Daewoo Doosan Mega 300-V Shop Manual 023-00041AE - PDF DOWNLOAD by www.heydownloads.com

Mega 300-V Shop Manual 023-00041AE Serial Number 1001 and Up (Tier I & II) December 2002

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.

023-00041AE Shop Manual

Trim Out The Label Along The Lines And Insert Into Pocket On The Binder Spine

Pub. No. 023-00041AE

Mega 300-V

Instructions

Serial Number 1001 and Up (Tier I & II)

Pub.No. 023-00041AE

Product Label

1TABLE OF CONTENTS Safety Wheel Loader Safety .......................................................................... S0103010K

Speciﬁcations Specifications for Mega 300-V............................................................ S0203080K

General Maintenance General Maintenance Procedures .........................................................S0302000 Standard Torques ..................................................................................S0309000

Upper Structure Counterweight..................................................................................... S0403030K Fuel Transfer Pump ...............................................................................S0405500 Hydraulic Oil Tank .............................................................................. S0406050K

Lower Structure and Chassis Center Joint (Articulation Joint)........................................................... S0502030K

Engine and Drive Train Front Axle (Volvo SLA 15/W).............................................................. S0602180K Rear Axle (Volvo SLA 12/W) .............................................................. S0602190K Parking Brake Caliper (Volvo) ...............................................................S0603000 Air Conditioner .................................................................................... S0605050K Transmission and Torque Converter (ZF 4WG-210) .......................... S0607090K Transmission Error Codes (ZF) .......................................................... S0607900C

Hydraulics Accumulator...........................................................................................S0703000 Cylinders............................................................................................. S0705005K Fan Drive Hydraulic Motor (Haldex) ................................................... S0707100K

Table of Contents Page I

Main Pump (Denison) ......................................................................... S0708485K Brake Pedal Valve .............................................................................. S0709250K Main Control Valve (Toshiba) ............................................................. S0709456K Pilot Control Valve .............................................................................. S0709477K Priority Valve (Danfoss) ...................................................................... S0709651K Power Steering Unit............................................................................ S0709730K Restriction Valve................................................................................. S0709751K Hydraulic Schematic (Mega 300-V) .................................................... S0793070K

Electrical System Electrical System ................................................................................ S0802200K Electrical Schematic (Mega 300-V) .................................................... S0893070K

Attachments

Table of Contents Page 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 300-V (Tier I)

1001 thru 2000

Mega 300-V (Tier II)

2001 and Up

Mega 400-V

1001 and Up

Mega 500-V (Tier I)

1001 thru 2000

Mega 500-V (Tier II)

2001 and Up

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 Page 2

Wheel Loader Safety

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.

“Location of Safety Labels” on page 6.

“Unauthorized Modifications” on page 6.

“General Hazard Information” on page 7.

“Before Starting Engine” on page 15.

“Machine Operation” on page 18.

“Maintenance” on page 25.

“Battery” on page 33.

“Towing” on page 35.

10.

“Shipping and Transportation” on page 36.

Wheel Loader Safety

S0103010K 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.

S0103010K Page 4

Wheel Loader Safety

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.

Wheel Loader Safety

S0103010K 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.

S0103010K Page 6

Wheel Loader Safety

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.

Wheel Loader Safety

S0103010K 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. While working on the machine, never use inadequate tools. They could break or slip, causing injury, or they may not adequately perform intended functions.

S0103010K Page 8

HAOA020L

Figure 1

Wheel Loader Safety

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.

•

Never use cleaning.

compressed

air

for

•

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.

ARO1770L

Figure 2

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 (both feet and one hand or one foot and both hands) with the handholds and steps to ensure that you support yourself securely.

HA3O1003

Figure 3

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.

Wheel Loader Safety

S0103010K 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 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.

Figure 4

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

S0103010K Page 10

Wheel Loader Safety

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 so that it cannot move.

HDO1010L

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 extinguisher at regular intervals and make sure that all work site crew members are adequately trained in its use.

HDO1009L

Figure 8

•

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.

Wheel Loader Safety

S0103010K 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 Protective Structure and/or ROPS/Roll Over Protective Structure reinforcement system.

HAOA110L

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 relocating fasteners. Any serious impact or damage to system requires a complete integrity reevaluation. Reinstallation, recertification and/ or replacement of system may be necessary.

HAOA100L

Figure 10

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.

S0103010K Page 12

Wheel Loader Safety

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 danger.

Wheel Loader Safety

ARO1770L

Figure 11

S0103010K 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 glass.

S0103010K Page 14

Figure 12 RIGHT SIDE

Wheel Loader Safety

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 highvoltage 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.

Figure 13

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.

Wheel Loader Safety

S0103010K 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.

S0103010K Page 16

Wheel Loader Safety

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.

Wheel Loader Safety

S0103010K 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. Replace damaged safety labels and lost or damaged operator’s manuals.

HAOA151L

Figure 14

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.

S0103010K Page 18

Wheel Loader Safety

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 not possible to level area or avoid working on a slope, reducing size and cycling rate workload is recommended.

TURBO-II

)

m(16''

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 always avoid working bucket over downhill side of machine when parked perpendicular to slope. Avoid full extensions of bucket in a downhill direction. Lifting bucket too high, too close to machine, while wheel loader is turned uphill can also be hazardous.

Wheel Loader Safety

400 m

m(16

'') AHO0970L

Figure 16

S0103010K Page 19

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

MINIMUM SAFE DISTANCE

6.6 kV

3 m (9’ 10")

33.0 kV

4 m (13’ 1")

66.0 kV

5 m (16’ 5")

154.0 kV

8 m (26’ 3")

275.0 kV

10 m (32’ 10")

Figure 17

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.

S0103010K Page 20

Wheel Loader Safety

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 loader and plan ahead while working. Park wheel loader away from overhangs before work shut down.

HDO1042L

Figure 18

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 commonly understood signal so that other members of work crew can warn operator to slow or halt work in an impending hazardous situation.

HAOA171L

Figure 19

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.

Wheel Loader Safety

S0103010K 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.

S0103010K Page 22

Wheel Loader Safety

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.

Wheel Loader Safety

S0103010K 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

S0103010K Page 24

Wheel Loader Safety

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

Warning tags for controls are available from Daewoo distributors; see Figure 23. CLEAN BEFORE INSPECTION OR MAINTENANCE

HAOC920L

Clean the machine before carrying out inspection and maintenance. This prevents dirt from getting into the machine and also ensures safety during maintenance.

Figure 23

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.

Wheel Loader Safety

S0103010K 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. There is also danger that the battery gas may catch fire and cause and explosion.

HDO1040L

Figure 26

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.

S0103010K Page 26

Wheel Loader Safety

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.

Wheel Loader Safety

S0103010K 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 unauthorized persons from entering.

S0103010K Page 28

HDO1041L

Figure 28

Wheel Loader Safety

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 getting on or off the machine, use the steps and handrails, and maintain a three-point contact (both feet and one hand or both hands and one foot) to support yourself securely.

ARO1380L

Figure 29

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.

Wheel Loader Safety

S0103010K 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.

S0103010K Page 30

Wheel Loader Safety

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.

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.

Wheel Loader Safety

S0103010K 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 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.

•

Always put oil drained from your 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.

HAOA470L

Figure 31

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.

S0103010K Page 32

Wheel Loader Safety

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.

Wheel Loader Safety

S0103010K 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 machine or vehicle do not allow the two machines to touch. Wear safety glasses or goggles while required battery connections are made.

HAOA310L

Figure 33

•

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 nonseriesconnected 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.

S0103010K Page 34

Wheel Loader Safety

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.

Wheel Loader Safety

S0103010K 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 attachments.

configuration

and

•

Weight, radius.

height

lifting

•

Safe rigging of load.

•

Proper handling of suspended load.

lifting

and

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.

S0103010K Page 36

Wheel Loader Safety

1SPECIFICATIONS

S0203080K

1SPECIFICATIONS FOR MEGA 300-V CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that is in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility.

SPECIFICATIONS FOR MEGA 300-VS0203080K MODEL

SERIAL NUMBER RANGE

Mega 300-V (Tier I)

1001 thru 2000

Mega 300-V (Tier II)

2001 and Up

S0203080K Page 1

TABLE OF CONTENTS Component Locations .................................................................................... 4 General Specifications ................................................................................... 6 Engine Performance Curves .......................................................................... 8 Working Range and Dimensions.................................................................. 12 Working Capacities ...................................................................................... 15 Bucket Capacity .................................................................................... 15 Tipping Load ......................................................................................... 15 Material Weight ............................................................................................ 15 Approximate Weight of Workload Materials .......................................... 15

S0203080K Page 2

Specifications for Mega 300-V

S0203080K Page 3

COMPONENT LOCATIONS Figure 1 identifies the location of major machine components.

Figure 1

S0203080K Page 4

Specifications for Mega 300-V

Reference Number

Description

Reference Number

Description

Bucket Tooth

Cac Cooler

Bucket

Radiator

Air Conditioner Condenser

Grill

Rear Wheel Cover

Fan

Battery Box

Fuel Tank

Rear Light

Engine Oil Filler Pipe

Counterweight

Engine Oil Filter

Fan Motor

Engine Oil Level Gauge

Towing Pin

Rear Axle Pivot

Tool Box / Fuel Pump

Rear Axle

Oil Tank

Drive Shaft (Rear)

Tilt Lever

Transmission

Front Wheel Cover

Transmission Oil Filter

Bucket Cylinder

Drive Shaft (Center)

Headlight Support

Center Pin

Ladder

Steering Wheel Cylinder

Work Light

Boom Cylinder

Operator’s Cab

Drive Shaft (Front)

Air Cleaner

Parking Brake

Pre-cleaner

Front Axle

Engine

Loader Arm

Muffler

Link

Specifications for Mega 300-V

S0203080K Page 5

GENERAL SPECIFICATIONS MEGA 300-V Item

Specification

Serial Number

1001 thru 2000

Standard Bucket Capacity

2.90 m3

Vehicle Weight

17,300 kg (38,150 lb)

2001 and Up

(3.80 yd )

Engine Type

Daewoo DE12TIS

Daewoo DE08TIS

Rated power (SAE J 1995 gross)

235 ps @ 2,100 rpm (232 hp @ 2,100 rpm)

212 ps @ 2,100 rpm (209 hp @ 2,100 rpm)

Max. Torque (SAE J 1995 gross)

110 kg•m / 1,200 rpm (796 ft lb @ 1,200 rpm)

92 kg•m / 1,300 rpm (666 ft lb @ 1,300 rpm)

Transmission Full Automatic Power -Shift

Full Automatic Power Shift

Speeds

4 Forward, 3 Reverse

Brake Systems Service Brakes

4 Wheel, Wet Multi Disks, Dual Pedal

Parking Brake

Dry Disc on Front Axle

Performance Travel Speed (1 / 2 / 3 / 4)

7.6 (4.7) / 13.5 (8.4) / 24.0 (14.9) / 36.5 (22.7) km/h (mph)

Steering Angle

+ 40°

Min. Tire Turning Radius (OutTire Center)

5,470 mm (17’ - 11")

Max Tractive Effort

16,400 kg (36,156 lb)

Max. Breakout Force

18,500 kg (40,790 lb)

Bucket Rise Time

5.4 Seconds

Bucket Dump Time

1.5 Seconds

Bucket Descent Time

4.0 Seconds

Maximum Gradeability

58% (30°)

Working Range Dump Height at 45° (w/o teeth)

2,962 mm (9’ - 8")

Dump Reach at 45° (w/o teeth)

1,152 mm (3’ - 9")

Max Dump Angle at Fully Raised

47°

Max Tilt Angle at Carry

47°

Travel Dimension

S0203080K Page 6

Overall Length

8,085 mm (26’ - 6")

Overall Width

2,920 mm (9’ - 7")

Overall Height

3,470 mm (11’ - 5")

Wheel Base

3,200 mm (10’ - 6")

Tread

2,150 mm (7’ - 0")

Ground Clearance

470 mm (1’ - 6")

Specifications for Mega 300-V

S0203080K Page 7

ENGINE PERFORMANCE CURVES

AMS0210L

Figure 2 (S/N 1001 thru 2000)

S0203080K Page 8

Specifications for Mega 300-V

Serial Number

1001 thru 2000

Engine Type

DE12TIS

Rated Power

235 ps @ 2,100 rpm (232 hp @ 2,100 rpm)

Maximum Torque

110 kg•m @ 1,200 rpm (795 ft lb @ 1,200 rpm)

Fuel Consumption

160 g / ps.h

Performance Standard

NOTE:

SAE J 1995 gross

Barometric Pressure: 760 mm (30") Mercury Temperature: 20°C (68°F) W/O Cooling Fan: Driven by hydraulic fan motor Alternator: 24 V, 50 amp Exhaust System: Complete, attached Air Cleaner; Installed

Specifications for Mega 300-V

S0203080K Page 9

BIS0240L

Figure 3 (S/N 2001 and Up)

S0203080K Page 10

Specifications for Mega 300-V

Serial Number

2001 and Up

Engine Type

DE08TIS

Rated Power

212 ps @ 2,200 rpm (209 hp @ 2,200 rpm)

Maximum Torque

92 kg•m @ 1,300 rpm (666 ft lb @ 1,300 rpm)

Fuel Consumption

160 g / ps.h

Performance Standard

NOTE:

SAE J 1995 gross

Barometric Pressure: 760 mm (30") Mercury Temperature: 20°C (68°F) W/O Cooling Fan: Driven by hydraulic fan motor Alternator: 24 V, 50 amp Exhaust System: Complete, attached Air Cleaner; Installed

Specifications for Mega 300-V

S0203080K 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.

G E

B (D) A

I H b

AMO0370L

Figure 4

S0203080K Page 12

Specifications for Mega 300-V

Category

Dimension

Overall Length (A)

8,085 mm (26’ 6")

Overall Width (B)

2,920 mm (9’ 7")

Overall Height (C)

3,470 mm (11’ 5")

Bucket Width (D)

2,920 mm (9’ 7")

Wheel Base (E)

3,200 mm (10’ 6")

Tread (F)

2,150 mm (7’ 0")

Ground Clearance (G)

470 mm (1’ 6")

Dump Height, to tooth (H)

2,780 mm (9’ 1")

Dump Distance, to Bucket Edge (I)

1,152 mm (3’ 9")

Dump Height to Bucket Pivot (K)

4,000 mm (13’ 1")

Max. Dump Angle at Fully Raised (a)

47°

Max. Tilt Angle at Carry (b)

47°

Tire Size

23.5-25-16 PR(L3)

Specifications for Mega 300-V

S0203080K Page 13

Figure 5, illustrate working range when machine is equipped with optional Pallet. E

D AMS0220L

Figure 5 Reference Number

Dimension

Reference Number

Dimension

1519.5 mm (4’ 11")

1,800 mm (5’ 11")

1873.5 mm (6’ 2")

798 mm (2’ 7")

3749.5 mm (12’ 3")

36.4°

8834.5 mm (28’ 12")

34.7°

S0203080K Page 14

Specifications for Mega 300-V

WORKING CAPACITIES BUCKET CAPACITY Standard toothed bucket has a capacity of 2.9 m3 (3.8 yd3). An optional bucket equipped with a cutting edge and no teeth has a capacity of 2.9 m3 (3.8 yd3). TIPPING LOAD Static Tipping Load with bucket in Over Front position is 13,500 kg (28,890 lb). With bucket in Fully Turned position, Static Tipping Load is 11,100 kg (24,480 lb).

MATERIAL WEIGHT The data below describes weight of a cubic meter (cubic yard) of many types of workload materials. APPROXIMATE WEIGHT OF WORKLOAD MATERIALS LOW WEIGHT OR DENSITY 1,100 KG/M3 (1,850 LB/YD3), OR LESS

MEDIUM WEIGHT OR DENSITY 1,600 KG/M3 (2,700 LB/YD3), OR LESS

HIGH WEIGHT OR DENSITY 2,000 KG/M3 (3,370 LB/YD3), OR LESS

Charcoal

401 kg/m3 (695 lb/yd3)

---------------------

Coke, blast furnace size

433 kg/m3 (729 lb/yd3)

---------------------

Coke, foundry size

449 kg/m3 (756 lb/yd3)

---------------------

Coal, bituminous slack, piled

801 kg/m3 (1,350 lb/yd3)

---------------------

Coal, bituminous r. of m., piled

881 kg/m3 (1,485 lb/yd3)

---------------------

Coal, anthracite

897 kg/m3 (1,512 lb/yd3)

---------------------

Clay, DRY, in broken lumps

1,009 kg/m3 (1,701 lb/yd3)

---------------------

Clay, DAMP, natural bed

---------------------

1,746 kg/m3 (2,943 lb/yd3)

---------------------

MATERIAL

Specifications for Mega 300-V

S0203080K Page 15

MATERIAL

LOW WEIGHT OR DENSITY 1,100 KG/M3 (1,850 LB/YD3), OR LESS

MEDIUM WEIGHT OR DENSITY 1,600 KG/M3 (2,700 LB/YD3), OR LESS

HIGH WEIGHT OR DENSITY 2,000 KG/M3 (3,370 LB/YD3), OR LESS

Cement, Portland, DRY granular

---------------------

1,506 kg/m3 (2,583 lb/yd3)

---------------------

Cement, Portland, DRY clinkers

---------------------

1,362 kg/m3 (2,295 lb/yd3)

---------------------

Dolomite, crushed

---------------------

1,522 kg/m3 (2,565 lb/yd3)

---------------------

Earth, loamy, DRY, loose

---------------------

1,202 kg/m3 (2,025 lb/yd3)

---------------------

Earth, DRY, packed

---------------------

1,522 kg/m3 (2,565 lb/yd3)

---------------------

Earth, WET, muddy

---------------------

1,762 kg/m3 (2,970 lb/yd3)

Gypsum, calcined, (heated, powder)

961 kg/m3 (1,620 lb/yd3)

---------------------

Gypsum, crushed to 3 inch size

---------------------

1,522 kg/m3 (2,565 lb/yd3)

---------------------

Gravel, DRY, packed fragments

---------------------

1,810 kg/m3 (3,051 lb/yd3)

Gravel, WET, packed fragments

---------------------

1,922 kg/m3 (3,240 lb/yd3)

Limestone, graded above 2

---------------------

1,282 kg/m3 (2,160 lb/yd3)

---------------------

Limestone, graded 1-1/2 or 2

---------------------

1,362 kg/m3 (2,295 lb/yd3)

---------------------

Limestone, crushed

---------------------

1,522 kg/m3 (2,565 lb/yd3)

---------------------

Limestone, fine

---------------------

1,602 kg/m3 (2,705 lb/yd3)

Phosphate, rock

---------------------

1,282 kg/m3 (2,160 lb/yd3)

---------------------

S0203080K Page 16

Specifications for Mega 300-V

LOW WEIGHT OR DENSITY 1,100 KG/M3 (1,850 LB/YD3), OR LESS

MEDIUM WEIGHT OR DENSITY 1,600 KG/M3 (2,700 LB/YD3), OR LESS

HIGH WEIGHT OR DENSITY 2,000 KG/M3 (3,370 LB/YD3), OR LESS

Salt

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

---------------------

Snow, light density

529 kg/m3 (891 lb/yd3)

---------------------

Sand, DRY, loose

---------------------

1,522 kg/m3 (2,565 lb/yd3)

---------------------

Sand, WET, packed

---------------------

1,922 kg/m3 (3,240 lb/yd3)

Shale, broken

---------------------

1,362 kg/m3 (2,295 lb/yd3)

---------------------

Sulphur, broken

529 kg/m3 (1,620 lb/yd3)

---------------------

MATERIAL

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.

Specifications for Mega 300-V

S0203080K Page 17

S0203080K Page 18

Specifications for Mega 300-V

1GENERAL MAINTENANCE

S0302000 R1

1GENERAL MAINTENANCE PROCEDURES CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that is in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility.

GENERAL MAINTENANCE PROCEDURESS0302000 MODEL ALL MODELS

SERIAL NUMBER RANGE ALL RANGES

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 Page 2

General Maintenance Procedures

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.

General Maintenance Procedures

S0302000 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.

Never weld when the engine is running. Battery cables must be disconnected before the welding procedure is started.

Never weld on a wet or damp surface. The presence of moisture causes hydrogen embrittlement and structural weakening of the weld.

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.

During equipment setup, always attach ground cables directly to the area or component being welded to prevent arcing through bearings, bushings, or spacers.

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.

S0302000 Page 4

General Maintenance Procedures

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.

General Maintenance Procedures

S0302000 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.

Prepare joint surfaces before assembly by checking alignment and flatness. Clean and repair corrosion or any other damage.

Follow bolt torque recommendations and all other assembly requirements.

S0302000 Page 6

General Maintenance Procedures

NOTE:

Grease lip assembly.

seals

before

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.

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.

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.

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

General Maintenance Procedures

S0302000 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:

S0302000 Page 8

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.

General Maintenance Procedures

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

General Maintenance Procedures

S0302000 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

S0302000 Page 10

General Maintenance Procedures

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

General Maintenance Procedures

S0302000 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

S0302000 Page 12

General Maintenance Procedures

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. Replace bearing if over heating damage is indicated. Check seals and other related parts for damage.

Figure 17

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

General Maintenance Procedures

S0302000 Page 13

S0302000 Page 14

General Maintenance Procedures

S0309000 R1

1STANDARD TORQUES

CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that is in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility.

STANDARD TORQUESS0309000 MODEL ALL MODELS

SERIAL NUMBER RANGE ALL RANGES

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 Page 2

Standard Torques

TORQUE VALUES FOR STANDARD METRIC FASTENERS The units for the torque values are kg•m (ft lb).

NOTE:

Grade Dia. x Pitch (mm)

M5 x Std. M6 x Std. M7 x Std. M8 x Std. M8 x 1 M10 x Std. M10 x 1 M12 x Std. M12 x 1.5 M14 x Std. M14 x 1.5 M16 x Std. M16 x 1.5 M18 x Std. M18 x 1.5 M20 x Std. M20 x 1.5 M22 x Std. M22 x 1.5 M24 x Std. M24 x 1.5

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

(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

(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

(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

(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

(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

(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

(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

(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

(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

(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

(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

(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

(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

(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

(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

(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

(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

(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

(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

(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

(166.35)

(253.15)

(267.62)

(224.22)

(325.48)

(202.52)

(441.21)

(484.61)

(535.24)

(672.66)

(744.99)

Standard Torques

S0309000 Page 3

TORQUE VALUES FOR STANDARD U.S. FASTENERS TYPE

S.A.E. GRADE

1 OR 2

BOLT HEAD MARKING

DESCRIPTION WILL HAVE NO MARKINGS IN THE CENTER OF THE HEAD. 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.)

Joints are rigid, that is, no gaskets or compressible materials are used.

When reusing nuts or bolts, use minimum torque values. NOTE:

NOTE:

S0309000 Page 4

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.

When reusing bolts and nuts in service, use minimum torque values.

Standard Torques

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 THREAD SIZE

1/4" - 20 1/4" - 28 5/16" - 18 5/16" - 24 3/8" - 16 3/8" - 24 7/16" - 14 7/16" - 20 1/2" - 13 1/2" - 20 9/16" - 12 9/16" - 18 5/8" - 11 5/8" - 18 3/4" - 10 3/4" - 16 7/8" - 9 7/8" - 14 1" - 8 1" - 14 1 1/8" - 7 1 1/8" - 12 1 1/4" - 7 1 1/4" - 12 1 3/8" - 6 1 3/8" - 12 1 1/2" - 6 1 1/2" - 12 1 3/4" - 5 2" - 4 1/2 NOTE:

GRADE 5 (3 RADIAL DASHES ON HEAD) NEWTON FOOT POUNDS METER (ft lb) (N•m) 6 8 7 9 13 18 15 20 24 33 27 37 38 52 42 57 58 79 65 88 84 114 93 126 115 156 130 176 205 278 240 312 305 414 334 454 455 617 510 691 610 827 685 929 860 1166 955 1295 1130 1532 1290 1749 1400 2034 1690 2291 2370 3213 3550 4813

GRADE 8 (6 RADIAL DASHES ON HEAD) FOOT POUNDS (ft lb)

NEWTON METER (N•m)

9 11 18 21 34 38 54 60 82 90 120 132 165 185 290 320 455 515 695 785 990 1110 1400 1550 1830 2085 2430 2730 3810 5760

12 15 24 28 46 52 73 81 111 122 163 179 224 251 393 434 617 698 942 1064 1342 1505 1898 2102 2481 2827 3295 3701 5166 7810

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.

Standard Torques

S0309000 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.

Phosphate coated bolts used with phosphate coated prevailing torque nuts (nuts with distorted threads or plastic inserts).

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

1/4" 5/16" 3/8" 7/16" 1/2" 9/16" 5/8" 3/4" 7/8" 1" 1 - 1/8" 1 - 1/4" 1 - 3/8" 1 - 1/2" 1 - 3/4" 2

S0309000 Page 6

KILOGRAM METER (kg•m)

FOOT POUNDS (ft lb)

1.1 2.2 3.9 6.2 9.7 13.8 19.4 33.2 53.9 80.2 113.4 160.4 210.2 279.4 347.1 522.8

8 16 28 45 70 100 140 240 390 580 820 1160 1520 2020 2510 3780

Standard Torques

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

CLAMP TYPE AND SIZE

RADIATOR, AIR CLEANER, BOOTS, ETC.

HYDRAULIC SYSTEM

KILOGRAM METER (kg•m)

INCH POUNDS (in lb)

KILOGRAM METER (kg•m)

INCH POUNDS (in lb)

"T" Bolt (Any Diameter)

0.68 - 0.72

59 - 63

-------

------

Worm Drive - Under 44 mm (1-3/4 in) Open Diameter

0.2 - 0.3

20 - 30

0.5 - 0.6

40 - 50

Worm Drive - Over 44 mm (1-3/4 in) Open Diameter

0.5 - 0.6

40 - 50

-------

------

Worm Drive - All "UltraTite"

0.6 - 0.7

50 - 60

0.5 - 0.6

40 - 50

Standard Torques

S0309000 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 SIZE (*)

BOLT SIZE

1/2" 3/4" 1" 1 - 1/4" 1 - 1/2" 2" 2 - 1/2" 3" 3 - 1/2"

5/16" 3/8" 3/8" 7/16" 1/2" 1/2" 1/2" 5/8" 5/8"

KILOGRAM METER (kg•m)

FOOT POUNDS (ft lb)

2.1 - 2.5 3.0 - 3.7 3.7 - 4.8 4.8 - 6.2 6.4 - 8.0 7.6 - 9.0 10.9 - 12.6 19.1 - 20.7 16.2 - 18.4

15 - 18 22 - 27 27 - 35 35 - 45 46 - 58 55 - 65 79 - 91 138 - 150 117 - 133

(*) - Inside diameter of flange on end of hydraulic tube or hose fitting. NOTE:

S0309000 Page 8

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

Standard Torques

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 scale or dial.

Figure 1

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:

I= NOTE:

AxT A+B

12 x 300 12 + 12

3600 24

= 150

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.

Standard Torques

S0309000 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.

S0309000 Page 10

Standard Torques

I. "Loctite" Fastener Adhesives

Application

Color

Removal

Break-away Cure Strength (in lb) of Sealer Alone

Low strength for 6 mm (1/4") or smaller fasteners.

Purple

Hand tools

Medium strength for 6 mm (1/4") and larger fasteners.

Blue

Hand tools

High strength for high grade fasteners subject to shock, stress and vibration.

Red

Heat/260°C (500°F) Remove HOT

160

271

Extra high strength for fine thread fasteners up to 25 mm (1") diameter.

Red

Heat/260°C (500°F) Remove HOT

160

272

High temperature/high strength for hostile environments to 232°C (450°F).

Red

Heat/316°C (600°F) Remove HOT

180

277

Extra high strength for coarse thread fasteners 25 mm (1") diameter and larger.

Red

Heat/260°C (500°F) Remove HOT

210

Product

222 242 243

262

(NO solvent)

II. "Loctite" Pipe Thread Sealant Product

Application

Color

Removal

Required Setup

545

"No-filler/non-clog" formula for highpressure hydraulic systems. Overapplication will not restrict or foul system components.

Purple

Hand tools

4 Hours (or 1/2 hour with Locquic "T" Primer)

656

Solvent-resistant, higher viscosity tapered thread sealer.

White

Hand tools

4 Hours (or 1/2 hour with Locquic "T" Primer)

III. "Loctite" gasket/flange sealer Product

Application

Color

Notes

Red

Use Locquic "N" primer for fast (1/2 - 4 hours) setup. Unprimed setup 4 - 24 hours.

518

Gasket eliminator specifically made for aluminum flanges/surfaces. For hydraulic systems to 34,475 kPa (5,000 psi).

504

Low pressure/wide-gap gasket eliminator compound. Fills gaps to 0.0012 mm (0.030"), cures to rigid seal.

Orange

Use Locquic "N" primer for faster (1/2 - 4 hours) setup. Unprimed setup 4 - 24 hours.

515

General purpose, fast setup, flexible-cure gasket eliminator. For nonrigid assemblies subject to shock, vibration or deflection.

Purple

Use Locquic "N" primer for faster (1/4 - 2 hours) setup. Unprimed setup 1 - 12 hours.

Standard Torques

S0309000 Page 11

IV. "Loctite" retaining compounds Product

Application

Color

Notes

609

For bushings, sleeves, press-fit bearings, splines and collars. For gaps to 0.0002 mm (0.005"), temperatures to 121°C (250°F).

Green

Use Locquic "N" primer for increased bond strength and all cold temperature applications.

620

For high temperatures to 232°C (450°F).

Green

Same as 609, above.

680

For high strength bonds and tight clearance gaps, to 0.00008 mm (0.002").

Green

Same as 609, above.

V. "Loctite" Adhesives Product

Application

Color

Notes

380

Black Max instant adhesive for shock and vibration-resistant bonds.

Black

May take 120 hours to reach full cure strength.

454

Adhesive for porous surfaces.

Clear

Full strength in 24 hours.

480

Increased strength (+50%), shock and vibration-resistant.

Black

Full strength in 24 hours.

S0309000 Page 12

Standard Torques

1UPPER STRUCTURE

Return to Master Table of Contents

S0403030K R2

1COUNTERWEIGHT

COUNTERWEIGHT

S0403030K

MODEL

SERIAL NUMBER RANGE

Mega 200-V (Tier I & II)

1001 and Up

Mega 250-V (Tier I)

1001 thru 2000

Mega 250-V (Tier II)

2001 and Up

Mega 300-V (Tier I)

1001 thru 2000

Mega 300-V (Tier II)

2001 and Up

Mega 400-V

1001 and Up

S0403030K Page 1

Return to Master Table of Contents

TABLE OF CONTENTS Specifications ................................................................................................. 3 Counterweight ................................................................................................ 3

S0403030K Page 2

Counterweight

Return to Master Table of Contents

SPECIFICATIONS NOTE:

Weight. Model

Weight

Serial Number Range

Mega 200-V

622 kg (1,370 lb)

S/N 1001 and Up

Mega 250-V

992 kg (2,190 lb)

S/N 1001 thru 2000

Mega 250-V

1,100 kg (2,430 lb)

S/N 2001 and Up

Mega 300-V

1,100 kg (2,430 lb)

S/N 1001 thru 2000

Mega 300-V

1,100 kg (2,430 lb)

S/N 2001 and Up

Mega 400-V

1,550 kg (3,420 lb)

S/N 1001 and Up

COUNTERWEIGHT 1

AJS0620L

Figure 1 NOTE:

Counterweight

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

S0403030K Page 3

Return to Master Table of Contents

S0403030K Page 4

Counterweight

S0405500

1FUEL TRANSFER PUMP

FUEL TRANSFER PUMPS0405500 MODEL

SERIAL NUMBER RANGE

Mega 130

0001 and Up

Mega 160

0001 and Up

Mega 200-III

1001 and Up

Mega 200-V (Tier I & II)

1001 and Up

Mega 250-III

1001 and Up

Mega 250-V (Tier I)

1001 thru 2000

Mega 250-V (Tier II)

2001 and Up

Mega 300-V (Tier I)

1001 thru 2000

Mega 300-V (Tier II)

2001 and Up

Mega 400-III PLUS

1001 and Up

Mega 400-V

1001 and Up

Mega 500-V

1001 thru 2000

Mega 500-V (Tier II)

2001 and Up

Solar 75-V

1001 and Up

Solar 130LC-V

0001 and Up

Solar 130W-V

0001 and Up

Solar 140W-V

1001 and Up

Solar 160W-V

1001 and Up

Solar 170LC-V

1001 and Up

Models continued on back of cover.

S0405500 Page 1

MODEL

SERIAL NUMBER RANGE

Solar 170W-V

1001 and Up

Solar 180W-V

1001 and Up

Solar 200W-V

0001 and Up

Solar 210W-V

1001 and Up

Solar 220LC-V

0001 and Up

Solar 220LL

1001 and Up

Solar 220N-V

1001 and Up

Solar 225LC-V

1001 and Up

Solar 250LC-V

1001 and Up

Solar 255LC-V

1001 and Up

Solar 290LC-V

0001 and Up

Solar 290LL

1001 and Up

Solar 300LC-V

1001 and Up

Solar 300LL

1001 and Up

Solar 330LC-V

1001 and Up

Solar 340LC-V

1001 and Up

Solar 400LC-V

1001 and Up

Solar 420LC-V

1001 and Up

Solar 450LC-V

1001 and Up

Solar 470LC-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 Page 2

Fuel Transfer Pump

GENERAL DESCRIPTION THEORY OF OPERATION

Figure 1

Description

Reference Number

Motor

Inlet Hose

Pump

Outlet Hose

2-1

Pump Cover

Check Valve

2-2

Rotor and Vane

Strainer Cap

Reference Number

Description

Fuel pump consists of motor, pump, switch and hose assembly.

Figure 2

Fuel Transfer Pump

S0405500 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

S0405500 Page 4

Fuel Transfer Pump

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 hole of screw in the housing.

Figure 7

Be careful when installing screw. The cover screw may be attracted by the motor magnet.

Fuel Transfer Pump

S0405500 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.

S0405500 Page 6

Fuel Transfer Pump

S0406050K

1HYDRAULIC OIL TANK

HYDRAULIC OIL TANKS0406050K MODEL

SERIAL NUMBER RANGE

Mega 300-V (Tier I)

1001 thru 2000

Mega 300-V (Tier II)

2001 and Up

S0406050K Page 1

TABLE OF CONTENTS General Description........................................................................................ 3 Parts List ................................................................................................. 3 Specifications .......................................................................................... 4

S0406050K Page 2

Hydraulic Oil Tank

GENERAL DESCRIPTION PARTS LIST

Figure 1

Reference Number

Description

Reference Number

Description

Return Filter

Air Breather

By-pass Valve

Level Gauge

Spring

Drain Plug

Suction Filter

Hydraulic Oil Tank

S0406050K Page 3

SPECIFICATIONS

Mega 300-V Type

Pressurized Sealing

Capacity (System)

210 liters (55 U.S. gal.)

Air breather Open Pressure

0.40 kg/cm2 (5.7 psi)

Vacuum pressure

0.035 kg/cm2 (0.5 psi) at 900 liters (238 U.S. gal.)/min

Return Filter Filtration rating

10 µ

Pressure drop

0.2 kg/cm2 (3 psi) at 600 liters (159 U.S. gal.)

Suction Filter

S0406050K Page 4

177 µ

Hydraulic Oil Tank

1LOWER STRUCTURE AND CHASSIS

S0502030K

1CENTER JOINT (ARTICULATION JOINT) CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that is in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility.

CENTER JOINT (ARTICULATION JOINT)S0502030K MODEL

SERIAL NUMBER RANGE

Mega 300-V (Tier I)

1001 thru 2000

Mega 300-V (Tier II)

2001 and Up

S0502030K Page 1

TABLE OF CONTENTS General Description........................................................................................ 3 Maintenance Standard ............................................................................ 4

S0502030K Page 2

Center Joint (Articulation Joint)

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. Prior to moving (traveling) the loader, make sure the frame lock plate is set to the original position.

Center Joint (Articulation Joint)

Figure 1

S0502030K Page 3

MAINTENANCE STANDARD

Figure 2

S0502030K Page 4

Center Joint (Articulation Joint)

Unit: mm No.

Check item

Clearance between upper hinge pin and rear frame

Criteria

Standard size

Tolerance

Remedy

Standard clearance

Clearance limit

66.7

-0.040 -0.076

+0.060 +0.030

0.070 0.136

Clearance between upper hinge pin and spacer (small)

66.7

-0.040 -0.076

+0.060 +0.030

0.070 0.136

Clearance between upper hinge pin and bearing

66.7

-0.040 -0.076

0 -0.015

0.055 0.076

Clearance between upper hinge pin and spacer (large)

66.7

-0.040 -0.076

+0.060 +0.030

0.055 0.076

Clearance between rear frame and spacer (large)

+0.060 +0.030

-0.036 -0.090

0.066 0.15

Clearance between front frame and upper hinge bearing

122.3

-0.048 -0.088

-0.037 -0.062

-0.011 -0.125

Clearance between lower hinge pin and rear frame

66.7

-0.020 -0.076

+0.046 0

0.020 0.122

Clearance between lower hinge pin and bearing

66.7

-0.020 -0.076

0 -0.015

0.035 0.076

Clearance between front frame and lower hinge bearing

122.3

-0.048 -0.088

-0.037 -0.062

-0.11 -0.125

Height of upper hinge spacer (small)

28.5 +0 -0.13

Height of upper hinge spacer (large)

55.5 +0 -0.13

Shim thickness for upper hinge and retainer (front frame)

0.5 - 1.04

Shim thickness for upper hinge and retainer (rear frame)

2.24 3.55

Tightening torque of upper hinge retainer mounting bolt

When adjusting with shim: 4 ±0.2 kg•m

Tightening torque of upper hinge retainer mounting bolt

When adjusting with shim: 4 ±0.2 kg•m

Final value: 13 ±1.0 kg•m Final value: 13 ±1.0 kg•m Retighten

Tightening torque of upper hinge pin mounting bolt

13 ±1.0 kg•m

Tightening torque of lower hinge pin mounting bolt

13 ±1.0 kg•m

Center Joint (Articulation Joint)

Replace

S0502030K Page 5

S0502030K Page 6

Center Joint (Articulation Joint)

1ENGINE AND DRIVE TRAIN

S0602180K

1FRONT AXLE (VOLVO SLA 15/W) 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.

FRONT AXLE (VOLVO SLA 15/W)S0602180K MODEL

SERIAL NUMBER RANGE

Mega 300-V (Tier I)

1001 thru 2000

Mega 300-V (Tier II)

2001 and Up

S0602180K Page 1

TABLE OF CONTENTS General Description........................................................................................ 5 Outline..................................................................................................... 5 Drive Axle................................................................................................ 5 Axle Mount ....................................................................................... 5 Differential (Standard) ............................................................................. 8 Differential Operation ....................................................................... 8 Limited Slip Differential Cross Section (Option) ............................... 8 Parking Brake Operation ......................................................................... 9 Parts List ............................................................................................... 11 Front Axle Housing ........................................................................ 11 Front Axle Differential..................................................................... 12 Front Planetary Gear Set ............................................................... 14 Parking Brake................................................................................. 16 Scheduled Maintenance............................................................................... 20 After First 250 Hours ............................................................................. 20 Every 150 hours .................................................................................... 20 Every 1500 Hours ................................................................................. 21 Lubricant Specifications ........................................................................ 21 General Disassembly and Reassembly Instructions .................................... 22 General Instructions .............................................................................. 22 Assembling Leakproof Components ..................................................... 23 Axle Disassembly ......................................................................................... 23 Drain Oil ................................................................................................ 23 Final Drive ............................................................................................. 24 Differential Assembly............................................................................. 28 Overhauling Super Max Trac Assembly ................................................ 31 Checking Clearance on Assembled Disc Packs.................................... 31 Axle Reassembly.......................................................................................... 32 Determining Thickness of Adjustment Shims........................................ 32 Inner Oil Recirculation Piping................................................................ 33

S0602180K Page 2

Front Axle (Volvo SLA 15/W)

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

Front Axle (Volvo SLA 15/W)

S0602180K Page 3

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Front Axle (Volvo SLA 15/W)

GENERAL DESCRIPTION OUTLINE Front Axle Frame-Fixed, Semi-Floating

Type Serial Number

1001 thru 2000

2001 and Up

Overall Reduction Ratio Differential type

24.685

STD.

Max. Trac (Locking Ration: 30%)

OPT.

Super Max Trac (Limited Slip: 45%)

Max Static Load

35,700.0 kg (78,710 lb)

Max Output Torque

11,800.0 kg•m (85,350 ft lb)

Type Brake

Parking Brake

Multi Wet Disc

Torque

2,532 kg•m @ 80 Bar (18,314 ft lb @ 1,160 psi)

2,362 kg•m @ 80 Bar (17,084 ft lb @ 1,160 psi)

Type

C-CLAMP SAHR

SAHR CALIPER DISC BRAKE

Torque

306.0 kg•m (2,213 ft lb)

342.0 kg•m (2,474 ft lb)

70 - 140 Bar (1,015 - 2,030 psi))

102 - 230 Bar (1,479 - 3,336 psi)

Release Press.

Drive Flange

DRIVE AXLE The drive axle consists of the differential, final reduction gear assembly, wet type hydraulic disk brake unit, and axle shafts to which wheels are attached. The power from the drive unit is transmitted through the drive shafts to the front and rear drive axles. The power is then transmitted to the differential where it is divided into the right and left axle shafts to the final reduction gear assembly on each shaft end thus driving the wheels. The wet type hydraulic disk brake unit is installed in front of the final reduction gear assembly and serves as a service brake. Axle Mount The front axle is bolted directly to the front frame. The rear axle is supported by the trunnion method in which axle supports are installed across the rear axle and bolted to the rear frame. Consequently, the rear axle is cradled up and down around the center line of the differential according to the ground condition the loader travels. The trunnion-mounted drive axle helps improve operator comfort because loaders with a trunnion-mounted drive axle jolt less than those with the conventional cradle-supported drive axle, when they travel on bad ground conditions.

Front Axle (Volvo SLA 15/W)

S0602180K Page 5

SECTION A AJS0641L

Figure 1 DRIVE AXLE ASSEMBLY

S0602180K Page 6

Front Axle (Volvo SLA 15/W)

Reference Number

Description

Reference Number

Description

Front Axle

Bushing

Rear Axle

Thrust Plate

Axle Support (Front)

Thrust Cap

Axle Support (Rear)

Thrust Washer

Packing

NOTE:

1) 28 kg•m (200 ft lb) Threaded area: Loctite #262.

NOTE:

2) 140 kg•m (1010 ft lb).

NOTE:

3) 170 kg•m (1230 ft lb).

NOTE:

4) Inner surface: Grease (Assemble with chamfered surface toward axle.)

NOTE:

5) Assemble with lip pointing outward.

NOTE:

6) Assemble with groove pointing toward plate (7).

NOTE:

7) Apply grease and assemble.

Front Axle (Volvo SLA 15/W)

S0602180K 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 Number

Description

Reference Number

Description

Pinion Gear

Spider

Side Gear

Drive Pinion

Axle Shaft

Ring Gear

Differential Gear Case

Limited Slip Differential Cross Section (Option) Figure 3, shows a cross-sectional view of the parts contained in the limited slip differential.

S0602180K Page 8

Front Axle (Volvo SLA 15/W)

Reference Number

Description

Ring Gear

Bevel Pinion

Cross

Upper Thrust Ring

Outer Disc

Inner Disc

Cover

Clutch Disc

Side Gear

Lower Thrust Ring

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

Front Axle (Volvo SLA 15/W)

S0602180K Page 9

S0602180K Page 10

Front Axle (Volvo SLA 15/W)

PARTS LIST Front Axle Housing

Figure 4 Reference Number

Description

Reference Number

Description

Housing; Front

O-ring

Plug; Magnetic

Tube Assembly

O-ring

Bolt

Plug; Drain

O-ring

Tube Assembly - R.H.

Breather; Air

Tube Assembly - L.H.

Bolt

Front Axle (Volvo SLA 15/W)

S0602180K Page 11

Front Axle Differential

Figure 5

S0602180K Page 12

Front Axle (Volvo SLA 15/W)

Reference Number

Description

Reference Number

Description

Carrier Assembly

Spider

Carrier; Front

Washer; Thrust

Cap

Washer; Thrust

Bolt

Flange Assembly

Case Assembly

Flange

Case - L.H.

Cover

Case - R.H.

Holder

Bolt

Nut

Washer; Plain

Bolt

Set; Bevel

Shim T = 0.1 mm

Pinion; Bevel

Shim T = 0.3 mm

Gear; Bevel Ring

Shim T = 0.5 mm

Nut

Shim T = 1.0 mm

Bearing

Shim T = 0.3 mm

Bearing

Shim T = 0.5 mm

Pump

Seal; Oil

Bolt

Gear; Side

Washer; Plain

Pinion; Differential

Pin; Split

Front Axle (Volvo SLA 15/W)

Shim T = 0.1 mm

Pin; Spring

S0602180K Page 13

Front Planetary Gear Set

Figure 6

S0602180K Page 14

Front Axle (Volvo SLA 15/W)

Reference Number

Description

Reference Number

Description

Drum Assembly-hub

Bolt

Drum; Hub

Bolt

Pin; Planetary

Ring; Retaining

Gear; Planetary

Ring; Retaining

Spacer

Plate; Lock

Bearing; Needle

Plate

Washer; Thrust

Stud; Wheel

Washer; Thrust

Nut; Wheel

Plug

Washer; Thrust

O-ring

Drum

Shaft; Bevel Gear

Disc; Brake

Hub; Wheel

Spacer

Spindle Assembly-L.H.

Spring; Return

Spindle Assembly-R.H.

Cover

Spindle-l.h.

Rod; Push

Spindle-r.h.

Plate

Seal

Piston

Spacer

O-ring

Bolt

O-ring

Cover

Bearing D140x195x291

Gear; Sun

Bearing

Gear; Ring

Seal; Oil

Support

O-ring

Ring; Retaining

O-ring

Nut; Adjusting

Disc

Breather

Plug

NOTE:

No. of Brake Discs (Front): 4 EA (Rear): 4 EA

Front Axle (Volvo SLA 15/W)

S0602180K Page 15

Parking Brake

Figure 7 (S/N 1001 thru 2000)

S0602180K Page 16

Front Axle (Volvo SLA 15/W)

Reference Number

Description

Reference Number

Description

Rod; End

Body; Cylinder

Nut; Hex

Guide; Ring

Rod

Rod; Packing

Sleeve

Dust; Wiper

Nut; Hex

Spring

Cover

Flange

Cover; Tie Rod

Nut; Stopper

Caliper; Clamp

Tie Rod

Bolt; Hex

Washer; Spring

Plate; Wa

Disc; Brake

Dust; Wiper

Bolt; Hex

Rod; Packing

Washer; Spring

Guide; Ring

Bolt; Hex

Stud

Washer; Spring

Nut; Hex

Pin; Split

Washer; Spring

Cylinder Kit

Front Axle (Volvo SLA 15/W)

S0602180K Page 17

Figure 8 (S/N 2001 and Up)

S0602180K Page 18

Front Axle (Volvo SLA 15/W)

Reference Number

Description

Reference Number

Description

Bracket

Bolt

Nut

Disc

Cover

Bolt

O-ring

Spring Washer

Bolt

Brake Caliper

Breather

body

Cap

Pad

Bolt

Shuttle

Nut

Ring

Split Pin

Wagnet

Ring

Piston

Seal

Ring

Plate Ring

O-ring

Lock Plate

Front Axle (Volvo SLA 15/W)

S0602180K Page 19

SCHEDULED MAINTENANCE

Figure 9

AFTER FIRST 250 HOURS Replace oil in axle assembly as follows: 1.

Differential Unit. •

Remove fill plug (1) and drain oil from drain plug (2).

•

Replace drain plug (2) and refill through plug (1) until oil if overflowing.

Side Final Drives. •

Position plug (3) at bottom, remove plug and drain oil.

•

Refill by rotating hub 90o (so "OIL LEVEL" writing is horizontal) and add oil until it overflows, replace plug (3).

EVERY 150 HOURS Check oil in axle assembly as follows: 1.

Differential Unit. •

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

S0602180K Page 20

Front Axle (Volvo SLA 15/W)

Side Final Drives. •

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

EVERY 1500 HOURS Replace oil in axle assembly as follows: 1.

Differential Unit. •

Remove fill plug (1) and drain oil from drain plug (2)

•

Replace drain plug (2) and refill through plug (1) until oil if overflowing.

Side Final Drives. •

Position plug (3) at bottom, remove plug and drain oil.

•

Refill by rotating hub 90o (so "OIL LEVEL" writing is horizontal) and add oil until it overflows, replace plug (3).

LUBRICANT SPECIFICATIONS For differential and final drive units: •

Oil specification: MOBIL INFILREX 33 80 W 90

•

Corresponding to: SAE 90 or SAE 80 W 90 rating

NOTE:

Daewoo recommends oils with LIMITED-SLIP (LS) additives to prevent noise when brakes are actuated.

Front Axle (Volvo SLA 15/W)

S0602180K Page 21

GENERAL DISASSEMBLY AND REASSEMBLY INSTRUCTIONS WARNING! Never use gasoline, solvents, or other flammable fluids to clean components. Only use approved commercial solvents that are nonflammable and nontoxic.

IMPORTANT Use only GENUINE DAEWOO SPARE PARTS to warrant proper operations and prevent interchangeability problems. GENERAL INSTRUCTIONS 1.

Thoroughly clean and dry axle before disassembly.

All components should be thoroughly cleaned and dried before reassembly. Dirt, chips, and foreign material may cause failures.

All ducts and castings should be thoroughly cleaned and dried to remove dirt, chips, and foreign material to prevent damage after reassembly.

Reassembly should be done in a clean shop, and should be as dust free as possible.

Make sure tools and equipment are at hand.

When reassembling Daewoo strongly recommends to replace the following parts with new. •

Seal Rings.

•

O-rings.

•

Gaskets.

•

Threaded rings with notched collar.

•

Any component damaged during disassembly.

When mounting heat fitted components, make sure of their proper position and direction of assembly, after they have cooled.

To heat bearings, use proper heating plates, piping, or suitable ovens. NOTE:

Never heat parts by using a torch. Oil bath, heated by a torch, maybe used to warm components.

Lubricate all sections concerned when reassembling shafts, bearings, etc.

10.

Lubricate O-rings before installing them in relevant seats to prevent kinking during assembly, such a position would impair proper sealing.

11.

Replace gears only in matched sets to make sure of proper tooth mating.

S0602180K Page 22

Front Axle (Volvo SLA 15/W)

ASSEMBLING LEAKPROOF COMPONENTS 1.

Use of proper sealing compounds is recommended when assembling matched parts to be sealed against fluid leakage (oil or water), and no sealing gasket is used.

Best results are reached, with said compounds, when matching surfaces are thoroughly cleaned, degreased, and dried before spreading a uniform coat over contact area.

Daewoo suggests to use the following compounds: •

Loctite Plastic Gasket

•

Rhodorsil CAF 1

•

Silastic 732 RTV

AXLE DISASSEMBLY

Figure 10

DRAIN OIL 1.

Differential Unit. •

Remove fill plug (1) and drain oil from drain plug (2).

Side Final Drives. •

Position plug (3) at bottom, remove plug and drain oil.

Front Axle (Volvo SLA 15/W)

S0602180K Page 23

FINAL DRIVE

Figure 11

S0602180K Page 24

Front Axle (Volvo SLA 15/W)

WARNING! Lift and handle all heavy components by using proper equipment. Make sure that assemblies or components are lifted and held with the use of proper slings and hooks. Use specific lifting eyes. Always make sure that people are out of the way when lifting. 1.

Remove six cover mounting screws (1), then remove final drive cover (2). NOTE:

Cover (2) is provided with three threaded holes for puller screws.

Remove O-ring (3).

Using a puller screw, remove axle shaft backing plate (4).

Provide suitable support for side gear carrier (6), then remove screws (5) fixing side gear carrier to wheel hub (7), and pry side gear carrier (6) to separate from wheel hub (7).

Pull side gear carrier (6) out of wheel hub.

Remove lock ring (9) retaining sun gear (10), and remove sun gear from wheel shaft (14).

Remove disc carrier hub (11) along with thrust washer (12) resting against wheel hub sleeve.

Remove solid and lined brake discs (13).

Remove wheel shaft (14).

10.

Remove lock ring (15) securing lock (16), then remove ring nut (17).

Front Axle (Volvo SLA 15/W)

S0602180K Page 25

Figure 12

Spring Retainer Installed A

NOTE:

Spring Retainer

Ring Nut

Pressure Plate

Return Spring

Install a spring retainer (A), secured thru three threaded holes of disc pressure plate (18), to compress return spring (19) and allow removal of ring nut (17).

11.

Unlock and remove ring nut (17) from sleeve (27).

12.

Remove pressure plate (18) along with brake return spring retainer (A).

13.

Provide suitable support for wheel hub (7) and pull ring gear unit (21) and support (22) from hub.

14.

Remove six rods (24) in seats on ring gear support (22).

15.

Using a screwdriver, pry off lock ring (23) from ring gear (21).

16.

Disassemble ring gear support (22) from ring gear (21). NOTE:

17.

Should replacement of outer wheel bearing (25) inner race be mandatory, old part can be removed by a proper puller, or by a remover that can be inserted in specific holes of ring gear support (22).

Remove brake return spring retainer (A) and disassemble return spring (19), retaining cup (20), and pressure plate (18).

S0602180K Page 26

Front Axle (Volvo SLA 15/W)

18.

Using compressed air thru brake oil ducting, remove brake actuating piston (26) from wheel hub sleeve (27).

19.

Remove and replace with new two O-rings (28) and (29) in seats on brake actuating piston.

20.

Remove complete wheel hub (7).

21.

Remove O-ring (8).

22.

Pry off seal (30) from wheel hub (7), and remove inner race with roller cage of inner wheel bearing (31).

23.

Using a proper remover, push out outer races of inner and outer wheel bearings (25) and (30) from wheel hub (7). NOTE:

Should sleeve (27) be damaged, it can be removed by undoing relevant screws (32). At reassembly, smear proper sealing compound on axle case joining flange, then tighten screws. Torque to 900 ±45 N•m (91.8 ±4.6 kg•m / 663.8 ±30 ft lb).

24.

Mark side gear pins (33), various components and seats (34) for identification of original position at reassembly.

25.

Arrange side gear carrier (6) on wooden blocks and push out pins (33) with proper remover.

26.

Pick up all needle rollers (35). NOTE:

27.

It is important to keep matched needle rollers (35) and thrust washers (36) with relevant pin (33), this is consequent to predetermined assembly tolerance limits.

Remove side gears (37) and relevant thrust washers (38). NOTE:

No gear can be removed before having released all of them.

Front Axle (Volvo SLA 15/W)

S0602180K Page 27

DIFFERENTIAL ASSEMBLY

Figure 13 1.

Release and remove six screw (1) that secure outer recirculation piping (2) and three seals (3).

Check wear condition of components and repair or replace as required.

Unlock and remove screws (4) retaining differential assembly, then remove differential assembly from axle case.

S0602180K Page 28

Front Axle (Volvo SLA 15/W)

Figure 14 4.

Hammer out spring pins (2) locking slotted rings (3).

Mark caps (4) to match parts at reassembly.

Remove screws (5), caps (4), and slotted rings (3).

Remove differential case assembly from support (11).

Straighten locking notches on pinion nut collar (6), position reaction tool on drive flange to unlock nut (6), release pinion nut, remove drive flange (9) from pinion shank along with washer (8).

Pry seal (10) from drive flange.

Front Axle (Volvo SLA 15/W)

S0602180K Page 29

10.

Remove bevel pinion (7) from differential support (11), hammer pinion shank with a proper removal tool. NOTE:

Be careful not to damage threads on pinion (7).

11.

Pick up inner race of pinion shank bearing (13).

12.

Remove outer races of outer and inner pinion bearings (13) and (14) from differential support (11), pick up shims (15). NOTE:

13.

Be careful not to loose shims (15) for pinion axial position adjustment, store in a safe place for reassembly.

Remove spacer (16) with shims (17) for bearing pre-load adjustment, using a proper puller remove inner race of pinion under head bearing (14). NOTE:

Be careful not to loose shims for bearing pre-load adjustment, store in a safe place for reassembly.

14.

Mark differential half cases (18) and (19) for reference at reassembly, then remove screws (19a) and separate half cases (18) and (19).

15.

Make a visual and dimensional check of wear on sun gears (21), side gears (20), thrust washers (22) and (23), friction discs (22a), backing discs (22), and spider (24).

16.

Using a proper puller, remove bearings (25) from half cases (18) and (19).

17.

Clamp ring gear (26) in a vise fitted with soft caps, then remove screws (27) securing ring gear (26) to half case (18).

18.

Fit inner races of differential bearings (25) on half cases (18) and (19) NOTE:

19.

Mount bevel ring gear (26) on half case (18), secure with screws (27). NOTE:

20.

This operation should be carried out by heating equipment or use a proper installer.

Torque to 900 ±45 N•m (91.8 ±4.6 kg•m / 663.8 ±30 ft lb).

Position differential components in their proper seats.

S0602180K Page 30

Front Axle (Volvo SLA 15/W)

OVERHAULING SUPER MAX TRAC ASSEMBLY 1.

Select backing discs (22) to reach, as assembling is completed, prescribed clearance of 0.05 - 0.10 mm (0.0020 0.0039") all around both disc packs. NOTE:

When packing friction and backing disc, pay particular care to position of first disc (22a), it is molybdenum plated on one side only. Disc (22a) is in contact with sun gear (21), and molybdenum plated side must face backing disc (22).

Join half cases (18) and (19) matching reference marks made at disassembly.

Mount and secure case halves (18) and (19) with screws (19a). NOTE:

Figure 15

Torque to 220 ±11 N•m (22.4 ±1.12 kg•m / 162.3 ±8 ft lb).

CHECKING CLEARANCE ON ASSEMBLED DISC PACKS 1.

Check should be carried out all around at points placed at 120o to one another on both disc packs to prevent mileacting recording of values due to spider and sun gear play. NOTE:

Should recorded clearance not be as specified, disc packs must be reformed to prescribed value of 0.05 - 0.10 mm (0.0020 - 0.0039"). Figure 16

Front Axle (Volvo SLA 15/W)

S0602180K Page 31

AXLE REASSEMBLY DETERMINING THICKNESS OF ADJUSTMENT SHIMS

Figure 17 1.

Some dimensions should be recorded before starting reassembly of bevel pinion to determine thickness of spacer to be fitted between inner (under head) pinion bearing and backing of relevant seat in differential support.

Record dimension from ring gear axis to seat inner (under head) pinion bearing (that will be identified as "A"). •

A number "X" prefix by symbol "±" is marked on bevel pinion face. This value is expressed in tenth of millimeter, indicates deviation from theoretical distance from pinion under head to ring gear axis. •

Example: "D" = 54.85 mm.

Compute thickness of shim "S" for proper axial position of bevel pinion: S = A - (B + D). •

Example: B = 231.7 + 0.1 = 231.8 mm.

Measure thickness of pinion head bearing and identify as "D." •

Example: +1 = +0.1 mm.

Consequently, the true distance (identified as "B") will be: B = 321.7 ± deviation. •

Example: "A" = 290.6 mm.

Example: S = 290.6 - (231.8 + 54.85) = 3.95 mm.

Increase by 0.05 mm the computed thickness value to compensate subsequent bearing pre-load. Round off to nearest tenth of millimeter to computed thickness value. •

Example: 4.02 rounded off = 4 mm. 3.88 rounded off = 3.9 mm.

S0602180K Page 32

Front Axle (Volvo SLA 15/W)

INNER OIL RECIRCULATION PIPING

Figure 18 1.

Remove pipes (A) and (B), remove seals (C) from axle housing.

Check wear condition of pipes (A) and (B), replace with new if required.

Replace seals (C) with new.

Front Axle (Volvo SLA 15/W)

S0602180K Page 33

DIFFERENTIAL ASSEMBLY

Figure 19

AXIAL POSITION OF BEVEL PINION 1.

Press fit inner race of inner (under head) bearing (14) on pinion by using heating equipment or use of proper installer.

Position shim (15), see "Determining Thickness of Adjustment Shims," in its seat and press fit outer races of inner (under head) and outer bearings (13) and (14) of pinion.

S0602180K Page 34

Front Axle (Volvo SLA 15/W)

Fit impeller (16) on pinion along with shims (17) for bearing pre-load adjustment, then mount inner race of pinion outer bearing (13). NOTE:

To facilitate proper pre-load computation, it is advisable to mount as many shims as required to warrant a pinion end play and not a pre-load (that could be excessive) on bearings.

Fit drive flange (9) on pinion (7), position specific reaction tool and tighten nut (6). Remove reaction tool. NOTE:

Torque from 570 - 630 N•m (58 - 64 kg•m / 419 - 463 ft lb).

Check pinion end play using a dial gauge, then disassemble and change shims to eliminate all end play and reach intended pre-load.

Reassembly components, check that proper pre-load of bearing corresponding to a revolving torque (no seal installed). NOTE:

Revolving torque of 2 - 4 N•m (0.2 - 0.4 kg•m / 1.5 - 3.0 ft lb).

As the prescribed pre-load of bearings has been reached, remove drive flange (9) and fit lip seal (10) into its proper seat.

Remount drive flange (9) and tighten to specified torque. NOTE:

Torque from 570 - 630 N•m (58 - 64 kg•m / 419 - 463 ft lb).

Position differential assembly with ring gear on support (11), insert ring nut (3), and temporarily adjust back lash.

10.

Mount caps (4), being careful not to invert position, secure support to differential with screws (5). NOTE:

Torque to 880 - 920 N•m (90 - 94 kg•m / 650 - 680 ft lb).

11.

Check differential end play with a dial gauge.

12.

Screw in a ring nut to have a notch aligned against slot of lockplate, and actuate opposite nut up to eliminate end play. NOTE:

When end play is eliminated, set bearing preload by screwing in ring nut one more notch.

ADJUSTING BACKLASH 1.

Position a dial gauge perpendicular to ring gear (26) tooth, with pinion steady check backlash. •

Standard backlash of bevel gear set: 0.30 - 0.41 mm (0.0118 - 0.0161").

•

To obtain backlash within specified range, rotate both ring nuts (3), displacing them same number of notches.

•

Moving toward ring gear to pinion, if backlash is too LARGE.

•

Moving away ring gear to pinion, if backlash is too SMALL.

Front Axle (Volvo SLA 15/W)

Figure 20

S0602180K Page 35

ADJUSTING TOOTH CONTACT 1.

Coat face of 7 or 8 teeth of bevel gear lightly with red lead. Hold bevel gear by hand to act as a brake, rotate pinion gear forward and backward, then inspect pattern left on teeth.

Correct Pattern Drive Side.

Figure 21 Neutral Side.

Figure 22 Increase Pinion Distance Drive Side.

Figure 23 Neutral Side.

Figure 24

S0602180K Page 36

Front Axle (Volvo SLA 15/W)

Decrease Pinion Distance Drive Side.

Figure 25 Neutral Side.

Figure 26 NOTE:

When adjusting bevel gear, do not change pre-load of bearing. Adjust by rotating both ring nuts the same number of notches.

Fit spring pins (2) to lock differential ring nuts.

Make two lock notches on pinion nut collar (6).

Front Axle (Volvo SLA 15/W)

S0602180K Page 37

S0602180K Page 38

Front Axle (Volvo SLA 15/W)

SECURING DIFFERENTIAL TO AXLE HOUSING

Figure 27 1.

Thoroughly clean mating surfaces, apply sealing compound and mount differential assembly on axle housing, and secure with screws (4). NOTE:

Torque to 330 ±16.5 N•m (33.7 ±1.69 kg•m / 243.4 ±12.2 ft lb).

Install outer oil recirculation piping (2) with new seals (3), and secure with six screws (1).

Front Axle (Volvo SLA 15/W)

S0602180K Page 39

FINAL DRIVE

Figure 28 1.

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

S0602180K Page 40

Front Axle (Volvo SLA 15/W)

Position inner race with roller cage of wheel inner side bearing (31) before fitting lip seal (31).

Install O-ring (8).

Install wheel inner bearing (31) into sleeve (27). NOTE:

Support wheel hub (7) during assembly stage to prevent damage to seal.

Lubricate seals (28) and (29) on piston (26), then insert at travel end on wheel hub sleeve (27).

Using heating equipment or proper installer, fit inner race of wheel outer bearing (25) on ring gear support (22), then mount support (22) in ring gear (21) and secure with lock ring (23).

Mount ring gear (21) and support (22) unit onto sleeve (27).

Fit six rods (24) into seats on ring gear support (22).

Install spring retainer and compress spring (19) with retaining cup (20) onto pressure plate (18).

10.

Mount pressure plate and spring assembly onto ring gear support (22).

11.

Hand screw ring nut (17) onto wheel hub sleeve (27).

12.

With a wrench, tighten ring nut (17) to the prescribed pre-load for wheel bearings and corresponding to a revolving torque, checking alignment of lock plates (16). NOTE:

Revolving Torque: 15 - 30 N•m (1.5 - 3.1 kg•m / 11.1 - 22.1 ft lb).

NOTE:

To prevent recording wrong torque values, it is advisable to seat bearing properly before checking, by revolving wheel hub repeatedly.

13.

Remove spring retainer compressing brake actuator return spring.

14.

Insert lock plates (16) securing ring nut and install lock ring (15).

15.

Arrange three side gear gears (37) in proper seats of side gear carrier (6). NOTE:

Two rows of needle rollers of same selection class should be used for replacement in each single side gear pin.

16.

Insert outer thrust washers (36), apply grease to pin lower portion (head end) and position the first row of needle rollers, insert spacer and apply grease to upper portion of pin, then position second row of needle rollers (35).

17.

Position outer thrust washers (38) of side gear on side gear carrier and align holes.

18.

Insert and force fit complete pins (33). NOTE:

Avoid any bump or knock that could cause rollers to fall.

19.

Insert wheel shaft (14).

20.

Insert thrust washer (39).

21.

Mount disc carrier hub (11) onto wheel shaft (14).

22.

Mount brake discs, alternating solid discs and lined discs. (See "Determining Space Available to Form Brake Disc Pack"). NOTE:

Insert a solid disc (outer teeth) facing pressure plate (12).

23.

Insert sun gear (10) and secure with lock ring (9).

24.

Mount side gear carrier (6) on side gear unit and secure onto wheel hub (7) with screws (5). NOTE:

Torque to: 70 ±3.5 N•m (7.1 ±0.4 kg•m / 51.6 ±2.6 ft lb).

25.

Force fit wheel shaft backing plate (4).

26.

Mount O-ring seal (3) on edge.

Front Axle (Volvo SLA 15/W)

S0602180K Page 41

27.

Rotate and align pins (33) to allow mounting of cover (2), which also acts as a pin lock to prevent their rotation.

28.

Fit side final drive cover (2).

29.

Apply sealing compound to screws (1) and secure cover (2). NOTE:

Torque to: 35 ±1.75 N•m (3.6 ±0.18 kg•m / 25.8 ±1.29 ft lb).

DETERMINING SPACE AVAILABLE TO FORM BRAKE DISC PACK 1.

Record depth from seating surface of side gear carrier on wheel hub to outer edge of ring gear, identify value as "A."

Record depth from ring gear outer edge to brake pressure plate, identify value as "B."

Subtract value "B" from value "A" and identify as value "D." •

Example: A - B = D. Figure 29

Record depth from disc reaction face to outer edge of side gear carrier, identify value as "C."

Add value "C" to value "D" to provide space available to form brake disc pack. •

Example: C + D = X

Figure 30

S0602180K Page 42

Front Axle (Volvo SLA 15/W)

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

Figure 31

Front Axle (Volvo SLA 15/W)

S0602180K Page 43

PARKING BRAKE (S/N 1001 THRU 2000)

Figure 32

S0602180K Page 44

Front Axle (Volvo SLA 15/W)

DISASSEMBLY 1.

Unlock right and left counternuts (1) of adjustment sleeve (2).

Remove nuts (3) retaining hydraulic cylinder (5) to bracket (4), then undo sleeve (2) and remove cylinder (5).

Undo two screws (7) securing caliper to support, then remove brake caliper assembly (6).

Undo eight screws (8) and remove brake disc (9) from drive flange.

Remove split pin (10) from stem (14), unscrew spring reaction nut (11), then remove thrust washer (13) and spring (12). NOTE:

In case of leaks, remove stem (14) to replace seals (15) seated in cylinder body (5).

REASSEMBLY 1.

Reassembly hydraulic cylinder (5).

Mount brake disc (9) on drive flange and lock eight screws (8). NOTE:

Mount caliper assembly (6) to support and lock two screws (7). NOTE:

Torque from 185 - 205 Nm (18.9 - 20.9 kg•m / 136.3 - 151.2 ft lb).

Mount hydraulic cylinder (5) on support (4) with lock washer and two nuts (3). NOTE:

Torque from 62 - 68 Nm (6.3 - 6.9 kg•m / 45 - 50 ft lb).

Torque from 43 - 48.7 Nm (4.4 - 5.0 kg•m / 31.7 - 35.9 ft lb).

Connect linkage thru adjustment sleeve (2).

ADJUSTMENT 1.

Apply pressure to cylinder (5) of 70 - 140 bar (1,015 - 2,030 psi), checking that stem (14) is at travel end (about 65 mm {2.56"} of spring compression.

Actuate sleeve (2) to adjust disc (9) to pad clearance up to 0.25 mm (0.009") reach on each side. NOTE:

For fine adjustment of clearance on each side of pads it is necessary to undo counternut (16) and actuate screw (17).

Release pressure and check that stem (14) return travel is about 40 mm (1.58").

Restore pressure and check that clearance and travel remain unchanged (repeating many times).

Lock counternuts (1) and (16) of pad adjustment screws (17) and sleeve (2).

Front Axle (Volvo SLA 15/W)

S0602180K Page 45

PARKING BRAKE (S/N 2001 AND UP) NOTE:

S0602180K Page 46

Refer to "Parking Brake (S0603000)" for S/N 2001 and Up.

Front Axle (Volvo SLA 15/W)

S0602190K

1REAR AXLE (VOLVO SLA 12/W) 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.

REAR AXLE (VOLVO SLA 12/W)S0602190K MODEL

SERIAL NUMBER RANGE

Mega 300-V (Tier I)

1001 thru 2000

Mega 300-V (Tier II)

2001 and Up

S0602190K Page 1

TABLE OF CONTENTS General Description........................................................................................ 5 Outline..................................................................................................... 5 Drive Axle................................................................................................ 5 Axle Mount ....................................................................................... 5 Differential (Standard) ............................................................................. 8 Differential Operation ....................................................................... 8 Limited Slip Differential Cross Section (Option) ............................... 8 Parts List ............................................................................................... 11 Rear Axle Housing ......................................................................... 11 Rear Axle Differential ..................................................................... 12 Rear Axle Planetary Gear Set ....................................................... 14 Scheduled Maintenance............................................................................... 16 After First 250 Hours ............................................................................. 16 Every 150 hours .................................................................................... 17 Every 1500 Hours ................................................................................. 17 Lubricant Specifications ........................................................................ 17 General Disassembly and Reassembly Instructions .................................... 18 General Instructions .............................................................................. 18 Assembling Leakproof Components ..................................................... 19 Axle Disassembly ......................................................................................... 19 Drain Oil ................................................................................................ 19 Final Drive ............................................................................................. 20 Differential Assembly............................................................................. 25 Overhauling Super Max Trac Assembly ................................................ 28 Checking Clearance on Assembled Disc Packs.................................... 28 Axle Reassembly.......................................................................................... 29 Determining Thickness of Adjustment Shims........................................ 29 Differential Assembly............................................................................. 30 Axial Position of Bevel Pinion ................................................................ 30 Adjusting Backlash................................................................................ 31

S0602190K Page 2

Rear Axle (Volvo SLA 12/W)

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

Rear Axle (Volvo SLA 12/W)

S0602190K Page 3

S0602190K Page 4

Rear Axle (Volvo SLA 12/W)

GENERAL DESCRIPTION OUTLINE Rear Axle Type

Trunnion Mounting, Semi-Floating

Overall Reduction Ratio Differential type

24.685 STD.

Max. Trac (Locking Ration: 30%)

OPT.

Super Max Trac (Limited Slip: 45%)

Max Static Load

28,500.0 kg (62,830 lb)

Max Output Torque

8,790.0 kg•m (63,580 ft lb)

Brake

Type

Multi Wet Disc

Torque

2,362 kg•m @ 80 Bar (17,084 ft lb @ 1,160 psi)

Drive Flange

DRIVE AXLE The drive axle consists of the differential, final reduction gear assembly, wet type hydraulic disk brake unit, and axle shafts to which wheels are attached. The power from the drive unit is transmitted through the drive shafts to the front and rear drive axles. The power is then transmitted to the differential where it is divided into the right and left axle shafts to the final reduction gear assembly on each shaft end? thus driving the wheels. The wet type hydraulic disk brake unit is installed in front of the final reduction gear assembly and serves as a service brake. Axle Mount The front axle is bolted directly to the front frame. The rear axle is supported by the trunnion method in which axle supports are installed across the rear axle and bolted to the rear frame. Consequently, the rear axle is cradled up and down around the center line of the differential according to the ground condition the loader travels. The trunnion-mounted drive axle helps improve operator comfort because loaders with a trunnion-mounted drive axle jolt less than those with the conventional cradle-supported drive axle, when they travel on bad ground conditions.

Rear Axle (Volvo SLA 12/W)

S0602190K Page 5

SECTION A AJS0641L

Figure 1 DRIVE AXLE ASSEMBLY

S0602190K Page 6

Rear Axle (Volvo SLA 12/W)

Reference Number

Description

Reference Number

Description

Front Axle

Bushing

Rear Axle

Thrust Plate

Axle Support (Front)

Thrust Cap

Axle Support (Rear)

Thrust Washer

Packing

NOTE:

1) 28 kg•m (200 ft-lb) Threaded area: Loctite #262.

NOTE:

2) 140 kg•m (1010 ft lb).

NOTE:

3) 170 kg•m (1230 ft lb).

NOTE:

4) Inner surface: Grease (Assemble with chamfered surface toward axle.)

NOTE:

5) Assemble with lip pointing outward.

NOTE:

6) Assemble with groove pointing toward plate (7).

NOTE:

7) Apply grease and assemble.

Rear Axle (Volvo SLA 12/W)

S0602190K Page 7

Figure 2 DIFFERENTIAL GEAR OPERATION

Reference Number

Description

Reference Number

Pinion Gear

Spider

Side Gear

Drive Pinion

Axle Shaft

Ring Gear

Differential Gear Case

Description

Limited Slip Differential Cross Section (Option) Figure 3, shows a cross-sectional view of the parts contained in the limited slip differential.

S0602190K Page 8

Rear Axle (Volvo SLA 12/W)

Reference Number

Description

Ring Gear

Bevel Pinion

Cross

Upper Thrust Ring

Outer Disc

Inner Disc

Cover

Clutch Disc

Side Gear

Lower Thrust Ring

Figure 3

Rear Axle (Volvo SLA 12/W)

S0602190K Page 9

S0602190K Page 10

Rear Axle (Volvo SLA 12/W)

PARTS LIST Rear Axle Housing

Figure 4 Reference Number

Description

Reference Number

Description

Housing; Rear

Plug; Drain M27x2

Plug; Magnetic

O-ring

Breather; Air

Rear Axle (Volvo SLA 12/W)

S0602190K Page 11

Rear Axle Differential

Figure 5

S0602190K Page 12

Rear Axle (Volvo SLA 12/W)

Reference Number

Description

Reference Number

Description

Carrier Assembly

Flange

Carrier; Rear

Cover

Cap

Holder

Bolt

Nut

Case Assembly

Bearing

Case-L.H.

Nut

Case-R.H.

Bolt

Shim T = 0.1 mm

Washer; Plain

Shim T = 0.3 mm

Set; Bevel

Shim T = 0.5 mm

Pinion; Bevel

Shim T = 1.0 mm

Gear; Bevel Ring

Nut

Spacer T = 20.525 mm

Bearing

Spacer T = 20.550 mm

Bearing

Spacer T = 20.575 mm

Bearing

Beam; Cross

Spacer T = 20.500 mm

Shim T = 0.1 mm Shim T = 0.3 mm

Seal; Oil

Gear; Side

Washer

Pinion; Differential

Spider

Pin; Spring

Washer; Thrust

Pin; Split

Washer; Thrust

Bolt

Screw

Washer; Plain

Flange Assembly

Pin; Split

Rear Axle (Volvo SLA 12/W)

Shim T = 0.5 mm

S0602190K Page 13

Rear Axle Planetary Gear Set

Figure 6

S0602190K Page 14

Rear Axle (Volvo SLA 12/W)

Reference Number

Description

Reference Number

Description

Drum Assembly - Hub.

Bolt

Drum; Hub

Bolt

Pin; Planetary

Ring; Retaining

Gear; Planetary

Ring; Retaining C

Spacer

Plate; Lock

Bearing; Needle

Plate

Washer; Thrust

Stud; Wheel

Washer; Thrust

Nut; Wheel

Plug

Washer; Thrust

O-ring

Drum

Shaft

Disc; Brake

Hub; Wheel

Spring; Return

Spindle Assembly-L.H.

Cover

Spindle Assembly-R.H.

Rod; Push

Spindle-L.H.

Plate

Spindle-R.H.

Piston

Seal

O-ring

Spacer

O-ring

Bolt

Bearing

Cover

Bearing; Tapper Roller

Gear; Sun

Seal; Oil

Gear; Ring

O-ring

Support

O-ring

Ring; Retaining

Disc

Nut; Adjusting

Plug

Breather; Oil

NOTE:

No. of Brake Discs (Front): 4 EA (Rear): 4 EA

Rear Axle (Volvo SLA 12/W)

S0602190K Page 15

SCHEDULED MAINTENANCE

Figure 7

AFTER FIRST 250 HOURS Replace oil in axle assembly as follows: 1.

Differential Unit. •

Remove fill plug (1) and drain oil from drain plug (2).

•

Replace drain plug (2) and refill through plug (1) until oil if overflowing.

Side Final Drives. •

Position plug (3) at bottom, remove plug and drain oil.

•

Refill by rotating hub 90o (so "OIL LEVEL" writing is horizontal) and add oil until it overflows, replace plug (3).

S0602190K Page 16

Rear Axle (Volvo SLA 12/W)

EVERY 150 HOURS Check oil in axle assembly as follows: 1.

Differential Unit. •

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

Side Final Drives. •

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

EVERY 1500 HOURS Replace oil in axle assembly as follows: 1.

Differential Unit. •

Remove fill plug (1) and drain oil from drain plug (2).

•

Replace drain plug (2) and refill through plug (1) until oil if overflowing.

Side Final Drives. •

Position plug (3) at bottom, remove plug and drain oil.

•

Refill by rotating hub 90o (so "OIL LEVEL" writing is horizontal) and add oil until it overflows, replace plug (3).

LUBRICANT SPECIFICATIONS For differential and final drive units: •

Oil specification: MOBIL INFILREX 33 80 W 90

•

Corresponding to: SAE 90 or SAE 80 W 90 rating

NOTE:

Daewoo recommends oils with LIMITED-SLIP (LS) additives to prevent noise when brakes are actuated.

Rear Axle (Volvo SLA 12/W)

S0602190K Page 17

IMPORTANT Use only GENUINE DAEWOO SPARE PARTS to warrant proper operations and prevent interchangeability problems. GENERAL INSTRUCTIONS 1.

Thoroughly clean and dry axle before disassembly.

All components should be thoroughly cleaned and dried before reassembly. Dirt, chips, and foreign material may cause failures.

All ducts and castings should be thoroughly cleaned and dried to remove dirt, chips, and foreign material to prevent damage after reassembly.

Reassembly should be done in a clean shop, and should be as dust free as possible.

Make sure tools and equipment are at hand.

When reassembling Daewoo strongly recommends to replace the following parts with new. •

Seal Rings.

•

O-rings.

•

Gaskets.

•

Threaded rings with notched collar.

•

Any component damaged during disassembly.

When mounting heat fitted components, make sure of their proper position and direction of assembly, after they have cooled.

To heat bearings, use proper heating plates, piping, or suitable ovens. NOTE:

Never heat parts by using a torch. Oil bath, heated by a torch, maybe used to warm components.

Lubricate all sections concerned when reassembling shafts, bearings, etc.

10.

Lubricate O-rings before installing them in relevant seats to prevent kinking during assembly, such a position would impair proper sealing.

11.

Replace gears only in matched sets to make sure of proper tooth mating.

S0602190K Page 18

Rear Axle (Volvo SLA 12/W)

ASSEMBLING LEAKPROOF COMPONENTS 1.

Use of proper sealing compounds is recommended when assembling matched parts to be sealed against fluid leakage (oil or water), and no sealing gasket is used.

Best results are reached, with said compounds, when matching surfaces are thoroughly cleaned, degreased, and dried before spreading a uniform coat over contact area.

Daewoo suggests to use the following compounds: •

Loctite Plastic Gasket

•

Rhodorsil CAF 1

•

Silastic 732 RTV

AXLE DISASSEMBLY

Figure 8

DRAIN OIL 1.

Differential Unit. •

Remove fill plug (1) and drain oil from drain plug (2).

Side Final Drives. •

Position plug (3) at bottom, remove plug and drain oil.

Rear Axle (Volvo SLA 12/W)

S0602190K Page 19

FINAL DRIVE

Figure 9

S0602190K Page 20

Rear Axle (Volvo SLA 12/W)

Remove six cover mounting screws (1), then remove final drive cover (2). NOTE:

Cover (2) is provided with three threaded holes for puller screws.

Remove O-ring (3).

Using a puller screw, remove axle shaft backing plate (4).

Provide suitable support for side gear carrier (6), then remove screws (5) fixing side gear carrier to wheel hub (7), and pry side gear carrier (6) to separate from wheel hub (7).

Pull side gear carrier (6) out of wheel hub.

Remove lock ring (9) retaining sun gear (10), and remove sun gear from wheel shaft (14).

Remove disc carrier hub (11) along with thrust washer (12) resting against wheel hub sleeve.

Remove solid and lined brake discs (13).

Remove wheel shaft (14).

10.

Remove lock ring (15) securing lock (16), then remove ring nut (17).

Rear Axle (Volvo SLA 12/W)

S0602190K Page 21

Figure 10

Spring Retainer Installed

NOTE:

Spring Retainer

Ring Nut

Pressure Plate

Return Spring

Install a spring retainer (A), secured thru three threaded holes of disc pressure plate (18), to compress return spring (19) and allow removal of ring nut (17).

11.

Unlock and remove ring nut (17) from sleeve (27).

12.

Remove pressure plate (18) along with brake return spring retainer (A).

13.

Provide suitable support for wheel hub (7) and pull ring gear unit (21) and support (22) from hub.

14.

Remove six rods (24) in seats on ring gear support (22).

15.

Using a screwdriver, pry off lock ring (23) from ring gear (21).

16.

Disassemble ring gear support (22) from ring gear (21). NOTE:

17.

Should replacement of outer wheel bearing (25) inner race be mandatory, old part can be removed by a proper puller, or by a remover that can be inserted in specific holes of ring gear support (22).

Remove brake return spring retainer (A) and disassemble return spring (19), retaining cup (20), and pressure plate (18).

S0602190K Page 22

Rear Axle (Volvo SLA 12/W)

18.

Using compressed air thru brake oil ducting, remove brake actuating piston (26) from wheel hub sleeve (27).

19.

Remove and replace with new two O-rings (28) and (29) in seats on brake actuating piston.

20.

Remove complete wheel hub (7)

21.

Remove O-ring (8).

22.

Pry off seal (30) from wheel hub (7), and remove inner race with roller cage of inner wheel bearing (31).

23.

Using a proper remover, push out outer races of inner and outer wheel bearings (25) and (30) from wheel hub (7). NOTE:

24.

Mark side gear pins (33), various components and seats (34) for identification of original position at reassembly.

25.

Arrange side gear carrier (6) on wooden blocks and push out pins (33) with proper remover.

26.

Pick up all needle rollers (35). NOTE:

27.

It is important to keep matched needle rollers (35) and thrust washers (36) with relevant pin (33), this is consequent to predetermined assembly tolerance limits.

Remove side gears (37) and relevant thrust washers (38). NOTE:

No gear can be removed before having released all of them.

Rear Axle (Volvo SLA 12/W)

S0602190K Page 23

S0602190K Page 24

Rear Axle (Volvo SLA 12/W)

DIFFERENTIAL ASSEMBLY

Figure 11 1.

Remove screws (1) retaining differential assembly, then remove differential assembly from axle case.

Rear Axle (Volvo SLA 12/W)

S0602190K Page 25

Figure 12 2.

Hammer out spring pins (2) locking slotted rings (3).

Mark caps (4) to match parts at reassembly.

Remove screws (5), caps (4), and slotted rings (3).

Remove differential case assembly from support (11).

Straighten locking notches on pinion nut collar (6), position reaction tool on drive flange to unlock nut (6), release pinion nut, remove drive flange (9) from pinion shank along with washer (8).

Pry seal (10) from drive flange.

S0602190K Page 26

Rear Axle (Volvo SLA 12/W)

Remove bevel pinion (7) from differential support (11), hammer pinion shank with a proper removal tool. NOTE:

Be careful not to damage threads on pinion (7).

Pick up inner race of pinion shank bearing (13).

10.

Remove outer races of outer and inner pinion bearings (13) and (14) from differential support (11), pick up shims (15). NOTE:

11.

Be careful not to loose shims (15) for pinion axial position adjustment, store in a safe place for reassembly.

Remove spacer (16) with shims (17) for bearing pre-load adjustment, using a proper puller remove inner race of pinion under head bearing (14). NOTE:

Be careful not to loose shims for bearing pre-load adjustment, store in a safe place for reassembly.

12.

Mark differential half cases (18) and (19) for reference at reassembly, then remove screws (19a) and separate half cases (18) and (19).

13.

Make a visual and dimensional check of wear on sun gears (21), side gears (20), thrust washers (22) and (23), friction discs (22a), backing discs (22), and spider (24).

14.

Using a proper puller, remove bearings (25) from half cases (18) and (19).

15.

Clamp ring gear (26) in a vise fitted with soft caps, then remove screws (27) securing ring gear (26) to half case (18).

16.

Fit inner races of differential bearings (25) on half cases (18) and (19). NOTE:

17.

Mount bevel ring gear (26) on half case (18), secure with screws (27). NOTE:

18.

This operation should be carried out by heating equipment or use a proper installer.

Torque to 480 ±24 N•m (48.9 ±2.5 kg•m / 354 ±17.7 ft lb).

Position differential components in their proper seats.

Rear Axle (Volvo SLA 12/W)

S0602190K Page 27

OVERHAULING SUPER MAX TRAC ASSEMBLY 1.

Select backing discs (22) to reach, as assembling is completed, prescribed clearance of 0.05 - 0.10 mm (0.0020 0.0039") all around both disc packs. NOTE:

Join half cases (18) and (19) matching reference marks made at disassembly.

Mount and secure case halves (18) and (19) with screws (19a). NOTE:

Figure 13

Torque to 120 ±6 N•m (12.2 ±0.61 kg•m / 88.5 ±4.4 ft lb).

CHECKING CLEARANCE ON ASSEMBLED DISC PACKS 1.

Check should be carried out all around at points placed at 120o to one another on both disc packs to prevent mileacting recording of values due to spider and sun gear play. NOTE:

S0602190K Page 28

Should recorded clearance not be as specified, disc packs must be reformed to prescribed value of 0.05 - 0.10 mm (0.0020 - 0.0039").

Figure 14

Rear Axle (Volvo SLA 12/W)

AXLE REASSEMBLY DETERMINING THICKNESS OF ADJUSTMENT SHIMS

Figure 15 1.

Record dimension from ring gear axis to seat inner (under head) pinion bearing (that will be identified as "A"). •

Example: "D" = 54.15 mm.

Compute thickness of shim "S" for proper axial position of bevel pinion: S = A - (B + D). •

Example: B = 208 + 0.1 = 208.1 mm.

Measure thickness of pinion head bearing and identify as "D." •

Example: +1 = +0.1 mm.

Consequently, the true distance (identified as "B") will be: B = 208 ± deviation. •

Example: "A" = 266.1 mm.

Example: S = 266.1 - (208.1 + 54.15) = 3.85 mm.

Increase by 0.05 mm the computed thickness value to compensate subsequent bearing pre-load. Round off to nearest tenth of millimeter to computed thickness value. •

Example: 4.02 rounded off = 4 mm. 3.88 rounded off = 3.9 mm.

Rear Axle (Volvo SLA 12/W)

S0602190K Page 29

DIFFERENTIAL ASSEMBLY

Figure 16

AXIAL POSITION OF BEVEL PINION 1.

Press fit inner race of inner (under head) bearing (14) on pinion by using heating equipment or use of proper installer.

Position shim (15), see "Determining Thickness of Adjustment Shims," in its seat and press fit outer races of inner (under head) and outer bearings (13) and (14) of pinion.

S0602190K Page 30

Rear Axle (Volvo SLA 12/W)

Fit spacer (16) on pinion along with shims (17) for bearing pre-load adjustment, then mount inner race of pinion outer bearing (13). NOTE:

To facilitate proper pre-load computation, it is advisable to mount as many shims as required to warrant a pinion end play and not a pre-load (that could be excessive) on bearings.

Fit drive flange (9) on pinion (7), position specific reaction tool and tighten nut (6). Remove reaction tool. NOTE:

Torque from 570 - 630 N•m (58.1 - 64.2 kg•m / 420 - 460 ft lb).

Check pinion end play using a dial gauge, then disassemble and change shims to eliminate all end play and reach intended pre-load.

Reassembly components, check that proper pre-load of bearing corresponding to a revolving torque (no seal installed). NOTE:

Revolving torque of 2.0 - 4.0 N•m (0.2 - 0.4 kg•m / 1.5 - 3.0 ft lb).

As the prescribed pre-load of bearings has been reached, remove drive flange (9) and fit lip seal (10) into its proper seat.

Remount drive flange (9) and tighten to specified torque. NOTE:

Torque from 570 - 630 N•m (58.1 - 64.2 kg•m / 420 - 460 ft lb).

Position differential assembly with ring gear on support (11), insert ring nut (3), and temporarily adjust back lash.

10.

Mount caps (4), being careful not to invert position, secure support to differential with screws (5). NOTE:

Torque to 650 ±32.5 N•m (66.3 ±3.3 kg•m / 479.4 ±24.0 ft lb).

11.

Check differential end play with a dial gauge.

12.

Screw in a ring nut to have a notch aligned against slot of lockplate, and actuate opposite nut up to eliminate end play. NOTE:

When end play is eliminated, set bearing preload by screwing in ring nut one more notch.

ADJUSTING BACKLASH 1.

Position a dial gauge perpendicular to ring gear (26) tooth, with pinion steady check backlash. •

Standard backlash of bevel gear set: 0.15 - 0.20 mm (0.0059 - 0.0079").

•

To obtain backlash within specified range, rotate both ring nuts (3), displacing them same number of notches.

•

Moving toward ring gear to pinion, if backlash is too LARGE.

•

Moving away ring gear to pinion, if backlash is too SMALL.

Rear Axle (Volvo SLA 12/W)

Figure 17

S0602190K Page 31

ADJUSTING TOOTH CONTACT 1.

Coat face of 7 or 8 teeth of bevel gear lightly with red lead. Hold bevel gear by hand to act as a brake, rotate pinion gear forward and backward, then inspect pattern left on teeth.

Correct Pattern Drive Side.

Figure 18 Neutral Side.

Figure 19 Increase Pinion Distance Drive Side.

Figure 20 Neutral Side.

Figure 21

S0602190K Page 32

Rear Axle (Volvo SLA 12/W)

Decrease Pinion Distance Drive Side.

Figure 22 Neutral Side.

Figure 23 NOTE:

When adjusting bevel gear, do not change pre-load of bearing. Adjust by rotating both ring nuts the same number of notches.

Fit spring pins (2) to lock differential ring nuts.

Make two lock notches on pinion nut collar (6).

Rear Axle (Volvo SLA 12/W)

S0602190K Page 33

S0602190K Page 34

Rear Axle (Volvo SLA 12/W)

SECURING DIFFERENTIAL TO AXLE HOUSING

Figure 24 1.

Thoroughly clean mating surfaces, apply sealing compound and mount differential assembly on axle housing, and secure with screws (1). NOTE:

Torque to 330 ±16.5 N•m (33.7 ±1.69 kg•m / 243.4 ±12.2 ft lb)

Rear Axle (Volvo SLA 12/W)

S0602190K Page 35

FINAL DRIVE

Figure 25 1.

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

S0602190K Page 36

Rear Axle (Volvo SLA 12/W)

Position inner race with roller cage of wheel inner side bearing (31) before fitting lip seal (31).

Install O-ring (8).

Install wheel inner bearing (31) into sleeve (27). NOTE:

Support wheel hub (7) during assembly stage to prevent damage to seal.

Lubricate seals (28) and (29) on piston (26), then insert at travel end on wheel hub sleeve (27).

Using heating equipment or proper installer, fit inner race of wheel outer bearing (25) on ring gear support (22), then mount support (22) in ring gear (21) and secure with lock ring (23).

Mount ring gear (21) and support (22) unit onto sleeve (27).

Fit six rods (24) into seats on ring gear support (22).

Install spring retainer and compress spring (19) with retaining cup (20) onto pressure plate (18).

10.

Mount pressure plate and spring assembly onto ring gear support (22).

11.

Hand screw ring nut (17) onto wheel hub sleeve (27).

12.

With a wrench, tighten ring nut (17) to the prescribed pre-load for wheel bearings and corresponding to a revolving torque, checking alignment of lock plates (16). NOTE:

Revolving Torque: 15 - 30 N•m (1.5 - 3.1 kg•m / 11.1 - 22.1 ft lb).

NOTE:

To prevent recording wrong torque values, it is advisable to seat bearing properly before checking, by revolving wheel hub repeatedly.

13.

Remove spring retainer compressing brake actuator return spring.

14.

Insert lock plates (16) securing ring nut and install lock ring (15).

15.

Arrange three side gear gears (37) in proper seats of side gear carrier (6). NOTE:

Two rows of needle rollers of same selection class should be used for replacement in each single side gear pin.

16.

17.

Position outer thrust washers (38) of side gear on side gear carrier and align holes.

18.

Insert and force fit complete pins (33). NOTE:

Avoid any bump or knock that could cause rollers to fall.

19.

Insert wheel shaft (14).

20.

Insert thrust washer (39).

21.

Mount disc carrier hub (11) onto wheel shaft (14).

22.

Mount brake discs, alternating solid discs and lined discs. (See "Determining Space Available to Form Brake Disc Pack"). NOTE:

Insert a solid disc (outer teeth) facing pressure plate (12).

23.

Insert sun gear (10) and secure with lock ring (9).

24.

Mount side gear carrier (6) on side gear unit and secure onto wheel hub (7) with screws (5). NOTE:

Torque to: 70 ±3.5 N•m (7.1 ±0.4 kg•m / 51.6 ±2.6 ft lb).

25.

Force fit wheel shaft backing plate (4).

26.

Mount O-ring seal (3) on edge.

Rear Axle (Volvo SLA 12/W)

S0602190K Page 37

27.

Rotate and align pins (33) to allow mounting of cover (2), which also acts as a pin lock to prevent their rotation.

28.

Fit side final drive cover (2).

29.

Apply sealing compound to screws (1) and secure cover (2). NOTE:

Torque to 35 ±1.75 N•m (3.6 ±0.18 kg•m / 25.8 ±1.29 ft lb).

DETERMINING SPACE AVAILABLE TO FORM BRAKE DISC PACK 1.

Record depth from seating surface of side gear carrier on wheel hub to outer edge of ring gear, identify value as "A."

Record depth from ring gear outer edge to brake pressure plate, identify value as "B."

Subtract value "B" from value "A" and identify as value "D." •

Example: A - B = D Figure 26

Record depth from disc reaction face to outer edge of side gear carrier, identify value as "C."

Add value "C" to value "D" to provide space available to form brake disc pack. •

Example: C + D = X

Figure 27 6.

Figure 28

S0602190K Page 38

Rear Axle (Volvo SLA 12/W)

S0603000 R1

1PARKING BRAKE CALIPER (VOLVO) 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.

PARKING BRAKE CALIPER (VOLVO)S0603000 MODEL

SERIAL NUMBER RANGE

Mega 200-III

1026 thru 1040, 1055 thru 1060, 1071 and Up

Mega 250-III

1037 thru 1051, 1067 thru 1086, 1132 and Up

Mega 250-V (Tier I)

1001 thru 2000

Mega 250-V (Tier II)

2001 and Up

Mega 300-V (Tier I)

1001 thru 2000

Mega 300-V (Tier II)

2001 and Up

S0603000 Page 1

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

S0603000 Page 2

Parking Brake Caliper (Volvo)

GENERAL DESCRIPTION OPERATION 1.

Parking brake is a dry disc caliper type and is installed on the front axle.

The force of the spring stack (3) inside the brake chamber is used to apply the brake mechanically; it is released by hydraulic pressure.

If the park brake system pressure drops below the pressure required to compress the actuator spring, the spring force will apply the parking brake even if the park brake switch is in the "OFF" position.

The pad and disc wear is compensated by a mechanical adjustment device.

Disc (1) is installed to the front axle input flange and rotates together with the input shaft.

Figure 1 Reference Number

Description

Reference Number

Description

Parking Brake Disc

Disc Spring Stack

Caliper

Parking Brake Caliper (Volvo)

S0603000 Page 3

PARKING BRAKE APPLIED When the operator pushes the parking brake switch to the "ON" position the solenoid valve is de-energized and the hydraulic pressure from the accumulator is cut off by the solenoid valve. At the same time, the oil from brake chamber (8) is drained to the hydraulic tank. Therefore, disc spring stack (5) together with adjuster screw (6), push rod (3) and pad (2) to move towards the brake disc. Then brake pads (2) are pushed against the disc and the parking brake is applied.

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

S0603000 Page 4

Parking Brake Caliper (Volvo)

PARTS LIST

Figure 4 Reference Number

Description

Reference Number

Description

Caliper

Disc Spring Stack

Pad

Adjuster Screw

Push. Rod

Guide Pins

Piston

Oil Chamber

SPECIAL TOOLS AND MATERIALS LUBRICANTS AND SEALANTS Fuchs Renocal FN 745

Parking Brake Caliper (Volvo)

S0603000 Page 5

TROUBLESHOOTING, TESTING AND ADJUSTMENT PARKING BRAKE SYSTEM 1.

Upon initial installation the parking brake has to be bled using bleed screw (2).

The tightening torque of bleed screw (2): 12+4 N•m. (9+3 ft Ib).

Figure 5 CHECKING AND ADJUSTING PARKING BRAKE •

Measurement condition.

•

Hydraulic pressure: Maximum set pressure. Item

Standard Value

Permissible Value

Thickness of Pad

5.0 mm (0.1969 in)

2.0 mm (0.0787 in)

WARNING! Block the tires securely. MEASURING PAD THICKNESS 1.

Turn the starter switch to the "ON" position. (Ensure the brake system is fully charged.)

Push the parking brake switch "OFF" to release the parking brake.

Measure the thickness of each pad (2). A.

When the starter switch is turned to "OFF," the parking brake is applied automatically.

Measure two pads.

If the thickness is not within the permissible value, both pads must be replaced as or set.

For details of pad replacement, see DISASSEMBLY AND ASSEMBLY.

MEASURING DISC / PAD CLEARANCE Item

Standard Value

Permissible Value

Clearance Between Disc and Pad (a + b)

0.25 - 0.50 mm (0.0098 - 0.0197 in)

1.0 mm (0.0394 in)

S0603000 Page 6

Parking Brake Caliper (Volvo)

MEASURING PROCEDURE 1.

Push the parking brake switch "OFF" to release parking brake.

Insert the thickness gauge between disc (1) and pad (2), then measure the clearance on both sides of the disc. NOTE:

The clearance value mentioned above indicates the total value of both sides (a + b).

Figure 6

ADJUSTMENT NOTE:

Upon initial installation and as a result of pad and disc wear, the brake must be adjusted according to the following steps.

Turn the starter switch "ON," then push the parking brake switch "OFF" to release the parking brake. * When the starter switch is turned to "OFF," the parking brake is applied automatically, so be careful not to turn it "OFF."

Remove sheet cover (12, Figure 7).

Loosen lock nut (11, Figure 7), wrench size 24 mm.

Release disc spring stack (5, Figure 7) by screwing adjuster screw (7) clockwise with an allen wrench until pads (3 and 4) contact the disc.

Turn adjuster screw (7, Figure 7) counterclockwise until the desired gap is reached.

Item

Standard Value

Clearance Between Disc and Pad (a + b)

0.25 - 0.50 mm (0.0098 - 0.0197 in)

Secure adjuster screw (7, Figure 7) by tightening lock nut (11) with a tightening torque of 150+10 N•m (111+7 ft Ib). NOTE:

When replacing the pads always replace both pads as a set.

NOTE:

After adjusting, measure the parking brake performance again and check that it is within specification.

Parking Brake Caliper (Volvo)

S0603000 Page 7

Reference Number

Description

Caliper

3, 4

Brake Pad

Spring Stack

Piston

Adjuster Screw

Push Rod

Thrust Ring

Oil Chamber

Lock Nut

Sheet Cover

RELEASING THE PARKING BRAKE IN EMERGENCY CASE NOTE:

If the parking brake does not function due to a failure in the electrical or hydraulic systems, it can be manually released as follows.

Remove sheet cover (12, Figure 7).

Loosen lock nut (11, Figure 7), wrench size 24 mm.

Turn adjuster screw (7, Figure 7) counterclockwise until the parking brake is released using an allen wrench 8 mm.

S0603000 Page 8

Figure 7

Parking Brake Caliper (Volvo)

DISASSEMBLY GENERAL 1.

For safe braking characteristics, it is vital that the brake is kept in good working order. The brake should therefore be checked at regular service intervals and worn parts must be replaced.

The rubber parts should be replaced after 2 years or when damaged.

Only original spare parts of the brake manufacturer may be used.

Repair and service work on the brake may only be carried out by trained personnel.

The brake design avoids the use of special tools, i.e. for repair and service work only standard tools are necessary. The brake should be adjusted during the service intervals or if the vehicle looses grade holding ability. NOTE:

If, during an emergency brake application, the vehicle is decelerated by the parking brake only, the brake disc and the brake pads have to be inspected for damage.

CHANGING BRAKE PADS 1.

Brake pads must be changed when the remaining lining thickness is 2.0 mm (0.0787 in) or when brake linings are burned or glazed. Pads specified by the vehicle or brake manufacturer must be used exclusively.

Guide surfaces or guide parts for the brake pads must be cleaned. Solvents containing mineral oil or sharp edged tools must not be used.

The protection boot for the push rod must be checked to make sure it is in perfect condition.

Upon changing the brake pads the disc, too, has to be inspected with regard to wear.

If the brake is equipped with magnets, those have to be cleaned before the new pads are fitted.

WORK SEQUENCE DURING CHANGE OF BRAKE PADS 1.

Remove sheet cover (20, Figure 11) respectively rubber cap (23).

Loosen lock nut (11, Figure 11), wrench size 24 mm.

Release the force of the disc spring stack by turning adjuster screw (7, Figure 11) counterclockwise, using an Allen key 8 mm. Alternative; Apply hydraulic pressure on the brake and turn the adjuster screw counterclockwise.

Remove split pin (17, Figure 11) and unscrew castle nut (16), wrench size 24 mm.

Pull guide pin (2, Figure 11) out of the brake until brake pads (3) and (4) can be removed.

CAUTION! The brake caliper (1, Figure 11) may rotate around the other guide pin. 6.

Insert new brake pads (3, Figure 11) and (4) and push guide pin (2) back into position. Screw castle nut (11) on the guide pin and secure with split pin (17) following work sequence according to Figure 25.

Adjust the brake.

Parking Brake Caliper (Volvo)

S0603000 Page 9

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

Figure 8

Figure 9

S0603000 Page 10

Parking Brake Caliper (Volvo)

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

Figure 10

Parking Brake Caliper (Volvo)

S0603000 Page 11

Check Item Wear of Brake Pads (Thickness of Friction Material)

Standard Size

Tolerance

Repair Limit

5.0 mm (0.1969 in)

2.0 mm (0.0787 in)

Face Run Out of Disc

0.050 mm (0.0020 in)

0.150 mm (0.0059 in)

Thickness of plate must be under 11.50 mm (0.4528 in)

Rebuild

Less than 11.50 mm (0.4528 in)

Replace

1.0 mm (0.0394 in)

Adjust

Wear of Disc (Thickness of Disc Plate)

Criteria

12.70 mm (0.50 in)

-0.10 mm (0.0039 in)

Clearance Between Pad and Disc (Total of Both Sides)

Tightening Torque of Bolt

14.2 - 15.7 kg•m (103 - 114 ft lb)

Tightening Torque of Bolt

11.4 - 12.6 kg•m (82 - 91 ft lb)

Tightening Torque of Bolt

14 - 16 kg•m (101 - 116 ft lb)

Tightening Torque of Bolt

1.36 - 1.54 kg•m (10 - 11 ft lb)

Tightening Torque of Bolt

3 - 4 kg•m (22 - 29 ft lb)

S0603000 Page 12

0.3750 mm (0.0148 in)

±0.1250 mm (0.0049 in)

Remedy Replace

Tighten

Parking Brake Caliper (Volvo)

REASSEMBLY Using Figure 11 to Figure 29 with the work sequences and notes, the assembly instruction shows in steps the complete assembly of the brake. If the application of grease is required, FUCHS RENOCAL FN 745 has to be used for normal use (-50°C up to +120°C). For special use greases with a wider temperature range contact your supplier. The disc brake is dismantled in reverse sequence. Figure 11, shows the individual parts of a brake design with a protection device against dirt consisting of a cover made of sheet material, an O-ring and the screws (22). Figure 12, shows a brake design with a rubber cap as protection.

Figure 11

Figure 12 Reference Number

Description

Reference Number

Description

Brake Caliper

Sealing Ring

Guide Bolt

Securing Ring

3 and 4

Brake Pad

Protection Boot

Disc Spring Stack

Castle Nut

Piston

Split Pin

Adjuster Screw

Sheet Cover

Push Rod

O-ring

Thrust Ring

Screw

Lock Nut

Rubber Boot

Sealing Ring

Parking Brake Caliper (Volvo)

S0603000 Page 13

Insert sealing ring (12, Figure 13) into the groove of brake caliper (1). NOTE:

The sealing ring has to be mounted with the sealing lip pointing towards the oil chamber.

Grease the groove.

Insert sealing ring (13, Figure 14) in the groove of brake caliper (1).

Figure 13

NOTE:

The sealing ring has to be mounted with the sealing lip pointing towards the oil chamber. see Figure 8

Grease the groove.

Push rod (8, Figure 15) has to be assembled with piston (6) thus the groove. See arrow is outside the piston.

Figure 14

Figure 15 6.

Press piston (6, Figure 16) which is assembled with push rod (8) into the brake caliper. NOTE:

Grease the piston, because it slides easier through sealing ring (12) see Figure 13.

Figure 16

S0603000 Page 14

Parking Brake Caliper (Volvo)

Insert disc spring stack (5, Figure 17) completely into piston (6). Do not change the disc springs within the stack. NOTE:

The orientation of the installed disc spring stack with 5 disc springs has to be in accordance with Figure 18. The orientation of the installed spring stack with 6 disc spring has to be according to Figure 19. The installation or replacement of the disc spring stack is only allowed as a complete assembly.

Figure 17

Grease disc spring stack.

Figure 18

Figure 19

Parking Brake Caliper (Volvo)

S0603000 Page 15

Grease thrust ring (9, Figure 20) and assemble it according to Figure 8; it has to center the disc spring stack.

10.

Insert sealing ring (14, Figure 21) in the groove. See arrow of brake caliper (1).

11.

Press protection boot (15, Figure 22) using an assembly tool into its seat (see arrow) in brake caliper (1). Push the bead of protection boot (15) into the groove of push rod (8).

Figure 20

Figure 21

NOTE:

The rubber part must not be destroyed and seat in caliper has to be greased before assembly.

Figure 22 12.

Screw adjuster screw (7, Figure 23) using an allen wrench 8 mm into piston (6).

Figure 23

S0603000 Page 16

Parking Brake Caliper (Volvo)

13.

Screw lock nut (11, Figure 24), wrench size 24 mm, on adjuster screw (7) until it touches piston. NOTE:

The lock nut is tightened to a tightening torque of 150 ±10 N•m (110 ±7 ft Ib) after the brake is installed in the vehicle and the gap is adjusted.

Figure 24 14.

15.

The brake caliper is assembled with bracket (not shown in Figure 25) using two guide pins. Install first guide pin (2, Figure 25) by pushing it through guide hole in brake caliper (1) and bracket from actuation side (See Figure 25) Insert brake pads (3 and 4). Assemble all the above parts by pushing the second guide pin through the guide hole in the caliper and bracket and the abutment and guide recesses of the brake pads. Install castle nuts (16), wrench size 24 mm, tightening torque 20 N•m (15 ft Ib). Secure both castle nuts with split pin (17). Screw bleeder valve (18, Figure 26) into threaded hole. See arrow in brake caliper (1), wrench size 11 mm. NOTE:

16.

Figure 25

The tightening torque for the bleeder is 12 + 4 N•m (9 + 3 ft Ib).

Fit dust cap (19, Figure 26) on bleeder valve (18) after brake is bled.

Figure 26

Parking Brake Caliper (Volvo)

S0603000 Page 17

17.

After brake is adjusted. brake caliper is protected at operation side with a cover against dirt. According to brake type, it can be a cover from sheet material Figure 27 or a rubber cap Figure 28.

18.

Insert O-ring (21, Figure 27) on its seat in sheet cover (20) (See arrow and Figure 11).

19.

Assemble sheet cover with screw (22, Figure 27), wrench size 1.0 mm.

20.

Fasten rubber cap (23, Figure 28) in groove of brake caliper (1).

21.

To avoid noise produced by rattling brake pads, the pads are kept by magnets (25, Figure 29) in their abutment areas of the push rod and the brake caliper reaction side. For installation see the following work sequence.

22.

Press magnet with the friction ring (See arrow) in its seat in push rod (8, Figure 29).

23.

Press magnet with the friction ring (26, Figure 29) (See arrow, in its seat at the brake caliper reaction side).

24.

Insert O-ring (24, Figure 29) in the groove. See arrow of push rod (8).

Figure 27

Figure 28

NOTE:

S0603000 Page 18

Figure 29

The magnets must not be damaged upon installation. When installed the magnets are not to jut out of the push rod or the pad abutment area of the brake caliper reaction side.

Parking Brake Caliper (Volvo)

Return to Master Table of Contents

S0605050K

1AIR CONDITIONER

AIR CONDITIONER

S0605050K

MODEL

SERIAL NUMBER RANGE

Mega 130

0001 and Up

Mega 160

0001 and Up

Mega 200-V (Tier I & II)

1001 and Up

Mega 250-V (Tier I)

1001 thru 2000

Mega 250-V (Tier II)

2001 and Up

Mega 300-V (Tier I)

1001 thru 2000

Mega 300-V (Tier II)

2001 and Up

Mega 400-V

1001 and Up

Mega 500-V

1001 thru 2000

Mega 500-V (Tier II)

2001 and Up

S0605050K Page 1

Return to Master Table of Contents

TABLE OF CONTENTS General Description........................................................................................ 3 Refrigerant Circulation.................................................................................... 4 Control Panel.................................................................................................. 6 Control Specifications..................................................................................... 7 Temperature Level Control and Display.......................................................... 8 Air Discharge According to Path Selection..................................................... 9 Air-conditioning System Circuit Diagram...................................................... 12 Troubleshooting ............................................................................................ 14 Weight of R134a Gas Used In Machines ..................................................... 18 Refrigerant System Repairs ......................................................................... 20 Refrigerant Safe Handling Procedures ................................................. 20 Repair and Replacement Procedure..................................................... 21 Refrigerant Recovery ............................................................................ 23 Vacuuming Refrigerant System............................................................. 23 Leakage Check ..................................................................................... 24 Refrigerant Charging............................................................................. 25 Inspecting System For Leakage............................................................ 27

S0605050K Page 2

Air Conditioner

Return to Master Table of Contents

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 airconditioning system should be performed with the starter switch in the "O" (OFF) position. NOTE:

Air Conditioner

Figure 2

Refer to appropriate operation and maintenance manual for latest service intervals.

S0605050K Page 3

Return to Master Table of Contents

REFRIGERANT CIRCULATION 1

5 4 7

HBOI020L

Figure 3 Reference Number

Description

Reference Number

Description

Evaporator

Compressor

Expansion Valve

Blower Fan

Condenser

Receiver Dryer

Condenser Fan

S0605050K Page 4

Air Conditioner

Return to Master Table of Contents 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.

Air Conditioner

S0605050K Page 5

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CONTROL PANEL

OFF

A/C

MID

COOL

WARM

HDA6047L

Figure 4

INPUT

OUTPUT

CONTROL PANEL

DISPLAY TEMPERATURE SENSOR

LOW SPEED RELAY

OFF SW

MID SPEED RELAY

A / C SW VENT SW

BLOWER MOTOR

HIGH SPEED RELAY

DEF. SW HEAT SW FRE SW REC SW

A/C CONTROL PANEL

TEMP. CONTROL ACTUATOR

MIX DOOR

VENT ACTUATOR

VENT CONTROL

DEF. ACTUATOR

FOOT / DEF.

INTAKE ACTUATOR

RECYCLE/FRESH AIR CONTROL

COMP. RELAY

COMPRESSOR

CONDENSER FAN RELAY

CONDENSER FAN

LOW SW MID SW HI SW COOL SW WARM SW

TEMPERATURE CONTROL ACTUATOR

HDA6048L

Figure 5

S0605050K Page 6

Air Conditioner

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CONTROL SPECIFICATIONS Control Item Temperature Control

Control Switch

Control Specifications

"COOL" Switch "WARM" Switch

MAX COOL 100%

50%

MAX HOT 0%

HDA6049L

Figure 6 Temperature control switch consists of a 24 step variable selector. The display uses 7, Green / Red twocolor LED’s to display the selected temperature. Blower Fan Speed Control

"OFF" Switch "LOW" Switch "MID" Switch "HI" Switch

HI RELAY MID RELAY LOW RELAY

OFF

LOW

MID

HI HDA6050L

Figure 7 Compressor Control

Temperature Sensor COMP ON

COMP OFF 1.5 C

4.0 C HDA6051L

Figure 8

Air Conditioner

S0605050K Page 7

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TEMPERATURE LEVEL CONTROL AND DISPLAY Step

LED 1

LED 2

LED 3

LED 4

LED 5

LED 6

LED 7

Position Sensor Voltage

Remark

Green

4.50 V ±0.2

MAX. COOL

Green

4.33 V ±0.2

Green

4.15 V ±0.2

Red

Green

3.98 V ±0.2

Red

Green

3.80 V ±0.2

Red

Green

3.63 V ±0.2

Red

Green

3.46 V ±0.2

Red

Green

3.28 V ±0.2

Red

Green

3.11 V ±0.2

Red

Green

2.93 V ±0.2

Red

Green

2.76 V ±0.2

Red

Green

2.59 V ±0.2

Red

Green

2.41 V ±0.2

Red

Green

2.24 V ±0.2

Red

Green

2.07 V ±0.2

Red

Green

1.89 V ±0.2

Red

Green

1.72 V ±0.2

Red

Green

1.54 V ±0.2

Red

Green

1.37 V ±0.2

Red

Green

1.20 V ±0.2

Red

Green

1.02 V ±0.2

Red

0.85 V ±0.2

Red

0.67 V ±0.2

Red

0.50 V ±0.2

S0605050K Page 8

MAX. HOT

Air Conditioner

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AIR DISCHARGE ACCORDING TO PATH SELECTION Vent

AJS0540L

Figure 9 Reference Number

Description

Reference Number

Description

Select Switch

3-2

Rear Vent (L)

Front Vent

Heater Core

2-1

Front Vent (R)

Evaporator Core

2-2

Front Vent (L)

Air Filter

Rear Vent

Blower Motor

3-1

Rear Vent (R)

Air Conditioner

S0605050K Page 9

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6 7

3-1 3-2 2

2 AJS0551L

Figure 10 Reference Number

Description

Reference Number

Description

Select Switch

Heater Core

Foot Vent

Evaporator Core

Rear Vent

Air Filter

3-1

Rear Vent (R)

Blower Motor

3-2

Rear Vent (L)

S0605050K Page 10

Air Conditioner

Return to Master Table of Contents Defroster

1 6 7

3 2

3-1 3-2

AJS0561L

Figure 11 Reference Number

Description

Reference Number

Description

Select Switch

Heater Core

Defroster Vent

Evaporator Core

Rear Vent

Air Filter

3-1

Rear Vent (R)

Blower Motor

3-2

Rear Vent (L)

Air Conditioner

S0605050K Page 11

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AIR-CONDITIONING SYSTEM CIRCUIT DIAGRAM

Figure 12

S0605050K Page 12

Air Conditioner

Return to Master Table of Contents Reference Number

Description

Reference Number

Description

Battery

A/C Control Panel

Battery Relay

A/C Unit

Fusible Link

15-1

Blower Motor

Circuit Breaker

15-2

Resister

Fuse Box

15-3

High Speed Relay

Headlight Switch

15-4

Mid Speed Relay

Condenser Fan Relay

15-5

Low Speed Relay

Condenser Fan Motor

15-6

Compressor Relay

Recirculate / Fresh Air Control Actuator

Foot / Defrost Control Actuator

15-7

Vent Actuator

15-8

Receiver Drier

Temperature Control Actuator

Diode

15-9

Compressor

Temperature Sensor (Evaporator)

Air Conditioner

S0605050K Page 13

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TROUBLESHOOTING Refrigerant Pressure Check

Figure 13 1.

Open all doors and windows.

Install manifold gauge set.

Start engine and maintain engine speed at 1,800 - 2,000 rpm.

Check high / low pressure of refrigerant. High Pressure: 8 - 10 kg/cm2 (114 - 142 psi) Low Pressure: Approximately 1 kg/cm2 (14 psi)

Possible Cause: Low Refrigerant Level Step

Inspection Item

Remedy

Check for traces of refrigerant oil.

Using a leak detection device or soapy water check for refrigerant leakage at all major components and joints.

Yes

Reassemble using tightening torque.

Go to next step.

Yes

Repair leaking component.

Recharge pressure.

system

correct

High Pressure: Over 23 kg/cm2 (327 psi) Low Pressure: Approximately 2.5 - 3.0 kg/cm2 (36 - 43 psi)

Possible Cause: Overcharge, Frost on condenser Step 1

Inspection Item Check for condenser contamination.

S0605050K Page 14

Remedy pin

damage

Yes

Clean, repair or replace condenser.

Refrigerant overcharge.

Air Conditioner

Return to Master Table of Contents High Pressure: Approximately 20 - 25 kg/cm2 (284 - 356 psi) Low Pressure: Approximately 2.5 - 3.5 kg/cm2 (36 - 50 psi)

Possible Cause: Air in system. 1.

Recover any remaining refrigerant.

Vacuum out system.

Recharge system. NOTE:

If the system has been exposed to the air for a long period of time, replace the receiver dryer. High Pressure: Over 6 kg/cm2 (85 psi) Low Pressure: Approximately 760 mmHg (Negative Pressure)

Possible Cause: Refrigerant does not circulate Step

Inspection Item 1.

Connect manifold gauge and start engine.

Turn on air conditioner.

Set blower switch to HIGH position.

Turn air conditioner OFF and wait 10 minutes.

Recheck high / low pressure readings.

High Pressure: 13 - 19 kg/cm2 (185 - 270 psi) Low Pressure: 1.5 - 3.3 kg/cm2 (21 - 47 psi)

Remedy

Yes

Moisture in receiver dryer.

system,

replace

Contaminated system, expansion valve.

replace

(Replace assembly.)

evaporator

core

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.

When the absorbed moisture freezes the pressure readings may look normal. Careful readings should be made to determine whether pressure is in normal range. Recover any remaining refrigerant.

Vacuum out system.

Recharge system.

NOTE:

Air Conditioner

If the system has been exposed to the air for a long period of time, replace the receiver dryer.

S0605050K Page 15

Return to Master Table of Contents High Pressure: Over 22 - 23 kg/cm2 (313 - 327 psi) Low Pressure: 2.5 kg/cm2 (36 psi)

Possible Cause: Refrigerant pressure problem due to defective expansion valve or temperature sensor. Step 1

Inspection Item

Remedy

Inspect whether the temperature sensor is installed properly.

Yes

Replace expansion valve.

Exchange duct sensor.

High Pressure: Over 7 - 11 kg/cm2 (100 - 156 psi) 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.

S0605050K Page 16

Air Conditioner

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Air Conditioner

S0605050K Page 17

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WEIGHT OF R134A GAS USED IN MACHINES Model

S0605050K Page 18

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 130-III

950 ±20 grams (33 ±0.7 oz.)

Solar 130LC-V

850 ±20 grams (30 ±0.7 oz.)

Solar 130W-III

950 ±20 grams (33 ±0.7 oz.)

Solar 130W-V

850 ±20 grams (30 ±0.7 oz.)

Solar 140W-V

850 ±20 grams (30 ±0.7 oz.)

Solar 160W-V

850 ±20 grams (30 ±0.7 oz.)

Solar 170LC-V

850 ±20 grams (30 ±0.7 oz.)

Solar 170W-III

1100 ±20 grams (38 ±0.7 oz.)

Solar 180W-V

850 ±20 grams (30 ±0.7 oz.)

Solar 200W-III

1100 ±20 grams (38 ±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 220LC-V

850 ±20 grams (30 ±0.7 oz.)

Solar 220LL

850 ±20 grams (30 ±0.7 oz.)

Solar 225LC-V

850 ±20 grams (30 ±0.7 oz.)

Solar 250LC-V

850 ±20 grams (30 ±0.7 oz.)

Solar 255LC-V

850 ±20 grams (30 ±0.7 oz.)

Solar 280LC-III

1250 ±20 grams (44 ±0.7 oz.)

Solar 290LC-V

850 ±20 grams (30 ±0.7 oz.)

Solar 290LL

850 ±20 grams (30 ±0.7 oz.)

Air Conditioner

Return to Master Table of Contents Model Solar 300LC-V

Air Conditioner

Weight of Gas 850 ±20 grams (30 ±0.7 oz.)

Solar 300LL

850 ±20 grams (30 ±0.7 oz.)

Solar 330-III

1250 ±20 grams (44 ±0.7 oz.)

Solar 330LC-V

850 ±20 grams (30 ±0.7 oz.)

Solar 340LC-V

850 ±20 grams (30 ±0.7 oz.)

Solar 400LC-III

1250 ±20 grams (44 ±0.7 oz.)

Solar 400LC-V

850 ±20 grams (30 ±0.7 oz.)

Solar 420LC-V

850 ±20 grams (30 ±0.7 oz.)

Solar 450LC-III

1250 ±20 grams (44 ±0.7 oz.)

Solar 450LC-V

850 ±20 grams (30 ±0.7 oz.)

Solar 470LC-V

850 ±20 grams (30 ±0.7 oz.)

S0605050K Page 19

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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.

The new refrigerant has improved cooling characteristics than the old type and care should be used not to overcharge the system.

Do not over tighten connections when working on refrigerant system.

The new refrigerant system standards require new tools, equipment and parts. DO NOT attempt to use equipment use in servicing the old refrigerant system.

S0605050K Page 20

Air Conditioner

Return to Master Table of Contents 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.

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.

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.

Use a vacuum pump to evacuate refrigerant system of air.

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.

Operating Condition. A.

Run engine at maximum engine speed.

Select "HI" blower fan speed and select A/C switch to "ON."

Set the temperature control switch for maximum cooling and leave running for approximately 20 minutes.

NOTE:

Air Conditioner

The manifold gauge dial pointer can vary depending on the outdoor temperatures.

S0605050K Page 21

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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

S0605050K Page 22

Air Conditioner

Return to Master Table of Contents REFRIGERANT RECOVERY

Reference Number

Description

To Compressor

Low Pressure Side

High Pressure Side

From Receiver

Refrigerant Recovery Tank

Be careful not to switch the connections for the low and high pressure valves.

3 4

Attach the manifold gauges and the refrigerant recovery unit to the refrigerant lines as shown. NOTE:

5 HDA6067L

Figure 16

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.

When the manifold gauge dial falls below 3.5 kg/cm2 (50 psi), slowly open the low pressure valve.

Open both the high and low pressure valves slowly until the manifold gauge dials indicates 0 kg/cm2 (0 psi).

VACUUMING REFRIGERANT SYSTEM Reference Number

2 Description

To Compressor

Low Pressure Side

High Pressure Side

From Receiver

Vacuum Pump

When the A/C system has been exposed to the air, it must be vacuumed out. Perform vacuum process for 30 minutes for complete moisture and air evacuation.

Vacuuming Procedure. NOTE:

HDA6068L

Figure 17

Attach the manifold gauges and vacuum pump to the refrigerant system as shown.

Turn on the vacuum pump and open both valves.

When the low pressure gauge shows approximately 710 mmHg, close both valves and turn off vacuum pump.

Air Conditioner

S0605050K Page 23

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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.

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

Turn on the vacuum pump and slowly open both valves.

Allow vacuum pump to run for additional 20 minutes until the low pressure gauge dial reads approximately 750 mmHg.

Close both valves and stop the vacuum pump.

Installation of Refrigerant Container.

Reference Number

Description

Handle

Hose Connection

Mounting Disk

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 position.

Figure 19

Attach the manifold gauge center hose to the valve assembly.

Turn the disc in the clockwise direction and securely mount valve onto refrigerant container.

Turn the valve handle in the clockwise direction and puncture the container seal with the pin.

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.

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.

After attaching the manifold gauge, open the high side valve.

Charge system until the low side gauge dial indicates a pressure of 1 kg/cm2 (14 psi) and close the high side valve.

S0605050K Page 24

Air Conditioner

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Using a refrigerant leak detector or soapy water check each joint for leakage. Reference Number

Description

Refrigerant Leak Detection Device

If a leak is detected, check for O-ring damage or correct tightening torque and replace or repair as necessary.

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.

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.

NOTE:

When exchanging refrigerant containers, press the manifold gauge low side valve to eliminate air from the charging hose.

Reference Number

Description

To Compressor

Low Pressure Side

High Pressure Side

From Receiver

Refrigerant Supply Container

Charge the system by opening the manifold gauge low side valve. Initial charge amount: 100 g (3.5 ounces).

Air Conditioner

5 HDA6072L

Figure 21

S0605050K Page 25

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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.

Open the manifold gauge low side valve and charge system to standard capacity.

NOTE:

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)

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.

Close low pressure side valve.

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

S0605050K Page 26

Air Conditioner

Return to Master Table of Contents 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.

Reference Number

Description

Pressure

High Pressure

Low Pressure

Compressor Stop

Figure 22

Inspection Procedure 1.

High pressure side. Compressor outlet →condenser inlet →receiver dryer inlet →air conditioner unit inlet

Low pressure side. Compressor inlet →air conditioner unit outlet

Compressor. Compressor shaft area, bolt hole area and magnetic clutch area.

Receiver dryer. Pressure switch and plug area.

Connection valve area. Inspect all valve areas. Verify all valves are capped to prevent leaking. Check for foreign material inside of valve cap.

Interior of air conditioner unit. After stopping engine, insert detector probe into drain hose. (Leave inserted for 10 seconds minimum.) NOTE:

Air Conditioner

When inspecting leakage from the air conditioner unit, perform the inspection in a wellventilated area.

S0605050K Page 27

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S0605050K Page 28

Air Conditioner

S0607090K

1TRANSMISSION AND TORQUE CONVERTER (ZF 4WG-210) CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that is in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility.

TRANSMISSION AND TORQUE CONVERTER (ZF 4WG-210)S0607090K MODEL

SERIAL NUMBER RANGE

Mega 300-V (Tier I)

1001 thru 2000

Mega 300-V (Tier II)

2001 and Up

S0607090K Page 1

TABLE OF CONTENTS Drive Train Description ................................................................................... 6 Transmission and Torque Converter............................................................... 7 Powershift Transmission.......................................................................... 8 Transmission Control............................................................................... 8 Schedule of Measuring Points and Connection 4 WG-210................... 10 Oil Circuit Diagram 4WG-210 Forward 1st Speed ................................ 12 Transmission Electrical Components ........................................................... 14 TCU (Transmission Control Unit) .......................................................... 15 Transmission Control Valve ................................................................... 15 Transmission Oil Temperature Sensor .................................................. 16 Engine Pick-up Sensor.......................................................................... 16 Central Gear Pick-up Sensor ................................................................ 16 Turbine Pick-Up Sensor ........................................................................ 17 Output Speed Sensor............................................................................ 17 Shift Lever Switch (DW-3) ..................................................................... 17 Auto Select Switch ................................................................................ 19 Display .................................................................................................. 19 Transmission Faults Codes .......................................................................... 20 Fault Display.......................................................................................... 20 CAN - Message..................................................................................... 20 Description of Fault Codes .................................................................... 20 Abbreviations ........................................................................................ 21 Definition of Operation Modes............................................................... 21 Normal ........................................................................................... 21 Substitute Clutch Control ............................................................... 21 Limp-home ..................................................................................... 21 Transmission Shut Down ............................................................... 21 TCU Shut Down ............................................................................. 21 Table of Fault Codes ............................................................................. 22 Measurement of Resistance at Actuator/sensors and Cable ................ 22

S0607090K Page 2

Transmission and Torque Converter (ZF 4WG-210)

Actuator.......................................................................................... 22 Cable.............................................................................................. 22 Transmission Electrical Circuits.................................................................... 24 Transmission Controller Circuit ............................................................. 24 Traveling Circuits ................................................................................... 26 Neutral ........................................................................................... 26 Forward First Gear ......................................................................... 27 Forward Second Gear.................................................................... 28 Forward Third Gear........................................................................ 29 Forward Fourth Gear ..................................................................... 30 Reverse First Gear......................................................................... 31 Reverse Second Gear.................................................................... 32 Reverse Third Gear........................................................................ 33 Kick-down.............................................................................................. 34 Overview ........................................................................................ 34 Kick-down: Forward Second Gear to Forward First Gear (Auto Selector Switch "O"- Manual Mode) ..................................... 35 Kick-down (Auto Selector Switch "I" - Auto Mode) ......................... 37 Transmission Cutoff............................................................................... 39 LIS (Load Isolation System) - Option .................................................... 41 Installation View (S/N 1001 thru 2000)......................................................... 44 Inner Section ......................................................................................... 44 Front View ............................................................................................. 45 Front View with Disc Brake ................................................................... 46 Side View .............................................................................................. 47 Side View with Disc Brake..................................................................... 48 Rear View.............................................................................................. 49 Rear View with Disc Brake .................................................................... 50 Installation View (S/N 2001 and Up) ............................................................ 52 Inner Section ......................................................................................... 52 Front View ............................................................................................. 53 Front View with Disc Brake ................................................................... 54 Side View .............................................................................................. 55

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 3

Side View with Disc Brake..................................................................... 56 Rear View.............................................................................................. 57 Rear View with Disc Brake .................................................................... 58 Special Tools ................................................................................................ 59 Gearshift System................................................................................... 59 Engine Connection................................................................................ 61 Pressure Oil Pump ................................................................................ 62 Gearbox Housing .................................................................................. 63 Input ...................................................................................................... 65 Coupling ................................................................................................ 66 Output ................................................................................................... 72 Power Take-off ...................................................................................... 73 Hydraulic Control Unit (HSG-94) .................................................................. 74 Disassembly.......................................................................................... 76 Reassembly .......................................................................................... 79 Transmission Disassembly ........................................................................... 85 Hydraulic Control Unit (HSG-94) and Duct plate................................... 85 Engine Connection - Converter............................................................. 86 Hydraulic Pump..................................................................................... 88 Converter Back Pressure Valve ............................................................ 89 Remove Output, Input and Clutches ..................................................... 90 Disassemble Clutch - KV and KR ......................................................... 95 Disassemble Clutch - K1, K2 and K3 .................................................... 98 Disassemble Clutch - K4..................................................................... 100 Disassemble Drive Shaft ..................................................................... 101 Transmission Reassembly.......................................................................... 103 Install Oil Tube..................................................................................... 103 Reassemble Clutch - KV and KR ........................................................ 105 Reassemble Clutch - K1, K2 and K3................................................... 112 Reassemble Clutch - K4 ..................................................................... 119 Pre-assemble Drive Shaft ................................................................... 125 Pre-assemble and Install Output......................................................... 126 Install Pre-assembled Drive Shaft and Clutches................................. 128

S0607090K Page 4

Transmission and Torque Converter (ZF 4WG-210)

Install Pump Shaft (Power Take-off) .................................................... 131 Install Output Flanges ......................................................................... 132 Converter Back Pressure Valve .......................................................... 134 Oil Feed Housing - Transmission Pump .............................................. 134 Engine Connection - Converter........................................................... 136 Converter Safety Valve........................................................................ 139 Mount Duct Plate and Hydraulic Control Unit...................................... 139 Install Plugs and Oil Level Tube .......................................................... 140 Speed Sensor and Inductive Transmitters .......................................... 141

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 5

DRIVE TRAIN DESCRIPTION Figure 1, shows layout of drive train assemblies. The engine (1, Figure 1) drives a torque converter (2), which drives a power shift transmission (3). Two output shafts extend out of the transmission. Each output shaft has a drive shaft attached to it. Front drive shaft (4) drives a final drive shaft (6) that drives the front differential (7). A parking brake (8, Figure 1) is mounted on the 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

Description

Reference Number

Engine

Parking Brake

Torque Converter

Front Axle Housing

Transmission

Reduction Gearing

Front Drive Shaft

Service Brake

Final Drive Shaft

Rear Differential

Rear Drive Shaft

Rear Axle Housing

Front Differential

Reference Number

S0607090K Page 6

Description

Transmission and Torque Converter (ZF 4WG-210)

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 Serial Number

Torque Converter

Mega 300-V 1001 thru 2000

Model

4WG 210 (Full Auto)

Type

3-Element, 1-Stage, Single-phase, E/G mounted with flexible plate

Oil Cooler

Water-cooled (multi-plate) and Air-cooled

Charging Pump

105 liters/min (28 U.S. gal.) at 2,000 rpm

Hydraulic Pump P.T.O

1:1

T/C Size Stall Ratio Safety Relief

ø 340.0 mm (13.39 in) 2,813

3.06 11 Bar (160 psi)

Type

Full Power Shift, Counter shaft

Speeds

4 Forward / 3 Reverse

Ratio Transmission Power Shift Control Pressure Shift Control Oil Capacity

F: 3.745 / 2.089 / 1.072 / 0.636 R: 3.551 / 1.981 / 1.017

F: 4.152 / 2.089 / 1.072 / 0.636 R: 3.937 / 1.981 / 1.017

16 - 18 Bar (230 - 260 psi) Electric Shift with Proportional Valve 38 liters (10 U.S. gal)

Dry Weight Output Flange

2001 and Up

470 kg (1,036 lb) Front

7C Mechanics

Rear

7C Mechanics

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 7

POWERSHIFT TRANSMISSION The multispeed reversing transmission in countershaft design is power shiftable by hydraulically actuated multidisk clutches. All gears are constantly meshing and carried on anti-friction bearings. The gear wheels, bearings and clutches are cooled and lubricated with oil. The 4-speed reversing transmission is equipped with 6 multidisk clutches. At the shifting, the actual plate pack is compressed by a piston, movable in axial direction, which is pressurized by pressure oil. A compression spring takes over the pushing back of the piston, thus the release of the plate pack. As to the layout of the transmission and the specifications of the closed clutches in the single speeds, See “Schedule of Measuring Points and Connection 4 WG-210” on page -10. and “Oil Circuit Diagram 4WG210 Forward 1st Speed” on page 12. TRANSMISSION CONTROL Transmission control, See “Schedule of Measuring Points and Connection 4 WG-210” on page -10., Electro-hydraulic unit on page -11 and “Oil Circuit Diagram 4WG-210 Forward 1st Speed” on page 12. The transmission pump, necessary for the oil supply of the converter, and for the transmission control, is sitting in the transmission on the engine-dependent input shaft. The feed rate of the pump is Q = 105 lpm at nEngine = 2000 min-1. This pump is sucking the oil via the coarse filter out of the oil sump and delivers it via the ZF-Fine filter - the filters is fitted externally from the transmission - to the main pressure valve. ZF-Fine filter Filtration ratio according to ISO 4572: β30 ≥ 75 β15 = 25 β10 = 5.0 Filter surface at least: 2 x 6,700 cm2 = 13,400 cm2 Dust capacity according to ISO 4572 at least: 17g The six clutches of the transmission are selected via the 6 proportional valves P1 to P6. The proportional valve (pressure regulator unit) is composed of pressure regulator (e.g. Y6). follow-on slide and vibration damper. The control pressure of 9 bar (130 psi) for the actuation of the follow-on slides is created by the pressure reducing valve. The pressure oil [16 +2 bar (230 +30 psi)] is directed via the follow-on slide to the respective clutch. Due to the direct proportional selection with separated pressure modulation for each clutch, the pressure to the clutches, which are engaged in the gear change, will be controlled. In this way, a hydraulic intersection of the clutches to be engaged and disengaged becomes possible. This is creating spontaneous shifts without traction force interruption. At the shifting, the following criteria will be considered: •

Speed of engine, turbine, central gear train and output.

•

Transmission temperature.

•

Shifting mode (up, down, reverse shifting and speed engagement out of Neutral).

•

Load condition (full and part load, traction, overrun inclusive consideration of load cycles during the shifting).

S0607090K Page 8

Transmission and Torque Converter (ZF 4WG-210)

The main pressure valve is limiting the max. control pressure to 16 +2 bar (230 +30 psi) and releases the main stream to the converter and lubricating circuit. In the inlet to the converter, a converter safety valve is installed which protects the converter from high internal pressure (opening pressure 11 bar (160 psi)). Within the converter, the oil serves to transmit the power according to the well-known hydro-dynamic principle. To avoid cavitation, the converter must be always completely filled with oil. This is achieved by a converter pressure backup valve, rear-mounted to the converter, with an opening pressure of at least 5 bar (70 psi). The oil, escaping out of the converter, is directed to a heat exchanger. From the heat exchanger, the oil is directed to the transmission and there to the lubricating oil circuit, so that all lubricating points are supplied with cooled oil. The allocation of the pressure regulators to the single speeds can be seen on the “Schedule of Measuring Points and Connection 4 WG-210” on page 10 and “Oil Circuit Diagram 4WG-210 Forward 1st Speed” on page 12.

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 9

SCHEDULE OF MEASURING POINTS AND CONNECTION 4 WG-210 The marked positions (e.g. 53) correspond with the positions on the “Oil Circuit Diagram 4WG-210 Forward 1st Speed” on page 12. The measurements have to be carried out at hot transmission (about 80° - 95° C). No.

Denomination of the Position

Connection

Marking on the Valve Block H

Measuring Points for Pressure Oil and Temperature 51

Converter Inlet - Opening pressure 9 bar (130 psi)

M10 x 1

Converter Exit - Opening pressure 3.5 bar (50 psi)

M14 x 1.5

Clutch Forward 16 +2 bar (230 +30 psi) KV

M10 x 1

Clutch Reverse 16 +2 bar (230 +30 psi) KR

M10 x 1

Clutch Reverse 16 +2 bar (230 +30 psi) K1

M10 x 1

Clutch Reverse 16 +2 bar (230 +30 psi) K2

M10 x 1

Clutch Reverse 16 +2 bar (230 +30 psi) K3

M10 x 1

Clutch Reverse 16 +2 bar (230 +30 psi) K4

M10 x 1

Converter Exit Temperature 100° C, Short-time 120° C

M14 x 1.5

System Pressure 16 +2 bar (230 +30 psi)

M10 x 1

Measuring Points for Delivery Rates 15

Connection to the Heat Exchanger

1 5/16"-12 UNF-2B

Connection from the Heat Exchanger

1 5/16"-12 UNF-2B

Inductive Transmitter and Speed Sensor 21

Inductive Transmitter n Turbine

M18 x 1.5

Speed Sensor n Output and Speedometer

-------

Inductive Transmitter n Central Gear Train

M18 x 1.5

Inductive Transmitter n Engine

M18 x 1.5

Connections 49

Plug Connection on the Hydraulic Control Unit

Pilot Pressure (Option)

M16 x 1.5

System Pressure (Option)

M16 x 1.5

S0607090K Page 10

Transmission and Torque Converter (ZF 4WG-210)

Figure 2

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 11

OIL CIRCUIT DIAGRAM 4WG-210 FORWARD 1ST SPEED The marked positions (e.g. 53) correspond with the positions on “Schedule of Measuring Points and Connection 4 WG-210” on page 10.

Reference Number

Positions

Heat Changer

WGV

Converter Back Pressure Valve 3.50 bar (50 psi)

WSV

Converter Relief Valve 9 bar (130 psi)

HDV

System Pressure Valve 16 +2 bar (230 +30 psi)

RV-9

Pressure Reducing Valve 9 bar (130 psi)

NFS

Follow-on Slide

Oscillation Damper

Orifice

Proportional Valve - Clutch K4

Proportional Valve - Clutch KR

Proportional Valve - Clutch K1

Proportional Valve - Clutch K3

Proportional Valve - Clutch KV

Proportional Valve - Clutch K2

Y1 - Y6

Pressure Regulator

TEMP

Temperature Sensor

Figure 3

S0607090K Page 12

Transmission and Torque Converter (ZF 4WG-210)

LEGEND: = System Pressure = Controlled Clutch Pressure = Pilot Pressure = Converter Inlet Pressure = Converter Exit Pressure = Lubrication = Return Flow Into The Sump AMS1110L

Figure 4

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 13

TRANSMISSION ELECTRICAL COMPONENTS

AMS0870L

Figure 5 Reference Number

Description

Reference Number

Description

Transmission Controller

Display

Transmission Control Valve

Transmission Cutoff Switch

Transmission Oil Temperature Sensor

Transmission Cutoff Pressure Switch

Engine Pick-Up Sensor

Downshift Switch

Central Gear Pick-up Sensor

Safety Start Switch

Turbine Pick-up Sensor

Fuse Box

Output Speed Sensor

Parking Brake Switch

Shift Lever Switch

Control Unit

Auto Select Switch

Starter Controller

S0607090K Page 14

Transmission and Torque Converter (ZF 4WG-210)

Reference Number

Description

Speedometer

TCU (TRANSMISSION CONTROL UNIT) 1.

Sending a control signal transmitted from the shift lever to the control valve, generates a speed.

At the auto mode, transmits the appreciate signals to the control valves according to the load and engine rpm.

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.

Specification of the proportional solenoid valve •

Resistance: 19 ±1.9 ohm at 20°C

•

Pressure: 0.8 - 8.3 kg/cm2 (11.4 - 118 psi)

AJS0210L

Figure 7

The contained temperature sensor detects the temperature of the control valve and transmits the electrical signal to the TCU, and serves TCU determines gears to change. •

Neutral: At temperature less than 30°C

•

1st or 2nd gear: At temperature less than -10°C

•

Normal Operation: At temperature greater than -10°C

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 15

TRANSMISSION OIL TEMPERATURE SENSOR 1.

Detecting a oil temperature of transmission and send a control signal to transmission oil temperature gauge.

Specification •

Resistance 216 ±30 Ohm (at 60°C) 81.2 ±10 Ohm (at 90°C) 36.5 ±3.5 Ohm (at 120°C)

AJS0220L

Figure 8

18.7 ±2.1 Ohm (at 150°C) ENGINE PICK-UP SENSOR 1.

Detect a revolution of gear array in engine side.

Specification •

Resistance: 1050Ω ± 10% (at 20°C)

•

Fasten torque: 30 N•m (22 ft lb)

•

Gap: 0.5 + 0.3 mm (0.0197 +0.0118 in)

•

Output: 4 Pulse/Rev.

AJS0230L

Figure 9 CENTRAL GEAR PICK-UP SENSOR 1.

Detect a revolution of central gear array

Specification •

Resistance: 1050Ω ±10% (at 20°C)

•

Fasten torque: 30 N•m (22 ft lb)

•

Gap: 0.5 + 0.3 mm (0.0197 +0.0118 in)

•

Output: 91 Pulse/Rev. AJS0240L

Figure 10

S0607090K Page 16

Transmission and Torque Converter (ZF 4WG-210)

TURBINE PICK-UP SENSOR 1.

Detect a revolution of gear array in turbine side.

Specification •

Resistance: 1050Ω ± 10% (at 20°C)

•

Fasten torque: 30 N•m (22 ft lb)

•

Gap: 0.5 + 0.3 mm (0.0197 +0.0118 in)

•

Output: 59 Pulse/Rev.

AJS0250L

Figure 11 OUTPUT SPEED SENSOR 1.

Detect a revolution of gear array in transmission output side.

Specification •

Voltage Supply: 20 V - 32 V

•

Operation Frequency: 2 Hz - 5 KHz

•

Fasten torque (M8): 23 N•m (17 ft lb)

•

Gap: 0.5 + 0.3 mm (0.0197 +0.0118 in)

•

Output: 60 Pulse/Rev.

3(+) 2(SIG) 1(-)

1.5

40 AJS0260L

Figure 12

SHIFT LEVER SWITCH (DW-3) 1.

Forward, Reverse and Shift •

F: Forward

•

N: Neutral

•

R: Reverse

•

1,2,3,4: Shift Step * Forward shift range: 1 - 4

SHIFT SWITCH

* Reverse shift range: 1 - 3 2.

Kick-Down (Down Shift) Switch •

LEVER LOCK KEY (N/D) AJS0270L

Figure 13

KD: Kick-Down Switch

Lever Lock Key •

N: Neutral (The lever is not moved.)

•

D: Driving (The lever is released.)

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 17

Switch Circuit

(B3) AD3 (B3) AA AD3

G G

(B2) AD2 (B2) BB AD2

AD1 (B1) (B1) CC AD1

(KD) AD7 (KD) DD AD7

(+/VP) ED1 (+/VP) AA ED1

Gr Gr

(N) AD6 (N) DD AD6

(F) AD4 (F) BB AD4

(R) AD5 (R) CC AD5

22 33

11 11

22 33 22 33

X1 X1

X2 X2

AJS0280L AJS0280L

Figure 14 5.

Terminal Position and Color TERMINAL COLOR

D C B A

(AD6) GREY (AD5) PINK (AD4) YELLOW (VP) RED

(AD7) VIOLET (AD1) BLUE (AD2) GREEN (AD3) BLACK AJS0290L

Figure 15

S0607090K Page 18

Transmission and Torque Converter (ZF 4WG-210)

Switch Connection

GEAR GEAR TERMINAL TERMINAL ED1 VP ED1 VP AD1 AD1 AD2 AD2 AD3 AD3 AD4 AD4 AD5 AD5 AD6 AD6 AD7 AD7

FORWARD FORWARD 11 22 33

REVERSE REVERSE 44

NEUTRAL NEUTRAL 22 33

KICK KICK DOWN DOWN

B1 B1 B2 B2 B3 B3 V V R R AS AS KD KD AJS0300L AJS0300L

Figure 16

AUTO SELECT SWITCH This is an auto/manual select switch.

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

Automatic shifting takes place between gears. •

Forward: 2nd - 3rd - 4th

•

Reverse: 2nd - 3rd

HLB2007L

Figure 17

When the switch is in the "0" - (Manual) position, the shifting is returned to the manual mode and the control signal shifts the transmission to gear selected by the operator.

DISPLAY Fault codes are given in a separate section "Transmission Error Codes (ZF)."

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 19

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

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 neutral. If more than one fault is detected, each fault code is shown for about 1 second.

left character

right character

S T O P

CAN - MESSAGE The TCU sends the fault code of a detected fault in the specified CAN - message, while the fault is active.

(special symbols a-h)

HBOE630L

Figure 18

If more than one fault is detected, the fault code scrolls. DESCRIPTION OF FAULT CODES

S0607090K Page 20

First Number

Meaning of Number

1 Hex

Digital Input Signal

2 Hex

Analog Input Signal

3 Hex

Speed Signal

4 Hex

Can Signal Error

5 Hex

Can Signal Error

6 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

Transmission and Torque Converter (ZF 4WG-210)

ABBREVIATIONS Throughout this section the following abbreviations are used to indicate various conditions. Abbreviations O.C.

Open Circuit

S.C.

Short Circuit

OP-Mode

OPeration Mode

TCU

Transmission Control Unit

ABS

Anti Blocking System

ASR

Anti Slipping Regulation

EEC

Electronic Engine Controller

PTO

Power Take Off

CCO

Clutch Cut Off

DEFINITION OF OPERATION MODES Normal There is no failure detected in transmission system or failure has no or slight effects on transmission control. TCU will work without or in special cases with little limitations. (see following table) Substitute Clutch Control TCU cannot change gears or direction under control of normal clutch modulation. TCU uses substitute strategy for clutch control. All modulations are only time controlled. (Comparable with EST 25) Limp-home The detected failure in the system has strong limitations to transmission control. TCU can engage only one gear in each direction. In some cases only one direction will be possible. TCU will shift the transmission into neutral at the first occurrence of the failure. First, the operator must shift the gear selector into neutral position. If output speed is less than a threshold for neutral to gear and the operator shifts the gear selector into forward or reverse, the TCU will select the limp-home gear. If output speed is less than a threshold for reversal speed and TCU has changed into the limp-home gear and the operator selects a shuttle shift, TCU will shift immediately into the limp-home gear of the selected direction. If output speed is greater than the threshold, TCU will shift the transmission into neutral. The operator has to slow down the vehicle and must shift the gear selector into neutral position. Transmission Shut Down TCU has detected a severe failure that disables control of the transmission. TCU will shut off the solenoid valves for the clutches and also the common power supply (VPS1). Transmission shifts to Neutral. The park brake will operate normally, also the other functions which use ADM 1 to ADM 8. The operator has to slow down the vehicle. The transmission will stay in neutral. TCU Shut Down TCU has detected a severe failure that disables control of system. TCU will shut off all solenoid valves and also both common power supplies (VPS1, VPS2). The park brake will engage, also all functions are disabled which use ADM 1 to ADM 8. The transmission will stay in neutral.

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 21

TABLE OF FAULT CODES Fault codes are given in a separate section "Transmission Error Codes (ZF)." MEASUREMENT OF RESISTANCE AT ACTUATOR/SENSORS AND CABLE Actuator open circuit:R12 ≈ R1G ≈ R2G ≈ ∞

short cut to ground:R12 ≈ R;R1G ≈ 0, R2G ≈ R or R1G ≈ R, R2G ≈ 0(for S.C. to ground, G is 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 connected to battery voltage).

G HBOE640I

Figure 19 Cable UBat

open circuit: R12 ≈ R1P ≈ R1C ≈ R2P ≈ R2C ≈ ∞ short cut to ground:

P (power supply) TCU Actuator /

R12 ≈ 0;R1C ≈ R2C ≈ 0,R1P ≈ R2P ≈ ∞

short cut to battery:

Sensor

C (chassis)

R12 ≈ 0,R1C ≈ R2C ≈ ∞,R1P ≈ R2P ≈ 0

Gnd

HBOE650I

Figure 20

S0607090K Page 22

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 23

TRANSMISSION ELECTRICAL CIRCUITS TRANSMISSION CONTROLLER CIRCUIT

AMS0880L

Figure 21

S0607090K Page 24

Transmission and Torque Converter (ZF 4WG-210)

Reference Number

Description

Reference Number

Description

Transmission Controller

Down Shift Switch

Transmission Selector Switch

Safety Start Relay

Transmission Control Valve

Output Speed Sensor

Fuse Box

Speed Pick-up

Auto Selector Switch

Speedometer

Transmission Cutoff Selector Switch

Parking Brake Switch

Control Unit

Transmission Cutoff Pressure Switch

Starter Controller

Display

The transmission proportioning solenoid valves are shown here as (Y1 thru Y6, Figure 21).

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 25

TRAVELING CIRCUITS Neutral

AMS0890L

Figure 22 Reference Number

Description

Reference Number

Description

Transmission Controller

Safety Start Relay

Transmission Selector Switch

Output Speed Sensor

Transmission Control Valve

Speed Pick-up

Fuse Box

Speedometer

Auto Selector Switch

Parking Brake Switch

Display

Control Unit

Down Shift Switch

Starter Controller

When all transmission solenoid valves are de-energized (OFF) the transmission is in "NEUTRAL."

S0607090K Page 26

Transmission and Torque Converter (ZF 4WG-210)

Forward First Gear

AMS0900L

Figure 23 Reference Number

Description

Reference Number

Description

Transmission Controller

Safety Start Relay

Transmission Selector Switch

Output Speed Sensor

Transmission Control Valve

Speed Pick-up

Fuse Box

Speedometer

Auto Selector Switch

Parking Brake Switch

Display

Control Unit

Down Shift Switch

Starter Controller

Transmission solenoid valves (Y3 and Y5, Figure 23) are energized when in forward first gear.

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 27

Forward Second Gear

AMS0910L

Figure 24 Reference Number

Description

Reference Number

Description

Transmission Controller

Safety Start Relay

Transmission Selector Switch

Output Speed Sensor

Transmission Control Valve

Speed Pick-up

Fuse Box

Speedometer

Auto Selector Switch

Parking Brake Switch

Display

Control Unit

Down Shift Switch

Starter Controller

Transmission solenoid valves (Y5 and Y6, Figure 24) are energized when in forward second gear.

S0607090K Page 28

Transmission and Torque Converter (ZF 4WG-210)

Forward Third Gear

AMS0920L

Figure 25 Reference Number

Description

Reference Number

Description

Transmission Controller

Safety Start Relay

Transmission Selector Switch

Output Speed Sensor

Transmission Control Valve

Speed Pick-up

Fuse Box

Speedometer

Auto Selector Switch

Parking Brake Switch

Display

Control Unit

Down Shift Switch

Starter Controller

Transmission solenoid valves (Y4 and Y5, Figure 25) are energized when in forward third gear.

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 29

Forward Fourth Gear

AMS0930L

Figure 26 Reference Number

Description

Reference Number

Description

Transmission Controller

Safety Start Relay

Transmission Selector Switch

Output Speed Sensor

Transmission Control Valve

Speed Pick-up

Fuse Box

Speedometer

Auto Selector Switch

Parking Brake Switch

Display

Control Unit

Down Shift Switch

Starter Controller

Transmission solenoid valves (Y2 and Y4, Figure 26) are energized when in forward fourth gear.

S0607090K Page 30

Transmission and Torque Converter (ZF 4WG-210)

Reverse First Gear

AMS0940L

Figure 27 Reference Number

Description

Reference Number

Description

Transmission Controller

Safety Start Relay

Transmission Selector Switch

Output Speed Sensor

Transmission Control Valve

Speed Pick-up

Fuse Box

Speedometer

Auto Selector Switch

Parking Brake Switch

Display

Control Unit

Down Shift Switch

Starter Controller

Transmission solenoid valves (Y2 and Y3, Figure 27) are energized when in reverse first gear.

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 31

Reverse Second Gear

AMS0950L

Figure 28 Reference Number

Description

Reference Number

Description

Transmission Controller

Safety Start Relay

Transmission Selector Switch

Output Speed Sensor

Transmission Control Valve

Speed Pick-up

Fuse Box

Speedometer

Auto Selector Switch

Parking Brake Switch

Display

Control Unit

Down Shift Switch

Starter Controller

Transmission solenoid valves (Y2 and Y6, Figure 28) are energized when in reverse second gear.

S0607090K Page 32

Transmission and Torque Converter (ZF 4WG-210)

Reverse Third Gear

AMS0960L

Figure 29 Reference Number

Description

Reference Number

Description

Transmission Controller

Safety Start Relay

Transmission Selector Switch

Output Speed Sensor

Transmission Control Valve

Speed Pick-up

Fuse Box

Speedometer

Auto Selector Switch

Parking Brake Switch

Display

Control Unit

Down Shift Switch

Starter Controller

Transmission solenoid valves (Y2 and Y4, Figure 29) are energized when in reverse third gear.

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 33

KICK-DOWN Overview 1.

There are two kick-down switches shown Figure 30, and it is possible for operators to select either one of them according to the condition.

If the kick-down switch is depressed while the machine moving, downshifting takes place automatically. As a result, faster digging and moving is possible. When in the manual mode the kick-down can only be activated.

If a change in travel direction takes place or the downshift switch is depressed a second time, the kick-down function is automatically released.

S0607090K Page 34

AJS0400L

Figure 30

Transmission and Torque Converter (ZF 4WG-210)

Kick-down: Forward Second Gear to Forward First Gear (Auto Selector Switch "O"- Manual Mode)

AMS1070L

Figure 31 Reference Number

Description

Reference Number

Transmission Controller

Transmission Selector Switch

Transmission Cutoff Pressure Switch

Transmission Control Switch

Display

Fuse Box

Down Shift Switch

Auto Selector Switch

Output Speed Sensor

Transmission Cutoff Selector Switch

Speed Pick-up

Speedometer

Parking Brake Switch

Transmission and Torque Converter (ZF 4WG-210)

Description

S0607090K Page 35

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

A B HLB2007L

Figure 32

S0607090K Page 36

Transmission and Torque Converter (ZF 4WG-210)

Kick-down (Auto Selector Switch "I" - Auto Mode)

AMS1080L

Figure 33 Reference Number

Description

Reference Number

Transmission Controller

Transmission Selector Switch

Transmission Cutoff Pressure Switch

Transmission Control Switch

Display

Fuse Box

Down Shift Switch

Auto Selector Switch

Output Speed Sensor

Transmission Cutoff Selector Switch

Speed Pick-up

Speedometer

Parking Brake Switch

Transmission and Torque Converter (ZF 4WG-210)

Description

S0607090K Page 37

When the auto selector switch (Figure 33) is in the "I" position, the "29" terminal of transmission controller is energized. This allows the transmission to automatically upshift and downshift gears depending on the load and on the engine speed. If either kick-down switch (Figure 30) is activated, a pulse signal is sent to the "22" terminal of transmission controller. This signal shifts the transmission to the next lowest gear. Automatic Gear Selection

Downshift Switch "Activated"

Fourth Gear

Downshift to Third Gear

Third Gear

Downshift to Second Gear

Second Gear

Downshift to First Gear

First Gear

Remains in First Gear

When either kick-down switch (Figure 30) is depressed a second time, the transmission pulse signal of the "22" is interrupted and the transmission returns to normal operation. NOTE:

The fourth to the third gear changes without any rpm change when the downshift switch is pressed.

NOTE:

The third to the second gear, and the third to the first gear, changes occur when the rpm is reduced 200 - 300 rpm from current setting.

S0607090K Page 38

Transmission and Torque Converter (ZF 4WG-210)

TRANSMISSION CUTOFF When the brake pedal is depressed while transmission cutoff switch (Figure 34) is in the "I" position, the transmission cutoff pressure switch turns "ON" and current is supplied to the "66" terminal of the transmission controller.

All current being supplied to the transmission solenoid valves (Y1 thru Y6) is cutoff and the transmission is in "NEUTRAL." NOTE:

To protect transmission, transmission cutoff switch does not function in third and fourth gears.

I HA3O2018

Figure 34

CAUTION! When the machine is traveling or working in the place of inclination, the transmission cutoff switch (Figure 34) must be placed in position 'O' for the purse of using engine braking and the normal braking function at the same time.

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 39

AMS0980L

Figure 35 Reference Number

Description

Reference Number

Description

Transmission Controller

Down Shift Switch

Transmission Selector Switch

Safety Start Relay

Transmission Control Switch

Output Speed Sensor

Fuse Box

Speed Pick-up

Auto Selector Switch

Speedometer

Transmission Cutoff Select Switch

Parking Brake Switch

Control Unit

Transmission Cutoff Pressure Switch

Starter Controller

Display

S0607090K Page 40

Transmission and Torque Converter (ZF 4WG-210)

LIS (LOAD ISOLATION SYSTEM) - OPTION Excessive bucket pitching is drastically reduced and good flotation is maintained for minimum operator fatigue and maximum productivity. LIS is useful for sites where frequent cycles of loading and carry are needed or rough terrain.

When the LIS switch is "I" and the vehicle speed is above 8.0 km/h (4.97 MPH), the LIS solenoids valves (14) are energized and the LIS system is "ON." When the LIS switch is "I" and the vehicle speed is below 6.0 km/h (3.73 MPH) the LIS solenoids valves (14) are de-energized and the LIS system is "OFF." NOTE:

I HA0O2026

Figure 36

If the LIS switch is in the "O" position, despite the vehicle speed the LIS solenoid valves (14) de-energized and the LIS system is not operating.

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 41

AMS0970L

Figure 37 Reference Number

Description

Reference Number

Description

Transmission Controller

Output Speed Sensor

Shift Lever Switch

Speed Pick-up (3)

Fuse Box 1

LIS Switch (Option)

Auto Selector Switch

LIS Solenoid Valve

Display

Speedometer

Down Shift Switch

Parking Brake Switch

Safety Start Relay

Fuse Box 2

S0607090K Page 42

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 43

INSTALLATION VIEW (S/N 1001 THRU 2000) INNER SECTION

Figure 38 Reference Number

Description

Reference Number

Description

Clutch Shaft "KR"

Transmission Pump

Power Take-off; Coaxial; Engine-Dependent

Input Flange - Input Through Universal Shaft

Clutch Shaft "KV"

Converter

Clutch Shaft "K2"

Clutch Shaft "K3"

Input Transmitter for Engine Speed

Output Flange - Rear

Clutch Shaft "K4"

Output Flange - Converter Side

Converter Relief Valve

Clutch Shaft "K1"

S0607090K Page 44

Output Shaft

Transmission and Torque Converter (ZF 4WG-210)

FRONT VIEW

Figure 39 Reference Number

Description

Reference Number

Lifting Lugs

Drive Flange - Input Through Universal Shaft

Oil Drain Plug with Magnetic Insert M38x1.5

output Flange - Converter Side

Transmission Suspension Bores M20

Attachment Possibility for Emergency

Model Identification Plate

Attachment Possibility for Emergency Steering Pump

Transmission and Torque Converter (ZF 4WG-210)

Description

S0607090K Page 45

FRONT VIEW WITH DISC BRAKE

Figure 40 Reference Number

Description

Reference Number

Description

Lifting Lugs

Model Identification Plate

Drive Flange - Input Through Universal Shaft

output Flange - Converter Side

Oil Drain Plug with Magnetic Insert M38x1.5

Attachment Possibility for Oil Filter Pipe with Oil Dipstick (Converter Side)

Transmission Suspension Bores M20

Attachment Possibility for Emergency Steering Pump

S0607090K Page 46

Transmission and Torque Converter (ZF 4WG-210)

SIDE VIEW

Figure 41 Reference Number

Description

Reference Number

Description

Box Filter (Fine Filter)

Oil Filler Pipe with Oil Dipstick

Drive Flange - Input Through Universal Shaft

Cover

Output Flange - Rear

Converter Bell Housing

Breather

Oil Drain Plug with Magnetic Insert M38x1.5

Transmission - Case Cover

Output Flange - Converter Side

Filter Head with Alarm Switch

Transmission Case

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 47

SIDE VIEW WITH DISC BRAKE

Figure 42 Reference Number

Description

Reference Number

Description

Drive Flange - Input Through Universal Shaft

Box Filter (Fine Filter)

Disc Brake (Parking Brake)

Cover

Converter Bell Housing

Output Flange with Disc Brake Rear

Breather

Transmission - Case Cover

Oil Drain Plug with Magnetic Insert M38x1.5

Filter Head with Alarm Switch

Output Flange - Converter Side

Transmission Case

S0607090K Page 48

Transmission and Torque Converter (ZF 4WG-210)

REAR VIEW

Figure 43 Reference Number

Description

Reference Number

Description

Lifting Lugs

Output Flange - Rear

Power Take-off; Coaxial; Engine-Dependent

Box Filter (Fine Filter)

Filter Head with Connection for Alarm Switch

Port-System Pressure M16x1.5 ((Option-e.g. to Parking Brake Valve)

Electro-Hydraulic Control

Port-Return Line M26x1.5 (Option-e.g. from Parking Brake)

Oil Filter Pipe with Oil Dipstick

Transmission Suspension Bores M20

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 49

REAR VIEW WITH DISC BRAKE

Figure 44 Reference Number

Description

Reference Number

Lifting Lugs

Power Take-off; Coaxial; Engine-Dependent

Electro-Hydraulic Control

X Filter (Fine Filter)

Port Return Line M26x1.5 (Option e.g. from Parking Brake)

Filter Head with Connection for Alarm Switch

Disc Brake

Transmission Suspension Bores M20

Port-System Pressure M16x1.5 ((Option-e.g. to Parking Brake Valve)

S0607090K Page 50

Description Attachment Possibility for Oil Filler Pipe with Oil Dipstick (Rear)

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 51

INSTALLATION VIEW (S/N 2001 AND UP) INNER SECTION

Figure 45 Reference Number

Description

Reference Number

Description

Clutch Shaft "KR"

Transmission Pump

Power Take-off; Coaxial; Engine-Dependent

Flexible Plate

Converter

Clutch Shaft "KV"

Clutch Shaft "K2"

Input Transmitter for Engine Speed

Clutch Shaft "K3"

Clutch Shaft "K4"

Output Flange - Rear

Converter Relief Valve

Output Flange - Converter Side

Clutch Shaft "K1"

Output Shaft

S0607090K Page 52

Transmission and Torque Converter (ZF 4WG-210)

FRONT VIEW

Figure 46 Reference Number

Description

Reference Number

Description

Lifting Lugs

Output Flange - Converter Side

Flexible Plate

Transmission Suspension Bores M20

Oil Drain Plug with Magnetic Insert M38x1.5

Attachment Possibility for Emergency Steering Pump

Attachment Possibility for Oil Filler Pipe with Oil Dipstick

Oil Filler Pipe with Oil Dipstick

4 5

Model Identification Plate

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 53

FRONT VIEW WITH DISC BRAKE

Figure 47 Reference Number

Description

Reference Number

Description

Lifting Lugs

output Flange - Converter Side

Flexible Plate

Transmission Suspension Bores M20

Oil Drain Plug with Magnetic Insert M38x1.5

Attachment Possibility for Oil Filler Pipe with Oil Dipstick (Converter Side)

Attachment Possibility for Emergency Steering Pump

Model Identification Plate

S0607090K Page 54

Transmission and Torque Converter (ZF 4WG-210)

SIDE VIEW

Figure 48 Reference Number

Description

Reference Number

Description

Flexible Plate

Box Filter (Fine Filter)

Converter

Oil Filler Pipe with Oil Dipstick

Converter Bell Housing

Output Flange - Rear

Breather

Transmission - Case Cover

Oil Drain Plug with Magnetic Insert M38x1.5

Filter Head with Alarm Switch

Output Flange - Converter Side

Transmission Case

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 55

SIDE VIEW WITH DISC BRAKE

Figure 49 Reference Number

Description

Reference Number

Description

Flexible Plate

Disc Brake (Parking Brake)

Converter

Converter Bell Housing

Output Flange with Disc Brake Rear

Breather

Transmission - Case Cover

Oil Drain Plug with Magnetic Insert M38x1.5

Filter Head with Alarm Switch

Output Flange - Converter Side

Box Filter (Fine Filter)

Transmission Case

S0607090K Page 56

Transmission and Torque Converter (ZF 4WG-210)

REAR VIEW

Figure 50 Reference Number

Description

Reference Number

Description

Lifting Lugs

Output Flange - Rear

Power Take-off; Coaxial; Engine-Dependent

Box Filter (Fine Filter)

Filter Head with Connection for Alarm Switch

Port-System Pressure M16x1.5 ((Option-e.g. to Parking Brake Valve)

Electro-Hydraulic Control

Port-Return Line M26x1.5 (Option-e.g. from Parking Brake)

Oil Filler Pipe with Oil Dipstick

Transmission Suspension Bores M20

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 57

REAR VIEW WITH DISC BRAKE

Figure 51 Reference Number

Description

Reference Number

Lifting Lugs

Power Take-off; Coaxial; EngineDependent

X Filter (Fine Filter)

Electro-Hydraulic Control

Port Return Line M26x1.5 (Option e.g. from Parking Brake)

Filter Head with Connection for Alarm Switch

Port-System Pressure M16x1.5 (Option-e.g. to Parking Brake Valve)

Transmission Suspension Bores M20

Attachment Possibility for Oil Filler Pipe with Oil Dipstick (Rear)

S0607090K Page 58

Description Output Flange with Disc Brake (Rear)

Transmission and Torque Converter (ZF 4WG-210)

SPECIAL TOOLS GEARSHIFT SYSTEM

Figure 52

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 59

Figure 53

S0607090K Page 60

Transmission and Torque Converter (ZF 4WG-210)

ENGINE CONNECTION

Figure 54

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 61

PRESSURE OIL PUMP

Figure 55

S0607090K Page 62

Transmission and Torque Converter (ZF 4WG-210)

GEARBOX HOUSING

Figure 56

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 63

Figure 57

S0607090K Page 64

Transmission and Torque Converter (ZF 4WG-210)

INPUT

Figure 58

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 65

COUPLING

Figure 59

S0607090K Page 66

Transmission and Torque Converter (ZF 4WG-210)

Figure 60

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 67

Figure 61

S0607090K Page 68

Transmission and Torque Converter (ZF 4WG-210)

Figure 62

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 69

Figure 63

S0607090K Page 70

Transmission and Torque Converter (ZF 4WG-210)

Figure 64

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 71

OUTPUT

Figure 65

S0607090K Page 72

Transmission and Torque Converter (ZF 4WG-210)

POWER TAKE-OFF

Figure 66

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 73

HYDRAULIC CONTROL UNIT (HSG-94) Figure 67, 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 67

S0607090K Page 74

Transmission and Torque Converter (ZF 4WG-210)

Section A -A

Figure 68 Section B - B

Figure 69

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 75

DISASSEMBLY 1.

Figure 70, shows complete control unit.

Mark the installation position of the different covers, the housing and the cable harness with the valve housing.

Loosen socket head screws.

Separate duct plate, 1st gasket, intermediate plate and 2nd gasket from the valve housing.

Figure 70

Figure 71

(S) Box spanner (Torx TX-27) - 5873 042 002

Figure 72

S0607090K Page 76

Transmission and Torque Converter (ZF 4WG-210)

Remove retaining clip.

Loosen socket head screws.

Separate cover from housing and cable harness.

Figure 73

(S) Box spanner (Torx TX - 27) - 5873 042 002

Figure 74 8.

Disassemble opposite cover.

Disconnect pressure regulator and remove cable harness.

10.

Loosen socket head screws, remove fixing plate and pressure regulators (3x).

Figure 75

(S) Box spanner (Torx TX - 27) - 5873 042 002

Figure 76

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 77

11.

Loosen two socket head screws and locate housing provisionally, using adjusting screws. (Housing is spring loaded). Then loosen remaining socket and screws. (S) Box spanner (Torx TX - 27) - 5873 042 002 (S) Adjusting screws - 5870 204 036

Figure 77 12.

Separate housing from valve housing by loosening adjusting screws uniformly. (S) Adjusting screws - 5870 204 036

Figure 78 13.

Remove components (Figure 79).

14.

Remove opposite pressure regulators, housing and components accordingly (Figure 80).

Figure 79

Figure 80

S0607090K Page 78

Transmission and Torque Converter (ZF 4WG-210)

REASSEMBLY

Check all components for damage and replace if necessary. Prior to 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.

NOTE:

Insert diaphragms with concave side facing upward until contact is obtained. Installation arrows.

NOTE: 1.

Figure 82, components: Reference Number

shows

position, the

Figure 81

see

following

Description

Vibration Damper (3x Spool and Compression Spring)

Follow On Site (3x Spool and Compression Spring)

Pressure Reducing Valve (1x Spool and Compression Spring)

Figure 82

Install components according to Figure 82. NOTE:

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

Figure 83

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 79

Install two adjusting screws.

Assemble gasket (1, Figure 84) and housing cover (Figure 84). Position housing cover uniformly, using adjusting screws, until contact is obtained and remove cylindrical pins (assembly aid) again (Figure 85). NOTE:

Pay attention housing covers.

different

NOTE:

Install recess Ø 15.0 mm (0.5906 in) (2, Figure 84), facing spring of pressure reducing valve.

Figure 84

(S) Adjusting screws - 5870 204 036

Figure 85 5.

Fasten housing cover using socket head screws. NOTE:

Torque limit 5.5 N•m (4 ft lb).

(S) Box spanner (Torx TX-27) - 5873 042 002

Figure 86

S0607090K Page 80

Transmission and Torque Converter (ZF 4WG-210)

Install pressure regulators and secure using fixing plates and socket head screws. NOTE:

Install fixing plate, with claw facing downward. Pay attention to radial installation position of pressure regulators, see Figure 87.

NOTE:

Torque limit 5.5 N•m (4 ft lb).

(S) Box spanner (Torx TX-27) - 5873 042 002 Figure 87 7.

Pre-assemble opposite side. A.

Figure 88, shows components: Reference Number

the

following

Description

Main Pressure Valve (1x Spool and Compression Spring.)

Follow On Slide (3x Spool and Compression Spring)

Vibration Damper (3x Spool and Compression Spring)

Install components Figure 88.

Preload compression springs of the follow on slides and locate spool provisionally using cylindrical pins Ø 5 mm (0.1969 in) (assembly aid). See arrows.

Install two adjusting screws.

Assemble gasket (1, Figure 89) and housing cover, and position them uniformly against shoulder, using adjusting screws.

NOTE:

Figure 89

Pay attention to different housing covers, install the recess Ø 19 mm (0.7480 in) (2, Figure 89), facing the main pressure valve.

Fasten housing cover using socket head screws.

NOTE: G.

according

Figure 88

Torque limit 5.5 N•m (4 ft lb).

Remove cylindrical pins (assembly aid) again. (S) Adjusting screws - 5870 204 036 (S) Box spanner (Torx TX-27) - 5873 042 002

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 81

Install pressure regulators and secure using fixing plates and socket head screws.

NOTE:

Install fixing plates, with claw facing downward. Pay attention to radial installation position of pressure regulators, see Figure 90.

NOTE:

Torque limit 5.5 N•m (4 ft lb).

(S) Box spanner (Torx TX-27) - 5873 042 002 I.

Figure 90

Introduce cable harness and connect pressure regulators (6x).

NOTE:

Pay attention to installation position of cable harness, see also markings (Figure 71).

Figure 91 J.

Introduce female connector against shoulder, with groove facing guide nose of cover.

Install gaskets (Figure 92) and fasten cover using socket head screws.

NOTE:

Torque limit 5.5 N•m (4 ft lb).

(S) Box spanner (Torx TX-27) - 5873 042 002

Figure 92 L.

Secure female connector using retaining clamp, see Figure 93.

Install opposite cover.

Figure 93

S0607090K Page 82

Transmission and Torque Converter (ZF 4WG-210)

Install two adjusting screws and mount gasket I.

NOTE:

Pay attention to different gaskets, see Figure 94 and Figure 97.

(S) Adjusting screws - 5870 204 063

Figure 94 8.

Intermediate plate-version with screens: A.

Insert screens (6x) flash -mounted into bore of intermediate plate, see Figure 95.

NOTE:

Pay attention to installation position- screens are facing upward (facing duct plate).

Figure 95 B.

Mount intermediate plate, with screens with screens facing upward.

Mount gasket II.

Figure 96

Figure 97

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 83

Mount duct plate and fasten it uniformly using socket head screws.

NOTE:

Torque limit 9.5 N•m (7 ft lb).

(S) Box spanner (Torx TX-27) - 5873 042 002

Figure 98 E.

Equip screw plugs (8x) with new Orings and install them.

NOTE:

Torque limit 6 N•m (4 ft lb).

NOTE:

The installation of hydraulic control unit is described in following section, “Mount Duct Plate and Hydraulic Control Unit” on page 139.

Figure 99

S0607090K Page 84

Transmission and Torque Converter (ZF 4WG-210)

TRANSMISSION DISASSEMBLY 1.

Fasten transmission on the assembly car. (S) Assembly car - 5870 350 000 (S) Strips - 5870 350 063 (S) Support - 5870 350 090

Figure 100 HYDRAULIC CONTROL UNIT (HSG-94) AND DUCT PLATE 1.

Loosen two socket head screws and install adjusting screws.

Loosen remaining socket head screws and separate valve housing from duct plate. (S) Adjusting screws (M6) - 5870 204 063 (S) Box spanner (Torx TX-27) - 5870 042 002 Figure 101

Remove both gaskets and intermediate plate.

Loosen socket head screws and hex. nuts (Figure 102) and separate duct plate from gearbox housing. Remove gasket. (S) Box spanner (Torx TX-27) - 5870 042 004

Figure 102

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 85

Pull converter safety valve out of housing bore.

Figure 103 ENGINE CONNECTION - CONVERTER 1.

Remove lock plate and loosen hex. head screws.

Remove disk and pry drive flange off shaft.

Loosen screw connection.

Figure 104 NOTE:

Mark radial installation position of the housing cover.

Figure 105 4.

Separate converter, along with cover from the transmission, using lifting device. (S) Set of eye bolts - 5870 204 002

Figure 106

S0607090K Page 86

Transmission and Torque Converter (ZF 4WG-210)

Press drive shaft resp. converter out of the cover (ball bearing).

Squeeze retaining ring out and remove ball bearing.

Figure 107

(S) Set of internal pliers - 5870 900 013

Figure 108 7.

Loosen hex. head screws and separate diaphragm from the converter.

Loosen hex. head screws and separate drive shaft from the diaphragm.

Figure 109

Figure 110

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 87

Remove inductive transmitter (n Engine).

10.

Loosen hex. head screws and remove converter bell.

Figure 111

Figure 112 HYDRAULIC PUMP 1.

Loosen socket head screws.

Apply separate device (S) on the gear teeth run out of the stator shaft and pull (compl.) using two-leg puller carefully out of the housing bores.

Figure 113

(S) Separating device - 5870 300 024 (S) Two-leg puller - 5870 970 004

Figure 114

S0607090K Page 88

Transmission and Torque Converter (ZF 4WG-210)

Separate hydraulic pump from stator shaft.

Separate control disk from pump. NOTE:

If traces due to running-in should be encountered in the pump housing or on the control disk, the complete pump has to be replaced.

Lay on control disk again and secure it using grooved pins (2x).

Loosen socket head screws and the two hex. head screws and remove oil feed housing.

Figure 115

Remove gasket. (S) Box spanner (Torx, TX-40) - 5873 023 004

Figure 116 CONVERTER BACK PRESSURE VALVE 1.

Preload compression spring and remove lock plate.

Remove released components.

Loosen hex. head screws. Remove cover and gasket.

Figure 117

Figure 118

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 89

REMOVE OUTPUT, INPUT AND CLUTCHES 1.

Remove lock plate, loosen hex. head screws and pry converter-side output flange off the shaft.

Pry shaft seal out of the housing bore.

Tilt transmission 180° and remove rearside output flange accordingly. (S) Pry bar - 5870 345 065

Figure 119 4.

Remove speed sensor and both inductive transmitters (Arrows).

Loosen hex. nuts and remove both covers (Arrows).

Loosen screw housing cover).

Drive both cylindrical pins out (Arrows).

Figure 120

connection

(housing/

Figure 121 NOTE:

The following figures show the common removal of all clutches.

The removal of single clutches without use of the special tool (Handles - 5870 260 010) due to the installation conditions is extremely difficult. NOTE:

Besides there is the danger of injuries. Figure 122

S0607090K Page 90

Transmission and Torque Converter (ZF 4WG-210)

Locate all clutches using handles (S) in the housing cover.

10.

Install eye bolts and hang in the lifting device. (S) Handles (6 pieces needed) - 5870 260 010 (S) Eye bolt 2x (M20) - 0636 804 003 (S) Eye bolt 1x (M16) - 0636 804 001 (S) Puller device - 5870 000 017 (S) Lifting chain - 5870 281 047

11.

Separate housing cover along with clutches from the gearbox housing using lifting device.

12.

Fasten housing cover on the assembly car.

Figure 123

Figure 124 (S) Assembly car - 5870 350 000 (S) Clamping bracket - 5870 350 089

Figure 125 13.

Loosen socket head screws and remove output shaft and the two oil collecting plates.

Figure 126

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 91

14.

Pull off tapered roller bearing.

15.

Remove opposite tapered roller bearing accordingly. (S) Grab sleeve - 5873 002 038 (S) Basic set - 5873 002 001

Figure 127 16.

Tilt gearbox housing 180°.

17.

Figure 128, shows the arrangement of the single clutches and the input in the housing cover. Reference Number

18.

Description

Input

Clutch - Forward

Clutch - Reverse

Clutch - 1st Speed

Clutch - 2nd Speed

Clutch - 3rd Speed

Clutch - 4th Speed

Figure 128

Remove handles (S) (Figure 129). (S) Handles - 5870 260 010

Figure 129

S0607090K Page 92

Transmission and Torque Converter (ZF 4WG-210)

19.

Lift Clutch-K4 a bit using pry bars and remove Clutch-K1.

20.

Remove Clutch-K2.

21.

Remove Clutch-K3.

22.

Lift Clutch - KV and KR using pry bars and remove Clutch - K4.

Figure 130

Figure 131

Figure 132

(S) Pry bar - 5870 345 065

Figure 133

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 93

23.

Lift Clutch - KV and Clutch - KR and input together out of the housing cover.

24.

Remove outer bearing races out of the housing bores.

IMPORTANT If contrary to the ZFRecommendation the tapered roller bearing of the clutches and of the input and output will not be replaced, the allocation (inner bearing races to outer bearing races) must at least be maintained.

Figure 134

Mark inner bearing races and outer bearing races accordingly to each other. 25.

Tilt housing cover 90°.

26.

Squeeze retaining ring out and separate pump shaft from housing cover.

27.

Squeeze rectangular ring out (Arrow) and press ball bearing from the shaft.

Figure 135

Figure 136

S0607090K Page 94

Transmission and Torque Converter (ZF 4WG-210)

DISASSEMBLE CLUTCH - KV AND KR 1.

Squeeze rectangular ring out (Arrow). NOTE:

The following figures show the disassembly of Clutch - KV. The disassembly of Clutch - KR is similar.

Figure 137 2.

Pull tapered roller bearing from the shaft.

Remove opposite tapered roller bearing accordingly. (S) Grab sleeve - 5873 001 057 (S) Grab sleeve - 5873 001 059 (S) Basic set - 5873 001 000

Figure 138 4.

Squeeze retaining ring out.

Separate plate carrier from the shaft.

Figure 139 (S) Three0leg puller - 5870 970 003

Figure 140

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 95

Squeeze snap ring out and remove plate pack.

Preload compression spring, squeeze snap ring out and remove components.

Figure 141

(S) Assembly aid - 5870 345 088

Figure 142 8.

Lift piston using compressed air out of the cylinder bore and remove it.

Remove both O-rings (Arrows).

Figure 143

Figure 144

S0607090K Page 96

Transmission and Torque Converter (ZF 4WG-210)

10.

Lift idler gear a bit using pry bars (Figure 145).

11.

Apply puller and separate idler gear from the clutch shaft (Figure 146).

12.

Squeeze retaining ring out and remove ball bearing.

Figure 145

NOTE:

The disassembly of Clutch - KR has to be carried out accordingly.

Figure 146

Figure 147

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 97

DISASSEMBLE CLUTCH - K1, K2 AND K3 NOTE:

The following figures show the disassembly of Clutch - K3. The disassembly of the Clutches K1 and K2 is similar.

Squeeze rectangular ring out. Pull tapered roller bearing from the shaft.

Remove the opposite bearing accordingly.

tapered

roller

(S) Grab sleeve (Bearing 33800) - 5873 001 059

Figure 148

(S) Grab sleeve (Bearing 33800) - 5873 002 038 (S) Basic set - 5873 001 000 (S) Basic set - 5873 002 001 3.

Remove running disk, axial needle cage and axial washer.

Remove idler gear.

Figure 149

Figure 150

S0607090K Page 98

Transmission and Torque Converter (ZF 4WG-210)

Remove needle bearings and the axial bearing (compl.).

Squeeze snap ring out and remove plate pack.

Preload cup-spring pack and squeeze snap ring out. Remove released components.

Figure 151

Figure 152

(S) Assembly aid - 5870 345 088

Figure 153 8.

Squeeze retaining ring (S) into the groove of the plate carrier.

Apply puller on the retaining ring and pull plate carrier from the clutch shaft. (S) Puller - 5870 970 004 (S) Retaining ring - 0630 502 053

Figure 154

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 99

DISASSEMBLE CLUTCH - K4 1.

Squeeze rectangular ring out (Arrow).

Pull tapered roller bearing from the shaft.

Remove opposite tapered roller bearing accordingly.

Figure 155

(S) Grab sleeve - 5873 001 057 (S) Grab sleeve - 5873 001 059 (S) Basic set - 5873 001 000

Figure 156 4.

Squeeze retaining ring out and separate plate carrier from the shaft. (S) Three-leg puller - 5870 971 003

Figure 157 5.

Squeeze snap ring out and remove plate pack.

Figure 158

S0607090K Page 100

Transmission and Torque Converter (ZF 4WG-210)

Preload cup-spring pack and squeeze snap ring out.

Remove released components. Remove piston. (S) Assembly aid - 5870 345 088

Figure 159 8.

Lift piston using compressed air out of the cylinder bore and remove it.

Take off the idler gear and remove released components.

Figure 160

NOTE:

The separation of shaft and gear is not possible (shrink fit).

Figure 161 DISASSEMBLE DRIVE SHAFT 1.

Squeeze rectangular ring out.

Pull off tapered roller bearing. Remove opposite tapered roller bearing accordingly. (S) Grab sleeve - 5873 002 045 (S) Basic set - 5873 002 001 (S) Basic set - 5873 002 006

Figure 162

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 101

If necessary, press turbine shaft out of the drive shaft. NOTE:

The turbine shaft is axially fixed with a snap ring which will be destroyed at the pressing out.

Figure 163

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Transmission and Torque Converter (ZF 4WG-210)

TRANSMISSION REASSEMBLY INSTALL OIL TUBE

IMPORTANT To ensure the correct installation of the oil tubes, the use of the indicated special tool (S) is imperative. 1.

Insert suction pipe (1), pressure pipes (2) and pressure pipe lubrication (3) into the housing bores.

Fasten suction and pressure pipes using socket head screws. NOTE:

Torque limit (M8/8.8) 23 N•m (17 ft lb)

Figure 164 3.

Tilt housing 180°.

Roll suction and pressure pipes (Arrows) into the housing bores, using special tool.

IMPORTANT The pipe end must be maximally plane with the housing face. If necessary, equalize projection of pipe. (S) Rolling tool - 5870 600 003

Figure 165

(S) Rolling tool - 5870 600 005 (S) Rolling tool - 5870 600 007

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 103

Insert O-rings (2x/pipe) into the annular grooves of the two oil tubes and oil them.

Assemble both oil tubes (Arrows) until contact is obtained.

Equip screw plug with new O-ring and install it.

Figure 166

NOTE:

Torque limit 140 N•m (103 ft lb).

Figure 167 8.

Insert both oil tubes (Arrows) into the housing cover, tilt housing cover 180° and roll oil tubes into the housing bores. (S) Rolling tool - 5870 600 008

IMPORTANT The pipe end must be maximally plane with the housing face. If necessary, equalize projection of pipe.

S0607090K Page 104

Figure 168

Transmission and Torque Converter (ZF 4WG-210)

10.

Mount studs (M8 x 25). NOTE:

Torque limit (studs) 9.0 N•m (7 ft lb).

NOTE:

Wet screw-in thread with loctite (Type-No. 262).

Equip plugs (Arrows) with new O-ring and install them. NOTE:

Torque limit (M16x1.5) 40 N•m (30 ft lb).

NOTE:

Torque limit (M18x1.5) 50 N•m (37 ft lb).

NOTE: 11.

Figure 169

Torque limit (M26x1.5) 80 N•m (39 ft lb).

Insert sealing cover, with the recess facing upward. NOTE:

Wet contact face with Loctite (Type-No. 262).

Figure 170 REASSEMBLE CLUTCH - KV AND KR NOTE:

The following figures show the reassembly of the Clutch - KV. The reassembly of the Clutch KR has to be carried out accordingly.

Pre-assemble Plate Carrier (Figure 171 thru Figure 174). A.

Check function of the purge valve.

NOTE: B.

Ball must not stick, if necessary, clean with compressed air.

Figure 171

Insert both O-rings (Arrows) scroll free into the grooves of the piston and oil.

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 105

Introduce piston until contact is obtained.

NOTE:

Pay attention to the installation position, see Figure 172.

Figure 172 D.

Install disk, compression spring and guide ring.

Preload compression spring and secure it using snap ring.

Figure 173

(S) Assembly aid - 5870 345 088

Figure 174

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Transmission and Torque Converter (ZF 4WG-210)

Plate pack- KV, KR Figure 175, shows the installation position of the components.

The plate arrangement resp. stacking of clutch - KV and KR is identical.

NOTE:

Reference Number

Description

Plate Carrier

Piston

Outer Plate - One Sided Coated (1 Piece)

Inner Plates (10 Pieces)

Outer Plate - Coated on Both Sides (10 Pieces)

Snap Ring [optional s = 2.1 - 4.2 mm (0.0827 - 0.1654 in)]

End Shim

NOTE:

Effective number surface = 20.

Figure 175

friction

IMPORTANT Install outer plate (3) with the uncoated side facing the piston. •

Adjust Plate Clearance = 2.7 +0.2 mm (0.1654 +0.0079 in).

NOTE:

For the adjustment of the plate clearance are snap rings of different thickness available. To ensure a faultless measuring result, install plates for the moment without oil.

Introduce plate pack accordingly to Figure 175. Figure 176

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 107

Lay on the end shim and squeeze the snap ring in (e.g. s = 2.55 mm (0.10 in)).

Press on end shim with about 100 N (10 kg), apply dial indicator and set it at zero (Figure 178).

Press on the end shim, using screw driver against snap ring until contact is obtained (upward) and read plate clearance on the dial indicator (Figure 179).

Figure 177

Figure 178

NOTE:

In case of a deviation from the required plate clearance, correct with corresponding snap ring (s = 2.1 - 4.2 mm (0.08 - 0.17 in)).

After the adjustment of the plate clearance has been carried out, remove the plate pack, oil plates and install it again.

Figure 179

(S) Magnetic stand - 5870 200 055 (S) Dial indicator 5870 200 057

IMPORTANT Use oil according to the list of lubricants TE-ML 03.

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Transmission and Torque Converter (ZF 4WG-210)

Introduce idler gear until all inner plates are accommodated. NOTE:

This step makes the later assembly of the idler gear easier.

Remove the idler gear again.

Mount stud (Arrow).

Figure 180 NOTE:

Wet screw-in thread with Loctite (Type-No. 241).

NOTE:

Torque limit (M10) 17 N•m (13 ft lb).

Figure 181 10.

Insert ball bearing until contact is obtained and secure using retaining ring.

11.

Assemble needle bearing.

Figure 182

Figure 183

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 109

12.

Press idler gear against shoulder. NOTE:

Support it on the inner bearing race.

Figure 184 13.

Heat inner diameter of plate carrier (about 120°C). (S) Hot-air blower 220V - 5870 221 500 (S) Hot-air blower 110V - 5870 221 501

Figure 185 14.

Assemble pre-assembled plate carrier until contact is obtained.

15.

Locate plate carrier axially using retaining ring.

Figure 186

Figure 187

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Transmission and Torque Converter (ZF 4WG-210)

16.

Check function of clutch using compressed air. NOTE:

At correctly installed components, the closing resp. opening of the clutch is clearly audible.

Figure 188 17.

Press tapered shoulder.

roller

bearing

against

18.

Install opposite tapered roller bearing accordingly.

19.

Squeeze rectangular rings in (Arrows) and let them snap in.

Figure 189

Figure 190

Transmission and Torque Converter (ZF 4WG-210)

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REASSEMBLE CLUTCH - K1, K2 AND K3 1.

The following figures show the reassembly of Clutch-K3. The reassembly of the Clutches-K1 and K2 has to be carried out accordingly.

Install stud (Arrow). NOTE:

Wet screw-in thread with Loctite (Type-No. 241).

NOTE:

Torque limit (M10) 17 N•m (13 ft lb). Figure 191

Heat inner diameter of plate carrier (Figure 192) and assemble plate carrier until contact is obtained (Figure 193). (S) Hot-air blower 220V - 5870 221 500 (S) Hot-air blower 110V - 5870 221 501

Figure 192

Figure 193 4.

Check function of the purge valve. NOTE:

Ball must not stick, if necessary clean with compressed air.

Insert both O-rings (Arrows) scroll free into the grooves of the piston and oil.

Figure 194

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Transmission and Torque Converter (ZF 4WG-210)

Introduce piston until contact is obtained. NOTE:

Pay attention to the installation position, see Figure 195.

Figure 195 7.

Lay on cup-spring pack and guide ring. NOTE:

Pay attention to the stacking of the cup springs, see page -114.

Figure 196 8.

Preload cup-spring pack and secure it using snap ring. (S) Assembly aid - 5870 345 088

Figure 197

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 113

Plate pack- K1

IMPORTANT The plate arrangement of Clutch-K1is not identical with Clutch-K2 and K3. In this connection see Figure 198. Reference Number

Description

Plate Carrier

Piston

Outer Plate - One Sided Coated (1 Piece)

Inner Plates (9 Pieces)

Outer Plate - Coated on Both Sides (9 Pieces)

Snap Ring (Optional s = 2.1 - 4.2 mm (0.08 - 0.17 in))

End Shim

Figure 198

Effective number of friction surface = 18.

NOTE: •

Adjust plate clearance = 2.4+0.2 mm (0.05 +0.01 in)

Plate pack- K2 and K3 Reference Number

Description

Plate Carrier

Piston

Outer Plate - One Sided Coated (1 Piece)

NOTE: •

Inner Plates (7 Pieces)

Outer Plate - Coated on Both Sides (7 Pieces)

Snap Ring (Optional s = 2.1 - 4.2 mm (0.08 - 0.17 in))

End Shim

Effective number surface = 14.

friction Figure 199

Adjust plate clearance = 1.8+0.2 mm (0.07 +0.01 in)

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Transmission and Torque Converter (ZF 4WG-210)

IMPORTANT Install outer plate (3) with the uncoated side facing the piston. 9.

Introduce plate pack according to Figure 198 and Figure 199. NOTE:

For the adjustment of the plate clearance are snap rings with different thickness available. To ensure a faultless measuring result, install the plates for the moment without oil.

Figure 200 10.

Lay on the end shim and squeeze retaining ring in (e.g. s = 3.1 mm (0.12 in)).

11.

Press on the end shim with about 100 N (10 kg), apply dial indicator and set it at zero (Figure 202).

12.

Push the end shim using screw driver against snap ring until contact is obtained (upward) and read plate clearance on the dial indicator (Figure 203).

Figure 201

NOTE:

In case of a deviation from the required plate clearance, correct with corresponding snap ring (s= 2.1 - 4.2 mm (0.08 - 0.17 in)).

Transmission and Torque Converter (ZF 4WG-210)

Figure 202

S0607090K Page 115

13.

After the adjustment of the plate clearance has been carried out, remove the plate pack, oil plates and install it again.

IMPORTANT Use oil according to the list of lubricants TE-ML 03. (S) Magnetic stand - 5870 200 055 (S) Dial indicator - 5870 200 057 14.

Figure 203

Assemble running disk (1) (55 x 78 x 5), axial needle cage (2) and axial washer (3) (55 x 78 x 1). NOTE:

Install running disk (1), with the chamber facing the axial needle cage.

Figure 204 15.

Assemble both needle bearing.

16.

Introduce idler gear until all inner plates are accommodated.

Figure 205

Figure 206

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Transmission and Torque Converter (ZF 4WG-210)

17.

Assemble axial washer (3) (55 x 78 x), axial needle cage (2) and running disk (1) (55 x 78 x 5). NOTE:

Install running disk (1), with the chamber facing the axle needle cage.

IMPORTANT Only if the running disk is overlapping with the shaft collar is ensured that all inner plates are accommodated. 18.

Press tapered shoulder.

roller

bearing

Figure 207

against

Press opposite tapered roller bearing against shoulder.

Figure 208 19.

Check function compressed air. NOTE:

the

clutch

using

At correctly installed components, the closing resp. opening of the clutch is clearly audible.

Figure 209

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 117

20.

Squeeze rectangular ring in (Arrow) and let it snap in. Install opposite rectangular ring accordingly.

21.

Tilt clutch into horizontal position and install spur gear K4 until all inner plates are accommodated.

Figure 210

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Transmission and Torque Converter (ZF 4WG-210)

REASSEMBLE CLUTCH - K4 1.

Cool shaft (about -80°C) and assemble it until contact is obtained.

Secure gear axially using retaining ring.

Figure 211 (S) set of external pliers - 5870 900 015

Figure 212 3.

Install stud (Arrow). NOTE:

Wet screw-in thread with Loctite (Type-No. 241).

NOTE:

Torque limit (M10) 17 N•m (13 ft lb).

Figure 213 4.

Check function of the purge valve. NOTE:

Ball must not stick, if necessary clean with compressed air.

Insert both O-rings (Arrows) scroll free into the grooves of the piston and oil them.

Figure 214

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 119

Introduce piston until contact is obtained. NOTE:

Pay attention to the installation position, see Figure 215.

Figure 215 7.

Install cup-spring pack and guide ring. NOTE:

Pay attention to the stacking of the cup springs, see Figure 218.

Figure 216 8.

Preload cup-spring pack and secure it using snap ring. (S) Assembly aid - 5870 345 088

Figure 217

S0607090K Page 120

Transmission and Torque Converter (ZF 4WG-210)

Plate pack - K4 Figure 218, shows the installation position of the components. Reference Number

Description

Plate Carrier

Piston

Outer Plate - One Sided Coated (1 Piece)

Inner Plates (9 Pieces)

Outer Plate - Coated on Both Sides (9 Pieces)

Snap Ring (Optional s = 2.1 - 4.2 mm (0.08 - 0.17 in))

7 NOTE: •

Figure 218

End Shim

Effective number surface = 10.

friction

Adjust plate clearance = 1.2+0.2 mm (0.05 +0.01 in)

IMPORTANT Install outer plate (3) with the uncoated side facing the piston. 10.

Introduce plate pack according to Figure 218. NOTE:

For the adjustment of the plate clearance are snap rings with different thickness available. To ensure a faultless measuring result, install the plates for the moment without oil.

Figure 219

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 121

11.

Lay on end shim and squeeze snap ring in (e.g. s = 3.4 mm (0.13 in)).

12.

Press on the end shim with about 100 N (10 kg), apply dial indicator and set it at zero (Figure 221).

13.

Push the end shim using screw driver against snap ring until contact is obtained (upward) and read plate clearance on the dial indicator (Figure 223).

Figure 220

NOTE:

14.

In case of a deviation from the required plate clearance, correct with corresponding snap ring. (s = 2.1 - 4.2 mm) (0.08 - 0.17 in).

Figure 221

After the adjustment of the plate clearance has been carried out, remove plate pack, oil plates and install it again.

IMPORTANT Use oil according to the list of lubricants TE-ML 03. (S) Magnetic stand - 5870 200 055 (S) Dial indicator - 5870 200 057 15.

NOTE:

16.

Figure 222

Introduce idler gear until all inner plates are accommodated.

This step makes the later assembling of the idler gear easier.

Remove idler gear again.

Figure 223

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Transmission and Torque Converter (ZF 4WG-210)

17.

Assemble both axial washer and needle cage. NOTE:

Upper and lower axial washer have the same thickness (55 x 78 x 1).

Figure 224 18.

Assemble both needle bearings.

19.

Assemble idler gear.

20.

Assemble axial washer (3) (55 x 78 x 1), needle cage (2) and running disk (1) (55 x 78 x 5).

Figure 225

Figure 226

NOTE:

Install running disk (1), with the chamber facing the needle cage.

Figure 227

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 123

21.

Heat inner diameter of the plate carrier (about 120°C). Assemble pre-assembled plate carrier until all inner plates are accommodated.

CAUTION! Use safety gloves.

Figure 228 22.

Secure plate carrier axially using retaining ring. (S) Set of external pliers - 5870 900 015

Figure 229 23.

Check function of the clutch by means if compressed air. NOTE:

At correctly installed components, the closing resp. opening of the clutch is clearly audible.

Figure 230 24.

Press tapered roller bearing against shoulder. Install opposite tapered roller bearing.

Figure 231

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Transmission and Torque Converter (ZF 4WG-210)

25.

Squeeze rectangular ring in (Arrow) and let it snap in. Install opposite rectangular ring.

Figure 232 PRE-ASSEMBLE DRIVE SHAFT 1.

Cool drive shaft (about -80°C). heat the gear (about +120°C) and assemble it until contact is obtained.

Secure gear axially using retaining ring.

Squeeze snap ring into the groove of the turbine shaft.

Figure 233

Figure 234

Figure 235

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 125

Introduce turbine shaft until the snap ring snaps into the groove of the drive shaft turbine shaft is axially secured.

Press tapered roller bearing against shoulder. Squeeze rectangular ring into the groove of the drive shaft and let it snap in.

Install opposite tapered roller bearing.

Figure 236

Figure 237 PRE-ASSEMBLE AND INSTALL OUTPUT 1.

Lay on screening plate.

Heat tapered roller bearing and assemble it until contact is obtained.

Install opposite tapered roller bearing accordingly.

Figure 238

Figure 239

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Transmission and Torque Converter (ZF 4WG-210)

Insert all outer bearing races into the bearing bores of the housing. Install O-ring (Arrows). NOTE:

At the use of already run bearings, pay attention to the allocation of the outer bearing races.

Reference Number

Description

Input

Clutch - Forward

Clutch - Reverse

Clutch - 1st Speed

Clutch - 2nd Speed

Clutch - 3rd Speed

Clutch - 4th Speed

Output

Lay on screening plate.

Insert pre-assembled output shaft.

Figure 240

Figure 241 NOTE:

Secure screening plates using socket head screws.

NOTE:

Torque limit (M8/8.8) 23 N•m (17 ft lb).

Figure 242

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 127

INSTALL PRE-ASSEMBLED DRIVE SHAFT AND CLUTCHES 1.

Insert all outer bearing races into the bearing bores of the housing cover.

At the reuse of already run bearings, pay attention to the allocation of the outer bearing races.

NOTE:

Reference Number

Description

Input

Clutch - Forward

Clutch - Reverse

Clutch - 1st Speed

Clutch - 2nd Speed

Clutch - 3rd Speed

Clutch - 4th Speed

Output Figure 243

Insert Clutch - KR, drive shaft and Clutch KV together into the housing cover.

IMPORTANT Prior to the installation of the clutches and the drive shaft, grease rectangular rings and align them centrally.

Figure 244 3.

Lift drive gear and position Clutch-K4.

Figure 245

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Transmission and Torque Converter (ZF 4WG-210)

Install Clutch-K3.

Position Clutch-K2.

Lift Clutch - K4 and position Clutch-K1.

Figure 249, shows the installation position of the single clutches in the housing cover.

Grease rectangular rings (Arrows) and align them centrally.

Figure 246

Figure 247

Figure 248

Figure 249

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 129

Secure all clutches using handles (S). (S) Handle (6 pieces needed) - 5870 260 010

Figure 250 10.

Tilt housing cover 180°C.

11.

Install eye bolts (Arrows). (S) Eye bolt 2x (M20) - 0636 804 003 (S) Eye bolt 1x (M16) - 0636 804 001 (S) Puller device - 5870 000 017

Figure 251 12.

Grease O-rings of the two oil tubes (see also Figure 166). Wet mounting face with sealing compound Loctite (Type-No. 574).

13.

Position pre-assembled housing cover using lifting device carefully on the gearbox housing until contact is obtained (Figure 252). NOTE:

Pay attention to the overlapping of the oil tubes with the bores in the housing cover.

(S) Lifting chain - 5870 281 047 Figure 252 14.

Remove handles (S) again.

Figure 253

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Transmission and Torque Converter (ZF 4WG-210)

15.

Install both cylindrical pins centrally to the housing face.

16.

Fasten housing cover using hex. head screws.

Figure 254

NOTE:

Torque limit (M10/8.8) 46 N•m (34 ft lb).

NOTE:

Pay attention to the position of the fixing plates, see Arrow.

Figure 255 INSTALL PUMP SHAFT (POWER TAKE-OFF) 1.

Install ball bearing.

Squeeze rectangular ring in (Arrow) and let it snap in.

Grease rectangular ring, align it centrally and introduce pump shaft until contact is obtained.

Figure 256

Figure 257

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 131

Secure pump shaft using retaining ring.

Insert O-ring (Arrow) into the annular groove of the oil feed covers.

Figure 258

Figure 259 6.

Fasten both covers (Arrows) using hex. nuts (use plain washers). NOTE:

Torque limit 23 N•m (17 ft lb).

Figure 260 INSTALL OUTPUT FLANGES 1.

Install shaft seal with the sealing lip facing the oil chamber. NOTE:

At the use of the prescribed driver, the exact installation position is obtained. Wet rubber0coated outer diameter with spirit. Grease sealing lip.

(S) Driver - 5870 048 213

Figure 261

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Transmission and Torque Converter (ZF 4WG-210)

Assemble output flange.

Insert O-ring (Arrow) into the gap of drive flange and shaft.

Fasten output flange using disk and hex, head screws.

Figure 262

NOTE:

Torque limit (M10/8.8) 46 N•m (34 ft lb).

Figure 263 5.

Secure hex. head screws using lock plate. (S) Driver 5870 057 009 (S) Handle 5870 260 002

Install converter-side accordingly.

output

flange

Figure 264

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 133

CONVERTER BACK PRESSURE VALVE 1.

Figure 265, shows the components of the converter back pressure valve. Reference Number

Description

Piston

Compression Spring

Pressure Plate

Lock Plate

NOTE:

Install pressure plate with the spigot (∅6 mm (0.24 in)) facing the lock plate.

Introduce components according to Figure 265, preload and secure using lock plate.

Equip plug (Arrow) with new O-ring and install it. NOTE:

Figure 265

Torque limit (M14 x 1.5) 25 N•m (18 ft lb).

Figure 266 OIL FEED HOUSING - TRANSMISSION PUMP 1.

Install two adjusting screws (Arrows) and lay on gasket. (S) Adjusting screws (M18) - 5870 204 011

Figure 267

S0607090K Page 134

Transmission and Torque Converter (ZF 4WG-210)

Lay on oil feed housing and secure it provisionally using socket head screws. NOTE:

Screw socket head screws only in until contact is obtained - do not tighten.

Figure 268 3.

Install two adjusting screws and introduce stator shaft until contract is obtained. NOTE:

Pay attention to the overlapping of the bores.

(S) Adjusting screws (M10) - 5870 204 007

Figure 269 4.

Insert O-ring (Arrow) into the annular groove and oil it.

Introduce transmission pump (compl.) and put it using socket head screws (for the moment without O-rings) evenly against shoulder.

Remove socket head screws again.

Figure 270

Figure 271

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 135

Equip socket head screws with new Orings (Arrow). NOTE:

Grease O-rings.

Figure 272 8.

Fasten transmission pump using socket head screws. NOTE:

Torque limit 46 N•m (34 ft lb).

Figure 273 9.

Fasten oil feed housing using socket head screws and hex. head screws (2 pieces). NOTE:

Torque limit (Socket head screws) 23 N•m (17 ft ibs).

NOTE:

Torque limit (Hex. head screws) 46 N•m (34 ft ibs).

NOTE:

Pay attention to the position of the fixing plate, see Arrow.

(S) Box spanner (Torx, TX-40) - 5870 042 004 Figure 274 ENGINE CONNECTION - CONVERTER 1.

Fasten converter bell using hex. head screws. NOTE:

Torque limit (M10/10.9) 68 N•m (50 ft lb).

Figure 275

S0607090K Page 136

Transmission and Torque Converter (ZF 4WG-210)

Screw drive shaft and diaphragm together. NOTE:

Torque limit (M12/10.9) 115 N•m (85 ft lb).

Figure 276 3.

Fasten diaphragm using hex. head screws on the converter. NOTE:

Torque limit (M12/10.9) 115 N•m (85 ft lb).

NOTE:

Insert hex. head screws with Loctite (Type-No. 262).

Introduce obtained.

converter

NOTE:

Pulse disk of the converter must be positioned centrally to the bore of the inductive transmitter, see Figure 279. Only in this way will be ensured that the converter is perfectly introduced.

Figure 277 4.

until

contact

Figure 278

Figure 279

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 137

Insert ball bearing until contact is obtained and secure it using retaining ring.

Assemble housing cover.

Install drive flange, lay on disk and pull cover using hex. head screws evenly against shoulder.

Figure 280

NOTE:

Torque limit (M8/10.9) 34 N•m (25 ft lb).

NOTE:

Pay attention to the radial installation position of the cover, see Figure 281.

Figure 281 8.

Secure hex. head screws using lock plate. (S) Driver - 5870 057 010 (S) Handle - 5870 260 002

Figure 282 9.

Fasten cover using hex. head screws and nuts on the converter bell. NOTE:

Torque limit (M10/8.8) 46 N•m (34 ft lb).

Figure 283

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Transmission and Torque Converter (ZF 4WG-210)

10.

Mount gasket and fasten cover using hex. head screws. NOTE:

Torque limit (M8/8.8) 23 N•m (17 ft lb).

Figure 284 CONVERTER SAFETY VALVE 1.

Insert converter safety valve (compl.) into the housing bore.

Figure 285 MOUNT DUCT PLATE AND HYDRAULIC CONTROL UNIT 1.

Install components according to the Figure 286. NOTE:

Torque limit (M8) 23 N•m (17 ft lb) (Hex. nuts and socket head screws).

NOTE:

Pay attention to the installation position of the different gaskets, see Figure 286.

Reference Number

Description

Gasket

Duct Plate

Gasket

Intermediate Plate

Gasket

Figure 286

(S) Adjusting screws - 5870 204 063 (S) Box spanner (Torx TX-40) - 5873 042 004

Transmission and Torque Converter (ZF 4WG-210)

S0607090K Page 139

Equip screw plug (Arrow) with new O-ring and install it. NOTE:

Torque limit (M16/1.5) 30 N•m (22 ft lb).

Figure 287 3.

Fasten hydraulic control unit (HSG-94) using socket head screws. NOTE:

Torque limit (M6) 9.5 N•m (7 ft lb).

(S) Adjusting screws - 5870 204 063 (S) Box spanner (Torx TX-27) - 5873 042 002

Figure 288 INSTALL PLUGS AND OIL LEVEL TUBE 1.

Equip both plugs (Arrows) with new Orings and install them. NOTE:

Torque limit (M18 x 1.5) 50 N•m (37 ft lb).

NOTE:

Torque limit (M26 x 1.5) 80 N•m (59 ft lb).

Figure 289

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Transmission and Torque Converter (ZF 4WG-210)

Install oil level tube (Arrow). NOTE:

Mount new gasket.

NOTE:

Torque limit (M8/109) 34 N•m (25 ft lb).

Figure 290 3.

Install cover plate (1, Figure 291). NOTE:

Install new gasket.

NOTE:

Torque limit (M8/8.8) 23 N•m (17 ft lb).

Equip screw plug (2, Figure 291) with new O-ring and install it. NOTE:

Torque limit (M38 x 1.5) 140 N•m (103 ft lb).

Figure 291 SPEED SENSOR AND INDUCTIVE TRANSMITTERS 1.

The Figure 292 and Figure 293 show the installation position of the single inductive transmitters and the speed sensor. Reference Number

Description

Speed Sensor n-Output and Speedometer

Inductive Transmitter n-Turbine

Inductive Transmitter n-Central Gear Train

Inductive Transmitter n-Engine

Transmission and Torque Converter (ZF 4WG-210)

Figure 292

S0607090K Page 141

Grease O-rings and install speed sensor and inductive transmitters. NOTE:

Torque limit 23 N•m (17 ft lb) (Socket head screw / Speed sensor).

NOTE:

Torque limit 30 N•m (22 ft lb) (Inductive transmitter).

Figure 293 3.

Install breather (Arrow). NOTE:

Torque limit 12 N•m (9 ft lb).

Figure 294

S0607090K Page 142

Transmission and Torque Converter (ZF 4WG-210)

S0607900C R2

1TRANSMISSION ERROR CODES (ZF) CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that is in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility.

TRANSMISSION ERROR CODES (ZF)S0607900C MODEL

SERIAL NUMBER RANGE

Mega 130

1003 and Up

Mega 160

1021 and Up

Mega 200-V (Tier I & II)

1001 and Up

Mega 250-V (Tier I)

1001 thru 2000

Mega 250-V (Tier II)

2001 and Up

Mega 300-V (Tier I)

1001 thru 2000

Mega 300-V (Tier II)

2001 and Up

Mega 400-III PLUS

1001 and Up

Mega 400-V

1001 and Up

Mega 500-V

1001 thru 2000

Mega 500-V (Tier II)

2001 and Up

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

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Transmission Error Codes (ZF)

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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

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 neutral position. If more than one fault is detected, each fault code is shown for about 1 second. Reference Letter

Description

a, f

Automatic Range (Upshifting and Downshifting)

b, c, d, e

left character

right character

S T O P

(special symbols a-h)

HBOE630L

Figure 1

Preselected Gear

EST-37 has detected error and is flashing.

This character will not be used at the EST-37.

S0607900C Page 4

Transmission Error Codes (ZF)

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

5 Hex

CAN Signal Error

6 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

Transmission Error Codes (ZF)

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DISPLAY DURING OPERATION Symbol

Meaning

1F, 1R

Actual gear and direction.

2F, 2R

Left digit shows actual gear.

3F, 3R

Right digit shows actual direction.

Remarks ---------------

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 power up or a severe fault.

Go engage a gear, first move shift selector to neutral position and again to F or R position.

Oil temperature too low, no gear available.

Warm up engine / transmission.

Oil temperature low, only one gear available.

Warm up engine / transmission.

1 bar (special symbol)

Manual mode 1. gear.

---------------

2 bars

Manual mode 2. gear.

---------------

3 bars

Manual mode 3. gear.

---------------

4 bars

Manual mode 4. gear.

---------------

4 bars and 2 arrows

Automatic mode.

---------------

Bars flashing

6 WG: converter lockup clutch open.

Difference of engine and turbine speed above 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).

---------------

Warning sump temperature.

Changes between actual gear/direction while driving, in neutral only displayed if no fault is detected (spanner).

Warning retarder temperature.

Changes between actual gear/direction while driving, in neutral only displayed if no fault is detected (spanner).

Warning high engine speed.

Changes between actual gear/direction while driving, in neutral only displayed if no fault is detected (spanner).

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Transmission Error Codes (ZF)

Symbol PN

Meaning Direction F or R selected while parking brake engaged.

Remarks Transmission in neutral until parking brake is 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.

Transmission Error Codes (ZF)

Checked wiring from TCU to display.

S0607900C 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:

S0607900C Page 8

VPS2: is the LIS (option power supply).

Transmission Error Codes (ZF)

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.

Clutch Pack

Mega 130 4WG-100

Mega 160 4WG-130

Mega 250-V 4WG-190

Mega 300-V 4WG-210

Mega 400-III PLUS 4WG-260

Mega 400-V 4WG-260

Mega 500-V 4WG-310

Solenoid Valve (Proportioning Valve) Number

Transmission Error Codes (ZF)

S0607900C 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: Fault Code (hex) 11

This fault code list is valid for the ZF Software Versions V 53.x to V58.0 Meaning of the Fault Code (Possible reason for fault detection.)

Logical error at gear range signal. TCU detected a wrong signal combination for gear range. • Cable from shift lever to TCU is broken.

Reaction of the TCU TCU shifts transmission to neutral. OP-Mode: transmission shut down.

Possible Steps to Repair

Remarks

Check cables from TCU to shift lever.

Failure cannot be detected in systems with DW2/DW3 shift lever.

Check signal combinations of shift lever positions for gear range.

Fault is taken back if TCU detects a valid signal for position.

• Cable is defective and is contacted to battery voltage or vehicle ground. • Shift lever is defective. 12

Logical error at direction select signal. TCU detected a wrong signal combination for direction. • Cable from shift lever to TCU is broken.

TCU shifts transmission to neutral. OP-Mode: transmission shut down.

Check cables from TCU to shift lever. Check signal combinations of shift lever positions F-N-R.

Fault is taken back if TCU detects a valid signal for direction at shift lever.

• Cable is defective and is contacted to battery voltage or vehicle ground. • Shift lever is defective. 17 **

S.C. to ground at Solenoid LIS1 (Function No. 1). TCU detected a wrong voltage at output pin, that looks like a S.C. to vehicle ground. • Cable is defective and is contacted to vehicle ground. • Solenoid LIS1 (Function No. • 1) device has an internal defect.

Customer specific.

Check cable from TCU to Solenoid LIS1 (Function No. 1) device. Check connectors from Solenoid LIS1 (Function No. 1) to TCU.

1) See “Measurement of Resistance at Actuator/sensors and Cable” on page 35.

Check resistance of Solenoid LIS1 (Function No. 1) 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.

S0607900C Page 10

Transmission Error Codes (ZF)

Fault Code (hex) 18 **

Meaning of the Fault Code (Possible reason for fault detection.)

Reaction of the TCU

Possible Steps to Repair

Remarks

S.C. to battery voltage at Solenoid LIS1 (Function No. 1).

Customer specific.

Check cable from TCU to Solenoid LIS1 (Function No. 1) device.

1) See “Measurement of Resistance at Actuator/sensors and Cable” on page 35.

TCU detected a wrong voltage at output pin, that looks like a S.C. to battery voltage.

Check connectors from Solenoid LIS1 (Function No. 1) to TCU.

• Cable is defective and is contacted to battery voltage.

Check resistance of Solenoid LIS1 (Function No. 1) device.

• Solenoid LIS1 (Function No. 1) device has an internal defect. • Connector pin is contacted to battery voltage. 19 **

O.C. at Solenoid LIS1 (Function No. 1).

Customer specific.

TCU detected a wrong voltage at output pin, that looks like a O.C. for this output pin.

Check cable from TCU to Solenoid LIS1 (Function No. 1) device. Check connectors from Solenoid LIS1 (Function No. 1) device to TCU.

• Cable is defective and has no connection to TCU.

1) See

“Measurement of Resistance at Actuator/sensors and Cable” on page 35.

Check resistance of Solenoid LIS1 (Function No. 1) device.

• Solenoid LIS1 (Function No. 1) device has an internal defect. • Connector has no connection to TCU. 1A **

S.C. to ground at Solenoid LIS2 (Function No. 2). TCU detected a wrong voltage at output pin, that looks like a S.C. to vehicle ground. • Cable is defective and is contacted to vehicle ground. • Solenoid LIS2 (Function No. 2) device has an internal defect.

Customer specific.

Check cable from TCU to Solenoid LIS2 (Function No. 2) device. Check connectors from Solenoid LIS2 (Function No. 2) device to TCU.

1) See

“Measurement of Resistance at Actuator/sensors and Cable” on page 35.

Check resistance of Solenoid LIS2 (Function No. 2) device.

Transmission Error Codes (ZF)

S0607900C Page 11

Fault Code (hex) 1B **

Meaning of the Fault Code (Possible reason for fault detection.)

Reaction of the TCU

Possible Steps to Repair

Remarks

S.C. to battery voltage at Solenoid LIS2 (Function No. 2).

Customer specific.

Check cable from TCU to Solenoid LIS2 (Function No. 2) device.

1) See “Measurement of Resistance at Actuator/sensors and Cable” on page 35.

TCU detected a wrong voltage at output pin, that looks like a S.C. to battery voltage.

Check connectors from Solenoid LIS2 (Function No. 2) device to TCU.

• Cable is defective and is contacted to battery voltage.

Check resistance of Solenoid LIS2 (Function No. 2) device.

• Solenoid LIS2 (Function No. 2) device has an internal defect. • Connector pin is contacted to battery voltage. 1C **

O.C. at Solenoid LIS2 (Function No. 2).

Customer specific.

TCU detected a wrong voltage at output pin, that looks like a O.C. for this output pin.

Check cable from TCU to Solenoid LIS2 (Function No. 2) device. Check connectors from Solenoid LIS2 (Function No. 2) device to TCU.

• Cable is defective and has no connection to TCU.

1) See

“Measurement of Resistance at Actuator/sensors and Cable” on page 35.

Check resistance of Solenoid LIS2 (Function No. 2) device.

• Solenoid LIS2 (Function No. 2) device has an internal defect. • Connector has no connection to TCU. 25

S.C. to battery voltage or O.C. at transmission sump temperature sensor input. The measured voltage is too high:

No reaction, TCU uses default temperature. OP-Mode: normal.

Check cable from TCU to sensor.

---------------

Check connectors. Check temperature sensor.

• Cable is defective and is contacted to battery voltage. • Cable has no connection to TCU. • Temperature sensor has an internal defect. • Connector pin is contacted to battery voltage or is broken. * 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.

S0607900C Page 12

Transmission Error Codes (ZF)

Fault Code (hex) 26

Meaning of the Fault Code (Possible reason for fault detection.) S.C. to ground at transmission sump temperature sensor input. The measured voltage is too low:

Reaction of the TCU No reaction, TCU uses default temperature.

Possible Steps to Repair Check cable from TCU to sensor.

Remarks

---------------

Check connectors.

OP-Mode: normal.

Check temperature sensor.

OP-Mode: substitute clutch control.

Check cable from TCU to sensor.

• Cable is defective and is contacted to vehicle ground. • Temperature sensor has an internal defect. • Connector pin is contacted to vehicle ground. 31

S.C. to battery voltage or O.C. at engine speed input. TCU measures a voltage higher than 7.00 V at speed input pin.

---------------

Check connectors. Check speed sensor.

• Cable is defective and is contacted to battery voltage. • Cable has no connection to TCU. • Speed sensor has an internal defect. • Connector pin is contacted to battery voltage or has no contact. 32

S.C. to ground at engine speed input. TCU measures a voltage less than 0.45V at speed input pin.

OP-Mode: substitute clutch control.

Check cable from TCU to sensor.

---------------

Check connectors. Check speed sensor.

• Cable / connector is defective and is contacted to vehicle ground. • Speed sensor has an internal defect. * 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.

Transmission Error Codes (ZF)

S0607900C Page 13

Fault Code (hex) 33

Meaning of the Fault Code (Possible reason for fault detection.)

Reaction of the TCU

Logical error at engine speed input.

OP-Mode: substitute clutch control.

TCU measures a engine speed over a threshold and the next moment the measured speed is zero.

Possible Steps to Repair Check cable from TCU to sensor. Check connectors.

Remarks

This fault is reset after power up of TCU.

Check speed sensor. Check sensor gap.

• Cable / connector is defective and has bad contact. • Speed sensor has an internal defect. • Sensor gap is incorrect. 34

S.C. to battery voltage or O.C. at turbine speed input.

OP-Mode: substitute clutch control.

Check cable from TCU to sensor.

TCU measures a voltage higher than 7.00 V at speed input pin.

If a failure is existing at output speed,

Check connectors.

• Cable is defective and is contacted to battery voltage.

---------------

Check speed sensor.

TCU shifts to neutral. OP-Mode: limp home.

• Cable has no connection to TCU. • Speed sensor has an internal defect. • Connector pin is contacted to battery voltage or has no contact. 35

S.C. to ground at turbine speed input.

OP-Mode: substitute clutch control.

Check cable from TCU to sensor.

TCU measures a voltage less than 0.45V at speed input pin.

If a failure is existing at output speed,

Check connectors.

• Cable / connector is defective and is contacted to vehicle ground.

TCU shifts to neutral.

---------------

Check speed sensor.

OP-Mode: limp home.

• Speed sensor has an internal defect. * 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.

S0607900C Page 14

Transmission Error Codes (ZF)

Fault Code (hex) 36

Meaning of the Fault Code (Possible reason for fault detection.)

Reaction of the TCU

Logical error at turbine speed input.

OP-Mode: substitute clutch control.

Check cable from TCU to sensor.

TCU measures a turbine speed over a threshold and at the next moment the measured speed is zero.

If a failure is existing at output speed,

Check connectors.

• Cable / connector is defective and has bad contact.

TCU shifts to neutral.

Possible Steps to Repair

Remarks

This fault is reset after power up of TCU.

Check speed sensor. Check sensor gap.

OP-Mode: limp home.

• Speed sensor has an internal defect. • Sensor gap is incorrect. 37

S.C. to battery voltage or O.C. at internal speed input.

OP-Mode: substitute clutch control.

TCU measures a voltage higher than 7.00 V at speed input pin.

Check cable from TCU to sensor.

---------------

Check connectors. Check speed sensor.

S.C. to ground at internal speed input. TCU measures a voltage less than 0.45V at speed input pin.

OP-Mode: substitute clutch control.

Check cable from TCU to sensor.

---------------

Check connectors. Check speed sensor.

Transmission Error Codes (ZF)

S0607900C Page 15

Fault Code (hex) 39

Meaning of the Fault Code (Possible reason for fault detection.)

Reaction of the TCU

Logical error at internal speed input.

OP-Mode: substitute clutch control.

TCU measures a internal speed over a threshold and at the next moment the measured speed is zero.

Possible Steps to Repair Check cable from TCU to sensor. Check connectors.

Remarks

This fault is reset after power up of TCU.

Check speed sensor. Check sensor gap.

• Cable / connector is defective and has bad contact. • Speed sensor has an internal defect. • Sensor gap is incorrect. 3A

S.C. to battery voltage or O.C. at output speed input.

Special mode for gear selection;

Check cable from TCU to sensor.

TCU measures a voltage higher than 12.5 V at speed input pin.

OP-Mode: substitute clutch control.

Check connectors.

• Cable is defective and is contacted to battery voltage. • Cable has no connection to TCU.

---------------

Check speed sensor.

If a failure is existing at turbine speed, TCU shifts to neutral. OP-Mode: limp home.

• Speed sensor has an internal defect. • Connector pin is contacted to battery voltage or has no contact. 3B

S.C. to ground at output speed input.

Special mode for gear selection.

Check cable from TCU to sensor.

TCU measures a voltage less than 1.00V at speed input pin.

OP-Mode: substitute clutch control.

Check connectors.

• Cable / connector is defective and is contacted to vehicle ground.

If a failure is existing at turbine speed,

• Speed sensor has an internal defect.

---------------

Check speed sensor.

TCU shifts to neutral. OP-Mode: limp home.

* 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.

S0607900C Page 16

Transmission Error Codes (ZF)

Fault Code (hex) 3C

Meaning of the Fault Code (Possible reason for fault detection.)

Reaction of the TCU

Possible Steps to Repair

Logical error at output speed input.

Special mode for gear selection.

Check cable from TCU to sensor.

TCU measures a output speed over a threshold and at the next moment the measured speed is zero.

OP-Mode: substitute clutch control.

Check connectors.

• Cable / connector is defective and has bad contact. • Speed sensor has an internal defect.

If a failure is existing at turbine speed,

Remarks

This fault is reset after power up of TCU.

Check speed sensor. Check sensor gap.

TCU shifts to neutral. OP-Mode: limp home.

• Sensor gap is incorrect. 3E

Output speed zero doesn’t fit to other speed signals.

Special mode for gear selection.

If transmission is not neutral and the shifting has finished,

OP-Mode: substitute clutch control.

TCU measures output speed zero and turbine speed or internal speed not equal to zero.

If a failure is existing at turbine speed,

• Speed sensor has an internal defect.

TCU shifts to neutral.

Check sensor signal of output speed sensor.

This fault is reset after power up of TCU.

Check sensor gap of output speed sensor. Check cable from TCU to sensor.

OP-Mode: limp home.

• Sensor gap is incorrect. 71

S.C. to battery voltage at clutch K1. The measured resistance value of valve is out of limit, voltage at K1 valve is too high. • Cable / connector is defective and has contact to battery voltage. • Cable / connector is defective and has contact to another regulator output of TCU.

TCU shifts to neutral. OP-Mode: limp home. If failure at another clutch is pending. TCU shifts to neutral. OP-Mode: TCU shut down.

Check cable from TCU to gearbox. Check connectors from TCU to gearbox. Check regulator resistance. 1)

1) See

“Measurement of Resistance at Actuator/sensors and Cable” on page 35.

Check internal wire harness of gearbox.

• Regulator has an internal defect. * 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.

Transmission Error Codes (ZF)

S0607900C Page 17

Fault Code (hex) 72

Meaning of the Fault Code (Possible reason for fault detection.)

Reaction of the TCU

S.C. to ground at clutch K1.

TCU shifts to neutral.

The measured resistance value of valve is out of limit, voltage at K1 valve is too low.

OP-Mode: limp home.

• Cable / connector is defective and has contact to vehicle ground. • Regulator has an internal defect. 73

TCU shifts to neutral. OP-Mode: TCU shut down.

O.C. at clutch K1.

TCU shifts to neutral.

The measured resistance value of valve is out of limit.

OP-Mode: limp home.

• Cable / connector is defective and has no contact to TCU.

If failure at another clutch is pending.

• Regulator has an internal defect. 74

If failure at another clutch is pending.

S.C. to battery voltage at clutch K2. The measured resistance value of valve is out of limit, voltage at K2 valve is too high. • Cable / connector is defective and has contact to battery voltage. • Cable / connector is defective and has contact to another regulator output of TCU.

TCU shifts to neutral. OP-Mode: TCU shut down. TCU shifts to neutral. OP-Mode: limp home. If failure at another clutch is pending. TCU shifts to neutral. OP-Mode: TCU shut down.

Possible Steps to Repair Check cable from TCU to gearbox. Check connectors from gearbox to TCU. Check regulator resistance. 1)

Remarks

1) See “Measurement of Resistance at Actuator/sensors and Cable” on page 35.

Check internal wire harness of gearbox. Check cable from TCU to gearbox. Check connectors from gearbox to TCU. Check regulator resistance. 1)

1) See “Measurement of Resistance at Actuator/sensors and Cable” on page 35.

Check internal wire harness of gearbox. Check cable from TCU to gearbox. Check connectors from gearbox to TCU. Check regulator resistance. 1)

1) See

“Measurement of Resistance at Actuator/sensors and Cable” on page 35.

Check internal wire harness of gearbox.

• Regulator has an internal defect. 75

S.C. to ground at clutch K2.

TCU shifts to neutral.

The measured resistance value of valve is out of limit, voltage at K2 valve is too low.

OP-Mode: limp home.

• Cable / connector is defective and has contact to vehicle ground. • Regulator has an internal defect.

If failure at another clutch is pending. TCU shifts to neutral. OP-Mode: TCU shut down.

Check cable from TCU to gearbox. Check connectors from gearbox to TCU. Check regulator resistance. 1)

1) See “Measurement of Resistance at Actuator/sensors and Cable” on page 35.

Check internal wire harness of gearbox.

* 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.

S0607900C Page 18

Transmission Error Codes (ZF)

Fault Code (hex) 76

Meaning of the Fault Code (Possible reason for fault detection.) O.C. at clutch K2.

TCU shifts to neutral.

The measured resistance value of valve is out of limit.

OP-Mode: limp home.

• Cable / connector is defective and has no contact to TCU.

If failure at another clutch is pending.

• Regulator has an internal defect. 77

Reaction of the TCU

S.C. to battery voltage at clutch K3. The measured resistance value of valve is out of limit, voltage at K3 valve is too high. • Cable / connector is defective and has contact to battery voltage. • Cable / connector is defective and has contact to another regulator output of TCU.

TCU shifts to neutral. OP-Mode: TCU shut down. TCU shifts to neutral. OP-Mode: limp home. If failure at another clutch is pending. TCU shifts to neutral. OP-Mode: TCU shut down.

Possible Steps to Repair Check cable from TCU to gearbox. Check connectors from gearbox to TCU. Check regulator resistance. 1)

Remarks

1) See “Measurement of Resistance at Actuator/sensors and Cable” on page 35.

Check internal wire harness of gearbox. Check cable from TCU to gearbox. Check connectors from gearbox to TCU. Check regulator resistance. 1)

1) See “Measurement of Resistance at Actuator/sensors and Cable” on page 35.

Check internal wire harness of gearbox.

• Regulator has an internal defect. 78

S.C. to ground at clutch K3.

TCU shifts to neutral.

The measured resistance value of valve is out of limit, voltage at K3 valve is too low.

OP-Mode: limp home.

• Cable / connector is defective and has contact to vehicle ground. • Regulator has an internal defect. 79

If failure at another clutch is pending. TCU shifts to neutral. OP-Mode: TCU shut down.

O.C. at clutch K3.

TCU shifts to neutral.

The measured resistance value of valve is out of limit.

OP-Mode: limp home.

• Cable / connector is defective and has no contact to TCU.

If failure at another clutch is pending.

• Regulator has an internal defect.

TCU shifts to neutral. OP-Mode: TCU shut down.

Check cable from TCU to gearbox. Check connectors from gearbox to TCU. Check regulator resistance. 1)

1) See “Measurement of Resistance at Actuator/sensors and Cable” on page 35.

Check internal wire harness of gearbox. Check cable from TCU to gearbox. Check connectors from gearbox to TCU. Check regulator resistance. 1)

1) See “Measurement of Resistance at Actuator/sensors and Cable” on page 35.

Check internal wire harness of gearbox.

* 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.

Transmission Error Codes (ZF)

S0607900C Page 19

Fault Code (hex) 7D

Meaning of the Fault Code (Possible reason for fault detection.) S.C. to ground at engine derating device. • Cable is defective and is contacted to vehicle ground. • Engine derating device has an internal defect.

Reaction of the TCU Engine derating will be on until TCU power down even if fault vanishes (loose connection). OP-Mode: normal.

S.C. to battery voltage at engine derating device.

No reaction. OP-Mode: normal.

• Cable / connector is defective and is contacted to battery voltage.

O.C. at engine derating device.

Check connectors from engine derating device to TCU.

Check cable from TCU to engine derating device.

Remarks

1) See “Measurement of Resistance at Actuator/sensors and Cable” on page 35. (Only Mega 500-V)

Only Mega 500-V

Check connectors from backup alarm device to TCU.

• Engine derating device has an internal defect.

Check cable from TCU to engine derating device.

Check resistance 1) of engine derating device.

• Connector pin is contacted to vehicle ground. 7E

Possible Steps to Repair

Check resistance 1) of backup alarm device. No reaction. OP-Mode: normal.

TCU detected a wrong voltage at output pin, that looks like a O.C. for this output pin.

Check cable from TCU to engine derating device. Check connectors from engine derating device to TCU.

• Cable is defective and has no connection to TCU.

Check resistance 1) of engine derating device.

• Engine derating device has an internal defect.

1) See

“Measurement of Resistance at Actuator/sensors and Cable” on page 35. (Only Mega 500-V)

• Connector has no connection to TCU. 81

S.C. to battery voltage at clutch K4. The measured resistance value of valve is out of limit, voltage at K4 valve is too high. • Cable / connector is defective and has contact to battery voltage. • Cable / connector is defective and has contact to another regulator output of TCU.

TCU shifts to neutral. OP-Mode: limp home. If failure at another clutch is pending. TCU shifts to neutral. OP-Mode: TCU shut down.

Check cable from TCU to gearbox. Check connectors from gearbox to TCU. Check regulator resistance. 1)

1) See “Measurement of Resistance at Actuator/sensors and Cable” on page 35.

Check internal wire harness of gearbox.

• Regulator has an internal defect. * 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.

S0607900C Page 20

Transmission Error Codes (ZF)

Fault Code (hex) 82

Meaning of the Fault Code (Possible reason for fault detection.)

Reaction of the TCU

S.C. to ground at clutch K4.

TCU shifts to neutral.

The measured resistance value of valve is out of limit, voltage at K4 valve is too low.

OP-Mode: limp home.

• Cable / connector is defective and has contact to vehicle ground. • Regulator has an internal defect. 83

TCU shifts to neutral. OP-Mode: TCU shut down.

O.C. at clutch K4.

TCU shifts to neutral.

The measured resistance value of valve is out of limit.

OP-Mode: limp home.

• Cable / connector is defective and has no contact to TCU.

If failure at another clutch is pending.

• Regulator has an internal defect. 84

If failure at another clutch is pending.

S.C. to battery voltage at clutch KV. The measured resistance value of valve is out of limit, voltage at KV valve is too high. • Cable / connector is defective and has contact to battery voltage.

TCU shifts to neutral. OP-Mode: TCU shut down. TCU shifts to neutral. OP-Mode: limp home. If failure at another clutch is pending. TCU shifts to neutral. OP-Mode: TCU shut down.

Possible Steps to Repair Check cable from TCU to gearbox. Check connectors from gearbox to TCU. Check regulator resistance. 1)

Remarks

1) See “Measurement of Resistance at Actuator/sensors and Cable” on page 35.

Check internal wire harness of gearbox. Check cable from TCU to gearbox. Check connectors from gearbox to TCU. Check regulator resistance. 1)

1) See “Measurement of Resistance at Actuator/sensors and Cable” on page 35.

Check internal wire harness of gearbox. Check cable from TCU to gearbox. Check connectors from gearbox to TCU. Check regulator resistance. 1)

1) See

“Measurement of Resistance at Actuator/sensors and Cable” on page 35.

Check internal wire harness of gearbox.

• Cable / connector is defective and has contact to another regulator output of TCU. • Regulator has an internal defect. 85

S.C. to ground at clutch KV.

TCU shifts to neutral.

The measured resistance value of valve is out of limit, voltage at KV valve is too low.

OP-Mode: limp home.

• Cable / connector is defective and has contact to vehicle ground. • Regulator has an internal defect.

If failure at another clutch is pending. TCU shifts to neutral. OP-Mode: TCU shut down.

Check cable from TCU to gearbox. Check connectors from gearbox to TCU. Check regulator resistance. 1)

1) See

“Measurement of Resistance at Actuator/sensors and Cable” on page 35.

Check internal wire harness of gearbox.

* 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.

Transmission Error Codes (ZF)

S0607900C Page 21

Fault Code (hex) 86

Meaning of the Fault Code (Possible reason for fault detection.) O.C. at clutch KV.

TCU shifts to neutral.

The measured resistance value of valve is out of limit.

OP-Mode: limp home.

• Cable / connector is defective and has no contact to TCU.

If failure at another clutch is pending.

• Regulator has an internal defect. 87

Reaction of the TCU

S.C. to battery voltage at clutch KR. The measured resistance value of valve is out of limit, voltage at KR valve is too high. • Cable / connector is defective and has contact to battery voltage.

TCU shifts to neutral. OP-Mode: TCU shut down. TCU shifts to neutral. OP-Mode: limp home. If failure at another clutch is pending. TCU shifts to neutral. OP-Mode: TCU shut down.

Possible Steps to Repair Check cable from TCU to gearbox. Check connectors from gearbox to TCU. Check regulator resistance. 1)

Remarks

1) See “Measurement of Resistance at Actuator/sensors and Cable” on page 35.

Check internal wire harness of gearbox. Check cable from TCU to gearbox. Check connectors from gearbox to TCU. Check regulator resistance. 1)

1) See “Measurement of Resistance at Actuator/sensors and Cable” on page 35.

Check internal wire harness of gearbox.

• Cable / connector is defective and has contact to another regulator output of TCU. • Regulator has an internal defect. 88

S.C. to ground at clutch KR.

TCU shifts to neutral.

The measured resistance value of valve is out of limit, voltage at KR valve is too low.

OP-Mode: limp home.

• Cable / connector is defective and has contact to vehicle ground. • Regulator has an internal defect. 89

If failure at another clutch is pending. TCU shifts to neutral. OP-Mode: TCU shut down.

O.C. at clutch KR.

TCU shifts to neutral.

The measured resistance value of valve is out of limit.

OP-Mode: limp home.

• Cable / connector is defective and has no contact to TCU.

If failure at another clutch is pending.

• Regulator has an internal defect.

TCU shifts to neutral. OP-Mode: TCU shut down.

Check cable from TCU to gearbox. Check connectors from gearbox to TCU. Check regulator resistance. 1)

1) See “Measurement of Resistance at Actuator/sensors and Cable” on page 35.

Check internal wire harness of gearbox. Check cable from TCU to gearbox. Check connectors from gearbox to TCU. Check regulator resistance. 1)

1) See

“Measurement of Resistance at Actuator/sensors and Cable” on page 35.

Check internal wire harness of gearbox.

* 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.

S0607900C Page 22

Transmission Error Codes (ZF)

Fault Code (hex) 91 **

Meaning of the Fault Code (Possible reason for fault detection.)

Reaction of the TCU

S.C. to ground at relay reverse warning alarm.

Backup alarm will be on until TCU power down even if fault vanishes (loose connection).

TCU detected a wrong voltage at output pin, that looks like a S.C. to vehicle ground.

OP-Mode: normal.

• Cable is defective and is contacted to vehicle ground.

Possible Steps to Repair Check cable from TCU to backup alarm device. Check connectors from backup alarm device to TCU.

Remarks

1) See “Measurement of Resistance at Actuator/sensors and Cable” on page 35.

Check resistance 1) of backup alarm device.

• Backup alarm device has an internal defect. • Connector pin is contacted to vehicle ground. 92 **

S.C. to battery voltage at relay reverse warning alarm.

No reaction. OP-Mode: normal.

TCU detected a wrong voltage at output pin, that looks like a S.C. to battery voltage.

Check cable from TCU to backup alarm device. Check connectors from backup alarm device to TCU.

• Cable is defective and is contacted to battery voltage.

See “Measurement of Resistance at Actuator/sensors and Cable” on page 35.

Check resistance 1) of backup alarm device.

• Backup alarm device has an internal defect. • Connector pin is contacted to battery voltage. 93 **

O.C. at relay reverse warning alarm. TCU detected a wrong voltage at output pin, that looks like a O.C. for this output pin. • Cable is defective and has no connection to TCU. • Backup alarm device has an internal defect.

No reaction. OP-Mode: normal.

Check cable from TCU to backup alarm device. Check connectors from backup alarm device to TCU.

1) See

“Measurement of Resistance at Actuator/sensors and Cable” on page 35.

Check resistance 1) of backup alarm device.

• Connector has no connection to TCU. * 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.

Transmission Error Codes (ZF)

S0607900C Page 23

Fault Code (hex) 94 **

Meaning of the Fault Code (Possible reason for fault detection.) S.C. to ground at relay starter interlock.

Reaction of the TCU No reaction. OP-Mode: normal.

TCU detected a wrong voltage at output pin, that looks like a S.C. to vehicle ground.

Possible Steps to Repair Check cable from TCU to starter interlock relay. Check connectors from starter interlock relay to TCU.

• Cable is defective and is contacted to vehicle ground.

Remarks

1) See “Measurement of Resistance at Actuator/sensors and Cable” on page 35.

Check resistance 1) of starter interlock relay.

• Starter interlock relay has an internal defect. • Connector pin is contacted to vehicle ground. 95 *

O.C. at LIS1 solenoid valve.

No reaction.

The measured resistance value of the valve is out of limit.

OP-Mode: normal.

Check the connectors from valve to TCU.

• Cable/connector is defective and has no contact to TCU. S.C. to battery voltage at relay starter interlock.

If fault code 95 and 98 are both being displayed for about one second each, see combined fault code.

Check the valve resistance.

• Valve has an internal defect. 95 **

Check the cable from TCU to the valve.

No reaction. OP-Mode: normal.

TCU detected a wrong voltage at output pin, that looks like a S.C. to battery voltage.

Check cable from TCU to starter interlock relay. Check connectors from starter interlock relay to TCU.

• Cable is defective and is contacted to battery voltage.

1) See

“Measurement of Resistance at Actuator/sensors and Cable” on page 35.

Check resistance 1) of starter interlock relay.

• Starter interlock relay has an internal defect. • Connector pin is contacted to battery voltage. 95 * 98 * Each fault code shown for about one second.

S.C. battery voltage or ground at LIS1 solenoid valve or LIS2 solenoid valve. • Cable is defective and is contacted to vehicle ground or vehicle ground.

No reaction. OP-Mode: normal.

Check the cable from TCU to the valve.

---------------

Check the connector. Check the valve.

• Cable has no connection to TCU. • Valve has an internal defect. • Connector pin is contacted to battery voltage or is broken. • 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.

S0607900C Page 24

Transmission Error Codes (ZF)

Fault Code (hex) 96 **

Meaning of the Fault Code (Possible reason for fault detection.)

Reaction of the TCU

O.C. at relay starter interlock.

No reaction.

TCU detected a wrong voltage at output pin, that looks like a O.C. for this output pin.

OP-Mode: normal.

Possible Steps to Repair Check cable from TCU to starter interlock relay. Check connectors from starter interlock relay to TCU.

• Cable is defective and has no connection to TCU.

Remarks

1) See “Measurement of Resistance at Actuator/sensors and Cable” on page 35.

Check resistance 1) of starter interlock relay.

• Starter interlock relay has an internal defect. • Connector has no connection to TCU. 98 *

O.C. at LIS2 solenoid valve.

No reaction.

The measured resistance value of the valve is out of limit.

OP-Mode: normal.

Check the connectors from valve to TCU.

• Cable/connector resistance and has no contact to TCU. Slippage at clutch K1.

TCU shifts to neutral.

TCU calculates a differential speed at closed clutch K1. If this calculated value is out of range, TCU interprets this as slipping clutch.

OP-Mode: limp home.

• Low pressure at clutch K1. • Low main pressure. • Wrong signal at internal speed sensor. • Wrong signal at output speed sensor. • Sensor gap is incorrect. • Clutch is defective.

If fault code 95 and 98 are both being displayed for about one second each, see combined fault code.

Check the valve resistance.

• Valve has an internal defect. B1

Check the cable from TCU to the valve.

If failure at another clutch is pending. TCU shifts to neutral. OP-Mode: TCU shut down.

Check pressure at clutch K1.

---------------

Check main pressure in system. Check sensor gap at internal speed sensor. Check sensor gap at output speed sensor. Check signal at internal speed sensor. Check signal at output speed sensor. Replace clutch.

* Only Mega 400-III PLUS ** Only Series "V" Gray shaded boxes are error codes for other applications. They are only given for general reference purposes.

Transmission Error Codes (ZF)

S0607900C Page 25

Fault Code (hex) B2

Meaning of the Fault Code (Possible reason for fault detection.)

Reaction of the TCU

Possible Steps to Repair

Slippage at clutch K2.

TCU shifts to neutral.

TCU calculates a differential speed at closed clutch K2. If this calculated value is out of range, TCU interprets this as slipping clutch.

OP-Mode: limp home.

Check pressure at clutch K2.

• Low pressure at clutch K2. • Low main pressure.

If failure at another clutch is pending. TCU shifts to neutral. OP-Mode: TCU shut down.

• Wrong signal at internal speed sensor.

• Clutch is defective. TCU shifts to neutral.

TCU calculates a differential speed at closed clutch K3. If this calculated value is out of range, TCU interprets this as slipping clutch.

OP-Mode: limp home.

• Wrong signal at internal speed sensor. • Wrong signal at output speed sensor. • Sensor gap is incorrect. • Clutch is defective.

Check sensor gap at internal speed sensor. Check sensor gap at output speed sensor.

Replace clutch.

Slippage at clutch K3.

• Low main pressure.

Check main pressure in system.

Check signal at output speed sensor.

• Sensor gap is incorrect.

• Low pressure at clutch K3.

---------------

Check signal at internal speed sensor.

• Wrong signal at output speed sensor.

Remarks

If failure at another clutch is pending. TCU shifts to neutral. OP-Mode: TCU shut down.

Check pressure at clutch K3.

---------------

* 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.

S0607900C Page 26

Transmission Error Codes (ZF)

Fault Code (hex) B4

Meaning of the Fault Code (Possible reason for fault detection.)

Reaction of the TCU

Possible Steps to Repair

Slippage at clutch K4.

TCU shifts to neutral.

TCU calculates a differential speed at closed clutch K4. If this calculated value is out of range, TCU interprets this as slipping clutch.

OP-Mode: limp home.

Check pressure at clutch K4.

• Low pressure at clutch K4. • Low main pressure.

If failure at another clutch is pending. TCU shifts to neutral. OP-Mode: TCU shut down.

• Wrong signal at internal speed sensor.

Remarks

---------------

Check main pressure in system. Check sensor gap at internal speed sensor. Check sensor gap at turbine speed sensor. Check signal at internal speed sensor.

• Wrong signal at turbine speed sensor. • Sensor gap is incorrect.

Check signal at turbine speed sensor.

• Clutch is defective.

Replace clutch. B5

Slippage at clutch KV.

TCU shifts to neutral.

TCU calculates a differential speed at closed clutch KV. If this calculated value is out of range, TCU interprets this as slipping clutch.

OP-Mode: limp home.

• Low pressure at clutch KV. • Low main pressure. • Wrong signal at internal speed sensor. • Wrong signal at turbine speed sensor. • Sensor gap is incorrect. • Clutch is defective.

If failure at another clutch is pending. TCU shifts to neutral. OP-Mode: TCU shut down.

Check pressure at clutch KV.

---------------

Check main pressure in system. Check sensor gap at internal speed sensor. Check sensor gap at turbine speed sensor. Check signal at internal speed sensor. Check signal at turbine speed sensor. Replace clutch.

* Only Mega 400-III PLUS ** Only Series "V" Gray shaded boxes are error codes for other applications. They are only given for general reference purposes.

Transmission Error Codes (ZF)

S0607900C Page 27

Fault Code (hex) B6

Meaning of the Fault Code (Possible reason for fault detection.)

Reaction of the TCU

Possible Steps to Repair

Slippage at clutch KR.

TCU shifts to neutral.

TCU calculates a differential speed at closed clutch KR. If this calculated value is out of range, TCU interprets this as slipping clutch.

OP-Mode: limp home.

Check pressure at clutch KR.

• Low pressure at clutch KR. • Low main pressure.

If failure at another clutch is pending. TCU shifts to neutral. OP-Mode: TCU shut down.

• Wrong signal at internal speed sensor.

Remarks

---------------

Check main pressure in system. Check sensor gap at internal speed sensor. Check sensor gap at turbine speed sensor. Check signal at internal speed sensor.

• Wrong signal at turbine speed sensor. • Sensor gap is incorrect.

Check signal at turbine speed sensor.

• Clutch is defective.

Replace clutch. B7

Overtemp sump.

No reaction.

Cool down machine.

TCU measured a temperature in oil sump that is over allowed threshold.

OP-Mode: normal.

Check oil level.

S.C. to battery voltage at power supply for sensors.

See fault codes No. 21 - 2C.

Check temperature sensor.

TCU measures more than 6V at the pin AU1 (5V sensor supply).

S.C. to ground at power supply for sensors.

Check cables and connectors to sensors, which are supplied from AU1.

Fault codes No. 21 to No. 2C may be a reaction of this fault.

Check the power supply at the pin AU1 (should be approximately 5V). See fault codes No. 21 - 2C.

TCU measures less than 4V at the pin AU1 (5V sensor supply).

---------------

Check cables and connectors to sensors, which are supplied from AU1.

Fault codes No. 21 to No. 2C may be a reaction of this fault.

Check the power supply at the pin AU1 (should be approximately 5V).

Low power at battery.

Shift to neutral.

Measured voltage at power supply is lower than 18 V.

OP-Mode: TCU shut down.

Check power supply battery.

---------------

Check cables from batteries to TCU. Check connectors from batteries to TCU.

* 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.

S0607900C Page 28

Transmission Error Codes (ZF)

Fault Code (hex) D4

Meaning of the Fault Code (Possible reason for fault detection.)

Reaction of the TCU

High power at battery.

Shift to neutral.

Measured voltage at power supply is higher than 32 V.

OP-Mode: TCU shut down.

Possible Steps to Repair Check power supply battery.

Remarks

---------------

Check cables from batteries to TCU. Check connectors from batteries to TCU.

Error at switch 1 for valve power supply VPS1. TCU switched on VPS1 and measured VPS1 is off or TCU switched off VPS1 and measured VPS1 is still on.

Shift to neutral.

Check fuse.

OP-Mode: TCU shut down.

Check cables from gearbox to TCU.

---------------

Check connectors from gearbox to TCU.

• Cable or connectors are defect and are contacted to battery voltage.

Replace TCU.

• Cable or connectors are defect and are contacted to vehicle ground. • Permanent power supply KL30 missing. • TCU has an internal defect. D6

Error at switch 2 for valve power supply VPS2. TCU switched on VPS2 and measured VPS2 is off or TCU switched off VPS2 and measured VPS2 is still on. • Cable or connectors are defect and are contacted to battery voltage.

Shift to neutral.

Check fuse.

OP-Mode: TCU shut down.

Check cables from gearbox to TCU.

---------------

Check connectors from gearbox to TCU. Replace TCU.

• Cable or connectors are defect and are contacted to vehicle ground. • Permanent power supply KL30 missing. • TCU has an internal defect. * 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.

Transmission Error Codes (ZF)

S0607900C Page 29

Fault Code (hex) E3

Meaning of the Fault Code (Possible reason for fault detection.) S.C. to battery voltage at display output.

Reaction of the TCU No reaction. OP-Mode: normal.

Possible Steps to Repair Check the cable from TCU to the display.

TCU sends data to the display and measures always a high voltage level on the connector.

Check the connectors at the display.

• Cable or connectors are defective and are contacted to battery voltage.

Change display.

Remarks

---------------

• Display has an internal defect. E4

S.C. to ground at display output.

No reaction. OP-Mode: normal.

Check the cable from TCU to the display.

TCU sends data to the display and measures always a high voltage level on the connector.

Check the connectors at the display.

• Cable or connectors are defective and are contacted to vehicle ground.

Change display.

---------------

• Display has an internal defect. F1

General EEPROM fault. TCU cannot read nonvolatile memory. • TCU is defective.

Configuration lost. TCU has lost the correct configuration and can't control the transmission.

Transmission stay neutral.

Replace TCU.

Often shown together with fault code F2.

Reprogram the correct configuration for the vehicle (e.g. with cluster controller,...).

---------------

Replace TCU!

This fault occurs only if an test engineer did something wrong in the application of the vehicle.

Check clutch.

TCU shows also the affected clutch on the Display.

OP-Mode: TCU shut down. Transmission stay neutral. OP-Mode: TCU shut down.

• Interference during saving data on nonvolatile memory. • TCU is brand new or from another vehicle. F3

Application error. Something of this application is wrong.

F5 **

Clutch failure. AFP was not able to adjust clutch filling parameters. • One of the AFP-Values is out of limit.

Transmission stay neutral. OP-Mode: TCU shut down. Transmission stay neutral. OP-Mode: TCU shut down.

* 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.

S0607900C Page 30

Transmission Error Codes (ZF)

Fault Code (hex) F6 **

Meaning of the Fault Code (Possible reason for fault detection.)

Reaction of the TCU

Clutch Adjustment Data lost.

No reaction,

TCU was not able to read correct clutch adjustment parameters.

Default values = 0 for AFP offsets used.

Possible Steps to Repair Execute AFP.

Remarks

---------------

OP-Mode: normal.

• Interference during saving data on nonvolatile memory. • TCU is brand new. * 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.

Transmission Error Codes (ZF)

S0607900C Page 31

TABLE OF FAULT CODES - ERGO-CONTROL Error Code Number

Meaning of Error Code

Remarks

Logical error at gear range signal.

Logical error at direction select signal.

Short circuit to battery voltage at clutch cutoff input.

Short circuit to ground or open circuit at clutch cutoff input.

Short circuit to battery voltage at load sensor input.

Not used.

Short circuit to ground or open circuit at load sensor input.

Not used.

Short circuit to battery voltage or open circuit at temperature sensor input.

Short circuit to ground at temperature sensor input.

Short circuit to battery voltage at engine speed input.

Short circuit to ground or open circuit at engine speed input.

Logical error at engine speed input.

Short circuit to battery voltage at turbine speed input.

Short circuit to ground or open circuit at turbine speed input.

Logical error at turbine speed input.

Short circuit to battery voltage at internal speed input.

Short circuit to ground or open circuit at internal speed input.

Logical error at internal speed input.

Short circuit to battery voltage at output speed input.

Short circuit to ground or open circuit at output speed input.

Logical error at output speed input.

Short circuit to battery voltage at clutch K1.

Short circuit to ground at clutch K1.

Open circuit at clutch K1.

Short circuit to battery voltage at clutch K2.

Short circuit to ground at clutch K2.

Open circuit at clutch K2.

S0607900C Page 32

Transmission Error Codes (ZF)

Error Code Number

Meaning of Error Code

Remarks

Short circuit to battery voltage at clutch K3.

Short circuit to ground at clutch K3.

Open circuit at clutch K3.

Short circuit to battery voltage at converter clutch.

Not used.

Short circuit to ground at converter clutch.

Not used.

Open circuit at converter clutch.

Not used

Short circuit battery voltage at clutch K4.

Short circuit to ground at clutch K4.

Open circuit at clutch K4.

Short circuit to battery voltage at clutch KV.

Short circuit to ground at clutch KV.

Open circuit at clutch KV.

Short circuit to battery voltage at clutch KR.

Short circuit to ground at clutch KR.

Open circuit at clutch KR.

Short circuit battery voltage at relay reverse warning alarm.

Short circuit to ground at relay reverse warning alarm.

Open circuit at relay reverse warning alarm.

Short circuit to battery voltage at relay starter interlock.

Short circuit to ground at relay starter interlock.

Open circuit at relay starter interlock.

Short circuit to battery voltage at park brake solenoid.

Short circuit ground at park brake solenoid.

Open circuit at park brake solenoid.

Slippage at clutch K1.

Slippage at clutch K2.

Slippage at clutch K3.

Slippage at clutch K4.

Transmission Error Codes (ZF)

S0607900C Page 33

Error Code Number

Meaning of Error Code

Remarks

Slippage at clutch KV.

Slippage at clutch KR.

Short circuit to battery voltage at power supply for sensors.

Short circuit to ground at power supply for sensors.

Low power at battery.

High power at battery.

Error at switch 1 for valve power supply.

Error at switch 2 for valve power supply.

Short circuit to battery at speedometer output.

Not used.

Short circuit to ground or open circuit at speedometer output.

Not used.

Short circuit to battery voltage at display output.

Not used.

Short circuit to ground or open circuit at display output.

Not used.

Error at communication on CAN.

General EEPROM fault.

Configuration lost.

Application error.

S0607900C Page 34

Transmission Error Codes (ZF)

MEASUREMENT OF RESISTANCE AT ACTUATOR/ SENSORS AND CABLE ACTUATOR Open circuit:R12 ≈ R1G ≈ R2G ≈ ∞

Short cut to ground:R12 ≈ R;R1G ≈ 0, R2G ≈ R or R1G ≈ R, R2G ≈ 0(for S.C. to ground, G is 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 connected to battery voltage.

G HBOE640I

Figure 2 CABLE UBat

open circuit: R12 ≈ R1P ≈ R1C ≈ R2P ≈ R2C ≈ ∞ short cut to ground:

P (power supply) TCU Actuator /

R12 ≈ 0;R1C ≈ R2C ≈ 0,R1P ≈ R2P ≈ ∞

short cut to battery:

Sensor

C (chassis)

R12 ≈ 0,R1C ≈ R2C ≈ ∞,R1P ≈ R2P ≈ 0

Gnd

HBOE650I

Figure 3

Transmission Error Codes (ZF)

S0607900C Page 35

S0607900C Page 36

Transmission Error Codes (ZF)

1HYDRAULICS

S0703000 R3

1ACCUMULATOR

ACCUMULATOR

S0703000

MODEL

SERIAL NUMBER RANGE

Mega 130

0001 and Up

Mega 160

0001 and Up

Mega 200-III

1001 and Up

Mega 200-V

1001 and Up

Mega 250-III

1001 and Up

Mega 250-V

1001 and Up

Mega 300-V (Tier I)

1001 thru 2000

Mega 300-V (Tier II)

2001 and Up

Mega 400-III PLUS

1001 and Up

Mega 400-V

1001 and Up

Mega 500-V

1001 thru 2000

Mega 500-V (Tier II)

2001 and Up

Solar 130LC-V

0001 and Up

Solar 130W-V

0001 and Up

Solar 170LC-V

1001 and Up

Solar 170W-V

1001 and Up

Solar 200W-V

0001 and Up

Solar 220LC-V

0001 and Up

Solar 220LL

1001 and Up

Models continued on back of cover.

S0703000 Page 1

MODEL

SERIAL NUMBER RANGE

Solar 220N-V

1001 and Up

Solar 250LC-V

1001 and Up

Solar 290LC-V

0001 and Up

Solar 290LL

1001 and Up

Solar 330LC-V

1001 and Up

Solar 400LC-V

1001 and Up

Solar 450LC-V

1001 and Up

S0703000 Page 2

Accumulator

GENERAL DESCRIPTION The accumulator is a gas-charged storage device designed to hold a reserve quantity of hydraulic fluid under pressure. Accumulators are used in hydraulic circuits in much the same way that condensers (or capacitors) are used to collect, store and maintain electrical charge in a circuit. In a hydraulic circuit, minor variations or lags in pump output that might otherwise cause unsteady or irregular operation are made up from the supply of pressurized oil in the accumulator. Reference Number

Description

Screw Plug

Sealing Ring

Diaphragm

Fluid Valve

Steel Pressure Vessel

Figure 1

Accumulators are solidly constructed to resist the high operating pressures of the fluids they contain. There are only three main moving parts: a valve assembly at the top allows adding or expelling gas from the compressible, 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: 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.

When the pre-pressure charge of gas (usually nitrogen) is introduced through the valve at the top of the accumulator, the diaphragm expands to maximum size. The valve button in the center of the diaphragm pushes into the fluid opening in the bottom chamber, sealing off the lower valve. If the pressure of the gas charge exceeds system oil pressure, no fluid enters the accumulator. The button also keeps the diaphragm from protruding into the lower valve opening. Figure 2

Accumulator

S0703000 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.

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.

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.

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 Serial Number

System

Charge Pressure

Volume

Mega 130

S/N 0001 - 1003

Pilot

15 kg/cm2 (210 psi)

320 cc (19.53 in3)

Mega 130

S/N 0001 and Up

Brake System

9 kg/cm2 (130 psi)

500 cc (30.51 in3)

Mega 160

S/N 0001 - 1020

Brake System

8 kg/cm2 (115 psi)

500 cc (30.51 in3)

Mega 160

S/N 0001 - 1020

Pilot

15 kg/cm2 (210 psi)

320 cc (19.53 in3)

Mega 160

S/N 1021 and Up

Brake System

30 kg/cm2 (430 psi)

750 cc (45.77 in3)

Mega 200-III

S/N 1001 - 1386

Brake System

15 kg/cm2 (210 psi)

320 cc (19.53 in3)

Mega 200-III

S/N 1001 - 1386

Pilot

15 kg/cm2 (210 psi)

320 cc (19.53 in3)

Model

S0703000 Page 4

Accumulator

Model

Serial Number

System

Charge Pressure

Volume

Mega 200-III

S/N 1387 and Up

Brake System

40 kg/cm2 (570 psi)

750 cc (45.77 in3)

Mega 200-V

S/N 1001 and Up

Brake System

15 kg/cm2 (210 psi)

320 cc (19.53 in3)

Mega 250-III

S/N 1001 and Up

Brake / Pilot System

30 kg/cm2 (430 psi)

750 cc (45.77 in3)

Mega 250-V

S/N 1001 and Up

Brake / Pilot System

15 kg/cm2 (210 psi)

320 cc (19.53 in3)

Mega 300-V

S/N 1001 and Up

Brake System

30 kg/cm2 (430 psi)

750 cc (45.77 in3)

Mega 300-V

S/N 1001 and Up

Pilot

15 kg/cm2 (210 psi)

320 cc (19.53 in3)

Mega 400-III

S/N 1001 and Up

Brake System

Mega 400-III

S/N 1001 and Up

Pilot

Mega 400-III PLUS

S/N 1001 and Up

Brake / Pilot System

30 kg/cm2 (430 psi)

750 cc (45.77 in3)

Mega 400-V

S/N 1001 and Up

Brake System

30 kg/cm2 (430 psi)

750 cc (45.77 in3)

Mega 400-V

S/N 1001 and Up

Pilot

15 kg/cm2 (210 psi)

320 cc (19.53 in3)

Mega 500-V

S/N 1001 2000

thru

Brake System

30 kg/cm2 (430 psi)

750 cc (45.77 in3)

Mega 500-V

S/N 1001 2000

thru

Pilot

15 kg/cm2 (210 psi)

320 cc (19.53 in3)

Solar 130LC-V

S/N 0001 and Up

Pilot / Travel

10 kg/cm2 (140 psi)

320 cc (19.53 in3)

Solar 130W-V

S/N 0001 and Up

Brake System

30 kg/cm2 (430 psi)

750 cc (45.77 in3)

Solar 130W-V

S/N 0001 and Up

Pilot

10 kg/cm2 (140 psi)

320 cc (19.53 in3)

Solar 130W-V

S/N 0001 and Up

Transmission

8 kg/cm2 (115 psi)

750 cc (45.77 in3)

Solar 170LC-V

S/N 1001 and Up

Pilot / Travel

10 kg/cm2 (140 psi)

320 cc (19.53 in3)

Solar 170W-V

S/N 1001 and Up

Brake System

30 kg/cm2 (430 psi)

750 cc (45.77 in3)

Solar 170W-V

S/N 1001 and Up

Pilot

10 kg/cm2 (140 psi)

320 cc (19.53 in3)

Accumulator

S0703000 Page 5

Model

Serial Number

System

Charge Pressure

Volume

Solar 170W-V

S/N 1001 and Up

Transmission

8 kg/cm2 (115 psi)

750 cc (45.77 in3)

Solar 200W-V

S/N 0001 and Up

Brake System

30 kg/cm2 (430 psi)

750 cc (45.77 in3)

Solar 200W-V

S/N 0001 and Up

Pilot

10 kg/cm2 (140 psi)

320 cc (19.53 in3)

Solar 200W-V

S/N 0001 and Up

Transmission

8 kg/cm2 (115 psi)

750 cc (45.77 in3)

Solar 220LC-V

S/N 0001 and Up

Pilot / Travel

10 kg/cm2 (140 psi)

320 cc (19.53 in3)

Solar 220LL

S/N 1001 and Up

Pilot / Travel

10 kg/cm2 (140 psi)

320 cc (19.53 in3)

Solar 220N-V

S/N 1001 and Up

10 kg/cm2 (140 psi)

320 cc (19.53 in3)

Solar 250LC-V

S/N 1001 and Up

Pilot / Travel

10 kg/cm2 (140 psi)

320 cc (19.53 in3)

Solar 290LC-V

S/N 0001 and Up

Pilot / Travel

10 kg/cm2 (140 psi)

320 cc (19.53 in3)

Solar 290LL

S/N 1001 and Up

Pilot / Travel

10 kg/cm2 (140 psi)

320 cc (19.53 in3)

Solar 330LC-V

S/N 1001 and Up

Pilot / Travel

10 kg/cm2 (140 psi)

320 cc (19.53 in3)

Solar 400LC-V

S/N 1001 and Up

Pilot / Travel

10 kg/cm2 (140 psi)

320 cc (19.53 in3)

Solar 450-V

S/N 1001 and Up

Pilot / Travel

10 kg/cm2 (140 psi)

320 cc (19.53 in3)

S0703000 Page 6

Accumulator

ACCUMULATOR CHARGING WARNING! In the event of a diaphragm or upper valve failure, or any type of accident or handling fault, the upper chamber of the accumulator could at some point require re-pressurization. Depending upon the specific procedures and safety precautions recommended for the type and model accumulator that has been installed on your machine, a specialized adapter and/or filling tool may be required to perform the procedure. Consult your dealer or Daewoo After Sales Service for more information and follow recommended procedures carefully. All accumulators may contain gas held under high pressure. Careless handling or improper disassembly could release explosive stored energy, resulting in an accident or injury. NOTE:

Some machines use 320 cc (19.53 in3) Bosch Accumulators with a nitrogen precharge (P1) pressure of 15 kg/cm2 (213 psi). Always verify pre-charge pressure by checking the manufacturer’s data label on the exterior of the accumulator.

CHARGING THE ACCUMULATOR WITH NITROGEN 1.

Remove the protective cap (10, Figure 3) and the protective plug (11) from the accumulator (6).

Figure 3

Accumulator

S0703000 Page 7

Reference Number

Description

Reference Number

Nitrogen Cylinder Fitting

Hose, 3 Meters (10 ft) Long

Cylinder to Accumulator Adapter

Check Valve

Nitrogen Bleeder Valve

Pressure Gauge

Nut O-ring

Sealing Nut

Protective Cap

Accumulator

Protective Plug

Sealing Ring

Description

Clean area around seal ring (12).

Thread the sealing nut (5, Figure 3) of adapter (7) onto accumulator. Tighten adapter securely. Close nitrogen bleeder vale (8).

Thread nitrogen cylinder fittings (1, Figure 3) onto nitrogen cylinder.

Open valve on nitrogen cylinder and charge accumulator to a appropriate pressure (P1). Close valve on nitrogen cylinder. NOTE:

Wait 2 or 3 minutes for nitrogen to warm to ambient temperature. This will stabilize pressure.

Slowly open nitrogen bleeder valve (8). Open valve (8) until gauge (4) reading is equal to primary pressure. Close bleeder valve.

Unscrew adapter (7, Figure 3) from accumulator (6).

Thread protective plug (11, Figure 3) into accumulator. Tighten to 3 kg•m (22 ft lb).

Check for nitrogen leaks around protective plug (11, Figure 3). Coat area around protective plug (11) with soapy water. If soap bubbles form, retighten protective plug (11).

10.

Install protective cap (10, Figure 3) on accumulator.

WARNING! Accumulator store nitrogen under high pressure. Before replacing an accumulator, install an adapter (7) with a bleeder valve (8) on the accumulator. Slowly and carefully bleed off all nitrogen before removing the accumulator from the hydraulic system. NOTE:

S0703000 Page 8

After an accumulator has been installed, or after an accumulator has been recharged with (P1) after the first week of operation. Check for a pressure drop due to leaks. If no pressure drop is found after the first week, check again after 3 more weeks. If no pressure drop is found after 3 weeks, check after one year.

Accumulator

S0705005K

1CYLINDERS

CYLINDERS

S0705005K

MODEL

SERIAL NUMBER RANGE

Mega 250-V (Tier II)

2001 and Up

Mega 300-V (Tier II)

2001 and Up

S0705005K Page 1

TABLE OF CONTENTS General Description........................................................................................ 4 Theory of Operation ................................................................................ 5 Parts List ................................................................................................. 6 Troubleshooting, Testing and Adjustment..................................................... 12 Disassembly ................................................................................................. 16 Cleaning and Inspection (Wear Limits and Tolerances) ............................... 18 Reassembly.................................................................................................. 19

S0705005K Page 2

Cylinders

S0705005K Page 3

GENERAL DESCRIPTION The machine contains boom cylinders, buckets cylinders and steering cylinders. Each cylinder contains a cylinder tube, piston rod, piston, and cylinder head. See Figure 1. The piston is held to piston rod by a nut. A dust seal protects the U-ring and oil seal from dirt and also prevents oil from leaking out of the cylinder.

Figure 1 Reference Number

Description

Reference Number

Description

Retaining Ring

Seal O-ring

Dust Seal

Piston

U-Ring

Spring

Seat O-ring

Cylinder Tube

Port (A)

O-ring, Backup Ring

Cushion Plate

Bushing

Wear Ring

Cylinder Head

Piston Nut

Bolt

Port (B)

Piston Rod

S0705005K Page 4

Cylinders

THEORY OF OPERATION 1.

Piston

Oil Path A

Oil Path B

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

Figure 1

(P: Pressure, π = 3.14, B: Cylinder Inside Diameter) 1.

Cylinder Inside Diameter - B

Oil Path A

Oil Path B

Rod Diameter

When the cylinder rod is retracted, oil flow through the circuit from the pump to the front side of the cylinder generates a force (F2) that 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.

Figure 2

F2 = P x π(B2-R2) 4 Because the volume of oil needed to lengthen the cylinder rod (Q1) is greater than the volume of oil required to retract the cylinder rod, it takes more time to decrease cylinder stroke length than it does to lengthen it. Q1 = S x π(B2) 4

Figure 3

Q2 = S x π(B2-R2) 4 Q1 > Q2

Cylinders

S0705005K Page 5

PARTS LIST Bucket Hydraulic Cylinder

1 2 23

24 20 19

26 27 14

28 16 15 18

11 13

7 21

8 10 3

4 29

BAS0170L

Figure 4

S0705005K Page 6

Cylinders

Reference Number

Description

Reference Number

Description

Tube Assembly

Wear Ring

Steel Bush

Dust Ring

Rod Assembly

O-ring

Steel Bush

Piston Nut

Rod Cover

Lock Ring

Du-bush

Socket Hex Bolt

Retaining Ring

Pipe Assembly

U-packing

O-ring

Backup Ring

Spring Washer

Dust wiper

Hex Bolt

O-ring

Pipe Clamp

Backup Ring

Spring Washer

O-ring

Hex Bolt

Piston

Grease Nipple Seal Kit

Glyd Ring

Cylinders

S0705005K Page 7

Lift Hydraulic Cylinder

1 2

33 22

23 21

30 32 29

30 31

27 28 19 18 13

20 6

17 7 10 12 11

15 14

7 9

BAS0180L

Figure 5

S0705005K Page 8

Cylinders

Reference Number

Description

Reference Number

Description

Tube Assembly

Piston Nut

Steel Bush

Lock Ring

Rod Assembly

Socket Hex Bolt

Rod Cover

Pipe Assembly

Du-bush

O-ring

Retaining Ring

Spring Washer

U-packing

Hex Bolt

Backup Ring

Pipe Assembly-r

Dust wiper

O-ring

Spring Washer

Backup Ring

Socket Hex Bolt

O-ring

Pipe Clamp

Piston

Spring Washer

Glyd Ring

Hex Bolt

Wear Ring

Hex Bolt

Dust Ring

Grease Nipple Seal Kit

O-ring

Cylinders

S0705005K Page 9

Steering Hydraulic Cylinder

2 27

27 23 24 26 1

20 19 14

18 6 12 13

10 11

5 9

3 27

BAS0190L

Figure 6

S0705005K Page 10

Cylinders

Reference Number

Description

Reference Number

Description

Tube Assembly

Glyd Ring

Steel Bush

Wear Ring

Rod Assembly

Dust Ring

Steel Bush

O-ring

Rod Cover

Piston Nut

Du-bush

Lock Ring

U-packing

Cushion Plunger

Backup Ring

Stop Ring

Dust wiper

Check Valve

O-ring

Spring

Backup Ring

Plug

O-ring

Washer

Grease Nipple Seal Kit

Piston

Cylinders

S0705005K Page 11

TROUBLESHOOTING, TESTING AND ADJUSTMENT Problem

Possible Cause

Oil leaking between cylinder head (16) and piston rod (18). (Index nos. refer to Figure 1)

Foreign material in U-ring (3).

Remedy Remove foreign material.

Scratches in U-ring (3).

Replace U-ring (3).

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 (4).

Remove foreign material.

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 piston rod (18).

If scratches are not deep, hone with an oil stone and lubricate. If scratches are deep, replace piston rod (18).

Deep scratches on inner surface of bushing (15).

Replace Bushing.

Oil leaking between cylinder head (16) and cylinder tube (13).

Damage to O-rings (14).

Replace O-rings (14).

Oil leaking from welded area of cylinder tube (13).

Damage to welded area.

Replace cylinder tube (13).

S0705005K Page 12

Cylinders

Problem

Cause

Remedy

Oil leaking between cylinder head (16) and piston rod (18). (Index nos. refer to Figure 1).

Foreign material in U-ring (3, Figure 1)

Remove foreign material.

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, Figure 1).

Remove foreign material.

Scratches in dust seal (2, Figure 1).

Replace dust seal (2).

Damage to dust seal (2, Figure 1).

Replace dust seal (2).

Foreign material in seal O-ring (4, Figure 1).

Remove foreign material.

Scratches in seal O-ring (4, Figure 1).

Replace O-ring (4).

Damage to Figure 1).

Replace O-ring (4).

seal

O-ring

(4,

Scratch on sealing surface of piston rod (18, Figure 1).

If scratches are not deep, hone with an oil stone and lubricate. If scratches are deep, replace piston rod (18).

Deep scratches on inner surface of bushing (15, Figure 1).

Replace bushing.

Oil leaking between cylinder head (16) and cylinder tube (13).

Damage to O-rings (14, Figure 1).

Replace O-rings (14).

Oil leaking from welded area of cylinder tube (13).

Damage to welded area.

Replace cylinder tube (13).

Cylinder drops from pull of gravity.

Light scratches on sealing surface of cylinder tube (13, Figure 1).

Hone out scratches with oil stone.

Deep scratches on sealing surface of cylinder tube (13, Figure 1).

Replace cylinder tube (13).

Deep scratches on sealing surface of piston O-rings (10, Figure 1).

Replace O-rings (10).

Foreign material in U-ring (3, Figure 1).

Remove foreign material.

Cylinders

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) twisted.

Replace nylon wear rings (7).

Nylon wear rings (7, Figure 1) scratched.

Replace nylon wear rings (7).

Nylon wear rings (7, Figure 1) have other damage.

Replace nylon wear rings (7).

S0705005K Page 13

Problem Slow bucket movements.

and

boom

Low pressure, shown by weak upward movement of boom and bucket.

Cylinder drops when control valve is in neutral.

Vibration or excessive noise.

S0705005K Page 14

Cause

Remedy

Reduced oil flow due to dirty filter or dirty intake line.

Disassemble and clean parts.

Air drawn into circuit through loose connections.

Tighten intake connections.

Reservoir oil level too low.

Fill reservoir to correct level.

Relief valve pressure setting incorrect.

Adjust relief valve pressure.

Damaged pump shaft or pump drive sleeve.

Replace damaged parts.

Pump worn internally.

Replace parts.

damaged

worn

damaged

Relief valve sticking.

Disassemble and cartridge. Clean or cartridge.

inspect replace

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.

Reduced oil flow due to dirty filter or dirty intake line.

Disassemble and clean parts.

Reservoir oil level too low.

Fill reservoir to correct level.

Relief valve pressure setting incorrect.

Adjust relief valve pressure.

Pump worn internally.

Replace parts.

damaged

worn

damaged

Relief valve sticking.

Disassemble and cartridge. Clean or cartridge.

inspect replace

Worn cylinder seals.

Replace worn parts.

Low pump output due to dirty discharge pipes.

Remove and clean discharge pipes.

Relief valve spring is weak. Relief valve poppet worn.

Replace worn parts.

Worn plunger in control valve.

Replace plunger.

Stuck overload relief valve due to worn seat surface.

Replace worn parts.

Loose pipes or joints.

Tighten parts.

Worn piston seal on hydraulic cylinder.

Replace seal.

Excessive resistance in pump intake line.

Inspect intake line and clean or replace as necessary.

Air being drawn into intake line.

Inspect pipe joints and tighten.

Chattering relief valve.

Change oil, replace valve.

pump

Cylinders

Problem Air bubbles in oil.

Frequent rubber hose damage.

Cylinders

Cause Wrong type of operating oil.

Remedy 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.

System pressure too high.

Adjust relief valve pressure.

Hoses breaking due to contact with another machine parts.

Restrain contact.

hoses

prevent

S0705005K Page 15

DISASSEMBLY NOTE:

Keep on hand a container large enough to hold all of the oil in cylinder being repaired. When cylinder rod and head are removed, oil will run out of cylinder.

Use an allen wrench to remove bolts that hold cylinder head to cylinder tube. See Figure 7.

Support cylinder rod with a lifting sling. See Figure 8. Slide cylinder rod out of cylinder tube. Rotate cylinder rod slightly as it is being pulled from cylinder tube. This will make it easier to pull rod out of tube.

Set cylinder rod assembly in a repair fixture and secure rod in place. See Figure 9. Use a power wrench and socket to remove nut that holds piston on rod.

Figure 7

Figure 8

Figure 9

S0705005K Page 16

Cylinders

Remove piston nut (1, Figure 10), piston assembly (2), cushion flange (3), and cylinder head assembly (4). Reference Number

Description

Piston Nut

Piston Assembly

Cushion Flange

Cylinder Head Assembly Figure 10

Do not remove slipper seal, backup ring, and back ring from piston. If these three items are not scratched or damaged. See Figure 11. Once these 3 items are removed from piston, they must be replaced. They cannot be reused. Exercise caution when removing slipper seal to prevent damage to piston O-ring groove. Remove wear rings from piston.

Figure 11 6.

When disassembling cylinder head do not remove slipper seal, backup ring, back ring, or dust seal unless items are scratched or damaged. If seals are removed from head, they must be replaced. They cannot be reused. Remove snap ring, (1, Figure 12). Use a screwdriver to remove dust seal (2) from head. Reference Number

Description

Snap Ring

Dust Seal

Cylinders

Figure 12

S0705005K Page 17

Use caution to prevent damage to any parts of U-packing (1, Figure 13). Remove U-packing (1). Remove O-ring (2), and ring (3). Reference Number

Description

U-Packing

O-Ring

Ring

Figure 13

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

S0705005K Page 18

Cylinders

REASSEMBLY NOTE:

Check cylinder head grooves for U-packing and dust seal. If edges of grooves are sharp or have burns, use an oil stone to smooth surface. See Figure 14.

Figure 14 1.

Apply grease to inner part of cylinder head and to U-packing groove. See Figure 15.

Install split backup ring into its groove by compressing ring. See Figure 16. Make sure that ends of ring do not overlap.

Figure 15

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 Upacking.

Figure 16

Cylinders

S0705005K Page 19

Insert one side of U-packing in its groove. See Figure 17.

Carefully push down on other side of Upacking until entire U-packing is seated in its groove. See Figure 18.

Check to be sure that U-packing and backup ring are correctly installed by pushing with your hand on inner diameter of U-packing. See Figure 19.

Figure 17

Figure 18

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.

NOTE:

Figure 19 6.

Use grease or an adhesive to hold split backup ring (1, Figure 20) in place. Install split backup ring (1) in groove closets to flange on cylinder head. Reference Number

Description

Split Backup Ring

Continuous Backup Ring

Figure 20

S0705005K Page 20

Cylinders

Place continuous backup ring in warm water. See Figure 21. Water temperature should be 30 - 50°C (86 - 122°F). Leave ring in water for 2 - 3 minutes. Slide continuous backup ring (2, Figure 20) over cylinder head and into its groove.

Install an O-ring over each of backup rings. See Figure 22.

Use a seal installing jig to install dust seal into cylinder head. See Figure 23. Install snap ring.

Figure 21

Figure 22

Figure 23

Cylinders

S0705005K Page 21

10.

On piston, check corners of grooves that piston rings will be mounted in. See Figure 24. If any burrs, roughness, or sharp edges (1) are present, use an oil stone to smooth roughened areas and dull sharp edges.

11.

Apply grease or hydraulic oil to corner of piston at position A. See Figure 25.

12.

Insert one end of backup ring into its groove. See Figure 26. Use your hand to slide other end of ring into groove.

13.

Use warm water to expand slipper seal. See Figure 27. This will make seal easier to install. Set slipper seal in 60 -100° C (140 - 212° F) water for 5 minutes or longer.

Figure 24

Figure 25

Figure 26

Figure 27

S0705005K Page 22

Cylinders

14.

Insert one end of slipper seal, (1, Figure 28) into its groove. Use your hand to slide other end of slipper seal into groove.

WARNING! Before piston is inserted into cylinder tube, make sure that slipper seal is no longer expanded. If seal is still expanded, it could catch on threaded portion of cylinder tube. An expanded seal could also jam inside cylinder tube. 15.

Figure 28

Install two backup rings, (1, Figure 29). One ring fits on either side of slipper seal (2). Reference Number

Description

Backup Ring

Slipper Seal

Figure 29

Cylinders

S0705005K Page 23

16.

Install wear ring (1, Figure 30) on piston.

Figure 30 17.

Set cylinder rod (1, Figure 31) into a repair fixture (2). Securely clamp rod to fixture. Exercise caution to prevent nicks or scratches to chrome plated areas of rod. chrome plated area is oil sealing surface of rod. Reference Number

Description

Cylinder Rod

Repair Fixture Figure 31

18.

Slide cylinder head assembly (1, Figure 32) onto cylinder rod (2). Use caution to prevent threads on rod from damaging seal inside cylinder head. Reference Number

Description

Cylinder Head

Cylinder Rod

Figure 32

S0705005K Page 24

Cylinders

19.

Install cushion flange (1, Figure 33) on cylinder rod (2). Slide piston assembly (3) onto cylinder rod (2). Reference Number

Description

Cushion Flange

Cylinder Rod

Piston Assembly

Figure 33 20.

Install piston nut (1, Figure 34) and tighten it with an impact wrench. Then use a torque wrench to tighten nut (1) to specified torque. After nut has been tightened, check to see that cushion flange moves.

Figure 34 21.

Slide rod assembly into cylinder tube. Align punch mark (1, Figure 35) with port (2) in cylinder tube. This will align hole (3) in cylinder head with port (2). Reference Number

Description

Punch Mark

Port

Hole

Figure 35

Cylinders

S0705005K Page 25

22.

Install bolts in cylinder head and tighten them to torque specified in bolt torque chart. See Figure 36. Double check to make sure that hole in cylinder head is align with port in cylinder tube. NOTE:

S0705005K Page 26

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 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.

Figure 36

Cylinders

S0707100K

1FAN DRIVE HYDRAULIC MOTOR (HALDEX) CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that is in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility.

FAN DRIVE HYDRAULIC MOTOR (HALDEX)S0707100K MODEL

SERIAL NUMBER RANGE

Mega 300-V (Tier I)

1001 thru 2000

Mega 300-V (Tier II)

2001 and Up

Mega 400-V

1001 and Up

Mega 500-V (Tier II)

2001 and Up

S0707100K Page 1

S0707100K Page 2

Fan Drive Hydraulic Motor (Haldex)

GENERAL DESCRIPTION THEORY OF OPERATION

AJS0770L

Figure 1 Fan Drive System Schematic Reference Number

Description

Reference Number

Description

Pump (Brake, Pilot, Fan Drive)

Fan Motor

Supply Valve (Brake, Pilot, Fan motor)

Fan

Relief Valve

Sequency Valve

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 sequency valve (3) of brake / pilot / fan motor supply valve (2). In case that the pressure of brake circuit rise up to 120.0 kg/cm2 (1,710 psi), the sequency valve (3) allows oil to flow fan motor (4). From fan motor (4), oil flows through oil cooler (7) and to the tank. Fan drive pump (common as brake and pilot pump) is a fixed displacement, vane pump. The pump is attached to the end of steering pump and common suction port as steer pump.

Fan Drive Hydraulic Motor (Haldex)

S0707100K Page 3

FAN RPM 1,300

const

750

On the fan drive motor, at engine speed of 1,620 rpm and above 1,620 rpm, the relief valve on the fan drive pump opens to dump excess flow back to hydraulic tank and thus the fan motor speed 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 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

S0707100K Page 4

Fan Drive Hydraulic Motor (Haldex)

PARTS LIST

3 4

5 7 6

7 5

10 9

4 3 2 14

AJS0780L

Figure 3 Reference Number

Description

Reference Number

Description

Front Bearing

Drive Gear

Back Up Ring

Coupling

Seal

Cover

Bearing Block

Bolt

O-ring

Plug

Gear Housing

Spring

Dowel Pin

Ball

Idler Gear

Relief Valve Cartridge

Fan Drive Hydraulic Motor (Haldex)

S0707100K Page 5

SPECIFICATIONS Item Fan Motor

Fan

Specification Displacement

31.0 cc (1.89 in3)

Relief Valve Setting ∆ p/1 turn

70 ±5 kg/cm2 (1000 ±70 psi) 16.5 kg/cm2 (235 psi)

Maker (Model)

HALDEX (WM9A1-31...)

Fan Size

∅812 (32")

Type

Sucker, plastic -8 driven by hydraulic motor

Fan rpm (at motor relief ∆ p)

1,300 rpm @ 70 ±5 kg/cm2 (1000 ±70 psi))

Fan Drive Pump

S0707100K Page 6

24.9 cc (1.52 in3)

Fan Drive Hydraulic Motor (Haldex)

S0708485K R1

1MAIN PUMP (DENISON) 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.

MAIN PUMP (DENISON)S0708485K MODEL

SERIAL NUMBER RANGE

Mega 300-V (Tier I)

1001 thru 2000

Mega 300-V (Tier II)

2001 and Up

S0708485K Page 1

TABLE OF CONTENTS General Description........................................................................................ 4 General ................................................................................................... 4 Description .............................................................................................. 4 Theory of Operation ................................................................................ 5 Parts List ................................................................................................. 8 Specifications ........................................................................................ 10 Special Tools ................................................................................................ 11 Seal Driver ............................................................................................ 11 Protective Cone..................................................................................... 11 Troubleshooting ............................................................................................ 12 Overhaul....................................................................................................... 14 General ................................................................................................. 14 Changing Rotation ................................................................................ 15 Changing Cartridges ............................................................................. 16 Changing Port Locations....................................................................... 16 Changing Shaft or Shaft Seal................................................................ 17 Disassembly of Pump ........................................................................... 18 End Cap ......................................................................................... 18 Shaft End ....................................................................................... 19 Shaft............................................................................................... 19 Reassembly of Pump ............................................................................ 19 Shaft End ....................................................................................... 19 Center Housing and "D" Unitized Cartridge (P1) ........................... 20 "C" Unitized Cartridge (P2) and End Cap ...................................... 20 Unitized Pumping Cartridges ......................................................... 21 Disassembly of "C" Cartridge................................................................ 22 Reassembly of "C" Cartridge ................................................................ 23 Disassembly of "D" Cartridge................................................................ 24 Reassembly of "D" Cartridge ................................................................ 25 Installation .................................................................................................... 26

S0708485K Page 2

Main Pump (Denison)

Mounting ............................................................................................... 26 Piping .................................................................................................... 26 Fluids..................................................................................................... 27 Type ............................................................................................... 27 Anti-wear Additives ........................................................................ 27 Non Petroleum Base or Fire Resistant Fluids ................................ 27 Operating Temperature .................................................................. 27 Pump inlet Conditions .................................................................... 28 Start-up Procedures ..................................................................................... 29 Pre-start Check ..................................................................................... 29 Priming .................................................................................................. 29

Main Pump (Denison)

S0708485K Page 3

GENERAL DESCRIPTION GENERAL This manual covers installation, operation, maintenance and overhaul instructions for the Denison T6DC series vane type double pumps. DESCRIPTION

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

S0708485K Page 4

Main Pump (Denison)

THEORY OF OPERATION The pumping operation of this unit (each cartridge) is obtained by providing a fixed interior cam surface and a rotating inner member (rotor) containing vanes which are held in contact with the inner cam surface. As the rotor is rotated by the drive shaft, the vanes are urged outward against the outward sloping cam surface, forming a cavity at the inlet ports of the port plates. Atmospheric pressure and suction created by the expanding cavity between the rotating vanes fill the inlet cavity with fluid. As the rotation continues and the vanes that had previously moved outward and now have fluid trapped between them and the port plates, follow the inward slope of the cam which decreases the cavity containing the trapped fluid and discharge the fluid at system pressure thru the pressure port openings in the port plates. The rotating portion of the unitized cartridges feature the use of pressure actuated vanes which are urged against the cam ring by pins located in the bottom of each rotors vane slot. Initial force to bring the vanes in contact with the cam ring contour during start up is provided by centrifugal force. When pumping operation starts and pressure is established, fluid under pressure fills the pin cavity thru the feed holes. The feed holes open to the pressure port twice every revolution. All other times they are closed off by the port plate. This pressure under the pin provides the force necessary to keep the vanes in contact with the cam contour. NOTE:

When operating the pump at the maximum outlet pressure, the pump shaft rotation should not be allowed to fall below 600 RPM in order to maintain proper vane to cam ring contact.

The inlet or suction flow for both the "D" cartridge and "C" cartridge feeds through a common 76.2 mm (3.0 in) port in the center housing, through the large ports of each port plate for each cartridge and through the center hole in the suction zone of each cam ring. To determine the performance characteristics of a given model, refer to table I on (See page 6):

Main Pump (Denison)

S0708485K Page 5

Table I. Operating Characteristics - Typical (24 cSt)

Pressure Port

Series

Volumetric displacemnet.Vp

Flow Q (l/min) & n=1,500 RPM

Input power P (kW) & n=1,500 RPM

p=0bar

p=140bar

p=240bar

p=7bar

p=140bar

p=240bar

014

47.6 ml/rev

74.4

62.1

55.9

2.5

18.0

30.6

020

66.0 ml/rev

99.0

89.7

83.5

2.8

24.4

41.7

024

79.5 ml/rev

119.3

110.0

103.8

3.0

29.6

49.8

028

89.7 ml/rev

134.5

125.2

119.0

3.2

32.7

55.9

031

98.3 ml/rev

147.4

138.1

131.9

3.3

35.7

61.0

035

111.0 ml/rev

166.5

157.2

151.0

3.5

40.1

68.7

038

120.3 ml/rev

180.4

171.1

164.9

3.7

43.3

74.2

042***

136.0 ml/rev

204.0

194.7

188.5

4.0

48.7

83.7

045***

145.7 ml/rev

218.5

209.2

203.0

4.1

52.1

89.5

050***

158.0 ml/rev

237.0

227.7

224.0**

4.4

57.0

85.0**

003

10.8 ml/rev

16.2

11.2

7.7

1.3

5.3

8.4

005

17.2 ml/rev

25.8

20.8

17.3

1.4

7.5

12.2

006

21.3ml/rev

31.9

26.9

23.4

1.5

8.9

14.7

008

26.4 ml/rev

39.6

34.6

31.1

1.6

10.7

17.7

010

34.1 ml/rev

51.1

46.1

42.6

1.7

13.4

22.3

012

37.1 ml/rev

55.6

50.6

47.1

1.7

14.4

24.1

014

46.0 ml/rev

69.0

64.0

60.5

1.9

17.6

29.5

017

58.3 ml/rev

87.4

82.4

78.9

2.1

21.9

36.9

020

63.8 ml/rev

95.7

90.7

87.2

2.2

23.8

40.2

022

70.3 ml/rev

105.4

100.4

96.9

2.3

26.1

44.1

025*

79.3 ml/rev

18.9

113.9

110.4

2.5

29.2

49.5

028*

88.8 ml/rev

133.2

128.2

124.7**

2.8

32.7

48.5**

031*

100.0 ml/rev

150.0

145.0

151.5**

2.8

36.5

54.4**

* 025 - 028 - 031= 2,500 RPM max. ** 028 - 031 - 050 = 210 bar max. int. *** 042 - 045 - 050 = 2,200 RPM max. Port connection can be furnished with metric threads.

S0708485K Page 6

Main Pump (Denison)

S0708485K Page 7

PARTS LIST

Figure 2

S0708485K Page 8

Main Pump (Denison)

Deference Number

Description

Deference Number

Description

End Cap

Ring; Backup

Seal; Section

Pin; Dowel

Seal; Section

Housing

Ring; Backup

Pin; Dowel

Seal; Section

Pin; Dowel

Rotor

Port Plate; Rear

Bush

Screw

Cam Ring

Washer; Lock

Vane

Port Plate; Rear

Pin; Dowel

Cam Ring

Port Plate; Press

Vane

Bolt

Seal; Section

Coupling

Seal; Section

O-ring

Bolt

Seal; Section

Pump; Gear

Ring; Retaining

Bolt

Bearing; Ball

Bolt

Seal; Section

Cartridge Kit (P1)

Shaft

Cartridge Kit (P2)

Ring; Section

Seal Kit

Cap; Mounting

Shaft & Bearing Kit

Port Plate; Press

Port Plate Kit (C)

Rotor

Port Plate Kit (D)

Main Pump (Denison)

S0708485K Page 9

SPECIFICATIONS Item

Specification

Engine Pump Model Number

DE12TIS Main Pump

Steering Pump

DE08TIS Pilot Pump

T67CCA-B25-B22-B06-3R32

Main Pump

Steering Pump

Pilot Pump

T67CCAY-B20-B22-B06-3R32

Type

Vane

Displacement

79.5 cc (4.85 in3)

70.3 cc (4.29 in3)

19.6 cc (1.20 in3)

63.8 cc (3.89 in3)

70.3 cc (4.29 in3)

19.6 cc (1.20 in3)

* Maximum Flow Rate

167 l/min (44.1 gpm)

148 l/min (39.1 gpm)

41 l/min (10.8 gpm)

134 l/min (35.4 gpm)

148 l/min (39.1 gpm)

41 l/min (10.8 gpm)

Pump Pressure

200 kg/cm2 (2,840 psi)

185 kg/cm2 (2,631 psi)

120 kg/cm2 (1,707 psi)

200 kg/cm2 (2,840 psi)

185 kg/cm2 (2,631 psi)

120 kg/cm2 (1,707 psi)

Weight

43.50 kg (96 lb) (* at rated rpm)

S0708485K Page 10

Main Pump (Denison)

SPECIAL TOOLS Special tools will help to properly install the shaft seal. A shaft seal driver of propel size must be used to install the shaft seal. A protective cone must be used over the shaft end to prevent damage to the shaft seal when installing the shaft. The remainder of the pump disassembly and assembly can be accomplished with normal repair shop tools and good repair practices. Refer to Figure 3 and Figure 4 for proper configuration and dimensions for the seal driver and protective cone. SEAL DRIVER NOTE:

1. Remove all burrs and break sharp edges. 0.25/0.31R. 2. Length "A" to heat treated to HRC 50-55. 3. Length "A" to have a 1.5-3S full length, with a smooth intersection between chamber and dia "B." 4. Grease O.D. of length "A" before installing shaft seal onto tool to prevent damage to the seal. Material SCM4 (HRC = 27-23) or equivalent.

Figure 3

PROTECTIVE CONE NOTE:

1. Remove all burrs and break sharp edges. 0.25/0.31R. 2. Teflon preferred, alternate SCM4 treated after machining to HRC 40-45. 3. Install protective cone over shaft extension and grease O.D. to prevent damage to shaft seal. 4. Length "A" to have a 1.5 - 3S full length, with a smooth intersection between chamber and dia. "B."

Main Pump (Denison)

Figure 4

S0708485K Page 11

TROUBLESHOOTING The internal parts of this pump are lubricated by the operating fluid, therefore, preventative maintenance is limited to keeping the fluid in the system clean. The system filters should be replaced frequently and if a suction strainer is used it must not be allowed to become restricted. When possible, dirt should not he allowed to accumulate on the pump or around the shaft seal. All fittings and bolts should be tight. NOTE:

It is especially important that the suction or inlet piping and fittings be tight and in good repair to prevent air from being drawn into the system.

In the event the pump does not perform properly or a malfunction occurs, refer to the "Trouble Shooting Chart" before proceeding with an overhaul.

Trouble External Leakage.

Leakage at Fittings.

Probable Cause

Possible Remedy

Seal failure.

Replace seal.

Damaged casting.

Replace casting.

Damaged or defective seal between housing and mounting cap.

Replace seal.

Cracked or damaged flange or fittings.

Replace flange or fittings.

Damaged or defective flange threads or screws too long.

Replace screws.

Damaged or defective O-ring seal.

Replace O-ring seal.

Burr on mating surfaces.

Remove burr.

Loss in pump RPM under load.

Power source too small for pump being used.

Provide larger power source.

Pump not delivering oil

Pump does not prime.

Bleed air from system.

Wrong direction on shaft rotation.

Reverse direction of shaft.

flange.

Use

shorter

Covert pump to reverse direction of rotation. (Check rotation arrows on identification. plate and cam ring.)

S0708485K Page 12

Tank fluid level too low.

Add fluid and check level to be certain suction line is submerged.

Fluid inlet line or suction strainer clogged or undersized.

Clean strainer of all foreign material. Provide proper size strainer (should have a capacity equal to 2 x pump volume in flow).

Air leak in suction line.

Tighten and seal Replace seals.

Fluid viscosity too heavy to pick up prime.

Use lighter viscosity fluid.

Broken pump shaft or internal parts.

Replace damaged parts overhaul instructions.

connection.

per

Main Pump (Denison)

Trouble Pump not developing pressure

Noisy or erratic operation

Seal failure

Main Pump (Denison)

Probable Cause

Possible Remedy

Relief valve setting too low.

Reset relief valve.

Relief valve sticking open.

Check for defective malfunctioning valve.

Vane hold out pins not loading vanes.

Disassemble and check pins for burrs or damage: Check for foreign material.

Free recirculation of fluid to tank being allowed.

Check directional control valve for open center or neutral position. Check for open bypass valve.

Air leak at pump inlet or suction lines.

Check for air leaks by pouring system fluid around joints and listen for change in sound level. Tighten as required.

Housing and mounting cap separation.

Check bolts for proper torque.

Restricted or clogged inlet line or strainer.

Provide larger inlet line or strainer. Clean strainer.

Excessive pump RPM (cavitation).

Provide power source that does not exceed maximum pump RPM recommendations for existing inlet conditions.

Worn vanes, cam ring or port plates.

Disassemble per overhaul instructions and replace worn parts.

Worn vane holdout pins.

Disassemble per overhaul instructions. Replace pins if worn.

Worn bearings.

Disassemble and replace.

Excessive inlet pressure

Decrease inlet pressure. Inlet pressure must not exceed 2.5 bar (35 psi).

S0708485K Page 13

OVERHAUL

Figure 5

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

S0708485K Page 14

Main Pump (Denison)

CHANGING ROTATION These instructions detail the procedure to change direction of rotation of a pump. 1.

Drain all fluid from the pump and thoroughly clean exterior surface.

Secure the pump in a vise with the shaft extended down. Clamp the vise on the mounting cap, not on the housing.

Remove the seven screws (1, Figure 5) from the end cap (2). Remove the end cap by pulling outward. Remove the O-ring (3) from the end cap.

Remove the "C" cartridge (4) from the end cap and lay on a clean surface. Refer to -- during cartridge directional change.

Before performing work on the "C" cartridge, note when viewing the pressure plate, a right-hand (CW) pump will have the directional arrow on the cam ring pointing (CW). For left-hand (CCW) pump rotation the arrow on the cam ring will point (CCW).

Remove the two screws from the "C" cartridge (4a, Figure 5) and remove the port plate (4c). Remove and invert the cam ring (4e).

Note that dowel pins (4j) and (4d) are not inserted in the same holes for (CCW) as for (CW) operation. The arrow on the cam ring (4e) must point in the direction the pump is intended to run.

Install the cam ring on the pressure plate over the rotor. Install the port plate (4c) and secure with two screws through the cam ring and into the pressure plate.

Remove the four screws (15) and separator the center housing (5) from the mounting cap (14). It may be necessary to use a gear puller to remove the "D" cartridge (6) by hooking the arms under the cam ring. Care must be taken not to damage the cam ring or mounting cap.

10.

Before performing work on the "D" cartridge refer to Figure 5 and notice the difference in assembly of the right-hand and left-hand units.

11.

Remove the four screws (6a, Figure 5) and lock washers (6b). Remove the port plate (6d). Invert the cam ring (6f). NOTE:

The arrow on the cam ring must indicate the same direction as the arrow on the pressure plate next to the dowel pin hole.

12.

Install the cam ring on the pressure plate over the rotor. Install the port plate and secure with four screws and lock washers through the cam ring and into the pressure plate. Tighten with a screw diver.

13.

Install "D" cartridge in center housing making sure the drive lock pin in the port place seats in the hole in the center housing.

14.

Lubricate the "D" cartridge O-rings and place mounting cap and shaft assembly over front cartridge. Make sure the shaft passes thru the "D" rotor. Rotate shaft back and forth to make sure the splines in the rotor engage.

15.

Orient pressure port in the desired direction and line up the screw holes. Draw the mounting cap down onto the center housing by alternately tightening two screws in diagonally opposed holes.

16.

Install the other two screws and torque all four to 18.7 kg•m (135 ft lb).

17.

Install the "C" cartridge in the center housing over the shaft making sure the drive lock pin in the port plate seats in the hope in the center the housing.

18.

Lubricate "C" cartridge pressure plate O-rings and place end cap over pressure plate. Orient port to proper direction and make sure the screw holes line up.

19.

Draw the end cap onto the center housing by alternately lightening two screws in opposite holes.

20.

Install the other five screws and torque all seven to 6.2 kg•m (45 ft lb).

Main Pump (Denison)

S0708485K Page 15

CHANGING CARTRIDGES When changing cartridges the following instructions should be observed. 1.

Drain all fluid from pump and thoroughly clean exterior surface.

Secure unit in a vise with the shaft extended down. Clamp the vise on the mounting cap, not on the housing.

Remove the seven screws (1, Figure 5) and end cap (2) and cartridge. Note position of the pressure port in reference to the suction port. Remove the seat (3) from cap.

Remove the "C" cartridge assembly (P2) from end cap. It may be necessary to use a gear puller with its arms hooked under the cam ring. It may also be removed by prying up against the cam ring. Care must be taken not to damage the cam ring or cap.

Remove the four screws (15) and separate the center housing (5) from the mounting cap (14). Items 6 thru 14 will be removed as a unit. It may be necessary to use a gear puller to remove the "D" cartridge (6) by hooking the arms under the cam ring. Care must be taken not to damage the cam ring or the mounting cap.

Place the center housing (5) with large open end up and install the "D" cartridge in the housing. Make sure the pin (6c, Figure 5) enters drilled hole in housing.

Install the mounting cap (14) with the attached shaft assembly by inserting the shaft through the cartridge assembly. Rotate the shaft to engage the spline in the rotor. NOTE:

Position the P1 outlet port and the inlet port in the housing to the required position by turning the mounting cap.

Install the four screws and alternately tighter two to draw down mounting cap. Torque all four to 78.7 kg•m (570 ft lb).

Install the "C" cartridge in the small end of the housing. Make certain the pin in the per plate enters the drilled hole in housing.

10.

Install seal (3) on end cap. Apply hydraulic fluid on all the seals to assist in assembly. Install end cap (2) over the cartridge and rotate until the P2 outlet is in the desired position.

11.

Install the seven screws and alternately tighten two to draw down end cap. Torque all seven to 6.20 kg•m (45 ft lb).

CHANGING PORT LOCATIONS These instructions detail the procedure to change the port locations. 1.

Drain the fluid from the pump and thoroughly clean the exterior surface.

Secure the pump in a vise with the shaft extended down. Clamp the vise on the mounting cap, not on the housing.

Remove the seven screws that secure the end cap (2). Remove the end cap and the "C" cartridge assembly from the center housing.

Separate the end cap from the cartridge assembly and install the cartridge back into the center housing. It may be removed by use of a gear puller with the arms hooked under the cam ring or by prying up against the cam ring. Care must be taken not to damage the ring.

Replace the O-ring (3) on the end cap. Lubricate all O-rings after installation. Position the end cap in the desired position and secure with seven screws. Torque to 6.22 kg•m (45 ft lb).

Remove the four screws that secure the mounting cap to the housing and pull the mounting cap and "D" cartridge from the center housing. Remove the "D" cartridge from the mounting cap.

S0708485K Page 16

Main Pump (Denison)

Replace the cartridge in the center housing. Make certain the pin in the port plate enters the drilled hole In the housing.

Install new O-ring (13) in mounting cap and position cap in the desired position. Install four screws and torque to 18.7 kg•m (135 ft lb).

Fill the pump with hydraulic fluid.

CHANGING SHAFT OR SHAFT SEAL When necessary to change the shaft seal or shaft the following steps should be observed. 1.

Drain the unit of hydraulic fluid.

Remove the four screws (15, Figure 5) and separate the center housing from the mounting cap. Items 6 thru 14 will be removed as a unit. Remove the cartridge assembly from the mounting cap.

Remove the O-ring (13) from the cap. Remove retaining ring (7) and press or drive the shaft assembly from the cap. Use a soft faced hammer and gently tap the end of the shaft. If shaft seal is not to be changed, use the protective cone (Figure 4) when driving out the shaft. Remove the seal if it is to be changed.

To assemble a new shaft assembly use the following procedure. Install retaining ring (10, Figure 5) In groove nearest drive end of shaft by passing ring over the internal serration. Do not install it over the drive end of the shaft as this may damage the seal surface next to the groove.

Install the ball bearing (9) by pressing on the inner bearing race until seated against ring (10). Install retaining ring (8). Make sure both rings are fully seated in grooves.

Use seal driver (Figure 3) and press shaft seal into the mounting cap. Grease seal lips. NOTE:

The open face of seal must be toward installation tool. If a sealant is not furnished on the O.D. of the seal apply a light coat of approved sealing compound to the O.D. of the seal. Extreme care must be taken to avoid depositing any of the sealing compound on the seal element or the shaft.

Install protective nose cone (Figure 4) over external drive end of shaft subassembly and then by pressing on the outer race of the ball bearing, press the shaft into the mounting cap.

CAUTION! Do not press on end of shaft. 8.

Install retaining ring (7) to hold shaft in place. Make sure ring is fully seated In groove.

Place cartridge in housing. Install O-ring in mounting cap and insert shaft assembly down through the "D" cartridge engaging the matching serrations.

CAUTION! Take special care the splines of the shaft and rotor engage smoothly. If necessary rotate the shaft slightly to obtain n smooth engagement. 10.

Locate P1 port in proper position and secure mounting cap to housing with four screws. Torque to 18.7 kg•m (135 ft lb).

Main Pump (Denison)

S0708485K Page 17

DISASSEMBLY OF PUMP

Figure 6 Sometimes a malfunction in the small section of the pump, "C" cartridge (P2), can be corrected without removing the pump from the power source. To service the large section, "D" cartridge, (P1) the complete pump must be removed. 1.

Drain all fluid from the pump and thoroughly clean the exterior surface.

Prepare a clean, lint free surface on which to lay the internal parts for inspection and repair.

Inspect all internal parts for scratches, nicks and excessive wear. Slight imperfections may be removed with a fine India stone.

All parts must be cleaned with a suitable solvent and dried with clean, dry compressed air. Protect parts from dirt and rust until time of assembly with a film of clean hydraulic fluid.

During assembly all lapped and ground surfaces must be lubricated with clean hydraulic fluid. Use extreme care not to damage these surfaces.

Secure the pump in a vise or other suitable holding fixture with the shaft (11) extended down. Note position of the two outlet ports (P1 & P2) with reference to the inlet port in the center housing (5) before removing any screws so that the two outlet ports may be returned to their original position at reassembly. Discard all seals as they are removed. End Cap 1.

Remove the seven screws (1) from the end cap (2). Remove the end cap by pulling outward. Remove the rubber seal (3) from the end cap.

Remove the "C" unitized cartridge (4) from the end cap (2) and lay aside on a clean surface for disassembly and inspection later. See Figure 5 for cartridge disassembly and assembly instructions.

S0708485K Page 18

Main Pump (Denison)

Shaft End 1.

Remove the four screws (15) and separate the center housing (5) from the mounting cap (14). Items (6 through 14) will be removed as a unit. Remove cartridge from mounting cap with puller or by carefully prying against cam ring and mounting cap. Be careful not to damage the cam ring or mounting cap. Lay the cartridge aside for inspection later. See Figure 5 for cartridge disassembly and assembly instructions.

Remove the rubber seal (13) from the mounting cap, Remove retaining ring (7) and press the shaft and hearing assembly (items 8, 9, 10 and 11) from the mounting cap. Remove shaft seal (12) from the mounting cap.

Shaft 1.

Examine the ball bearing (9) for wear before removing it from the shaft. Apply a little pressure to the outer race and relate the bearing to check the balls and race for wear or cracks and check for looseness. Remove the bearing from the shaft if a replacement is needed. Inspect the outside diameter of the shaft at the point of contacts with bearing in the "C" cartridge and the sealing surface for the shaft seal. Do not remove the bearing from the shaft if both are reusable. Omit the next procedure if not required.

Remove retaining ring (8) and press bearing (9) from the shaft (11). Remove retaining ring (10). NOTE:

See Figure 7 for critical areas on the shaft.

WARNING! Retaining ring (10) must be removed by passing over the bearing surface of the shaft and never over the shaft seal surface. A damaged seal surface will cause the shaft seal to leak. REASSEMBLY OF PUMP Immerse the seals and bearing in clean hydraulic fluid to make the reassembly easier and to provide initial lubrication. Shaft End 1.

Place the mounting cap (14) on a clean surface with the large open end facing up. Use a shaft seal driver (See Figure 3) and install the shaft seal (12) in the cap (14). Make certain the open side of the seal is toward the inside of the mounting cap. The shaft seal driver wilt prevent damage to the seal during installation.

Main Pump (Denison)

S0708485K Page 19

Install retaining ring (10) in the groove on the shaft between the bearing surface and the seal surface. Do not allow the retaining ring to touch the seal surface on the shaft. Press bearing (9) over the same end of the shaft and install retaining ring (8). See Figure 7. Be sure retaining rings (8 and 10) are fully seated in grooves.

Apply lubricating fluid to the inside of the shaft seal (12) and install the shaft assembly (8, 9, 10 and 11) in the mounting cap (14).

Install retaining ring (7) in the mounting cap (14) and against the bearing (9) to held the shaft assembly in place. Make certain retaining ring (7) is fully seated in the groove.

Install seal (13) on the pilot of the mounting cap (14).

Figure 7

Center Housing and "D" Unitized Cartridge (P1) 1.

Place the center housing (5) on a clean flat surface with the large open end up and install the "D" unitized cartridge assembly (6) in the housing. Make certain that Driv-Lok pin (Figure 5, Item 6c) enters the drilled hole in the housing.

Apply lubricating fluid to the two seals on the cartridge (6) and seal (13) on the mounting cap (14). This fluid will lessen the chance of damaging the seals when installing the mounting cap.

Install the mounting cap (14) with the attached shaft assembly by inserting the shaft through the cartridge assembly and into the center housing (5). Rotate the shaft to engage the spline in the rotor. NOTE:

Position the P1 outlet port in the mounting cap (14) and the inlet port in the center housing (5) in required position by turning the mounting cap.

Install tIne four screws (15) and alternately lighten two opposed screws to draw down cap. Torque all four screws to 18.7 kg•m (135 ft lb).

"C" Unitized Cartridge (P2) and End Cap 1.

Install the "C" unitized cartridge assembly (4) in the small end of the center housing (5). Make certain that the Driv-Lok pin (Figure 5, Item 4b) enters the drilled hole in the housing.

Install rubber seal (3) on end cap (2) (Figure 6).

Apply lubricating fluid to the two seals on the cartridge (4) and to seal (3) on the end cap (2).

Install end cap (2) over the exposed end of cartridge (4) arid rotate until the P2 outlet is in the desired position.

Install the seven screws (1) and alternately tighten two opposed screws to draw down cap. Torque all seven screws to 5.2 kg•m (38 ft lb).

S0708485K Page 20

Main Pump (Denison)

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

Figure 8

Main Pump (Denison)

S0708485K Page 21

DISASSEMBLY OF "C" CARTRIDGE

Figure 9 1.

Remove the two screws (4a) and the port plate (4c). The Driv-Lok pin (4b) is pressed into the port plate and should not be removed unless damaged and replacement is required.

Remove dowel pin (4d) cam ring (4e) and dowel pin (4j).

Remove the vanes (4f), and the pins (4g) from the rotor.

Remove the seals (4m and 4n) and backup ring (4q) from the pressure plate.

Wash all the metal parts in cleaning solvent and dry thoroughly. Discard the rubber seals. Place all the parts on a clean lint free surface and inspect for wear marks, nicks and burrs. Light scoring on the wear

S0708485K Page 22

Main Pump (Denison)

surfaces of the port plate and pressure plate may be removed by lapping. The vanes must move freely in the rotor slots and not bind or have excessive play. The edges of the vanes and the rotor slots may be stoned with a fine India stone to remove all burrs. Inspect the cam ring for excessive wear (ripples or washboard marks on the contour). Replace a badly worn or defective cam ring and any parts that can not be reconditioned. All metal parts that have been lapped or stoned, must be washed again in clean solvent and dried before they are assembled. Make certain that all internal passages in the port plate, pressure plate, rotor, and vanes are open and clean. REASSEMBLY OF "C" CARTRIDGE The "C" cartridge is made up using the same parts regardless of the direction of rotation. Refer to Figure 9 and observe that screws (4a) and dowel pins (4d and 4j) are not inserted in the same holes for left-hand (CCW) as for right-hand (CW) operation. The arrow on the cam ring (4e) must point in the direction that the pump is intended to run. 1.

Place the pressure plate (4k) on a clean flat surface with the wear face up and apply clean hydraulic fluid to the face. NOTE:

Again, Check the rotation of the pump where this cartridge will be used.

Insert dowel pin (4j) in the pressure plate using the hole nearest the arrow that indicates the desired rotation.

Center the rotor assembly (4h) on the pressure plate with the splined side of the rotor up.

Insert one vane holdout pin (4g) in each vane slot in the rotor assembly. The holdout pins must move freely and be inserted against the bottom of the hole.

Install the vanes (4f) in the rotor with the flat side of the vane toward the center of the rotor.

Place the cam ring (4e) over the dowel pin (4j). The arrow on the cam ring must indicate the same directions as the arrow which is closer to dowel pin (4j) in the pressure plate (4k).

Install dowel pin (4d) in the cam ring. If the Driv-Lok pin (4b) was removed from the port plate (4c), it must be replaced.

If removed, press the Driv-Lok pin (4b) into the hole provided in the back of the port plate (4c) (grooved end first).

Pour clean hydraulic fluid over the cam ring and rotor assembly and install the port plate assembly (4c) over the dowel pin (4d). The port plate must be positioned to allow the two screws (4a) to pass through the cam ring and enter the pressure plate.

10.

Insert the two screws (4a) and tighten. Install seals (4m and 4n) and backup ring (4q) on the pressure plate. NOTE:

Contoured side of the backup ring must face seal.

Main Pump (Denison)

S0708485K Page 23

DISASSEMBLY OF "D" CARTRIDGE

Figure 10 1.

Remove the four screws (6a), lock washers (6b) and the port plate (6d). The Driv-Lok pin (6c) is pressed into the port plate and should not be removed unless damaged and replacement is required.

Remove dowel pin (6e), cam ring (6f) and dowel pin (6k).

Remove the vanes (6g), and the pins (6h) from the rotor (6j).

Remove the seals (6n and 6p) and backup plate (6q) from the pressure palate (6m). Wash all the metal parts in cleaning solvent and duty thoroughly. Discard the rubber seals.

S0708485K Page 24

Main Pump (Denison)

Place all the parts on a clean lint free surface and inspect for wear marks, nicks and burrs, Light scoring on the wear surfaces of the port plates may be removed by tapping. The vanes must move freely in the rotor slots and not bind or have excessive play. The edge of the vanes and the rotor slots may be stoned with a fine India stone to remove all burrs. Inspect the cam ring for excessive wear (ripples or washboard marks on the contour). Replace a badly worn or defective cam ring and any parts that can not be reconditioned. All metal parts that have been lapped or stoned must be washed again in clean solvent and dried before they are assembled. Make certain that all internal passages in the port plate, rotor and vanes are open and clean. REASSEMBLY OF "D" CARTRIDGE 1.

Place pressure plate (6m) on a clean bench with the wear face up and apply clean hydraulic fluid. Install dowel pin (6k) in pressure plate in the hole nearest the arrow that indicates the desired rotation.

Center the rotor (6j) on the pressure plate with the splined side of the rotor up.

Insert one vane pin (6h) in each vane slot in the rotor. The pins must move freely and be inserted against the bottom of the hole.

Install the vanes (6g) in the rotor with the flat side of the vane toward the center of the rotor.

Install the cam ring (6f) over the dowel pin (6k) with the arrow pointing in the direction that the pump is intended to run. Install dowel pin (6e) in cam ring, NOTE:

The arrow on the cam ring must indicate the same direction as the stamped arrow on the pressure plate.

If removed, press the Driv-Lok pin (6c) into the back of the port plate (6d) (Grooved End First).

Pour clean hydraulic fluid over the cam ring and motor and install the port plate (6d) over the dowel pin (6k) so the pin is in the hole nearest the arrow that indicates the desired rotation.

Insert the four screws (6a) and lock washers (6b) through the port plate (6d), cam ring (61) and into the pressure plate (6m) and tighten with a screw driver. Install seals (6n and 6p) and backup ring (6q) on the pressure plate. NOTE:

The contoured side of the backup ring must face the seal.

Main Pump (Denison)

S0708485K Page 25

INSTALLATION MOUNTING This pump may be mounted In any position, however it is recommended that a horizontal position be used whenever possible. The Inlet port and the outlet port of the "D" section (shaft end) (P1) allows four relative positions In 90° interval: The Inlet port and the outlet port of the "C" section (cap end) (P2) allows eight relative positions in 45° intervals. If so desired, the porting relationship between the inlet and the "D" section outlet may be changed by removing the four bolts securing the mounting cap to the center housing and rotating the mounting cap relative to the center housing to the desired porting arrangements. When replacing the four bolts they be torqued to the recommended value 18.7 kg•m (135 ft lb). The porting relationship between the inlet and the "C" section outlet may be changed by following the procedure in the section "Changing Port Location." The mounting hub and mounting bolt hole location conform to SAE-C, 2 bolt standard in both the spline and key shaft options. For proper operation, the pump shaft must be in alignment with the power source shaft and should be checked with a dial Indicator. The mounting pad or adaptor into which the pump pilots must be concentric with the power source shaft within 0.15 mm (0.0059 in) TIR. The shaft concentricities are particularly important if the pump shaft Is rigidly connected to the power source without a flexible coupling or a coupling that allows only for minor misalignment. PIPING All fluid lines, either pipe, tubing or flexible hose must be of adequate size and strength to assure free flow to and from the pump. NOTE:

Do not use galvanized pipe.

Galvanized coating may flake off after continued use. The inlet line must be of proper size to prevent restriction of the fluid flow to the pump. Excessive inlet restrictions will prevent proper operation and may cause damage due to cavitation. The inlet piping must be sized to meet or exceed the minimum inlet requirements as outlined in below table II. Table II - Inlet Pressure, Minimum - as measured at pump inlet flange with petroleum base fluids. Multiply absolute pressures by multiplier shown in TABLE IV to find inlet pressures for Fire Resistant Fluids. Speed

Gauge Pressure

Absolute Pressure

PSIG

Bar

in. Hg.

mm Hg.

PSIA

Bar

1200

-3

-0.20

(-)6

(-)152

8.0

0.55

1500

-3

-0.20

(-)6

(-)152

9.0

0.62

1800

-3

-0.20

(-)6

(-)152

10.5

0.72

2500

+4.2a

+0.28a

+8.4a

212a

18.7a

1.29a

Except for pumps with 045 cam ring which are rated as follows at their 2,500 RPM max. 2500

+4.7

+0.32

+0.64

+16.2

19.2

1.32

If rigid pipe or tubing is used, the workmanship must be accurate in order to eliminate strain on the pump housing, mounting cap or end cap or the fluid connectors. Sharp bend, elbows or reducers In the lines should be eliminated or minimized whenever possible. All system piping must be cleaned with solvent or equivalent cleaning agent before connecting to the pump.

S0708485K Page 26

Main Pump (Denison)

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

Denison Fluid spec.

T6DC Continuous

T6DC Intermittent

Speed RPM

Pressur e PSI

Pressure Bar

Speed RPM

Pressur e PSI

Pressure Bar

HF-0

2,500

3,000/ 3,500

207/241

2,500

3,000/ 4,000

241/276

HF-2

2,500

172

2,500

3,000

207

Non antiwear petroleum base

HF-1

1,800

2,500

172

2,500

3,000

207

Water-in-oil emulsions

HF-3

1,800

2,000

138

1,800

2,500

172

Water Glycols

HF-4

1,800

2,000

138

1,800

2,500

172

Synthetic fluids

HF-5

1,800

2,500

172

1,800

3,000

207

Antiwear petroleum base

Non Petroleum Base or Fire Resistant Fluids When it is necessary to use these types of fluids, the T6DC pump can be used. To determine performance characteristics or ratings for a particular fluid, a Denison Sales Representative should be consulted. Operating Temperature For the most efficient pump operation, refer to below table IV. Table IV - Operating Temperature Fluid Type

Denison Spec.

Max. temp. °F

°C

Max. System Pressure PSI

Bar

Suction Pressure Multiplier

Antiwear petroleum base fluids for severe duty

HF-0

210

100

3500/4000

241/276

1.0

Antiwear petroleum base fluids

HF-2

210

100

3000

207

1.0

Non antiwear petroleum base fluids

HF-1

210

100

3000

207

1.0

Water-in-oil invert emulsions

HF-3

120

2500

172

1.25

Water glycols

HF-4

120

2500

172

1.25

synthetic fluids (Phosphate ester & others)

HF-5

160

3000

207

1.35

Main Pump (Denison)

S0708485K Page 27

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

When an inlet strainer is used, it should have a minimum capacity equal to twice the flow output of the pump.

S0708485K Page 28

Main Pump (Denison)

START-UP PROCEDURES PRE-START CHECK Before initial starting of the pump, the following checks should be made. 1.

Check the rotation of the power source to be sure the pump will rotate in the direction indicated by the arrow on the pump identification tag.

Check inlet and discharge to be sure all connections are tight and connected properly.

Check all mounting bolts and flanges to be sure they are tight and properly aligned.

When possible the rotating element or pump shaft should be rotated by hand to assume that it rotates freely.

PRIMING If the pump is installed with a positive head on the inlet, priming will be instantaneous upon start up. It is recommended that a minimum pump shaft speed of 600 RPM be obtained for priming, however, this speed will vary with different inlet and outlet conditions. When a pressure relief valve is used at the outlet, it should be backed off to the minimum setting. When possible, an air bleed off should be provided in the circuit to facilitate purging the system of air. When it is not possible or practical to provide a positive head at the pump inlet or the installation is such that a suction lift results, the following procedure is recommended. 1.

Manually fill the pump housing with fluid.

Start relation in a jogging manner until a prime is picked up.

Bleed off air that may become trapped in the pump.

To prevent possible damage to the internal parts, the pump should never be started dry or without internal lubrication. If the pump does not prime properly or pressure cannot be obtained within 15 seconds it should be shut down and condition corrected.

Main Pump (Denison)

S0708485K Page 29

S0708485K Page 30

Main Pump (Denison)

S0709250K

1BRAKE PEDAL VALVE

BRAKE PEDAL VALVES0709250K MODEL

SERIAL NUMBER RANGE

Mega 300-V (Tier I)

1001 thru 2000

Mega 300-V (Tier II)

2001 and Up

S0709250K Page 1

TABLE OF CONTENTS General Description........................................................................................ 3 Theory of Operation ................................................................................ 3 Specification............................................................................................ 4 Brake System (S/N 1001 thru 2000) .............................................................. 5 Brake System (S/N 2001 and Up) .................................................................. 6 Brake, Pilot and Fan Motor Supply Valve ....................................................... 7 Specifications (S/N 1001 thru 2000) ....................................................... 8 Specifications (S/N 2001 and Up) ........................................................... 9

S0709250K Page 2

Brake Pedal Valve

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

AJS0720L

Figure 1

Brake Pedal Valve

S0709250K 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 T2

6 BR

BR2

BR1

AJS0740L

Figure 2 Description

Reference Number

Primary Control Spool

Upper Spring

Secondary Control Spool

Main Control Spring

Lower Spring

Working Element

Reference Number

Description

SPECIFICATION

S0709250K Page 4

Item

Specification

Braking Pressure

60 ±3 kg/cm2 (835 ±43 psi)

Pedal Force

21 ±2.0 kg (46 ±4.4 lb)

Operating Angle

18.0 ±2.0°

Brake Pedal Valve

BRAKE SYSTEM (S/N 1001 THRU 2000) 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 cutoff current to a solenoid operated hydraulic valve in the transmission. This prevents operation of the forward clutch in the transmission. This prevents the transmission from driving the wheels forward when the brake pedal is pressed.

Figure 3 BRAKE HYDRAULIC CIRCUIT Reference Number

Description

Reference Number

Description

Rear Axle

Brake Valve

Transmission Cutoff Switch

Pilot Pump

Front Axle

Pilot Supply Line

Brake

Low Pressure Warning Switch

Brake Pedal

Parking Brake Valve

Stop Light Switch

Low Pressure Warning Switch

Parking Brake

Brake and Pilot Filter

Accumulators: Brake

Brake Pedal Valve

S0709250K Page 5

BRAKE SYSTEM (S/N 2001 AND UP) 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 4). Pressing the brake pedal (5) will open cutoff switch (2). When the transmission cutoff switch in the operator’s cab is selected, this will cutoff current to a solenoid operated hydraulic valve in the transmission. This prevents operation of the forward clutch in the transmission. This prevents the transmission from driving the wheels forward when the brake pedal is pressed.

BIS0180L

Figure 4 BRAKE HYDRAULIC CIRCUIT Reference Number

Description

Reference Number

Description

Rear Axle

Brake Valve

Transmission Cutoff Switch

Pilot Pump

Front Axle

Pilot Supply Line

Brake

Low Pressure Warning Switch

Brake Pedal

Parking Brake Valve

Stop Light Switch

Low Pressure Warning Switch

Parking Brake

Brake and Pilot Filter

Accumulators: Brake

S0709250K Page 6

Brake Pedal Valve

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.

AJS0750L

Figure 5 VALVE CARTRIDGE IDENTIFICATION AND PILOT LOCATION Reference Number

Description

Reference Number

Description

Body (200*120*79)

Check (C3)

Sequence (C1)

Solenoid (C4,5)

Reducing (C2)

Coil (C4,5)

Brake Pedal Valve

S0709250K Page 7

(S/N 1001 thru 2000)

AJS0760L

Figure 6 HYDRAULIC CIRCUIT

SPECIFICATIONS (S/N 1001 THRU 2000) Item Max. Operating Pressure Max. Flow

120.0 kg/cm2 (1,710 psi)

System Flow

20 lpm (5.28 gpm) C1

120 ±2 kg/cm2 @53 lpm (1,710 ±28 psi @ 14 gpm)

28 ±2 kg/cm2 @ 20 lpm (398 ±28 psi @ 5.28 gpm)

C3 Cracking Pressure Port Size

S0709250K Page 8

210.0 kg/cm2 (3,000 psi) 53.0 lpm (14 gpm)

System Pressure Setting Pressure

Specifications

2.40 kg/cm2 (34.1 psi)

FO, F1, M

PF 1/2 O-ring

TP1, TP2, LPWS, LKWS

PF 1/4 O-ring

All other ports

PF 3/8 O-ring

Brake Pedal Valve

(S/N 2002 and up)

BIS0190L

Figure 7 HYDRAULIC CIRCUIT

SPECIFICATIONS (S/N 2001 AND UP) Item Max. Operating Pressure System Pressure

120.0 kg/cm2 (1,710 psi)

System Flow

20 l/min (5.28 gpm) C1

120 ±2 kg/cm2 @53 l/min (1,710 ±28 psi @ 14 gpm)

28 ±2 kg/cm2 @ 20 l/min (398 ±28 psi @ 5.28 gpm)

C3 Cracking Pressure Port Size

Brake Pedal Valve

210.0 kg/cm2 (3,000 psi) 53.0 l/min (14 gpm)

Max. Flow

Setting Pressure

Specifications

2.40 kg/cm2 (34.1 psi)

FO, F1, M

PF 1/2 O-ring

TP1, TP2, LPWS, LKWS

PF 1/4 O-ring

All other ports

PF 3/8 O-ring

S0709250K Page 9

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Brake Pedal Valve

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S0709456K

1MAIN CONTROL VALVE (TOSHIBA) 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.

MAIN CONTROL VALVE (TOSHIBA)S0709456K MODEL

SERIAL NUMBER RANGE

Mega 250-V (Tier I)

1001 thru 2000

Mega 250-V (Tier II)

2001 and Up

Mega 300-V (Tier I)

1001 thru 2000

Mega 300-V (Tier II)

2001 and Up

S0709456K Page 1

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TABLE OF CONTENTS General Description........................................................................................ 3 Specifications ................................................................................................. 5 Operation........................................................................................................ 6 Neutral..................................................................................................... 6 Bucket/option Spool Operation................................................................ 6 Boom Spool Operation............................................................................ 7 Boom Float....................................................................................... 7 Relief Valve ............................................................................................. 7 Main Relief Valve ............................................................................. 7 Port Relief Valve............................................................................... 7 Operation (Main Relief Valve) ................................................................. 8 Operation in Inoperative State ......................................................... 8 Operation (A) ................................................................................... 8 Operation (B) ................................................................................... 8 Operation (Port Relief Valve)................................................................... 9 In the Inoperative State.................................................................... 9 Operation (A) ................................................................................... 9 Operation (B) ................................................................................... 9 Operation (C) ................................................................................. 10 Sucking Operation ......................................................................... 10

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Main Control Valve (Toshiba)

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GENERAL DESCRIPTION The main control valve controls the operation of the bucket, boom, and option cylinders. The bucket spool has priority over the boom spool. Pump output flows to port P on the main control valve.See Figure 1. Maximum pressure is prevented from exceeding the desired level by the main relief valve (1). See hydraulic schematic (Figure 2). When all spools on the main control valve are in the neutral position (when the pilot valve is not being operated), oil passes through port P, the bucket spool, the boom spool, the option spool, and passes out T, the tank port. Oil that passes out the tank port passes through a filter and returns to tank. Two overload relief valve (2) are installed in the bucket circuit to protect circuit components in the event of abnormally high pressure. One valve works as a relief valve while the other valve works as an anticavitation valve to provide additional oil flow to the opposite side of the bucket cylinders. Boom spool has two important roles in loader work at the floating position. One is that it is possible to lower the boom by its weight without oil supply from the pump, and that, at the same time, the oil from the pump makes it possible to combine with the bucket crowd at the max. height of bucket through the bucket line. Another is that boom and bucket are positioned at the level as the cylinder ports A and B are open as a leveling function of ground. There is a suction check valve (3) in the boom power port. When the boom is dropped suddenly by its weight, the cylinder bottom has a cavitation with a lack of oil supply. The check valve supplements oil to prevent the cavitation.

AMS0330L

Figure 1

Main Control Valve (Toshiba)

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AJS0660L

Figure 2 CONTROL VALVE HYDRAULIC CIRReference Number

Description

Reference Number

Option Valve Port

Bucket Crowd Valve Port

Option Cylinder Port (to Option Cylinder Tube)

Boom Down Valve Port

Bucket Dump Port (to Bucket Cylinder Rod)

Boom Up Port (to Boom Cylinder Tube)

Option Valve Port

Bucket Dump Valve Port

Boom Up Valve Port

Float Valve Port

Bucket Crowd Port (to Bucket Cylinder Tube)

(1)

Main Relief Valve

Boom Lower Port (to Boom Cylinder Rod)

S0709456K Page 4

Description

Pump Port

Tank Port

Option Cylinder Port (to Option Cylinder Rod)

(2)

Overload Relief Valve

(3)

Anticavitation Check Valve

Main Control Valve (Toshiba)

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SPECIFICATIONS

Name Type

2-Spool (STD.)

3-Spool (OPT.)

WA28D4F1-51

WA28D5F2D5-52

Pilot Control with Float spool ∅ 28 mm (1.10 in)

Spool Diameter Spool Arrangement

Bucket - Boom

Bucket - Boom - Auxiliary

Main relief pressure

200 kg/cm @ 160 liters/min (2,840 psi @ 42.24 gpm)

Overload relief pressure

240 kg/cm2 @ 30 liters/min (3,400 psi @ 7.92 gpm)

Main Control Valve (Toshiba)

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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 Number

Description

Reference Number

Description

Load Check

Tank Passage

Port A1

Center By-pass Passage

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.

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Main Control Valve (Toshiba)

Return to Master Table of Contents BOOM SPOOL OPERATION Boom Float

Figure 4 OPERATION IN BOOM FLOAT

Reference Number

Description

Reference Number

Description

Port A2

Center By-pass Passage

Port B2

Tank Passage

When the control lever is pushed further down from the "Down" position to the "Float" position, the boom spool moves as indicated in the illustration. Due to this motion the neutral passage is opened. The pressure oil flows as if in neutral position. The cylinder ports (A2) and (B2) are connected to the low pressure oil passage. As a result, the boom floats over the ground surface according to the contour of the ground. The oil discharged from the boom cylinder rod side is sent to the tail side and the oil forced out from its tail side is sent to the rod side respectively through the low-pressure oil passage in the control valve. RELIEF VALVE Main Relief Valve The main relief valve is 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.

Main Control Valve (Toshiba)

S0709456K Page 7

Return to Master Table of Contents 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)

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Main Control Valve (Toshiba)

Return to Master Table of Contents 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)

Main Control Valve (Toshiba)

S0709456K Page 9

Return to Master Table of Contents 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

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Main Control Valve (Toshiba)

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S0709477K

1PILOT CONTROL VALVE CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that is in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility.

PILOT CONTROL VALVES0709477K MODEL

SERIAL NUMBER RANGE

Mega 300-V (Tier I)

1001 thru 2000

Mega 300-V (Tier II)

2001 and Up

S0709477K Page 1

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TABLE OF CONTENTS General Description (S/N 1001 thru 2000)..................................................... 3 Pilot Valve Operation............................................................................... 3 General Description (S/N 2001 and up) ......................................................... 5 Pilot Valve Operation............................................................................... 5 Standard.................................................................................................. 6 Option...................................................................................................... 8 Pilot System ................................................................................................. 10

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Pilot Control Valve

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GENERAL DESCRIPTION (S/N 1001 THRU 2000) When no force is applied to the lever (1, Figure 1), the return spring (4) positions the lever at the "NEUTRAL" position. When the lever is moved, plunger (5) is moved, which pushes down the return spring (4). At the same time, spool (2) is moved by spring (3). When spool (2) moves down, a groove (6) in the spool opens the pilot pressure line to the line that the lever controls. This allows the pilot pressure to flow to the boom or bucket control valve, where the pilot pressure operates the control valve. When the lever is completely moved in one direction, the solenoid (7) energizes the electromagnet (8) and holds the lever in the fully moved position. PILOT VALVE OPERATION The lever handle is positioned on the right side of the operator’s seat. This single lever controls the following machine functions: raise boom, lower boom, bucket crowd, and bucket dump. The lever positions are identified as follows: F-Float L-Lower N-Neutral R-Raise H-Hold Position C-Bucket Crowd D-Bucket Dump HR-Holds lever in Raise Mode.

Pilot Control Valve

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Figure 1 Reference Number

Description

Reference Number

Description

Lever

Plunger

Valve Spool

Spool Groove

Regulating Spring

Solenoid

Return Spring

Electro-magnet

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Pilot Control Valve

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GENERAL DESCRIPTION (S/N 2001 AND UP) When no force is applied to the lever (33, Figure 2), the return spring (4) positions the lever at the "NEUTRAL" position. When the lever is moved, plunger (5) is moved, which pushes down the return spring (4). At the same time, spool (2) is moved by spring (3). When spool (2) moves down, a groove (6) in the spool opens the pilot pressure line to the line that the lever controls. This allows the pilot pressure to flow to the boom or bucket control valve, where the pilot pressure operates the control valve. When the lever is completely moved in one direction, the solenoid (7) energizes the electromagnet (8) and holds the lever in the fully moved position. PILOT VALVE OPERATION The lever handle is positioned on the right side of the operator’s seat. This single lever controls the following machine functions: raise boom, lower boom, bucket crowd, and bucket dump. The lever positions are identified as follows: F-Float L-Lower N-Neutral R-Raise H-Hold Position C-Bucket Crowd D-Bucket Dump HR-Holds lever in Raise Mode.

Pilot Control Valve

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33 29

25 31 27 20

26 28

15 21 19 9

7 22

6 3

BAS0130L

Figure 2

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Pilot Control Valve

Return to Master Table of Contents Reference Number

Description

Reference Number

Description

Body

Plate

O-ring

Washer

Plug

Nut

Spring

Plug

Spring Seat

Nut

Spool

Set Screw

Spring Seat

Nut

Spring

Nut

Stopper

Connector

Plug

Nut

Rod Seal

Boot

O-ring

Handle Ass’y

Push Rod

Spring Pin

Plate

Plug

Rod Stopper

Housing

Du Bushing

Holder Rear

Rod

Terminal

Magnet

Seal Wire

Plate

Housing

Joint Ass’y

Holder Rear

Joint Ass’y

Clip Band

Pilot Control Valve

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4 5 1

9 2

7 11 6 10

12 13

14 15 16 15

BAS0200S

Figure 3

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Pilot Control Valve

Return to Master Table of Contents Reference Number

Description

Reference Number

Description

Main Handle Assembly

Main Handle U Joint

Handle Nut

7mm Cable Clamp

Handle Mounting Plate

Plunger

Button Red

Plunger

Button Grey

Capsule Assembly

Auxilliary Handle Assembly

Capsule Assembly

Boot

Capsule Assembly

Mounting Capscrews

Block

Cable Assembly

Pilot Control Valve

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PILOT SYSTEM The pilot system uses low pressure oil to operate the main control valves. The main components of the pilot system are pump (1), pressure reducing valve (3), accumulator (4), pilot cutoff valve (5) and pilot valves (6 and 7). With the engine running, oil flows from hydraulic tank to pilot pump (1) The oil flows from the pump through pressure reducing valve (3) to pilot cutoff valve (5). The pressure reducing valve maintains pilot system pressure at 28 kg/cm2 (398 psi). From the pilot cutoff valve the oil flows into the pilot control valves. Pilot valve (6) is a closed center valve. The oil cannot flow through the valve when it is in the HOLD position because it is a closed center valve. When the control lever is moved to the DUMP position, oil flows through oil lines to the ends of the bucket spool of main control valve (8). This causes the main control valve spool to move. Movement of the spool opens passages for attachment pressure oil to flow to the rod end of the bucket cylinder (9). Spool movement also opens a passage for return oil from the head end of the bucket cylinder to flow back to hydraulic tank. Attachment pressure oil acts on the rod end of the bucket cylinder and, because the head end of the cylinder is now vented to tank, the bucket will dump. When the control lever is moved to the CROWD position, oil flows through oil lines to the ends of the bucket spool of main control valve (8). This causes the main control valve spool to move in the opposite direction. Movement of the spool in this direction opens passages for pressure oil to flow to the head end of the tilt cylinder. Spool movement also opens a passage for return oil from the rod end of the tilt cylinder to flow back to the hydraulic tank. Attachment pressure oil acts on head end of the tilt cylinder and because the rod end of the cylinder is now vented to tank, the bucket will crowd.

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Pilot Control Valve

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AMS0340L

Figure 4 Description

Reference Number

Pilot Pump

Pilot Valve (Mono, STD.)

Brake and Pilot Filer

Pilot Valve (Two Lever, OPT.)

Pressure Reducing Valve

Main Control Valve

Accumulator: Pilot

Bucket Cylinder

Pilot Cutoff Valve

Boom Cylinder

Reference Number

Pilot Control Valve

Description

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Pilot Control Valve

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S0709651K

1PRIORITY VALVE (DANFOSS) 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.

PRIORITY VALVE (DANFOSS)S0709651K MODEL

SERIAL NUMBER RANGE

Mega 300-V (Tier I)

1001 thru 2000

Mega 300-V (Tier II)

2001 and Up

S0709651K Page 1

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TABLE OF CONTENTS General Description........................................................................................ 4 Theory of Operation ................................................................................ 4 Parts List ................................................................................................. 5 Specifications .......................................................................................... 6 Disassembly ................................................................................................... 6 Reassembly.................................................................................................... 9

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Priority Valve (Danfoss)

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Priority Valve (Danfoss)

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

Figure 1

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Priority Valve (Danfoss)

Return to Master Table of Contents Reference Number

Description

Reference Number

Description

Spool

Steering Supply Port

Spring

Loader Supply Port

Pressure Port

Pilot Port

Reference Number

Description

Reference Number

Description

Plug PP

Spring [7 bar (100 psi)]

O-ring

Plug LS

Spool

Orifice

Housing

PARTS LIST

Figure 1

Priority Valve (Danfoss)

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Return to Master Table of Contents SPECIFICATIONS Priority Valve

Specification

Control Pressure

7.0 kg/cm2 (100 psi)

Rated Flow

160 lpm (42 gpm)

DISASSEMBLY 1.

The following tools are necessary to repair the priority valve. See Figure 2. Open end wrench - 27 mm Slip joint pliers Nylon rod Allen wrenches - 5 mm, 8 mm, 10 mm

Figure 2 2.

Use the open end wrench to loosen the PP plug. See Figure 3.

Remove the O-ring.

Use the open end wrench to loosen the LS plug. See Figure 4.

Remove the O-ring.

Figure 3

Figure 4

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Priority Valve (Danfoss)

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Remove the spring. See Figure 5.

Use a nylon rod to push the spool out of the bore. See Figure 6.

Figure 5

Figure 6 8.

Use an 8 mm allen wrench to remove the plug from the pressure relief valve. See Figure 7.

Figure 7 9.

Use a 10 mm allen wrench to unthread the pressure relief valve from its bore. See Figure 8.

Figure 8

Priority Valve (Danfoss)

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Hold the pressure relief valve with a pliers and use a 5 mm allen wrench to remove the set screw. See Figure 9.

11.

The pressure relief valve is composed of a valve housing, valve needle, spring, and set screw. See Figure 10.

12.

Clean all parts with a nonflammable, nontoxic solvent.

13.

Carefully inspect all parts. Replace all worn or broken parts. Use only new Orings to assemble the valve.

14.

Coat all parts with oil before assembling them.

Figure 9

Figure 10

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Priority Valve (Danfoss)

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REASSEMBLY 1.

The relief valve pressure can be changed by changing springs. The following table displays the characteristics of the 3 springs available. See Figure 11.

Figure 11

Pressure

Wire Diameter (d)

Coil Inner Diameter (Di)

Spring Height (H)

4 bar (60 psi)

2.5 mm (0.0984")

12.5 mm (0.492")

50 mm (1.968 in)

7 bar (100 psi)

3.0 mm (0.1181")

12.5 mm (0.492")

50 mm (1.968 in)

10 bar (145 psi)

3.2 mm (0.1259")

12.5 mm (0.492")

50 mm (1.968 in)

Figure 12 shows the PP plug and the spool.

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

Figure 12

Figure 13

Priority Valve (Danfoss)

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Install the spring and the LS plug into the bore. See Figure 14. Use a new O-ring on the plug.

Use the 27 mm wrench to tighten the PP plug and the LS plug to 6 kg•m (43 ft lb). See Figure 15.

Figure 14

Figure 15 6.

Assemble the valve needle, spring, and set screw into the pressure relief valve housing. See Figure 10.

Thread the pressure relief valve into the body of the priority valve and tighten it. See Figure 16.

Figure 16 8.

Install the plug into the pressure relief valve bore. Tighten the plug to 5 kg•m (36 ft lb). See Figure 17.

Figure 17

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Priority Valve (Danfoss)

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S0709730K R1

1POWER STEERING UNIT CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that is in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility.

POWER STEERING UNITS0709730K MODEL

SERIAL NUMBER RANGE

Mega 300-V (Tier I)

1001 thru 2000

Mega 300-V (Tier II)

2001 and Up

Mega 400-V

1001 and Up

Mega 500-V

1001 thru 2000

Mega 500-V (Tier II)

2001 and Up

S0709730K Page 1

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

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Power Steering Unit

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GENERAL DESCRIPTION POWER STEERING SYSTEM Power Steering Unit. The machine contains a fully hydraulic steering unit. See Figure 1. Rotating the steering wheel controls hydraulic flow through the steering valve. Figure 2, shows the hydraulic schematic for the steering system. The steering valve meters the volume of pump flow that is supplied to the steering cylinders Reference Number

Description

Bearing

Centering Springs

Sleeve

Center Pin

Check Valve

Gerotor

End Cap

Spool

Drive Shaft

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 wheel will cause the gerotor to draw oil from the hydraulic tank and send this oil to the steering cylinders.

Figure 1

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).

Power Steering Unit

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AJS0700L

Figure 2 STEERING CIRCUIT Reference Number

Description

Reference Number

Description

Steering Unit

Valve block

Priority Valve

Steer Pump

Steering Cylinder

Cushion Valve

Supply Line to Main Control Valve

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Power Steering Unit

Return to Master Table of Contents Neutral Operation With the steering wheel in the neutral position (wheels turned neither right nor left), the spool (2, Figure 3) and sleeve (1) are stationary at the position where the center pin (6) becomes centered in the spool space by the centering springs (3). Oil flow through the load sensing line (LS), port L, port R, and port T are bypassed to the tank line and the oil supply (P) is blocked by the directional spool in the steering unit (1, Figure 2). Even if an external force is applied to the steering cylinder, the steering unit is protected because the oil path is blocked by the directional spool. Reference Number

Description

Sleeve

Spool

Centering Spring

Spool

Sleeve

Center Pin

Drive shaft Figure 3

Right Turn The spool (2, Figure 3) is engaged with the spline of the steering shaft. When the steering wheel is turned to the right, the spool turns. The sleeve (1) is connected to the spool (2) by centering springs (3). When spool turns, the sleeve turns. The sleeve turning angle is about 10° less than the spool turning angle. This allows the longitudinal slots in the spool to align with the ports in the sleeve. Oil from port P on the steering unit (1, Figure 2) travels through the control spool and is directed to port R which directs the oil to the steering cylinders (3, Figure 2). The amount of flow metered to port R is controlled by the amount of steering wheel rotation. Excess oil flow through port P that is not metered to port R, is directed by the spool to port T and is then directed through the il cooler and into the tank. Left Turn The spool (2, Figure 3) is engaged with the spline of the steering shaft. When the steering wheel is connected to the spool (2) by centering springs (3). When the spool turns, the sleeve turns. The sleeve turning angle is about 10° less than the spool turning angle. This allows the longitudinal slots in the spool to align with the ports in the sleeve. When the steering wheel is turned to the left, oil from port P on the steering unit (1, Figure 2) is directed through the control spool in the steering unit, out port L and into the steering cylinders (3, Figure 2). The amount of oil flow metered to port L is controlled by the amount of steering wheel rotation. Excess oil flow through port P that is not metered to port L, is directed by the spool to port T and is then directed through the oil cooler and into the tank. GEROTOR OPERATION If the engine or pump is not operating, the steering unit (1, Figure 2) works as a manual pump when the steering wheel is turned. The gerotor will work when the input torque to the steering wheel is less than 12 kg•m (87 ft lb). If the necessary input torque is greater than this, the gerotor will not function. When the steering wheel is turned, the gerotor creates a vacuum that draws oil from port T. See Figure 2. The gerotor pumps this oil through the control spool and into the steering cylinders. Return oil flows back to the spool and is used to lubricate the steering unit (1, Figure 2). The return oil then flows back into the tank line and is recirculated back to the gerotor and the steering cylinders.

Power Steering Unit

S0709730K Page 5

Return to Master Table of Contents CUSHION VALVE OPERATION Function The cushion valve absorbs any excessive peak pressure that my be generated during initial movement of the steering wheel or during a change in steering direction. The cushion valve also prevents excessive high pressure and shock that can result from steering load inertia. Working Principle If a high pressure oil is fed back to port R, it pushes spring (3) and opens poppet (2). This operation directs the high pressure oil to port L through the center hole in spool (12) and the check valve poppet in port L part. At the same time, oil reaches the pressure room of the plug through orifice (8). This operation closes the passage from port R to port L. This releases the pressure and prevents machine shock by intercepting oil. If a low pressure oil flows, the cushion operation is not necessary. It is due to the speed of closing spool (12) is faster than the speed of opening poppet (2), therefore, the cushion valve does not work.

Figure 4

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Power Steering Unit

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Power Steering Unit

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Return to Master Table of Contents PARTS LIST An exploded view of the steering unit is shown in Figure 5.

Figure 5

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Power Steering Unit

Return to Master Table of Contents Reference Number

Description

Reference Number

Seal Ring

Housing

Spacer - 25 mm (If equipped)

Spool

Sleeve

Spacer Bushing (If equipped)

Ball

O-ring 80.5 x 1.5 mm

Threaded Bushing

Middle Plate

O-ring

Distributor Plate

Backing Ring (If equipped)

Thrust Washers

Thrust Bearing

Spacer Ring

Cross Pin

Neutral Springs

Shaft

Spacer - 13.8 mm (If equipped)

Description

Rotor

O-ring - 79.92 x 1.78 mm

Cylinder Gear

End Cover

Washer

Roll Pin 2.5 x 32 mm

Bolt

SPECIFICATIONS Specification Steering Unit Type Gerotor Displacement

Power Steering Unit

Mega 300-V

Mega 400-V

Mega 500-V Mega 500-V (Tier II)

Load Sensing, Dynamic Signal, Nonreaction 1,000 cc/rev (61 in3/rev)

200 cc/rev (12.2 in3/rev)

315 cc/rev (19.2 in3/rev)

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SPECIAL TOOLS The tools necessary for steering unit repair are illustrated below. 1.

Stabilizing base. See Figure 6.

Figure 6 2.

O-ring assembly tool. See Figure 7.

Seal driver. See Figure 8.

Figure 7

Figure 8

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Power Steering Unit

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

Figure 9

Power Steering Unit

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TROUBLESHOOTING, TESTING AND ADJUSTMENT Problem

Cause

Steering wheel does not operate smoothly

Broken or damaged oil pump.

Steering wheel has a heavy feel.

Difficult to drive in a straight line

Noise during steering Steering system leaking oil

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Remedy Replace pump.

Stuck or damaged relief valve.

Repair or replace.

Stuck, damaged or worn out steering valve.

Clean, repair or replace.

Restricted hose or pipe. Leaking or restricted hose, pipe, or connection.

Clean, repair or replace.

Mechanical defect in steering gear.

Repair or replace.

Oil level low in reservoir.

Add oil.

Low oil pressure due to broken or damaged oil pump.

Replace 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 steering gearbox.

Replace damaged parts.

Defective spool in steering valve.

Tighten lock nut.

Stuck or damaged steering valve or damaged or defective spring.

Repair or replace.

Improper fit of track line.

Repair or replace.

Low oil level in reservoir.

Add oil.

Restricted inlet pipe or filter.

Clean or replace

Worn or damaged O-ring and oil seal of pipe and steering valve.

Replace worn or damaged parts.

Power Steering Unit

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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.

Remove bolts from steering unit end cover. See Figure 10.

Remove end cover from unit. See Figure 11.

Lift cylinder gear off unit. See Figure 12. Remove two O-rings.

Figure 10

Figure 11

Figure 12

Power Steering Unit

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Remove spacer bushing and spacer from cylinder gear (If equipped). See Figure 13. NOTE:

Refer to parts manual for our unit to determine if these parts are installed.

Figure 13 6.

Remove shaft from housing. See Figure 14.

Remove distributor plate from housing. See Figure 15.

Remove O-ring from top of middle plate. See Figure 16.

Figure 14

Figure 15

Figure 16

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Lift middle plate off housing. See Figure 17.

10.

Remove O-ring from housing. See Figure 18.

11.

Unscrew threaded bushing and remove it. See Figure 19.

12.

Remove cross pin. See Figure 20.

Figure 17

Figure 18

Figure 19

Figure 20

Power Steering Unit

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Shake ball out of housing. See Figure 21.

14.

Pull sleeve and spool out of housing. See Figure 22.

15.

Remove thrust bearing and thrust washers from sleeve. See Figure 23. Remove spacer ring. Be sure to remove spacer ring. It can stick in sleeve.

16.

Carefully slide control spool out of sleeve. See Figure 24.

Figure 21

Figure 22

Figure 23

Figure 24

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Push neutral position springs out of groove in spool. See Figure 25.

18.

Remove dust seal from housing. See Figure 26. Remove O-ring and backup ring from inside housing.

19.

Figure 27, shows all parts removed from steering unit. Clean all parts before assembly. Use only new O-rings and seals.

Figure 25

Figure 26

Figure 27

CLEANING AND INSPECTION For general cleaning and inspection procedures, refer to "General Maintenance Procedures" section.

Power Steering Unit

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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)

Install springs in spool slot. See Figure 28. Springs must be positioned as shown in Figure 29.

Figure 28

Figure 29 2.

Position springs so that amount of spring protruding out of spool is equal on both sides. See Figure 30.

Figure 30

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

Figure 31

Figure 32 4.

Center springs in sleeve. See Figure 33.

Figure 33

Power Steering Unit

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Install seal ring on sleeve. See Figure 34. Burnish seal ring with a smooth object until seal does not protrude past diameter of sleeve.

Figure 34 6.

Rotate seal ring. See Figure 35. It must rotate freely without resistance.

Figure 35 7.

Turn sleeve 180°. Install cross pin into sleeve and spool. See Figure 36.

Figure 36

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Install two thrust washers and thrust bearing over end of spool. See Figure 37. The sequence of the parts installation is shown in Figure 38.

Figure 37 Reference Number

Description

Thrust Washer

Thrust Bearing

Thrust Washer

Spool

Sleeve

Figure 38 9.

Oil O-ring and backup ring and then install them on an O-ring assembly tool. See Figure 39.

Figure 39

Power Steering Unit

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Insert assembly tool down into bore of steering unit. See Figure 40.

Figure 40 11.

Use assembly tool to install O-ring and backup ring into bore. See Figure 41.

12.

Unbolt housing from stabilizing base. Hold housing in a horizontal position. See Figure 42. Insert sleeve and spool into bore.

Figure 41

Figure 42

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The sleeve will push the O-ring and backup ring into correct position. See Figure 43.

Figure 43 14.

Bolt housing back into stabilizing base. See Figure 44.

15.

Insert ball into hole. See Figure 45.

Figure 44

Figure 45

Power Steering Unit

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Install threaded bushing into hole that ball was placed into. See Figure 46. Lightly tighten bushing. The top of the bushing must be lower than the surface of housing.

17.

Lubricate O-ring with 20 weight mineral oil and install it in groove. See Figure 47.

18.

Install middle plate onto housing. See Figure 48. Be sure to properly align plate holes with holes in housing.

19.

Lubricate O-ring with 20 weight mineral oil and install it in groove. See Figure 49.

Figure 46

Figure 47

Figure 48

Figure 49

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Install distributor plate. See Figure 50. Be sure to properly align plate holes with holes in middle plate.

21.

Install shaft into bore of housing. See Figure 51. Position slot in shaft to engage cross pin.

22.

Position rotor so that cross pin is between two teeth as shown by position of screwdriver. See Figure 52.

Figure 50

Figure 51

Figure 52

Power Steering Unit

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Lubricate two O-rings with 20 weight mineral oil and install them in grooves of cylinder gear. Slide cylinder gear into position on housing. See Figure 53.

24.

Use a bolt to align holes in cylinder gear with bolt holes in housing. See Figure 54.

Figure 53

Figure 54 25.

Install spacer bushing. See Figure 55. Remove bolt that was installed in previous step (If equipped.). OSPL 630:1 = 3.80 mm (0.1496 in) (15, Figure 5) OSPL 800 (16, Figure 5) OSPL 1000 (16, Figure 5) NOTE:

Refer to parts manual for our unit to determine if these parts are installed. Figure 55

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Power Steering Unit

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Use a screwdriver to install OSPL 800 and 1000 spacers (If equipped.). See Figure 56. NOTE:

Refer to parts manual for our unit to determine if these parts are installed.

Figure 56 27.

Install end cover. See Figure 57.

28.

Install a washer and roll pin into hole shown in Figure 58.

29.

Install six remaining bolts and tighten them. See Figure 59. Cross tighten bolts and roll pin to 48.1 N•m (35 ft lb).

Figure 57

Figure 58

Figure 59

Power Steering Unit

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Turn steering unit over and work from opposite side. Set dust seal in position on housing. See Figure 60.

31.

Use a seal driver and a plastic hammer to install dust seal. See Figure 61.

32.

Install plastic plugs to prevent dirt from entering steering unit. See Figure 62.

Figure 60

Figure 61

Figure 62

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Figure 63, shows port identification for steering unit. L = Left pressure port. R = Right pressure port T = Tank port P = Pressure from pump.

Figure 63

INSTALLATION The following table shows torque specifications for hydraulic fittings used to install steering unit. Tightening Torque kg•m (ft lb) Type of

1/4 RG

1/2 RG

Screw Fitting

1/4 BSP.F

1/2 BSP.F

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

Power Steering Unit

7/16-20UNF

2 (15)

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Power Steering Unit

S0709751K R1

1RESTRICTION VALVE

RESTRICTION VALVES0709751K MODEL

SERIAL NUMBER RANGE

Mega 300-V (Tier I)

1001 thru 2000

Mega 300-V (Tier II)

2001 and Up

S0709751K Page 1

TABLE OF CONTENTS General Description........................................................................................ 3 Theory of Operation ................................................................................ 3 UNLOADING CIRCUIT (S/N 1001 thru 2000)......................................... 4 UNLOADING CIRCUIT (S/N 2001 and Up) ............................................ 5 Unloader Cartridge Identification (S/N 1001 thru 2000).......................... 6 Unloader Cartridge Identification (S/N 2001 and Up) ............................. 7 Specifications .......................................................................................... 8

S0709751K Page 2

Restriction Valve

GENERAL DESCRIPTION THEORY OF OPERATION The restriction valve is made up of four bypass check valve C1, C2, C3, and C4. Output from the steering pump passes through the priority valve that is part of the steering cylinder. See the hydraulic schematic. (Figure 1 or Figure 2). This flow then passes out of the steering cylinder and enters the restriction valve at port EF. This allows output from the steering pump to join flow from the main pump to supply the boom, bucket, and option control valves.

Restriction Valve

S0709751K Page 3

UNLOADING CIRCUIT (S/N 1001 THRU 2000)

to OIL COOLER to TANK

PUMP to OIL COOLER to CONTROL VALVE

79.5 cm3/rev 169 l/min

to OIL COOLER

70.3 cm/rev

148 l/min

to OIL COOLER

19.6 cm3/rev 41 l/min

(from CONTROL V/V)

UNLOADER VALVE

PRIORITY VALVE

BIS0200L

Figure 1

S0709751K Page 4

Restriction Valve

UNLOADING CIRCUIT (S/N 2001 AND UP)

to OIL COOLER to TANK

PUMP to OIL COOLER to CONTROL VALVE

79.5 cm3/rev 169 l/min

to OIL COOLER

70.3 cm/rev

148 l/min

to OIL COOLER

19.6 cm3/rev 41 l/min

(from 'T' PORT of ORBITROL) (from CONTROL V/V)

UNLOADER VALVE

OIL COOLER PRIORITY VALVE

FAN MOTOR

BIS0210L

Figure 2 Valve

Restriction Valve

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UNLOADER CARTRIDGE IDENTIFICATION (S/N 1001 THRU 2000)

AMS0530L

Figure 3 VALVE CARTRIDGE IDENTIFICATION (S/N 1001 thru 2000)

Reference Number

Description

Remark

Body

125× 99× 184

Sub Block

125× 99× 79

Check Valve

Floating Body

HrC30 ~ 35

Poppet

HrC38 ~ 45

Guide

Hex. Nut

Spring

O-ring

Backup Ring

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Restriction Valve

UNLOADER CARTRIDGE IDENTIFICATION (S/N 2001 AND UP)

BIS0020L

Figure 4 VALVE CARTRIDGE IDENTIFICATION (S/N 2001 and Up)

Reference Number

Description

Remark

Body

125× 99× 263

Hex Plug

O-ring

Hex Plug

O-ring

Restriction Valve

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SPECIFICATIONS Item

Specification

Maximum Rated Pressure

210 bar (3,050 psi)

Rated Flow Ports to P1

170 l/min (44.88 gpm)

Rated Flow Ports to P3

320 l/min (84.48 gpm)

Rated Flow Ports to R1, R2

520 l/min (137.28 gpm)

Rated Flow Ports to C

100 l/min (26.40 gpm)

2 ±0.2 Bar (29 ±3 psi) Cracking Pressure

C2, 3, 4

0.7 ~ 2 Bar (10 - 29 psi)

Setting Pressure

Port Size

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2" SAE Flange Port (M12, 1.75)

1-1/2" SAE Flange Port (M12, 1.75)

P1, P3

1-1/4" SAE Flange Port (M12, 1.75)

HT, EF

3/4" PF O-ring

TPM

1/4" PF O-ring

1/4" PF O-ring (Supplied Plugged)

1" PF O-ring

Restriction Valve

S0793070K R1

1HYDRAULIC SCHEMATIC (MEGA 300-V) CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that is in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility.

HYDRAULIC SCHEMATIC (MEGA 300-V)S0793070K MODEL

SERIAL NUMBER RANGE

Mega 300-V (Tier I)

1001 thru 2000

Mega 300-V (Tier II)

2001 and Up

S0793070K Page 1

TABLE OF CONTENTS General Description........................................................................................ 3 Mega 300-V (Tier I) (S/N 1001 thru 2000) ..................................................... 4 Mega 300-V (Tier II) (S/N 2001 and Up) ........................................................ 6

S0793070K Page 2

Hydraulic Schematic (Mega 300-V)

GENERAL DESCRIPTION Schematic(s) presented in this section are laid out on facing pages. An overlapping edge has been taken into consideration so that a photocopy can be made and pasted together to make a complete schematic.

Figure 1

Hydraulic Schematic (Mega 300-V)

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

Figure 2 (S/N 1001 thru 2000)

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Hydraulic Schematic (Mega 300-V)

* OPTIONAL EQUIPMENT

MEGA 300-V BIS0030L

Hydraulic Schematic (Mega 300-V)

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MEGA 300-V (TIER II) (S/N 2001 AND UP)

Figure 3 (S/N 2001 and Up)

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Hydraulic Schematic (Mega 300-V)

MEGA 300-V BIS0160L

Hydraulic Schematic (Mega 300-V)

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Hydraulic Schematic (Mega 300-V)

1ELECTRICAL SYSTEM

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S0802200K R1

1ELECTRICAL SYSTEM

ELECTRICAL SYSTEMS0802200K MODEL

SERIAL NUMBER RANGE

Mega 300-V (Tier I)

1001 thru 2000

Mega 300-V (Tier II)

2001 and Up

S0802200K Page 1

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TABLE OF CONTENTS Overview ........................................................................................................ 4 Electric Wire Color ........................................................................... 4 Electric Supply System .................................................................................. 6 Engine Starting Circuit ................................................................................... 8 Operation During Start Process .............................................................. 8 Operation After Start Process ............................................................... 10 Engine Preheating System (S/N 1001 thru 2000) ........................................ 12 Principle of Operation............................................................................ 12 Engine Preheating System (S/N 2001 and Up)............................................ 14 Principle Of Operation........................................................................... 14 Engine Stop System..................................................................................... 16 Operation In Engine Running Mode...................................................... 16 Operation In Engine Stop Mode............................................................ 18 Charging System.......................................................................................... 20 Monitoring System ....................................................................................... 21 Monitoring System (S/N 1001 thru 2000).............................................. 21 Instrument Panel (S/N 1001 thru 2000) ................................................ 22 Function Check (S/N 1001 thru 2000)................................................... 23 Monitoring System Schematic (S/N 1001 thru 2000)............................ 24 Monitoring System (S/N 2001 and Up) ................................................. 26 Instrument Panel (S/N 2001 and Up) .................................................... 27 Function Check (S/N 2001 and Up) ...................................................... 28 Monitoring System Schematic (S/N 2001 and Up) ............................... 28 Operation .............................................................................................. 30 Instruments .................................................................................... 30 Pilot Lights ..................................................................................... 31 Initial Operation.............................................................................. 33 Control Unit Operation ................................................................... 34 Characteristic of Operation ............................................................ 35 Windshield Wiper ......................................................................................... 36

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Electrical System

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

Electrical System

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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 the air-conditioning control actuator. The system contains two 12 volt batteries connected in series and a three phase AC generator with a rectifier. The electric wiring used in the system is easily identifiable by the insulator color. The color symbols used in the electrical system are listed in the following chart. Electric Wire Color Symbol

Color

Symbol

Color

White

Red

Green

Gray

Orange

Pink

Black

Yellow

Blue

Brown

Light Green

Violet

NOTE:

RW: Red wire with White stripe. R - Base Color, W - Stripe Color.

NOTE:

S0802200K Page 4

0.85G: Nominal sectional area of wire core less insulator = 0.85 mm2 (0.03 in2).

Electrical System

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Electrical System

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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 (back up for car stereo memory)

"B" terminal of starter switch and No. 22 terminal of air conditioner control panel.

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.

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Electrical System

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AMS0010L

Figure 1 Reference Number

Description

Reference Number

Description

Battery

Starter Switch

Battery Relay

Fuse Box

Fusible Link

Alternator

Circuit Breaker

Diode

Electrical System

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

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Electrical System

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AMS0020L

Figure 2 STARTER CIRCUIT (1) - WHILE STARTING Reference Number

Description

Reference Number

Description

Battery

Starter Relay

Battery Relay

Starter

Fusible Link

Alternator

Circuit Breaker

Transmission Selector Switch

Starter Switch

Diode

Fuse Box

Transmission Controller

Starter Controller

Safety Starter Relay

Electrical System

S0802200K Page 9

Return to Master Table of Contents OPERATION AFTER START PROCESS Once the engine has been started, the belt driven alternator (10) generates a current. The output generated by the alternator is a square wave pulse voltage through the "P" terminal and the frequency of the pulse voltage is proportional to the rotation of the alternator. The starter controller (7) monitors the frequency of the output current. Once the frequency equivalent to 500 rpm is sensed the connection between "S" and "E" terminals and the connection between "B" and "PP" terminals are opened. As a result the rotation of the starter (9) is stopped. Once the engine is running, the starter (9) will not operate even if the starter switch (5) is moved to the start position, preventing possible damage to the starter (9).

AMS0030L

Figure 3 OPERATION OF START CIRCUIT (2) - IMMEDIATELY AFTER START Reference Number

Description

Reference Number

Description

Battery

Starter Relay

Battery Relay

Starter

Fusible Link

Alternator

Circuit Breaker

Transmission Selector Switch

Starter Switch

Diode

Fuse Box

Transmission Controller

Starter Controller

Safety Starter Relay

S0802200K Page 10

Electrical System

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Electrical System

S0802200K Page 11

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ENGINE PREHEATING SYSTEM (S/N 1001 THRU 2000) The engine preheating system consists of a grid type resistance heater between the engine air cleaner and intake manifold, a terminal switch which is used to monitor engine temperature, a preheat controller which turns "ON" a grid type resistance heater and a preheat indicator. PRINCIPLE OF OPERATION 1. When water temperature is lower than 10°C (50°F) (Thermal switch is "OFF.") •

With the starter switch in PREHEAT position, the signal current flows from the "R1" terminal of starter switch to NO. 8 terminal of preheat controller. Then current from the fuse flows through coil of preheat relay, No. 5 terminal of preheat controller, No. 6 terminal of preheat controller, and then to ground. This current makes the preheat relay contact closed, and thus current from battery flows to glow plug via circuit breaker and preheat relay. 3.5 seconds after starter switch is turned to preheat position, the preheat light will turn "ON" to indicate that preheating is finished.

2. When water temperature is higher than 10°C (50°F) (Thermal switch is "ON.") •

The preheat pilot is lit as soon as starter switch is turned to PREHEAT position, and the preheating current does not flow. This means that preheating is not necessary when water temperature is higher than 10°C (50°F).

S0802200K Page 12

Electrical System

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AMS0040L

Figure 4 ENGINE PREHEAT CIRCUIT (S/N 1001 thru 2000) Description

Reference Number

Description

Battery

Preheat Relay

Battery Relay

Glow Plug

Fusible Link

Thermal Switch

Circuit Breaker

Alternator

Starter Switch

Instrument Panel

Fuse Box

Diode

Preheat Controller

Reference Number

Electrical System

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ENGINE PREHEATING SYSTEM (S/N 2001 AND UP) The engine preheating system is consists of a grid type resistance heater between the engine air cleaner and intake manifold, a terminal switch which is used to monitor engine temperature, a preheat controller which turns "ON" a grid type resistance heater and a preheat indicator. PRINCIPLE OF OPERATION 1. When water temperature is lower than 10°C (50°F) (Thermal switch is "OFF.") •

With the starter switch in PREHEAT position, the signal current flows from the "R1" terminal of starter switch to NO. 8 terminal of preheat controller. Then current from the fuse flows through coil of preheat relay, No. 5 terminal of preheat controller, No. 6 terminal of preheat controller, and then to ground. This current makes the preheat relay contact closed, and thus current from battery flows to air heater via circuit breaker and preheat relay. 19 seconds after starter switch is turned to preheat position, the preheat light will turn "ON" to indicate that preheating is finished.

2. When water temperature is higher than 10°C (50°F) (Thermal switch is "ON.") •

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Electrical System

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AMS0040L

Figure 5 ENGINE PREHEAT CIRCUIT (S/N 2001 and up) Description

Reference Number

Description

Battery

Preheat Relay

Battery Relay

Air Heater

Fusible Link

Thermal Switch

Circuit Breaker

Alternator

Starter Switch

Instrument Panel

Fuse Box

Diode

Preheat Controller

Reference Number

Electrical System

S0802200K Page 15

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ENGINE STOP SYSTEM The engine stop circuit consists of a starter switch (3), engine stop motor (4) and engine stop relay (5). There are two modes of operation - engine running and engine stop. OPERATION IN ENGINE RUNNING MODE When the starter switch (3) is turned to the "ON" position, the contact points "30" and "87" of the engine stop relay (5) are closed due to current flowing from the battery (1), to the fusible link (2), to the "B" terminal of the starter switch (3), to the "ACC" terminal of starter switch (3), to the "86" terminal of engine stop relay (5) to the battery (1) and then to the ground. As a result, the engine stop motor (6) is rotated by the current flow from the battery (1) to the fusible link (2) to the fuse box (4) to "B" terminal of the engine stop motor (6) to the "P2" terminal of engine stop motor (6), to the "87" terminal of engine stop relay (5), to the "30" terminal of the engine stop relay (5), to the "A" terminal of engine stop motor (6) to the "E" terminal of engine stop motor (6), and then to the ground. The engine stop motor opens (pushes) the fuel shut off lever of the fuel injection pump and the system is in the running mode. The engine stop motor rotates 180° and comes to a stop due to the cam switch which shuts off the current to the motor.

AMS0050L

Figure 6 ENGINE STOP CIRCUIT - RUNNING MODE Reference Number

Description

Reference Number

Description

Battery

Fuse Box

Fusible Link

Engine Stop Relay

Starter Switch

Engine Stop Motor

S0802200K Page 16

Electrical System

Return to Master Table of Contents When the starter switch is in the "ON" position, the internal components of the engine stop motor’s cam switch is in the position shown.

AMS0060L

Figure 7

Electrical System

S0802200K Page 17

Return to Master Table of Contents OPERATION IN ENGINE STOP MODE When the starter switch (3) is in the "OFF" position, the electric current flow to the coil of the engine stop relay (5) is shut off. As a result, the "30" and "87a" contact point of the engine stop relay are connected and current is supplied to the engine stop motor from the battery (1), to the fusible link (2), to the fuse box (4) to the "B" terminal of engine stop motor (6), to the "P1" terminal of engine stop motor (6), to the "87a" terminal of engine stop relay (5), to the "30" terminal of engine stop relay (5), to the "E" terminal of engine stop motor (6), to the ground, and then the motor is rotated. The shut off lever of the fuel injection pump, linked to the engine stop motor by a cable, is moved to the close (pull) position and the engine is stopped. The engine stop motor moves 180° from the running mode position and is stopped by the internal cam switch which cuts off the current to the motor.

AMS0070L

Figure 8 ENGINE STOP CIRCUIT - STOP MODE Reference Number

Description

Reference Number

Description

Battery

Fuse Box

Fusible Link

Engine Stop Relay

Starter Switch

Engine Stop Motor

S0802200K Page 18

Electrical System

Return to Master Table of Contents When the starter switch is in the "OFF" position, the internal components of the engine stop motor’s cam switch is in the position shown.

AMS0080L

Figure 9

Electrical System

S0802200K Page 19

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

AMS0090L

Figure 10 CHARGING CIRCUIT Reference Number

Description

Reference Number

Description

Battery

Starter Switch

Battery Relay

Fuse Box

Fusible Link

Alternator

Circuit Breaker

Diode

S0802200K Page 20

Electrical System

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MONITORING SYSTEM MONITORING SYSTEM (S/N 1001 THRU 2000)

AMS0100L

Figure 11 (S/N 1001 thru 2000) Reference Number

Description

Reference Number

Instrument Panel

Engine Oil Pressure Switch

Battery

Hazard Warning Light Switch

Alternator

Turn Signal Light Switch

Speed Sensor

High Beam Switch

Coolant Temperature Sensor

Work Light Switch

Fuel Sensor

Brake Oil Pressure Switch

Transmission Oil Temperature Sensor

Parking Brake Pressure Switch

Emergency Steering Switch

Preheat Controller

Control unit

Air Cleaner Indicator

Brake Oil Filter Switch

Engine Coolant Temperature Switch

Description

The monitoring system displays the various data and warning signals onto the instrument panel by processing the information gathered from the various sensors throughout the equipment.

Electrical System

S0802200K Page 21

Return to Master Table of Contents INSTRUMENT PANEL (S/N 1001 THRU 2000)

AMS0110L

Figure 12 (S/N 1001 thru 2000)

S0802200K Page 22

Electrical System

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Reference Number

Description

Reference Number

Description

Speed Meter

Charging Warning Light

Tachometer

Hour Meter

Turn and Hazard Warning Light

Fuel Gauge

High Beam Indicator

Engine Coolant Temperature Gauge

Turn and Hazard Warning Light

Transmission Oil Temperature Gauge

Work Light Indicator

Preheat Completion Indicator

Brake Oil Pressure Warning Light

Air Cleaner Clogging Warning Light

Brake Oil Filter Clogging Warning Light

Parking Brake Indicator

Engine Coolant Temperature Warning Light

Emergency Steering Indicator

Engine Oil Pressure Warning Light

FUNCTION CHECK (S/N 1001 THRU 2000) When the starter switch is turned to the "ON" position, all displays, switch lights and warning lights except turn and hazard warning light, high beam indicator, work light indicator and emergency steering indicator will be lit for two seconds and the warning buzzer will sound. Any lights which do not turn "ON" during the function check should be replaced.

Electrical System

S0802200K Page 23

Return to Master Table of Contents MONITORING SYSTEM SCHEMATIC (S/N 1001 THRU 2000)

AMS0120L

Figure 13 (S/N 1001 thru 2000)

S0802200K Page 24

Electrical System

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Reference Number

Description

Air Cleaner Clogging Warning Indicator

Forward Lever Switch

Engine Oil Pressure Switch

Reverse Lever Switch

High Beam Switch

Coolant Temperature Switch

Left Turn Signal Switch

Brake Oil Pressure Switch

Right Turn Signal Switch

Parking Brake Pressure Switch

Alternator

Control Unit

Alarm Buzzer

Alarm Relay

Battery

Battery Relay

Circuit Breaker

Fuse Box

Preheat Controller

Reference Number

Description

Instrument Panel

Headlight Switch

Work Light Switch

Emergency Steering Switch

Speed Sensor

Coolant Temperature Sensor

Fuel Sensor

Transmission Oil Temperature Sensor

Electrical System

Brake Oil Filter Switch

S0802200K Page 25

Return to Master Table of Contents MONITORING SYSTEM (S/N 2001 AND UP)

BIS0040L

Figure 14 (S/N 2001 and up) Reference Number

Description

Reference Number

Instrument Panel

Battery

Engine Coolant Temperature Switch

Alternator

Engine Oil Pressure Switch

Speed Sensor

Hazard Warning Light Switch

Coolant Temperature Sensor

Turn Signal Light Switch

Fuel Sensor

High Beam Switch

Transmission Oil Temperature Sensor

Work Light Switch

Brake Oil Pressure Switch

Preheat Controller

Parking Brake Pressure Switch

Air Cleaner Indicator

Emergency Steering Switch

Control unit

Description

The monitoring system displays the various data and warning signals onto the instrument panel by processing the information gathered from the various sensors throughout the equipment.

S0802200K Page 26

Electrical System

Return to Master Table of Contents INSTRUMENT PANEL (S/N 2001 AND UP)

BIS0050L

Figure 15 (S/N 2001 and up) Reference Number

Description

Reference Number

Speed Meter

Tachometer

Hour Meter

Charging Warning Light

Fuel Gauge

Engine Coolant Temperature Gauge

Turn and Hazard Warning Light

High Beam Indicator

Transmission Oil Temperature Gauge

Turn and Hazard Warning Light

Preheat Completion Indicator

Work Light Indicator

Brake Oil Pressure Warning Light

Unused Light

Parking Brake Indicator

Emergency Steering Indicator

8 9

Electrical System

Air Cleaner Clogging Warning Light Engine Coolant Temperature Warning Light

Description Engine Oil Pressure Warning Light

S0802200K Page 27

Return to Master Table of Contents FUNCTION CHECK (S/N 2001 AND UP) When the starter switch is turned to the "ON" position, all displays, switch lights and warning lights except turn and hazard warning light, high beam indicator, work light indicator and emergency steering indicator will be lit for two seconds and the warning buzzer will sound. Any lights which do not turn "ON" during the function check should be replaced.

MONITORING SYSTEM SCHEMATIC (S/N 2001 AND UP)

BIS0220L

Figure 16 (S/N 2001 and up)

S0802200K Page 28

Electrical System

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Reference Number

Description

Reference Number

Description

Instrument Panel

Engine Oil Pressure Switch

Headlight Switch

Forward Lever Switch

Coolant Temperature Switch

Reverse Lever Switch

Brake Oil Pressure Switch

High Beam Switch

Left Turn Signal Switch

Parking Brake Pressure Switch

Right Turn Signal Switch

Alternator

Work Light Switch

Control Unit

Emergency Steering Switch

Alarm Buzzer

Speed Sensor

Alarm Relay Battery

Coolant Temperature Sensor

23 24

Battery Relay

Fuel Sensor

Circuit Breaker

Transmission Oil Temperature Sensor

Fuse Box

Preheat Controller

Air Cleaner Clogging Warning Indicator

Electrical System

S0802200K Page 29

Return to Master Table of Contents OPERATION Instruments Sensor Specification Function

Input

Display

Terminal

Input Specification 10 Km/h- 852 Hz 20 Km/h- 1704 Hz 30 Km/h- 2556 Hz

Speedometer

CN1-4

40 Km/h- 3408 Hz

CN1-5

*ƒ = 85.2 V [Hz] ƒ : Frequency of T/M Controller v : Speed [km/h] 500 rpm - 123 Hz 1000 rpm - 246 Hz 1500 rpm - 368 Hz 2000 rpm - 491 Hz

Tachometer

CN1-3

2500 rpm - 614 Hz 3000 rpm - 737 Hz *ƒ = 0.2456 N [Hz] ƒ : Frequency of alternator "P" terminal N : Engine rpm

Hour Meter

CN1-2

ALTERNATOR "R" Terminal voltage (24V)

0012.eps

EMPTY - Above 90 Ohm Fuel Gauge

Level

CN1-7

1/2 - 38 Ohm FULL - Below 10 Ohm

S0802200K Page 30

Electrical System

Return to Master Table of Contents Sensor Specification Function

Input

Display

Terminal

Input Specification

50°C - Above 188.2 Ohm 67°C - 102 Ohm Engine Coolant Temperature Gauge

CN1-6

105°C - 32 Ohm 125°C - Below 19.8 Ohm

50°C - Above 322.8 Ohm

Transmission Oil Temperature Gauge

CN1-8

120°C - 36.5 Ohm 150°C - Below 18.6 Ohm

Pilot Lights Symbol

Description

Input Terminal

Preheat

CN2-1

Light turns "ON" when preheat process is completed. (Approximately 19 seconds from start.)

Air Cleaner

CN2-2

Light turns "ON" when air cleaner is clogged

Coolant Temperature

CN2-3

Light up when coolant temperature increases over 102°C.

HAOA639L

Operation

Remarks

HAOA660L

(When terminal input is connected)

HAOA51AL

Engine Oil Pressure HAOA620L

Electrical System

CN2-4

Light turns "ON" when engine oil pressure drops below 1.6 kg/cm2 (23 psi)

After starting engine, if engine oil pressure is insufficient after 8 seconds, a warning buzzer will sound.

S0802200K Page 31

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Description

Input Terminal

Charging

CN2-5

Operation

Remarks

Light turns "ON" when not charging.

Under normal conditions, will turn "ON" before engine start-up and shut off once engine is running.

(and "R" terminal output drops below 24V)

HAOA610L

Left Turn and Hazard Light

CN2-6

Light turns "ON" when left turn signal or hazard light is operated. (Terminal input is to 24V)

Right Turn and Hazard Light

CN2-8

Light turns "ON" when right turn signal or hazard light is operated. (Terminal input is to 24V)

High Beam

CN2-7

Light turns "ON" when high beam is operated. (Terminal input is to 24V)

HGB2008L

Work Light

CN2-9

Light turns "ON" when work light is operated.

Light turns "OFF" when the engine is started.

(Terminal input is to 24 V) Brake Oil Pressure

CN2-10

0717B

Light turns "OFF" when brake oil pressure increases over 65 kg/ cm2 (925 psi), and light turns "ON" when brake oil pressure drops below 60 kg/cm2 (853 psi).

Under normal conditions, will turn "ON" before engine start-up and shut off once engine is running.

(When terminal input is connected) Parking Brake

P 0717A

CN2-12

Light turns "ON" when the parking brake switch is applied and parking brake pressure is above 65 kg/cm2 (925 psi).

Under any conditions, will be alight before engine start-up.

(24V is inputted to the input terminal)

S0802200K Page 32

Electrical System

Return to Master Table of Contents Symbol

Description

Input Terminal

Operation

Brake Oil Filter Pressure

CN2-11

Light turns "ON" when the brake oil filter pressure is above 5 kg/ cm2 (71 psi), light turns "OFF" when the brake oil filter pressure is below 4.7 kg/cm2 (67 psi).

Emergency Steering

CN2-13

Light turns "ON" when the vehicle speed is above 5 km/h and the steering pressure is below 10 kg/cm2 (142 psi).

0012.eps

Remarks

This is option parts.

(When the test switch is applied)

Initial Operation Item Initial Operation

Electrical System

Input (Terminal) CN 1-1

Output (Operation and initial setting mode) •

All warning lights are turned "ON" and turned "OFF" after 2 seconds. (Except for turn signal indicator, high beam indicator, work light indicator and transmission cutoff indicator and emergency steering indicator.

•

Warning buzzer is activated and turned "OFF" after 2 seconds.

•

Monitoring system displays present condition.

S0802200K Page 33

Return to Master Table of Contents Control Unit Operation

Figure 17 Reference Number

Description

Reference Number

Description

Instrument Panel

Alternator

Starter Switch

Engine Oil Pressure Switch

Forward Lever Switch

Reverse Lever Switch

Coolant Temperature Switch

Fuse Box

Brake Oil Pressure Switch

Control Unit

Warning Buzzer

Parking Brake Pressure Switch

S0802200K Page 34

Electrical System

Return to Master Table of Contents Characteristic of Operation Input 1

When the starter switch is "ON"

When "R" terminal voltage of alternator

When "R" terminal voltage of alternator is above 12 ±1 V

Electrical System

Output All warning lights are turned "ON" and turned "OFF" after 2 - 2.5 seconds.

is below 12 ±1 V

Charging light turns "ON" (L5)

is above 12 ±1 V

Charging light turns "OFF" (L5)

Engine oil pressure switch is "ON"

Warning buzzer sounds after 8 ±1 seconds.

Coolant temperature switch is "ON"

Warning buzzer sounds immediately

Brake oil pressure switch is "ON"

Warning buzzer sounds immediately

Forward or Reverse lever switch is "ON" and Parking brake pressure switch is "ON."

Warning buzzer sounds immediately

S0802200K Page 35

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WINDSHIELD WIPER FRONT WINDSHIELD WIPER You can control windshield wiper by operating wiper washer switch (2). 1.

Low speed wiper action (1st) Wiper acts in low speed through fuse box (1) to the 15,53 terminal of wiper switch (2) to the L,E terminal of wiper motor (5).

High speed wiper action (2nd) Wiper acts in high speed through Fuse box (1) to the 15,53b terminal of wiper switch (2) to the H,E terminal of wiper motor (5).

When you turn "OFF" switch during low speed wiper action (1st) or High speed wiper action (2nd), electric currents flow through Fuse box (1) to the B,S terminal of wiper motor (5) to the 87a,30 terminal of wiper relay (3) to the 31b,53 terminal of wiper switch (2) - L,E terminal of wiper motor (5). Wiper acts until wiper rotates to the stop position, than the wiper stops.

Intermittent wiper action Fuse box (1) to the 15,J terminal of wiper switch (2) to the 1,4 terminal of wiper timer (4) are connected intermittently, and electric current flow into 86,85 terminal of wiper relay (3) than 87 terminal and 30 terminal are connected. Therefore, electric current flow through fuse box (1) to the 87,30 terminal of wiper relay (3) to the 31b,53 terminal of wiper switch (2) to the L,E terminal of wiper motor (5), and wiper operates intermittently in low speed.

Front Windshield Wiper Circuit

AMS0140L

Figure 18

S0802200K Page 36

Electrical System

Return to Master Table of Contents Reference Number

Description

Reference Number

Description

Fuse Box (1)

Wiper Motor

Wiper Washer Switch

Washer Tank

Wiper Relay

Diode

Wiper Timer

REAR WINDSHIELD WIPER You can control rear windshield wiper by pressing wiper washer switch (2) in the switch panel. 1.

1st wiper action (Wiper and washer activate the same time, automatic return) Fuse box (1), to the washer tank (4), to the 5,7 terminal of switch (20) are connected, then activates windshield washers. Also fuse box (1), to the B,L terminal of wiper motor (3), to the diode (5), to the 5,7 terminal of switch (2) are connected, then activates wiper.

AMS0150L

Figure 19 REAR WINDSHIELD WIPER 1ST ACTION CIRCUIT Reference Number

Description

Reference Number

Description

Fuse Box (2)

Washer Tank

Wiper/washer Switch

Diode

Wiper Motor

Electrical System

S0802200K Page 37

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2nd wiper action (Only wiper action) Fuse box (1), to the B,L terminal of wiper motor (3), to the 4,2 terminal of switch (2) are connected, then activates wiper.

When you turn "OFF" windshield wiper switch in 1st or 2nd position, electric current flows fuse box (1), to the B,L terminal of wiper motor (3), to the 4,6 terminal of wiper switch (2), to the diode (6), to the S,E terminal of wiper motor (3).

AMS0160L

Figure 20 REAR WINDSHIELD WIPER STOP CIRCUIT Reference Number

Description

Reference Number

Description

Fuse Box (2)

Washer Tank

Wiper/washer Switch

Diode

Wiper Motor

S0802200K Page 38

Electrical System

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Electrical System

S0802200K Page 39

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LIGHTING SYSTEM LIGHT CIRCUIT (S/N 1001 THRU 2000)

AMS0170L

Figure 21 LIGHT CIRCUIT (S/N 1001 thru 2000)

S0802200K Page 40

Electrical System

Return to Master Table of Contents Reference Number

Description

Reference Number

Description

Fuse Box 1

License Plate Light

Blinker Unit

Instrument Panel

Headlight Switch

Diode

Combination Switch

Front Work Light Switch

Shift Lever Switch

Front Work Light

Hazard Switch

Rear Work Light Switch

Stop Light Switch

Work Light Relay

Headlight Relay

Rear Work Light 1

Reverse Relay

Rear Work Light 2

Headlight (L)

Fuse Box 2

Headlight (R)

Starter Switch

Front Combination Light (L)

Pilot Buzzer

Front Combination Light (R)

Alarm Relay 1

Rear Combination Light (L)

Alarm Relay 2

Rear Combination Light (R)

Electrical System

S0802200K Page 41

Return to Master Table of Contents The lighting system consists of the headlight, the position light, the turn signal light, the hazard light, the stop light, the license plate light, the work light, the rotating beacon light (option) and the switches, which are used to turn "ON" the lights. 1.

When the headlight switch (3) is in the first step, through the fuse box 1(1) to the "2," "6" terminal of headlight switch (3), the following lights will be alight. A.

The front combination light (L) (12) and rear combination light (L) through the fuse box 2(23).

The front combination light (R) (13) and rear combination light (R) through the fuse box 2(23).

The illumination lights through the "9" terminal of all kind of rocker switches include the headlight switch (3), the front work light switch (19), the rear work light (21) and the hazard switch (6).

The license plate light (16).

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.

Also if the combination switch (4) is in the "t " position, the current flows to the "56a" terminal and it allow the high beam light, which is in the headlight (L) (10) and the headlight (R) (11), to be 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.

And if the combination switch (4) is in the "s " position, the current flows to the "56b" terminal and it allows the low light, which is in the headlight (L) (10) and the headlight (R) (11), to be 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) (11) will be turned "ON," and the other current flows to the "CN2-7" terminal of instrument panel (17) and the headlight indicator will be alight. The combination switch (4) is returned automatically.

When the combination switch (4) is in the "←"(or "→")position, the current flows from the fuse box 1(1), to the blinker unit (2), to the "L" (or "R") terminal through "49a" terminal of combination switch (4), to the "C" terminal of front combination light (L) (12) and the rear combination light (L) (14) (or to the front combination light (R) (13) and the rear combination light (R) (15)). This current makes the turn signal light turn "ON." At the same time the current flows to the "CN2-6" terminal (or to the CN28 terminal) of instrument panel and the turn signal light indicator L6(or L8) will be alight.

If you operates the hazard light switch (6), the current flows from to the fuse box 1(1), to the blinker unit (2), to the "5," "1" terminal of hazard switch (6), to the diode (18), to the front combination light (L) (12) and the front combination light (R) (13), to the "C" terminal of rear combination light (L) (14) and rear combination light (R) (15). This current makes the turn signal light turn "ON." At the same time through the "2," "6" terminal of hazard switch (6), the voltage is applied to the "9" terminal and the illumination light used to symbol light will be 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.

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

S0802200K Page 42

Electrical System

Return to Master Table of Contents "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 "ON," the current flows the from fuse box 1(1), to the stop light switch (7) and to the "F" terminal of rear combination light (L) (14) and rear combination light (R) (15), and the stop light will be alight.

When the front work light switch (19) is in the "ON" position, the current flows from the fuse box 1(1), to the "5," "1" terminal of front work light switch (19) and to the front work light (20). This current makes the front work lights turn "ON." At the same time the work light indicator,L9," is turned "ON" due to the current flowing from the diode (8) to the "CN2-9" terminal of instrument panel (17).

When the rear work light switch (21) is in the second step, the contact points "30" and "87" of the work light relay (22) is closed due to the flowing current from the fuse box 1(1), to the "2" and "6" terminal of the work light switch (21), to the "86" terminal of the work light relay (22) and to the ground. Thus the current flows from the fuse box 1(1), to the work light relay (22) and to the rear work light 1(23) mounted on right/left rear fender. As a result the rear work light (23) light turns "ON." At the same time the work light indicator "L9" light turns "ON" due to the current flowing from the diode (18) to the "CN2-9" terminal of the instrument panel.

When the rear work light switch (21) is in the second step, the contact points "30" and "87" of the work light relay (22) is closed due to the flowing current from the fuse box 1(1), to the "2" and "6" and "3" terminal of the work light switch (21), the rear working (23) is operated like being described above clause "8" and the rear work light (24) mounted on the cabin light turns "ON" at the same time.

10.

When the headlight switch (3) is in the first step or in the second step while the starter switch (26) is in the "OFF" position, the contact point "30," "87" of alarm relay 1(28) is closed due to the excited current, which flows to the coil of alarm relay 1(28) and the pilot buzzer (27) will sound. But when the headlight switch (3) is in the first step or in the second step while the starter switch (26) is in the "ON" position, the contact point "3," "87" of alarm relay 2(29) is closed due to the excited current, which flows to the coil of alarm relay 2(29). At the same time the current is not supplied to the "30" terminal of alarm relay 1(28) and the pilot buzzer will not sound any more.

Electrical System

S0802200K Page 43

Return to Master Table of Contents LIGHT CIRCUIT (S/N 2001 AND UP)

BIS0230L

Figure 22 LIGHT CIRCUIT (S/N 2001 and up)

S0802200K Page 44

Electrical System

Return to Master Table of Contents Reference Number

Description

Reference Number

Description

Fuse Box 1

License Plate Light

Blinker Unit

Instrument Panel

Headlight Switch

Diode

Combination Switch

Front Work Light Switch

Shift Lever Switch

Front Work Light

Hazard Switch

Rear Work Light Switch

Stop Light Switch

Work Light Relay

Headlight Relay

Rear Work Light 1

Reverse Relay

Rear Work Light 2

Headlight (L)

Fuse Box 2

Headlight (R)

Starter Switch

Front Combination Light (L)

Pilot Buzzer

Front Combination Light (R)

Alarm Relay 1

Rear Combination Light (L)

Alarm Relay 2

Rear Combination Light (R)

Electrical System

S0802200K Page 45

Return to Master Table of Contents The lighting system is consists of the headlight, the position light, the turn signal light, the hazard light, the stop light, the license plate light, the work light, the rotating beacon light (option) and the switches, which 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).

The front combination light (R) (13) and rear combination light (R) through the fuse box 2(23).

The illumination lights through the "9" terminal of all kind of rocker switches include the headlight switch (3), the front work light switch (19), the rear work light (21) and the hazard switch (6).

The license plate light (16).

And if the combination switch (4) is in the "s " position, the current flows to the "56b" terminal and it allows the low light, which is in the headlight (L) (10) and the headlight (R) (11), to be 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) (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.

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 CN28 terminal) of instrument panel and the turn signal light indicator L6(or L8) will be alight.

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.

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Electrical System

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.

When the front work light switch (19) is in the "ON" position, the current flows from the fuse box 1(1), to the "5," "1" terminal of front work light switch (19) and to the front work light (20). This current makes the front work lights turned up. At the same time the work light indicator,L9," is turned up due to the current flowing from the diode (8) to the "CN2-9" terminal of instrument panel (17).

When the rear work light switch (21) is in the first step, the current flows from the fuse box 1 (1) to t he "2" and "6" terminal of the work light switch (21). Thus the current flows from the fuse box 1 (1), to the work light switch (21) and to the rear work light 2 (24) mounted on the cabin. As a result the rear work light (24) light turns "ON".

When the rear work light switch (21) is in the second step, the contact points "30" and "87" of the work light relay (22) is closed due to the flowing current from the fuse box 1(1), to the "2" and "6" and "3" terminal of the work light switch (21), to the "86" terminal of the work light relay (22) and to the ground. Thus the current flows from the fuse box 1(1), to the work light relay (22) and to the rear work light 1(23) mounted on right/left rear fender. As a result the rear work light (23) light turns "ON." At the same time the work light indicator "L9" light turns "ON" due to the current flowing from the diode (18) to the "CN2-9" terminal of the instrument panel. (Option)

10.

Electrical System

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EMERGENCY STEERING SYSTEM (OPTION) BLOCK DIAGRAM

7 8

AJS0460L

Figure 23 EMERGENCY STEERING SYSTEM BLOCK DIAGRAM Reference Number

Description

Reference Number

Description

Fuse Box

Emergency Steering Pump

Emergency Steering Switch

Emergency Steering Indicator

Emergency Steering Timer

Transmission Controller

Emergency Steering Pressure Switch

Battery

When the speed of the vehicle exceeds 5 km/h and the secondary steering pressure is less than 10 kg/cm2 (142 psi), an electrically powered hydraulic pump will be operated for a time limited 60 seconds and thus the emergency steering is possible. This system includes the electrically powered hydraulic pump, which is controlled by the emergency steering timer (3). The emergency steering timer (3) obtains signals from the emergency steering pressure switch (4) and the transmission controller (7). When the emergency steering is activated, the emergency steering indicator (6) light turns "ON."

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Electrical System

Return to Master Table of Contents 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).

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

When the starter switch is "ON," the characteristic of operation is following.

4 5

AJS0450L

Figure 24

No.

Wire size and Color

0.85 WL

0.85G

0.85WB

0.85W

0.85B

Reference Number

Description

Emergency Steering Timer

Emergency Steering Pressure Switch

Transmission Controller

Emergency Steering Pump

Starter Switch

3 AJS0470L

Figure 25 EMERGENCY STEERING TIMER CIRCUIT Input Condition S0

When in the "ON" position

Vehicle Speed -

OFF

When above 5 km/h

will be operated only one time and stop after 60±10 seconds.

When below 5 km/h

OFF

Electrical System

Output (Emergency Steering Pump)

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Return to Master Table of Contents Emergency Steering Pump This is an electrically powered hydraulic pump and includes an emergency steering relay (1,Figure 26),which is excited by the signal of the emergency steering timer.

AJS0480L

Figure 26 EMERGENCY STEERING PUMP

Emergency Steering Switch 1.

When the switch is in the "I" position, the emergency steering pump and the emergency steering indicator of the instrument panel are activated simultaneously. The basic usage of this switch is testing function whether the emergency steering system is all right or not.

O I AJO0011L

WARNING

Figure 27 EMERGENCY STEERING SWITCH

Make sure that no persons are near the machine when testing the function of the emergency steering system, there is a risk that someone may be crushed between the front and the rear frame. 3.

This returns automatically pressed down. NOTE:

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when

not

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

Electrical System

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

11 5 8 1

2 4 9

3 AJS0490L

Figure 28 EMERGENCY STEERING SYSTEM CIRCUIT Reference Number

Description

Reference Number

Description

Fuse Box

Emergency Steering Indicator

Emergency Steering Switch

Fusible Link

Emergency Steering Timer

Diode

Emergency Steering Pressure Switch

Transmission Controller

Headlight Switch

Emergency Steering Pump

Battery

Electrical System

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

FLOAT KICK-OUT (OPTION) 6 2 11

7 8

1 11

AJS0500L

Figure 29 ELECTRIC DETENT CIRCUIT Reference Number

Description

Reference Number

Description

Fuse Box

Return to Dig Magnetic

Float Kick-out Switch (Option)

Raise Proximity Switch

Raise / Float Relay

Float Proximity Switch (Option)

Return to Dig Relay

Return to Dig Proximity Switch

Raise Magnetic

Diode

Float Magnetic

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).

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Electrical System

Return to Master Table of Contents As a result the magnetic (5) is de-energized and the locked lever is returned to "NEUTRAL" position, boom lifting is stopped. 2.

Boom Float Kick-Out (Option) With the float kick-out switch shown in Figure is in the "I" position and the float magnetic (6) is energized and the work lever 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 float kick-out switch (2) and to the "0" and "-" terminal of the raise proximity switch (9). As a result the magnetic (6) is deenergized and the locked lever is returned to "NEUTRAL" position, and boom lowering is stopped.

O I HA0O2027

Figure 30

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

OPERATION INDICATOR

±1

•

Operating Distance: (0.3937 ±0.0394 in).

•

Operation Indicator Light: Light turns "ON" when the object is detected.

POSITIONER

(OPERATING DISTANCE)

MAIN CIRCUIT

POWER

AJS0510L

Figure 31

Electrical System

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Electrical System

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S0893070K

1ELECTRICAL SCHEMATIC (MEGA 300-V) CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that is in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility.

ELECTRICAL SCHEMATIC (MEGA 300-V)S0893070K MODEL

SERIAL NUMBER RANGE

Mega 300-V (Tier I)

1001 thru 2000

Mega 300-V (Tier II)

2001 and Up

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TABLE OF CONTENTS General Description........................................................................................ 3 Mega 300-V.................................................................................................... 4

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Electrical Schematic (Mega 300-V)

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Figure 1

Electrical Schematic (Mega 300-V)

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MEGA 300-V

Figure 2

S0893070K Page 4

Electrical Schematic (Mega 300-V)

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MEGA 300-V AMS0190L

Electrical Schematic (Mega 300-V)

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S0893070K Page 6

Electrical Schematic (Mega 300-V)

1ATTACHMENTS