Body
3 Coupling (Splined) 22 Cover
4 Flange (Mounting) 23 Bolt, M12 x 120
5 Bushing 24 Plate, Adapter
6 Seal (Shaft) 25 Pin, Dowel
7 Retaining Ring 26 Bushing
8 O-ring 27 Bushing
9 Plate 28 Gear
10 Seal (Element) 29 Gear
11 Seal (Energizer) 30 Body
12 Body 31 Cover
14 O-ring 32 Bolt
15 Washer 34 Ring, Backup
16 Screw, Socket Set - M12 35 Seal
17 Nut, M12 36 O-ring
18 Gear 37 Washer, Lock
19 Gear

Page 5
Low Noise Option Kit
APS0500L
Figure 3

Page 6
Reference Reference
Number Number
1 Gear 20 Coupling, Splined
2 Gear 21 Body
3 Connector (Splined) 22 Cover
4 Flange (Mounting) 23 Bolt, M12 x 120
5 Bushing 24 Plate, Adapter
6 Seal (Shaft) 25 Pin, Dowel
7 Retaining Ring 26 Bushing
8 O-ring 27 Bushing
9 Plate 28 Gear
10 Seal (Element) 29 Gear
11 Seal (Energizer) 30 Body
12 Body 31 Cover
14 O-ring 32 Bolt
15 Washer 34 Ring, Backup
16 Screw, Socket Set - M12 35 Seal
17 Nut, M12 36 O-ring
18 Gear 37 Washer, Lock
19 Gear

Page 7
Page 8
S0709260C
1BRAKE PEDAL
VALVE
CAUTION!
BRAKE PEDAL VALVES0709260C


December 2002
Brake Pedal Valve S0709260C

Page 1
TABLE OF CONTENTS
Specification............................................................................................ 4
Brake System ................................................................................................. 5
Brake and pilot supply valve.................................................................... 5
Brake, pilot and fan motor supply valve................................................... 6
Brake, Pilot and Fan Motor Supply Valve ....................................................... 7
Standard.................................................................................................. 7
Specifications .......................................................................................... 8
Option...................................................................................................... 9
Specifications ........................................................................................ 10
S0709260C 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 45 ±3 bars (652
±44 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 45.0 ±3 kg/cm2

(640 ±43 psi)
18 ±2 kg
Pedal Force
(40 ±4 lb)
Operating Angle 18 ±2°

Page 4
BRAKE SYSTEM
Multiple wet disc 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 discs, 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 cab is
selected, this will cut off 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.
BRAKE AND PILOT SUPPLY VALVE
(3) (4) (1)

(7)
(6)
FRONT AXLE CLOSES 3 B

STOP
(2)
BR1 BR2
L.H Brake valve REAR AXLE
OPENS 25 B
T/M DISCONNECT
45B
P1 T1 P2 T2
0.5 BAR (5)
(8)
(9)
1.5 BAR (12)
R.H Brake pedal
* TUV Only
40B 40B 40B
0.7L 0.7L 0.7L

65bar
LPWS A1 P1 P2 A2 A3
(PFO1/4) (PFO3/8) (PFO3/8) (PFO3/8) (PFO3/8) (PFO3/8)
TANK
C1 C2
ULTP (13)
(PFO1/4)
(15) C3
(10) P
(PFO1/2)
C10
BRAKE/PILOT 10 micron 60B
PUMP C4 PARK PKWS
10 cm3 /rev (PFO3/8)
C11 (14) (PFO1/4)
STEER PUMP
41 cm3 /rev
C6 (11)
H.P FILTER C9 45bar
LOADER PUMP
44 cm3 /rev C5 to PILOT 20 l/min
(PFO3/8)
at 28 bar
28B
PUMP C7
C8
TP
T1 (PFO1/4)
(PFO1/2) (PFO3/8) (PFO1/4) (PFO1/4)
A4 15B T3 T2
BRAKE & PILOT SUPPLY VALVE 0.32L
APS0240L
Figure 3 Brake Hydraulic Circuit (Tier I)

Page 5
BRAKE, PILOT AND FAN MOTOR SUPPLY VALVE
(3) (4)
(7)
(6)
(9)
CLOSES 3 B
STOP
(2)
FRONT AXLE
BR1 BR2
L.H Brake valve REAR AXLE
OPENS 25 B
T/M DISCONNECT
(1)
(5) 45B
P1 T1 P2 T2
(8)
(12)
0.5 BAR R.H Brake pedal
40B 65bar 40B 15B
0.7L (PFO1/4) (PFO3/8) (PFO3/8) 0.7L 0.32L

(PFO3/8)
1.5 BAR (PFO3/8) A1 LPWS P1 P2 A2

A3 TP1
(PFO3/8)
C3-1 C3-2 (11)
∅1.2 C2 C3-3
TANK TP2 (PFO3/8)
(PFO1/4)
to PILOT
2
FO 28kgf/cm
(PFO1/2) C4
2 C6
C1 60kgf/cm SAFETY
120kgf/cm2
FI C3-4 PA
(PFO3/8)
(PFO1/2)
Fan motor(Opt.) C7 PARK
0.75" LPWS 45bar
OIL COOLER 100 L/MIN C5
(10) 90bar M PK
150kgf/cm2
10 micron 16ccr (PFO1/2) (PFO1/4)
BRAKE/PILOT
BRAKE & PILOT & FAN MOTOR A4 (PFO3/8)
T1
(PFO3/8)
T2
PUMP 40B (PFO1/4)
(14)
14 cm3 /rev SUPPLY V/V(Opt.) 0.7L * TUV Only (13)
STEER PUMP 0.5"
41 cm3 /rev
(15)
LOADER PUMP
44 cm3 /rev
APS0250L
Figure 4 Brake Hydraulic Circuit
Reference Reference
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 6
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.
STANDARD
PA
C7
C6 T3
C2
7 6
2 4 5
P2 T1 C9
1
PK
A3
A2
UL LP C4
C5
A1
A4 TP
C8
P NO.
P1 C3 LOT NO.
2 8 9 3 7 6
C1
T2
C11
PI
C10
APS0260L
Figure 5 Brake and Pilot Supply Valve
Reference Reference
Number Number
1 Body (79*127*180) 6 Solenoid Valve (C8,C9)
2 Check Valve (C1,C2) 7 Coil (C8,C9)
3 Check Valve (C3,C4,C5) 8 Priority Valve (C10)
4 Unloading Valve (C6) 9 Reducing Valve (C11)
5 Relief Valve (C7)

Page 7
LP A1 P1 P2 A2 A3
C1 C2
UL
C10 C3 C4
P PA
C11
C6
C9 PK
C5
PI
C8
C7
T1 TP
A4 T3 T2
APS0270L
Figure 6 Hydraulic Circuit
SPECIFICATIONS
Item Specifications
Max. Rated Pressure 210 kg/cm2

(3,000 psi)
30 lpm
Rated Flow
(7.92 gpm)
C6 120 - 140 ±2 kg/cm2

(1,710 - 1,990 ±28 psi)
Setting Pressure C7 28 - 31 kg/cm2

(398 - 441 psi)
C11 60 ±2 kg/cm2
(850 ±28 psi)
P, T1 PF 1/2 O-ring
UL, TP, T2, T3 PF 1/4 O-ring
Port Size
LP. PK ∅ 30 PF 1/4 BSP
All other ports PF 3/8 O-ring

Page 8
OPTION
A1
PI
C7
A3
1 8 6 5
3
4
P1
LP
T1 C4
3
TP1
C2
C3-3
TP2
VDL 24 VDC
KOREA CORPORATION
7
C1
C3-1
FO
VDL 24 VDC
KOREA CORPORATION
C6
C3-4
PA
FI
C5
P2
M A4
T2
C3-2
A2 PK
APS0280L
Figure 7 Low Noise Kit (Brake and Fan Motor Supply Valve)
Reference Reference
Number Number
1 Body (200*127*79) 5 Solenoid (C4, C5)
2 Sequence (C1) 6 Coil (C4,C5)
3 Reducing (C2) 7 Reducing (C6)
4 Check (C3) 8 Relief (C7)

Page 9
A1 LP P1 P2 A2 A3 TP1
C3-1 C3-2
ø1.2 C2 C3-3
TP2 PI
28
FO kgf/cm 2 C4
60 kgf/cm 2 C6
SAFETY
2 C3-4
120 kgf/cm
PA
C1
FI
C7 C5 PK
M 150 kgf/cm 2
A4 T1 T2
APS0290L
Figure 8 Hydraulic Circuit
SPECIFICATIONS
Item Specifications
Max. Rated Pressure 210 kg/cm2

(3,000 psi)
30 lpm
Rated Flow
(7.92 gpm)
120 ±2 kg/cm2 (1,710 ±28 psi)
C1
(Input P:150 kg/cm2 (2,130 psi),
Q:30 lpm (7.92 gpm))
28 ±2 kg/cm2 (400 ±28 psi)
C2
Q:20 lpm (5.28 gpm))
Setting Pressure C3 Cracking Pressure 2.4 kg/cm2 (34 psi)
60 ±2 kg/cm2 (850 ±28 psi)
C6
Q:20 lpm (5.28 gpm))
150 ±2 kg/cm2 (2.130 ±28 psi)
C7
Q:30 lpm (7.92 gpm))

Page 10
Item Specifications
F0, F1, M PF 1/2 O-ring
TP1, TP2, T2 PF 1/4 O-ring
Port Size
LP. LK ∅ 30 PF 1/4 BSP
All other ports PF 3/8 O-ring

Page 11
Page 12
S0709457C
R1
1MAIN CONTROL VALVE

(HUSCO)
CAUTION!
MAIN CONTROL VALVE (HUSCO)S0709457C


December 2002
Main Control Valve (Husco) S0709457C

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
S0709457C Main Control Valve (Husco)

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.
9/16 - 18 UNF O-ring Ports (ai, a2, a3)
(3) (2) (2)
3A 3B
a3 b3
2A 2B
a2 b2
1A 1B
a1 b1
P
R (1) 9/16 - 18 UNF O-ring Ports (ai, a2, a3)
APS0300L
Figure 1

Page 3
(1)
a2 a1 a3
P b2 b1 b3
195 BAR
R (2-SPOOL,STD.)
CONTROL V/V
BUCKET
230 B
(DUMP) (CROWD) (2)

1B
BUCKET CYL. 1A
BOOM
(3)
(LOWER/FLOAT)
2B
BOOM CYL. (RAISE) 2A
OPTION
230 B
OPTION DEVICE(INC. PIPING)
3B
3A
(3-SPOOL, OPTION)
LOG FORK SYSTEM
APS0310L
Figure 2 Control valve hydraulic circuit
Reference Reference
Number Number
a3 Option Valve Port 3B Option Cylinder Port
b2 Bucket Crowd Valve Port (to Option Cylinder Tube)
a1 Boom Down Valve Port / 1B Bucket Dump Port
Float Valve Port (to Bucket Cylinder Rod)
b3 Option Valve Port 2A Boom Up Port
(to Boom Cylinder Tube)
a2 Bucket Dump Valve Port
P Pump Port
b1 Boom Up Valve Port
R Tank Port
1A Bucket Crowd Port
(to Bucket Cylinder Tube) 3A Option Cylinder Port
(to Option Cylinder Rod)
(1) Main Relief Valve
(2) Overload Relief Valve
2B Boom Lower Port /
Float Valve Port (3) Anticavitation Check Valve
(to Boom Cylinder Rod)

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

Name AX26587-6 AX26587-2
Type Pilot Control with Float Spool
Spool Diameter ∅ 19.05 mm (0.750 in)
Spool Arrangement Bucket - Boom Bucket - Boom - Aux.
Main relief pressure 200 kg/cm @ 180 lpm (1,450 ft lb @ 47.5 gpm)
2
Overload relief pressure 230 kg/cm2 @ 20 lpm (1,660 ft lb @ 5.3 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 By-pass Passage
3 Port B1
When the bucket spool moves in the direction indicated by the arrow
The neutral oil passage is closed by the spool and the pressure oil pushes open the load check valve to
flow to the cylinder port (A1) from which it is directed into the bucket cylinder rod side.
The oil discharged from the bucket cylinder tail side flows through the cylinder port (B1) to the low pressure
oil passage.

Page 6
BOOM SPOOL OPERATION
Boom Float
Figure 4 OPERATION IN BOOM FLOAT
Reference Reference
Number Number
1 Port A2 4 Center By-pass Passage
2 Port B2 5 Tank Passage
3 Tank Passage
When the control lever is further pushed down from the “Down” position to the “Float” position, the boom
spool moves as indicated in the illustration.
Due to this motion the neutral passage is opened. The pressure oil flows as if in neutral position. The
cylinder ports (A2) and (B2) are connected to the low-pressure oil passage. As a result, the booms float
over the ground surface according to its irregularities. The oil discharged from the boom cylinder rod side is
sent to the tail side and the oil forced out from its tail side is sent to the rod side respectively through the
low-pressure oil passage in the control valve.
RELIEF VALVE
Main Relief Valve

The main relief valve is located 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 located 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
S0709478C
R1
1PILOT CONTROL
VALVE
CAUTION!
PILOT CONTROL VALVES0709478C


December 2002
Pilot Control Valve S0709478C

Page 1
TABLE OF CONTENTS
Pilot Valve Operation............................................................................... 3
Standard.................................................................................................. 4
Option...................................................................................................... 6
Pilot System ................................................................................................... 8
Mega 200-V............................................................................................. 9
Mega 250-V........................................................................................... 10
S0709478C Pilot Control Valve

Page 2
GENERAL DESCRIPTION
When no force is applied to the lever (1, Figure 1), the return spring (4) positions the lever at the
"NEUTRAL" position. When the lever is moved, plunger (5) is moved, which pushes down the return spring
(4). At the same time, spool (2) is moved by spring (3). When spool (2) moves down, a groove (6) in the
spool opens the pilot pressure line to the line that the lever controls. This allows the pilot pressure to flow to
the boom or bucket control valve, where the pilot pressure operates the control valve. When the lever is
completely moved in one direction, the solenoid (7) energizes the electromagnet (8) and holds the lever in
the fully moved position.
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
STANDARD
33
29 34
32 30
25
31
27
20
26
28 24
17 23
16
22
15
21
19
9 18
5 12
4 13
8
11
7
22
6
3 20
2
1 35
42
41 40 39 38 36 37 38 39
BAS0130L
Figure 1

Page 4
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 Assembly
13 Push Rod 34 Spring Pin
14 Plate 35 Plug
15 Rod Stopper 36 Housing
16 Du-bushing 37 Holder Rear
17 Rod 38 Terminal
18 Magnet 39 Seal Wire
19 Plate 40 Housing
20 Joint Assembly 41 Holder Rear
21 Joint Assembly 42 Clip Band

Page 5
OPTION
4
5
11
10
8
12
13
14
15
16
15
17
BAS0200S
Figure 2

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

Page 7
PILOT SYSTEM
The pilot system uses low pressure oil to operate the main control valves. The main components of the
pilot system are pump (1), pressure reducing valve (3), accumulator (4), pilot cutoff valve (5) and pilot
valves (6 and 7).
With the engine running, oil flows from hydraulic tank to pilot pump (1) The oil flows from the pump through
pressure reducing valve (3) to pilot cutoff valve (5). The pressure reducing valve maintains pilot system
pressure at 28 kg/cm2 (450 psi).
From the pilot cutoff valve the oil flows into the pilot control valves. Pilot valve (6) is a closed center valve.
The oil cannot flow through the valve when it is in the HOLD position because it is a closed center valve.
When the control lever is moved to the DUMP position, oil flows through oil lines to the ends of the bucket
spool of main control valve (8). This causes the main control valve spool to move. Movement of the spool
opens passages for attachment pressure oil to flow to the rod end of the bucket cylinder (9).
Spool movement also opens a passage for return oil from the head end of the bucket cylinder to flow back
to hydraulic tank. Attachment pressure oil acts on the rod end of the bucket cylinder and, because the head
end of the cylinder is now vented to tank, the bucket will dump.
When the control lever is moved to the CROWD position, oil flows through oil lines to the ends of the bucket
spool of main control valve (8). This causes the main control valve spool to move in the opposite direction.
Movement of the spool in this direction opens passages for pressure oil to flow to the head end of the tilt
cylinder. Spool movement also opens a passage for return oil from the rod end of the tilt cylinder to flow
back to the hydraulic tank. Attachment pressure oil acts on head end of the tilt cylinder and because the
rod end of the cylinder is now vented to tank, the bucket will crowd.

Page 8
MEGA 200-V
(7) Kick-down Horn
OPT. OPT.
DUMP CROWD AUTO RETURN RAISE LOWER
TO DIG
D.C D.R D.F D.R D.F
T
P
2 4 3 1 5 6
(3) (4)
0.5 BAR
* TUV Only
40B 40B 40B
0.7L 0.7L 0.7L
LPWS A1 P1 P2 A2 A3
1.5 BAR (PFO1/4) (PFO3/8) (PFO3/8) (PFO3/8) (PFO3/8) (PFO3/8)
C1 C2
ULTP Horn Kick-down
(PFO1/4)
(6)
C3
P
OIL TANK (PFO1/2)
C10
60B
TO DIG
C4 PARK D.C D.R D.F
(PFO3/8)
C11
C6 PKWS
C9 (PFO1/4)
T
C5 PILOT P 2 4 3 1
(PFO3/8)
OIL COOLER (5)
100 L/MIN
28B
C7 TP
T1 C8
(1) (PFO1/4)
(PFO3/8) (PFO3/8) (PFO1/4) (PFO1/4)

10 micron A4 15B T3 T2
3
14 cm/rev BRAKE & PILOT SUPPLY VALVE 0.32L
3
41 cm/rev (2)
P1 P3 200 l/min at 6.9 B at 2,400 rpm
3
44 cm/rev 1.25 1.25"
C1 TPM 320 l/min max
<
0.25"
200 BAR
W22D5F6-25
EF (8)
0.75 (2-SPOOL,STD.)
AUTO RETURN TO DIG
R2
(9) Æ140xÆ75x490
BUCHET CYLINDER BUCKET
1.5
230 B
HT
<
<
C2 C3 0.75
(DUMP) (CROWD)
C R1
1B
0.75" 2.5 B
1.25
1.5 BOOM RAISE
(10) KICK-OUT
1A
RESTRICTION VALVE
BOOM
(LOWER/PLOT)
STEERING LINE
Æ120xÆ70X780 2B
EF CF
BOOM CYLINDER (RAISE) 2A
LS
OPTION
OPTION DEVI CE
230 B
P 3B
PRIORITY VALVE 3A W22D5F6+D5-16

* (3-SPOOL, OPTION)
LOG FORK SYSTEM(OPT.)
APS0320L
Figure 3
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 9
MEGA 250-V
UNLOADER VALVE
STEERING LINE
PRIORITY VALVE
AOS0580L
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 10
S0709650
R1
1PRIORITY VALVE
CAUTION!
PRIORITY VALVE S0709650


December 2002
Priority Valve S0709650

Page 1
TABLE OF CONTENTS
Parts List ................................................................................................. 5
Specifications .......................................................................................... 6
Special Tools .................................................................................................. 6
Disassembly ................................................................................................... 6
Cleaning and Inspection (Wear Limits and Tolerances) ................................. 8
Reassembly.................................................................................................... 9
S0709650 Priority Valve

Page 2
GENERAL DESCRIPTION
THEORY OF OPERATION
Figure 1
Oil output from the steering pump flows through the priority valve to both the loader supply line and to the
steering circuit. During operation of the steering wheel, the priority valve shifts and supplies pump flow only
to the steering circuit. This results in smooth operation of the steering circuit.
At rest, the spool (1, Figure 2) maintains an open path between inlet port P and steering outlet port CF.
Port EF is kept closed by the force from spring (2). The spool (1) contains a drilled passage. The passage
is open to port CF and is also open to both ends of the spool. At the neutral position of the steering unit, oil
from port P flows through port CF and into the drilled passage in the spool. At this time, oil flowing out of
CF is blocked at the control spool of the steering unit. This raises the pressure in port CF. At this time, port
LS is open to the chamber on the far right side of the priority valve. Port LS is not open to the chamber on
the far left side of the valve. As oil flows through the drilled passage in the spool, pressure builds on the left
side of the spool but pressure is low on the right side of the spool because oil can drain into port LS. When
oil pressure on the left side of the spool rises above the force of spring (2, Figure 2), the spool (1) shifts the
right. This allows pump flow at port P to flow out both ports CF and EF. Now both the loader supply line and
the steering supply line are charged with flow from the steering pump. Whenever the steering wheel is
turned, the spool in the steering unit directs some oil flow back to port LS. This equalizes the oil pressure
on both ends of the spool (1). The spring now shifts the spool to the left. This closes off the passage from
port P to port EF. This makes all steering pump flow now available only to the steering circuit from port CF.

Page 3
Figure 2
Reference Reference
Number Number
1. Spool CF Steering Supply Port
2. Spring ED Loader Supply Port
P Pressure Port LS Pilot Port

Page 4
PARTS LIST
Figure 3
Reference Reference
Number Number
1 Plug 5 Spring
2 O-ring 6 Plug
3 Spool 7 Orifice
4 Housing

Page 5
SPECIFICATIONS
Priority Valve Specification

Mega 130 Mega 160
Mega 200-III
Mega 200-V
Mega 250-III
Mega 250-V
Model Danfoss OLS 120 Danfoss OLS 160 DYN
Control Pressure 7 kg/cm2 (100 psi) 7 kg/cm2 (100 psi)
Rated Flow 120 lpm (32 gpm) 160 lpm (42 gpm)
SPECIAL TOOLS
1. The following tools are necessary to repair
the priority valve. See Figure 4.
Open end wrench - 27 mm
Slip joint pliers
Nylon rod
Allen wrenches - 5 mm, 8 mm and 10 mm
Figure 4
DISASSEMBLY
1. Use open end wrench to loosen PP plug.
See Figure 5. Remove O-ring.
Figure 5

Page 6
2. Use open end wrench to loosen LS plug.

See Figure 6. Remove O-ring.
Figure 6
3. Remove spring. See Figure 7.
Figure 7
4. Use a nylon rod to push spool out of bore.
See Figure 8.
Figure 8
5. Use an 8 mm allen wrench to remove plug
from pressure relief valve. See Figure 9
Figure 9

Page 7
6. Use a 10 mm allen wrench to unscrew

pressure relief valve from its bore. See
Figure 10.
Figure 10
7. Hold pressure relief valve with a pliers and
use a 5 mm allen wrench to remove set
screw. See Figure 11.
Figure 11
8. The pressure relief valve is composed of a
valve housing, valve needle, spring and
set screw. See Figure 12.
Figure 12
CLEANING AND INSPECTION (WEAR LIMITS AND

TOLERANCES)
Clean all parts with a nonflammable, nontoxic solvent.
Carefully inspect all parts. Replace all worn or broken parts. Use only new O-rings to assemble the valve.
Cost all parts with oil before assembling them.

Page 8
REASSEMBLY
NOTE: The relief valve pressure can be changed by changing springs. The following table
displays the characteristics of the three springs available. See Figure 13.
Wire Coil Spring

Pressure
Diameter Diameter Height
in Bars
(A) (B) (C)
4.0 bar 2.5 mm 12.5 mm 50.0 mm
(58 psi) (0.0984") (0.4921") (1.9685")
7.0 bar 3.0 mm 12.5 mm 50.0 mm
(100 psi) (0.1181") (0.4921") (1.9685")
10.0 bar 3.2 mm 12.5 mm 50.0 mm
(145psi) (0.1260") (0.4921") (1.9685")
Figure 13
1. Figure 14, shows PP plug and spool.
Figure 14

Page 9
2. Figure 16, shows outer spool and outer PP

plug. Plug is installed with spool.
Figure 15
3. Install spool into bore. See Figure 16. Use
a nylon rod to position spool in neutral
position.
Figure 16
4. Install spring and LS plug into bore. See
Figure 17. Use a new O-ring on plug.
Figure 17
5. Use a 27 mm wrench to tighten PP plug
and LS plug to 6 kg•m (44 ft lb). See
Figure 18.
Figure 18

Page 10
6. Assemble valve needle, spring and set

screw into pressure relief valve housing.
See Figure 19. Thread pressure relief
valve into body of priority valve and tighten
it. See Figure 19.
Figure 19
7. Install plug into pressure relief valve bore.
Tighten plug to 5 kg•m (36 ft lb). See
Figure 20.
Figure 20

Page 11

Page 12
S0709705C
1POWER STEERING
UNIT
CAUTION!
POWER STEERING UNITS0709705C


December 2002
Power Steering Unit S0709705C

Page 1
TABLE OF CONTENTS
Power Steering System........................................................................... 3
Gerotor Operation ................................................................................... 6
Cushion Valve Operation......................................................................... 7
Parts List ................................................................................................. 8
Specifications .......................................................................................... 9
Special Tools ................................................................................................ 10
Disassembly ................................................................................................. 13
Cleaning and Inspection............................................................................... 17
Reassembly.................................................................................................. 18
Installation .................................................................................................... 29
S0709705C 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 3, 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
Mega 200-V
0.4 BAR OIL COOLER
P1 P3
1.25 1.25"
1.5 BAR C1 TPM
<
0.25"
100 L/MIN
EF L R
0.75
OIL TANK
R2
1.5
HT 175 BAR
(1)
<
<
(5) C2 C3 0.75
3
14 cm/rev C R1 T LS
0.75" 1.25 P
1.5 2.5 B
3
41 cm/rev RESTRICTION VALVE
LS
3
44 cm/rev 230 BAR 230 BAR
(6) <
EMR. STEER
CHECK V/V
5Bar EF CF
∅70x ∅35x396
EMR. STEER (3)
PRESSURE SENCER
LS
< <
VKLU2B
(4)
10ccr (2)
24v DC MOTER PUMP

for EMERG. STEER
ELECTRIC EMR. STEER SYSTEM(OPT.)

APS0330L
Figure 2 Steering Circuit
Reference Reference
Number Number
1 Steering Unit 4 Cushion Valve
2 Priority Valve 5 Steer Pump
3 Steering Cylinder 6 Supply Line to Main Control
Valve

Page 4
Mega250-V
AOS0590L
Figure 3 Steering Circuit
Reference Reference
Number Number
1 Steering Unit 4 Cushion Valve
2 Priority Valve 5 Steer Pump
3 Steering Cylinder 6 Supply Line to Main Control
Valve

Page 5
Neutral Operation
With the steering wheel in the neutral position (wheels turned neither right nor left), the spool (2, Figure 4)
and sleeve (1) are stationary at the position where the center pin (6) becomes centered in the spool space
by the centering springs (3). Oil flow through the load sensing line (LS), port L, port R, and port T are
bypassed to the tank line and the oil supply (P) is blocked by the directional spool in the steering unit (1,
Figure 3). Even if an external force is applied to the steering cylinder, the steering unit is protected because
the oil path is blocked by the directional spool.
Reference
Description
Number
1 Sleeve
2 Spool
3 Centering Spring
4 Spool
5 Sleeve
6 Center Pin
7 Drive shaft
Figure 4
Right Turn
The spool (2, Figure 4) is engaged with the spline of the steering shaft. When the steering wheel is turned
to the right, the spool turns. The sleeve (1) is connected to the spool (2) by centering springs (3). When
spool turns, the sleeve turns. The sleeve turning angle is about 10° less than the spool turning angle. This
allows the longitudinal slots in the spool to align with the ports in the sleeve. Oil from port P on the steering
unit (1, Figure 3) travels through the control spool and is directed to port R which directs the oil to the
steering cylinders (3, Figure 3). The amount of flow metered to port R is controlled by the amount of
steering wheel rotation. Excess oil flow through port P that is not metered to port R, is directed by the spool
to port T and is then directed through the il cooler and into the tank.
Left Turn
The spool (2, Figure 4) is engaged with the spline of the steering shaft. When the steering wheel is
connected to the spool (2) by centering springs (3). When the spool turns, the sleeve turns. The sleeve
turning angle is about 10° less than the spool turning angle. This allows the longitudinal slots in the spool
to align with the ports in the sleeve. When the steering wheel is turned to the left, oil from port P on the
steering unit (1, Figure 3) is directed through the control spool in the steering unit, out port L and into the
steering cylinders (3, Figure 3). The amount of oil flow metered to port L is controlled by the amount of
steering wheel rotation. Excess oil flow through port P that is not metered to port L, is directed by the spool
to port T and is then directed through the oil cooler and into the tank.
GEROTOR OPERATION
If the engine or pump is not operating, the steering unit (1, Figure 3) works as a manual pump when the
steering wheel is turned. The gerotor will work when the input torque to the steering wheel is less than 12
kg•m (87 ft lb). If the necessary input torque is greater than this, the gerotor will not function. When the
steering wheel is turned, the gerotor creates a vacuum that draws oil from port T. See Figure 3. The
gerotor pumps this oil through the control spool and into the steering cylinders. Return oil flows back to the
spool and is used to lubricate the steering unit (1, Figure 3). The return oil then flows back into the tank line
and is recirculated back to the gerotor and the steering cylinders.

Page 6
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 the port R, it pushes the spring (3) and opens the poppet (2). This
operation directs the high pressure oil to port L through the center hole in spool (12) and the check valve
poppet in port L part. At the same time, oil reaches the pressure room of the plug through orifice (8). This
operation closes the passage from port R to port L. This releases the pressure and prevents machine
shock by intercepting oil. If a low pressure oil flows, the cushion operation is not necessary. It is due to the
speed of closing spool (12) is faster than the speed of opening poppet (2), therefore, the cushion valve
does not work.
Figure 5

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

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
Type Load Sensing, Dynamic Signal, Nonreaction
Gerotor
Displacement 630 cc/rev (38.44 in3/rev)
Rated Flow 80 liter/min (21.12 U.S. gal) 63 liter/min (16.63 U.S. gal)

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

Page 10
4. Torque wrench, 0 - 5 kg•m (0 - 35 ft lb).

See Figure 10. 13 mm socket. Ratchet
handle. 12 mm screwdriver. 6 mm
screwdriver. 2 mm screwdriver. Plastic
hammer.
Figure 10

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 11.
Figure 11
3. Remove end cover from unit. See Figure
12
Figure 12
4. Lift cylinder gear off unit. See Figure 13.
Remove two O-rings.
Figure 13

Page 13
5. Remove spacer bushing and spacer from

cylinder gear (If equipped). See Figure 14.
NOTE: Refer to parts manual for our
unit to determine if these parts
are installed.
Figure 14
6. Remove shaft from housing. See Figure
15.
Figure 15
7. Remove distributor plate from housing.
See Figure 16.
Figure 16
8. Remove O-ring from top of middle plate.
See Figure 17.
Figure 17

Page 14
9. Lift middle plate off housing. See Figure

18.
Figure 18
10. Remove O-ring from housing. See Figure
19.
Figure 19
11. Unscrew threaded bushing and remove it.
See Figure 20.
Figure 20
12. Remove cross pin. See Figure 21.
Figure 21

Page 15
13. Shake ball out of housing. See Figure 22.
Figure 22
14. Pull sleeve and spool out of housing. See
Figure 23.
Figure 23
15. Remove thrust bearing and thrust washers
from sleeve. See Figure 24. Remove
spacer ring. Be sure to remove spacer
ring. It can stick in sleeve.
Figure 24
16. Carefully slide control spool out of sleeve.
See Figure 25.
Figure 25

Page 16
17. Push neutral position springs out of groove

in spool. See Figure 26.
Figure 26
18. Remove dust seal from housing. See
Figure 27. Remove O-ring and backup ring
from inside housing.
Figure 27
19. Figure 28, shows all parts removed from
steering unit. Clean all parts before
assembly. Use only new O-rings and
seals.
Figure 28
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 29.

Springs must be positioned as shown in
Figure 30.
Figure 29
Figure 30
2. Position springs so that amount of spring
protruding out of spool is equal on both
sides. See Figure 31.
Figure 31

Page 18
3. Insert spool into sleeve. See Figure 32.

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 33.
Figure 32
Figure 33
4. Center springs in sleeve. See Figure 34.
Figure 34

Page 19
5. Install seal ring on sleeve. See Figure 35.

Burnish seal ring with a smooth object until
seal does not protrude past diameter of
sleeve.
Figure 35
6. Rotate seal ring. See Figure 36. It must
rotate freely without resistance.
Figure 36
7. Turn sleeve 180°. Install cross pin into
sleeve and spool. See Figure 37.
Figure 37

Page 20
8. Install two thrust washers and thrust

bearing over end of spool. See Figure 38.
The sequence of the parts installation is
shown in Figure 39.
Figure 38
Reference
Description
Number
1 Thrust Washer
2 Thrust Bearing
3 Thrust Washer
4 Spool
5 Sleeve
Figure 39
9. Oil O-ring and backup ring and then install
them on an O-ring assembly tool. See
Figure 40.
Figure 40

Page 21
10. Insert assembly tool down into bore of

steering unit. See Figure 41.
Figure 41
11. Use assembly tool to install O-ring and
backup ring into bore. See Figure 42.
Figure 42
12. Unbolt housing from stabilizing base. Hold
housing in a horizontal position. See
Figure 43. Insert sleeve and spool into
bore.
Figure 43

Page 22
13. The sleeve will push the O-ring and

backup ring into correct position. See
Figure 44.
Figure 44
14. Bolt housing back into stabilizing base.
See Figure 45.
Figure 45
15. Insert ball into hole. See Figure 46.
Figure 46

Page 23
16. Install threaded bushing into hole that ball

was placed into. See Figure 47. Lightly
tighten bushing. The top of the bushing
must be lower than the surface of housing.
Figure 47
17. Lubricate O-ring with 20 weight mineral
oil and install it in groove. See Figure 48.
Figure 48
18. Install middle plate onto housing. See
Figure 49. Be sure to properly align plate
holes with holes in housing.
Figure 49
19. Lubricate O-ring with 20 weight mineral oil
and install it in groove. See Figure 50.
Figure 50

Page 24
20. Install distributor plate. See Figure 51. Be

sure to properly align plate holes with
holes in middle plate.
Figure 51
21. Install shaft into bore of housing. See
Figure 52. Position slot in shaft to engage
cross pin.
Figure 52
22. Position rotor so that cross pin is between
two teeth as shown by position of
screwdriver. See Figure 53.
Figure 53

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 54.
Figure 54
24. Use a bolt to align holes in cylinder gear
with bolt holes in housing. See Figure 55.
Figure 55
25. Install spacer bushing. See Figure 56.
Remove bolt that was installed in previous
step (If equipped.).
OSPL 630:1 = 3.8 mm (0.1496 in) (15,
Figure 6)
OSPL 800 (16, Figure 6)
OSPL 1000 (16, Figure 6)
are installed.
Figure 56

Page 26
26. Use a screwdriver to install OSPL 800 and

1000 spacers (If equipped.). See Figure
57.
are installed.
Figure 57
27. Install end cover. See Figure 58.
Figure 58
28. Install a washer and roll pin into hole
shown in Figure 59.
Figure 59
29. Install six remaining bolts and tighten
them. See Figure 60. Cross tighten bolts
and roll pin to 48 Nm (35 ft lb).
Figure 60

Page 27
30. Turn steering unit over and work from

opposite side. Set dust seal in position on
housing. See Figure 61.
Figure 61
31. Use a seal driver and a plastic hammer to
install dust seal. See Figure 62.
Figure 62
32. Install plastic plugs to prevent dirt from
entering steering unit. See Figure 63.
Figure 63

Page 28
33. Figure 64, shows port identification for

steering unit.
L = Left pressure port.
R = Right pressure port
T = Tank port
P = Pressure from pump.
Figure 64
INSTALLATION
The following table shows torque specifications for hydraulic fittings used to install steering unit.
Maximum
Tightening Torque
kg•m (ft lb)
Type of 1/4 RG 1/2 RG
Screw Fitting 1/4 BSP.F 1/2 BSP.F
7/16-20UNF
R 1/4 R 1/2
G l/4 G 1/2
Cutting Edge 4 (29) 10 (72)
Copper Washer 2 (15) 3 (22)
Aluminum Washer 3 (22) 8 (58)
O-ring 2 (15)

Page 29

Page 30
S0709752C
1RESTRICTION VALVE
CAUTION!
RESTRICTION VALVES0709752C

December 2002
Restriction Valve S0709752C

Page 1
TABLE OF CONTENTS
Unloader Cartridge Identification ............................................................ 4
Specifications .......................................................................................... 5
S0709752C 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). This flow then passes out of the steering cylinder and enters the
restriction valve at port EF. This allows output from the steering pump to join flow from the main pump to
supply the boom, bucket, and option control valves.
Pump
Brake/Pilot Pump (to Brake & Pilot V/V) to TANK
3
14 cm/rev
Steer Pump
3
41 cm/rev
Loader Pump P1 P3
3
44 cm/rev 1.25 1.25"
(to Control V/V)
C1 TPM
0.25"
EF
0.75
R2
1.5
HT
C2 C3 0.75
C R1
0.75" 2.5 B
1.25
1.5 (from Control V/V)
RESTRICTION VALVE
to Steer Line
EF CF
LS
P
Priority V/V
APS0340L
Figure 1 UNLOADING CIRCUIT

Page 3
UNLOADER CARTRIDGE IDENTIFICATION
P3
R1
7 6 4 1 3
2
C1
HT
R3
EF
TPM
C R2 P1
APS0350L
Figure 2 VALVE CARTRIDGE IDENTIFICATION
Reference
Description Remark
Number
1 Body 99x125x140
2 Sub Block 63x99x129
3 Check Valve C1
4 Check Valve C2,3
5 Wrench Bolt M12x1.75x60L
6 O-ring
7 Plug Bolt R3

Page 4
SPECIFICATIONS
Item Specification
Maximum Rated Pressure 210 bar
(3,050 psi)
Rated Flow Ports to P1, P3 210 lpm
(55.48 gpm)
Rated Flow Ports to EF 100 lpm
(26.42 gpm)
Rated Flow Ports to R 300 lpm
(79.25 gpm)
C1 2 ±0.2 Bar
(29 ±3 psi)
Setting Pressure Cracking Pressure
C2, 3 0.7 - 2 Bar
(10 - 29 psi)
R, R2, R3 1-1/4" SAE Flange Port (M12, 1.75)
P1 1" SAE Flange Port (M10, 1.5)
Port Size HT, EF, C 3/4" PF O-ring
TPM 1/4" PF O-ring
R3 1/4" PF O-ring (Supplied Plugged)

Page 5

Page 6
S0793015C
1HYDRAULIC
SCHEMATIC
(MEGA 200-V)
CAUTION!
HYDRAULIC SCHEMATIC (MEGA 200-V)S0793015C


December 2002
Hydraulic Schematic (Mega 200-V) S0793015C

Page 1
TABLE OF CONTENTS
Mega 200-V (Standard).................................................................................. 4
Mega 200-V (Option)...................................................................................... 6
S0793015C Hydraulic Schematic (Mega 200-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 200-V (STANDARD)
Hydraulic Schematic(Standard)
CLOSES 3 B
STOP
* TUV Only
FRONT AXLE
BR1 BR2
L.H Brake valve
OPENS 25 B
T/M DISCONNECT
45B
P1 T1 P2 T2
40B 40B 40B
0.7L 0.7L 0.7L
LPWS A1 P1 P2 A2 A3
1.5 BAR (PFO1/4) (PFO3/8) (PFO3/8) (PFO3/8) (PFO3/8) (PFO3/8)
C1 C2
ULTP
(PFO1/4)
C3
P
TANK (PFO1/2)
C10
60B
C4 PAR
(PFO3/8)
C11
C6 PKW
C9 (PFO1/4)
C5 PILO
(PFO3/8)
OIL COOLER 100 L/MIN

28B
C7 TP
T1 C8 (PFO1/4)
(PFO1/2) (PFO3/8) (PFO1/4) (PFO1/4)

BRAKE/PILOT 10 micron
PUMP A4 15B T3 T2
3
10 cm/rev BRAKE & PILOT SUPPLY VALVE 0.32L
STEER PUMP
3
41 cm/rev
H.P FILTER
LOADER PUMP P1 P3 200 l/min at 6.9 B at 2,4
3
44 cm/rev 1.25 1.25"
<
0.25"
EF
PUMP 0.75
L R
EMERG.STEER R2
CHECK V/V 1.5
HT
<
<
C2 C3 0.75
5Bar
C R1
EMERG.STEER 0.75" 2.5 B
1.25
1.5
PRESS/ S/W
STEER UNIT
RESTRCITION VALVE 175 BAR
T LS
P
VALVE BLOCK
LS
230 BAR 230 BAR
EF CF
10ccr <
- M
LS
24v DC MOTER PUMP

for EMERG. STEER
ø70 x ø35 x 396 STEERING CYL.
P CUSHION V/V
PRIORITY V/V < <
* ELECTRIC EMERGENCY STEERING
Figure 2

Page 4
* OPTIONAL EQUIPMENT
* JOYSTICK VALVE Kick-down Horn
(3-SP. OPT.)
OPT. OPT.
TO DIG
D.C D.R D.F D.R D.F

CLOSES 3 B
STOP
R2
REAR AXLE
OPENS 25 B T
T/M DISCONNECT
P
45B
2 4 3 1 5 6
P2 T2
40B 40B
0.7L 0.7L
2 A2 A3
3/8) (PFO3/8) (PFO3/8)
JOYSTICK VALVE Horn Kick-down

(2-SP. STD.)

TO DIG
C4 PARK D.C D.R D.F
(PFO3/8)
PKWS
C9 (PFO1/4)
T
5 PILOT P 2 4 3 1
(PFO3/8)
TP
C8 (PFO1/4)
/8) (PFO1/4) (PFO1/4)
4 15B T3 T2
0.32L
200 l/min at 6.9 B at 2,400 rpm
320 l/min max

195 BAR
(2-SPOOL,STD.)
CONTROL V/V
R
BUCKET
230 B
(DUMP) (CROWD)
1B
ø140 x ø75 x 490
BUCKET CYL. 1A
STEER UNIT
BOOM
LS
(LOWER/FLOAT)
VALVE BLOCK ø120 x ø70 X 780 2B

0 BAR
OPTION
230 B
3B
STEERING CYL.
3A
(3-SPOOL, OPTION)
CUSHION V/V
LOG FORK SYSTEM
MEGA 200-V
APS0430L

Page 5
MEGA 200-V (OPTION)
Hydraulic Schematic(Option)
CLOSES 3 B
STOP
FRONT AXLE
BR1 BR2
L.H Brake valve
OPENS 25 B
T/M DISCONNECT
45B
P1 T1 P2 T2
40B 65bar 40B 15B
0.7L (PFO1/4) (PFO3/8) (PFO3/8) 0.7L 0.32L

(PFO3/8)
1.5 BAR (PFO3/8) A1 LPWS P1 P2 A2

A3
(PFO3/8
C3-1 C3-2
Æ1.2 C2 C3-3
TANK TP2
(PFO1/4)
2
FO 28kgf/cm
(PFO1/2)
2 C6
C1 60kgf/cm SAF
120kgf/cm2
FI C3-4
(PFO1/2)
Fan motor(Opt.) C7
0.75"
OIL COOLER 100 L/MIN
70bar M 150kgf/cm2
10 micron 16ccr (PFO1/2)
BRAKE/PILOT
BRAKE & PILOT & FAN MOTOR A4 (PFO3/8)
T1
(PFO3/8)
T2
PUMP 40B (PFO1/4)
14 cm3/rev SUPPLY V/V(Opt.) 0.7L * TUV Only
STEER PUMP 0.5"

41 cm3/rev
H.P FILTER
LOADER PUMP P1 P3 200 l/min at 6.9 B at
44 cm3/rev 1.25 1.25"
<
0.25"
EF
PUMP 0.75
L R
EMERG.STEER R2
CHECK V/V 1.5
HT
<
<
C2 C3 0.75
5Bar
C R1
EMERG.STEER 0.75" 2.5 B
1.25
1.5
PRESS/ S/W
STEER UNIT
RESTRCITION VALVE 175 BAR
T LS
P
VALVE BLOCK
LS
230 BAR 230 BAR
EF CF
10ccr <
- M
LS
24v DC MOTER PUMP

for EMERG. STEER
Æ70xÆ35x396 STEERING CYL.
P CUSHION V/V
PRIORITY V/V < <
* ELECTRIC EMERGENCY STEERING
Figure 3

Page 6
* OPTIONAL EQUIPMENT
* JOYSTICK VALVE Kick-down Horn
(3-SP. OPT.)
OPT. OPT.
TO DIG
D.C D.R D.F D.R D.F

CLOSES 3 B
STOP
BR2
REAR AXLE
OPENS 25 B T
T/M DISCONNECT
P
45B
2 4 3 1 5 6
P2 T2
40B 15B
(PFO3/8) 0.7L 0.32L

(PFO3/8)
P2 A2
A3 TP1
(PFO3/8)
1 C3-2 JOYSTICK VALVE Horn Kick-down

(2-SP. STD.)
Æ1.2 C2 C3-3
PILOT DUMP CROWD AUTO RETURN RAISE LOWER

2 (PFO3/8) TO DIG
28kgf/cm
C4 D.C D.R D.F
2 C6
SAFETY
C3-4 PA
(PFO3/8)
T
PARK
P 2 4 3 1
LPWS 45bar
C5
PK
(PFO1/4)
A4 (PFO3/8)
T1
(PFO3/8)
T2
40B (PFO1/4)
0.7L * TUV Only
200 l/min at 6.9 B at 2,400 rpm
320 l/min max

195 BAR
(2-SPOOL,STD.)
CONTROL V/V
R
BUCKET
230 B
(DUMP) (CROWD)
1B
Æ140xÆ75x490
BUCKET CYL. 1A
STEER UNIT
BOOM
LS
(LOWER/FLOAT)
VALVE BLOCK Æ120xÆ70X780 2B

230 BAR
OPTION
230 B
3B
STEERING CYL.
3A
(3-SPOOL, OPTION)
CUSHION V/V
< LOG FORK SYSTEM
MEGA 200-V
APS0440L

Page 7

Page 8
1ELECTRICAL SYSTEM
S0802015C
R1
1ELECTRICAL SYSTEM
CAUTION!
Electrical System S0802015C


December 2002

Page 1
TABLE OF CONTENTS
Overview ........................................................................................................ 4
Electric Wire Color ........................................................................... 4
Electric Supply System .................................................................................. 5
Engine Starting Circuit ................................................................................... 7
Operation During Start Process .............................................................. 7
Operation After Start Process (Mega 200-V) .......................................... 9
Operation After Start Process (Mega (250-V)....................................... 10
Engine Preheating System........................................................................... 11
Mega 200-V / 250-V (Tier I) .................................................................. 11
Mega 200-V / 250-V (Tier II) ................................................................. 14
Engine Stop System..................................................................................... 17
Operation In Engine Running Mode...................................................... 17
Operation In Engine Stop Mode............................................................ 20
Charging System.......................................................................................... 22
Monitoring System ....................................................................................... 23
Instrument Panel ................................................................................... 24
Function Check ..................................................................................... 25
Monitoring System Schematic .............................................................. 26
Mega 200-V ................................................................................... 26
Mega 250-V ................................................................................... 28
Operation .............................................................................................. 30
Instruments .................................................................................... 30
Pilot Lights ..................................................................................... 32
Initial Operation.............................................................................. 33
Control Unit Operation ................................................................... 34
Characteristic of Operation ............................................................ 35
Windshield Wiper ......................................................................................... 36
Front windshield wiper .......................................................................... 36
Front Windshield Wiper Circuit....................................................... 36
Rear Windshield wiper .......................................................................... 37
S0802015C Electrical System

Page 2
Lighting System............................................................................................ 40
Light Circuit (Mega 200-V) .................................................................... 40
Light Circuit (Mega 250-V) .................................................................... 44
Emergency Steering System (Option).......................................................... 47
Block Diagram ....................................................................................... 47
Emergency Steering System Components ........................................... 48
Emergency Steering Timer ............................................................ 48
Emergency Steering Pump ............................................................ 49
Emergency Steering Switch........................................................... 49
Emergency Steering System Electric Circuit ........................................ 50
Electric Detent System ................................................................................. 51
Electric Circuit ....................................................................................... 51
Boom Kick-Out ...................................................................................... 52
Return To Dig ........................................................................................ 53
Proximity Switch............................................................................. 53

Page 3
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 car stereo and 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 4
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. Cab light, fuel pump switch, No. 1 terminal of DC-DC converter (backup for car 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 5
5
6
3
8
4 2
AJS0010L
Figure 1 ELECTRICAL POWER CIRCUIT DIAGRAM
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 6
ENGINE STARTING CIRCUIT
OPERATION DURING START PROCESS
When the starter switch is turned to the start position, safety start relay (14) is opened by the current flow
from the connected "52" and "67" terminal of transmission controller (13) and the "S" and "E" terminal of
starter controller (7) are connected. At this time the contacts in starter relay (8) are closed by the current
flow from battery (1), to fusible link (3), to the "B" terminal of starter switch (5), to the "C" terminal of starter
switch (5), to the "C" terminal of 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 starter (9) is pushed
forward and makes contact with the ring gear of the flywheel and internal contacts of the starter are
connected.
The current flows from battery (1), to the "A" terminal of battery relay (2), to the "B" terminal of battery relay
(2), and then to the "B" terminal of starter (9). The starter motor is rotated and the engine is started.
The engine can be cranked only when transmission selector switch (11) is in the neutral position. If
transmission selector switch (11) is in forward or reverse, the current that flows switch (11) to starter
controller (7) opens the path to ground for starter relay (8). This prevents start relay (8) from closing.

Page 7
AJS0020L
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 8
OPERATION AFTER START PROCESS (MEGA 200-V)
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 rotation of the alternator. 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 as well as the connection between "B" and "PP" terminals are opened. As a result the
rotation of starter (9) is stopped. Once the engine is running, starter (9) will not operate even if starter
switch (5) is moved to the start position, preventing possible damage to starter (9).
BAS0090L
Figure 3 OPERATION OF START CIRCUIT (2) - IMMEDIATELY AFTER START
Reference Reference
Number Number

Page 9
OPERATION AFTER START PROCESS (MEGA (250-V)
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 rotation of the alternator. 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 as well as the connection between "B" and "PP" terminals are opened. As a result the
rotation of starter (9) is stopped. Once the engine is running, starter (9) will not operate even if starter
switch (5) is moved to the start position, preventing possible damage to starter (9).
AJS0030L
Figure 4 OPERATION OF START CIRCUIT (2) - IMMEDIATELY AFTER START
Reference Reference
Number Number

Page 10
ENGINE PREHEATING SYSTEM
MEGA 200-V / 250-V (TIER I)
This circuit uses a thermal switch to monitor engine temperature. An independently operating electronic
preheat controller operates only when the engine is cold. It turns on a grid type resistance heater between
the engine air cleaner and intake manifold. Incoming air that is warmed before entry into the manifold and
engine cylinder combustion chambers greatly improves engine starting efficiency. See Figure 5.
The contacts inside thermal switch (9) are normally open. When the temperature of the coolant drops
below 10°C (50°F), the contacts close. When starter key (1) is turned to the preheat position, the closed
contacts allow controller (7) to begin current flow to heating relay (11), which controls current flow (120
amps) to heating element (13). Controller (7) also turns on the preheat complete pilot light in the operator’s
cab (8) after the heating element has been heated for 19 seconds. Heating element (13) will heat for 19
seconds each time the starter key is turned to the preheat position.
The controller switches off current flow to the heater 15 seconds after the engine has started.
The heater remains on for 15 seconds in order to promote more complete cylinder combustion, speed
warm-up and reduce start-up cycle emissions.
A pulse signal is generated at alternator terminal “R” as soon as engine rpm exceeds 500 rpm.
The signal goes to controller terminal “2” to allow timing the 15 second shut off sequence.
NOTE: As long as the starter switch is at the PREHEAT position, signal current between the “RI”
starter terminal and controller terminal “8” sends a signal from the “5” terminal of the
controller to the “C” of the preheat relay, closing the relay contacts to turn on the heater.
See Figure 6.
When the engine is already warm, and coolant temperature is above 10°C (50°F), intake air preheating is
not required. The contacts inside the thermal switch are closed at that temperature, cutting off controller
current flow and turning on the “preheat complete” light at the top corner of the gauge panel as soon as the
key is turned, not after 15 seconds.

Page 11
3
6
4
12 5
2
13
7
13
8 1
10
11
AJS0040L
Figure 5 ENGINE PREHEAT CIRCUIT
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 12
NOTE: The preheat relay has a
replaceable protective fuse.
See Figure 6.
Reference
Description
Number
1 Terminal B
2 Fuse
3 Amperage Marked
4 Terminal H
5 Terminal C
Figure 6

Page 13
MEGA 200-V / 250-V (TIER II)
This circuit uses a thermal switch to monitor engine temperature. An independently operating electronic
preheat controller operates only when the engine is cold. It turns on a grid type resistance heater between
the engine air cleaner and intake manifold. Incoming air that is warmed before entry into the manifold and
engine cylinder combustion chambers greatly improves engine starting efficiency. See Figure 5.
The contacts inside thermal switch (10) are normally open. When the temperature of the coolant drops
below 10°C (50°F), the contacts close. When starter switch (5) is turned to the preheat position, the closed
contacts allow controller (7) to begin current flow to preheat relay (8), which controls current flow (120
amps) to air heater (9). Controller (7) also turns on the preheat complete pilot light in the operator’s cab
(12) after the air heater has been heated for 19 seconds. Air heater (9) will heat for 19 seconds each time
the starter switch is turned to the preheat position.
The controller switches off current flow to the heater 20 seconds after the engine has started.
The heater remains on for 20 seconds in order to promote more complete cylinder combustion, speed
warm-up and reduce start-up cycle emissions.
A pulse signal is generated at alternator terminal “P” as soon as engine rpm exceeds 500 rpm.
The signal goes to controller terminal “2” to allow timing the 20 second shut off sequence.
NOTE: As long as the starter switch is at the PREHEAT position, signal current between the “RI”
starter terminal and controller terminal “8” sends a signal from the “5” terminal of the
controller to the “C” of the preheat relay, closing the relay contacts to turn on the heater.
See Figure 6.
When the engine is already warm, and coolant temperature is above 10°C (50°F), intake air preheating is
not required. The contacts inside the thermal switch are closed at that temperature, cutting off controller
current flow and turning on the “preheat complete” light at the top corner of the gauge panel as soon as the
key is turned, not after 20 seconds.

Page 14
3
6
4
12 5
2
13
8 1
10
11
BAS0100L
Figure 7 ENGINE PREHEAT CIRCUIT
Reference Reference
Number Number
1 Battery 7 Preheat Controller
2 Battery Relay 8 Preheat Relay
3 Fusible Link 9 Air Heater
4 Circuit Breaker 10 Thermal Switch
5 Starter Switch 11 Alternator
6 Fuse Box 12 Instrument Panel

Page 15
NOTE: The preheat relay has a
replaceable protective fuse.
See Figure 6.
H B
Reference
Description D C
Number
1 Terminal B
2 Fuse
3 Terminal H 1 3
4 Terminal C 4
2
5 Terminal D
BAS0160L
Figure 8

Page 16
ENGINE STOP SYSTEM
The engine stop circuit consists of a starter switch (3), engine stop motor (6), and engine stop relay (5).
There are two modes of operation - engine running and engine stop.
OPERATION IN ENGINE RUNNING MODE

When starter switch (3) is turned to the ON position, the contact points "30" and "87" of engine stop relay
(5) are closed due to current flowing from battery (1), to fusible link (2), to the "B" terminal of starter switch
(3), to the "ACC" terminal of starter switch (3), to the "86" terminal of engine stop relay (5) to battery (1)
and then to the ground. As a result, engine stop motor (6) is rotated by the current flow from battery (1) to
fusible link (2) to fuse box (4) to the "B" terminal of 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 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 shutoff 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.
AJS0050L
Figure 9 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 17
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.
AJS0060L
Figure 10

Page 18
Page 19
OPERATION IN ENGINE STOP MODE
When starter switch (3) is in the "OFF" position, the electric current flow to the coil of 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 battery (1), to fusible link (2), to 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 shutoff 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.
5
6
4
2
AJS0070L
Figure 11 ENGINE STOP CIRUIT - 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 20
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.
AJS0080L
Figure 12

Page 21
CHARGING SYSTEM
When starter switch (5) is turned to the "ON" position, an initial excited current flows to the field coil of
alternator (7) through battery relay (2) and circuit breaker (4). When the engine is started from this
condition alternator (7) starts charging. Current flows from the "B+" terminal of alternator (7), to circuit
breaker (4), to battery relay (2), and to battery (1).
The alternator also supplies electric current to other electrical components. When alternator (7) starts to
operate, a current flows from the "R" terminal of alternator to diode (8) and then to battery relay (2) coil
securing a path for the charging current to battery (1). Thus, preventing the possibility of a high voltage
build up and possible damage to the electric system.
AJS0090L
Figure 13 CHARGING CIRCUIT
Reference Reference
Number Number
1 Battery 5 Starter Switch
2 Battery Relay 6 Fuse Box
4 Circuit Breaker 8 Diode

Page 22
MONITORING SYSTEM
2
19 3
18
4
1
17 5
16 6
15
7
8
13 14 12 11 10 9
AOS0910L
Figure 14
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 Working Light Switch
Sensor 16 Brake Oil Pressure Switch
8 Preheat Controller 17 Parking Brake Pressure Switch
9 Air Cleaner Indicator 18 Emergency Steering Switch
19 Control unit
The monitoring system displays various data and warning signals onto the instrument panel by processing
information gathered from various sensors throughout the equipment.

Page 23
INSTRUMENT PANEL
9 10 11 12 13 14 15 16 17
8 18
7 19
4 1 3 2 5 6
AMP MIC 13P AMP MIC 17P
(CN1) (CN2)
AOS0920L
Figure 15

Page 24
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 Working Light Indicator
Indicator 16 Brake Oil Pressure
8 Air Cleaner Clogging Warning Light
Warning Light 17 Unused Light
9 Engine Coolant 18 Parking Brake Indicator
Temperature Warning Light 19 Emergency Steering
Indicator
FUNCTION CHECK
When the starter switch is turned to the “ON” position, all displays, switch lights, and warning lights except
the turn and hazard warning light, high beam indicator, working light indicator, and emergency steering
indicator will be lit for two seconds and the warning buzzer will sound. Any lights that do not turn "ON"
during the function check should be replaced.

Page 25
MONITORING SYSTEM SCHEMATIC
Mega 200-V
BAS0080L
Figure 16

Page 26
Reference Reference
Number Number
1 Instrument Panel 16 Engine Oil Pressure Switch
2 Headlight Switch Coolant Temperature
17
3 Forward Lever Switch Switch
4 Reverse Lever Switch 18 Brake Oil Pressure Switch
5 High Beam Switch Parking Brake Pressure
19
Switch
6 Left Turn Signal Switch
20 Alternator
7 Right Turn Signal Switch
21 Control Unit
8 Work Light Switch
22 Alarm Buzzer
9 Emergency Steering Switch
23 Alarm Relay
10 Speed Sensor
24 Battery
Coolant Temperature
11 25 Battery Relay
Sensor
12 Fuel Sensor 26 Circuit Breaker
Transmission Oil 27 Fuse Box
13
Temperature Sensor 28 Fusible Link
Air Cleaner Clogging 29 Preheat Controller
15
Warning Indicator

Page 27
Mega 250-V
AOS0930L
Figure 17

Page 28
Reference Reference
Number Number
1 Instrument Panel 16 Engine Oil Pressure Switch
2 Headlight Switch Coolant Temperature
17
3 Forward Lever Switch Switch
4 Reverse Lever Switch 18 Brake Oil Pressure Switch
5 High Beam Switch Parking Brake Pressure
19
Switch
6 Left Turn Signal Switch
20 Alternator
7 Right Turn Signal Switch
21 Control Unit
8 Work Light Switch
22 Alarm Buzzer
9 Emergency Steering Switch
23 Alarm Relay
10 Speed Sensor
24 Battery
Coolant Temperature
11 25 Battery Relay
Sensor
12 Fuel Sensor 26 Circuit Breaker
Transmission Oil 27 Fuse Box
13
Temperature Sensor 28 Fusible Link
Air Cleaner Clogging 29 Preheat Controller
15
Warning Indicator

Page 29
OPERATION
Instruments
Sensor Specification
Function Display Input
Input Specification
Terminal
10 Km/h- 905 Hz
20 Km/h- 1811 Hz
M200-V 30 Km/h- 2716 Hz
40 Km/h- 3622 Hz
*ƒ = 90.55 V [Hz]
CN1-4 10 Km/h- 704 Hz
Speedometer
CN1-5 20 Km/h- 1407 Hz
M250-V 30 Km/h- 2111 Hz
40 Km/h- 2814 Hz
*ƒ = 70.36 V [Hz]
ƒ : Frequency of T/M Controller
v : Speed [km/h]
500 rpm - 90 Hz
1000 rpm - 179 Hz
1500 rpm - 268 Hz
2000 rpm - 358 Hz
2500 rpm - 447 Hz
Tachometer CN1-3
3000 rpm - 537 Hz
*ƒ = 0.179 N [Hz]
ƒ : Frequency of alternator "P"
terminal
N : Engine rpm
ALTERNATOR “P”
Hour Meter CN1-2
Terminal voltage (24V)
0012.eps

Page 30
Sensor Specification
Function Display Input
Input Specification
Terminal
EMPTY - Above 90 Ohm

Fuel Level
CN1-7 1/2 - 38 Ohm
Gauge
FULL - Below 10 Ohm
50°C - Above 188.2 Ohm

Engine Coolant 67°C - 102 Ohm
Temperature CN1-6
Gauge 105°C - 32 Ohm
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

Page 31
Pilot Lights
Input
Symbol Description Operation Remarks
Terminal
Preheat CN2-1 Light turns "ON" when
preheat process is
completed. (Approximately
HAOA630L
19 seconds from start.)
Air Cleaner CN2-2 Light turns "ON" when air
cleaner is clogged
HAOA660L
Coolant CN2-3 Light turns "ON" when

Temperature coolant 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 drops engine oil pressure is
below 1.6 kg/cm2 (23 psi) insufficient after 8 seconds,
HAOA620L
a warning buzzer will
sound.
Charging CN2-5 Light turns "ON" when not Under normal conditions,
charging. will light up before engine
start up and shut off once
(and "R" terminal output
engine is running.
HAOA610L
drops below 24V)

Left Turn and CN2-6 Light turns "ON" when left
Hazard Light turn signal or hazard light
is operated.
(Terminal input is to 24V)
Right Turn CN2-8 Light turns "ON" when right
and Hazard turn signal or hazard light
Light is operated.
High Beam CN2-7 Light turns "ON" when high
beam is operated.
HGB2008L
Work Light CN2-9 Light turns "ON" when Light off when the engine is
work light is operated. started.
(Terminal input is to 24 V)

Page 32
Input
Symbol Description Operation Remarks
Terminal
Brake Oil CN2-10 Lights off when brake oil Under normal conditions,
Pressure pressure increases over 65 will light up before engine
kg/cm2 (925 psi) and light start up and shut off once
0717B
turns "ON" when brake oil engine is running.
pressure drops below 60
kg/cm2 (850 psi).
(When terminal input is
connected)
Parking CN2-12 Light turns "ON" when the Under any conditions, will
Brake parking brake switch is be alight before engine
P 0717A
applied and parking brake
pressure is above 65 kg/
start up.
cm2 (925 psi).

(24V is inputted to the
input terminal)
Emergency CN2-13 Light turns "ON" when the This is option parts.
Steering vehicle speed is above 5
km/h and the steering
AJO0450L pressure is below 10 kg/
cm2 (140 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, working light indicator and transmission
cutoff indicator and emergency steering indicator.
• Warning buzzer is activated and turned off after 2
seconds.
• Monitoring system displays present conditions.

Page 33
Control Unit Operation
5
2
1
6
7 8
13 AMP MIC 13P

9
10
11
12 AOS0940L
Figure 18
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
13 Alarm Relay

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.
Charging light turns
is below 12±1 V
When “R” terminal voltage of "ON" L5
2
alternator Charging light turns
is above 12±1 V
"OFF" L5
Warning buzzer sounds
Engine oil pressure switch is “ON”
after 8±1 seconds.
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 the 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
3. When you turn off the 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 the 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 the 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 the wiper operates
intermittently in low speed.
Front Windshield Wiper Circuit
Figure 19

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

You can control the rear windshield wiper by pressing wiper washer switch (2) located in the switch panel.
1. 1st wiper action (Wiper and washer activate at the same time, automatic return).
Fuse box (1), to washer tank (4), to the 5,7 terminal of switch (20) are connected, then activates the
windshield washers. Also fuse box (1), to the B,L terminal of wiper motor (3), to diode (5), to the 5,7
terminal of switch (2) are connected, then activates the wiper.
3
2
6 5
5
4
AJS0170L
Figure 20 REAR WINDSHIELD WIPER 1ST ACTION CIRCUIT
Reference Reference
Number Number
1 Fuse Box 4 Washer Tank
2 Wiper/washer Switch 5 Diode
3 Wiper Motor 6 Diode
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 the 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 diode (6), to the S,E

Page 37
1
3
2
6 5
5
4
AJS0160L
Figure 21 REAR WINDSHIELD WIPER STOP CIRCUIT
Reference Reference
Number Number
1 Fuse Box 4 Washer Tank
2 Wiper/washer Switch 5 Diode
3 Wiper Motor 6 Diode

Page 38
Page 39
LIGHTING SYSTEM
LIGHT CIRCUIT (MEGA 200-V)
27
28
19 21
20
23 26
25
2
7
8 3
12 10 11 13
6
18
4
24
14 16 15
5
BAS0150L
Figure 22 LIGHT CIRCUIT

Page 40
Reference Reference
Number Number
1 Fuse Box 1 15 Rear Combination Light (R)
2 Blinker Unit 16 License Plate Light
3 Headlight Switch 17 Instrument Panel
4 Combination Switch 18 Diode
5 Shift Lever Switch 19 Front Working Light Switch
6 Hazard Switch 20 Front Working Light
7 Stop Light Switch 21 Rear Working Light Switch
8 Headlight Relay 22 Working Light Relay
9 Reverse Relay 23 Rear Working Light
10 Headlight (L) 24 Fuse Box 2
11 Headlight (R) 25 Starter Switch
12 Front Combination Light (L) 26 Pilot Buzzer
13 Front Combination Light (R) 27 Alarm Relay 1
14 Rear Combination Light (L) 28 Alarm Relay 2
The lighting system is consists of the headlight, the position light, the turn signal light, the hazard light, the
stop light, the license plate light, the working light, the rotating beacon light (option) and the switches,
which is used to turn "ON" the lights.
1. When the headlight switch (3) is in the first step, through the fuse box 1 (1) to the "2," "6" terminal of
headlight switch (3), the following lights will be alight.
A. The front combination light (L) (12) and rear combination light (L) through the fuse box 2 (23).
B. The front combination light (R) (13) and rear combination light (R) through the fuse box 2 (23).
C. The illumination lights through the "9" terminal of all kind of rocker switches include the
headlight switch (3), the front working light switch (19), the rear working light (21) and the
hazard switch (6).
D. The license plate light (16).
2. When the headlight switch (3) is in the second step, the current flows through the fuse box 1 (1), to
the "2," "3" terminal of headlight switch (3) and to the "86," "85" terminal of headlight relay (8), and the
"30," "87" terminal of headlight relay (8) is connected. As a result, through the fuse box 1 (1) to the
"30," "87" terminal of headlight relay (8), the voltage is applied to the "56" terminal of combination
switch (R) (4).
A. At this time if the combination switch (4) is in the "0" position, the current flows to the "56b"
terminal and it allow the low light, which is in the headlight (L) (10) and the headlight (R) (11), to
be alight.
B. Also if the combination switch (4) is in the "▼ " position, the current flows to the "56a" terminal
and it allow the high light, which is in the headlight (L) (10) and the headlight (R) (11), to be
alight. At the same time the current flows to the "CN2-7" terminal of instrument panel (17) and
the headlight indicator L7 will be alight.
C. And if the combination switch (4) is in the "▲ " position, the current flows to the "56b" terminal
and it allows the low light, which is in the headlight (L) (10) and the headlight (R) (11), to be
alight.
At the same time another current flows from the fuse box 1 (1) to the "15/1," "56b" terminal of
combination switch (4) and the high light, which is in the headlight (L) (10) and the headlight (R)

Page 41
(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 alight. 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 alight.
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 alight. 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 alight.
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
"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 alight.
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 alight.
7. When the front working light switch (19) is in the "ON" position, the current flows from the fuse box 1
(1), to the "5," "1" terminal of front working light switch (19) and to the front working light (20). This
current makes the front working lights turned up. At the same time the working light indicator,L9," is
turned up due to the "CN2-9" terminal of instrument panel (17).
8. When the rear working light switch (21) is in the first step, the current flows from the fuse box (1), to
the "5" and "1" terminal of the working light switch (21). As a result the rear working light (23)
mounted on the cabin turns "ON".
When the headlight switch (3) is in the first step or in the second step while the starter switch (25) is in the
"OFF" position, the contact point "30," "87" of alarm relay 1 (27) is closed due to the excited current, which
flows to the coil of alarm relay 1 (27) and the pilot buzzer (26) will sound. But when the headlight switch (3)
is in the first step or in the second step while the starter switch (25) is in the "ON" position, the contact point
"3," "87" of alarm relay 2 (28) is closed due to the excited current, which flows to the coil of alarm relay 2
(28). At the same time the current is not supplied to the "30" terminal of alarm relay 1 (27) and the pilot
buzzer will not sound any more.

Page 42
Page 43
LIGHT CIRCUIT (MEGA 250-V)
22
28 29
23
20 19 21
24 27
18 18
17
1
26
2
7
8 3
12 10 11 13
6
18
4
25
14 16 15
5
AJS0180L
Figure 23 LIGHT CIRCUIT

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 Working Light Switch
5 Shift Lever Switch 20 Front Working Light
6 Hazard Switch 21 Rear Working Light Switch
7 Stop Light Switch 22 Working Light Relay
8 Headlight Relay 23 Rear Working Light 1
9 Reverse Relay 24 Rear Working 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)
The lighting system is consists of the headlight, the position light, the turn signal light, the hazard light, the
stop light, the license plate light, the working light, the rotating beacon light (option) and the switches,
which is used to turn "ON" the lights.
1. When the headlight switch (3) is in the first step, through the fuse box 1 (1) to the "2," "6" terminal of
headlight switch (3), the following lights will be alight.
A. The front combination light (L) (12) and rear combination light (L) through the fuse box 2 (23).
B. The front combination light (R) (13) and rear combination light (R) through the fuse box 2 (23).
C. The illumination lights through the "9" terminal of all kind of rocker switches include the
headlight switch (3), the front working light switch (19), the rear working light (21) and the
hazard switch (6).
D. The license plate light (16).
2. When the headlight switch (3) is in the second step, the current flows through the fuse box 1 (1), to
the "2," "3" terminal of headlight switch (3) and to the "86," "85" terminal of headlight relay (8), and the
"30," "87" terminal of headlight relay (8) is connected. As a result, through the fuse box 1 (1) to the
"30," "87" terminal of headlight relay (8), the voltage is applied to the "56" terminal of combination
switch (R) (4).
A. At this time if the combination switch (4) is in the "0" position, the current flows to the "56b"
terminal and it allow the low light, which is in the headlight (L) (10) and the headlight (R) (11), to
be alight.
B. Also if the combination switch (4) is in the "▼ " position, the current flows to the "56a" terminal
and it allow the high light, which is in the headlight (L) (10) and the headlight (R) (11), to be
alight. At the same time the current flows to the "CN2-7" terminal of instrument panel (17) and
the headlight indicator L7 will be alight.
C. And if the combination switch (4) is in the "▲ " position, the current flows to the "56b" terminal
and it allows the low light, which is in the headlight (L) (10) and the headlight (R) (11), to be
alight.

Page 45
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 alight. 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 alight.
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 alight. 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 alight.
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
"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 alight.
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 alight.
7. When the front working light switch (19) is in the "ON" position, the current flows from the fuse box 1
(1), to the "5," "1" terminal of front working light switch (19) and to the front working light (20). This
current makes the front working lights turned up. At the same time the working 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 working light switch (21) is in the second step, the contact points "30" and "87" of the
working light relay (22) is closed due to the flowing current from the fuse box 1 (1), to the "2" and "6"
terminal of the working light switch (21), to the "86" terminal of the working light relay (22) and to the
ground. Thus the current flows from the fuse box 1 (1), to the working light relay (22) and to the rear
working light 1 (23) mounted on right/left rear fender. As a result the rear working light (23) light turns
"ON." At the same time the working indicator light "L9" turns "ON" due to the current flowing from the
diode (18) to the "CN2-9" terminal of the instrument panel.
9. When the rear working light switch (21) is in the second step, the contact points "30" and "87" of the
working 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 working light switch (21), the rear working (23) is operated like being described
above clause "8" and the rear working light (24) mounted on the cabin 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 46
EMERGENCY STEERING SYSTEM (OPTION)
BLOCK DIAGRAM
3
5
6
1
8
4
AJS0460L
Figure 24 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
(140 psi), an electrically powered hydraulic pump will be operated for a time limited 60 seconds and thus
the emergency steering is possible. This system includes the electrically powered hydraulic pump, which is
controlled by the emergency steering timer (3). The emergency steering timer (3) obtains signals from the
emergency steering pressure switch (4) and the transmission controller (7). When the emergency steering
is activated, the emergency steering indicator (6) light turns "ON."

Page 47
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
No. Wire size and Color
Figure 25
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 26 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 48
Emergency Steering Pump
This is an electrically powered hydraulic pump
and includes an emergency steering relay
(1,Figure 27),which is excited by the signal of 1
the emergency steering timer.
AJS0480L
Figure 27 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
Figure 28 EMERGENCY STEERING SWITCH
WARNING
Make sure that no persons are near the machine when testing the function of the emergency
steering system, there is a risk that someone may be crushed between the front and the rear
frame.
3. This returns automatically when not pressed down.

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

Page 49
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 emergency steering timer (3) and emergency steering pressure switch (4) is
"OFF," the contact points "A" and "B" of emergency steering pump (5) is closed due to the current flowing
from fuse box (1), to the "C" and "D" coil of emergency steering pump (5), and to the "4" and "5" terminal of
emergency steering timer (3).
Thus the high current flows from battery (11) to the "A" and "B" terminal of 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 steering pump (5), to fusible link (7) and to the emergency steering
indicator.
6 7
11
5
8
1 10
9 3
AJS0490L
Figure 29 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 50
ELECTRIC DETENT SYSTEM
The electric detent system is separated into boom kick-out and return to dig. Each part consists of
magnetic locking lever and proximity switch detecting position of the bucket or boom.
ELECTRIC CIRCUIT
FLOAT KICK-OUT (OPTION)

6
2
5
11 3
9
7 4
8
1
10 11
AJS0500L
Figure 30 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

Page 51
BOOM KICK-OUT
When the work lever 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 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). 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 31, is in the "I" position and the float magnetic (6) is
energized and the work lever is held in "FLOAT," then boom is approaching to the float proximity
switch (9).
When the float proximity switch (9) 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/float
relay (3), to the terminal "5" and "1" of the O
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- I
energized and the locked lever is returned
to "NEUTRAL" position, and boom
lowering is stopped. HA0O2027
Figure 31

Page 52
RETURN TO DIG
After dumping, if the work lever is in the "CROWD" position, the work lever 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 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
• Operating Distance: 10±1 mm OPERATION INDICATOR
• Operation Indicator light POSITIONER
: Light turns "ON" when the object is

detected.
(OPERATING DISTANCE)
MAIN POWER
CIRCUIT
AJS0510L
Figure 32

Page 53
Page 54
S0893015C
1ELECTRICAL
SCHEMATIC
(MEGA 200-V)
CAUTION!
ELECTRICAL SCHEMATIC (MEGA 200-V)S0893015C


December 2001
Electrical Schematic (Mega 200-V) S0893015C

Page 1
TABLE OF CONTENTS
Mega 200-V (Tier I) ........................................................................................ 4
Mega 200-V (Tier II) ....................................................................................... 6
S0893015C Electrical Schematic (Mega 200-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 200-V (TIER I)
0.85RG REAR WORKING LAMP

ROTATING BEACON (2534-9049C)x4
87a ALARM RELAY 1
(FR)
(OPTION) FRONT 0.85B
24V 70W
87
30 1.25RY (2544-9033)
WORKING LAMP 0.85RW 1.25RW 87a
CN1 AMP MIC 13P 30
ROTATING BEACON (2534-1127)x2 0.85
0.85RG (RR) 0.85B 85 86
+ SIG (2RL006846-111) 24V 70W 0.5B 0.5RG 0.85B 87
CN1-4 0.85G
HELLA (FL) 0.85B
SPEED - CN1-5 0.85R (REAR FENDER) 85 86 0.5WR
0.85RW REAR LAMP SW
0.85B 1.25RG (2549-9109)
+ S (RL) REAR LAMP RELAY
CN1-3 0.5WG 0.85B +(2190-2036D20)
TACHO 0.85R 1 (2544-9033)
- CN1-13 0.85B 1.25RG
1 5 1.25RY 0
0.85RW 2
+ S CN1-6 W/TEMP SENSOR 5 7 6 I 1.25RY
0.85L 0.85RY
WATER (2547-6028 ) (CR) 0.85B 1.25B
- 7 1.25RW 3 II
TEMP 10 9 0.5WR
(17) 0.5B 9 10 0.5WR
10 9 (CABIN)
+ S 0.5B 0.5WR
CN1-7 0.85YR 0.85B FUEL SENSOR 0.85RW (18)
FRONT LAMP SW
FUEL - (547-00019 ) 0.5B (2549-9098) (CL) 0.85B
BEACON SW +(2190-2036D5)
+ (2549-9098) 0.5RL 0.5RL 2RY
S CN1-8 0.85GR 0.85B
T/M OIL TRANSMISSION OIL +(2190-2036D10) 1.25RY
1.25RY
- TEMP SENSOR
TEMP 0.5WG 0.5WG 0.5WG
(ZF 0510 308 844)
1 3 0.5RW 0.5RW 0.5RW 0.5RW
CN1-2
HOUR 2 0.85WR 0.85WR 0.85WR 0.85WR
0.85BW 0.85B 1.25R 1.25R 1.25R 1.25R
ILLUMINATION
0.85G 0.5BrW 0.5BrW
INDICATOR 0.85LB 0.85LB
(2170-9005)
CN1-9 0.85WR CONTROL UNIT 0.85L 0.85L
(543-00001)
CN1-1 1.25R
B 0.85L CIGAR LIGHTER
+ REAR WIPER SW
CHARGE CN2-5 0.5W 0.5W 3 1 0.85R STOP RUN E 0.85B (2549-9129 ) (545-00001)
L5
+(2190-2036D18)
ENG OIL PRESS CN2-4 0.5BY 0.5BY 4 2 0.5RW M L 2 0.85B
L4 0.85LW 0.85LW 4 II - 0.85B
TIME DELAY -
WATER TEMP CN2-3 0.5YB 0.5YB 5 S 0.85Y 0.85YB +
L3 6 0
BUZZER CIRCUIT 7 0.85B
0.85BR 5 I 0.85W
BRAKE OIL PRESS CN2-10 0.5YL 0.5YL 6 (19) 9 0.5WR
L10 10 0.5WR
REAR WIPER MOTOR
PARK BRAKE CN2-12 0.5Lg 0.5Lg 7 8 0.5BrW (2538-9005 ) 0.85G
L12
(11) 0.5B 0.85L
AIR CLEANER CN2-2 0.85BW (12) B
L2 0.85W
0.85L 0.85BR 0.85BR
BRAKE OIL FILTER CN2-11 0.85GR 0.85LR 10 9 0.85LB E 0.85B
L11 BLINKER
1.25RB 5 2 1 UNIT
PREHEAT CN2-1 0.5LB 0.85B 13 WINDOW WASHER
L1 (4916-9006 ) (2525-1011)
15A 15A 15A L
3W
CN2-16 0.85LR CN1 AMP MIC 13P + (R) - 0.85GY
0.85L 0.85BR 9 7
P 2W
WORKING CN2-9 0.5RL 0.5RL
L9 FUSE BOX 2 0.85RY
0.5GR 0.5GR 0.85BR + (F) - 0.85B
TURN SIGNAL (R) CN2-8 P (570-00002 ) HORN (H) H.F
L8 0.85B
0.5GL 0.5GL 2W (2516-9015)
TURN SIGNAL (L) CN2-6 0.5R 0.5R
L6 0.85BR 0.85B 10 8 0.85WR
HI BEAM 2RW EMERGENCY PUMP (OPT) NOTE.3
CN2-7 30A 10A 10A
L7 (13)
0.5LB 0.5LB 0.85RY
EMG STEERING CN2-13 6 4 3 HORN (L)
L13 L.F 0.85B
0.85BY (2516-9016)
ENG OIL PRESS SWITCH
0.85WR
0 85RW
CN2-17
0.85WR
0.85WL
0.7bar (65.27441-7007)
CN2 AMP MIC 17P 0.85YB 0.85B WATER TEMP SWITCH
0.85B 0.5LB 3W
GAUGE PANEL ASS'Y 103˚C (66.27435-6008)
1.25RB 0.5LB
(539-00028) 0.85YL 0.85B
BRAKE OIL PRESS SW 0.85RW 0.85RW
BRAKE OIL FILTER SW 0.85B 0.85GR 65bar (2549-9093 )
(2471-9054) 2RL 2RL
0.85Lg 0.85B PARK BRAKE PRESS SW 0.85BR 0.85BR 0.85RY
45bar (549-00039)
0.85WL
FLOAT KICK-OUT ASS'Y (OPTION) STD 0.85RB
0.85RB 0.85RB
FLOAT KICK-OUT SW OPT (FLOAT KICK-OUT)
0.85WR
(FLOAT KICK-OUT) (2549-9098 )
(16) 1 0.85R
+ 0.85RB +(2190-2036D22) 0.85R 0.85RY
4 HORN RELAY
1 RAISE FRONT FRONT
O 0.85W (2544-9033 )
5 MAGNET RAISE RELAY COMBI LAMP(L) HEAD LAMP(L) HEAD LAMP(R) COMBI LAMP(R) 0.
0.85RY 87a
- 0.85B 7 (2544-9033 ) (2534-1138A) (2534-1141 ) (2534-1141 ) (2534-1151A)
FLOAT (14)
2 87a 30
MAGNET 21W 10W 75/70W 75/70W 10W 21W 87
PROXIMITY SW 0.5B 10 9 0.5WR 0.85B 5 30 0.85RB
(4549-1148) 87
85 86 0.
0.5WR 85 86 0.85RB 0.85B 0.85B 0.

(RAISE)
0.85LY
+ 0.85RB 0.85RB
0.5B
(turn sig)
(turn sig)
(position)
(position)
0
0.85RW
0.85RW
0.85WR
0.85WR
0.85WR
0.85WL
0.85RW
0.85WL
0.85GL
0.85GR
0.85BR
0.5BrW
O 0.85RY 0.85RY
(high)
(high)
(low)
(low)
0.85R
0.85R
0.5GR
0.85B
0.85B
0.85G
0.5GL
0.5GL
0.5R
2RL
HORN SWITCH 2
- 0.85B
RETURN TO DIG 0.5LB 0.5BrY
MAGNET RETURN TO DIG RELAY 0.85RB
1 3
(2544-9033) (5)
(RETURN TO DIG) 3 0.85G 87a (ON JOYSTICK)-L
6 DISPLAY ILL RELAY
+ 0.85RB 0.85B 30 0.85RB 0.5GR 0.85GR
(2544-9033 )
87
O 0.85WG 87a 0.85GL 0.85GL
- 0.85B 85 86 0.85RB 30 0.5BY
0.85RW
0.5B 87
0.85R 0.85R
(15)
PROXIMITY SW 85 86 0.5WR
0.85WG 0.85WR
(4549-1148)x2
0.85GW 0.85GY
0.5B 0.85RY 0.5LB
0.5WR 0.85BR
0.5BrW 0.5BrW 0.85WR
WIPER MOTOR
(position)
(position)
(back up)
(back up)
(turn sig)
0.85RL (turn sig)

0.85GW
0.85GW
(stop)
(stop)
(stop)
(stop)
0.85GR
0.85WR
0.85RY
0.85RY
0.85GL
SAFETY START
0.85WL
0.85GW
0.85GW
(4538-9017 )
RELAY BACK UP RELAY 0.85B 0.85B
(2544-9033) H 0.85RY
(2544-9033 )
0.5BrW 87a 87a L 0.85YB
30 0.5RL 0.85RL 30 C A B D F E E F D B A C
87 87 0.85RY S 0.85Y 87a
LO
0.5Gr 85 86 85 86 0.5RL HI 87
0.5RL 0.5P 21W 21W 10W 12W 12W 12W 12W 10W 21W 21W 0.85LB
M STOP
5W
REAR COMBI LAMP (LH) REAR COMBI LAMP (RH) 0.5L 86
LICENCE LAMP - RUN B 0.85L
(2534-1159B ) (2534-1139A ) (2534-1158B )
DISPLAY
0.5Gr 52 5 0.5P (4539-6036 ) 0.85GW 0.85GW E
0.85GY 0.85B
30 0.85RL 2-4 1-4 0.5BY 5bar
8 BACK BUZZER STOP LAMP SW PARKING BRAKE SW
0.5L 4
14 0.85WG 2-1 2-3 0.85B (2516-1124 ) (2549-9098)
53
0.85GR + +(2190-2036D16)
57 0.85B - 1
(ZF 0750 133 022) 5 5
11 0.85WL 0.5B
7 0.85Or
15 0.85GW 2 1 0.85RL DOWN SHIFT SW
0.85R 12 18 0.85BrL 4 3 0.85B 0.85V 0.85WL 0.85WL 0.5WR 9 10
+ VPS1 7 0.85R 13 23 0.85RW 4 2
0.85G
4WG-160 T/M SELECTOR SWITCH

2RL
CHECK CONN (4549-6072)

TRANSMISSION TRANSMISSION 68 0.85RW (ON JOYSTICK)-R
DW-3 (ZF 0501 210 702)
VALVE ASS'Y Y1 1 0.85LW 56 CONTROLLER 36 0.85B
0.85G
HSG-94 EST-37 KICK 1 2 3 4
Y2 2 0.85YG 10 F N R 0.85Or
DOWN STEP STEP STEP STEP
Y3 3 0.85GL 32 (543-00020 ) 45 0.85RL 0.85RL X2-A VP (8)
Y4 4 0.85WB 55 (ZF 6009 065 280) 67 0.85Gr 0.85Gr X2-D AD6
Y5 5 0.85GR 9 DW-3 20 0.85BW 0.85BW X1-A 0.85B PARKING BRAKE
AD3
Y6 6 0.85WL 51 22 0.85V 0.85V X1-D RELEASE SOL-VALVE
AD7
63 0.85L 0.85L X1-C AD1
TEMP 8 0.85LB 39 65 0.85G 0.85G X1-B
(543-00035) AD2 COMPRESSOR
TEMP 9 0.85Br 46 43 0.85Y 0.85Y X2-B RECEIVER
(ZF 6009 065 281) AD4 (2208-6013B) (2204-603
ERGO-II (OPT) 64 0.85P 0.85P X2-C AD5 MAGNET
0.85LgR 19 21 0.85Or 0.85Or CLUTCH 0.85LW
(ENGINE) 0.85Lg 29 0.85W 0.85W
PILOT CUT OFF SW HIGH PRESS
SPEED 0.85LgW 41 1 1 (AUTO)
66 0.85RY 0.85L 0.85W (2549-9098) (4) CUT OFF SW
PICK-UP (TURBINE) 0.85Lg 5 0.85RL 5 +(2190-2036D17)
25bar 0.85RL
(ZF 0501 7 7 (MANU) PILOT CUT OFF
0.85LgB 42 T/M CUT OFF SW 1 0.85BW 1
209 688)x3 SOL-VALVE 0.85B 0.85B
(CENTRAL 5 0.85WL
0.85Lg 3 (4549-9080)
GEAR CHAIN) 0.5B 10 9 0.5WR 0.5WR 9 10 0.5B (9) 7
1 0.85B
2 0.85B 10 9 0.5WR
2 0.85YR 62 0.85B
T/M CUT OFF SW 2 AUTO SELECT SW 0.5B
1 0.85RB 4 6 (2549-9098) (2549-9098 )
3 CN6 AMP 68P +(2190-2036D15) +(2190-2036D9)
0.85RL
SPEED SENSOR 0.85RL 0.5WR
(ZF 0501 209 560)
Figure 2

Page 4
ALARM RELAY 1
5RY (2544-9033) ALARM RELAY 2 STARTER SWITCH CONNECTION
87a (2544-9033) ANTENNA SPEAKER TML B
PST BR R1 R2 C ACC NOTE.
30 0.85WL 87a (2541-9020)x2
OFF 1. DIODE PART NO.
5RG 0.85B 87 30 0.85WB (LH) (RH)
0.85LB 87 PREHEAT - DIODE (11)~(19) : 2548-1026
85 86 0.5WR - DIODE (1)~(9) : 2548-1027
REAR LAMP SW ON
85 86 0.5LR
(2549-9109) + - + - START
+(2190-2036D20) 3 7 0.85GrR
CAR TERMINAL NO
0 0.5B 10 1 0.85BY
STEREO
6 I 2 1.25RY 8
(2541-9019) 0.85GrL
HRS NO.GT7A-26PD-DS 26P AMP 9PT 1-480673 AMP 9PR 1-480672-0
3 II PILOT BUZZER 0.85LW 4 2 0.85BW AMP MIC 13P AMP MIC 17P
9 10 0.5WR (2516-1102A) 6 5 4 3 2 1 8 7 6 5 4 3 2 1
13
0.85WB - 3
12 11
10 9 8 7 6 5 4 3
2 1 3 2 1 1 2 3
0.85B 9 0.85BR
0.85RW + DC / DC 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 26 25 24 23 22 21 20 19 18 17 16 15 14 6 5 4 4 5 6
11 0.85L 0.85L 2
CONVERTER (CN1) (CN2) (CN3) 9 8 7 7 8 9
2RY 1
0.85WR (2531-1003)
1.25RY (CN4) (CN5)
STEREO RELAY T/M CONTROLLER (ZF 68P)
0.5WG (2544-9033) T/M SELECTOR SWITCH (PACKARD)
0.5RW 87a 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2
23 1
30 0.85L
0.85WR 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24
0.85LW 87
1.25R 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46
A B C D D C B A
0.5BrW 0.5B 85 86 0.5LR
(CN6) X1 X2
0.85LB
0.85L
STARTER STARTER
CONTROLLER STARTER RELAY
(65.26201-7044)
PER SW CIGAR LIGHTER 0.5LR (2543-9015) (2544-1022)
24V 4.5KW
29 ) (545-00001)
0.5BrW 0.5BrW N S 0.85BW 0.85BW D PP 3Y C
6D18)
2 0.85B - 0.85B 0.85WG 0.5WG P B
0.85BY C B 3W
0.5RW 0.5LR B E 0.85B
+
(3)
7 0.85B 2RY
0.85W
9 0.5WR 0.5WR 0.85RW 0.5RW
0.85G 0.85G 1.25RW/0.85WR 1.25RW
A
0.85L 1.25RY 1.25WR
B A
0.85W 0.85L
60B
E 0.85B
BLINKER P1 0.85LY 87a
1 UNIT 9 10 11 12 13 14 30 FUEL PUMP
(2525-1011) P2 0.85LW 87 (2401-1277A)
15A L 15A 15A 15A 15A 10A 10A
3W 1.25WR
0.85GY A B 85 86 1.25RW 1.25B
7 17 18 19 0.85RW
2W 2WR P
3W E
X2 0.85RY
HORN (H) 0.5B
H.F 0.85B FUSE BOX 1 ROOM LAMP
2W (2516-9015) 5W ENG STOP RELAY (2534-9063 )
(4510-1012A) 0.85B
ENG STOP MOTOR (2544-9033)
8 0.85WR 15 16 5W (2523-9016) 0.85RW 10W
10A 15A 15A 15A 15A 20A 15A 15A 30A

0.85RY 1.25WR 0.85BY 0.5G
3 HORN (L) 1 2 3 4 5 6 7 8
L.F 0.85B 2WR 2WR 2WR 2R
(2516-9016)
2RG/0.85GY
0.85WR
0.85RW
0.85GY
0.5LR 0.5LR
0.85WR
FUSIBLE LINK
1.25LR
0.85LB
0.85WL
1.25R 5W
0.85R
3W
2LR
2RL
(2527-1023A)
3W 3W 1.25WG
1.25WR
0.85BY
0.5LB 0.5LB 0.5RW
0.5LR
0.85RW 0.85RG 2LR CIRCUIT BREAKER 2R
(2527-9004) 60R
2RL 2RL 0.5RW C
EMG STEERING (OPT) ACC B A
0.85RY 0.85LB 1.25LR 8W 8W
0.5LB B
0.85WL 0.85WL 0.85RG
1.25RG 0.85RG R2 BR 1.25Br 1.25BrW 1.25BrW BR
0.85WR 0.85WR 0.85WR R1
(1) 1.25B E
0.85RY 0.85GY STARTER 1.25BrW
1.25WG
HORN RELAY HEAD LAMP RELAY SWITCH 60R

1.25LR
0.5RW
0.5RW
0.5BW
0.5BG
LAMP SWITCH
0.5LB
(2544-9033 ) (2544-9033 )
2LR
(2549-9109 ) (2549-1152) 8W BATTERY RELAY

0.85LY 1 1.25RG
87a 5 0.85GY 87a +(2190-2036D4) (2544-9024)
30 30 1.25WG 1.25WG
7 0
87 1.25WY 87 60B 60R
6 I 2 7 4 8
85 86 0.5LY 2 85 86
6 0.5B 0.5WY 3 II
2 0.5WG
8 9 10 PREHEAT
0.5WR (2)
CONTROLLER
0.5WL
0.85LY
0.5WR 6 0.85B - + - +
0.5B 0.5B 10 9 (2523-9002)
0.85WR
0.85WR
12V 100AH 12V 100AH

0.85WL
0.85BR
0.5B 1.25RW
HORN SWITCH 2
BATTERY
0.5LB 0.5BrY HAZARD SWITCH 1 3 5
SW TURN SIGNAL HEAD LAMP 0.85Br (2506-1104)x2
1 3 (2549-9138 )
N PREHEAT RELAY
(5) (6) +(2190-2036D2) TML
0.85BR
0.85YB
0.85LR
(ON JOYSTICK)-L 0.85GY CN4-8 (2544-1022)

49a
0.85GR 0.85GR CN4-4 C B 5W AVX 8W
R (7)
0.85GL 0.85GL CN4-1 AVX 1.25WG
L COMBINATION
0.85RW 1.25WY CN4-5 15˚C 0.85BR D PP AVX 2RW
56 SWITCH (R)
0.85R 0.85RW CN4-6 (4549-9418) R P B
56b
0.85R CN4-7 AVX
56a 5BW
0.85GY 0.85GY 0.85RG CN4-9
15/1 THERMO
0.5LB 0.85LB CN5-6
15(53a) SWITCH
0.85BR 0.85BR CN5-8
53c (65.27435 SG
0.85BrY CN4-2
WIPER MOTOR H -6003)
(turn sig)
(4538-9017 ) 0.5BL CN5-7

J
H 0.85RY 0.85RY CN5-3
53b
L 0.85YB 0.85YB CN5-1 GLOW PLUG R
C 53 (65.26803-7014) F
0.85BrL CN5-4
S 0.85Y 87a 31b E
LO 30 0.85BrL TML
HI J 0 I II OFF ON OFF ON
0.85LB 87 E
M STOP SW WIPER WASHER HORN 8B ALTERNATOR
86 85 (2502-9009)
- RUN 0.5L 0.5B
B 0.85L 24V 50A
1.25LR AIRCON UNIT 4WG-160 TRANSMISSION CONNECTION

E WIPER RELAY (4920-9050A)
0.85B 2LR FORWARD REVERSE
(2544-9033) CLUTCH SOLENOID
BLOWER 1 2 3 4 1 2 3
PARKING BRAKE SW 4 1 15
0.5L 0.5BL A/C CONTROL PANEL 2LR + - KV Y5
(2549-9098) M
(2543-9031A) 0.5RW 0.85LR 14 KR Y2
+(2190-2036D16) WIPER TIMER 2 0.5BL
1 (2537-9002 ) 22 K1 Y3
5 0.5B 5 3 0.5BL
0.85WL
7 K2 Y6
0.85Or
13 1.25LR K3 Y4
WL 0.5WR 9 10 CONDENSER FAN RELAY
K4 Y1
(2544-9033)
CONDENSER ASS'Y 87a
(2520-6004) 30 0.85LR
3 0.5LB 11 HIGH ERGO-II SELECTOR SWITCH (OPT)
0.85B - + 0.85L 87 5 0.5LY 12 MID
M 549-00009 (ZF 0501 209 869)
0.85Or 8 0.5LW 13 LOW
0.5YB 85 86 KICK
0.5LR F R N T+ T-
18 0.5GrG 9 REC DOWN
(8) X2-A
19 10 FRE + VP
0.5GrY
INTAKE X2-D
0.85B PARKING BRAKE 10 AD7 AS
0.5YB ACTUATOR
M X1-A
RELEASE SOL-VALVE AD3 B3
X1-D AD8 KD
23 0.5OrR 7 OPEN
X1-C AD1 B1
COMPRESSOR RELAY 20 0.5OrW 8 CLOSE
COMPRESSOR RECEIVER DRIER (2544-9033) VENT X1-B AD2 B2
(2208-6013B) (2204-6039A) 87a ACTUATOR
M X2-B
30 AD5 V
MAGNET 0.85LR X2-C
CLUTCH 0.85LW 0.85BW 87 14 3 AD6 R
0.5LgW (WARM)
0.5RB 85 86 15 0.5LgB 2 (COOL)

HIGH PRESS LOW PRESS 0.5LR M
CUT OFF SW CUT OFF SW 2 0.5YR 4 MIX
(4)
16 0.5YW 5 ACTUATOR
0.5RB 9 4 0.5YG 1
0.85B 0.85B
.85WL
0.5WR 11 1 0.5B 0.85B 6
THERMISTOR
LED 1~12
0.5WR
DUCT/DEF 26 1.25B 2B 16
DEF 2 0.5G 7
ACTUATOR
DUCT 3 0.5GW 6
(2213-9002 ) M CN3 HRS 26P CN1 AMP MIC 13P + 250 4P
0.5WR
MEGA 200-V
APS0420L

Page 5
MEGA 200-V (TIER II)
Figure 3

Page 6
MEGA 200-V (Tier II)
BHS0070L

Page 7
Page 8
1ATTACHMENTS
1PUBLICATION REQUEST FOR
PROPOSED REVISION
In Daewoo’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 Bill.Bernhardt@dhiac.com (If possible, use 1024 x 768
resolution.).
HAS THIS BEEN DISCUSSED WITH A DAEWOO SERVICE REPRESENTATIVE: YES NO
IF YES - WHO:
(It is advised to discuss this with a Daewoo service representative to ensure that the above correction is appropriate
and valid.)
Mail to:
Daewoo Heavy Industries America Corporation
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Attention: Publications

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SM-Daewoo Doosan MEGA 200-V Wheel Loader Service Repair Shop Manual-1

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Mega 200-V

023-00055AE Shop Manual

Trim Out The Label Along

Pub. No. 023-00055AE

Lower Structure and Chassis

Engine and Drive Train

WHEEL LOADER SAFETYS0103010K

Copyright 2002 Daewoo

Wheel Loader Safety S0103010K

To the Operator of a 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

ASBESTOS DUST HAZARD PREVENTION

MOUNTING AND DISMOUNTING

Wheel Loader Safety S0103010K

PRECAUTIONS WHEN HANDLING FLUIDS

S0103010K Wheel Loader Safety

FIRE EXTINGUISHER AND FIRST AID KIT

Wheel Loader Safety S0103010K

Any reinforcement system that is installed on

INSTALL ADDITIONAL SAFETY EQUIPMENT IF CONDITIONS REQUIRE

MAINTAIN STANDARD SAFETY EQUIPMENT IN GOOD CONDITION

S0103010K Wheel Loader Safety

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 SHOULD BE USED AT ALL

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

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

NEVER LET ANYONE RIDE ON

S0103010K Wheel Loader Safety

CLEAN BEFORE INSPECTION OR

Wheel Loader Safety S0103010K

FIRE PREVENTION AND EXPLOSION PREVENTION