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Mega 400-V Shop Manual 023-00040E Serial Number 1001 and Up February 2001

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.

023-00040E Shop Manual

1TABLE OF CONTENTS Return to Master Table of Contents

Safety Wheel Loader Safety .......................................................................... S0103010K

Specifications Specifications for Mega 400-V............................................................ S0203060K

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

Upper Structure Counterweight..................................................................................... S0403030K Fuel Transfer Pump ...............................................................................S0405500 Hydraulic oil tank ................................................................................ S0406030K

Lower Structure and Chassis Center Joint (Articulation Joint)........................................................... S0502010K

Engine and Drive Train Front Axle ........................................................................................... S0602150K Rear Axle ............................................................................................ S0602160K Air-Conditioner.................................................................................... S0605050K Transmission and Torque Converter (ZF) .......................................... S0607070K Transmission Error Codes (ZF) .......................................................... S0607900C

Hydraulics Accumulator...........................................................................................S0703000 Cylinders................................................................................................S0705010 Fan Drive Hydraulic Motor (Haldex) ................................................... S0707100K

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Main Pump (Denison T6DMY Series)................................................. S0708460K Steering and Brake Pump (Denison T67DB Siries)............................ S0708470K Brake Pedal Valve .............................................................................. S0709230K Main Control Valve (Toshiba) ............................................................. S0709455K Pilot Control Valve .............................................................................. S0709475K Flow Amplifier (Danfoss)..................................................................... S0709665K Power Steering Unit............................................................................ S0709730K Unloader Valve ................................................................................... S0709850K Hydraulic Schematic (Mega 400-V) .................................................... S0793050K

Electrical System Electrical System ................................................................................ S0802180K Electrical Schematic (Mega 400-V) .................................................... S0893050K

Attachments

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1SAFETY

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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 Mega 400-V

SERIAL NUMBER RANGE 1001 and Up

S0103010K Page 1

TABLE OF CONTENTS To the Operator of a Daewoo Wheel Loader .................................................. 3 General Safety Essentials .............................................................................. 4 Location of Safety Labels ............................................................................... 5 Unauthorized Modifications ............................................................................ 5 Work-Site Precautions.................................................................................... 6 Operation........................................................................................................ 8 Equipment .................................................................................................... 13 Maintenance................................................................................................. 17 Shipping and Transportation ........................................................................ 20

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Wheel Loader Safety

TO THE OPERATOR OF A DAEWOO WHEEL LOADER DANGER! Improper use of wheel loader could cause serious injury or death. Before operating wheel loader, or performing maintenance, operator or technician must read and understand entire Operation and Maintenance Manual. Any operation, maintenance, traveling or shipping methods that do not follow safety guidelines printed in this Manual could cause serious injury or death. 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 4

“Location of Safety Labels” on page 5

“Unauthorized Modifications” on page 5

“Operation” on page 8

“Equipment” on page 13

“Maintenance” on page 17

“Shipping and Transportation” on page 20

Wheel Loader Safety

S0103010K Page 3

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! Indicates 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! Indicates 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! Indicates a hazardous 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.

GENERAL SAFETY ESSENTIALS ACCESSORY APPLICATIONS 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.

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Wheel Loader Safety

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. Always replace damaged or faded decals.

UNAUTHORIZED MODIFICATIONS IMPORTANT If you need more information or have any questions or concerns about safe operating procedures or working wheel loader correctly in a particular application or in specific conditions of your individual operating environment, please consult your local Daewoo representative. Any modification made without authorization or written approval from Daewoo can create a safety hazard, for which machine owner must be held responsible. For safety’s sake, replace all OEM parts with correct authorized or genuine Daewoo part. For example, not taking time to replace fasteners, bolts or nuts with correct replacement parts could lead to a condition in which safety of critical assemblies is dangerously compromised.

Wheel Loader Safety

S0103010K Page 5

WORK-SITE PRECAUTIONS 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. 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

6.6kV

3 m (9' - 10")

33.0kV

4 m (13' - 1")

66.0kV

5 m (16' - 5")

154.0kV

8 m (26' - 3")

275.0kV

10 m (32' - 10")

Figure 1

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.

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Wheel Loader Safety

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. 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 shutdown. 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. 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(17''

440 m TURBO-II

On sloping surfaces, use caution when positioning wheel loader prior to starting a work cycle. Stay alert for instability situations in order 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

440 m

m(17

'') AJO0580L

Figure 2

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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 3

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.

OPERATION 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 but 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 can’t see clearly and something is happening behind you. Replace damaged safety labels and lost or damaged operator’s manuals.

HAOA151L

Figure 4

Do not let anyone operate machine unless they’ve been fully and completely trained, in safety and in operation of the machine.

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Wheel Loader Safety

BEFORE STARTING ENGINE, DO A “PRE-START” SAFETY CHECK: •

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 prior to start up.

•

Check gauges and monitor displays for normal operation prior to 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.

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 5 MOUNTING AND DISMOUNTING Never get on or off a moving machine. Do not jump on/off. Entry/egress path should be clear of mud, oil and spills and mounting hardware must be kept tight and secure. Always use handholds or steps and maintain at least 3-point contact of hands and feet. Never use controls as handholds. Never get up from operator’s seat or leave operator’s station and dismount machine if engine is running.

HLB1003L

Figure 6

Wheel Loader Safety

S0103010K Page 9

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 job 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. 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.

HAOA070L

Figure 7

ASBESTOS DUST HAZARD PREVENTION

Asbestos dust can be HAZARDOUS to your health if it is inhaled. If you handle materials containing asbestos fibers, follow these guidelines as given below: •

Never use compressed air for cleaning.

•

Use water for cleaning to keep down the dust.

•

Work on the machine or component with the wind at your back whenever possible.

•

Use an approved respirator.

TAKE TIME TO PROVIDE GOOD VISIBILITY Halt work if visibility is poor. Strong rains, snow, fog and extremely dusty conditions can all obscure visibility so badly that it is best to wait for weather to change or dust to settle before continuing operation. Night work in areas of limited visibility should be halted if installation of extra work lights on machine (or work area) is necessary. 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.

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Wheel Loader Safety

FUEL, OIL AND HYDRAULIC FLUID FIRE HAZARDS Add fuel, oil, antifreeze and hydraulic fluid to machine only in a well ventilated area. Machine must be parked with controls, lights and switches turned "OFF." 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 machine. Static electricity can produce dangerous sparks at fuel filling nozzle. In very cold, dry weather or other conditions that could produce static discharge, keep tip of fuel nozzle in constant contact with neck of fuel filling nozzle, to provide a ground.

HAOA120L

Figure 8

Keep fuel and other fluid reservoir caps tight and do not start engine until caps have been secured. BOOST STARTING OR CHARGING ENGINE BATTERIES Turn "OFF" all electrical equipment before connecting leads to battery. This includes electrical switches on battery charger or boost starting equipment. When boost-starting from another machine or vehicle do not allow two machines to touch. Wear safety glasses or goggles while required parallel battery connections – positive to positive and negative to negative – are made.

HAOA310L

24 volt battery units consisting of two seriesFigure 9 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 non-series-connected positive terminals and between negative terminal of booster battery and metal frame of machine being boosted or charged. Refer to procedure and illustration in Operation and Maintenance Manual. Connect positive cable first when installing cables and disconnect negative cable first when removing them. Final cable connection, at metal frame of machine being charged or boost-started, should be as far away from batteries as possible.

Wheel Loader Safety

S0103010K Page 11

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 10 TRAVEL PRECAUTIONS Engage frame lock for long-distance travel. 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. Attachment control levers should not be operated while traveling. Fold in work equipment so that outer end of boom is as close to machine as possible, and is low – 440 mm (17") above ground. Never travel over obstacles or slopes that will cause machine to tilt severely. Travel around any slope or obstacle that causes 10 degrees tilt, or more. 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. 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 a firm, level surface 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.

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Wheel Loader Safety

SHUTDOWN CONTROL FUNCTIONS After bucket has been lowered to overnight storage position, move all switches and controls to “OFF” position. Move parking brake switch to "LOCK" position. This will apply parking brake. Move pilot cutoff switch to "LOCK" position. This will disable bucket control lever. Move key in ignition 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.

EQUIPMENT ROUGH OPERATION MAY REQUIRE USE OF CERTIFIED SAFETY EQUIPMENT 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 11 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.

Wheel Loader Safety

HAOA100L

Figure 12

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INSTALL ADDITIONAL SAFETY EQUIPMENT IF CONDITIONS REQUIRE When working with a breaker or in some shear work applications, a front guard over windshield may be required. Windshield guard may or may not be OPS/certified, depending upon the specific application and working situation. 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. 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. 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 13 WINDOW GLASS BREAKING TOOL This loader is equipped with a glass breaking tool. It is located in the lower left side of the cab just rear of the door. This tool can be used in case of an emergency situation which requires the breaking of glass to exit from the operator’s cabin. Grip the handle firmly and use the sharp point to break the glass.

Figure 14

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Wheel Loader Safety

KEEP A FIRE EXTINGUISHER AT HAND It is recommended that an appropriately sized (2.27 kg [5 lb] or larger) multi-purpose “A/B/C” fire extinguisher be mounted in cab. Check and service fire extinguisher at regular intervals and make sure that all work site crew members are adequately trained in its use.

HAOA080L

Figure 15

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. 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.

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 job site hazard. Extra safety guards may be required. NEVER allow hoses to be hit, bent or interfered with during operation. OPERATOR’S CAB SHOULD BE KEPT CLEAN 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.

Wheel Loader Safety

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WEAR EYE PROTECTION AND SAFETY CLOTHING – USE PROPER TOOLS Contain long hair, and avoid wearing loose clothes or jewelry that could get caught in controls. Full eye protection, a hard hat, safety shoes and gloves may be required at job site. While working on machine, never use inadequate tools. They could break or slip, causing injury, or they may not adequately perform intended functions.

HAOA020L

Figure 16 BREATHING MASKS, EAR PROTECTION MAY BE REQUIRED Do not forget that some risks to your health may not be immediately apparent. Exhaust gases and noise pollution may not be visible, but these hazards can cause disabling or permanent injuries. NOTE:

Sound level in closed operator’s cab is 75 dB(A). Additional information on machine sound and vibration levels can be found in Shop Manual.

ASBESTOS FIBER HAZARD Materials containing asbestos fiber can be present on job 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: 1.

Use a respirator that is approved for use in an asbestos-laden atmosphere.

Use water for cleaning and for keeping dust down.

NEVER use compressed air for cleaning.

BATTERY ELECTROLYTE AND EXPLOSIVE GASES CAN BE LETHAL Flush eyes with water for 10-15 minutes if acid is splashed in face. Anyone who swallows acid must have immediate medical aid. Call Poison Control listing in the front cover of the telephone directory. 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.

HAOA440L

Figure 17

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.

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Wheel Loader Safety

USE LOW HEAT PORTABLE LIGHTING Hot surfaces on trouble lights or portable work lights can set off fuel or battery explosive gases.

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 18. 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.

HAOC920L

Figure 18

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 a firm, level surface 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.

Wheel Loader Safety

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COOL-DOWN IS REQUIRED PRIOR TO RADIATOR OR RESERVOIR CHECKS Stop engine and allow heat to dissipate before performing service on engine radiator or hydraulic fluid reservoir. Both assemblies have air vent levers at or near filler cap for venting built-up air pressure. Release levers before trying to take off filler caps and LOOSEN CAPS SLOWLY, prior to removal.

HAOA060L

Figure 19

PRESSURIZED HYDRAULIC OIL FLUID LEAKS CAN BE DANGEROUS Fluid leaks from hydraulic hoses or pressurized components can be difficult to see but pressurized oil has enough force to pierce 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.

HAOA420L

Figure 20

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. 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.

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Wheel Loader Safety

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. Never drain any petroleumbased product on ground or dispose of old oil in municipal waste collection containers, or in metropolitan sewer systems or rural landfills. Check state and local regulations for other requirements.

HAOA470L

Figure 21

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 of Operation and Maintenance Manual, 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.

Wheel Loader Safety

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SHIPPING AND TRANSPORTATION OBEY STATE AND LOCAL OVER-THE-ROAD REGULATIONS Check state and local restrictions regarding weight, width and length of a load prior to 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 job 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 22

•

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.

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Wheel Loader Safety

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1SPECIFICATIONS

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S0203060K

2SPECIFICATIONS FOR MEGA 400-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 400-VS0203060K MODEL Mega 400-V

SERIAL NUMBER RANGE 1001 and Up

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Specifications for Mega 400-V

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TABLE OF CONTENTS Component Locations .................................................................................... 4 General Specifications ................................................................................... 6 Engine Performance Curves .......................................................................... 8 Working Range and Dimensions.................................................................. 10 Working Capacities ...................................................................................... 13 Bucket Capacity .................................................................................... 13 Tipping Load ......................................................................................... 13 Material Weight ............................................................................................ 13 Approximate Weight of Workload Materials .......................................... 13

Specifications for Mega 400-V

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

2 3

10 11

18 20 19

13 12

22 21

23 24

35 34 43

40 39

37 36

30 32

AJO0390L

Figure 1

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Specifications for Mega 400-V

Return to Master Table of Contents 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 Lamp

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 Supporter

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 400-V

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GENERAL SPECIFICATIONS MEGA 400-V Item

Specification

Standard Bucket Capacity

3.90 cu. m (5.10 cu. yd.)

Vehicle Weight

22,040 kg (48,590 lbs.)

Engine Type

DE12TIA

Horsepower

295 ps @ 2,100 rpm (291 hp @ 2,100 RPM)

Max. Torque

130 kg•m / 1,200 RPM (940 ft. lbs. @ 1,200 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)

7.5 (4.6) / 13.5 (8.4) / 24.0 (14.9) / 36.5 (22.7) km/h (mph)

Steering Angle

+ 40°

Min. Tire Center)

Turning

Radius

(Out-Tire

5,959 mm

Max Tractive Effort

23,000 kg (50,710 lbs.)

Max. Breakout Force

22,000 kg (48,500 lbs)

Bucket Rise Time

5.8 Seconds

Bucket Dump Time

1.3 Seconds

Bucket Descent Time

3.4 Seconds

Maximum Gradeability

58% (30°)

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

3,175 mm (10' - 5")

Dump Reach at 45° (w/o teeth)

1,225 mm (4' - 0")

Max Dump Angle at Fully Raised

47°

Max Tilt Angle at Carry

47°

Travel Dimension

S0203060K Page 6

Overall Length

8,600 mm (28' - 3")

Overall Width

3,280 mm (10' - 9")

Overall Height

3,556 mm (11' - 8")

Wheel Base

3,500 mm (11' - 6")

Tread

2,300 mm (7' - 6")

Ground Clearance

510 mm (1' - 8")

Specifications for Mega 400-V

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Specifications for Mega 400-V

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130 120 110 100

250

200

150 160 140 1000

1500

2000

FUEL CONSUMPTION (g/ps.h)

POWER OUTPUT (ps)

300

TORQUE (kg.m)

ENGINE PERFORMANCE CURVES

REVOLUTION (rpm) AJS0580L

Figure 2

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Specifications for Mega 400-V

Return to Master Table of Contents Performance standard

KS-R1004

Power (Maximum / RPM

295 ps @ 2,100 rpm (291 hp @ 2,100 RPM)

Maximum Torque

130 kg•m / 1,200 RPM (940 ft. lbs. @ 1,200 RPM)

Fuel Consumption

160 g / ps.h

NOTE:

Barometric Pressure: 760 mm (30") Mercury Temperature: 20°C (68°F) W/O Cooling Fan: Driven by hydraulic fan motor Alternator: 24 V, 60 amp Exhaust System: Complete, attached Air Cleaner; Installed

Specifications for Mega 400-V

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WORKING RANGE AND DIMENSIONS Figure 3, illustrates exterior machine dimensions and working range of machine when it is equipped with a standard bucket.

G E

B(D) A

I β

AJS0590L

Figure 3

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Specifications for Mega 400-V

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Dimension

Overall Length (A)

8,600 mm (28' - 3")

Overall Width, without bucket (B)

2,985 mm (9' - 10")

Overall Height (C)

3,566 mm (11' - 8")

Bucket Width (D)

3,280 mm (10' - 9")

Wheel Base (E)

3,500 mm (11' - 6")

Tread (F)

2,300 mm (7' - 7")

Ground Clearance (G)

510 mm (1' - 8")

Dump Height, to tooth (H)

2,985 mm (9' - 9")

Dump Distance, to Bucket Edge (I)

1,225 mm (4' - 0")

Dump Height to Bucket Pivot (J)

4,300 mm (14' - 1")

Bucket Dump Angle, Raised (α)

47°

Bucket Tilt Angle, Carry (β)

47°

Tire Size

26.5-25-20 PR(L3)

Specifications for Mega 400-V

S0203060K Page 11

Return to Master Table of Contents Figure 4 and Figure 5, illustrate working range when machine is equipped with optional pallet or log fork. F

C B

b D AJS0600L

Figure 4 Reference Number

Dimension

Reference Number

Dimension

1,663 mm (5' - 5")

1,800 (5' - 11")

2,005 mm (6' - 7")

897 (3' - 3")

4,007 mm (13' - 2")

36°

9,420 mm (30' - 11")

37.5°

b A B

c AJS0610L

Figure 5 Reference Number

Dimension

Reference Number

Dimension

1,655 mm (5' - 5")

45°

2,840 mm (9' - 4")

22°

47°

S0203060K Page 12

Specifications for Mega 400-V

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WORKING CAPACITIES BUCKET CAPACITY Standard toothed bucket has a capacity of 3.9 m3 (5.1cu. yd.). An optional bucket equipped with a cutting edge and no teeth has a capacity of 3.9 m3 (5.1 cu. yd.). TIPPING LOAD Static Tipping Load with bucket in Over Front position is 16,420 kg (36,200 lbs.). With bucket in Fully Turned position, Static Tipping Load is 14,016 kg (30,900 lbs.).

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 400-V

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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)

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

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

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

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

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

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

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

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)

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

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

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

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

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

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

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

Dolomite, crushed

Earth, loamy, DRY, loose Earth, DRY, packed

Earth, WET, muddy

Limestone, crushed

Limestone, fine

Phosphate, rock

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Specifications for Mega 400-V

Return to Master Table of Contents 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)

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

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

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

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

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

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

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

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

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

MATERIAL

Sand, DRY, loose

Sand, WET, packed

Shale, broken

Sulphur, broken

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 400-V

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S0203060K Page 16

Specifications for Mega 400-V

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1GENERAL MAINTENANCE

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S0302000

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

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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

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General Maintenance Procedures

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WELDING PRECAUTIONS AND GUIDELINES IMPORTANT To avoid accidents, personal injury and the possibility of causing damage to the excavator 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 excavator 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 excavator (that is not always readily visible) could be caused. Always consult Daewoo After Sales Service before welding on integral components (car body, track frames, turntable, attachment) of the excavator. 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 excavator 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

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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 prior to 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 (as well as 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.

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General Maintenance Procedures

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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 multi-display 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

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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, non-combustible, 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 - as well as 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 prior to assembly by checking alignment and flatness. Clean and repair corrosion or any other damage.

Follow bolt torque recommendations and all other assembly requirements.

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General Maintenance Procedures

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Grease lip assembly.

seals

prior

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

Return to Master Table of Contents 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 matter. 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 can not 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

Return to Master Table of Contents 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

Return to Master Table of Contents 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

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General Maintenance Procedures

Return to Master Table of Contents 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

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Return to Master Table of Contents 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

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General Maintenance Procedures

Return to Master Table of Contents 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

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General Maintenance Procedures

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S0309000

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

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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

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TORQUE VALUES FOR STANDARD METRIC FASTENERS NOTE:

The units for the torque values are kg•m (ft lbs). 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

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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

Return to Master Table of Contents 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 NON-LUBRICATED (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 lbs) (N•m) 8 6 9 7 18 13 20 15 33 24 37 27 52 38 57 42 79 58 88 65 114 84 126 93 156 115 176 130 278 205 312 240 414 305 454 334 617 455 691 510 827 610 929 685 1166 860 1295 955 1532 1130 1749 1290 2034 1400 2291 1690 3213 2370 4813 3550

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

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

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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 lbs)

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

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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 PLUS OR MINUS 5 in lbs (0.1 kg•m)

CLAMP TYPE AND SIZE

RADIATOR, AIR CLEANER, BOOTS, ETC.

HYDRAULIC SYSTEM

KILOGRAM METER (kg•m)

INCH POUNDS (In. Lbs.)

KILOGRAM METER (kg•m)

INCH POUNDS (In. Lbs.)

"T" Bolt (Any Diameter)

0.6 - 0.7

55 - 65

-------

------

Worm Drive - 1-3/4 in. Open Diameter and Under

0.2 - 0.3

20 - 30

0.5 - 0.6

40 - 50

Worm Drive - Over 1-3/4 in. Open Diameter

0.5 - 0.6

40 - 50

-------

------

Worm Drive - All "UltraTite"

1.1 - 1.2

95 - 105

0.5 - 0.6

40 - 50

Standard Torques

S0309000 Page 7

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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 lbs)

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

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TORQUE WRENCH EXTENSION TOOLS Very large diameter, high grade fasteners (nuts, bolts, cap screws, etc.) require a great deal of turning force in order 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 lbs," the real force applied to the bolt is 300 ft lbs:

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

Return to Master Table of Contents 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 excavator, 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

Return to Master Table of Contents 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 to 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 to 4 hours) setup. Unprimed setup 4-24 hours.

515

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

Purple

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

Standard Torques

S0309000 Page 11

Return to Master Table of Contents 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

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1UPPER STRUCTURE

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S0403030K

2COUNTERWEIGHT

COUNTERWEIGHT

S0403030K

MODEL Mega 400-V

SERIAL NUMBER RANGE 1001 and Up

S0403030K Page 1

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

S0403030K Page 2

Counterweight

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SPECIFICATIONS NOTE:

Weight Mega 400-V

1,550 kg (3,417 lbs.)

COUNTERWEIGHT 1

AJS0620L

Figure 1 NOTE:

Counterweight

1) 250 kg•m (1,800 ft lbs)

S0403030K Page 3

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S0403030K Page 4

Counterweight

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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 250-III

1001 and Up

Mega 400-III PLUS

1001 and Up

Mega 400-V

1001 and Up

Solar 130LC-V

0001 and Up

Solar 130W-V

0001 and Up

Solar 200W-V

0001 and Up

Solar 170LC-V

1001 and Up

Solar 170W-V

1001 and Up

Solar 220LC-V

0001 and Up

Solar 220LL

1001 and Up

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

S0405500 Page 1

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TABLE OF CONTENTS General Description........................................................................................ 3 Theory of Operation ................................................................................ 3 Replacement of Rotor and Vane .................................................................... 4 Replacement of Rear Cover ........................................................................... 4 Replacement of Armature .............................................................................. 5

S0405500 Page 2

Fuel Transfer Pump

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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. 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 the circuit will reactivate allowing the pump to restart.

Fuel Transfer Pump

S0405500 Page 3

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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. 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 2

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. Loosen 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 3

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

S0405500 Page 4

Fuel Transfer Pump

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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. Loosen the pump cover and remove the rotor and vane. Insert a new armature into the housing.

Figure 4

Refer to “Replacement of Rear Cover” on page 4, 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.

Fuel Transfer Pump

S0405500 Page 5

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S0405500 Page 6

Fuel Transfer Pump

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S0406030K

2HYDRAULIC OIL TANK

HYDRAULIC OIL TANKS0406030K MODEL Mega 400-V

SERIAL NUMBER RANGE 1001 and Up

S0406030K Page 1

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S0406030K Page 2

Hydraulic oil tank

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GENERAL DESCRIPTION PARTS LIST

SECTION A

SECTION B

AJS0630L

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

S0406030K Page 3

Return to Master Table of Contents SPECIFICATIONS

Mega 400-V Type

Pressurized Sealing

Capacity (System)

265 liters (70 U.S. gal.)

Air breather Open Pressure

0.40 kg/sq cm (5.7 psi)

Vacuum pressure

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

Return Filter Filtration rating

10 µ

Pressure drop

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

Suction Filter

S0406030K Page 4

177 µ

Hydraulic oil tank

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1LOWER STRUCTURE AND CHASSIS

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S0502010K

2CENTER 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)S0502010K MODEL Mega 400-V

SERIAL NUMBER RANGE 1001 and Up

S0502010K Page 1

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

S0502010K Page 2

Center Joint (Articulation Joint)

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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

S0502010K Page 3

Return to Master Table of Contents MAINTENANCE STANDARD

AJS0710L

Figure 2

S0502010K Page 4

Center Joint (Articulation Joint)

Return to Master Table of Contents Unit: mm No.

Check item

Clearance between upper hinge pin and rear frame

Criteria

Standard size

Tolerance

Remedy

Standard clearance

Clearance limit

-0.030 -0.076

+0.071 +0.036

0.066 ~ 0.147

Clearance between upper hinge pin and spacer (small)

-0.030 -0.076

+0.060 +0.030

0.060 ~ 0.136

Clearance between upper hinge pin and bearing

-0.030 -0.076

0 -0.015

0.015 ~ 0.076

Clearance between upper hinge pin and spacer (large)

-0.030 -0.076

+0.060 +0.030

0.060 ~ 0.136

Clearance between rear frame and spacer (large)

-0.036 -0.090

+0.071 +0.036

0.072 ~ 0.161

Clearance between front frame and upper hinge bearing

130

0 -0.025

-0.048 -0.088

-0.023 ~ -0.088

Clearance between lower hinge pin and rear frame

-0.030 -0.076

+0.054 0

0.030 ~ 0.130

Clearance between lower hinge pin and bearing

-0.030 -0.076

0 -0.015

0.015 ~ 0.076

Clearance between front frame and lower hinge bearing

130

0 -0.025

-0.048 -0.088

-0.023 ~ -0.088

Height of upper hinge spacer (small)

33.5 ±0.1

Height of upper hinge spacer (large)

73±0.1

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: 8±0.2 kg•m

Tightening torque of upper hinge retainer mounting bolt

When adjusting with shim: 8±0.2 kg•m

16 17

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

S0502010K Page 5

Replace

Final value: 13 ±1.0 kg•m Final value: 30 ±1.0 kg•m

Retighten

Center Joint (Articulation Joint)

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S0502010K Page 6

Center Joint (Articulation Joint)

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1ENGINE AND DRIVE TRAIN

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S0602150K

2FRONT AXLE

FRONT AXLE

S0602150K

MODEL Mega 400-V

SERIAL NUMBER RANGE 1001 and Up

S0602150K 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) ............................... 9 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............................................................................... 18 After First 250 Hours ............................................................................. 18 Every 150 hours .................................................................................... 18 Every 1500 Hours ................................................................................. 19 Lubricant Specifications ........................................................................ 19 General Disassembly and Reassembly Instructions .................................... 20 General Instructions .............................................................................. 20 Assembling Leakproof Components ..................................................... 21 Axle Disassembly ......................................................................................... 21 Drain Oil ................................................................................................ 21 Final Drive ............................................................................................. 22 Differential Assembly............................................................................. 26 Overhauling Super Max Trac Assembly ................................................ 30 Checking Clearance on Assembled Disc Packs.................................... 31 Axle Reassembly.......................................................................................... 32 Determining Thickness of Adjustment Shims........................................ 32 Inner Oil Recirculation Piping................................................................ 33

S0602150K Page 2

Front Axle

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 ............................................................................................... 44 Disassembly.......................................................................................... 45 Reassembly .......................................................................................... 45 Adjustment ............................................................................................ 45

Front Axle

S0602150K Page 3

S0602150K Page 4

Front Axle

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

Type Overall Reduction Ratio Differential type

24.685 STD.

Max. Trac (Locking Ration: 35%)

OPT.

Super Max Trac (Limited Slip: 50%)

Max Static Load

46,900.0 kg (103,400 lbs)

Max Output Torque

17,500.0 kg•m (126,580 ft lbs)

Brake

Parking Brake

Type

Multi Wet Disc

Torque

4,263 kg•m at 80 Bar (30,834 ft lbs at 1,160 psi)

Torque

360.0 kg•m (2,600 ft lbs)

Release Press.

Drive Flange

70 - 140 Bar (1,015 - 2,030 psi) 8.5 C

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

S0602150K Page 5

SECTION A AJS0640L

Figure 1 DRIVE AXLE ASSEMBLY

S0602150K Page 6

Front Axle

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 (202.5 ft-lbs) Threaded area: LOCTITE#262

NOTE:

2) 140 kg-m (1012.6 ft-lbs)

NOTE:

3) 170 kg-m (1229.6 ft-lbs)

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

S0602150K 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

Pinion Gear

Spider

Side Gear

Drive Pinion

Axle Shaft

Ring Gear

Differential Gear Case

S0602150K Page 8

Description

Front Axle

Limited Slip Differential Cross Section (Option) Figure 3, shows a cross-sectional view of the parts contained in the limited slip differential. 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 (18, Figure 7). Parking brake release pressure is 70 - 140 bar (1,015 - 2,030 psi) (max). The brake cylinder retracts the brake set spring (22) 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, in order 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

S0602150K Page 9

S0602150K Page 10

Front Axle

PARTS LIST Front Axle Housing

Figure 4

Reference Number

Description

Reference Number

Description

Oil Fill Plug - M27 x 2

Oil Tube

Oil Drain Plug - M27 x 2

Cap Screw - M8 x 22

Front Axle Housing

Snap Ring - 20 mm Dia.

Axle Vent - M10 x 1

Oil Pipe, Right Side

Axle Shaft

Oil Pipe, Left Side

Tube Gasket - 2.62 x 26.65 mm Dia.

Cap Screw - M8 x 40

Front Axle

S0602150K Page 11

Front Axle Differential

Figure 5

S0602150K Page 12

Front Axle

Reference Number

Description

Pin - 8 mm Dia. x 40 mm

Shim - 1.0 mm

Bearing - JHM 720249/ 720210

Shim - 1.025 mm

Bearing Adjusting Nut

Shim - 1.075 mm

Cap Screw - M22 x 1.5 x 60

Shim - 1.100 mm

Outer Clutch Disc

Shim - 1.125 mm

Side Gear

Shim - 1.150 mm

Cross

Shim - 1.175 mm

Pinion Gear

Shim - 1.200

Thrust Washer

Shim - 1.225 mm

* 10

Shim - 3.5 mm

Shim - 1.250 mm

Shim - 3.6 mm

Shim - 1.275 mm

Shim - 3.7 mm

Shim - 1.300 mm

Shim - 3.8 mm

Shim - 1.325 mm

Cap Screw - M14 x1.5 x 140 mm

Shim - 1.350 mm

Middle Clutch Disc

Cap Screw - M16 x 1.5 x 55 mm

Plate

Rivet

Bearing H916600

Shim - 3.5 mm Shim - 3.6 mm Shim - 3.7 mm Shim - 3.9 mm Shim - 4.0 mm Shim - 4.1 mm Shim - 4.2 mm Shim - 4.3 mm Shim - 4.4 mm

Shim - 1.050 mm

Shim - 1.375 mm Shim - 1.400 mm Shim - 1.425 mm Shim - 1.450 mm Shim - 1.475 mm Shim - 1.500 mm 22

Nut

Flange Assembly

Bearing - JW70

Seal - 105 x 140 x 13 mm

Washer

110

Differential Support Assembly

120

Ring and Pinion Gear Assembly

130

Differential Carrier Assembly

140

Spacer Assembly

Shim - 4.5 mm 18

Pump

Shim - 0.5 mm

Front Axle

Description

S0602150K Page 13

Front Planetary Gear Set

Figure 6

S0602150K Page 14

Front Axle

Reference Number

Description

Reference Number

Description

Housing Cover

Thrust Washer

Cover Gasket - 3.53 x 304.4

Bearing - 180 mm Dia. x 250 x 45

Shaft Thrust Plate

Ring Gear Support

Cap Screw - M10 x 25

Ring Gear

Planetary Housing

Wheel Hub

Stud Bolt

Plug - M22 x 1.5

Plug Gasket

Piston Seal - 5.33 x 117.5 mm

Thrust Washer - 3 mm

Piston

Bearing

Bearing Spacer

Piston Seal - 5.34 x 142.9 mm

Differential Pinion Gear

Thrust Washer - 4.7 mm

Inner Bearing - 170 mm Dia. x 230 x 38

Differential Side Gear

Wheel Seal - 190 mm x 230 x 21.3

Snap Ring

Brake Disc Hub

Right Side Hub and Spindle Assembly

Brake Disc (x 6EA)

Bleeder Screw

Steel Disc - 2.5 mm

Cap Screw - M x 25

Steel Disc - 3.75 mm

Housing Seal Ring - 3.53 x 430.66 mm

Steel Disc - 4.50 mm

Left Side Hub Assembly

Snap Ring

Cap Screw - M22 x 1.5 x 70 mm

Pressure Plate

Nut

Spring

Spring Insert

Ring

Lockplate

Seal Ring

Hub Nut

Snap Ring

NOTE:

No. of Brake Discs (Front): 6 EA. (Rear): 5 EA.

Steel Disc - 3.25 mm

Front Axle

Washer

110

Housing Assembly

S0602150K Page 15

Parking Brake

Figure 7

S0602150K Page 16

Front Axle

Reference Number

Description

Reference Number

Description

Ball Socket

Cylinder

Lock Nut

Guide Ring

Adjusting Rod

Gasket

Adjusting Sleeve

Seal

Lock Nut - M14 x 2

Spring

Protective Cap

Flange

Joint Cover

Nut

Dowel Pin

Caliper Assembly

Tension Rod

Cap Screw - M10 x 40

Stem

Washer

Mounting Plate Assembly

Brake Disc

Seal

Cap Screw - M10 x 40

Gasket

Cap Screw - M12 x 35 x 1.75

Guide Ring

Threaded Stud

Cotter Pin

Nut - M x 10+

Washer

Gasket Kit - Contains items 12, 13, 14, 19, 20 and 21

Front Axle

S0602150K Page 17

SCHEDULED MAINTENANCE

Figure 8

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 90° (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.

Side Final Drives. •

Check oil by rotating hub 90° (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).

S0602150K Page 18

Front Axle

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 90° (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: Mil - L - 2105B API GL 5

•

Corresponding to: SAE 90 or SAE 80 W 90 rating

NOTE:

Front Axle

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

S0602150K Page 19

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

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.

In order to heat bearings, using 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.

S0602150K Page 20

Front Axle

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 prior to 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 9

DRAIN OIL 1.

Differential Unit. •

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

Side Final Drives. •

Front Axle

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

S0602150K Page 21

FINAL DRIVE

Figure 10

S0602150K Page 22

Front Axle

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.

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

S0602150K Page 23

Figure 11

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) located 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).

S0602150K Page 24

Front Axle

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 lbs).

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:

Front Axle

No gear can be removed prior to having released all of them.

S0602150K Page 25

DIFFERENTIAL ASSEMBLY

Figure 12

S0602150K Page 26

Front Axle

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.

Front Axle

S0602150K Page 27

Figure 13 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.

S0602150K Page 28

Front Axle

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 lbs).

Position differential components in their proper seats.

Front Axle

S0602150K Page 29

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:

S0602150K Page 30

Figure 14

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

Front Axle

CHECKING CLEARANCE ON ASSEMBLED DISC PACKS 1.

Check should be carried out all around at points placed at 120° 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 15

Front Axle

S0602150K Page 31

AXLE REASSEMBLY DETERMINING THICKNESS OF ADJUSTMENT SHIMS

Figure 16 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.

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Front Axle

INNER OIL RECIRCULATION PIPING

Figure 17 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

S0602150K Page 33

DIFFERENTIAL ASSEMBLY

Figure 18

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.

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

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Front Axle

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 Nm (58 - 64 kg•m / 419 - 463 ft lb).

Check pinion end play by means of 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 Nm (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 Nm (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 Nm (90 ~ 94 kg•m / 650 ~ 680 ft lb).

11.

Check differential end play with a dial gauge.

12.

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

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

ADJUSTING BACKLASH 1.

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

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

•

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

•

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

•

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

Front Axle

Figure 19

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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 20 Neutral Side.

Figure 21 Increase Pinion Distance Drive Side.

Figure 22 Neutral Side.

Figure 23

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Front Axle

Decrease Pinion Distance Drive Side.

Figure 24 Neutral Side.

Figure 25 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

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Front Axle

SECURING DIFFERENTIAL TO AXLE HOUSING

Figure 26 1.

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

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

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

Front Axle

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FINAL DRIVE

Figure 27

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Front Axle

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

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 Nm (1.5 - 3.1 kg•m / 11.1 - 22.1 ft lb).

NOTE:

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

13.

Remove spring retainer compressing brake actuator return spring.

14.

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

15.

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

Two rows of needle rollers of same selection class 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:

Front Axle

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

S0602150K Page 41

25.

Force fit wheel shaft backing plate (4).

26.

Mount O-ring seal (3) on edge.

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 Nm (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 28

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 29

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Front Axle

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 30

Front Axle

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PARKING BRAKE

Figure 31

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Front Axle

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 lockwasher 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

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Front Axle

Return to Master Table of Contents

S0602160K

3REAR AXLE

REAR AXLE

S0602160K

MODEL Mega 400-V

SERIAL NUMBER RANGE 1001 and Up

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TABLE OF CONTENTS General Description........................................................................................ 3 Outline..................................................................................................... 3 Drive Axle................................................................................................ 3 Differential (Standard) ............................................................................. 6 Parts List ................................................................................................. 9 Scheduled Maintenance............................................................................... 14 After First 250 Hours ............................................................................. 14 Every 150 hours .................................................................................... 15 Every 1500 Hours ................................................................................. 15 Lubricant Specifications ........................................................................ 15 General Disassembly and Reassembly Instructions .................................... 16 General Instructions .............................................................................. 16 Assembling Leakproof Components ..................................................... 17 Axle Disassembly ......................................................................................... 17 Drain Oil ................................................................................................ 17 Final Drive ............................................................................................. 18 Differential Assembly............................................................................. 23 Overhauling Super Max Trac Assembly ................................................ 25 Checking Clearance on Assembled Disc Packs.................................... 26 Axle Reassembly.......................................................................................... 27 Determining Thickness of Adjustment Shims........................................ 27 Differential Assembly............................................................................. 28 Axial Position of Bevel Pinion ................................................................ 28 Adjusting Backlash................................................................................ 29 Adjusting Tooth Contact ........................................................................ 30 Securing Differential to Axle Housing.................................................... 33 Final Drive ............................................................................................. 34 Determining Space Available to Form Brake Disc Pack........................ 36

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Rear Axle

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GENERAL DESCRIPTION OUTLINE Rear Axle Trunnion Mounting, Semi-Floating

Type Overall Reduction Ratio Differential type

24.685 STD.

Max. Trac (Locking Ration: 35%)

OPT.

Super Max Trac (Limited Slip: 50%)

Max Static Load

46,900.0 kg (103,400 lbs)

Max Output Torque

11,800.0 kg•m (85,350 ft lbs)

Brake

Parking Brake

Type

Multi Wet Disc

Torque

3,197 kg•m at 80 Bar (23,124 ft lbs at 1,160 psi)

Torque

360.0 kg•m (2,600 ft lbs)

Release Press.

Drive Flange

70 - 140 Bar (1,015 - 2,030 psi) 7C

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

Rear Axle

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SECTION A AJS0640L

Figure 1 DRIVE AXLE ASSEMBLY

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Rear Axle

Return to Master Table of Contents 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 (202.5 ft-lbs) Threaded area: LOCTITE#262

NOTE:

2) 140 kg-m (1012.6 ft-lbs)

NOTE:

3) 170 kg-m (1229.6 ft-lbs)

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

S0602160K Page 5

Return to Master Table of Contents 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

Pinion Gear

Spider

Side Gear

Drive Pinion

Axle Shaft

Ring Gear

Differential Gear Case

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Description

Rear Axle

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

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S0602160K Page 8

Rear Axle

Return to Master Table of Contents PARTS LIST Rear Axle Housing

Figure 4

Reference Number

Description

Reference Number

Description

Oil Fill Plug - M27 x 2

Axle Vent - M10 x 1

Oil Drain Plug - M27 x 2

Axle Shaft

Rear Axle Housing

Rear Axle

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Figure 5

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Rear Axle

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Reference Number

Description

Pin - 8 mm Dia. x 40 mm

Shim - 1.0 mm

Bearing - 95 x 145 x 32 mm

Shim - 0.1025 mm

Bearing Adjusting Nut

Shim - 1.050 mm

Cap Screw - M18 x 1.5 x 45

Shim - 1.075 mm

Outer Clutch Disc

Shim - 1.100 mm

Side Gear

Shim - 1.125 mm

Cross

Shim - 1.150 mm

Pinion Gear

Shim - 1.175 mm

Thrust Washer

Shim - 1.200 mm

Middle Clutch Disc

Shim - 1.225 mm

Cap Screw - M12 x 120 mm

Shim - 1.250 mm

Description

Shim - 3.0 mm

Shim - 1.275 mm

Shim - 3.10 mm

Shim - 1.300 mm

Shim - 3.20 mm

Shim - 1.325 mm

Shim - 3.20 mm

Shim - 1.350 mm

Shim - 3.30 mm

Shim - 1.375 mm

Cap Screw - M16 x 1.5 x 45

Shim - 1.400 mm

Plate

Shim - 1.425 mm

Rivet

Shim - 1.450 mm

Bearing

Shim - 1.475 mm

Shim - 3.5 mm

Shim - 1.500 mm

Shim - 3.6 mm

Nut

Shim - 3.7 mm

Flange

Shim - 3.8 mm

Bearing - 30311

Shim - 3.9 mm

Seal - 85 mm Dia. x 120 x 1/24

Shim - 4.1 mm

Washer

Shim - 4.2 mm

110

Differential Support Assembly

120

Ring and Pinion Gear Assembly

130

Differential Carrier Assembly

140

Spacer Assembly

Shim - 4.0 mm

Shim - 4.3 mm Shim - 4.4 mm Shim - 4.5 mm 18

Spacer

Shim - 0.5 mm

Rear Axle

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Return to Master Table of Contents Rear Axle Planetary Gear Set

Figure 6

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Rear Axle

Return to Master Table of Contents Reference Number

Description

Reference Number

Description

Housing Cover

Snap Ring - 92 mm Dia.

Cover Gasket - 3.35 mm x 278.99 Dia.

Thrust Washer

Bearing - 170 mm Dia. x 230 x 38

Shaft Thrust Plate

Cap Screw - M10 x 25

Ring Gear Support

Planetary Housing

Ring Gear

Wheel Hub

Plug - M22 x 1.5

Stud Bolt

Plug Gasket

Thrust Washer - 1.5 mm

Piston Seal - 5.33 x 109.5 mm

Bearing

Piston

Bearing Spacer

Differential Pinion Gear

Piston Seal - 5.33 x 133.7 mm

Thrust Washer - 3.0 mm

Differential Side Gear

Inner Bearing - 140 mm Dia. x 195 x 29

Snap Ring

* 37

Wheel Seal - 178 mm x 205 x 20

Brake Disc Hub

Brake Disc

Right Side Hub and Spindle Assembly.

Steel Disc - 2.5 mm

Bleeder Screw

Steel Disc - 3.75 mm

Cap Screw - M8 x 25

Steel Disc - 3.25 mm

Housing Seal Ring - 3.53 x 430.66 mm

Left Side Hub and Spindle Assembly

Cap Screw - M22 x 1.5 x 70 mm

Nut

Spacer Ring

Washer

110

Housing Assembly

Steel Disc - 4.5 mm 19

Snap Ring

Pressure Plate

Spring

Spring Insert

Lockplate

Hub Nut

NOTE:

No. of Brake Discs (Front) : 6 EA (Rear) : 5 EA

Rear Axle

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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 90° (so "OIL LEVEL" writing is horizontal) and add oil until it overflows, replace plug (3).

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Rear Axle

Return to Master Table of Contents 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 90° (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 90° (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: Mil - L - 2105B API GL 5

•

Corresponding to: SAE 90 or SAE 80 W 90 rating

NOTE:

Rear Axle

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

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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.

In order to heat bearings, using 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.

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Rear Axle

Return to Master Table of Contents 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 prior to 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. •

Rear Axle

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

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Return to Master Table of Contents FINAL DRIVE

Figure 9

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Rear Axle

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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

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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) located 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).

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Rear Axle

Return to Master Table of Contents 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:

Rear Axle

No gear can be removed prior to having released all of them.

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Rear Axle

Return to Master Table of Contents DIFFERENTIAL ASSEMBLY

Figure 11 1.

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

Rear Axle

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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.

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

S0602160K Page 24

Rear Axle

Return to Master Table of Contents 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 lbs).

Position differential components in their proper seats.

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 molibdenum plated on one side only. Disc (22a) is in contact with sun gear (21), and molibdenum 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:

Rear Axle

Figure 13

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

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Return to Master Table of Contents CHECKING CLEARANCE ON ASSEMBLED DISC PACKS 1.

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

S0602160K Page 26

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

Return to Master Table of Contents

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

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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.

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

S0602160K Page 28

Rear Axle

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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 Nm (58.1 - 64.2 kg•m / 420 - 460 ft lb).

Check pinion end play by means of 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 Nm (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 Nm (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 Nm (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

Figure 17

S0602160K Page 29

Return to Master Table of Contents 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

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Rear Axle

Return to Master Table of Contents 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

S0602160K Page 31

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S0602160K Page 32

Rear Axle

Return to Master Table of Contents SECURING DIFFERENTIAL TO AXLE HOUSING

Figure 24

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

Rear Axle

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

S0602160K Page 33

Return to Master Table of Contents FINAL DRIVE

Figure 25

S0602160K Page 34

Rear Axle

Return to Master Table of Contents 1.

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

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 Nm (1.5 - 3.1 kg•m / 11.1 - 22.1 ft lb).

NOTE:

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

13.

Remove spring retainer compressing brake actuator return spring.

14.

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

15.

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

Two rows of needle rollers of same selection class 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:

Rear Axle

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

S0602160K Page 35

Return to Master Table of Contents 25.

Force fit wheel shaft backing plate (4).

26.

Mount O-ring seal (3) on edge.

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 Nm (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

S0602160K Page 36

Rear Axle

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S0605050K

4AIR-CONDITIONER

AIR-CONDITIONER S0605050K MODEL M400-V

SERIAL NUMBER RANGE 1001 and Up

S0605050K Page 1

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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 Refrigerant System Repairs ......................................................................... 17 Refrigerant Safe Handling Procedures ................................................. 17 Repair and Replacement Procedure..................................................... 18 Refrigerant Recovery ............................................................................ 20 Vacuuming Refrigerant System............................................................. 20 Leakage Check ..................................................................................... 21 Refrigerant Charging............................................................................. 22 Inspecting System For Leakage............................................................ 24

S0605050K Page 2

Air-Conditioner

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GENERAL DESCRIPTION

AJS0880L

Figure 1 The heater and air-conditioner are combined into one blower unit located in the right control stand of operator's seat. If necessary, the operator can control inner temperature using the operation panel installed in the top of the right side door. The unit is equipped with an air filtration system which filters out dirt and dust particles from air being circulated into the operator"s cab. This filter (1, Figure 2) should be cleaned out at approximately every 500 hours and replaced with a new one every 1000 hours. NOTE:

In the event that the unit is being operated in a dusty environment, cleaning and replacement should be performed more frequently.

WARNING! All service and inspection of the air conditioning system should be performed with the starter switch in the "O" (OFF) position. NOTE:

Air-Conditioner

AJS0530L

Figure 2

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

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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 15.0 kg/sq cm (213.35 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 2.0 kg/sq cm (28.45 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 environmentallymandated standard.

Air-Conditioner

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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 LEDs 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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AJS0550L

Figure 10 Reference Number

Description

Reference Number

Description

Select Switch

Evaporator Core

Foot Vent

Air Filter

Heater Core

Blower Motor

S0605050K Page 10

Air-Conditioner

Return to Master Table of Contents Defroster

AJS0560L

Figure 11 Reference Number

Description

Reference Number

Description

Select Switch

Evaporator Core

Defroster Vent

Air Filter

Heater Core

Blower Motor

Air-Conditioner

S0605050K Page 11

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AIR-CONDITIONING SYSTEM CIRCUIT DIAGRAM

AJS0570L

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

Head Lamp 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

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TROUBLESHOOTING Refrigerant Pressure Check

HDA6074L

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: 8.0 - 10.0 kg/cm2 (114 - 142 psi) Low Pressure: Approximately 1.0 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 (35.56 - 42.67 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 (284.47 - 355.58 psi) Low Pressure: Approximately 2.5 - 3.5 kg/cm2 (35.56 - 49.78 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

Remedy

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: 13.0 - 19.0 kg/cm2 (185 - 270 psi)

Yes

Moisture in receiver dryer.

system,

replace

Contaminated system, expansion valve.

replace

(Replace assembly.)

evaporator

core

Low Pressure: 1.5 - 3.3 kg/cm2 (21.3 - 46.9 psi) High Pressure: Over 6 - 18 kg/cm2 (85 - 256 psi) Low Pressure: 500 mmHg (Negative Pressure) - Dial indicator needle unstable.

Possible Cause: Moisture in system has iced up the expansion valve. NOTE:

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

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 22.0 - 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 Inspect whether the temperature sensor is installed properly.

Air-Conditioner

Remedy Yes

Replace expansion valve.

Exchange duct sensor.

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High Pressure: Over 7.0 - 11.0 kg/cm2 (100 - 156 psi) Low Pressure: 4.0 - 6.0 kg/cm2 (57 - 85 psi)

Possible Cause: Low refrigerant pressure due to poor compressor compression Inspect and replace compressor if necessary.

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Air-Conditioner

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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.

Air-Conditioner

S0605050K Page 17

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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:

S0605050K Page 18

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

Air-Conditioner

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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

Air-Conditioner

S0605050K Page 19

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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.

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Air-Conditioner

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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.

HDA6069L

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 counter clockwise most position, with the puncture pin retracted and the mounting disk is in the raised position.

2 3

HDA6070L

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 (14.22 psi) and close the high side valve.

Air-Conditioner

S0605050K Page 21

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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.

HDA6071L

Figure 20

WARNING! For accurate refrigerant leak detection, perform leak detection procedure in a well ventilated area. REFRIGERANT CHARGING 1.

Perform the vacuuming procedure, vacuum holding and leaking tests as described in the proceeding headings. NOTE:

First charge the refrigerant system with 100g (3.5 ounces) of refrigerant with the engine off. Then using the manifold gauges as a guide fully charge the system with the engine running. When exchanging refrigerant containers, press the manifold gauge low side valve to eliminate air from the charging hose.

Reference 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).

5 HDA6072L

Figure 21

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)

S0605050K Page 22

Air-Conditioner

Return to Master Table of Contents 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 (184.90 - 284.47 psi)

Low Side Gauge

1.5 - 3.5 kg/cm2 (21.34 - 49.78 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.

Air-Conditioner

S0605050K Page 23

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

2 1

3 4

HDA6073L

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 matter inside of valve cap.

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

When inspecting leakage from the air-conditioning unit, perform the inspection in a well ventilated area.

S0605050K Page 24

Air-Conditioner

Return to Master Table of Contents

S0607070K

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

TRANSMISSION AND TORQUE CONVERTER (ZF)S0607070K MODEL Mega 400-V

SERIAL NUMBER RANGE 1001 and Up

S0607070K Page 1

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TABLE OF CONTENTS Drive Train Description ................................................................................... 5 Transmission and Torque Converter............................................................... 6 Powershift Transmission.......................................................................... 7 Transmission Control............................................................................... 7 Schedule of Measuring Points and Connection 4 WG-260 ..................... 8 Oil Circuit Diagram 4WG - 260 Forward 1st Speed .............................. 11 Transmission Electric Components .............................................................. 13 TCU (Transmission Control Unit) .......................................................... 14 Transmission Control Valve ................................................................... 14 Transmission Oil Temperature Sensor .................................................. 15 Engine Pick-Up Sensor ......................................................................... 15 Central Gear Pick-Up Sensor................................................................ 15 Turbine Pick-Up Sensor......................................................................... 16 Output Speed Sensor............................................................................ 16 Shift Lever Switch (DW-3) ..................................................................... 16 Auto Select Switch ................................................................................ 18 Display .................................................................................................. 18 Transmission Electrical Circuits.................................................................... 19 T/M Controller Circuit ............................................................................ 19 Travelling Circuits .................................................................................. 20 Neutral ........................................................................................... 20 Forward First Gear ......................................................................... 21 Forward Second Gear.................................................................... 22 Forward Third Gear........................................................................ 23 Forward Fourth Gear ..................................................................... 24 Reverse First Gear......................................................................... 25 Reverse Second Gear.................................................................... 26 Reverse Third Gear........................................................................ 27 Downshift .............................................................................................. 28 Overview ........................................................................................ 28

S0607070K Page 2

Transmission and Torque Converter (ZF)

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

Transmission and Torque Converter (ZF)

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

S0607070K Page 4

Transmission and Torque Converter (ZF)

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

Figure 1

Reference Number

Description

Reference Number

Description

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

Transmission and Torque Converter (ZF)

S0607070K Page 5

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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

4WG 260 (Full Auto)

Type

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

Oil Cooler Torque Converter

Mega 400-V

Model

Charging Pump Hydraulic Pump P.T.O

Water-cooled (multi-plate) and Air-cooled 115 l/min at 2,000 rpm 1:1

T/C Size

∅ 370 mm

Stall Ratio

2,985

Safety Relief

11 Bar (160 psi)

Type

Full Power Shift, Counter shaft

Speeds

4 Forward / 3 Reverse

Ratio

F : 3.73 / 2.206 / 1.969 / 0.624 R : 3.73 / 2.206 / 0.969

Power Shift Control Pressure

16 ~ 18 bar (232 ~ 261 psi)

Transmission

Shift Control

Electric Shift with Proportional Valve

Oil Capacity

50 l (13.2 U.S. gal)

Dry Weight

750 kg (1,653 lbs)

Output Flange

S0607070K Page 6

Front

8.5 C Mechanics

Rear

7 C Mechanics

Transmission and Torque Converter (ZF)

Return to Master Table of Contents POWERSHIFT TRANSMISSION The multi-speed reversing transmission in countershaft design is power shiftable by hydraulically actuated multi-disk clutches. All gears are constantly meshing and carried on antifriction bearings. The gear wheels, bearings and clutches are cooled and lubricated with oil. The 4-speed reversing transmission is equipped with 6 multi-disk clutches. At the shifting, the actual plate pack is compressed by a piston, movable in axial direction, which is pressurized by pressure oil. A compression spring takes over the pushing back of the piston, thus the release of the plate pack. As to the layout of the transmission as well as the specifications of the closed clutches in the single speeds, see “Schedule of Measuring Points and Connection 4 WG-260” on page 8 and “Oil Circuit Diagram 4WG - 260 Forward 1st Speed” on page 11. TRANSMISSION CONTROL Transmission control, see “Schedule of Measuring Points and Connection 4 WG-260” on page 8, Electrohydraulic unit on page -10 and “Oil Circuit Diagram 4WG - 260 Forward 1st Speed” on page 11. The transmission pump, necessary for the oil supply of the converter, and for the transmission control, is sitting in the transmission on the engine-dependent input shaft. The feed rate of the pump is Q = 105 l/min. at nEngine = 2000 min-1. This pump is sucking the oil via the coarse filter out of the oil sump and delivers it via the ZF-Fine filter - the filters is fitted externally from the transmission - to the main pressure valve. ZF-Fine filter Filtration ratio according to ISO 4572 : β30 ≥ 75 β15 = 25 β10 = 5.0 Filter surface at least : 2 x 6,700 cm2 = 13,400 cm2 Dust capacity according to ISO 4572 at least : 17g The six clutches of the transmission are selected via the 6 proportional valves P1 to P6. The proportional valve (pressure regulator unit) is composed of pressure regulator (e.g. Y6). follow-on slide and vibration damper. The control pressure of 9.0 bar (130.54 psi) for the actuation of the follow-on slides is created by the pressure reducing valve. The pressure oil (16 - 18 bar (230 - 260 psi)) is directed via the follow-on slide to the respective clutch. Due to the direct proportional selection with separated pressure modulation for each clutch, the pressure to the clutches, which are engaged in the gear change, will be controlled. In this way, a hydraulic intersection of the clutches to be engaged and disengaged becomes possible. This is creating spontaneous shiftings without traction force interruption. At the shifting, the following criteria will be considered: - Speed of engine, turbine, central gear train and output. - Transmission temperature. - Shifting mode (up-, down-, reverse shifting and speed engagement out of Neutral). - Load condition (full and part load, traction, overrun inclusive consideration of load cycles during the shifting).

Transmission and Torque Converter (ZF)

S0607070K Page 7

Return to Master Table of Contents The main pressure valve is limiting the max. control pressure to 16 - 18 bar (230 - 260 psi) and releases the main stream to the converter and lubricating circuit. In the inlet to the converter, a converter safety valve is installed which protects the converter from high internal pressure (opening pressure 11 bar (160 psi)). Within the converter, the oil serves to transmit the power according to the well-known hydro-dynamic principle. To avoid cavitation, the converter must be always completely filled with oil. This is achieved by a converter pressure back-up valve, rear-mounted to the converter, with an opening pressure of at least 5 bar (73 psi). The oil, escaping out of the converter, is directed to a heat exchanger. From the heat exchanger, the oil is directed to the transmission and there to the lubricating oil circuit, so that all lubricating points are supplied with cooled oil. The allocation of the pressure regulators to the single speeds can be seen on the “Schedule of Measuring Points and Connection 4 WG-260” on page 8 and “Oil Circuit Diagram 4WG - 260 Forward 1st Speed” on page 11. SCHEDULE OF MEASURING POINTS AND CONNECTION 4 WG-260 The marked positions (e. g. 53) correspond with the positions on the “Oil Circuit Diagram 4WG - 260 Forward 1st Speed” on page 11. The measurements have to be carried out at hot transmission (about 80° - 90°C). No.

Denomination of the Position

Connection

Marking on the Valve Block H

Measuring Points for Pressure Oil and Temperature 51

In front of the converter - Opening pressure 11 bar (160 psi)

M10 x 1

Behind the converter - Opening pressure 5 bar (73 psi)

M14 x 1.5

Clutch Forward 16 - 18 bar (230 - 260 psi) KV

M10 x 1

Clutch Reverse 16 - 18 bar (230 - 260 psi) KR

M10 x 1

Clutch Reverse 16 - 18 bar (230 - 260 psi) K1

M10 x 1

Clutch Reverse 16 - 18 bar (230 - 260 psi) K2

M10 x 1

Clutch Reverse 16 - 18 bar (230 - 260 psi) K3

M10 x 1

Clutch Reverse 16 - 18 bar (230 - 260 psi) K4

M10 x 1

Behind the Converter Temperature 100°C, Short-time 120°C

M14 x 1.5

System Pressure 16 - 18 bar (230 - 260 psi) K4

M10 x 1

Breather

M10 x 1

Connection to the Heat Exchanger

-------

Connection from the Heat Exchanger

-------

To the Filter

M42 x 2

From the Filter

M42 x 2

From the Filter Bypass

M42 x 2

Oil Filter Plug

M42 x 2

Plug Connection on the Electrohydraulic Control Unit

System Pressure (Option)

S0607070K Page 8

M16 x 1.5

Transmission and Torque Converter (ZF)

Return to Master Table of Contents No. 69

Denomination of the Position Control System (Option)

Connection

Marking on the Valve Block

M16 x 1.5

Inductive Transmitters and Speed Sensor 5

Inductive Transmitter n Turbine

M18 x 1.5

Inductive Transmitter n Central Gear Train

M18 x 1.5

Speed Sensor n Output and Speedometer

-------

Inductive Transmitter n Engine

Transmission and Torque Converter (ZF)

M18 x 1.5

S0607070K Page 9

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Figure 2

S0607070K Page 10

Transmission and Torque Converter (ZF)

Return to Master Table of Contents OIL CIRCUIT DIAGRAM 4WG - 260 FORWARD 1ST SPEED The marked positions (e. g. 53) correspond with the positions on “Schedule of Measuring Points and Connection 4 WG-260” on page 8

Reference Number

Positions

Heat Changer

WGV

Converter Back Pressure Valve 5 bar (73 psi)

WSV

Converter Safety Valve 11 bar (160 psi)

HDV

Main Pressure Valve 16 - 18 bar (230 - 260 psi)

RV-9

Pressure Reducing Valve 9 bar (130 pai)

NFS

Follow-on Slide

Vibration Damper

Orifice

Proportional Valve - Clutch KR

Proportional Valve - Clutch K4

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

Transmission and Torque Converter (ZF)

S0607070K Page 11

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ZF-FINE FILTER FILTER GRADE ACCORDING ISO 4572:

β30>75 β15=25 β10=5.0

LEGEND:

WT (SCOPE OF SUPPLY CUSTOMER)

= MAIN PRESSURE = REGULATED MAIN PRESSURE = PILOT PRESSURE = CONVERTER INPUT PRESSURE = CONVERTER OUTPUT PRESSURE = LUBRICATION

BYPASSVALVE ∆p=1.5bar

DUST CAPACITY ACCORDING ISO 4572: min. 17g 2 FILTER SURFACE cm 2 x 6,700 = 13,400 TRANSMISSION PUMP p = 16+2 bar Qp= 115 l/min-1at n = ENGINE 2000 min-1 COARSE FILTER MESH WIDTH µm : 450 FILTER SURFACE cm2 1000

= RETURN INTO THE SUMP

AJS0870L

Figure 4

S0607070K Page 12

Transmission and Torque Converter (ZF)

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TRANSMISSION ELECTRIC COMPONENTS 21

10 18 19 14

17 8

15 1 16 3

11 12

4 7

6 5

AJS0190L

Figure 5 Reference Number

Description

Reference Number

Description

T/M Controller

T/M Cut-off Pressure Switch

T/M Control Valve

Downshift Switch

T/M Oil Temperature Sensor

Safety Starter Switch

Engine Pick-Up Sensor

Fuse Box

Central Gear Pick-up Sensor

Parking Brake Switch

Turbine Pick-up Sensor

Control Unit

Output Speed Sensor

Starter Controller

Shift Lever Switch

LIS Switch (Option)

Auto Select Switch

LIS Solenoid Valve

Display

Speedometer

T/M Cut-off Switch

Transmission and Torque Converter (ZF)

S0607070K Page 13

Return to Master Table of Contents 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 ohm ± 1.9 ohm at 20°C. Pressure : 0.8 kgf/cm2 → 8.3 kgf/cm2

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

S0607070K Page 14

Transmission and Torque Converter (ZF)

Return to Master Table of Contents TRANSMISSION OIL TEMPERATURE SENSOR 1.

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

Specification •

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

AJS0220L

Figure 8

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

Detect a revolution of gear array in engine side.

Specification •

Resistance: 1050Ω ± 10% ( at 20°C)

•

Fasten torque: 3.06 kg•m (22.13 ft lbs)

•

Gap: 0.5 - 0.8 mm (0.0197 - 0.0315 in.)

•

Output : 4 Pulse/Rev.

AJS0230L

Figure 9

CENTRAL GEAR PICK-UP SENSOR 1.

Detect a revolution of central gear array

Specification •

Resistance : 1050Ω ± 20°C)

•

Fasten torque : 3.06 kg•m (22.13 ft lbs)

•

Gap : 0.5 - 0.8 mm (0.0197 - 0.0315 in.)

•

Output : 91 Pulse/Rev.

10% ( at

Transmission and Torque Converter (ZF)

AJS0240L

Figure 10

S0607070K Page 15

Return to Master Table of Contents TURBINE PICK-UP SENSOR 1.

Detect a revolution of gear array in turbine side.

Specification •

Resistance : 1050Ω ± 10% ( at 20°C)

•

Fasten torque : 3.06 kg•m (22.13 ft lbs)

•

Gap : 0.5 - 0.8 mm (0.0197 - 0.0315 in.)

•

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) : 2.35 kg•m (16.96 ft lbs)

•

Gap : 1.0 - 1.5 mm (0.0394 - 0.0591 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 * Reverse shift range : 1 ~ 3 2.

LEVER LOCK KEY (N/D)

Kick-Down (Down Shift) Switch •

SHIFT SWITCH

KD : Kick-Down Switch

AJS0270L

Figure 13

Lever Lock Key •

N : Neutral (The lever is not moved.)

•

D : Driving (The lever is released.)

S0607070K Page 16

Transmission and Torque Converter (ZF)

Return to Master Table of Contents 4.

Switch Circuit

A AD3 (B3)

B AD2 (B2)

C AD1 (B1)

D AD7 (KD)

A ED1 (+/VP)

D AD6 (N)

B AD4 (F)

C AD5 (R)

2 3

1 1

2 3 2 3

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 6.

Switch Connection

GEAR TERMINAL ED1 VP AD1

AD2

AD3

AD4

AD5

AD6

AD7

REVERSE

FORWARD 1

NEUTRAL 4

KICK DOWN

AJS0300L

Figure 16

Transmission and Torque Converter (ZF)

S0607070K Page 17

Return to Master Table of Contents 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

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.

B HLB2007L

Figure 17

DISPLAY NOTE:

S0607070K Page 18

See "Transmission Error Codes (ZF)" shop manual section.

Transmission and Torque Converter (ZF)

Return to Master Table of Contents

TRANSMISSION ELECTRICAL CIRCUITS T/M CONTROLLER CIRCUIT

AJS0310L

Figure 18

The transmission proportioning solenoid valves are shown here as (Y1 thru Y6, Figure 18).

Transmission and Torque Converter (ZF)

S0607070K Page 19

Return to Master Table of Contents TRAVELLING CIRCUITS Neutral

AJS0320L

Figure 19

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

S0607070K Page 20

Transmission and Torque Converter (ZF)

Return to Master Table of Contents Forward First Gear

AJS0330L

Figure 20

Transmission solenoid valves (Y3 and Y5, Figure 20) are energized when in forward first gear.

Transmission and Torque Converter (ZF)

S0607070K Page 21

Return to Master Table of Contents Forward Second Gear

AJS0340L

Figure 21

Transmission solenoid valves (Y5 and Y6, Figure 21) are energized when in forward second gear.

S0607070K Page 22

Transmission and Torque Converter (ZF)

Return to Master Table of Contents Forward Third Gear

AJS0350L

Figure 22

Transmission solenoid valves (Y4 and Y5, Figure 22) are energized when in forward third gear.

Transmission and Torque Converter (ZF)

S0607070K Page 23

Return to Master Table of Contents Forward Fourth Gear

AJS0360L

Figure 23

Transmission solenoid valves (Y2 and Y4, Figure 23) are energized when in forward fourth gear.

S0607070K Page 24

Transmission and Torque Converter (ZF)

Return to Master Table of Contents Reverse First Gear

AJS0370L

Figure 24

Transmission solenoid valves (Y1 and Y3, Figure 24) are energized when in reverse first gear.

Transmission and Torque Converter (ZF)

S0607070K Page 25

Return to Master Table of Contents Reverse Second Gear

AJS0380L

Figure 25

Transmission solenoid valves (Y1 and Y6, Figure 25) are energized when in reverse second gear.

S0607070K Page 26

Transmission and Torque Converter (ZF)

Return to Master Table of Contents Reverse Third Gear

AJS0390L

Figure 26

Transmission solenoid valves (Y1 and Y4, Figure 26) are energized when in reverse third gear.

Transmission and Torque Converter (ZF)

S0607070K Page 27

Return to Master Table of Contents DOWNSHIFT Overview 1.

There are two downshift switches down Figure 27, and it is possible for operators to select one of them according to the condition.

If the downshift switch is depressed during the machine moving, downshifting takes place automatically. As a result, fast digging and moving is possible. But at the manual mode the kick down can only be activated.

If a change or travelling direction takes place or the downshift switch is depressed a second time, downshifting is released automatically.

S0607070K Page 28

AJS0400L

Figure 27

Transmission and Torque Converter (ZF)

Return to Master Table of Contents Kick Down: Forward Second Gear to Forward First Gear (Auto Selector Switch "O"- Manual Mode)

AJS0410L

Figure 28

With the auto selector switch (Figure 29) is in the "O" and the forward second gear is selected, if either downshift switch (Figure 27) is activated, a pulse is sent to the '22' transmission controller. This signal energizes solenoid valves, (Y3 and Y5), which shifts the transmission to the forward first gear. When either switch (Figure 27) 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 29

Transmission and Torque Converter (ZF)

S0607070K Page 29

Return to Master Table of Contents Downshift (Auto Selector Switch "I" - Auto Mode)

AJS0420L

Figure 30

When the auto selector switch (Figure 30) is in the "I" position, the '29' terminal of transmission controller is energized. This allows the transmission to automatically upshift and downshift gears depending on the load and on the engine speed. If either downshift switch (Figure 27) is activated, a pulse signal is sent to the '22' terminal of transmission controller. This signal shifts the transmission to the next lowest gear. Automatic 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 downshift (Figure 27) is depressed a second time, the transmission pulse signal of the '22' is interrupted and the transmission returns to normal operation. NOTE:

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

NOTE:

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

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Transmission and Torque Converter (ZF)

Return to Master Table of Contents TRANSMISSION CUT OFF When the brake pedal is depressed while transmission cutoff switch (Figure 31) is in the "I " position, the transmission cut-off pressure switch turns "ON" and current is supplied to the '66' terminal of the transmission controller.

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

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

I HA3O2018

Figure 31

CAUTION! When the machine is travelling or working in the place of inclination, the transmission cut-off switch (Figure 31) must be placed in position 'O' for the purse of using engine braking and the normal braking function at the same time.

AJS0430L

Figure 32

Transmission and Torque Converter (ZF)

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

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 33

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

AJS0440L

Figure 34

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Transmission and Torque Converter (ZF)

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INSTALLATION VIEW INNER SECTION

Figure 35

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Transmission and Torque Converter (ZF)

Return to Master Table of Contents Reference Number

Description

Reference Number

Description Clutch K1

Engine Connection - Direct Mounting

8 9

Clutch K2

Converter

Clutch K3

Breather

Output - Front Axle

Drive

Output - Rear Axle

Electro-hydraulic Shift Control

Layshaft

Clutch K4

Clutch Kr

Clutch Kv

1st Power Take Off

Converter Charge and Control Pressure Pump

Transmission and Torque Converter (ZF)

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Figure 36 Reference Number

Description

Reference Number

Description

Lifting Lugs

Coarse Filter

Breather

Oil Drain Plug

Electrohydraulic Shift Control

Diaphragms - Direct Mounting

Converter

Attachment Possibility for Oil Filter Tube with Oil Dipstick (Converter-side)

Output Flange (Converter-side)

Oil Filler Tube with Oil Dipstick (Rear-side)

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Transmission and Torque Converter (ZF)

Return to Master Table of Contents SIDE VIEW

Figure 37 Reference Number

Description

Reference Number

Description

Diaphragms for Direct Mounting

Output Flange (Rear -side)

Converter

Converter Bell

Oil Filler Tube with Oil Dipstick (Rear-side)

Lifting Lug

Cover

Breather

Gearbox Housing

Electrohydraulic Shift Control

Output Flange (Converter-side)

Transmission Suspension M20

Transmission and Torque Converter (ZF)

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Figure 38 Reference Number

Description

Reference Number

1st Power Take-off

Pressure Line Clutch KV

Attachment Possibility for Emergency Steering Pump

2nd Power Take-off

Oil Filter Tube With Oil Dipstick

Lifting Lug

Model Identification Plate

Pressure Oil Line Clutch K1

Output Flange (Rear-side)

Pressure Oil Line Clutch K4

Pressure Oil Line Clutch K3

Lubricating Oil Line "S2" Clutch K4 / K3

Lubricatiing Oil Line "S1" Clutch KR / K2

Pressure Oil Line Clutch KR

Pressure Oil Line Clutch K2

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Description

Transmission and Torque Converter (ZF)

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HYDRAULIC CONTROL UNIT (HSG-94) The following illustration 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 39

Transmission and Torque Converter (ZF)

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Figure 40

DISASSEMBLY 1.

Illustration on Control unit.

right

shows

complete

Figure 41

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Transmission and Torque Converter (ZF)

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

Loosen socket head screws.

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

Remove retaining clip.

Loosen socket head screws.

Separate cover from housing and cable harness.

Figure 42

Figure 43

Figure 44

Figure 45

Transmission and Torque Converter (ZF)

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Disassemble opposite cover.

Disconnect pressure regulator and remove cable harness.

10.

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

11.

Loosen two socket head screws and locate housing provisionally, using adjusting screws. (Housing is under spring preload). Now, loosen remaining socket and screws.

12.

Separate housing from valve housing by loosening adjusting screws uniformly.

Figure 46

Figure 47

Figure 48

Figure 49

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Transmission and Torque Converter (ZF)

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Remove components (Figure 50).

14.

Remove opposite pressure regulators, housing as well as components accordingly (Figure 51).

Figure 50

Figure 51 REASSEMBLY NOTE:

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 prior to reassembly according to ZFList of lubricants TE-ML 03. Insert diaphragms with concave side showing upward until contact is obtained.

NOTE:

Installation arrows.

position,

Transmission and Torque Converter (ZF)

Figure 52

see

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Illustration on left shows the following components: Reference Number

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 53

Install components according to Figure 53. NOTE:

Preload compression spring of the follow on sitie slides and locate spool provisionally by means of cylindrical pins Ø 5.0 mm (0.1969 in.) (assembly aid), See Figure 54.

Figure 54 3.

Install two adjusting screws.

Assemble gasket (1, Figure 55) and housing cover (Figure 55). Now, position housing cover uniformly, using adjusting screws, until contact is obtained and remove cylindrical pins (assembly aid) again (Figure 55). NOTE:

Pay attention housing covers.

different

Install recess Ø 15.0 mm (0.5906 in.) (2, Figure 55), facing spring of pressure reducing valve.

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Figure 55

Transmission and Torque Converter (ZF)

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Figure 56 6.

Fasten housing cover by means of socket head screws. NOTE:

Torque limit 0.56 kg•m (4.06 ft lbs).

Figure 57 7.

Install pressure regulators and attach by means of fixing plates and socket head screws. NOTE:

Install fixing plate, with claw showing downward. Pay attention to radial installation position of pressure regulators, see Figure 58.

NOTE:

Torque limit 0.56 kg•m (4.06 ft lbs). Figure 58

Transmission and Torque Converter (ZF)

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Pre-assemble opposite side. A.

Illustration on left side shows the following components: Reference Number

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 59.

Preload compression springs of the follow on slides and locate spool provisionally by means of cylindrical pins Ø 5.0 mm (0.1969 in.) (assembly aid). See arrows.

Install two adjusting screws.

Assemble gasket (1, Figure 60) and housing cover, and position them uniformly against shoulder, using adjusting screws.

NOTE:

Pay attention to different housing covers, install the recess Ø 19.0 mm (0.7480 in.) (2, Figure 60), facing the main pressure valve.

Down, fasten housing cover means of socket head screws.

NOTE: G.

according

Figure 59

by Figure 60

Torque limit 0.56 kg•m (4.06 ft lbs).

Remove cylindrical pins (assembly aid) again.

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Transmission and Torque Converter (ZF)

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Install pressure regulators and attach by means of fixing plates and socket head screws.

NOTE: I.

Install fixing plates, with claw showing downward.

Pay attention to radial installation position of pressure regulators, see Figure 61.

NOTE:

Torque limit 5.5 N.

Figure 61 J.

Install cable harness and connect pressure regulators (6x)

NOTE:

Pay attention to installation position of cable harness, see also markings (Figure 42).

Figure 62 K.

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

Install gaskets (Figure 63) and fasten cover by means of socket head screws.

NOTE:

Torque limit 0.56 kg•m (4.06 ft lbs).

Figure 63 M.

Install female connector by means of retaining clamp, see Figure 64.

Install opposite cover.

Figure 64

Transmission and Torque Converter (ZF)

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Install two adjusting screws and mount gasket I.

NOTE:

Pay attention to different gaskets, see Figure 65 and Figure 68.

Figure 65 9.

Intermediate plate-Version with screens: A.

Insert screens (6x) flash -mounted into bore of intermediate plate, see Figure 66.

NOTE:

Pay attention to installation position- screens are showing upward (facing duct plate).

Figure 66 B.

Mount intermediate plate, with screens with screens showing upward.

Mount gasket II.

Figure 67

Figure 68

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Transmission and Torque Converter (ZF)

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Mount duct plate and fasten it uniformly by means of socket head screws.

NOTE:

Torque limit 0.97 kg•m (7.01 ft lbs).

Figure 69 E.

Equip screw plugs (8x) with new Orings and install them.

NOTE:

Torque limit 0.61 kg•m (4.43 ft lbs).

NOTE:

The installation of hydraulic control unit is described in following section, “Mount Hydraulic Control Unit (HSG-94)” on page 127.

Figure 70

Transmission and Torque Converter (ZF)

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TRANSMISSION DISASSEMBLY 1.

Fasten transmission on an appropriate support stand.

Disassemble complete shift control, remove pressure lines and duct plate.

Figure 71

Figure 72 CONVERTER-INPUT 1.

Separate torque converter transmission, using lifting device.

from

Figure 73

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Loosen screw connection.

Separate bearing cover from converter bell, using three jacking screws.

Pull oil feed flange out of converter bell, using special device (S).

Remove converter safety valve (composed of ball, spring and disk.).

Separate converter bell from gearbox housing, using lifting device and pry bar.

Figure 74

Figure 75

Figure 76

Figure 77

Transmission and Torque Converter (ZF)

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Remove shim.

Remove rectangular ring (Figure 79).

Press drive shaft out of spur gear bearing. Remove released inner bearing race and spur gear.

10.

If necessary, drive outer bearing race out of housing bores.

11.

Press inner bearing race from drive shaft.

Figure 78

Figure 79

Figure 80

Figure 81

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Transmission and Torque Converter (ZF)

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Remove converter pressure valve.

Figure 82 DRIVE SHAFT PUMP POWER TAKE-OFF 1.

Pull complete drive shaft out of gearbox housing (pump).

Remove rectangular ring (Figure 84).

Separate spur gear from shaft and remove snap ring (Figure 85).

Figure 83

Figure 84

Figure 85

Transmission and Torque Converter (ZF)

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Pull inner bearing race from spur gear.

Loosen socket head screw and remove it along with clamping plate.

Pull inner bearing race and drive from shaft.

Figure 86

Figure 87

NOTE:

Support puller on end face/ drive shaft. Pay attention to released shims.

Figure 88 7.

Separate inner bearing race from driver. NOTE:

Pay attention to released shim.

Remove snap rings (3x).

Figure 89

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Transmission and Torque Converter (ZF)

Return to Master Table of Contents TRANSMISSION PUMP 1.

Tilt gearbox housing 180°.

Loosen hex. head screws and remove both pump flanges.

Loosen socket head screws (M8) and position Puller device (s).

Pull transmission pump out of housing bore.

Figure 90

NOTE:

Tapping housing face is a help during extraction operation.

Figure 91 OUTPUT- LAYSHAFT ASSEMBLY 1.

Loosen screw connection and remove brake caliper.

Unlock and loosen hex. head screws, tap brake disk loose and separate it from output shaft.

Figure 92

Figure 93

Transmission and Torque Converter (ZF)

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Pry shaft seal out of housing bore.

Tilt gearbox housing.

Remove sealing covers (Figure 95).

Loosen hex. head screws.

Pull idler shaft by means of puller out of housing bore.

Figure 94

Figure 95

Figure 96

Figure 97

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Transmission and Torque Converter (ZF)

Return to Master Table of Contents 8.

Tilt gearbox housing 180°.

Loosen hex. head screws and pull bearing cover -K1/KV out of housing bore.

10.

Loosen hex. head screws and remove bearing cover KR/K2 and K3/K4.

11.

Remove rectangular rings (3 pieces/axle), see Figure 100.

12.

Remove snap ring and remove released washers.

Figure 98

Figure 99

Figure 100

Figure 101

Transmission and Torque Converter (ZF)

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Support output flange against gearbox housing, see Figure 102.

14.

Loosen hex. head screws and separate housing cover from gearbox housing, using forcing screws and lifting device.

15.

Unlock and loosen hex. head screws.

16.

Remove output flange and pry shaft seal out of housing.

17.

Loosen hex. head screws and remove oil baffle.

Figure 102

Figure 103

Figure 104

Figure 105

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Transmission and Torque Converter (ZF)

Return to Master Table of Contents 18.

Remove output gear along with shaft.

19.

Separate output shaft from spur gear.

20.

Pull inner bearing race from output gear.

21.

Remove plate.

Figure 106

Figure 107

Figure 108

Figure 109

Transmission and Torque Converter (ZF)

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Drive roller bearing out of housing bore and remove it.

Figure 110 DISASSEMBLE CLUTCHES AND LAYSHAFT GEAR 1.

Remove clutches - K3/K4, KR/K2 and KV/ K1- by means of lifting device. NOTE:

At the removal of the clutch K3/K4, displace clutch - KR/K2 in direction of arrow (Figure 111).

Figure 111 2.

Illustration on right shows clutches in removed condition.

Remove layshaft gear.

Figure 112

Figure 113

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Transmission and Torque Converter (ZF)

Return to Master Table of Contents DISASSEMBLE POWER TAKE-OFF II 1.

Remove snap ring and remove shim(s).

Pull PTO shaft by means of internal puller out of housing bore until outer bearing race is released.

Take shaft out of housing.

Pull inner bearing race from shaft (Figure 117).

Press opposite inner bearing race from shaft.

Figure 114

Figure 115

Figure 116

NOTE:

Separation of shaft and gear is not possible.

Figure 117

Transmission and Torque Converter (ZF)

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Return to Master Table of Contents DISASSEMBLE CLUTCHES Clutch - K3/K4 1.

Remove three rectangular rings (Figure 118).

Loosen slotted nut.

Figure 118 NOTE:

Slotted nut is secured with Loctite. To prevent damage of thread, heat slotted nut prior to loosen it (about 120°C (248°F)).

Figure 119 3.

Pull off taped roller bearing.

Removed flanged disk.

Figure 120

Figure 121

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Remove upper roller bearing.

Remove angle ring, snap ring, and thrust ring.

Press spur gear K3 from plate carrier and remove released roller bearing.

Remove split ring.

Figure 122

Figure 123

Figure 124

Figure 125

Transmission and Torque Converter (ZF)

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Remove snap ring and remove compl. Plate pack K3.

10.

Tilt clutch 180°.

11.

Loosen slotted nut.

Figure 126

NOTE:

Slotted nut is secured with Loctite. To prevent damage of thread, heat slotted nut prior to loosen it (about 120°C (248°F)).

Figure 127 12.

Pull off tapered roller bearing.

13.

Pull spur gear from plate carrier.

Figure 128

Figure 129

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Transmission and Torque Converter (ZF)

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Remove oil feed ring and pull ball bearing from plate carrier.

15.

Remove snap ring and remove compl. plate pack - K4.

16.

Preload compression spring by means of special device (S). Remove snap ring (Figure 132) and released components.

17.

Now, separate piston from plate carrier, using compressed air.

18.

Disassemble opposite piston accordingly.

Figure 130

Figure 131

Figure 132 Clutch - KR/K2 1.

Locate clutch by means of Special device (s) and loosen slotted nut.

Loosen opposite slotted nut (Figure 133) accordingly. NOTE:

The slotted nuts are secured with Loctite heat prior to loosen them.

Figure 133

Transmission and Torque Converter (ZF)

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Pull off tapered roller bearing.

Press spur gear K-2 from shaft.

Remove released shim and bush.

Pull off tapered roller bearing.

On opposite side, pull off tapered roller bearing.

Figure 134

Figure 135

Figure 136

Figure 137

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Transmission and Torque Converter (ZF)

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Pull spur gear KR from shaft.

Remove released inner bearing race, disassemble both outer bearing races and snap ring.

10.

Remove adjusting ring.

11.

Pull off tapered bearing).

12.

Disassemble plate packs KR and K2 as well as compression springs and piston (accordingly as at clutch K3/K4.

Figure 138

Figure 139 bearing

(spur

gear

Figure 140

Figure 141

Transmission and Torque Converter (ZF)

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Return to Master Table of Contents Clutch - KV/K1 1.

Loosen slotted nut.

Loosen opposite slotted nut (Figure 142) accordingly. NOTE:

The slotted nuts are secured with Loctite and require heating prior to loosen them.

Figure 142 3.

Remove tapered roller bearing.

Remove shim.

Using a suitable puller remove spur gear K1.

Now, remove snap ring and drive ball bearing from spur gear bore.

Figure 143

Figure 144

Figure 145

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Transmission and Torque Converter (ZF)

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Remove both rings.

Using a suitable puller second ball bearing (spur gear bearing).

On opposite side, pull off tapered roller bearing.

10.

Pull spur gear KV from shaft.

11.

Remove released inner bearing race, disassemble both outer bearing race and snap ring.

Figure 146

Figure 147

Figure 148

Figure 149

Transmission and Torque Converter (ZF)

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Remove adjusting ring.

13.

Pull off tapered roller bearing (spur gear bearing).

14.

Now, remove plate pack KV and K1 as well as compression springs and piston (accordingly as at clutch K3/K4.

Figure 150

Figure 151

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TRANSMISSION REASSEMBLY POWER TAKE-OFF II 1.

Cool shaft down (about 80°C (176°F)) and heat gear (about 120°C (248°F)) and assemble, resp. press it against shoulder.

Press inner bearing race against shoulder. Press opposite inner bearing race against shoulder until contract is obtained.

Insert outer bearing race (Figure 154) into housing bore until contact is obtained.

Figure 152

Figure 153

Figure 154

Transmission and Torque Converter (ZF)

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Position pre-assembled PTO shaft in housing.

Insert outer bearing race until contact is obtained-bearing must have free play.

Adjust PTO bearing free play, using disk (s) and snap ring.

Tilt gearbox housing 180°.

Insert sealing disk (Figure 158) into housing bore until contact is obtained.

Figure 155

Figure 156

Figure 157

NOTE:

Cover contact surfaces with Loctite #262).

IMPORTANT Do not damage centric orifice hole Ø 0.80 mm (0.0315 in.) during installation of sealing disk.

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Figure 158

Transmission and Torque Converter (ZF)

Return to Master Table of Contents CLUTCH K3/K4 1.

Install plate carrier by means of clamping ring (s).

Close both bores (Figure 159) by means of set screws. NOTE:

Insert set screws with Loctite #262.

Figure 159 Clutch K3 1.

Insert purge valve (Figure 160) until contact is obtained.

Insert both O-rings into ring grooves of piston, see Figure 161.

Oil O-rings and piston race, and insert piston until contact is obtained.

Figure 160

Figure 161

NOTE:

Pay attention to installation position of piston, see Figure 162.

Figure 162

Transmission and Torque Converter (ZF)

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Install disk (Figure 163) and compression spring.

Lay guide ring upon compression spring and assemble snap ring (Figure 163). NOTE:

Pay attention to installation position of guide ring install chamber (Figure 163) showing upward.

Figure 163 6.

Now, preload compression spring and install it by engaging snap ring (Figure 165).

Figure 164

Figure 165

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Transmission and Torque Converter (ZF)

Return to Master Table of Contents General Instructions for Plate Installation In principle, stacking of outer and inner plates has to be carried out alternately. The piston side has to be started with a one sided coated outer plate. At clutch-KR and KV, a one sided coated outer plate has to be additionally installed on the end shim side. The uncoated side must be always installed facing the piston, resp. the end shim. At plates with different thickness (inner plates), the thinner plates must be installed on the end shim side. Number and installation position of the plates, see also the corresponding Spare-Parts List. The respective clutch side can be identified on the length of the plate carrier, see Draft Dimension X. Install Plate pack - K3, see Draft as well as Figure 167, EXAMPLE A: Plate arrangement - K3 (long plate carrier side): Active number of the friction surfaces = 14. 1 outer plate

(one sided coated)

7 outer platess = 2.50 mm (0.0984 in.) 3 inner platess = 3.50 mm (0.1378 in.) 3 inner platess = 3.00 mm (0.1181 in.) 1 inner plate (optional)s = 2.00 - 4.00 mm (0.0787 - 0.1575 in.) Draft:

K3 X

HLA2130L

Figure 166

Transmission and Torque Converter (ZF)

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Install plate pack, mount end shim and attach it by means of snap ring.

Check plate clearance - K3 = 2.20 - 2.40 mm (0.0866 - 0.0945 in.) (Figure 168, EXAMPLE A).

Figure 167

Determined Dimension I from end face of plate carrier to end shim.

NOTE:

Dimension I e.g. 2.40 mm (0.0945 in.).

Figure 168 B.

Position end shim against snap ring (toward upward) until contact is obtained and determine Dimension II.

NOTE:

Dimension II e.g. 0.20 mm (0.0079 in.).

Figure 169

EXAMPLE A: Dimension I

2.40 mm (0.0945 in.)

Dimension II

- 0.20 mm (0.0079 in.)

Difference = Plate clearance

= 2.20 mm (0.0866 in.)

IMPORTANT In case of a deviation from the required plate clearance, correction can be carried out with corresponding inner plates. (optional s = 2.00 - 4.00 mm (0.0787 - 0.1575 in.)) or with different snap rings (Figure 167).

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Tilt clutch into horizontal position and install spur gear K3 until all inner plates are accommodated. NOTE:

This step will facilitate later spur gear installation. Now, tilt clutch again into vertical position and pull spur gear carefully out of plate pack.

Figure 170 4.

Insert split ring (Figure 171) with grease into recess. NOTE:

Pay attention to exact contact of split ring in bottom of recess.

NOTE:

Carry out following steps of Figure 172 and Figure 173 immediately in chronological order to prevent a cooling down of heated components.

Heat bearing bore of spur gear (Figure 172) as well as inner bearing race of roller bearing (Figure 173) to about 120°C (248°F).

Figure 171

Install heated spur gear until all inner plates are accommodated.

Figure 172

Transmission and Torque Converter (ZF)

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Insert heated inner bearing race until contact is obtained.

Install disk, lift spur gear slightly and install snap ring into annular groove of spur gear.

Install angle ring, with stepped face facing snap ring.

10.

Install inner bearing race and mount flanged disk.

Figure 173

Figure 174

Figure 175

NOTE:

Install flanged disk, with chamfer on inner diameter showing upward.

Figure 176

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Heat inner bearing race and place it against shoulder.

Figure 177

Transmission and Torque Converter (ZF)

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Return to Master Table of Contents Clutch - K4 Install purge valve, piston and compression spring accordingly as at clutch K3 (Figure 166). Install plate pack K4 and check plate clearance. Plate arrangement K4 (short plate carrier side): Active number of the friction surfaces = 12 1 outer plate (one sided coated) 6 outer platess = 2.50 mm (0.0984 in.) 4 outer platess = 3.50 mm (0.1378 in.) 1 inner plates = 3.00 mm (0.1181 in.) i1 inner plate (optional)s = 2.00 - 4.00 mm (0.0787- 0.1575 in.)

IMPORTANT Pay attention to the General Instructions for the Plate Installation (See page 75) Check plate clearance - K4 = 2.20 - 2.40 mm (0.0866 - 0.0945 in.) accordingly as at clutch K3 (See page 73). 1.

Tilt clutch into horizontal position and install spur gear K4 until all inner plates are accommodated. NOTE:

This step will facilitate the later reassembly of spur gear.

Now, tilt clutch again into vertical position and pull spur gear carefully out of plate pack.

Figure 178

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Spur gear K4

IMPORTANT The following steps (Figure 179 thru Figure 182) are describing reassembly of spur gear bearing-K4. Version with ball bearing. At the version with the tapered roller bearing, the reassembly has to be carried out accordingly as at spur gear-KR. In this connection pay attention to steps of Figure 190 thru Figure 200. 4.

Heat ball bearing and assemble it until contact is obtained, see Figure 179. NOTE:

Figure 179

Prior to install the spur gear (Figure 180), cool ball bearing.

Mount Oil feed ring (Figure 180).

Figure 180

IMPORTANT Carry out steps of Figure 181 and Figure 182 in immediate sequence, to prevent a cooling down of the components. Heat bearing bore of the spur gear (Figure 181) and ball bearing (Figure 182) to about 120°C. 6.

Install heated spur until all inner plates are accommodated.

Transmission and Torque Converter (ZF)

Figure 181

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Insert heated ball bearing until contact is obtained.

Heat tapered roller bearing and assemble it until contact is obtained.

Preload complete clutch pack through both inner bearing races (Figure 184) with 100 000 N (10 ton). In this way, the exact contact of the components, resp. the settling of the complete bearing is ensure.

10.

Mount disk. Wet thread of slotted nut with Loctite #262 and install slotted nut with chamfer showing downward (Figure 185).

Figure 182

Figure 183

Figure 184

Figure 185

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Tighten slotted nut. NOTE:

Torque limit 56.08 kg•m (405.66 ft lbs).

Figure 186 12.

Tilt clutch 180° (K3-side).

13.

Wet thread of slotted nut with Loctite #262 and install slotted nut with chamfer showing downward. NOTE:

Torque limit 81.58 kg•m (590.05 ft lbs).

Figure 187 14.

Check function of clutch by means of compressed air: A.

For this purpose, install rectangular rings, engage them and assemble bearing cover.

NOTE:

At correctly installed components, the closing resp. opening of the clutches is clearly audible.

Now, remove bearing cover again. Figure 188

Transmission and Torque Converter (ZF)

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Return to Master Table of Contents CLUTCH KR/K2 Install purge valves, piston and compression spring (each clutch side 1 set of the components) accordingly as at multi-disk clutch K3 (Figure 160 thru Figure 165). Install plate pack KR and K2 and check plate clearance, see also following Draft. Draft:

HLA2153L

Figure 189 Plate arrangement - KR (long plate carrier side): Active number of the friction surfaces = 24. 2 outer plates (one sided coated) 11 outer plates (s) = 2.50 mm (0.0984 in.) 11 inner plates (s) = 2.50 mm (0.0984 in.) 1 inner plate (optional) (s) = 2.00 mm (0.0787 in.)

IMPORTANT Pay attention to the General Instructions for the Plate Installation (See page 75). Check Plate clearance - K2 = 2.80 - 3.00 mm (0.1102 - 0.1181 in.) accordingly as at clutch K-3 (See page 73). Plate arrangement - K2 (short plate carrier side): Active number of friction surfaces = 16. 1 outer plate (one sided coated) 7 outer plates (s) = 2.50 mm (0.0984 in.) 3 inner plates (s) = 3.50 mm (0.1378 in.) 3 inner plates (s) = 3.00 mm (0.1181 in.)

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Return to Master Table of Contents 1 inner plate

(optional) (s) = 2.00 - 4.00 mm (0.0787 - 0.1575 in.)

IMPORTANT Pay attention to the General Instructions for the plate installation (See page 75). Check Plate clearance- K2 = 2.20 mm (0.0866 in.) accordingly as at clutch K3 (See page 73). Spur gear KR Components: Reference Number

Description

Inner Bearing Race

Outer Bearing Race

Spur Gear

Snap Ring

Adjusting Ring (Optional) Figure 190

Determines axial play of the spur gear bearing 0.03 - 0.08 mm (0.0012 - 0.0031 in.) (Figure 191). EXAMPLE B: A.

Install snap ring (4) and outer bearing race (2) against shoulder.

Place spur gear upon inner bearing race.

Figure 191

NOTE:

Support inner bearing race.

Figure 192

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Measure Dimension I from end face to inner bearing race.

NOTE:

Dimension I e.g. 24.95 mm (0.9823 in.).

Figure 193 D.

Determine Dimension II from end face to snap ring.

NOTE:

Dimension II e.g. 20.85 mm (0.8209 in.).

Figure 194 E.

Determine differential dimension from outer bearing race to inner bearing race on upper tapered roller bearing.

NOTE:

Figure 195, shows two tapered roller bearings with different measuring results.

NOTE:

Dimension III (Differential dimension) in the actual case e.g. 0.15 mm (0.0059 in.). HLA2159L

Figure 195

Figure 196

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Return to Master Table of Contents EXAMPLE B: Dimension I

24.95 mm (0.9823 in.)

Dimension II

- 20.85 mm (0.8209 in.)

Intermediate result Dimension III

+ 1.15 mm (0.0453 in.)

Result = Differential dimension - zero

= 4.25 mm (0.1673 in.)

Required Axial Play (0.03 - 0.08 mm (0.0012 0.0031 in.)) e.g

+ 0.05 mm (0.0020 in.)

Result = Adjusting Ring

= 4.30 mm (0.1693 in.)

F. 2.

4.10 mm (0.1614 in.)

Select adjusting ring with corresponding thickness.

Check axial play (Figure 197). A.

Install upper outer bearing race. Insert adjusting ring e.g. s = 4.30 mm (0.1693 in.) and inner bearing race. Preload spur gear bearing with about 50 000 N (5 to). Determine axial play.

NOTE:

At deviations from the required axial play 0.03 - 0.08 mm (0.0012 - 0.0031 in.) correct with corresponding adjusting ring. Figure 197

Heat lower tapered roller bearing and assemble it until contact is obtained.

Figure 198

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Install spur gear KR into pre-assembled plate carrier until all inner plates are accommodated.

Assemble adjusting ring e.g. s = 4.30 mm (0.1693 in.) (See EXAMPLE B).

Figure 199

NOTE:

Pay attention to installation position of oil feed grooves. They should be showing upward.

Now, heat upper inner bearing race (spur gear bearing) and assemble it until contact is obtained.

Heat inner bearing race (clutch bearing) and assemble it until contact is obtained.

Figure 200

Figure 201 Spur gear K2 Reference Number

Description

Tapered Roller Bearing

Bush

Shim

Spur Gear

Figure 202

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Adjust axial play of spur gear bearing 0.05 - 0.15 mm (0.0020 - 0.0059 in.) (Figure 203 thru Figure 206): A.

Place spur gear upon inner bearing race.

NOTE:

Support inner bearing race.

Figure 203 B.

Install bush as well as shim (s = 3.80 mm (0.1496 in.) / empirical value) and align it centrically.

Install upper tapered roller bearing.

Preload spur gear bearing with about 50,000 N (5 ton) and determined axial play.

Figure 204

Figure 205

NOTE:

At a deviation from required axial play 0.05 - 0.15 mm (0.0020 - 0.0059 in.), correct with corresponding shim (Figure 202).

Figure 206

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Heat inner bearing race and assemble it until contact is obtained.

10.

Install spur gear K2 until all inner plates are accommodated.

11.

Install bush and corresponding shim.

12.

Heat second tapered roller bearing of spur gear bearing and assemble it until contact is obtained.

Figure 207

Figure 208

Figure 209

Figure 210

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Heat inner bearing race (clutch bearing) and place it against shoulder.

14.

Preload complete clutch pack through both inner bearing races (Figure 212) with 100,000 N (10 ton) In this way, an exact contact of components, resp. the setting of the complete bearing is ensure.

15.

Install and tighten both slotted nuts.

Figure 211

Figure 212 NOTE:

Torque limit 81.58 kg•m (590.05 ft lbs).

NOTE:

Pay attention to installation position of slotted nuts chamfer is always facing inner bearing race. Secure slotted nuts with Loctite #262.

Figure 213

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Return to Master Table of Contents CLUTCH - KV/K1 Install purge valves, piston and compression spring (each clutch side 1 set of the components) accordingly as at clutch (Figure 160 thru Figure 165). Install plate pack - KV and K1 and check plate clearance, see also Draft. Draft.

HLA2178L

Figure 214 Plate arrangement - KV (long plate carrier side): Active number of friction surfaces = 24. 2 outer plates

(one sided coated)

11 outer plates (s) = 2.50 mm (0.0984 in.) 11 inner plates (s) = 2.50 mm (0.0984 in.) 1 inner plate (optional) (s) = 2.50 - 4.00 mm (0.0984 - 0.1575 in.)

IMPORTANT Pay attention to General Instructions for Plate Installation (See page 75).

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Check plate clearance- K1 = 2.20 - 2.40 mm (0.0866 - 0.0945 in.) accordingly as at clutch - K3 (See page 73).

Close both bores (Figure 215) by means of set screws. NOTE:

Insert set screws with Loctite #262).

Figure 215 Spur gear - KV Reference Number

Description

Bearings Inner Race

outer bearing Race

Spur Gear

Snap Ring

Ring (Optional)

Figure 216 3.

Determine axial play of spur gear bearing 0.03 - 0.08 mm (0.0012 - 0.0031 in.) (Figure 217, EXAMPLE C). A.

Install snap ring (4) in position and install outer bearing race (2) against shoulder.

Place spur gear upon inner bearing race.

Figure 217

NOTE:

Support inner bearing races.

Figure 218

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Measure Dimension I from end face to inner bearing race.

NOTE:

Dimension I e.g. 24.95 mm (0.9823 in.).

Figure 219 D.

Determine Dimension II from end face to snap ring.

NOTE:

Dimension II e.g. 20.85 mm (0.8209 in.).

Figure 220 E.

Determine Differential dimension from outer bearing race to inner bearing race on upper tapered roller bearing.

NOTE:

The illustration on right shows two tapered roller bearings with different measuring results.

NOTE:

Dimension III (Differential dimension) in actual case e.g. 0.15 mm (0.0059 in.). HLA2159L

Figure 221

Figure 222

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Return to Master Table of Contents EXAMPLE C Dimension I

24.95 mm (0.9823 in.)

Dimension II

- 20.85 mm (0.8209 in.)

Result A Dimension III

+ 1.15 mm (0.0453 in.)

Result = Differential Dimension - Zero

= 4.25 mm (0.1673 in.)

Required Axial Play (0.03 - 0.08 mm (0.0012 0.0031 in.)) e.g

+ 0.05 mm (0.0020 in.)

Result = Adjusting Ring

= 4.30 mm (0.1693 in.)

NOTE: 4.

4.10 mm (0.1614 in.)

Select adjusting ring with corresponding thickness.

Check axial play (Figure 223): A.

Install upper outer bearing race.

Insert adjusting ring e.g. s = 4.30 mm and inner bearing race. Preload spur gear bearing with about 50,000 N (5 ton) Determine axial play.

NOTE:

At deviations from the required axial play 0.03 - 0.08 mm (0.0012 - 0.0031 in.) correct with corresponding adjusting ring. Figure 223

Heat lower inner bearing race assemble it until contact is obtained.

and

Figure 224

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Install spur gear KR into pre-assembled plate carrier until all inner plates are accommodated.

Assemble adjusting ring e.g. s = 4.30 mm (See EXAMPLE C).

Figure 225

NOTE:

Pay attention to installation position - oil feed grooves are showing upward.

Now, heat upper inner bearing race (spur gear bearing) and assemble it until contact is obtained.

Heat inner bearing race (clutch bearing) and assemble it until contact is obtained).

Figure 226

Figure 227 Spur Gear - K1 Reference Number

Description

Ball Bearing

Ring (Optional)

Splash Ring

Snap Ring

Spur Gear

Ball Bearing Figure 228

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Adjust axial play of spur gear bearing = 0.01 - 0.04 mm (0.0004 - 0.0016 in.) (Figure 229 and Figure 230): A.

Determine thickness of splash ring (3) e.g. s = 17.15 mm (0.6752 in.).

Figure 229 NOTE:

Total dimension of snap ring 4 and ring 2 (optional) must be selected 0.01 - 0.04 mm (0.0004 - 0.0016 in.) thinner.

NOTE:

Total dimension of snap ring and ring therefore 17.14 - 17.11 mm (0.6736 - 0.6748 in.).

Figure 230 11.

Heat ball bearing and assemble it until contact is obtained. Now, cool ball bearing down to room temperature, to allow later installation of spur gear (Figure 234).

12.

Assemble ring (optional) and splash ring.

Figure 231

Figure 232

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Install snap ring into annular groove of spur gear.

Figure 233

IMPORTANT Carry out steps of Figure 234 and Figure 235, in immediate sequence to prevent cooling down of components. 14.

Heat bearing bores of spur gear (Figure 234) and ball bearing (Figure 235). Install spur gear until all inner plates are accommodated.

15.

Install heated ball bearing until contact is obtained.

16.

Assemble spacer (s = 1.50 mm (0.0591 in.)). Heat tapered roller bearing and place it against shoulder.

Figure 234

Figure 235

Figure 236

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Preload complete clutch pack through both inner bearing races (Figure 237) with 100 000 N (10 to). In this way, an exact contact of components, resp. the setting of the complete bearing is ensure.

18.

Secure clutch pack by means of disks (Figure 238) and slotted nuts.

Figure 237

NOTE:

Pay attention to installation position of slotted nuts, chamfer is always facing inner bearing race. Wet thread of slotted nuts with Loctite #262.

Figure 238 19.

Tighten both slotted nuts. NOTE:

Torque limit 56.08 kg•m (405.66 ft lbs).

Figure 239 20.

Install and engage rectangular rings (3x, see Figure 240).

Figure 240

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Assemble bearing cover and check function of clutches by means of compressed air. NOTE:

At correctly installed components, the closing resp. opening of the clutches is clearly audible. Now, remove bearing cover gain.

Figure 241 INSTALL MULTI-DISK CLUTCHES, LAYSHAFT GEAR AND OUTPUT GEAR 1.

Install snap rings in position, see Figure 242.

Install spacer ring.

Insert outer bearing race until contact is obtained.

Figure 242

Figure 243

NOTE:

Install spacer rings, resp. outer bearing races of clutch KR.K2 and KV/K1 accordingly, see Figure 244.

Figure 244

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Install roll pin.

Adjust axial play of layshaft gear bearing = 0.00 - 0.05 mm (0.0000 - 0.0020 in.).

(Figure 246, EXAMPLE D):

Figure 245

Determine Dimension I, see Figure 246.

NOTE:

Dimension I e.g. 57.10 mm (2.2480 in.).

Figure 246 B.

Install both inner bearing races and determine Dimension I: (total height of layshaft bearing).

NOTE:

Dimension II e.g. 53.95 mm (2.1240 in.).

Figure 247

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Determine Dimension III from contact face of inner bearing race to contact face of axle.

NOTE:

Dimension III e.g. 0.60 mm (0.0236 in.).

Figure 248 EXAMPLE D: Dimension II.

53.95 mm (2.1240 in.)

Dimension III

+ 0.60 mm (0.0236 in.)

Intermediate Result A

= 54.55 mm (2.1476 in.)

Dimension I Intermediate Result A

- 54.55 mm (2.1476 in.)

Result = Differential Dimension - Zero

= 2.55 mm (0.1004 in.)

NOTE: D. 7.

57.10 mm (2.2480 in.)

At a required axial play of 0.0 - 0.05 mm (0.0000 - 0.0020 in.), the shim has therefore to be selected thinner for max. 0.05 mm (0.0020 in.).

Shim thickness therefore 2.50 - 2.55 mm (0.0984 - 0.1004 in.).

Position shim and layshaft gear. NOTE:

The installation of layshaft gear can be carried out only after installation of clutch.

Figure 249

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Position clutch KV/K1 by means of lifting device.

Install clutch KR/K2.

10.

Displace clutch KR/K2 in direction of arrow (Figure 252) and position clutch K3/K4.

11.

Cool down outer bearing race and insert into housing bore until contact is obtained.

Figure 250

Figure 251

Figure 252

Figure 253

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Heat inner bearing race and assemble it until contact is obtained.

13.

Position oil baffle.

14.

Install output gear.

15.

Insert second oil baffle and fasten both plates by means of hex. head screws (mount plain washer).

Figure 254

Figure 255

Figure 256

NOTE:

Torque limit (M8/8.8) 2.35 kg•m (16.96 ft lbs).

NOTE:

Secure hex. head screws with Loctite #262.

Figure 257

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Cool down output shaft and install it until contact is obtained. NOTE:

Pay attention to installation position, see Figure 258.

Figure 258 17.

Wet mounting face with sealing compound (Loctite #574).

18.

Install two adjusting screws and position housing cover by means of lifting device on gearbox housing until contact is obtained.

19.

Install both cylindrical pins (1 and 2, Figure 260) and roll pin (3).

20.

Fasten housing cover by means of socket head screws (2 pieces) and hex. head screws.

Figure 259

Figure 260

NOTE:

Torque limit (M10/8.8) kg•m (33.93 ft lbs).

NOTE:

Pay attention to position of two socket head screws, see Figure 261.

4.69

Figure 261

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Adjust axial play of outer bearing = 0.03 0.05 mm (0.0012 - 0.0020 in. (Figure 262 thru Figure 264): A.

Determine Dimension I from plane face/housing to end face/output shaft.

NOTE:

Dimension I e.g 53.20 mm (2.0945 in.).

Figure 262 B.

Measure Dimension II from plane face/housing to contact face of ball bearing.

NOTE:

Dimension II e.g. 50.40 mm (1.9843 in.).

Figure 263 EXAMPLE E: Dimension I

22.

53.20 mm (2.0945 in.)

Dimension Ii

- 50.40 mm (1.9843 in.)

Difference

= 2.80 mm (0.1102 in.)

Required Axial Play (0.03 0.05 mm (0.0012 - 0.0020 in.)) e.g.

- 0.40 mm (0.0157 in.)

Gives Shim S

= 2.40 mm (0.0945 in.)

Assemble shim (e.g s = 2.40 mm (0.0945 in.)).

Figure 264

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Insert bearing until contact is obtained.

24.

Secure ball bearing by means of disk (s = 4.00 mm (0.1575 in.)) shim (optional) and snap ring free play.

25.

Install shaft seal with sealing lip showing downward.

Figure 265

Figure 266

NOTE:

At the use of the prescribed driver, the exact installation depth is obtained. Cover outer diameter with sealing compound Loctite #547. Grease sealing lip.

Figure 267 26.

Assemble output flange.

Figure 268

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Wet contact face of disk with sealing compound. Mount disk and fasten output flange by means of hex. head screws. NOTE:

Torque limit (M10/8.8) kg•m (33.93 ft lbs).

4.69

Figure 269 28.

Secure hex. head screws by means of lock plate.

29.

If necessary, install studs, insert O-ring into annular groove (Figure 271) and fasten cover by means of hex. nuts.

Figure 270

NOTE:

Torque limit (M10/8.8) kg•m (16.96 ft lbs).

NOTE:

Insert studs with Loctite #262.

2.35

Figure 271 30.

Install screw plug (1, Figure 272). Mount gasket and fasten cover (2) by means of hex. head screws. NOTE:

Torque limit (M10/8.8) kg•m (16.96 ft lbs).

2.35

Figure 272

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Fasten brake assemble (according to version) on housing, using hex. head screws. NOTE:

Torque limit (M14/10.9) 18.86 kg•m (136.45 ft lbs).

IMPORTANT At works on the brake assembly, the Specifications of the Brake Manufacturer, resp. Vehicle Manufacturer are binding. 32.

Cool down outer bearing races (clutches K3/K4 and KR/K2) and insert them into housing bores until contact is obtained.

33.

Adjust bearing preload - clutch K3/K4 = 0.15 - 0.20 mm (0.0059 - 0.0079 in.) (Figure 275 thru Figure 278):

Figure 273

Figure 274

Align clutches centrically by rotating output flange and place outer bearing race carefully against shoulder.

IMPORTANT Bearing must not be preload Bearing cage, resp. bearing rollers are stilled easy to be moved.

Transmission and Torque Converter (ZF)

Figure 275

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Determine Dimension I from outer bearing race to mounting face.

NOTE:

Dimension I e.g. 5.70 mm (0.2244 in.).

NOTE:

Apply several measuring points and determine average.

Figure 276 C.

Measure Dimension I from mounting face/cover to contact face/outer bearing race.

NOTE:

Dimension II e.g. 7.13 mm (0.2807 in.).

Figure 277 EXAMPLE F: Dimension II

7.13 mm (0.2807 in.)

Dimension I

- 5.70 mm (0.2244 in.)

Difference required bearing preload

34.

1.43 mm (0.0563 in.)

(0.15 - 0.20 mm (0.0059 - 0.0079 in.))

+ 0.17 mm (0.0067 in.)

Result = shim e.g.

= 1.60 mm (0.0630 in.)

Insert shim (e.g. s = 1.60 mm (0.0630 in.)) with grease into bearing cover. Insert Oring into annular groove (Figure 278) and grease it.

Figure 278

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Install rectangular rings (3 pieces, see Figure 279) and engage them. Now, grease rectangular rings and align them centrically.

36.

Pull cover by means of hex. head screws uniformly against shoulder.

Figure 279

NOTE: 37.

Torque limit (M10/8.8) kg•m (33.93 ft lbs).

4.69

Mount bearing cover KR/K2 accordingly. NOTE:

Bearing preload KR/K2 = 0.02 0.25 mm (0.0008 - 0.0098 in.).

Figure 280 38.

Close both bores of bearing cover KV/K1 by means of slotted plug. NOTE:

Insert slotted plug with Loctite #262.

Figure 281 39.

Adjust bearing preload clutch KV/K1 = 0.15 - 0.20 mm (0.0059 - 0.0079 in.) (Figure 282, EXAMPLE G). A.

Install outer bearing race.

Figure 282

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Press outer bearing race uniformly on and determine Dimension I from mounting face to outer bearing race.

NOTE:

Dimension I e.g. 64.95 mm (2.5571 in.).

NOTE:

Apply several measuring points ad determine average.

Figure 283 C.

Measure Dimension II from mounting face of cover (Figure 284) to contact face/outer bearing race.

NOTE:

Dimension II e.g. 63.90 mm (2.5157 in.).

Figure 284 EXAMPLE G:

40.

Dimension I

64.95 mm (2.5571 in.)

Dimension II

- 63.90 mm (2.5157 in.)

Difference

1.05 mm (0.0413 in.)

Required Bearing Preload (0.15 - 0.20 mm (0.0059 0.0079 in.)) e.g.

+ 0.15 mm (0.0059 in.)

Result = Shim S

= 1.20 mm (0.0472 in.)

Install shim (e.g s= 1.20 mm (0.0472 in.)) cool down outer bearing race and insert it until contact is obtained. Insert O-ring into annular groove (Figure 285) and grease it.

Figure 285

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Install rectangular rings (3 pieces) into annular grooves of clutch shaft (Figure 286) and engage them. Now, grease rectangular rings and align them centrically.

42.

Install two adjusting screws, install bearing cover and pull it uniformly against shoulder, using hex. head screws.

Figure 286

NOTE:

Torque limit (M10/8.8) kg•m (33.93 ft lbs).

4.69

Figure 287 43.

Tilt housing 180°. Align layshaft gear and shim centrically, cool down pre-assembled bolt and insert it until contact is obtained. NOTE:

Pay attention to overlapping of roll pin with bore in housing.

Figure 288 44.

Fix bolt axially by means of hex. head screw. NOTE:

Torque limit (M10/8.8) kg•m (33.93 ft lbs).

4.69

Figure 289

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Wet thread of hex. head screw Drive in sealing covers (1 thru 4, Figure 290) flush-mounted, with end face showing downward. Install sealing cover (5) with recess showing upward.

NOTE:

Wet thread surfaces with Loctite #262.

Figure 290 45.

Install shaft seal (Figure 291) with sealing lip showing downward. NOTE:

At the use of the prescribed driver (S), the exact installation position is obtained. Cover outer diameter with sealing compound Loctite #534). Grease sealing lip.

Figure 291 46.

Assemble output flange. Wet contact face of disk with sealing compound Loctite #574 and secure output flange by means of hex. head screws. NOTE:

Torque limit (M10/8.8) kg•m (33.93 ft lbs).

4.69

Figure 292 47.

Secure hex. head screws by means of lock plate.

Figure 293

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Return to Master Table of Contents INSTALL FILTER 1.

Mount filter (compl.). NOTE:

Grease sealing ring (Figure 294).

Figure 294 2.

Fasten cover by means of hex. head screws (mount plain washers). NOTE:

Install 295).

NOTE:

Torque limit (M8/8.8) 2.35 kg•m (16.96 ft lbs).

new

O-rings

(Figure

Figure 295 3.

Equip screw plug (1, Figure 296) with new O-ring and instal it. Mount gasket and fasten cover plate by means of hex. head screws (2). NOTE:

Torque limit 6.12 kg•m (44.25 ft lbs).

NOTE:

Torque limit (M8/8.8) 2.35 kg•m (16.96 ft lbs).

Figure 296 HYDRAULIC PUMP 1.

Press needle sleeve in, with reinforced shell facing press-in tool until contact is obtained.

Figure 297

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Insert outer bearing race until contact is obtained.

Cool pump to about 80°C (176°F). Clean area of suction and pressure port (1, Figure 299) again and wet it with Loctite #262. Assemble and oil O-ring (2).

Install two adjusting screws and install pump until contact is obtained.

Figure 298

Figure 299

NOTE:

Pay attention to installation position.

radial

Figure 300 5.

Install O-ring (Figure 301) and fasten pump flange, resp. pump by means of hex. head screws. NOTE:

Torque limit (M12/8.8) kg•m (58.27 ft lbs).

8.06

Figure 301

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Insert O-ring (Figure 302) into annular groove of pump flange (power take off) and oil it. Mount two adjusting screws and fasten flange by means of hex. head screws. NOTE:

Torque limit (M14/8.8) 12.75 kg•m (92.20 ft lbs).

Figure 302 DRIVE SHAFT (POWER TAKE-OFF PUMP) 1.

Install V-rings (3x) into recess of driver (internal gearing). Mount fitting key (Figure 303).

Adjust gap = 0.50 mm (0.0197 in.) (driverdrive shaft) Figure 304 thru Figure 308.

Assemble disk s = 1.90 mm (0.0748 in.) and place inner bearing race against shoulder.

Figure 303

Figure 304

Figure 305

Transmission and Torque Converter (ZF)

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Determine Dimension I from inner bearing race to end face/driver.

NOTE:

Dimension I e.g. 9.60 mm (0.3780 in.).

Figure 306 B.

Determine Dimension II (A - B).

NOTE:

Dimension II e.g. 10.60 mm.

Figure 307 EXAMPLE H:

Dimension II

10.60 mm (0.4173 in.)

Dimension I

- 9.60 mm (0.3780 in.)

Difference

1.00 mm (0.0394 in.)

Required Gap

+ 0.50 mm (0.0197 in.)

Gives Shim (S)

= 1.50 mm (0.0591 in.)

Assemble shim e.g s = 1.50 mm (0.0591 in.) and position driver, resp. inner bearing race against shoulder.

Figure 308

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Transmission and Torque Converter (ZF)

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Attach driver by means of clamping disk and socket head screw. NOTE:

Insert socket head screw with Loctite #242.

NOTE:

Torque limit (M10/8.8 DIN 6912) 3.26 kg•m (23.60 ft lbs).

Figure 309 6.

Press inner bearing race upon collar of drive gear power take off.

Install snap ring (Figure assemble drive gear.

Install and engage rectangular ring (Figure 312).

Figure 310 311)

and

Figure 311

Figure 312

Transmission and Torque Converter (ZF)

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Install pre-assembled drive shaft until contact is obtained. NOTE:

Pay attention to overlapping of fitting key/fitting key groove.

Figure 313 10.

Adjust axial play of drive shaft bearing = 0.0 - 0.05 mm (0.0000 - 0.0020 in.) Figure 314 thru Figure 316).

11.

Mount gasket. Mount outer bearing race, press it uniformly on and determine Dimension I from mounting face (gasket) to outer bearing race. NOTE:

Dimension I e.g. 129.55 mm (5.1004 in.).

NOTE:

Apply several measuring points and determine average. Figure 314

12.

Measure Dimension II from mounting face/ converter bell to contact face/outer bearing race. NOTE:

Dimension II e.g. 127.43 mm (5.0169 in.).

NOTE:

Shims are available in 0.05 mm (0.0020 in.) graduation.

Figure 315

13.

Insert shim e.g. s = 2.10 mm (0.0827 in.) and position outer bearing race against shoulder.

Figure 316

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Transmission and Torque Converter (ZF)

Return to Master Table of Contents INPUT - CONVERTER 1.

Insert outer bearing race into housing bore until contact is obtained and install bearing race, see Figure 317.

Install spur gear (Figure 318) starting from side, with long collar showing, and position it.

Insert both roll pins (Ø 2.50 mm (0.0984 in.) and Ø 1.50 mm (0.0591 in.)) flushmounted into bore (Figure 319) of drive shaft.

Cool down drive shaft and install it until contact is obtained.

Figure 317

Figure 318

Figure 319

Figure 320

Transmission and Torque Converter (ZF)

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Heat inner bearing race and assemble it until contact is obtained.

Place outer bearing race against shoulder.

Figure 321 NOTE:

Spur gear bearing must have free play.

Figure 322 7.

Adjust bearing preload of drive gear bearing 0.00 - 0.07 mm (0.0000 - 0.0028 in.).

(Figure 323, EXAMPLE K: A.

Measure Dimension I from mounting face to outer bearing race.

NOTE:

Dimension I e.g. 62.10 mm (2.4449 in.).

Figure 323 B.

Mount gasket (Figure 324) and determine Dimension II from mounting face to contact face of outer bearing race.

NOTE:

Dimension II e.g. 60.85 mm (2.3957 in.).

Figure 324

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Transmission and Torque Converter (ZF)

Return to Master Table of Contents EXAMPLE K: Dimension I

62.10 mm (2.4449 in.)

Dimension II

- 60.85 mm (2.3957 in.)

Difference

1.25 mm (0.0492 in.)

Bearing Preload (0.07 0.90 mm (0.0028 0.0354 in.)) e.g

0.05 mm (0.0020 in.)

Gives Shim

1.30 mm (0.0512 in.)

NOTE: 9.

Reassemble of shim, see Figure 328.

Insert needle bearing until contact is obtained Insert shaft seal flush mounted, with sealing lip showing downward. NOTE:

Wet outer diameter of shaft seal with sealing compound Loctite #574. Grease sealing lip.

Figure 325 10.

Install two adjusting screws and mount gasket. Install converter safety valve, composed of disk, compression spring and ball (1, Figure 326).

11.

Install rectangular ring into annular groove of drive shaft and engage it (2, Figure 326). Now, grease rectangular ring and align it centrically.

Figure 326

IMPORTANT Carry out following steps (Figure 327 thru Figure 330) immediately within short chronological order. 12.

Cool down oil feed flange about - 80°C (176°F) Clean area of suction and pressure port (Figure 327) again and wet it with Loctite #241. Figure 327

Transmission and Torque Converter (ZF)

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Make shim e.g. s = 1.30 mm (0.0512 in.) (See EXAMPLE K.). adhere with grease in bearing bore.

14.

Install oil feed flange until contact is obtained.

Figure 328

NOTE:

Pay attention to installation position.

radial

Figure 329 15.

Mount gasket (Figure 330) and install bearing cover. NOTE:

Torque limit (M10/8.8) kg•m (33.93 ft lbs).

4.69

NOTE:

Pay attention to installation position.

radial

Figure 330 16.

Insert roll pin until contact is obtained.

Figure 331

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Transmission and Torque Converter (ZF)

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Install converter pressure valve. Install temperature sensor (1, Figure 332) and screw plug (2). NOTE:

Install new O-ring each time.

Figure 332 18.

Heat housing bore (about 120°C (248°F)).

19.

Install two adjusting screws and mount gasket (1, Figure 334) Install converter bell by means of lifting device until contact is obtained and fasten it by means of hex. head screws.

Figure 333

NOTE:

Pay attention to radial installation position. Slight rotary motions of drive shaft will facilitate insertion.

NOTE:

Torque limit (M8/10.9) kg•m (25.08 ft lbs).

NOTE:

Torque limit (M12/10.9) 11.73 kg•m (84.82 ft lbs).

Transmission and Torque Converter (ZF)

3.47 Figure 334

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Fasten diaphragms (3x) on converter, using hex. head screws (mount plain washer). NOTE:

Insert hex. head screws with Loctite #243.

NOTE:

Torque limit (M10/8.8) kg•m (33.93 ft lbs).

4.69

Figure 335 2.

Install and engage rectangular ring (Figure 336). Now, grease rectangular and align it centrically.

Install converter by means of lifting drive until contact is obtained.

Tilt transmission 90°. Install breather (Figure 338) Insert pot flush mounted to housing surface.

Figure 336

Figure 337

NOTE:

Wet sealing surface with Loctite #262.

Figure 338

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Transmission and Torque Converter (ZF)

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Equip screw plug (1 and 2, Figure 339) with new O-rings and install them. Install both fixing plates (3). NOTE:

Torque limit (screw plug M42x2) 14.79 kg•m (106.95 ft lbs).

NOTE:

Torque limit (M16/8.8) 19.88 kg•m (143.82 ft lbs).

Figure 339 MOUNT HYDRAULIC CONTROL UNIT (HSG-94) 1.

Pre-assemble and mount plate (Figure 340 thru Figure 344).

Equip fittings (1 thru 6, Figure 340) with new O-rings and install them. Install screw plug (7 and 8). NOTE:

Install new O-rings each time.

Figure 340 3.

Install two adjusting screws (M6) and mount housing gasket. NOTE:

At the following steps (Figure 341 thru Figure 345) pay attention to installation position of different gaskets.

Figure 341 4.

Mount intermediate plate.

Figure 342

Transmission and Torque Converter (ZF)

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Mount 2nd gasket.

Mount plate and fasten it uniformly by means of socket head screws.

Figure 343

NOTE:

Torque limit 2.35 kg•m (16.96 ft lbs).

Figure 344 7.

Mount gasket.

Assemble complete control unit and fasten it uniformly by means of socket head screws (2x M6 x 105 and 21 x M6 x 80 mm)

Figure 345

NOTE:

Pay attention to position of two socket head screws M6 x 105, see Figure 346.

NOTE:

Torque limit 9.50 kg•m (68.71 ft lbs).

Figure 346

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Transmission and Torque Converter (ZF)

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Install pressure lines according to following draft.

IMPORTANT The arrangement of lines is different according to the Version. In this connection, pay attention to the Perspective Illustration in the corresponding Spare-Parts List. Reference Number

Description

Hydraulic Line Clutch KV

Hydraulic Line Clutch KR

Hydraulic Line Clutch K1

Hydraulic Line Clutch K2

Hydraulic Line Clutch K3

Hydraulic Line Clutch K4

Lubricating Oil Line Clutch KR/K2

Lubricating Oil Line Clutch K4/K3

Transmission and Torque Converter (ZF)

Figure 347

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Return to Master Table of Contents INDUCTIVE TRANSMITTER AND SPEED SENSOR 1.

The following illustrations show installation position of single inductive transmitters and speed sensor. Reference Number

Description

Inductive Transmission Ncentral Gear Train

Inductive Transmission Nengine

Inductive Transmission Nturbine

Speed Sensor Noutput and Speedometer

Figure 348

Figure 349

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Transmission and Torque Converter (ZF)

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Transmission and Torque Converter (ZF)

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Return to Master Table of Contents SETTING INDUCTIVE TRANSMITTER 1.

The following illustrations describe the reassembly, resp. the setting of the Inductive transmitter N engine (9, Figure 348). The reassembly of the Inductive transmitter N turbine (14) and N central gear train (5) has to be carried out accordingly.

IMPORTANT Pay attention to different setting dimensions. Setting dimension corresponds to distance between contact face-Inductive transmitter and tooth tip, see Figure 350. 2.

Setting dimensions - Inductive transmitter N engine (9, Figure 348) and n turbine (14, Figure 348) = 0.03 - 0.08 mm (0.0012 0.0031 in.).

Setting dimension - Inductive transmitter N central gear train (5, Figure 348) = 0.03 0.04 mm (0.0012 - 0.0016 in.).

Turn counting disk radially until one tooth tip is situated centrally to inductive transmitter hole.

Insert measuring pin (S) until end face has got contact on tooth tip, resp. the snap ring on screw - in face of housing.

Remove measuring pin and measure Dimension I from end face/measuring pin to snap ring.

Figure 350

Figure 351

NOTE: 7.

Dimension I e.g. 30.10 mm (1.1850 in.).

Measure Dimension II from contact faceinductive transmitter to contact face. NOTE:

Dimension II e.g. 30.00 mm (1.1811 in.).

Figure 352

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Transmission and Torque Converter (ZF)

Return to Master Table of Contents EXAMPLE L: Dimension I

30.10 mm (1.1850 in.)

Required Gap (0.03 - 0.08 mm (0.0012 - 0.0031 in.)) e.g

0.60 mm (0.0236 in.)

Gives Installation Dimension

= 29.50 mm (1.1614 in.)

EXAMPLE L: Dimension II

30.00 mm (1.1811 in.)

Installation Dimension

- 29.50 mm (1.1614 in.)

Difference = Shim

= 0.50 mm (0.0197 in.)

Assemble corresponding shim and wet thread (Figure 353) with Loctite #574.

Install inductive transmitter N engine (9Figure 354), N turbine (14) and N central gear train (5).

Figure 353

NOTE: 10.

Torque limit 3.06 kg•m (22.13 ft lbs).

Now, install screw plugs (Figure 354). NOTE:

Equip screw plugs with new Oring.

NOTE:

Torque limit (M26x1.5) 8.16 kg•m (59.0 ft lbs).

NOTE:

Torque limit (M18 x 1.5) 5.10 kg•m (36.88 ft lbs).

Transmission and Torque Converter (ZF)

Figure 354

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Illustration on right shows speed sensor 13. Reference Number

Description

Speed Sensor

Plate

O-ring Figure 355

Grease O-ring and fasten speed sensor (Figure 356) by means of socket head screw. NOTE:

Torque limit (M8/8.8) 2.35 kg•m (16.96 ft lbs).

IMPORTANT Prior to putting transmission into service, carry out oil filling according to Operation and Maintenance Manual. 3.

Figure 356

Setting dimension - speed sensor = 1.0 1.5 mm (0.0394 - 0.0591 in.).

Figure 357

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Transmission and Torque Converter (ZF)

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S0607900C

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 400-V

1001 and Up

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TABLE OF CONTENTS Abbreviations.................................................................................................. 3 Display............................................................................................................ 3 Display during operation................................................................................. 4 Definition of operating modes......................................................................... 6 Normal .................................................................................................... 6 Substitute Clutch Control ........................................................................ 6 Limp-home .............................................................................................. 6 Transmission-shutdown........................................................................... 6 Tcu-shutdown.......................................................................................... 6 Table of fault codes......................................................................................... 7 Measurement of Resistance at Actuator/sensors and Cable ....................... 25 Actuator................................................................................................. 25 Cable..................................................................................................... 25

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Transmission Error Codes (ZF)

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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

EEC

Electronic Engine Controller

PTO

Power Take Off

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

left character

right character

S T O P

(special symbols a-h)

HBOE630L

Figure 1

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 Cutoff

F or R flashing

Only 4WG310 Proto type Direction F or R selected while turbine speed is too high, CAUTION gear will engage if turbine speed drops

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

fault code

See fault code list

Select neutral to get fault code displayed

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)

Direction F or R selected while parking brake engaged

Transmission in neutral until parking brake is released CAUTION: Vehicle starts to move after release of parking brake

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Transmission Error Codes (ZF)

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Meaning

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)

Remarks

Checked wiring from TCU to display

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DEFINITION OF OPERATING MODES NORMAL There's no failure detected in the transmission-system or the 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 can't change the gears or the direction under the control of the normal clutch modulation. TCU uses the 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-SHUTDOWN 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-SHUTDOWN 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.

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Transmission Error Codes (ZF)

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TABLE OF FAULT CODES Fault Code (hex) 11

Meaning of the Fault Code (Possible reason for fault detection.) Logical error at gear range signal. TCU detected a wrong signal combination for the gear range. • Cable from shift lever to TCU is broken.

Reaction of the TCU

Possible Steps to Repair

TCU shifts transmission to neutral.

Check the cables from TCU to shift lever.

OP-Mode: transmission shutdown.

Check signal combinations of shift lever positions for gear range.

TCU shifts transmission to neutral.

Check the cables from TCU to shift lever.

OP-Mode: transmission shutdown.

Check signal combinations of shift lever positions F-NR.

Customer specific.

Check the cable from TCU to Solenoids Lis1 device.

Remarks

Failure cannot be detected in systems with DW2/DW3 shift lever. Fault is taken back if TCU detects a valid signal for the 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 the direction. • Cable from shift lever to TCU is broken.

Fault is taken back if TCU detects a valid signal for the direction at the shift lever.

• Cable is defective and is contacted to battery voltage or vehicle ground. • Shift lever is defective. 17

S.C. to ground at Solenoids Lis 1. TCU detected a wrong voltage at the output pin, that looks like a S.C. to vehicle ground.

Check the connectors from Solenoids Lis1 to TCU.

• Cable is defective and is contacted to vehicle ground.

1) See “Measurement of Resistance at Actuator/sensors and Cable” on page 25.

Check the resistance of Solenoids Lis1 device.

• Solenoids Lis1 device has an internal defect. • Connector pin is contacted to vehicle ground. 18

S.C. to battery voltage at Solenoids Lis1. TCU detected a wrong voltage at the output pin, that looks like a S.C. to battery voltage. • Cable is defective and is contacted to battery voltage. • Solenoids Lis1 device has an internal defect.

Customer specific.

Check the cable from TCU to Solenoids Lis1 device. Check the connectors from Solenoids Lis1 to TCU.

1) See “Measurement of Resistance at Actuator/sensors and Cable” on page 25.

Check the resistance of Solenoids Lis1 device.

• Connector pin is contacted to battery voltage.

Transmission Error Codes (ZF)

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Return to Master Table of Contents Fault Code (hex) 19

Meaning of the Fault Code (Possible reason for fault detection.) O.C. at Solenoids Lis1.

Reaction of the TCU

Possible Steps to Repair

Remarks

Customer specific.

Check the cable from TCU to Solenoids Lis1 device.

1) See “Measurement of Resistance at Actuator/sensors and Cable” on page 25.

TCU detected a wrong voltage at the output pin, that looks like a O.C. for this output pin.

Check the connectors from Solenoids Lis1 device to TCU.

• Cable is defective and has no connection to TCU. • Solenoids Lis1 device has an internal defect.

Check the resistance of Solenoids Lis1 device.

• Connector has no connection to TCU. 1A

S.C. to ground at Solenoids Lis2.

Customer specific.

TCU detected a wrong voltage at the output pin, that looks like a S.C. to vehicle ground.

Check the cable from TCU to Solenoids Lis2 device. Check the connectors from Solenoids Lis2 device to TCU.

• Cable is defective and is contacted to vehicle ground.

1) See “Measurement

of Resistance at Actuator/sensors and Cable” on page 25.

Check the resistance of Solenoids Lis2 device.

• Solenoids Lis2 device has an internal defect. • Connector pin is contacted to vehicle ground. 1B

S.C. to battery voltage at Solenoids Lis2.

Customer specific.

TCU detected a wrong voltage at the output pin, that looks like a S.C. to battery voltage.

Check the cable from TCU to Solenoids Lis2 device. Check the connectors from Solenoids Lis2 device to TCU.

• Cable is defective and is contacted to battery voltage.

1) See “Measurement

of Resistance at Actuator/sensors and Cable” on page 25.

Check the resistance of Solenoids Lis2 device.

• Solenoids Lis2 device has an internal defect. • Connector pin is contacted to battery voltage. 1C

O.C. at Solenoids Lis2. TCU detected a wrong voltage at the output pin, that looks like a O.C. for this output pin. • Cable is defective and has no connection to TCU. • Solenoids Lis2 device has an internal defect. • Connector has no connection to TCU.

S0607900C Page 8

Customer specific.

Check the cable from TCU to Solenoids Lis2 device. Check the connectors from Solenoids Lis2 device to TCU.

1) See “Measurement

of Resistance at Actuator/sensors and Cable” on page 25.

Check the resistance of Solenoids Lis2 device.

Transmission Error Codes (ZF)

Return to Master Table of Contents Fault Code (hex) 25

Meaning of the Fault Code (Possible reason for fault detection.) S.C. to battery voltage or O.C. at transmission sump temperature sensor input. The measured voltage is too high:

Reaction of the TCU No reaction,

TCU uses default temperature. OP-Mode: normal.

• Cable is defective and is contacted to battery voltage.

Possible Steps to Repair

Remarks

Check the cable from TCU to the sensor. Check the connectors. Check the temperature sensor.

• Cable has no connection to TCU. • Temperature sensor has an internal defect. • Connector pin is contacted to battery voltage or is broken. 26

S.C. to ground at transmission sump temperature sensor input. The measured voltage is too low: • Cable is defective and is contacted to vehicle ground.

No reaction,

TCU uses default temperature. OP-Mode: normal.

Check the cable from TCU to the sensor. Check the connectors. Check the temperature sensor.

• 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.

OP-Mode: substitute clutch control.

Check the cable from TCU to the sensor.

TCU measures a voltage higher than 7.00 V at speed input pin.

Check the connectors.

• Cable is defective and is contacted to battery voltage.

Check the speed sensor.

• 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.

OP-Mode: substitute clutch control.

Check the cable from TCU to the sensor.

TCU measures a voltage less than 0.45V at speed input pin.

Check the connectors.

• Cable / connector is defective and is contacted to vehicle ground.

Check the speed sensor.

• Speed sensor has an internal defect.

Transmission Error Codes (ZF)

S0607900C Page 9

Return to Master Table of Contents Fault Code (hex) 33

Meaning of the Fault Code (Possible reason for fault detection.) Logical error at engine speed input.

Reaction of the TCU

Possible Steps to Repair

Remarks

OP-Mode: substitute clutch control.

Check the cable from TCU to the sensor.

This fault is reset after power up of TCU.

TCU measures a engine speed over a threshold and the next moment the measured speed is zero.

Check the connectors. Check the speed sensor.

• Cable / connector is defective and has bad contact.

Check the sensor gap.

• Speed sensor has an internal defect. • Sensor gap has the wrong size. 34

S.C. to battery voltage or O.C. at turbine speed input.

OP-Mode: substitute clutch control.

Check the cable from TCU to the sensor.

TCU measures a voltage higher than 7.00 V at speed input pin.

If a failure is existing at output speed,

Check the connectors.

• Cable is defective and is contacted to battery voltage.

TCU shifts to neutral.

Check the speed sensor.

• Cable has no connection to TCU.

OP-Mode: limp home.

• 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 the cable from TCU to the sensor.

TCU measures a voltage less than 0.45V at speed input pin.

If a failure is existing at output speed,

Check the connectors.

• Cable / connector is defective and is contacted to vehicle ground.

TCU shifts to neutral.

Check the speed sensor.

OP-Mode: limp home.

• Speed sensor has an internal defect. 36

Logical error at turbine speed input.

OP-Mode: substitute clutch control.

Check the cable from TCU to the 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 the connectors.

TCU shifts to neutral.

Check the speed sensor.

• Cable / connector is defective and has bad contact.

OP-Mode: limp home.

This fault is reset after power up of TCU.

Check the sensor gap.

• Speed sensor has an internal defect. • Sensor gap has the wrong size.

S0607900C Page 10

Transmission Error Codes (ZF)

Return to Master Table of Contents Fault Code (hex) 37

Meaning of the Fault Code (Possible reason for fault detection.)

Reaction of the TCU

Possible Steps to Repair

S.C. to battery voltage or O.C. at internal speed input.

OP-Mode: substitute clutch control.

Check the cable from TCU to the sensor.

TCU measures a voltage higher than 7.00 V at speed input pin.

Check the connectors.

• Cable is defective and is contacted to battery voltage.

Check the speed sensor.

Remarks

• Cable has no connection to TCU. • Speed sensor has an internal defect. • Connector pin is contacted to battery voltage or has no contact. 38

S.C. to ground at internal speed input.

OP-Mode: substitute clutch control.

Check the cable from TCU to the sensor.

TCU measures a voltage less than 0.45V at speed input pin.

Check the connectors.

• Cable / connector is defective and is contacted to vehicle ground.

Check the speed sensor.

• Speed sensor has an internal defect. 39

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.

Check the cable from TCU to the sensor. Check the connectors.

This fault is reset after power up of TCU.

Check the speed sensor.

• Cable / connector is defective and has bad contact.

Check the sensor gap.

• Speed sensor has an internal defect. • Sensor gap has the wrong size. 3A

S.C. to battery voltage or O.C. at output speed input.

Special mode for gear selection;

Check the cable from TCU to the sensor.

TCU measures a voltage higher than 12.5 V at speed input pin.

OP-Mode: substitute clutch control.

Check the connectors.

• Cable is defective and is contacted to battery voltage.

If a failure is existing at turbine speed,

Check the speed sensor.

• Cable has no connection to TCU.

TCU shifts to neutral.

• Speed sensor has an internal defect.

OP-Mode: limp home.

• Connector pin is contacted to battery voltage or has no contact.

Transmission Error Codes (ZF)

S0607900C Page 11

Return to Master Table of Contents Fault Code (hex) 3B

Meaning of the Fault Code (Possible reason for fault detection.)

Possible Steps to Repair

S.C. to ground at output speed input.

Special mode for gear selection.

Check the cable from TCU to the sensor.

TCU measures a voltage less than 1.00V at speed input pin.

OP-Mode: substitute clutch control.

Check the connectors.

• Cable / connector is defective and is contacted to vehicle ground.

If a failure is existing at turbine speed,

Check the speed sensor.

• Speed sensor has an internal defect. 3C

Reaction of the TCU

TCU shifts to neutral. OP-Mode: limp home.

Logical error at output speed input.

Special mode for gear selection.

Check the cable from TCU to the 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 the connectors.

If a failure is existing at turbine speed,

Check the speed sensor.

TCU shifts to neutral.

Check the sensor gap.

• Cable / connector is defective and has bad contact. • Speed sensor has an internal defect.

Remarks

OP-Mode: limp home.

This fault is reset after power up of TCU.

• Sensor gap has the wrong size. 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 the sensor signal of output speed sensor.

This fault is reset after power up of TCU.

Check the sensor gap of output speed sensor. Check the cable from TCU to the sensor.

OP-Mode: limp home.

• Sensor gap has the wrong size. 71

S.C. to battery voltage at clutch K1(Y3). The measured resistance value of the valve is out of limit, the 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 the TCU.

TCU shifts to neutral. OP-Mode: limp home. If failure at another clutch is pending. TCU shifts to neutral. OP-Mode: TCU shutdown.

Check the cable from TCU to the gearbox. Check the connectors from TCU to the gearbox.

1) See “Measurement

of Resistance at Actuator/sensors and Cable” on page 25.

Check the regulator resistance. 1) Check internal wire harness of the gearbox.

• Regulator has an internal defect.

S0607900C Page 12

Transmission Error Codes (ZF)

Return to Master Table of Contents Fault Code (hex) 72

Meaning of the Fault Code (Possible reason for fault detection.)

Reaction of the TCU

Possible Steps to Repair

Remarks

S.C. to ground at clutch K1(Y3).

TCU shifts to neutral.

The measured resistance value of the valve is out of limit, the voltage at K1(Y3) valve is too low.

OP-Mode: limp home.

Check the cable from TCU to the gearbox.

1) See “Measurement of Resistance at Actuator/sensors and Cable” on page 25.

• Cable / connector is defective and has contact to vehicle ground. • Regulator has an internal defect. 73

If failure at another clutch is pending. TCU shifts to neutral. OP-Mode: TCU shutdown.

O.C. at clutch K1(Y3).

TCU shifts to neutral.

The measured resistance value of the 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.

S.C. to battery voltage at clutch K2(Y6). The measured resistance value of the valve is out of limit, the voltage at K2(Y6) valve is too high. • Cable / connector is defective and has contact to battery voltage.

OP-Mode: TCU shutdown.

TCU shifts to neutral. OP-Mode: limp home. If failure at another clutch is pending. TCU shifts to neutral. OP-Mode: TCU shutdown.

• Cable / connector is defective and has contact to another regulator output of the TCU.

Check the connectors from gearbox to TCU. Check the regulator resistance. 1) Check internal wire harness of the gearbox. Check the cable from TCU to the gearbox. Check the connectors from gearbox to TCU.

1) See “Measurement

of Resistance at Actuator/sensors and Cable” on page 25.

Check the regulator resistance. 1) Check internal wire harness of the gearbox. Check the cable from TCU to the gearbox. Check the connectors from gearbox to TCU.

1) See “Measurement

of Resistance at Actuator/sensors and Cable” on page 25.

Check the regulator resistance. 1) Check internal wire harness of the gearbox.

• Regulator has an internal defect. 75

S.C. to ground at clutch K2(Y6).

TCU shifts to neutral.

The measured resistance value of the valve is out of limit, the voltage at K2(Y6) valve is too low.

OP-Mode: limp home.

• Cable / connector is defective and has contact to vehicle ground. • Regulator has an internal defect.

S0607900C Page 13

If failure at another clutch is pending. TCU shifts to neutral. OP-Mode: TCU shutdown.

Check the cable from TCU to the gearbox. Check the connectors from gearbox to TCU.

1) See “Measurement

of Resistance at Actuator/sensors and Cable” on page 25.

Check the regulator resistance. 1) Check internal wire harness of the gearbox.

Transmission Error Codes (ZF)

Return to Master Table of Contents Fault Code (hex) 76

Meaning of the Fault Code (Possible reason for fault detection.)

Reaction of the TCU

Possible Steps to Repair

Remarks

O.C. at clutch K2(Y6).

TCU shifts to neutral.

The measured resistance value of the valve is out of limit.

OP-Mode: limp home.

Check the cable from TCU to the gearbox.

• Cable / connector is defective and has no contact to TCU.

If failure at another clutch is pending.

1) See “Measurement of Resistance at Actuator/sensors and Cable” on page 25.

• Regulator has an internal defect.

TCU shifts to neutral.

S.C. to battery voltage at clutch K3(Y4). The measured resistance value of the valve is out of limit, the voltage at K3(Y4) valve is too high. • Cable / connector is defective and has contact to battery voltage.

OP-Mode: TCU shutdown.

TCU shifts to neutral. OP-Mode: limp home. If failure at another clutch is pending. TCU shifts to neutral. OP-Mode: TCU shutdown.

• Cable / connector is defective and has contact to another regulator output of the TCU.

1) See “Measurement

of Resistance at Actuator/sensors and Cable” on page 25.

Check the regulator resistance. 1) Check internal wire harness of the gearbox.

• Regulator has an internal defect. 78

S.C. to ground at clutch K3(Y4).

TCU shifts to neutral.

The measured resistance value of the valve is out of limit, the voltage at K3(Y4) 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 shutdown.

O.C. at clutch K3(Y4).

TCU shifts to neutral.

The measured resistance value of the 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.

S0607900C Page 14

OP-Mode: TCU shutdown.

Check the cable from TCU to the gearbox. Check the connectors from gearbox to TCU.

1) See “Measurement of Resistance at Actuator/sensors and Cable” on page 25.

Check the regulator resistance. 1) Check internal wire harness of the gearbox. Check the cable from TCU to the gearbox. Check the connectors from gearbox to TCU.

1) See “Measurement

of Resistance at Actuator/sensors and Cable” on page 25.

Check the regulator resistance. 1) Check internal wire harness of the gearbox.

Transmission Error Codes (ZF)

Return to Master Table of Contents 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

Possible Steps to Repair

Remarks

Engine derating will be on until TCU power down even if fault vanishes (loose connection).

Check the cable from TCU to the engine derating device.

1) See “Measurement of Resistance at Actuator/sensors and Cable” on page 25.

OP-Mode: normal.

• Connector pin is contacted to vehicle ground.

S.C. to battery voltage at engine derating device.

Check the connectors from engine derating device to TCU. Check the resistance 1) of engine derating device.

No reaction. OP-Mode: normal.

• Cable / connector is defective and is contacted to battery voltage.

Check the cable from TCU to the engine derating device. Check the connectors from backup alarm device to TCU.

• Engine derating device has an internal defect.

Check the resistance 1) of backup alarm device. 7F

O.C. at engine derating device.

No reaction.

TCU detected a wrong voltage at the output pin, that looks like a O.C. for this output pin.

OP-Mode: normal.

Check the connectors from engine derating device to TCU.

• Cable is defective and has no connection to TCU. • Engine derating device has an internal defect.

S.C. to battery voltage at clutch K4(Y2). The measured resistance value of the valve is out of limit, the voltage at K4(Y2) 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 the TCU.

1) See “Measurement

of Resistance at Actuator/sensors and Cable” on page 25.

Check the resistance 1) of engine derating device.

• Connector has no connection to TCU. 81

Check the cable from TCU to the engine derating device.

TCU shifts to neutral. OP-Mode: limp home. If failure at another clutch is pending. TCU shifts to neutral. OP-Mode: TCU shutdown.

Check the cable from TCU to the gearbox. Check the connectors from gearbox to TCU.

1) See “Measurement of Resistance at Actuator/sensors and Cable” on page 25.

Check the regulator resistance. 1) Check internal wire harness of the gearbox.

• Regulator has an internal defect.

Transmission Error Codes (ZF)

S0607900C Page 15

Return to Master Table of Contents Fault Code (hex) 82

Meaning of the Fault Code (Possible reason for fault detection.)

Reaction of the TCU

Possible Steps to Repair

Remarks

S.C. to ground at clutch K4.

TCU shifts to neutral.

The measured resistance value of the valve is out of limit, the voltage at K4 valve is too low.

OP-Mode: limp home.

Check the cable from TCU to the gearbox.

1) See “Measurement of Resistance at Actuator/sensors and Cable” on page 25.

• Cable / connector is defective and has contact to vehicle ground. • Regulator has an internal defect. 83

If failure at another clutch is pending. TCU shifts to neutral. OP-Mode: TCU shutdown.

O.C. at clutch K4.

TCU shifts to neutral.

The measured resistance value of the 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.

S.C. to battery voltage at clutch KV. The measured resistance value of the valve is out of limit, the voltage at KV 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 the TCU.

OP-Mode: TCU shutdown.

TCU shifts to neutral. OP-Mode: limp home. If failure at another clutch is pending. TCU shifts to neutral. OP-Mode: TCU shutdown.

1) See “Measurement

of Resistance at Actuator/sensors and Cable” on page 25.

Check the regulator resistance. 1) Check internal wire harness of the gearbox. Check the cable from TCU to the gearbox. Check the connectors from gearbox to TCU.

1) See “Measurement

of Resistance at Actuator/sensors and Cable” on page 25.

Check the regulator resistance. 1) Check internal wire harness of the gearbox.

• Regulator has an internal defect. 85

S.C. to ground at clutch KV.

TCU shifts to neutral.

The measured resistance value of the valve is out of limit, the 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.

S0607900C Page 16

If failure at another clutch is pending. TCU shifts to neutral. OP-Mode: TCU shutdown.

Check the cable from TCU to the gearbox. Check the connectors from gearbox to TCU.

1) See “Measurement

of Resistance at Actuator/sensors and Cable” on page 25.

Check the regulator resistance. 1) Check internal wire harness of the gearbox.

Transmission Error Codes (ZF)

Return to Master Table of Contents Fault Code (hex) 86

Meaning of the Fault Code (Possible reason for fault detection.)

Reaction of the TCU

Possible Steps to Repair

Remarks

O.C. at clutch KV.

TCU shifts to neutral.

The measured resistance value of the valve is out of limit.

OP-Mode: limp home.

Check the cable from TCU to the gearbox.

• Cable / connector is defective and has no contact to TCU.

If failure at another clutch is pending.

1) See “Measurement of Resistance at Actuator/sensors and Cable” on page 25.

• Regulator has an internal defect.

TCU shifts to neutral.

S.C. to battery voltage at clutch KR. The measured resistance value of the valve is out of limit, the voltage at KR 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 the TCU.

OP-Mode: TCU shutdown.

TCU shifts to neutral. OP-Mode: limp home. If failure at another clutch is pending. TCU shifts to neutral. OP-Mode: TCU shutdown.

1) See “Measurement

of Resistance at Actuator/sensors and Cable” on page 25.

Check the regulator resistance. 1) Check internal wire harness of the gearbox.

• Regulator has an internal defect. 88

S.C. to ground at clutch KR.

TCU shifts to neutral.

The measured resistance value of the valve is out of limit, the 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 shutdown.

O.C. at clutch KR.

TCU shifts to neutral.

The measured resistance value of the 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.

Transmission Error Codes (ZF)

OP-Mode: TCU shutdown.

Check the cable from TCU to the gearbox. Check the connectors from gearbox to TCU.

1) See “Measurement of Resistance at Actuator/sensors and Cable” on page 25.

Check the regulator resistance. 1) Check internal wire harness of the gearbox. Check the cable from TCU to the gearbox. Check the connectors from gearbox to TCU.

1) See “Measurement

of Resistance at Actuator/sensors and Cable” on page 25.

Check the regulator resistance. 1) Check internal wire harness of the gearbox.

S0607900C Page 17

Return to Master Table of Contents Fault Code (hex) 91

Meaning of the Fault Code (Possible reason for fault detection.)

Reaction of the TCU

Possible Steps to Repair

Remarks

S.C. to ground at relay reverse warning alarm.

Backup alarm will be on until TCU power down even if fault vanishes (loose connection).

Check the cable from TCU to the backup alarm device.

1) See “Measurement of Resistance at Actuator/sensors and Cable” on page 25.

TCU detected a wrong voltage at the output pin, that looks like a S.C. to vehicle ground. • Cable is defective and is contacted to vehicle ground.

OP-Mode: normal.

Check the 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 the output pin, that looks like a S.C. to battery voltage.

• Connector pin is contacted to battery voltage. No reaction. OP-Mode: normal.

TCU detected a wrong voltage at the output pin, that looks like a O.C. for this output pin.

• Connector has no connection to TCU.

TCU detected a wrong voltage at the output pin, that looks like a S.C. to vehicle ground. • Cable is defective and is contacted to vehicle ground. • Starter interlock relay has an internal defect. • Connector pin is contacted to vehicle ground.

S0607900C Page 18

1) See “Measurement of Resistance at Actuator/sensors and Cable” on page 25.

Check the resistance 1) of backup alarm device.

• Backup alarm device has an internal defect.

S.C. to ground at relay starter interlock.

Check the cable from TCU to the backup alarm device. Check the connectors from backup alarm device to TCU.

• Cable is defective and has no connection to TCU.

1) See “Measurement of Resistance at Actuator/sensors and Cable” on page 25.

Check the resistance 1) of backup alarm device.

• Backup alarm device has an internal defect.

O.C. at relay reverse warning alarm.

Check the cable from TCU to the backup alarm device. Check the connectors from backup alarm device to TCU.

• Cable is defective and is contacted to battery voltage.

Check the connectors from backup alarm device to TCU.

No reaction. OP-Mode: normal.

Check the cable from TCU to the starter interlock relay. Check the connectors from starter interlock relay to TCU.

1) See “Measurement of Resistance at Actuator/sensors and Cable” on page 25.

Check the resistance 1) of starter interlock relay.

Transmission Error Codes (ZF)

Return to Master Table of Contents Fault Code (hex) 95

Meaning of the Fault Code (Possible reason for fault detection.) S.C. to battery voltage at relay starter interlock.

Reaction of the TCU No reaction. OP-Mode: normal.

TCU detected a wrong voltage at the output pin, that looks like a S.C. to battery voltage.

• Connector pin is contacted to battery voltage. O.C. at relay starter interlock.

No reaction.

TCU detected a wrong voltage at the output pin, that looks like a O.C. for this output pin.

OP-Mode: normal.

• Starter interlock relay has an internal defect.

Slippage at clutch K1(Y3).

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.

• Wrong signal at internal speed sensor. • Wrong signal at output speed sensor. • Wrong size of the sensor gap. • Clutch is defective.

Check the cable from TCU to the starter interlock relay.

1) See “Measurement of Resistance at Actuator/sensors and Cable” on page 25.

Check the resistance 1) of starter interlock relay.

• Connector has no connection to TCU.

• Low main pressure.

1) See “Measurement of Resistance at Actuator/sensors and Cable” on page 25.

Check the connectors from starter interlock relay to TCU.

• Cable is defective and has no connection to TCU.

• Low pressure at clutch K1(Y3).

Check the cable from TCU to the starter interlock relay.

Check the resistance 1) of starter interlock relay.

• Starter interlock relay has an internal defect.

Remarks

Check the connectors from starter interlock relay to TCU.

• Cable is defective and is contacted to battery voltage.

Possible Steps to Repair

If failure at another clutch is pending. TCU shifts to neutral. OP-Mode: TCU shutdown.

Check pressure at clutch K1(Y3). Check main pressure in the 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.

Transmission Error Codes (ZF)

S0607900C Page 19

Return to Master Table of Contents 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(Y6).

TCU shifts to neutral.

TCU calculates a differential speed at closed clutch K2(Y6). If this calculated value is out of range, TCU interprets this as slipping clutch.

OP-Mode: limp home.

Check pressure at clutch K2(Y6).

• Low pressure at clutch K2(Y6). • Low main pressure.

If failure at another clutch is pending. TCU shifts to neutral. OP-Mode: TCU shutdown.

• Wrong signal at internal speed sensor.

Remarks

Check main pressure in the system. Check sensor gap at internal speed sensor. Check sensor gap at output speed sensor. Check signal at internal speed sensor.

• Wrong signal at output speed sensor. • Wrong size of the sensor gap.

Check signal at output speed sensor.

• Clutch is defective.

Replace clutch. B3

Slippage at clutch K3(Y4).

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.

• Low pressure at clutch K3(Y4). • Low main pressure. • Wrong signal at internal speed sensor. • Wrong signal at output speed sensor. • Wrong size of the sensor gap. • Clutch is defective.

If failure at another clutch is pending. TCU shifts to neutral. OP-Mode: TCU shutdown.

Check pressure at clutch K3(Y4). Check main pressure in the 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.

S0607900C Page 20

Transmission Error Codes (ZF)

Return to Master Table of Contents 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(Y2).

TCU shifts to neutral.

TCU calculated a difference speed at 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(Y2).

• Low pressure at clutch K4(Y2).

OP-Mode: TCU shutdown.

• Low main pressure.

If failure at another clutch is pending. TCU shifts to neutral.

• Wrong signal at internal speed sensor.

Remarks

Check main pressure in the 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. • Wrong size of the sensor gap.

Check signal at turbine speed sensor.

• Clutch is defective.

Replace clutch. B5

Slippage at clutch KV(Y5).

TCU shifts to neutral.

TCU calculates a differential speed at closed clutch KV(Y5). If this calculated value is out of range, TCU interprets this as slipping clutch.

OP-Mode: limp home.

• Low pressure at clutch KV(Y5). • Low main pressure. • Wrong signal at internal speed sensor. • Wrong signal at turbine speed sensor. • Wrong size of the sensor gap. • Clutch is defective.

If failure at another clutch is pending. TCU shifts to neutral. OP-Mode: TCU shutdown.

Check pressure at clutch KV(Y5). Check main pressure in the 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.

Transmission Error Codes (ZF)

S0607900C Page 21

Return to Master Table of Contents 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(Y1).

TCU shifts to neutral.

TCU calculates a differential speed at closed clutch KR(Y1). 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 shutdown.

• Wrong signal at internal speed sensor. • Wrong signal at turbine speed sensor.

Remarks

Check main pressure in the system. Check sensor gap at internal speed sensor. Check sensor gap at turbine speed sensor. Check signal at internal speed sensor.

• Wrong size of the sensor gap. • Clutch is defective.

Check signal at turbine speed sensor. Replace clutch.

Overtemp sump.

No reaction.

Cool down machine.

TCU measured a temperature in the oil sump that is over the allowed threshold.

OP-Mode: normal.

Check oil level.

S.C. to battery voltage at power supply for sensors.

See fault codes no. 21 to 2C.

Check temperature sensor.

TCU measures more than 6V 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). D2

S.C. to ground at power supply for sensors.

See fault codes no. 21 to 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). D3

Low power at battery.

Shift to neutral.

Measured voltage at power supply is lower than XX V.

OP-Mode: TCU shutdown.

Check power supply battery. Check cables from batteries to TCU. Check connectors from batteries to TCU.

S0607900C Page 22

Transmission Error Codes (ZF)

Return to Master Table of Contents 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 XX V.

OP-Mode: TCU shutdown.

Possible Steps to Repair

Remarks

Check power supply battery. 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 shutdown.

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.

Shift to neutral.

Check fuse.

OP-Mode: TCU shutdown.

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. E3

S.C. to battery voltage 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 battery voltage.

Change display.

• Display has an internal defect.

Transmission Error Codes (ZF)

S0607900C Page 23

Return to Master Table of Contents Fault Code (hex) E4

Meaning of the Fault Code (Possible reason for fault detection.)

Reaction of the TCU

S.C. to ground at display output.

No reaction.

TCU sends data to the display and measures always a high voltage level on the connector.

OP-Mode: normal.

Possible Steps to Repair

Remarks

Check the cable from TCU to the display. 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.

No reaction.

TCU can't read non volatile memory.

OP-Mode: normal.

Replace TCU.

Often shown together with fault code F2.

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.

• TCU is defective. F3

Application error. Something of this application is wrong.

Clutch failure. AEB was not able to adjust clutch filling parameters. • One of the AEB-Values is out of limit.

Transmission stay neutral. OP-Mode: TCU shutdown. Transmission stay neutral. OP-Mode: TCU shutdown.

Clutch Adjustment Data lost.

No reaction,

TCU was not able to read correct clutch adjustment parameters.

Default values = 0 for AEB offsets used.

Execute AEB.

OP-Mode: normal.

• Interference during saving data on non volatile memory. • TCU is brand new.

S0607900C Page 24

Transmission Error Codes (ZF)

Return to Master Table of Contents

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: R12 ≈ 0;R1C ≈ R2C ≈ 0,R1P ≈ R2P ≈ ∞

P (power supply) TCU Actuator / 1

short cut to battery:

Sensor

C (chassis)

R12 ≈ 0,R1C ≈ R2C ≈ ∞,R1P ≈ R2P ≈ 0

Gnd

HBOE650I

Figure 3

Transmission Error Codes (ZF)

S0607900C Page 25

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S0607900C Page 26

Transmission Error Codes (ZF)

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1HYDRAULICS

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S0703000 R2

1ACCUMULATOR

ACCUMULATOR

S0703000

MODEL

SERIAL NUMBER RANGE

Mega 130

0001 and Up

Mega 160

0001 and Up

Mega 200-III

1001 and Up

Mega 250-III

1001 and Up

Mega 400-III PLUS

1001 and Up

Mega 400-V

1001 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

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 1

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S0703000 Page 2

Accumulator

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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

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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 Accumulator Model

Nitrogen Charge

Volume

Solar 130LC-V Solar 130W-V Solar 170LC-V Solar 170W-V Solar 220LC-V Solar 220LL Solar 220N-V Solar 250LC-V Solar 290LC-V Solar 290LL Solar 330LC-V Solar 400LC-V Solar 450LC-V Mega 130 Mega 160 Mega 400-V

15 kg/sq cm (213 psi)

320 cc (19.53 cu. in.)

Mega 250-III Mega 200-III Mega 400-III PLUS

30 kg/sq cm (427 psi)

S0703000 Page 4

Accumulator

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Accumulator

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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 excavator, 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 excavators use 320 cc (19.53 cu. in.) Bosch Accumulators with a nitrogen precharge (P1) pressure of 15 kg/sq cm. (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

S0703000 Page 6

Accumulator

Return to Master Table of Contents Reference Number

Description

Reference Number

Nitrogen Cylinder Fitting

Hose, 3 Meters (10 ft.) Long

Cylinder to Accumulator Adapter

Nitrogen Bleeder Valve

Check Valve

Nut O-ring

Pressure Gauge

Protective Cap

Sealing Nut

Protective Plug

Accumulator

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 lbs).

Check for nitrogen leaks around protective plug (11, Figure 3). Coat area around protective plug (11) with soapy water. If soap bubbles form, retighten protective plug (11).

10.

Install protective cap (10, Figure 3) on accumulator.

WARNING! Accumulator store nitrogen under high pressure. Before replacing an accumulator, install an adapter (7) with a bleeder valve (8) on the accumulator. Slowly and carefully bleed off all nitrogen before removing the accumulator from the hydraulic system. NOTE:

After an accumulator has been installed, or after an accumulator has been recharged with (P1) after the first week of operation. Check for a pressure drop due to leaks. If no pressure drop is found after the first week, check again after 3 more weeks. If no pressure drop is found after 3 weeks, check after one year.

Accumulator

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S0703000 Page 8

Accumulator

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S0705010

1CYLINDERS

CYLINDERS

S0705010

MODEL

SERIAL NUMBER RANGE

Mega 130

0001 and Up

Mega 160

0001 and Up

Mega 200-III

1001 and Up

Mega 250-III

1001 and Up

Mega 400-III PLUS

1001 and Up

Mega 400-V

1001 and Up

S0705010 Page 1

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TABLE OF CONTENTS General Description........................................................................................ 3 Theory of Operation ................................................................................ 4 Parts List ................................................................................................. 5 Troubleshooting, Testing and Adjustment....................................................... 7 Disassembly ................................................................................................. 10 Cleaning and Inspection (Wear Limits and Tolerances) ............................... 12 Reassembly.................................................................................................. 13

S0705010 Page 2

Cylinders

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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

Cylinders

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Description

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 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 2).

Figure 2

F1 = P x πB2 4 (P: Pressure, π = 3.14, B: Cylinder Inside Diameter) Reference Number

Description

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 3

F2 = P x π(B2-R2) 4 Because the volume of oil needed to lengthen the cylinder rod (Q1) is greater than the volume of oil required to retract the cylinder rod, it takes more time to decrease cylinder stroke length than it does to lengthen it. Q1 = S x π(B2) 4

Figure 4

Q2 = S x π(B2-R2) 4 Q1 > Q2

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Cylinders

Return to Master Table of Contents PARTS LIST Boom Hydraulic Cylinder

Figure 5

Reference Number

Description

Reference Number

Description

Cylinder Tube

Piston Ring

Cylinder Rod

U-Ring

Cylinder Head

U-Ring Holder

Bushing

Stopper

Snap Ring

U-nut

Packing Header

Lock Washer

U-Ring

Pin Bushing

Wiper Ring

Pin Bushing

Snap Ring

Grease Flitting

Piston

O-ring

Cylinders

S0705010 Page 5

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Figure 6

Reference Number

Description

Reference Number

Description

Cylinder Tube

U-ring Holder

Cylinder Rod

U-ring Holder

Cylinder Head

Stopper

Bushing

Castle Nut

Snap Ring

Shim

Packing Header

Dividing Pin

U-ring

Lock Washer

Wiper Ring

Pin Bushing

Piston

O-ring

Piston Ring

O-ring

U-ring

Plug

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Cylinders

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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).

Problem

Cause

Oil leaking between cylinder head (16) and piston rod (18). (Index nos. refer to Figure 1).

Foreign material in U-ring (3, Figure 1)

Cylinders

Remedy 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.

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Cause

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.

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).

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.

Slow bucket movements.

S0705010 Page 8

and

boom

Remedy

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.

Cylinders

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Cause

Remedy

Low pressure, shown by weak upward movement of boom and bucket.

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

Relief valve sticking.

worn

damaged

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.

Replace worn parts.

pump

Relief valve poppet worn. Cylinder drops when control valve is in neutral.

Vibration or excessive noise.

Air bubbles in oil.

Frequent rubber hose damage.

Cylinders

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.

Wrong type of operating oil.

Drain and fill with proper type of oil.

Oil level too low.

Raise to proper level.

Air trapped in system.

Perform cylinder bleeding procedure to remove air.

System pressure too high.

Adjust relief valve pressure.

Hoses breaking due to contact with another machine parts.

Restrain contact.

hoses

prevent

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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

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Cylinders

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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

S0705010 Page 11

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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.

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Cylinders

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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

S0705010 Page 13

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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

NOTE:

There are 2 backup rings used on outside of cylinder head. One backup ring is continuous. The other backup ring is open, split by an angled cut.

Figure 19 6.

Use grease or an adhesive to hold split backup ring (1, Figure 20) in place. Install split backup ring (1) in groove closets to flange on cylinder head. Reference Number

Description

Split Backup Ring

Continuous Backup Ring

Figure 20

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Cylinders

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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

S0705010 Page 15

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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 degree C (140 - 212 degree F) water for 5 minutes or longer.

Figure 24

Figure 25

Figure 26

Figure 27

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Cylinders

Return to Master Table of Contents 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

S0705010 Page 17

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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

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Cylinders

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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

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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:

S0705010 Page 20

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

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S0707100K

2FAN 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 Mega 400-V

SERIAL NUMBER RANGE 1001 and Up

S0707100K Page 1

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S0707100K Page 2

Fan Drive Hydraulic Motor (Haldex)

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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/sq cm (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

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 RPM 1,300

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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)

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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

S0707100K Page 5

Fan Drive Hydraulic Motor (Haldex)

Return to Master Table of Contents SPECIFICATIONS Item Fan Motor

Fan

Specification Displacement

31.0 cc (1.89 cu. in.)

Relief Valve Setting ∆ p/1 turn

70 ± 5 kg/sq cm (1000 ±70 psi) 16.5 kg/sq cm (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/sq cm (1000 ±70 psi))

Fan Drive Pump

S0707100K Page 6

24.9 cc (1.52 cu. in.)

Fan Drive Hydraulic Motor (Haldex)

S0708460K

3MAIN PUMP (DENISON T6DMY SERIES) 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 T6DMY SERIES)S0708460K MODEL Mega 400-V

SERIAL NUMBER RANGE 1001 and Up

S0708460K Page 1

TABLE OF CONTENTS General Description........................................................................................ 3 Construction ............................................................................................ 3 Principles of Operation............................................................................ 5 Parts List ............................................................................................... 12 Specifications ........................................................................................ 13 Special Tools and Materials.......................................................................... 14 Special Tools ......................................................................................... 14 Troubleshooting, Testing and Adjustment..................................................... 15 Disassembly ................................................................................................. 17 Cleaning and Inspection (Wear Limits and Tolerances) ............................... 21 Reassembly.................................................................................................. 22 Start-up Procedures ..................................................................................... 25

S0708460K Page 2

Main Pump (Denison T6DMY Series)

GENERAL DESCRIPTION This section describes the servicing of "T6DMY" series pumps. Some additional information is provided with regards to shaft seals and bolt torques for other models in the series. The T6DMY information in indicated with an asterisk (*) or shading when appropriate.

Figure 1

CONSTRUCTION General Pumps in this series are used to develop hydraulic fluid flow for operation of industrial and mobile equipment. The positive displacement pumping cartridges are of the rotary vane type with shaft side loads hydraulically balanced. Flow rate depends on pump size and speed at which it is driven. All units are designed so that direction of rotation, pumping capacity and port positions can be readily changed to suit particular applications.

Main Pump (Denison T6DMY Series)

S0708460K Page 3

Assembly and Construction The pump illustrated in Figure 2 is representative of all single pumps in this series. The unit consist principally of an inlet cover, outlet body, drive shaft and pumping cartridge. The principle components of the cartridge are an elliptical cam ring, a slotted rotor splined to the drive shaft, an inlet and outlet support plate fitted with four special seal packs, two flex side plates, and ten vanes and inserts fitted to the rotor slots. Fluid enters the cartridge through the inlet port in the cover and is discharged through the outlet flex side plate and support plate to the outlet port in the body.

Figure 2 Reference Number

Description

Reference Number

Description

Flex Side Plates

Outlet Cover

Seal Packs

Square Seal Ring

Rotor

Outlet Body

Insert

Outlet Support Plate

Vane

Shaft Bearing

Inlet Support Plate

Primary Seal

Ring

Shaft

Inlet Hole Thru Ring

S0708460K Page 4

Main Pump (Denison T6DMY Series)

PRINCIPLES OF OPERATION Pumping Cartridge As mentioned in "Construction," fluid flow is developed in the pumping cartridge. The action of the cartridge is illustrated in Figure 3. The rotor is driven within the ring by the drive shaft, which is coupled to a power source. As the rotor turns, centrifugal force on the vanes, aided by under-vane pressure fed from the outlet port, causes the vanes to follow the elliptical inner surface of the ring. Radial movement of the vanes and turning of the rotor causes the chamber volume between the vanes to increase as the vanes pass the inlet sections of the ring. This results in a low pressure condition which allows atmospheric pressure to force fluid into the chambers. An additional inlet fluid path exists through a drilled hole in the cam ring. This hole connects the inlet port directly to the inlet areas of the cam ring and provides an additional flow path for fluid to get into the cartridge. (See Figure 2.) Fluid is trapped between the vanes and carried past a sealing land to the outlet section of the ring. As the outlet section is approached, the chamber volume decreases and the fluid is forced out into the system. System pressure is fed under the vanes, assuring their sealing contact against the ring during normal operation.

Main Pump (Denison T6DMY Series)

S0708460K Page 5

Hydraulic Balance The pump ring is shaped so the two pumping chambers are formed 180° apart (Figure 3). Thus, opposing hydraulic forces which develop side loads on the shaft cancel out.

Figure 3 OPERATION OF BALANCED, VANE-TYPE CARTRIDGE. Reference Number

Description

Reference Number

Rotation

Shaft

Inlet

Outlet

Ring

Insert

Rotor

Rotation

Outlet

Vane

Inlet

S0708460K Page 6

Description

Main Pump (Denison T6DMY Series)

Vane Pressure Feed The intra-vane design provides a means of controlling the outward thrust of the vane against the ring and maintains tip loads within reasonable limits. In the intra-vane cartridge, full system pressure is continuously applied only to the area between the vane and insert. This area is small and thrust is correspondingly light. During vane travel through pressure areas, full system pressure is applied against the bottom area of the outer vane. The valving of pressure to and from the bottom area of the vane is through holes drilled in the rotor, as shown in Figure 4. This selective application of pressure maintains the vane in substantially constant radial hydraulic balance in all positions. Vane tip wear is compensated for automatically. As the vane wears, pressure moves the vane further out in the rotor slot holding the vane tip against the cam ring.

Figure 4 PRESSURE FEED TO VANES IN INTRA-VANE CARTRIDGE Reference Number

Description

Reference Number

Description

Pressure to Insert

Ring

Vane

Rotor

Sharper Edges (Lead Direction of Rotation

Direction of Rotation

Pressure to Bottom of Vane

Main Pump (Denison T6DMY Series)

S0708460K Page 7

Flex Side Plate Operation The flex side plates for both inlet and outlet are symmetrical. Pressure is fed behind each side plate into two kidney shaped cavities which are sealed by special seal packs. The two flex side plates and their associated kidney shaped cavities function in the following manner. As pressure builds up in the outlet, pressure also builds up in the cavities. The pressure in the cavities hold the flex side plates in hydrostatic balance against the rotor and provide optimum running clearances for minimum internal leakage and minimum friction (See Figure 5). The flex side plates also provide passages for feeding under vane pressure to the space between the vane and insert. The bronze faces of the flex side plates ride next to the rotor and provide excellent wear and cold start characteristics. The inlet and outlet support plates hold the flex side plates in position and contain passages which allow fluid to pass from the inlet to the pumping cartridge and from the cartridge to the outlet port.

Figure 5 FLEX SIDE PLATE OPERATION Reference Number

Description

Reference Number

Description

Flex Side Plates

Seal Packs

Kidney Shaped Cavities

S0708460K Page 8

NOTE: Upper Rotated 45°

Section

Main Pump (Denison T6DMY Series)

Inlet Bodies Two inlet body configurations and two shaft seal arrangements are available in this pump series. (See Figure 6* and Figure 7.) When a single shaft seal is used, a steel ball is pressed into the body. (See Figure 6.) Double shaft seal models use a plastic plug to seal the body drain opening. This prevents external contamination from entering the area between the seals. (Refer to Figure 7.) The outer shaft seal is rated 0.48 bar (7.0 psi) from an internal source and 0.14 bar (2.0 psi) from an external source. Double shaft seal models require a different shaft that may or may not be interchangeable with previous designs. This is due to an increase in shaft shoulder length to accommodate the second shaft seal. The overall shaft length of both models are the same as previous designs. Reference Number

Description

Standard Shaft

Steel Ball

11.176 mm (0.440 in.)

58.420 mm (2.30 in.)

Figure 6 SINGLE SHAFT SEAL ARRANGEMENT*

Main Pump (Denison T6DMY Series)

S0708460K Page 9

Reference Number

Description

Primary Seal

Secondary Seal

Special Shaft (Longer Seal Area)

Plastic Plug

16.002 mm (0.630 in.)

58.420 mm (2.30 in.)

Figure 7 DOUBLE SHAFT SEAL ARRANGEMENT

S0708460K Page 10

Main Pump (Denison T6DMY Series)

S0708460K Page 11

PARTS LIST

Figure 8

S0708460K Page 12

Main Pump (Denison T6DMY Series)

Reference Number

Description

Reference Number

Description

Body; Outlet

Plate; Outlet Support

Shaft; Seal

Pack; Seal

Spacer; Washer

Plate Kit; Flex Side

Shaft (No. 127)

Rotor

Bearing

Vane & Insert

Ring; Retaining

Plate; Inlet Support

Ring; Spirolox

Ring; Backup

Screw; Hex Head

O-ring

Cover

O-ring

Bolt

Ring; Seal

Ring

SPECIFICATIONS Main Pump

Specification

Type

Fixed vane

Displacement

121.5 cc/rev. (7.41 cu. in./rev.)

Maximum flow rate

240 liters/min. (63.4 gpm)

Main Pump (Denison T6DMY Series)

S0708460K Page 13

SPECIAL TOOLS AND MATERIALS SPECIAL TOOLS Two special tools are required to service these pumps. A driver should be used to assure installation of the primary shaft seal without damage, and a "bullet" should be placed over the end of the shaft, to avoid damaging the seal lip when the shaft is installed. Installation of the secondary seal does not require a driver. (See Figure 6.) NOTE:

If a shaft seal bullet is unavailable, wrap splines on shaft with masking tape to prevent damage to seal. Coat tape with oil while installing shaft. Be sure to remove all tape after installation.

The driver can be made from tubular stock as shown in Figure 9. The tool applies a uniform pressure to the recessed area of the seal, rather than to the lip of the seal. The inside diameter of the tool will not interfere with the garter spring located around the lip of the seal.

Figure 9 PRIMARY SHAFT SEAL DRIVER Pump Series

Length "A"

Undercut "B"

O.D. "C"

I.D. "D"

T6DMY-038

88.9 mm (3.500 in.)

8.407 mm (0.331 in.)

44.831 mm (1.765 in.)

41.199 mm (1.622 in.)

S0708460K Page 14

Main Pump (Denison T6DMY Series)

TROUBLESHOOTING, TESTING AND ADJUSTMENT The following table lists common difficulties experienced with vane pumps and hydraulic systems. It also indicates possible causes and remedies for each of the problems listed. It should always be remembered that many apparent pump failures are actually the failures of other parts of the system. The cause of improper operation is best diagnosed with adequate testing equipment and a thorough understanding of the complete hydraulic system. Problem Pump not delivering fluid.

Insufficient pressure buildup.

Possible Cause

Remedy

Driven in rotation.

wrong

direction

The drive direction must be changed immediately to prevent seizure. Refer to “Reassembly” on page -22, for correct ring position for each direction of rotation.

Coupling or disengaged.

shaft

sheared

Disassemble pump and check shaft and cartridge for damage. Replace necessary parts.

Fluid intake restricted.

pipe

reservoir

Check all strainers and filters for dirt and sludge. Clean if necessary.

Fluid viscosity too heavy to pick up prime.

Completely drain system. Add new filtered fluid of proper viscosity.

Air leaks at intake. Pump not priming.

Check inlet connections to determine where air is being drawn in. Tighten any loose connections. See that fluid in reservoir, is above intake pipe opening. Check minimum drive speed which may be too slow to prime pump.

Relief valve stuck open. (Models with integral relief valve only).

Disassemble pump and wash valve m clean solvent. Return valve to its bore and check for any stickiness. A gritty feeling on valve periphery can be polished with crocus cloth. Do not remove excess material round off edges of lands or attempt to polish bore. Wash all parts and reassemble pump.

Vane(s) stuck in rotor slot(s).

Disassemble pump. Check for dirt or metal chips. Clean parts thoroughly and replace any damaged pieces. If necessary, flush system and refill it with clean fluid.

System relief valve set too low.

Use a pressure gage to correctly adjust valve.

Main Pump (Denison T6DMY Series)

S0708460K Page 15

Problem Pump making noise,

S0708460K Page 16

Possible Cause

Remedy

Pump intake partially blocked.

Service intake strainers. Check fluid condition and, if necessary, drain and flush system. Refill with clean fluid.

Air leaks at intake or shaft seal. (Oil in reservoir would probably be foamy).

Check inlet connections and seal to determine where air is being drawn in. Tighten any loose connections and replace seal if necessary. See that fluid in reservoir is above intake pipe opening.

Pump drive speed too slow or too fast.

Operate pump at recommended speed.

Coupling misalignment.

Check if shaft seal bearing or other parts have been damaged. Replace any damaged parts. Realign coupled shafts.

Main Pump (Denison T6DMY Series)

DISASSEMBLY 1.

Basic pump disassembly; A.

Support pump on blocks or clamp body in a vise as shown in Figure 10. If a vise is used, use protective jaws to avoid damage to body and its machined surfaces. Match mark (1, Figure 10) pump body (2) and cover (3) for correct reassembly. Remove four cover screws (4) and lift cover off pump.

Remove cover O-ring. Pull and/or pry out cartridge as shown in Figure 11.

Figure 10

Figure 11 C.

Pry under coil and remove large spirolox ring and pull shaft and bearing from body. Drive shaft seals out of body. If it is necessary to remove shaft bearing, first remove small snap ring and then press shaft out of bearing while supporting bearing inner race.

Figure 12 REMOVING SPIROLOX RING

Main Pump (Denison T6DMY Series)

S0708460K Page 17

Cartridge disassembly; A.

Remove O-ring, back-up ring and square sealing ring from outlet support plate.

Scribe a line across outer surface of cartridge kit. (See Figure 13.) Scribe marking will provide a reference for parts during assembly.

Figure 13 C.

Place cartridge on a flat surface (outlet support plate down) and remove two socket head screws.

WARNING! Do not slide flex side plates across ring and rotor. Burrs on ring or rotor can cause deep scratches in soft brass surface. D.

Slide inlet support plate and seal packs off cartridge. DO NOT allow flex side plate to slide with support plate. (See Figure 14.)

Figure 14

Move flex side plate off center just enough to grab edge and lift up and away without sliding. (See Figure 15.)

Figure 15

S0708460K Page 18

Main Pump (Denison T6DMY Series)

If a small flat piece of wood is available, place it over ring and rotor and reverse cartridge to have outlet support plate pointing up. (See Figure 16.)

Figure 16 G.

Slide outlet support plate and seal packs off cartridge, do not allow flex side plate to slide with support plate. Refer to Figure 17.

Figure 17 H.

Move flex side plate off center just enough to lift up and away without sliding. (See Figure 18.)

Figure 18

Main Pump (Denison T6DMY Series)

S0708460K Page 19

Remove cam ring from rotor and vanes. Locate arrow stamped into rotor periphery. Remove vanes and inserts in order, starting at arrow. Keep them in order for inspection. (See Figure 19.)

NOTE:

Do not remove cartridge locating pins from inlet support plate unless they are damaged. Pins are of a drive-loc type and can be difficult to remove. Figure 19

S0708460K Page 20

Main Pump (Denison T6DMY Series)

CLEANING AND INSPECTION (WEAR LIMITS AND TOLERANCES) For general cleaning and inspection procedures, refer to "General Maintenance Procedures" section. All parts must be thoroughly cleaned and kept clean during inspection and assembly. The close tolerance of the parts makes this requirement very important. Clean all removed parts, using a commercial solvent that is compatible with the system fluid. Compressed air may be used in cleaning, but it must be filtered to remove water contamination. 1.

Discard shaft seal(s), O-rings, back-up rings and seal packs. Use a new seal kit for reassembly. Wash metal parts, blow them dry with air and place on a clean surface for inspection.

Check cartridge wear surfaces for pickup, scoring and excessive wear. Slight heat discoloration of flex side plate bronze surface is normal. Score marks deeper than 0.025 mm (0.001 in.) and scratches deeper than 0.051 mm (0.002 in.) indicate a new part is needed. Slight scoring and/or scratches can be removed with an oiled Arkansas stone.

CAUTION! DO NOT use a dry stone on the bronze surface or scratches will result. 3.

Inspect both sides of each vane and insert in order. If pickup, heavy wear or scoring is found, inspect the appropriate rotor slot. Replace scored parts.

Inspect the cam ring for vane chatter marks, wear and/or scratches. Replace if scoring is evident.

CAUTION! Replacement ring width must be identical to the ring being replaced or reduced life and/or output flow will result. The minimum ring to rotor clearance limits are noted below. MINIMUM ALLOWABLE RING ROTOR CLEARANCE MODEL T6DMY - 038

MINIMUM CLEARANCE LIMITS IN MM (INCHES) 0.038 mm (0.0015 in.)

NOTE:

All cartridge kit parts must be free of burrs. Stone the mating surfaces of each part with an oiled Arkansas stone prior to assembly.

NOTE:

Pre-assembled replacement cartridge kits are available. If the old cartridge is worn extensively, a new kit should be used.

Vane and rotor wear can be checked by inserting vane in rotor slot and checking for excessive play. Replace rotor and vanes if wear is evident.

Rotate bearing while applying pressure to check for wear, looseness and pitted or cracked races.

Inspect seal and bushing mating surfaces on shaft for scoring or wear. Replace shaft if marks cannot be removed by light polishing.

Main Pump (Denison T6DMY Series)

S0708460K Page 21

REASSEMBLY NOTE:

Coat all parts except seals and back-up rings with clean hydraulic fluid to facilitate assembly and provide initial lubrication. Use small amounts of petroleum jelly to hold Orings in place during assembly.

IMPORTANT During handling and shipping of precision machined cartridge parts, it is possible to raise burrs on sharp edges. All sharp edges on parts of a new cartridge kit should be stoned prior to installation. NOTE: 1.

To reverse direction of a new cartridge kit, simply reverse location of inlet and outlet support plates, and realign cartridge with cover. See steps 1H through 1J.

Cartridge reassembly - The direction of rotation is as viewed from shaft end, right-hand rotation is clockwise; left-hand, counterclockwise. NOTE:

If locating pins were removed from inlet support plate, install new pins with locking flutes located within inlet support plate. Drive new pins into support plate, with a soft tip hammer.

Place inlet and outlet support plates on a flat surface as shown in Figure 20. Install seal packs into cavities with seal retainer surface up. (Orings facing downward into cavities.)

Place a flex side plate over each of support plates with bronze wear surface facing up. Align scribe marks to make sure correct flex side plate is used with correct support plate.

NOTE:

Flex side plates develop a wear pattern with rotor and vanes and should not be interchanged.

For right-hand rotation units, set rotor on flat wooden board with arrow pointing right. (For left-hand rotation arrow should point left.) Assemble vanes and inserts into rotor in reverse order. (See Figure 21.) Make sure sharp chamfer edge of each vane leads in direction of rotation. All vanes must move freely in rotor slots with no evidence of bind.

Assemble cam ring over rotor and vanes with arrow pointing in same direction as rotor. Lubricate top surface of rotor and vanes liberally with system fluid.

S0708460K Page 22

Figure 20

Figure 21

Main Pump (Denison T6DMY Series)

Locate scribe mark on cam ring, outlet support plate, and flex side plate. Hold outlet support plate and flex side plate together and assemble over cam ring and rotor with scribe marks inline.

Hold cartridge together to prevent movement and turn assembly over so outlet support plate rests on a flat surface, and flat wooden board is up. (See Figure 22.) Remove flat wooden board.

Figure 22 G.

Lubricate exposed surface of rotor and vanes with system fluid. Locate scribe mark on inlet support plate and flex side plate. Hold inlet support plate and flex side plate together and assemble over cam ring and rotor with scribe marks in-line. (See Figure 23.)

NOTE:

The cast-in arrows located next to socket head screws, indicate cartridge direction of rotation.

Thread two socket head screws into cartridge until snug (hand tight).

NOTE:

The O.D. of all component parts of cartridge kit must be in-line with each other or cover cannot be installed. Align cartridge as follows:

Main Pump (Denison T6DMY Series)

Figure 23

S0708460K Page 23

Install cover over cartridge. Tap lightly on cover with your hand until each part centers. Remove cover gently so as not to disturb alignment. Torque socket head screws to torque noted on Figure 8, and recheck kit alignment with cover. Repeat until cartridge kit is aligned. (See Figure 24.)

Check rotor for bind by inserting index finger through shaft opening of inlet support plate. Hold cartridge kit in a horizontal shaft position and lift rotor with finger. Rotor should move freely back and forth within cartridge. If rotor binds, open kit, clean and stone all possible areas of bind, then reassemble using aforementioned procedure. Rotor MUST move freely within cartridge when assembled.

Basic pump reassembly - Clamp body in a vise or place on 2x4 wooden blocks to facilitate assembly. (See Figure 10 and Figure 11.)

Figure 24

Lubricate primary shaft seal with petroleum jelly and place in position within body, garter spring up. See Figure 6 for seal arrangements.

Use seal installation tool shown in Figure 9 to prevent damage to seal. Press seal into body until it bottoms out.

NOTE: C.

Two shaft seal arrangements are available in VQ pump series. See Figure 6 and Figure 7.

Lubricate secondary seal with petroleum jelly and place seal in position against shaft end of body. See Figure 7. Use a small hardwood block to drive seal evenly into body. Installation is complete when seal face is flush with front of body. DO NOT drive seal past flush as it can block body drain opening.

NOTE:

If shaft bearing was defective, install a new bearing as follows:

Press shaft into new bearing with an arbor press while supporting bearing inner race. Refer to Figure 6 and Figure 8 for correct location of bearing on shaft. Install a small snap ring behind bearing.

Place bearing spacer washer over shaft, against front of bearing. Use a "bullet" over shaft end to prevent damage to seal(s). Lubricate "bullet" with petroleum jelly and carefully push shaft through seals until bearing and spacer is in location within body. Install large spirolox ring into body snap ring groove behind bearing.

Install square sealing ring into body. See Figure 2 and Figure 8 (sectional view) for location.

Install O-ring and back-up ring on cartridge, outlet support plate hub. See Figure 8 for location.

Carefully install cartridge into body so one of the chamfers on cam ring aligns with cover inlet port.

Lubricate and install large cover to body O-ring in place.

S0708460K Page 24

Main Pump (Denison T6DMY Series)

Install cover in position; move back and forth until cartridge pins drop into cover holes.

Oil and install cover to body bolts (4 required). Torque to value noted in Figure 8.

Turn pump shaft by hand to verify freedom of cartridge.

START-UP PROCEDURES Whenever it is possible to do so, fill pump ports with system hydraulic fluid. This will make it easier for pump to prime when it is first started. Self-Priming - With a minimum drive speed of 600 RPM, a pump should prime almost immediately. Failure to prime within a reasonable length of time may result in damage due to lack of lubrication. Inlet lines must be tight and free from air leaks. However, it may be necessary to crack a fitting on outlet side of pump to purge entrapped air. No-Load Starting - These pumps are designed to start up with no load on pressure ports. They should never be started against a load or a closed center valve.

Main Pump (Denison T6DMY Series)

S0708460K Page 25

S0708460K Page 26

Main Pump (Denison T6DMY Series)

S0708470K

4STEERING AND BRAKE PUMP (DENISON T67DB SIRIES) 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.

STEERING AND BRAKE PUMP (DENISON T67DB SIRIES)S0708470K MODEL Mega 400-V

SERIAL NUMBER RANGE 1001 and Up

S0708470K Page 1

TABLE OF CONTENTS General Description........................................................................................ 3 Parts List ................................................................................................. 4 Special Tools .................................................................................................. 6 Troubleshooting, Testing and Adjustment....................................................... 7 Service and Maintenance............................................................................... 8 Circuit Inspection..................................................................................... 8 Adding Hydraulic Oil to System............................................................... 8 Adjustments ............................................................................................ 8 Lubrication .............................................................................................. 8 Replacement Parts.................................................................................. 9 Disassembly ................................................................................................. 10 Baisc Pump Disassembly...................................................................... 12 Cartridge Disassembly.......................................................................... 13 Cleaning and Inspection (Wear Limits and Tolerances) ............................... 16 Cleaning ................................................................................................ 16 Inspection, Repair and Replacement .................................................... 16 Reassembly.................................................................................................. 18 Cartridge Assembly............................................................................... 19 Basic Pump Assembly .......................................................................... 22 Start-up Procedures ..................................................................................... 23 Start-up ................................................................................................. 23 Test........................................................................................................ 23

S0708470K Page 2

Steering and Brake Pump (Denison T67DB Siries)

GENERAL DESCRIPTION The operating principle of a vane pump is illustrated in Figure 1. A slotted rotor is splined to the drive shaft and turns inside a cam ring. Vanes are fitted to rotor slots and follow inner surface of cam ring as the rotor turns. Centrifugal force and pressure under vanes hold them out against the cam ring. Pumping chambers are formed between the vanes and cam ring and are enclosed by two end plates. The pump is a balanced intra-vane design. See Figure 1. Outlet pressure is constantly applied to small intra-vane area of the vane. As the pump vane rotates through high and low quadrants, outlet pressure is alternately applied to the rest of under vane area. This varying pressure under the vane reduces wear and increases pump efficiency. Pump delivery can be changed by changing the ring or installing a new cartridge kit. Cartridge kit part numbers are tabulated in parts and service drawings.

Figure 1 VANE PUMP OPERATION

Steering and Brake Pump (Denison T67DB Siries)

S0708470K Page 3

PARTS LIST

Figure 2

S0708470K Page 4

Steering and Brake Pump (Denison T67DB Siries)

Reference Number

Description

Reference Number

Description

Body

Body; Inlet

Seal; Secondary

Bolt

Seal; Primary

Screw

Washer

Shaft

Pack Seal

Bearing

Plate Kit; Flex Side

Ring; Retaining

Ring

Ring; Lock

Plate; Inlet Support

Ring; Backup

Rotor

O-ring

Kit; Vane

Ring; Seal

Plate; Outlet Support

O-ring

Plate; Outlet Support

Ring; Seal

Pack; Seal

O-ring

Plate Kit; Flex Side

U-ring

Ring

Cover; Rear Flange

Rotor

Bolt

Vane & Insert

Plate; Inlet Support

Cartridge Kit, Center (Consists of 24 thru 36

Screw

Cartridge Kit, Shaft End (Consists of 9 thru 21)

Steering and Brake Pump (Denison T67DB Siries)

S0708470K Page 5

SPECIAL TOOLS A shaft seal driver (Figure 3) is the only special tool required for overhaul. NOTE:

In addition to the above tool, an arbor press may be required to service the shaft bearing.

Figure 3 SHAFT SEAL DRIVER (DIMENSIONS ARE IN INCHES.)

Model T67DB 031 - B08

S0708470K Page 6

Dimension A

71.933 ±0.025 mm (2.832 ±0.001 in.)

50.216 ±0.025 mm (1.977 ±0.001 in.)

44.653 ±0.025 mm (1.758 ±0.001 in.)

42.850 ±0.025 mm (1.687 ±0.001 in.)

6.350 mm (0.250 in.)

Steering and Brake Pump (Denison T67DB Siries)

TROUBLESHOOTING, TESTING AND ADJUSTMENT Table below lists the common difficulties experienced with vane pumps and hydraulic systems. It indicates, possible causes and remedies for each of the problems listed. Problem Excessive noise in pump.

Possible Cause

Remedy

Low oil level in reservoir.

Fill reservoir to proper level with recommended fluid.

Air in system.

Open reservoir cap and operate system until purged. Bleed hydraulic lines at highest point down stream of pump while system is under pressure.

Pump overheating.

System not pressure.

developing

Vacuum condition.

Check inlet (suction) line and fittings for air leaks.

Oil too thick.

Be certain correct type of oil is used in system. Warm up pump in cold weather until noise disappears.

Damaged or missing pump seals at mating surfaces.

Locate and replace damaged or missing seals.

Cartridge properly.

Reassemble cartridge kit.

kit

not

assembled

Pump inlet/outlet lines reversed.

Reconnect lines to proper port connections.

Internal leakage.

If excessive internal leakage exists, return to shop for complete overhaul.

Heat exchanger not functioning.

Locate trouble and repair or replace.

Relief valve open.

Repair or replace.

Loss of fluid internally (slippage).

Return to shop for evaluation and repair.

Cartridge properly.

Reassemble kit.

kit

not

assembled

Cartridge kit assembled opposite rotation.

Loss of fluid.

for

Reassemble kit to proper rotation.

Pump inlet/outlet lines reversed.

Reconnect lines to proper port connections.

Disconnected mechanism.

Locate and repair.

broken

drive

Ruptured hydraulic lines.

Locate and repair.

Leaking or missing seals.

Locate and repair.

Steering and Brake Pump (Denison T67DB Siries)

S0708470K Page 7

SERVICE AND MAINTENANCE CIRCUIT INSPECTION NOTE:

Periodic inspection of hydraulic fluid condition and tube or pipe line connections can save time consuming breakdowns and unnecessary and expensive repairs.

All hydraulic connections must be kept tight. A loose connection in a pressure line will permit fluid to leak out. If hydraulic oil level becomes so low as to uncover inlet pipe opening in reservoir, entensive damage to pump can result. In suction or return lines, loose connections permit air to be drawn into system, resulting in noisy and/or erratic operation.

Clean hydraulic oil is the best insurance for long service life. Therefore, the reservoir should be checked periodically for dirt and other contaminants. If hydraulic oil becomes contaminated, the system should be drained and reservoir thoroughly cleaned before adding new oil.

Filter elements should be checked and replaced at regular service intervolts. A clogged filter element results in a higher pressure drop. This can force particles through the filter which would ordinarily be trapped, or can cause the by-pass to open, resulting in a partial or complete loss of filtration.

Air bubbles in the reservoir can cause damage to pump and other components. If bubbles are seen, locate source of air and seal the leak.

A pump which is running excessively hot or noisy is a potential failure. Should a pump become noisy or overheated, immediately shut down the machine and correct problem.

ADDING HYDRAULIC OIL TO SYSTEM 1.

When hydraulic oil is added to replenish the system, it should be poured through a clean wire screen (200 mesh or finer), or preferably pumped through a 10 micron (absolute) filter.

It is important that hydraulic oil be clean and free of any substance which could cause improper operation or wear pumps and other hydraulic components. Therefore, use of cloth to strain hydraulic oil should be avoided to prevent lint from entering system.

ADJUSTMENTS 1.

No periodic adjustments are required, other than to maintain proper shaft alignment with driving medium.

LUBRICATION 1.

Internal lubrication is provided by the hydraulic oil in the system. Coat shaft splines with a dry lubricant (Molycoat or equivalent) to prevent wear.

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Steering and Brake Pump (Denison T67DB Siries)

REPLACEMENT PARTS 1.

Reliable operation throughout specified operating range is assured only if genuine Vickers parts are used (available through your Daewoo distributor). Sophisticated design process and material are used in the manufacture of these parts. NOTE:

Substitute replacement parts may result in early failure of pump assembly.

Commonly replaced parts are usually provided in the form of repair kits available through your Daewoo distributor. It is strongly recommended to use repair kits when a pump is overhauled.

Steering and Brake Pump (Denison T67DB Siries)

Figure 4 PREASSEMBLED CARTRIDGE KIT

S0708470K Page 9

DISASSEMBLY

Figure 5

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Steering and Brake Pump (Denison T67DB Siries)

Reference Number

Description

Reference Number

Description

Body

Body; Inlet

Seal; Secondary

Bolt

Seal; Primary

Screw

Washer

Shaft

Pack Seal

Bearing

Plate Kit; Flex Side

Ring; Retaining

Ring

Ring; Lock

Plate; Inlet Support

Ring; Backup

Rotor

O-ring

Kit; Vane

Ring; Seal

Plate; Outlet Support

O-ring

Plate; Outlet Support

Ring; Seal

Pack; Seal

O-ring

Plate Kit; Flex Side

U-ring

Ring

Cover; Rear Flange

Rotor

Bolt

Vane & Insert

Plate; Inlet Support

Cartridge Kit, Center (Consists of 24 thru 36

Screw

Cartridge Kit, Shaft End (Consists of 9 thru 21)

IMPORTANT Thoroughly clean exterior surfaces of pump prior to disassembly. There should not be any visible dirt, grease or other type of accumulation on outside of pump case. Clean off or blow dry all traces of cleaner and solvent before starting work.

IMPORTANT If at all possible, use a clean, dry container to catch oil. A clean container allows an evaluation to be made of the used oil. The presence or relative lack of metal wear shavings in used oil or obvious deterioration or contamination of the oil can provide a useful indicator of the pump’s general condition. NOTE:

Used oil is an environmental contaminant and should be disposed of promptly at approved recycling facilities. Prolonged physical contact with used oil has been thought by some to pose a health risk. Clean oil residue from hands and clothing promptly, and do not allow used oil containers to accumulate.

NOTE:

The area where pump is to be rebuilt should be well-lit, clean and protected from dust and/ or wind gusts that could carry in dust or grit. Use a rubber mat or other protective overlay on workbench area to prevent damaging or scratching any precision machined components.

Steering and Brake Pump (Denison T67DB Siries)

S0708470K Page 11

NOTE:

4535V models are slightly different from the models shown in Figure 7. Screws (4) are longer and fasten cover (5), inlet housing (19), and body (38) together. Screws (18) are omitted.

BAISC PUMP DISASSEMBLY 1.

Thoroughly clean pump exterior.

Use a prick punch and mark position of cover (37) and body (1) with respect to inlet housing (22) for correct reassembly.

Support the pump on blocks or clamp body (1) in a vise. Remove four cover screws (38) and lift cover (37) off pump. NOTE:

If a vise is used, use protective jaws to avoid damage to body and its machine surfaces.

Remove U-ring (36), O-ring (35), seal ring (34), and O-ring (33) from cartridge kit (39) and discard.

Pull and/or pry out center cartridge kit (39) from inlet housing (22).

Remove four screws (23) from inlet housing (22), then left off housing .

Pull shaft end cartridge kit (40) from body (1).

Pry under coil and remove spirolox ring (8) from body (1). (See Figure 6.)

Pull the shaft group (items 7, 6, and 5) from body (1). If bearing (6) or shaft (5) need replacement, remove retaining ring (7) with retaining ring pliers. Remove bearing (6) from shaft (5) by using an arbor press. Apply pressure to the inner race when removing bearing.

10.

Remove washer (4) and primary shaft seal (3) from body (1).

11.

Drive secondary shaft seal (2) out of mounting end of body (1).

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Figure 6 REMOVING SPIROLOX RING

Steering and Brake Pump (Denison T67DB Siries)

CARTRIDGE DISASSEMBLY 1.

Scribe a line across outer surface of cartridge kit to provide a reference for parts during assembly.

Place cartridge on a flat surface (outlet support plate down) and remove two socket head screws.

Figure 7

NOTE:

Do not slide flex side plates across ring and rotor. Burrs on ring and rotor can cause deep scratches in soft brass surface.

Slide inlet support plate and seal packs off cartridge. Do not allow flex side plate to slide with support plate. Figure 8

Move flex side plate off center just enough to grab edge and lift up and away without sliding.

Figure 9

Steering and Brake Pump (Denison T67DB Siries)

S0708470K Page 13

If a small flat piece of wood is available, place it over ring and rotor and reverse cartridge to have outlet support plate pointing up. Use wood to hold ring, rotor and vanes.

Figure 10 6.

Slide outlet support plate and seal packs off cartridge, do not allow flex side plate to slide with support plate.

Figure 11 7.

Move flex side plate off center just enough to lift up and away without sliding.

Figure 12

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Steering and Brake Pump (Denison T67DB Siries)

Remove cam ring from rotor and vanes. Locate the arrow stamped into rotor periphery. Remove vanes and inserts in order, starting at arrow. Keep them in order for inspection.

Do not remove cartridge locating pins from inlet support plate unless they are damaged, Pins are of a drive-loc type and can be difficult to remove.

Figure 13

Steering and Brake Pump (Denison T67DB Siries)

S0708470K Page 15

CLEANING AND INSPECTION (WEAR LIMITS AND TOLERANCES) For general cleaning and inspection procedures, refer to "General Maintenance Procedures" section. CLEANING All parts must be thoroughly cleaned and kept clean during inspection and assembly. Contamination of unit will cause excessive wear, leakage, and decreased service life. Use a commercial solvent which is compatible with the system fluid. Thoroughly clean all parts. Drying parts with compressed air after cleaning is not recommended, unless the air is completely filtered to remove water and contamination. INSPECTION, REPAIR AND REPLACEMENT Check all internal passages. Make sure they are clean and unobstructed. Examine all mating surfaces for nicks and burrs. Check locating pins and holes for wear and burrs. Check the condition of threaded parts and threaded holes. Check all snap ring recesses. Minor burrs can be removed with an India stone. Replace any part which shows wear or damage. The following parts are subject to special attention: 1.

Cartridge kits (39 and 40). In order to obtain maximum overhaul life of the pump, a complete cartridge kit should be installed if wear or scoring is noticed during the following inspection steps. A.

Inspect the mating surfaces of the rotors (15 and 28), outlet support plates (17 and 30), and inlet support plates (12 and 25) for wear and/or scoring.

Inspect vanes and inserts (16 and 29) for burrs, wear, and play in slots of rotors (15 and 28). Remove minor burrs with an India stone.

NOTE: C.

Figure 14 PREASSEMBLED CARTRIDGE

DO NOT use a dry stone on bronze surfaces or scratches will result

Inspect bushing for wear and scoring.

Check bearing (33) for wear, looseness, and pitted or cracked races.

Inspect seal and bushing mating surfaces on the shaft for scoring and wear. Replace shaft if marks cannot be removed by light polishing.

Remove burrs from outer edge of ring (27). Place rotor (15) and ring (27) on a flat surface. Measure ring/rotor clearance with a dial indicator. Ring/rotor clearance are noted in Table below.

S0708470K Page 16

Model

Minimum Clearance Limit In Inches

T67DB - 1308

0.018 mm (0.0007 in.)

T67DB - 031

0.038 mm (0.0015 in.)

Steering and Brake Pump (Denison T67DB Siries)

S0708470K Page 17

REASSEMBLY

Figure 15

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Steering and Brake Pump (Denison T67DB Siries)

Reference Number

Description

Reference Number

Description

Body

Screw

Seal; Secondary

Body; Inlet

Seal; Primary

Bolt

Washer

Screw

Shaft

Bearing

Pack Seal

Ring; Retaining

Plate Kit; Flex Side

Ring; Lock

Ring

Ring; Backup

Plate; Inlet Support

O-ring

Rotor

Ring; Seal

Kit; Vane

O-ring

Plate; Outlet Support

O-ring

Pack; Seal

Ring; Seal

Plate Kit; Flex Side

O-ring

Ring

U-ring

Rotor

Cover; Rear Flange

Vane & Insert

Bolt

Plate; Inlet Support

Cartridge Kit, Center

Cartridge Kit, Shaft End

NOTE:

Always replace old seals with new seals when overhauling a unit. If a cartridge kit needs replacement, new cartridge seals are included as part of the kit.

NOTE:

Apply a light film of hydraulic oil to all component parts except seals and back-up rings to facilitate assembly and provide initial lubrication. Use small amounts of petroleum jelly to hold O-rings in place during assembly. Install parts in reverse order of disassembly

IMPORTANT During handling and shipping of percision machined cartridge parts, it is possible to raise burrs on the sharp edges. All sharp edges on parts of a new cartridge kit should be stoned prior to installation. NOTE:

To reverse direction of a new cartridge kit, simply reverse location of the inlet and outlet support plated, and realign the cartridge with cover.

CARTRIDGE ASSEMBLY 1.

The direction of rotation is as viewed from shaft end, right hand rotation is clockwise, left hand rotation is counterclockwise. NOTE:

If locating pins were removed from the inlet support plate, install new new pins with locking flutes within inlet support plate. Drive new pins into support plate with a soft tip hammer.

Steering and Brake Pump (Denison T67DB Siries)

S0708470K Page 19

Place inlet and outlet support plates on a flat surface. Install seal packs into cavities with seal retainer surface up and O-rings facinf downward into cavities.

Place a flex side over each of the support plates with bronze wear surface facing up. Align scribe marks to make sure that correct flex side plate is used with correct support plate. NOTE:

Flex side plates develop a wear pattern with rotor and vanes, and should not be interchanged.

For right hand rotation units, set rotor on flat wooden board with arrow pointing right. For left hand rotation units, set rotor on flat wooden board with arrow pointing left. Assemble the vanes and insert into rotor in reverse order of removal. Make sure that sharp chamfer edge of each vane leads in direction of rotation. All vanes must move freely in rotor slots with no evidence of bind.

Assemble cam ring over rotor and vanes with arrow pointing in the same direction direction as rotor arrow. Lubricate top surface of rotor and vanes liberally with hydraylin oil.

Locate scribe mark on cam ring, outlet support plate, and flex side plate. Hold the outlet support plate and flex side plate together and assembly over the cam ring and rotor with scribe marks in line.

Hold cartridge together to prevent movement and the assembly along with the wooden board over so outlet support plate rests on a flat surface, and the board is up. Remove the board.

Figure 16

Figure 17

Figure 18

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Steering and Brake Pump (Denison T67DB Siries)

Lubricate the exposed surface of rotor and vanes with hydraulic oil. Locate the scribe mark on the inlet support plate and flex side plate. Hold inlet support and flex side plate together and assemble over cam ring and rotor with scribe mark in line. NOTE:

The cast-in arrows located next to socket head screws, indicate cartridge of rotation.

Thread the two socket head screws into cartridge until snug (hand tight).

10.

The O.D. of all component parts of the cartridge kit must be in line with each other or cover cannot be installed. Align the cartridge as follows:

11.

Install cover over the cartridge. Tap lightly on cover with your hand until each part centers. Remove the cover gently so as not to disturb alignment. Torque socket head screws to the torque noted below, and recheck kit alignment with cover. Repeat until cartridge is aligned.

12.

Figure 19

NOTE:

Center End Cartridge Kit Torque: 2 - 3 Nm (25 - 35 in. lb.)

NOTE:

Shaft End Cartridge Kit Torque: 11 Nm (100 in. lb.)

Check rotor for bind by inserting index finger through shaft opening of inlet support plate. Hold the cartridge kit in a horizontal shaft position and lift rotor with your finger, The rotor should move freely back and forth within the cartridge. If the rotor binds, open kit, clean and stone all posible areas of bind, then reassemble the cartridge kit using aforementioned procedure. The rotor MUST move freely within cartridge when assembled.

Steering and Brake Pump (Denison T67DB Siries)

S0708470K Page 21

BASIC PUMP ASSEMBLY 1.

Lubricate secondary seal (2) with petroleum jelly and place in position against shaft end of body (1). Use a small hardwood block to drive the seal evenly into body. Installation is complete when seal face is flush with front of the body. NOTE:

DO NOT drive seal past flush as it can block body drain opening.

Lubricate primary seal (3) with petroleum jelly and place in position inside of body (1) and press in place with shaft seal driver.

Figure 20

Install washer (4) into body (1).

If required, press bearing (6) on shaft (5) and secure with retaining ring (7). Use an arbor press for this operation and apply force to inner race area.

Check splined end of shaft to make certain it is free from nicks and burrs. A small nick or burr can damage shaft seal during installation. Coat splined portion of shaft with hydraulic oil. Carefully install the shaft group, (items 5, 6, and 7), through seals (2 and 3) and into body (1). Spread Spirolox ring (8) and feed it into groove located behind bearing. This will secure the shaft group within body (1).

Install sealing ring (11) into body (1).

If center cartridge kit (40) is replaced with a new kit, install kit into inlet body (1). If cartridge kits requires assembly, assemble in reverse order of disassembly. See “Cartridge Assembly”. During assembly, note the following precautions:

Make sure the arrows on rotor (17) and cam ring (16) are in same direction of pump rotation.

Make certain that sharp rdges of vane (18) lead in direction of rotation.

Make sure O-ring (10) and back-up ring (9) are assembled correctly. Apply a small amount of hydraulic oil to screws (21) and thread screws into cartridge (40). Install cartridge kit (40) into body (1).

Figure 21 POSITIONING VANES IN ROTOR

Install O-ring (11) over cartridge kit (40) and into O-ring groove of body (1).

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Steering and Brake Pump (Denison T67DB Siries)

Line up the two cartridge kit pins (20) with holes in housing (22) and then install housing. Position the housing according to punch marks made during step 2 of disassembly procedure. Attach housing to body with four screws (23). NOTE:

10.

Torque screws (23) to: 189 - 216 Nm (140 - 160 ft lbs).

If cartridge kit (39) is replaced with a new kit, line up pins (25) with holes in housing (22) and install kit into housing. If cartridge kit requires assembly, assemble in reverse order of disassembly. During assembly, note the following precautions: A.

Make sure the rotation arrows on rotor (30) and cam ring (28) are in direction of pump rotation.

Be certain sharp edges of vanes (31) lead in direction of pump rotation.

Make sure O-ring (35) and back-up ring (36) are assembled in the correct position.

NOTE: D.

Cartridge kit (39) is assembled into housing (22) in reverse manner of cartridge kit (40). Make sure rotation arrow of ring points in direction of rotation.

Apply a small amount of hydraulic oil to screws (24) and thread screws into cartridge kit.

11.

Install sealing ring (34) into cover (37).

12.

Install O-ring (33) over cartridge kit (39) against housing face.

13.

Position cover (37) over cartridge kit (39) according to prick marks made during step 2 of disassembly procedures. Install cover (37) and secure with screws (38). NOTE:

Torque screws (23) to: 54 - 68 Nm (40 - 50 ft lbs).

START-UP PROCEDURES START-UP 1.

Install the pump into the system. Make sure that drive shaft is aligned properly. All connections are tight, and hydraulic oil source is open to pump inlet, if an overhead reservoir is used, purge air from inlet line.

The pump should prime almost immediately with a minimum drive speed of 600 RPM. Intermittently operate (jog) the pump until it primes. It may be necessary to loosen the outlet fitting temporarily to purge trapped air. Failure of pump to prime in a short period of time indicates incorrect assembly or restricted flow from reservoir. NOTE:

With a minimum drive speed of 600 RPM, a pump should prime almost immediately if provision is made to initially purge air from the system.

TEST Use machine’s hydraulic system to test the pump.

Steering and Brake Pump (Denison T67DB Siries)

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Steering and Brake Pump (Denison T67DB Siries)

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S0709230K

5BRAKE PEDAL VALVE CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that is in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility.

BRAKE PEDAL VALVES0709230K MODEL Mega 400-V

SERIAL NUMBER RANGE 1001 and Up

S0709230K Page 1

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TABLE OF CONTENTS General Description........................................................................................ 3 Theory of Operation ................................................................................ 3 Specification............................................................................................ 4 Brake System ................................................................................................. 5 Brake, Pilot, and Fan Motor Supply Valve ...................................................... 6 Specifications .......................................................................................... 7

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Brake Pedal Valve

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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 80 ± 3 bars (1,160 ± 44 psi). If something in one of the circuits should fail, the other circuit will continue to operate.

AJS0720L

Figure 1

Brake Pedal Valve

S0709230K Page 3

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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 Reference Number

Description

Reference Number

Description

Primary Control Spool

Upper Spring

Secondary Control Spool

Main Control Spring

Lower Spring

Working Element

SPECIFICATION

S0709230K Page 4

Item

Specification

Braking Pressure

80 ± 3 kgf/cm2

Pedal Force

21 ± 2.0 kgf

Operating Angle

18.0 ± 2.0°

Brake Pedal Valve

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

AJS0730L

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 Lamp Switch

Low Pressure Warning Switch

Parking Brake

Brake and Pilot Filter

Accumulators : Brake

Brake Pedal Valve

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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 4 Valve Cartridge Identification and Pilot Location Reference Number

Description

Reference Number

Description

Body (200*120*79)

Check (C3)

Sequence (C1)

Solenoid (C4 and C5)

Reducing (C2)

Coil (C4 and C5)

S0709230K Page 6

Brake Pedal Valve

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AJS0760L

Figure 5 Hydraulic Circuit

SPECIFICATIONS

Item Max. Operating Pressure Max. Flow

120 kgf/cm2

System Flow

20 l/min C1

120 ± 2 kgf/cm2 (53 l/min)

37 ± 2 kgf/cm2 (20 l/min)

C3 Cracking Pressure Port Size

Brake Pedal Valve

210 kgf/cm2 53 l/min

System Pressure Setting Pressure

Specifications

2.4 kgf/cm2

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

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S0709230K Page 8

Brake Pedal Valve

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S0709455K

6MAIN 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)S0709455K MODEL Mega 400-V

SERIAL NUMBER RANGE 1001 and Up

S0709455K 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

S0709455K Page 2

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.

Figure 1

Main Control Valve (Toshiba)

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AJS0660L

Figure 2 Control valve hydraulic circuit Reference 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)

S0709455K 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.)

MRT40D1F1 - 56

MRT40D1F1D1 - 52

Pilot Control with Float spool ∅ 40 mm

Spool Diameter Spool Arrangement

Bucket - Boom

Bucket - Boom - Aux.

Main relief pressure

200 kg/cm at 210 l/min.

Overload relief pressure

240 kg/cm2 at 20 l/min.

Main Control Valve (Toshiba)

S0709455K Page 5

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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.

S0709455K Page 6

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 further pushed down from the “Down” position to the “Float” position, the boom spool moves as indicated in the illustration. Due to this motion the neutral passage is opened. The pressure oil flows as if in neutral position. The cylinder ports (A2) and (B2) are connected to the low-pressure oil passage. As a result, the booms float over the ground surface according to its irregularities. The oil discharged from the boom cylinder rod side is sent to the tail side and the oil forced out from its tail side is sent to the rod side respectively through the low-pressure oil passage in the control valve. RELIEF VALVE Main Relief Valve The main relief valve is located between the neutral oil passage and the low pressure oil passage (return oil passage) in the inlet section. Port Relief Valve The port relief valve is located between the rod side cylinder port and the low-pressure oil passage (return oil passage) in the bucket spool section. The combination valve, used as the port relief valve, serves both as the relief valve and an anticavitation valve.

Main Control Valve (Toshiba)

S0709455K 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)

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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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S0709475K

7PILOT 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 VALVES0709475K MODEL Mega 400-V

SERIAL NUMBER RANGE 1001 and Up

S0709475K Page 1

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TABLE OF CONTENTS General Description........................................................................................ 3 Pilot Valve Operation............................................................................... 3 Pilot System ................................................................................................... 6

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Pilot Control Valve

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GENERAL DESCRIPTION When no force is applied to the lever (1, Figure 1), the return spring (4) positions the lever at the "NEUTRAL" position. When the lever is moved, plunger (5) is moved, which pushes down the return spring (4). At the same time, spool (2) is moved by spring (3). When spool (2) moves down, a groove (6) in the spool opens the pilot pressure line to the line that the lever controls. This allows the pilot pressure to flow to the boom or bucket control valve, where the pilot pressure operates the control valve. When the lever is completely moved in one direction, the solenoid (7) energizes the electromagnet (8) and holds the lever in the fully moved position. PILOT VALVE OPERATION The lever handle is positioned on the right side of the operator’s seat. This single lever controls the following machine functions: raise boom, lower boom, bucket crowd, and bucket dump. The lever positions are identified as follows: F - Float L - Lower N - Neutral R - Raise H - Hold Position C - Bucket Crowd D - Bucket Dump HR - Holds lever in Raise Mode.

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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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 cut-off 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 cut-off valve (5). The pressure reducing valve maintains pilot system pressure at 28 kg/cm2 (450 psi). From the pilot cut-off valve the oil flows into the pilot control valves. Pilot valve (6) is a closed center valve. The oil can not 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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AJS0800L

Figure 2 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 Cut-off Valve

Boom Cylinder

Reference Number

Pilot Control Valve

Description

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Pilot Control Valve

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S0709665K

8FLOW AMPLIFIER (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.

FLOW AMPLIFIER (DANFOSS)S0709665K MODEL Mega 400-V

SERIAL NUMBER RANGE 1001 and Up

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Flow Amplifier (Danfoss)

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GENERAL DESCRIPTION

Figure 1

Flow Amplifier (Danfoss)

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Figure 2

S0709665K Page 4

Flow Amplifier (Danfoss)

Return to Master Table of Contents Reference Number

Description

Reference Number

Description

O-ring

Stopper

O-ring

Stopper

O-ring

Guide; Spring

O-ring

Screw; Drive

Washer

Plate; Name

Washer

Orifice

O-ring

Spring

O-ring

Spring

Housing

Spring

Check Valve

Plug

Screw

Washer

Washer; Spring

Orifice

Screw

Orifice

Washer; Spring

Orifice

End Cover

Throttle Check Valve

End Cover

Plug

Relief Valve

Spring

Plug

Spring

Shock and Suction Valve

SPECIFICATIONS Flow Amplifier

Specification

Type

Contains a directional valve, an amplification stage, a priority valve, a pilot pressure relief valve and suction valve.

Amplification Factor

Control Pressure

10.50 kg/sq cm (149.35 psi)

LS Relief Valve Setting

185.0 ±5.0 bar (2,683.24 ±72.52 psi))

Max. Oil Flow to Steering

125.0 l/min. (33.0 U.S. gpm)

Flow Amplifier (Danfoss)

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SPECIAL TOOLS AND MATERIALS SPECIAL TOOLS Guide screws Material: M8 x 1 Hook

Material: Wire

Figure 3

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Flow Amplifier (Danfoss)

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TROUBLESHOOTING, TESTING AND ADJUSTMENT

Figure 4 Flow Amplifier Circuit

Flow Amplifier (Danfoss)

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Possible Causes

Amplification too large

Dirty, leaky or missing check valve (1).

Clean or replace check valve.

Piston (2) sticks in the open position.

Clean and check that the piston moves easily.

Piston (2) sticks in the closed position.

Clean and check that the piston moves easily.

Piston (2) incorrectly installed (only OSQA/B-5).

Rotate the piston 180° on its axle.

Dirty orifices (3) in directional valve.

Clean or replace orifice.

Dirty orifices (4) in the combi-valve spool.

Clean or replace orifice.

Dirty orifices (5) in housing.

Clean or replace orifice.

Dirty orifices (6) in LS-port.

Clean or replace orifice.

Dirty orifices in throttle/check valve (7) in PP-port.

Clean or replace throttle/check valve.

One or both shock valves (8) set too low.

Setting takes a long time without special equipment. Contact the nearest service shop.

One or both anti-cavitation valves (9) leaky, or sticks.

Clean or replace completely shock/anti-cavitation valve(s).

Missing end-stop plate(s) pos. 10 for directional valve.

Fit end-stop plates.

Air in LS and/or PP pipes.

Bleed pipes.

Spring force in the built in priority valve too weak (11).

Replace spring with one which is more powerful. (There are three sizes : 4-7-10 bar).

Orifices in respectively LS-(6) or PP-(7) ports blocked.

Take out and clean orifices.

LS-pressure limitation valve (12) adjusted too low.

Remove plug and set to specified pressure.

Spool and sleeve in OSPBX steering unit put together incorrectly.

Take out spool set and turn the inner spool 180° in the outer sleeve. (See service manual)

Emergency control ball in steering unit missing.

Install new ball.

Pump does not run or is defective.

Repair or replace pump.

Amplification too small

Heavy turning of steering wheel and slow increase of amplification

No end stop in one or both directions.

“Hard” point when starting to turn the steering wheel

No pressure build-up

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Remedies

Flow Amplifier (Danfoss)

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DISASSEMBLY 1.

Dismantling counter pressure valve. A.

Unscrew plug with O-ring. (Hexagon socket for 8 mm internal hexagon.)

Figure 5 B.

Remove small spring (hook).

Figure 6 C.

Remove ball (magnetic rod).

Figure 7

Flow Amplifier (Danfoss)

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Remove piston.

Figure 8 E.

Remove spring.

Figure 9 F.

Counter pressure dismantled.

valve

shown

Figure 10

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Flow Amplifier (Danfoss)

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Counter pressure valve with orifice shown dismantled.

Figure 11 2.

Removing pressure relief valve. A.

Unscrew plug with washer (hexagon socket for 8 mm internal hexagon).

Screw pressure relief valve out (10 mm hexagon key).

Remove washer (magnetic rod).

Figure 12

Figure 13

Figure 14

Flow Amplifier (Danfoss)

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Dismantling pressure relief valve. A.

Hold cartridge and screw adjustment screw out (5 mm hexagon key).

Pressure relief dismantled.

Figure 15 valve

shown

Figure 16 4.

Removing end cover at PP-connection. A.

Unscrew screws with spring washer hexagon socket for 13 mm external hexagon and 10 mm internal hexagon.

Figure 17

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Flow Amplifier (Danfoss)

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Remove end cover.

Figure 18 C.

Remove stop and 2 springs.

Figure 19 D.

Remove spring.

Figure 20

Flow Amplifier (Danfoss)

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Remove plate and six O-rings.

Figure 21 F.

Remove spring guide.

Figure 22 5.

Removing end cover at LS-connection. A.

Unscrew screws with spring washer using hexagon socket for 13 mm external hexagon and 10 mm internal hexagon.

Figure 23

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Flow Amplifier (Danfoss)

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Remove end cover.

Figure 24 C.

Remove stop and two springs.

Figure 25 D.

Remove stop and spring.

Figure 26

Flow Amplifier (Danfoss)

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Remove plate and four O-ring.

Figure 27 F.

Remove spring guide.

Figure 28 6.

Removing spools. A.

Remove directional spool.

Figure 29

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Flow Amplifier (Danfoss)

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Remove amplifier spool.

Figure 30 C.

Remove priority valve spool.

Figure 31 7.

Removing orifice and throttle check valve. A.

Unscrew orifice in LS-connection with 6 mm hexagon key.

Figure 32

Flow Amplifier (Danfoss)

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Unscrew throttle check valve in PPconnection with 6 mm hexagon key.

Figure 33 C.

Unscrew orifice in housing with 4 mm hexagon key.

Figure 34 8.

Removing shock valves. A.

Remove shock valve with screwdriver and hexagon key.

Figure 35

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Flow Amplifier (Danfoss)

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Overview of dismantled parts. A.

Housing and accessories.

end

cover

with

Figure 36 B.

Spool with accessories.

Figure 37 10.

Dismantling of directional spool. A.

Unscrew orifice with 4 mm hexagon key. Use a mandrel.

Figure 38

Flow Amplifier (Danfoss)

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Directional spool shown dismantled.

Figure 39 11.

Dismantling of priority valve spool. A.

Unscrew plug or throttle check valve with 8 mm hexagon key.

Figure 40 B.

Priority valve spool with plug for external PP shown dismantled.

Figure 41

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Flow Amplifier (Danfoss)

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Priority valve spool with throttle check valve for internal PP shown dismantled.

Figure 42 12.

Dismantling of amplifier spool. A.

Carefully remove spring from recess with 3 mm screwdriver.

NOTE:

Avoid damage to spring ring.

Figure 43 B.

Carefully guide spring ring back.

Figure 44

Flow Amplifier (Danfoss)

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Carefully take spring ring from recess and guide it back with 3 mm screwdriver.

NOTE:

Avoid damage to spring ring.

Figure 45 D.

Press pin out gently with finger.

Figure 46 E.

Remove plug.

Figure 47

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Flow Amplifier (Danfoss)

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Remove spring.

Figure 48 G.

Remove pin with 3 mm screwdriver.

Figure 49 H.

Remove inner spool.

Figure 50

Flow Amplifier (Danfoss)

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Unscrew check valve with hexagon socket for 17 mm external hexagon and mandrel in pin hole.

Figure 51 J.

Unscrew orifice out of plug with 4 mm hexagon key. Use a mandrel.

Figure 52 K.

Amplifier spool shown dismantled.

Figure 53

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Flow Amplifier (Danfoss)

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Dismantling of check valve. A.

Unscrew plug with 4 mm hexagon key and hexagon socket for 17 mm external hexagon.

Figure 54 B.

Check valve shown dismantled.

Figure 55 14.

Dismantling of shock valve / suction valve. A.

Unscrew lock nut with hexagon socket for 13 mm external hexagon. Use a mandrel.

NOTE:

When readjusting shock valve hold lock nut with 13 mm ring spanner.

Figure 56

Flow Amplifier (Danfoss)

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Remove disc and spring.

Figure 57 C.

Remove housing.

Figure 58 D.

Unscrew pilot valve with hexagon socket for 19 mm external hexagon. Use a mandrel.

Figure 59

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Flow Amplifier (Danfoss)

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Remove pilot valve and spring.

Figure 60 F.

Remove spool.

Figure 61 G.

Unscrew adjustment screw remove spring and ball.

and

Figure 62

Flow Amplifier (Danfoss)

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Shock valve/suction valve shown dismantled.

Figure 63

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Flow Amplifier (Danfoss)

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CLEANING AND INSPECTION (WEAR LIMITS AND TOLERANCES) For general cleaning and inspection procedures, refer to "General Maintenance Procedures" section. CLEANING Clean all parts carefully with low aomatic kerosine. INSPECTION AND REPLACEMENT Replace all gaskets and sealing washers. Check al other parts carefully and replace if necessary. LUBRICATION Before assembly, lubricate all parts with hydraulic oil.

REASSEMBLY 1.

Assemble shock valve/suction valve. A.

Guide spring with cone into housing.

Figure 64

Flow Amplifier (Danfoss)

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Install adjustment screw.

Figure 65 C.

Install spool.

Figure 66 D.

Install spring.

Figure 67

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Flow Amplifier (Danfoss)

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Install pilot valve. Remember O-ring.

Figure 68 F.

Tighten with torque wrench for 19 mm external hexagon. Use a mandrel. Tightening torque: 2 ±0.5 daNm. (175 ±45 in. lbs.).

Figure 69 G.

Install housing.

Figure 70

Flow Amplifier (Danfoss)

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Install spring.

Figure 71 I.

Fir disc.

Figure 72 J.

Install lock nut. Tighten torque 1.5 ±0.2 daNm. (135 ±20 in. lbs.).

Figure 73

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Flow Amplifier (Danfoss)

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Assemble check valve. A.

Install ball, spring and plug.

Tightening torque: 0.5 ±1 daNm. (45 ±90 in. lbs.).

Figure 74 3.

Assembly of amplifier spool. A.

Install orifice in plug. Tightening torque: 0.5 ±1 daNm. (45 ±90 in. lbs.).

Figure 75 B.

Install check valve. Tightening torque: 2 ±0.3 daNm. (175 ±25 in. lbs.).

NOTE:

Avoid damaging spool surface. Remember O-ring.

Figure 76

Flow Amplifier (Danfoss)

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Place inner spool in correct position.

NOTE:

When assembling OSQA 5 and OSQB 5 there are two ways of installing inner spool. Only one is correct. The pilot channel which is faced upwards must be lined up with one of five amplification holes in the outer spool.

Figure 77 D.

Guide inner spool in.

Figure 78 E.

Install pin.

Figure 79

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Flow Amplifier (Danfoss)

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Push spring ring into position. Place spring ring into recess with ends facing away from pin plate.

Figure 80 G.

Install spring.

Figure 81 H.

Install plug.

Figure 82

Flow Amplifier (Danfoss)

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Install pin.

Figure 83 J.

Push spring ring into position. pLace spring ring into recess with ends facing away from pin holes.

Figure 84 4.

Assembly of priority valve spool. A.

Install plug or throttle check valve.

External pp: plug.

External pp: throttle check valve.

Tightening torque: 1 ±0.03 daNm. (90 ±25 in. lbs.).

Figure 85

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Flow Amplifier (Danfoss)

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Assembly of directional spool. A.

Screw in orifice.

Tightening torque: 0.5 ±0.1 daNm. (45 ±10 in. lbs.).

Figure 86 6.

Installation of orifice and throttle check valve. A.

Install orifice in housing.

Tightening torque: 0.5 ±0.1 daNm (45 ±10 in. lbs.).

Figure 87 C.

Install orifice in LS-connection.

Tighten torque: 1 ±0.3 daNm. (90 ±25 in. lbs..).

Figure 88

Flow Amplifier (Danfoss)

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Install throttle check valve in PPconnection.

Tighten torque: 1 ±0.3 daNm. (90 ±25 in. lbs..).

Comments on flow amplifiers with internal PP: A.

1/4 BSP.F in PP-connection: Install washer and plug. Tightening torque 4 ±0.3 daNm (355 ±25 in. lbs.).

7/116 - 20 UNF in PP-connection: Install O-ring and plug. Tightening torque: 1.5 ±0.5 daNm (135 ±45 in. lbs.). Figure 89

Installation of shock valves. A.

Guide shock valve in and secure it by hand. Remember O-ring.

Figure 90 9.

Assembly of pressure relief valve. A.

Guide adjustment screw, spring and cone up into cartridge.

Figure 91

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Flow Amplifier (Danfoss)

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Screw adjustment screw so far in that 10 mm hexagon key fully engages.

Figure 92 10.

Installation of pressure relief valve. A.

Let washer drop into hole.

Figure 93 B.

Install pressure relief valve. Tighten torque: 3 ±0.3 daNm. (265 ±25 in. lbs.).

Figure 94

Flow Amplifier (Danfoss)

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Install plug with washer. Tighten torque: 6 ±0.5 daNm. (530 ±45 in. lbs.).

Figure 95 11.

Installation of back pressure valve. A.

First Install spring in piston with vasoline. Install assembled piston and spring.

Figure 96 B.

Let ball drop down.

Figure 97

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Install spring in plug with vasoline. Install assembled plug and spring. Remember O-ring. Tightening torque 2.5 ±0.03 daNm (220 ±25 in. lbs.).

Figure 98 12.

Installation of spools. A.

Install directional priority valve spool.

NOTE:

spool.

Install

Spring control must be placed in correct position against LSconnection.

Figure 99 B.

Install spring.

NOTE:

Spring must connection.

LS-

Figure 100

Flow Amplifier (Danfoss)

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Install amplifier spool.

NOTE:

The orifice must be placed in correct position against LSconnection.

Figure 101 13.

Installation of end cover at PP-connection. A.

Install spring with amplifier spool.

NOTE:

vasoline

The spring must be installed at PP-connection.

Figure 102 B.

Install spring guide with vasoline.

Figure 103

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Install large and small springs with vasoline.

Figure 104 D.

Install guide screws.

Figure 105 E.

Install four large and two small Orings.

Figure 106

Flow Amplifier (Danfoss)

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Guide plate in.

Figure 107 G.

Install stop (thickness: 5 mm) in end cover with vasoline.

Figure 108 H.

Guide end cover in.

Figure 109

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Flow Amplifier (Danfoss)

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Install screw with spring washer.

Figure 110 J.

Install screw with spring washer. Tightening torque: 2.5 ±0.5 daNm.(220 ±45 in. lbs.).

Figure 111 14.

Installation of end cover at LS-connection. A.

Install guide screws.

Install remote control valve with vasoline.

Figure 112

Flow Amplifier (Danfoss)

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Install large and small springs with vasoline.

Figure 113 D.

Guide in plate with four O-rings.

Figure 114 E.

Install stop priority valve spool.

(thickness: 8 mm) with vasoline.

Figure 115

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Install stop for directional spool (thickness: 5 mm) with vasoline.

Figure 116 H.

Guide in end cover.

Figure 117 I.

Install large washer.

screw

with

spring

Figure 118

Flow Amplifier (Danfoss)

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Install screws with spring washers. Tightening torque: 2.5 ±0.5 daNm. (220 ±45 in. lbs.). Tightening torque for large screw: 8 ±1 daNm (710 ±90 in. lbs.).

Figure 119 K.

Install plastic plugs.

Figure 120

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Flow Amplifier (Danfoss)

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S0709730K

9POWER 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 Mega 400-V

SERIAL NUMBER RANGE 1001 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

Jerk Softner

Flow Amplifier

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. lbs.). 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

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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 the port R, it pushes the spring (3) and opens the poppet (2). And this operation directs the high pressure oil to the port L through the center hole in the spool (12) and the check valve poppet located in the port L part. At the same time, oil reaches the pressure room of the plug through the orifice (8). This operation closes the passage from the port R to the 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 that the speed of the closing the spool (12) is faster than the speed of the opening the 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 Steering Unit

Specification

Type

Load Sensing, Dynamic Signal, Non-reaction

Gerotor Displacement

200.0 cc/rev (12.20 cu. in./rev)

Power Steering Unit

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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. lbs.). 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.

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.

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

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 steering gearbox.

Replace damaged parts.

nut

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 parts.

worn

damaged

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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Power Steering Unit

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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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Power Steering Unit

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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. lbs.)

3/8 - 16 NC

4.8 kg•m (35 ft. lbs.)

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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Power Steering Unit

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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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Power Steering Unit

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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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Power Steering Unit

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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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Power Steering Unit

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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 located 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 = 3.8 mm (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 Nm (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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Power Steering Unit

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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. Maximum Tightening Torque kg•m (ft. lbs.) 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

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S0709850K

10UNLOADER VALVE

UNLOADER VALVE S0709850K MODEL Mega 400-V

SERIAL NUMBER RANGE 1001 and Up

S0709850K Page 1

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S0709850K Page 2

Unloader Valve

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GENERAL DESCRIPTION THEORY OF OPERATION The unloading valve is made up of three cartridges C1, C2, and C3. When pressure in the main pump output line is low, the unloading valve diverts output from the steering pump and directs it to the main pump output line. This line supplies the boom, bucket, and option control valves. This additional fluid creates faster cycle times. When pressure in the main pump output line is high, the unloading valve directs steering pump flow to tank. Output from the steering pump passes through the priority valve that is part of the flow amplifier. See the hydraulic schematic. (Figure 1). This flow then passes out of the flow amplifier and enters the unloader valve at port EF. This flow is present at port A of C3 and present at port B of C2. See Figure 2. This flow raises the check spool (2) at C3 when the pressure in the output line from the main pump is below 160 kg/ cm2 (2,275 psi) at port P2. This allows output from the steering pump to join flow from the main pump to supply the boom, bucket, and option control valves. The pressure at port B of C2 is also present at port C of C2. When pressure in the main pump output line is above 160 kg/cm2 (2,275 psi), this pressure forces spool (5) of C1 to move against the force of spring (6), which allows the oil in chamber C of C2 to flow through port D of C1 and back to tank. When oil in chamber C flows to tank through port D, the pressure in chamber C drops due to the venturi effect of the orifice (7) in check spool (4). This allows the pressure at B to lift check spool (4) off its seat. This allows the oil that is flowing into port B to flow past check spool (4) to tank. This is the output from the steering pump that is being directed back to tank.

AJS0670L

Figure 1 Unloading circuit

Unloader Valve

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Figure 2 UNLOADING VALVE CARTRIDGES Reference Number

Description

Reference Number

Description

C3 Spring

Valve Cartridge

C3 Check Spool

Valve Cartridge

C2 Spring

C1 Port

C4 Check Spool

C1 Port

C1 Check Spool

Unloading Valve Port

C1 Spring

C3 Port

Orifice

C3 Port

C2 Spool Chamber

Tank

Valve Cartridge

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Unloader Valve

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AJS0680L

Figure 3 Valve Cartridge Identification

Reference Number

Description

Remark

Body

125×99×184

Sub Block

125×99×79

Directional Valve

Check Valve

Logic Valve

Check Valve

C4, 5, 6, 7

Wrench Bolt

M8×1.25×20L

O-ring

Unloader Valve

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Item

Specification

Maximum Rated Pressure

210 Bar

Rated Flow Ports to P1

240 L/MIN

Rated Flow Ports to P3

430 L/MIN

Rated Flow Ports to R1, R2

700 L/MIN

Rated Flow Ports to C

100 L/MIN

Setting Pressure

Port Size

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160 - 165 Bar

2 ± 0.2 Bar Cracking Pressure

C4, 5, 6, 7

0.7 ± 0.1 Cracking Pressure

R1, R2

2" SAE Flange Port (M12, 1.75)

P1, EF, P3

1-1/4" SAE Flange Port (M12, 1.75)

HT, C

1" PF O-ring

TPM, TPS

1/4" PF O-ring

1/4" PF O-ring (Supplied Plugged)

Unloader Valve

S0793050K

11HYDRAULIC SCHEMATIC (MEGA 400-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 400-V)S0793050K MODEL Mega 400-V

SERIAL NUMBER RANGE 1001 and Up

S0793050K Page 1

TABLE OF CONTENTS General Description........................................................................................ 3 Mega 400-V.................................................................................................... 4

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Hydraulic Schematic (Mega 400-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 400-V)

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MEGA 400-V

Figure 2

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Hydraulic Schematic (Mega 400-V)

* OPTIONAL EQUIPMENT

MEGA 400-V AJS0890L

Hydraulic Schematic (Mega 400-V)

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Hydraulic Schematic (Mega 400-V)

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1ELECTRICAL SYSTEM

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S0802180K

2ELECTRICAL SYSTEM

S0802180K

MODEL Mega 400-V

SERIAL NUMBER RANGE 1001 and Up

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TABLE OF CONTENTS Overview ........................................................................................................ 3 Electric Supply System .................................................................................. 4 Engine Starting Circuit ................................................................................... 6 Operation During Start Process .............................................................. 6 Operation After Start Process ................................................................. 8 Engine Preheating System........................................................................... 10 Principle Of Operation........................................................................... 10 Engine Stop System..................................................................................... 12 Operation In Engine Running Mode...................................................... 12 Operation In Engine Stop Mode............................................................ 14 Charging System.......................................................................................... 16 Monitoring System ....................................................................................... 17 Instrument Panel ................................................................................... 18 Function Check ..................................................................................... 19 Monitoring System Schematic .............................................................. 20 Operation .............................................................................................. 22 Windshield Wiper ......................................................................................... 28 Front windshield wiper........................................................................... 28 Rear Windshield wiper .......................................................................... 29 Lighting System............................................................................................ 32 Light Circuit ........................................................................................... 32 Emergency Steering System (Option).......................................................... 36 Block Diagram ....................................................................................... 36 Emergency Steering System Components ........................................... 37 Emergency Steering System Electric Circuit ........................................ 39 Electric Detent System ................................................................................. 40 Electric Circuit ....................................................................................... 40 Boom Kick-Out ...................................................................................... 40 Return To Dig ........................................................................................ 41

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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 electric system is 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:

0.85G: Nominal sectional area of wire core less insulator = 0.85 mm2 (0.03 sq. in.).

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.

Cabin lamp, 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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5 6

3 8

8 1

AJS0010L

Figure 1 ELECTRICAL POWER CIRCUIT DIAGRAM Description

Reference Number

Description

Battery

Starter Switch

Battery Relay

Fuse Box

Fusible Link

Alternator

Circuit Breaker

Diode

Reference Number

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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AJS0020L

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

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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 as well as 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).

AJS0030L

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 Seletor Switch

Starter Switch

Diode

Fuse Box

Transmission Controller

Starter Controller

Safety Starter Relay

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Electrical System

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Electrical System

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ENGINE PREHEATING SYSTEM 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 (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 lamp panel will be lit to indicate that preheating is finished.

2. When water temperature is higher than 10°C (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.

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Electrical System

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3 6 4 12

5 2 13

7 13 1

8 10

11 9

AJS0040L

Figure 4 ENGINE PREHEAT CIRCUIT Reference Number

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

Electrical System

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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.

AJS0050L

Figure 5 ENGINE STOP CIRCUIT - RUNNING MODE Reference Number

Description

Reference Number

Description

Battery

Fuse Box

Fusible Link

Engine Stop Relay

Starter Switch

Engine Stop Motor

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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.

AJS0060L

Figure 6

Electrical System

S0802180K Page 13

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.

6 4

2 3 1

AJS0070L

Figure 7 ENGINE STOP CIRUIT - STOP MODE Reference Number

Description

Reference Number

Battery

Fuse Box

Fusible Link

Engine Stop Relay

Starter Switch

Engine Stop Motor

Description

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.

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Electrical System

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AJS0080L

Figure 8

Electrical System

S0802180K Page 15

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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.

AJS0090L

Figure 9 CHARGING CIRCUIT Reference Number

Description

Reference Number

Description

Battery

Starter Switch

Battery Relay

Fuse Box

Fusible Link

Alternator

Circuit Breaker

Diode

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Electrical System

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MONITORING SYSTEM 2

19 18

4 1

16 15

8 13

AJS0100L

Figure 10 Reference Number

Description

Reference Number

Description

Instrument Panel

Engine Oil Pressure Switch

Battery

Hazard Warning Lamp Switch

Alternator

Turn Signal Lamp Switch

Speed Sensor

High Beam Switch

Coolant Temperature Sensor

Working 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

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

S0802180K Page 17

Return to Master Table of Contents INSTRUMENT PANEL

AMP MIC 13P

AMP MIC 17P

(CN1)

(CN2)

AJS0110L

Figure 11

S0802180K Page 18

Electrical System

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Reference Number

Description

Reference Number

Description

Speed Meter

Charging Warning Lamp

Tachometer

Hour Meter

Turn and Hazard Warning Lamp

Fuel Gauge

High Beam Indicator

Engine Coolant Temperature Gauge

Turn and Hazard Warning Lamp

Transmission Oil Temperature Gauge

Working Light Indicator

Preheat Completion Indicator

Brake Oil Pressure Warning Lamp

Air Cleaner Clogging Warning Lamp

Brake Oil Filter Clogging Warning Lamp

Parking Brake Indicator

Engine Coolant Temperature Warning Lamp

Emergency Steering Indicator

Engine Oil Pressure Warning Lamp

FUNCTION CHECK When the starter switch is turned to the “ON” position, all displays, switch lamps and warning lamps except turn and harzard warning lamp, high beam indicator, working light indicator and emergency steering indicator will be lit for two seconds and the warning buzzer will sound. Any lamps which do not light up during the function check should be replaced.

Electrical System

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AJS0120L

Figure 12

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Electrical System

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Reference Number

Description

Reference Number

Description

Instrument Panel

Engine Oil Pressure Switch

Head Lamp 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

24 25

Battery Relay

Fuel Sensor

Circuit Breaker

Transmission Oil Temperature Sensor

Fuse Box

Fusible Link

Brake Oil Filter Switch

Preheat Controller

Air Cleaner Clogging Waring Indicator

Electrical System

S0802180K Page 21

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 “P” Terminal voltage (24V)

0012.eps

EMPTY - Above 90 Ohm Fuel Level Gauge

CN1-7

1/2 - 38 Ohm FULL - Below 10 Ohm

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Electrical System

Return to Master Table of Contents Sensor Specification Function

Display

Input Terminal

Input Specification

50°C - Above 188.2 Ohm 67°C - 102 Ohm Engine Coolant Temperature Gauge

Transmission Oil Temperature Gauge

Electrical System

CN1-6

105°C - 32 Ohm 125°C - Below 19.8 Ohm

50°C - Above 322.8 Ohm CN1-8

120°C - 36.5 Ohm 150°C - Below 18.6 Ohm

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Return to Master Table of Contents Pilot Lamp Symbol

Description

Input Terminal

Preheat

CN2-1

Lights up when preheat process is completed. (Approximately 19 seconds from start.)

Air Cleaner

CN2-2

Lights up when air cleaner is clogged

Coolant Temperature

CN2-3

Light up when coolant temperature increases over 102°C.

HAOA630L

Operation

Remarks

HAOA660L

(When terminal input is connected)

HAOA51AL

Engine Oil Pressure

CN2-4

Lights up when engine oil pressure drops below 1.6 kgf/cm2

After starting engine, if engine oil pressure is insufficient after 8 seconds, a warning buzzer will sound.

Charging

CN2-5

Lights up when not charging.

Under normal conditions, will light up before engine start up and shut off once engine is running.

HAOA620L

(and "R" terminal output drops below 24V)

HAOA610L

Left Turn and Hazard Lamp

CN2-6

Lights up when left turn signal or hazard lamp is operated. (Terminal input is to 24V)

Right Turn and Hazard Lamp

CN2-8

Lights up when right turn signal or hazard lamp is operated. (Terminal input is to 24V)

High Beam

CN2-7

Lights up when high beam is operated. (Terminal input is to 24V)

HGB2008L

Work Lamp

CN2-9

Lights up when work lamp is operated.

Light off when the engine is started.

(Terminal input is to 24 V)

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Electrical System

Return to Master Table of Contents Symbol

Description Brake Oil Pressure

Input Terminal CN2-10

0717B

Operation

Remarks

Lights off when brake oil pressure increases over 65 kgf/cm2, and lights up when brake oil pressure drops below 60 kgf/cm2.

Under normal conditions, will light up before engine start up and shut off once engine is running.

(When terminal input is connected) Parking Brake

CN2-12

P 0717A

Lights up when the parking brake switch is applied and parking brake pressure is above 65 kgf/cm2.

Under any conditions, will be alight before engine start up.

(24V is inputted to the input terminal) Brake Oil Filter Pressure

CN2-11

Lights up when the brake oil filter pressure is above 5 kgf/cm2, light off when the brake oil filter pressure is below 4.7 kgf/cm2.

Emergency Steering

CN2-13

Lights up when the vehicle speed is above 5 km/h and the steering pressure is below 10 kgf/cm2.

AJO0450L

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 lamps are turned on and turned off after 2 seconds. (Except for turn signal indicator, high beam indicator, working lamp indicator and transmission cut-off indicator and emergency steering indicator.

•

Warning buzzer is activated and turned off after 2 seconds.

•

Monitoring system displays present condition.

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Return to Master Table of Contents Control Unit Operation

5 2

1 6

7 3 4

9 10 11 12

AMP MIC 13P

Figure 13 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

Alarm Relay

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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 lamps are turned on and turned off after 2 ~ 2.5 seconds.

is below 12±1 V

Charging lamp lights up L5

is above 12±1 V

Charging lamp lights 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

S0802180K Page 27

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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

Figure 14

S0802180K Page 28

Electrical System

Return to Master Table of Contents Reference Number

Description

Reference Number

Description

Fuse Box

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) located 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.

1 3 2 6

5 4 AJS0170L

Figure 15 REAR WINDSHIELD WIPER 1ST ACTION CIRCUIT

Reference Number

Description

Reference Number

Description

Fuse Box

Washer Tank

Wiper/washer Switch

Diode

Wiper Motor

Diode

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).

Electrical System

S0802180K Page 29

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1 3 2 6

5 4 AJS0160L

Figure 16 REAR WINDSHIELD WIPER STOP CIRCUIT Reference Number

Description

Reference Number

Description

Fuse Box

Washer Tank

Wiper/washer Switch

Diode

Wiper Motor

Diode

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Electrical System

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Electrical System

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LIGHTING SYSTEM LIGHT CIRCUIT

22 28 23

17 1 26

8 12

13 18

6 4

25 9 14

15 5 AJS0180L

Figure 17 LIGHT CIRCUIT

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Electrical System

Return to Master Table of Contents Reference Number

Description

Reference Number

Description

Fuse Box 1

License Plate Lamp

Blinker Unit

Instrument Panel

Head Lamp Switch

Diode

Combination Switch

Front Working Lamp Switch

Shift Lever Switch

Front Working Lamp

Hazard Switch

Rear Working Lamp Switch

Stop Lamp Switch

Working Lamp Relay

Head Lamp Relay

Rear Working Lamp 1

Reverse Relay

Rear Working Lamp 2

Head Lamp (L)

Fuse Box 2

Head Lamp (R)

Starter Switch

Front Combination Lamp (L)

Pilot Buzzer

Front Combination Lamp (R)

Alarm Relay 1

Rear Combination Lamp (L)

Alarm Relay 2

Rear Combination Lamp (R)

The lighting system is consists of the head lamp, the position lamp, the turn signal lamp, the hazard lamp, the stop lamp, the license plate lamp, the working lamp, the rotating beacon lamp (option) and the switches, which is used to turn on the lamps. 1.

When the head lamp switch (3) is in the first step, through the fuse box 1 (1) to the "2," "6" terminal of head lamp switch (3), the following lamps will be alight. A.

The front combination lamp (L) (12) and rear combination lamp (L) through the fuse box 2 (23).

The front combination lamp (R) (13) and rear combination lamp (R) through the fuse box 2 (23).

The illumination lamps through the "9" terminal of all kind of rocker switches include the head lamp switch (3), the front working lamp switch (19), the rear working lamp (21) and the hazard switch (6).

The license plate lamp (16).

When the head lamp switch (3) is in the second step, the current flows through the fuse box 1 (1), to the "2," "3" terminal of head lamp switch (3) and to the "86," "85" terminal of head lamp relay (8), and the "30," "87" terminal of head lamp relay (8) is connected. As a result, through the fuse box 1 (1) to the "30," "87" terminal of head lamp 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 lamp, which is in the head lamp (L) (10) and the head lamp (R) (11), to be alight.

Also if the combination switch (4) is in the "▼ " position, the current flows to the "56a" terminal and it allow the high lamp, which is in the head lamp (L) (10) and the head lamp (R) (11), to be alight. At the same time the current flows to the "CN2-7" terminal of instrument panel (17) and the head lamp indicator L7 will be alight.

And if the combination switch (4) is in the "▲ " position, the current flows to the "56b" terminal and it allows the low lamp, which is in the head lamp (L) (10) and the head lamp (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

Electrical System

S0802180K Page 33

Return to Master Table of Contents combination switch (4) and the high lamp, which is in the head lamp (L) (10) and the head lamp (R) (11) will be turned up, and the other current flows to the "CN2-7" terminal of instrument panel (17) and the head lamp indicator will be alight. The combination switch (4) is returned automatically. 3.

When the combination switch (4) is in the "←" (or "→")position, the current flows from the fuse box 1 (1), to the blinker unit (2), to the "L" (or "R") terminal through "49a" terminal of combination switch (4), to the "C" terminal of front combination lamp (L) (12) and the rear combination lamp (L) (14) (or to the front combination lamp (R) (13) and the rear combination lamp (R) (15)). This current makes the turn signal lamp turned up. At the same time the current flows to the "CN2-6" terminal ( or to the CN2-8 terminal) of instrument panel and the turn signal lamp indicator L6 (or L8) will be alight.

If you operates the hazard lamp 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 lamp (L) (12) and the front combination lamp (R) (13), to the "C" terminal of rear combination lamp (L) (14) and rear combination lamp (R) (15). This current makes the turn signal lamp 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 lamp 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 lamp 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 "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 lamp (L) (14) and rear combination lamp (R) (15). And the reverse lamp will be alight.

When the brake pedal is depressed and at the same time the stop lamp switch (7) is turned up, the current flows the from fuse box 1 (1), to the stop lamp switch (7) and to the "F" terminal of rear combination lamp (L) (14) and rear combination lamp (R) (15). And the stop lamp will be alight.

When the front working lamp switch (19) is in the "ON" position, the current flows from the fuse box 1 (1), to the "5," "1" terminal of front working lamp switch (19) and to the front working lamp (20). This current makes the front working lamps turned up. At the same time the working lamp 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 working lamp switch (21) is in the second step, the contact points "30" and "87" of the working lamp relay (22) is closed due to the flowing current from the fuse box 1 (1), to the "2" and "6" terminal of the working lamp switch (21), to the "86" terminal of the working lamp relay (22) and to the ground. Thus the current flows from the fuse box 1 (1), to the working lamp relay (22) and to the rear working lamp 1 (23) mounted on right/left rear fender. As a result the rear working lamp (23) lights up. At the same time the working lamp indicator "L9" lights up due to the current flowing from the diode (18) to the "CN2-9" terminal of the instrument panel.

When the rear working lamp switch (21) is in the second step, the contact points "30" and "87" of the working lamp relay (22) is closed due to the flowing current from the fuse box 1 (1), to the "2" and "6" and "3" terminal of the working lamp switch (21), the rear working (23) is operated like being described above clause "8" and the rear working lamp (24) mounted on the cabin lights up at the same time.

10.

When the head lamp 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 head lamp 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.

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Electrical System

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Electrical System

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EMERGENCY STEERING SYSTEM (OPTION) BLOCK DIAGRAM

7 8

AJS0460L

Figure 18 EMERGENCY STEERING SYSTEM BLOCK DIAGRAM Reference Number

Description

Reference Number

Description

Fuse Box

Emg Steering Pump

Emg Steering Switch

Emg Steering Indicator

Emg Steering Timer

Transmission Controller

Emg Steering Pressure Switch

Battery

When the speed of the vehicle exceeds 5 km/h and the secondary steering pressure is less than 10 kgf/ cm2, 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) lights up.

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Electrical System

Return to Master Table of Contents EMERGENCY STEERING SYSTEM COMPONENTS Emergency Steering Timer 1.

Abtains 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 19

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 20 EMERGENCY STEERING TIMER CIRCUIT Input Condition S0

Vehicle Speed

Output (Emergency Steering Pump)

When in the "ON" position

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

S0802180K Page 37

Return to Master Table of Contents Emergency Steering Pump This is an electrically powered hydraulic pump and includes an emergency steering relay (1,Figure 21),which is excited by the signal of the emergency steering timer.

AJS0480L

Figure 21 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

Figure 22 EMERGENCY STEERING SWITCH

WARNING Make sure that no persons are near the machine when testing the function of the emergency steering system, there is a risk that someone may be crushed between the front and the rear frame. 3. This returns automatically when not pressed down. NOTE:

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

S0802180K Page 38

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" ans "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 lights up 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 23 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

Head Lamp Switch

Emergency Steering Pump

Battery

Electrical System

S0802180K Page 39

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ELECTRIC DETENT SYSTEM The electric detent system separated into boom kick-out and return to dig. An each part is consists of magnetic locking lever and proximity switch detecting the position of bucket or boom. ELECTRIC CIRCUIT

FLOAT KICK-OUT (OPTION)

2 11

7 8

1 11

AJS0500L

Figure 24 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). And when the boom is matched to setting position, lever locking is released and lever is returned to "NEUTRAL" position automatically and boom lowering (or lifting) is stopped. 1.

Boom Raise Kick-Out With the raise magnetic (5) is energized and the work lever is held in "RAISE," then boom is approaching to the raise proximity switch (8). When the raise proximity switch (8) and the boom are matched, the contact points "30" and "87a" of the raise/float relay (3) is opened due to the current flowing from the fuse box (1), to the coil of the raise relay (3) and to the "0" and "-" terminal of the raise proximity switch (8). As a result the magnetic (5) is de-energized and the locked lever is returned to "NEUTRAL" position, boom lifting is stopped.

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Electrical System

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Boom Float Kick-Out (Option) With the float kick-out switch shown in Figure 25, 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 25 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. And when the bucket is matched to setting position, the lever is returned to the "NEUTRAL" position and bucket crowding will be stopped. After this operation, if the boom is lowered the bucket is in parallel with ground. With the return to dig proximity switch (10) and the bucket positioner are matched, the contact points "30" and "87" of the return to dig relay (4) is closed due to the current flowing from fuse box (1), to the coil of the return to dig relay (4) and to the "0" and "-" terminal of the return to dig proximity switch (10). In this states, if the work lever is in the "CROWD" position, the lever is locked and the bucket positioner is approaching out of the return to dig proximity switch (10). That is, bucket is crowded. If the bucket positioner is out of the return to dig proximity switch (10), the float magnetic (9) is de-energized. As a result the lever is returned to "NEUTRAL" position and bucket is set to the selected digging angle. Proximity Switch •

Operating Distance : 10±1 mm

•

Operation Indicator lamp

OPERATION INDICATOR POSITIONER

: Lights up when the object is detected. (OPERATING DISTANCE)

MAIN CIRCUIT

POWER

AJS0510L

Figure 26

Electrical System

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Electrical System

S0893050K

3ELECTRICAL SCHEMATIC (MEGA 400-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 400-V)S0893050K MODEL Mega 400-V

SERIAL NUMBER RANGE 1001 and Up

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Electrical Schematic (Mega 400-V)

Figure 1

Electrical Schematic (Mega 400-V)

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MEGA 400-V

Figure 2

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Electrical Schematic (Mega 400-V)

MEGA 400-V AJS0900L

Electrical Schematic (Mega 400-V)

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Electrical Schematic (Mega 400-V)

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1ATTACHMENTS

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