Mega 250-V

Mega 250-V
Shop Manual
K1000898AE
Serial Number 3001 thru 4000 (Tier I)
Serial Number 4001 and Up (Tier II)
Doosan reserves the right to improve our products in a continuing process to provide the best possible
product to the market place. These improvements can be implemented at any time with no obligation to
change materials on previously sold products. It is recommended that consumers periodically contact their
distributors for recent documentation on purchased equipment.
This documentation may include attachments and optional equipment that is not available in your
machine’s package. Please call your distributor for additional items that you may require.
Illustrations used throughout this manual are used only as a representation of the actual piece of
equipment, and may vary from the actual item.
K1000898AE Shop Manual

Copyright 2011 Doosan
Pub.No. K1000898AE
Serial Number 4001 and Up (Tier II)
Serial Number 3001 thru 4000 (Tier I)
Mega 250-V
Product Label
Instructions
Trim Out The Label Along

The Lines And Insert Into
Pocket On The Binder Spine
Pub. No. K1000898AE

1TABLE OF CONTENTS
Safety
Wheel Loader Safety .......................................................................... S0103010K
Specifications
Specifications for Mega 250-V...............................................................S0203115
General Maintenance
General Maintenance Procedures .........................................................S0302000
Standard Torques ..................................................................................S0309000
Upper Structure
Counterweight..................................................................................... S0403030K
Fuel Transfer Pump ...............................................................................S0405500
Hydraulic Oil Tank .............................................................................. S0406060C
Lower Structure and Chassis

Center Joint (Articulation Joint)........................................................... S0502050C
Engine and Drive Train

Rear Axle (ZF - MT-L 3075)...................................................................S0602270
Front Axle (ZF - MT-L 3085) ..................................................................S0602280
Parking Brake Caliper (ZF) ....................................................................S0603001
Air Conditioner .................................................................................... S0605050K
Transmission and Torque Converter (ZF 4WG-190) .............................S0607140
Transmission Error Codes (ZF) .......................................................... S0607900C
Hydraulics
Accumulator........................................................................................ S0703010K
Cylinders............................................................................................. S0705005K
Fan Drive Hydraulic Motor (Haldex) ................................................... S0707110C
Main Pump (Denison T67CCA Series) ............................................... S0708500C
Brake Pedal Valve .................................................................................S0709271
Main Control Valve (Toshiba) ............................................................. S0709456K
Pilot Control Valve ............................................................................ S07094765A
Pilot Control Valve (FNR) ....................................................................S07094776
Priority Valve..........................................................................................S0709650
Power Steering Unit...............................................................................S0709735
Unloader Valve ................................................................................... S0709865A
Hydraulic Schematic (Mega 250-V) .................................................... S0793005D
Electrical System
Electrical System ................................................................................ S0802015C
Electrical Schematic (Mega 250-V) .................................................... S0893005C
Attachments
1SAFETY
S0103010K
2WHEEL LOADER
SAFETY
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
WHEEL LOADER SAFETYS0103010K

MODEL SERIAL NUMBER RANGE
Mega 200-V (Tier I & II) 1001 and Up
Mega 250-V (Tier I) 1001 thru 2000
Mega 250-V (Tier II) 2001 thru 3000
Mega 250-V (Tier II) 4001 and Up
Mega 300-V 3001 and Up

January 2011
Wheel Loader Safety S0103010K

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

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

Page 2
TO THE OPERATOR OF A WHEEL LOADER
DANGER!
Unsafe use of the wheel loader could lead to serious injury or death. Operating procedures,
maintenance and equipment practices or traveling or shipping methods that do not follow the
safety guidelines on the following pages could cause serious, potentially fatal injuries or
extensive damage to the machine or nearby property.
Please respect the importance of taking responsibility for your own safety, and that other people who may
be affected by your actions.
Safety information on the following pages is organized into the following topics.
1. “General Safety Essentials” on page 6.
2. “Location of Safety Labels” on page 6.
3. “Unauthorized Modifications” on page 6.
4. “General Hazard Information” on page 7.
5. “Before Starting Engine” on page 15.
6. “Machine Operation” on page 18.
7. “Maintenance” on page 25.
8. “Battery” on page 33.
9. “Towing” on page 35.
10. “Shipping and Transportation” on page 36.

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

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

Words "CAUTION," "WARNING," and "DANGER" used throughout this manual and on labels on machine
indicate hazards or unsafe practices. All three statements indicate that safety is involved. Observe
precautions indicated whenever you see the Safety Alert "Triangle," no matter which signal word appears
next to the "Exclamation Point" symbol.
CAUTION!
This word is used on safety messages and safety labels and indicates potential of a hazardous
situation that, if not avoided, could result in minor or moderate injury. It may also be used to alert
against a generally unsafe practice.
WARNING!
This word is used on safety messages and safety labels and indicates potential of a hazardous
situation that, if not avoided, could result in serious injury or death. It may also be used to alert
against a highly unsafe practice.
DANGER!
This word is used on safety messages and safety labels and indicates imminent hazard of a
situation that, if not avoided, is very likely to cause death or extremely serious injury. It may also
be used to alert against equipment that may explode or detonate if handled or treated carelessly.
Safety precautions are described in SAFETY from page 6 on.

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

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

Location of safety labels (decals) can vary from unit to unit. Refer to appropriate Operation and
Maintenance Manual, and Parts Manual for your unit.
There are several specific warning signs on this machine. The exact location of hazards and the
description of the hazards are reviewed in the appropriate Operation and Maintenance Manual.
Please become familiarized with all warning signs.
Make sure that all of the warning signs are legible. Clean the warning signs or replace the warning signs if
you cannot read the words. Replace the illustrations if the illustrations are not visible. When you clean the
warning signs, use a cloth, water and soap. Do not use solvent, gasoline, or other harsh chemicals to clean
the safety signs. Solvents, gasoline, or other harsh chemicals could loosen the adhesive that secures the
warning sign. Loose adhesive will allow the warning sign to fall off.
Replace any safety sign that is damaged, or missing. If a safety sign is attached to a part that is replaced,
install a safety sign on the replacement part.
UNAUTHORIZED MODIFICATIONS
Any modification made without authorization or written approval from Doosan can create a safety hazard,
for which the machine owner must be held responsible.
For safety's sake, replace all OEM parts with the correct authorized or genuine Doosan part. For example,
not taking the time to replace fasteners, bolts or nuts with the correct replacement parts could lead to a
condition in which the safety of critical assemblies is dangerously compromised.

Page 6
GENERAL HAZARD INFORMATION
SAFETY RULES
Only trained and authorized personnel can operate and maintain the machine.
Follow all safety rules, precautions and instructions when operating or performing maintenance on the
machine.
Do not operate the machine if you are not feeling well, if you are taking medication that makes you feel
sleepy, if you have been drinking, or if you are suffering from emotional problems. These problems will
interfere with your sense of judgement in emergencies and may cause accidents.
When working with another operator or with a person on work site traffic duty, be sure that all personnel
know the nature of the work and understand all hand signals that are to be used.
Always observe strictly any other rules related to safety.
SAFETY FEATURES
Be sure that all guards and covers are installed in their proper position. Have guards and covers repaired
immediately if damaged.
Be sure that you understand the method of use of safety features such as transmission lever neutral lock
and the seat belt, and use them properly.
Never remove any safety features. Always keep them in good operating condition.
Failure to use safety features according to the instructions in the Operation and Maintenance Manual could
result in serious bodily injury.

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

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

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

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

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

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

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

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

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

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

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

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

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

Page 13
ATTACHMENT PRECAUTIONS
Options kits are available through your dealer. Contact Doosan for information on available one-way
(single-acting) and two-way (double-acting) piping / valving / auxiliary control kits. Because Doosan cannot
anticipate, identify or test all attachments that owners may wish to install on their machines, please contact
Doosan for authorization and approval of attachments, and their compatibility with options kits.
ACCUMULATOR
The pilot control system is equipped with an accumulator. For a brief period of time after the engine has
been shut down, the accumulator will store a pressure charge that may enable hydraulic controls to be
activated. Activation of any controls may enable the selected function to operate under force of gravity.
When performing maintenance on the pilot control system, the hydraulic pressure in the system must be
released as describe in Operation and Maintenance Manual.
The accumulator is charged with high-pressure nitrogen gas, so it is extremely dangerous if it is handled in
the wrong way. Always observe the following precautions;
• Do not drill or make any holes in the accumulator or expose it any flame, fire or heat source.
• Do not weld on the accumulator, or try attaching anything to it.
• When carrying out disassembly or maintenance of the accumulator, or when disposing of the
accumulator, the charged gas must be properly released. Contact your Doosan distributor.
• Wear safety goggles and protective gloves when working on an accumulator. Hydraulic oil under
pressure can penetrate the skin and cause serious injuries.
ENGINE VENTILATION
Engine exhaust gases can cause loss of
judgment, loss of alertness, and loss of motor
control. These gases can also cause
unconsciousness, serious injury and fatal
accidents.
Make sure of adequate ventilation before
starting engine in any enclosed area.
You should also be aware of open windows,
doors or ductwork into which exhaust may be
carried, or blown by wind, exposing others to ARO1770L
danger. Figure 11

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

Page 15
CHECKS BEFORE STARTING ENGINE
Every day before starting the engine for the first time, carry out the following checks. If these checks are
not carried out properly, there is danger of serious injury.
• Completely remove all wood chips, leaves, grass, paper and other flammable materials
accumulated in the engine compartment and around the battery. They could cause a fire.
Remove any dirt from the window glass, mirrors, handrails, and steps.
• Do not leave tools or spare parts laying around in the operator's compartment. The vibration of
the machine when traveling or during operations may cause them to fall and damage or break
the control levers or switches. They may also get caught in the gap of the control levers and
cause the work equipment to malfunction or move dangerously. This may lead to unexpected
accidents.
• Check the coolant level, fuel level, and hydraulic tank oil level, and check for clogged air cleaner
and damage to the electrical wiring.
• Adjust the operator's seat to a position where it is easy to operate the machine, and check the
seat belt and mounts for damage and wear.
• Check the operation of the gauges and the angle of the mirrors, and check that the safety lever
is in "LOCKED" position.
• If any abnormalities are found in the above checks, carry out repairs immediately.
ENGINE STARTING
• Walk around your machine before getting in operator's cab. Look for evidence of leaking fluid,
loose fasteners, misaligned assemblies or any other indications of possible equipment hazard.
• All equipment covers and machinery safety guards must be in place, to protect against injury
while machine is being operated.
• Look around work site area for potential hazards, or people or property that could be at risk
while operation is in progress.
• NEVER start engine if there is any indication that maintenance or service work is in progress, or
if a warning tag is attached to controls in cab.
• A machine that has not been used recently, or is being operated in extremely cold temperatures,
could require a warm-up or maintenance service before start up.
• Check gauges and monitor displays for normal operation before starting engine. Listen for
unusual noises and remain alert for other potentially hazardous conditions at start of work cycle.
• Check tire inflation and check tires for damage or uneven wear. Perform maintenance before
operation.
• Do not short circuit the starting motor to start the engine. This is not only dangerous, but may
also damage the machine.
• When starting the engine, sound the horn as an alert.
• Start and operate the machine only while seated.

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

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

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

TIMES
Whenever engine is running, operator should be
seated at the control station with seat belt
properly engaged.
Figure 14
MOVEMENT ALARMS
If wheel loader is equipped with an audible travel movement alarm, test alarm on a daily basis. Audible
alarm should sound as soon as travel system is engaged.

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

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

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

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

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

6.6 kV 3 m (9' 10")
33.0 kV 4 m (13' 1")
66.0 kV 5 m (16' 5") Figure 16
154.0 kV 8 m (26' 3")
275.0 kV 10 m (32' 10")
Use these minimum distances as a guideline

only. Depending upon voltage in line and atmospheric conditions, strong current shocks can occur with
boom or bucket as far away as 4 - 6 m (13 - 20 ft) from power line. Very high voltage and rainy weather
could further decrease that safety margin.
NOTE: Before starting any type of operation near power lines (either above ground or buried
cable type) you should always contact power utility directly and work out a safety plan with
them.
BEFORE STARTING TO DIG, CONTACT AUTHORITIES

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

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

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

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

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

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

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

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

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

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

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

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

In icy cold weather avoid sudden travel movements and stay away from even very slight slopes. Machine
could skid off to one side very easily.
Snow accumulation could hide or obscure potential hazards. Use care while operating or while using
machine to clear snow.
Warming up engine for a short period may be necessary, to avoid operating with sluggish or reduced
working capacity. Jolting shocks and impact loads caused by bumping or bottoming boom or attachment
are more likely to cause severe stress in very cold temperatures. Reducing work cycle rate and work load
may be necessary.
When the temperature rises, frozen road surfaces become soft, so the machine travel becomes unstable.
In cold weather, do not touch metal surfaces with your bare hands. If you touch a metal surface in
extremely cold weather, your skin may freeze to the metal surface.
PARKING MACHINE
Avoid making sudden stops, or parking machine wherever it happens to be at the end of the work day. Plan
ahead so that the wheel loader will be on firm, level ground away from traffic and away from high walls, cliff
edges and any area of potential water accumulation or runoff. If parking on inclines is unavoidable, block
wheels to prevent movement. Lower bucket or other working attachment completely to ground, or to an
overnight support saddle. There should be no possibility of unintended or accidental movement.
When parking on public roads, provide fences, signs, flags, or lights, and put up any other necessary signs
to ensure that passing traffic can see the machine clearly, and park the machine so that the machine, flags,
and fences do not obstruct traffic.

Page 23
SHUTDOWN CONTROL FUNCTIONS
After bucket has been lowered to overnight storage position, move all switches and controls to "OFF"
position. Pull parking brake knob to "APPLIED" position. This will apply parking brake. Move pilot cutoff
switch to "LOCK" position. This will disable pilot control valve lever (joystick). Move key in starter switch to
"OFF" position, and remove key from switch.
Engage all lock-down security equipment that may have been installed on machine.
IMPORTANT
When hydraulic system maintenance or service work must be performed, be aware that
accumulators in system store fluid under pressure after system has been shut down. To release
hydraulic pressure in accumulators, operate control with engine "OFF" until accumulator
pressure is completely dissipated.
NEVER LET ANYONE RIDE ON

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

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

MAINTENANCE
HAOC920L
Clean the machine before carrying out
inspection and maintenance. This prevents dirt Figure 22
from getting into the machine and also ensures
safety during maintenance.
If inspection and maintenance are carried out when the machine is dirty, it will become more difficult to
locate the problems, and also there is danger that you may get dirt or mud in your eyes or that you may slip
and injure yourself.
When washing the machine, do the following;
• Wear shoes with nonslip soles to prevent yourself from slipping and falling on wet places.
• Wear safety glasses and protective clothing when washing the machine with high-pressure
steam.
• Take action to prevent touching high-pressure water and cutting your skin or having mud fly into
your eyes.
• Do not spray water directly on electrical components (sensors, connector) (1, Figure 23). If
water gets into the electrical system, there is danger that it will cause defective operation and
malfunction.
Figure 23
Pick up any tools or hammers that are laying in the work place, wipe up any grease or oil or any other
slippery substances, and clean the area to make it possible to carry out the operation in safety. If the work
place is left untidy, you may trip or slip and suffer injury.

Page 25
PROPER TOOLS
Use only tools suited to the task. Using
damaged, low qualify, faulty, or makeshift tools
could cause personal injury. There is danger
that pieces from, chisels with crushed heads, or
hammers, may get into your eyes and cause
blindness.
HDO1037L
Figure 24
USE OF LIGHTING
When checking fuel, oil, battery electrolyte, or
window washing fluid, always use lighting with
anti-explosion specifications. If such lighting
equipment is not used, there is danger of
explosion.
If work is carried out in dark places without
using lighting, it may lead to injury, so always
use proper lighting.
Even if the place is dark, never use a lighter or
flame instead of lighting. There is danger of fire. HDO1040L
There is also danger that the battery gas may Figure 25
catch fire and cause and explosion.
FIRE PREVENTION AND EXPLOSION PREVENTION

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

Page 26
BURN PREVENTION
When checking the radiator coolant level, shut down engine, let the engine and radiator cool down, then
check the coolant recovery tank. If the coolant level in the coolant recovery tank is near the upper limit,
there is enough coolant in the radiator.
Loosen the radiator cap gradually to release the internal pressure before removing the radiator cap.
ARO1360L
Figure 26
If the coolant level in the coolant recovery tank is below the lower limit, add coolant.
Cooling system conditioner contains alkali. Alkali can cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth.
Allow cooling system components to cool before you drain the cooling system.
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact
the skin.
Remove the hydraulic tank filter plug only after the engine has been stopped. Make sure that the hydraulic
tank filter plug is cool before you remove it with your bare hand. Remove the hydraulic tank filter plug slowly
to relieve pressure.
Relieve all pressure in the hydraulic oil system, in the fuel system, or in the cooling system before you
disconnect any lines, fittings, or related items.
Batteries give off flammable fumes that can explode.
Do not smoke while you are checking the battery electrolyte levels.
Electrolyte is an acid. Electrolyte can cause personal injury. Do not allow electrolyte to contact the skin or
the eyes.
Always wear protective glasses when you work on batteries.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Page 36
1SPECIFICATIONS
S0203115
1SPECIFICATIONS FOR
MEGA 250-V
CAUTION!
SPECIFICATIONS FOR MEGA 250-VS0203115


January 2011
Specifications for Mega 250-V S0203115

Page 1
TABLE OF CONTENTS
Component Locations .................................................................................... 4

General Specifications ................................................................................... 8
Engine Performance Curves ........................................................................ 10
Working Range and Dimensions.................................................................. 14
Working Capacities ...................................................................................... 17
Bucket Capacity .................................................................................... 17
Tipping Load ......................................................................................... 17
Material Weight ............................................................................................ 17
Approximate Weight of Workload Materials .......................................... 17
S0203115 Specifications for Mega 250-V

Page 2
Page 3
COMPONENT LOCATIONS
Figure 1 identifies the location of major machine components.
1 2 3 4 6
7
}
H
10
18 19 12 11
17
20
21
16
22
14 23
15 STQAN,HH
13 24
44 25
26
27
5
28(R)
29(R)
43 42 41 40 39 38 37 36 35 34 33 32 31 30
BZO0091L
Figure 1 (S/N 3001 thru 4000)

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

Page 5
Figure 2 identifies the location of major machine components.
1 2 3 4 6
7
~
9
I
10
18 19 12 11
17
5 20 21
16 22
14 15 23
TURBO-II
24
13
25
44 26
D100
27
28(R)
29(R)
43 42 41 40 39 38 37 36 35 34 33 32 31 30
BZO0010L
Figure 2 (S/N 4001 and Up)

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

Page 7
GENERAL SPECIFICATIONS
MEGA 250-V
Item Specification
Serial Number 3001 thru 4000 4001 and Up
Standard Bucket Capacity 3 3
2.4 m (3.1 yd )
Vehicle Weight 14,000 kg (30,865 lb) 14,200 kg (31,305 lb)
Engine
Model Doosan 1146T DE 58TIS
Turbo charged after Turbo charged air to air
Type
cooled after cooled
Emission Tier - I Tier - II
Rated.
165 ps @ 2,200 rpm
160 ps @ 2,200 rpm (163 hp) @ 2,200 rpm
Horsepower (see note) (158 hp @ 2,200 rpm) Max.
(Net) (SAE J1349) 172 ps @ 2,000 rpm
(170 hp) @ 2,000 rpm
(Gross) (SAE J1995)
69 kg•m @ 1,300 rpm 75 kg•m @ 1,300 rpm
Max. Torque (see note) (500 ft lb @ 1,300 rpm) (542 ft lb @ 1,300 rpm)
(Net) (SAE J1349) (Gross) (SAE J1995)
Transmission
Type Full Automatic Power Shift
Speeds 4 Forward, 3 Reverse
Brake Systems
Service Brakes Full Hydraulic, Separate Dual Line Wet Disks
Spring Applied Sliding Caliper Disk Brake / Hydraulically
Parking Brake
Released on Transmission
Performance
Travel Speed 7.5 - 37 km/h (4.7 - 23 MPH)
Steering Angle + 40°
Static Tipping Load 12,000 / 9,800 kg (26,455 / 21,605 lb)
(Straight / Full Turn)
Max. Breakout Force 13,200 kg (29,100 lb)
Bucket Rise Time 5.0 Seconds
Bucket Dump Time 1.2 Seconds
Bucket Descent Time 3.3 Seconds
Maximum Gradeability 58% (30°)
Travel Dimension
Overall Length (A) 7,500 mm (24' 7")
Overall Width (B) 2,740 mm (8' 12")
Overall Height (C) 3,320 mm (10' 11")
Bucket Width (D) 2,740 mm (8' 12")
Wheel Base (E) 3,020 mm (9' 11")
Tread (F) 2,040 mm (6' 8")

Page 8
MEGA 250-V
Item Specification
Ground Clearance (G) 430 mm (1' 5")
Dump Height, to tooth (H) 2,760 mm (9' 1")
Dump Distance, to Bucket Edge 1,060 mm (3' 6")
(I)
Minimum Tire Turning Radius (J) 5,166 mm (16' 11")
Bucket Angle, Raised (a) 46°
Bucket Angle (b), Lowered (at 45°
carry)
Bucket Angle (b), Lowered (on 38°
ground)
20.5 x 25 - 16 PR
Tire Size
20.5 x R25 (Option)
NOTE: "High torque rise"

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

Page 9
ENGINE PERFORMANCE CURVES
70
TORQUE (kg.m)
170 60
50
160
POWER OUTPUT (ps)
140
FUEL CONSUMPTION (g/ps.h)

120
180
160
100 140
1000 1200 1400 1600 1800 2000 2200 2400
REVOLUTION (rpm)
AOS0950L

Page 10
70
TORQUE (kg.m)
60
200
50
POWER OUTPUT (ps)
150
FUEL CONSUMPTION (g/ps.h)

100
180
170
160
150
1100 1500 2000

REVOLUTION (rpm)
BZS0030L

Page 11
MEGA 250-V
Serial Number 3001 thru 4000 4001 and Up
Emission Tier I Tier II
160 ps @ 2,200 rpm 172 ps @ 2,200 rpm
Power (Maximum / rpm) (158 hp @ 2,200 rpm) (170 hp @ 2,200 rpm)
; Net ;Gross
69 kg•m / 1,300 rpm 71 kg•m @ 1,400 rpm
Maximum Torque (500 ft lb @ 1,300 rpm) (514 ft lb @ 1,400 rpm)
;Net ;Gross
Fuel Consumption 170 g/ps•h (5.99 oz/hp•h) 160 g/ps•h (5.63 oz/hp•h)
Performance standard DIN 6270
NOTE: W/Cooling Fan W/O Cooling Fan
Barometric Pressure: 760 mm (30 in) Mercury
Temperature: 20°C (68°F)
Alternator: 24 V, 50 amp
Muffler: Not installed
Air Cleaner: Installed

Page 12
Page 13
WORKING RANGE AND DIMENSIONS
Figure 5, illustrates exterior machine dimensions and working range of machine when it is equipped with a
standard bucket.
40
C
G
B (D) A F
I
H
BZO0150L
Figure 5

Page 14
Category Dimension
7,500 mm
Overall Length (A)
(24' 7")
2,740 mm
Overall Width (B)
(8' 12")
3,320 mm
Overall Height (C)
(10' 11")
2,740 mm
Bucket Width (D)
(8' 12")
3,020 mm
Wheel Base (E)
(9' 11")
2,040 mm
Tread (F)
(6' 8")
Ground Clearance (G) 430 mm (1' 5")
2,760 mm
Dump Height, to tooth (H)
(9' 1")
1,060 mm
Dump Distance, to Bucket Edge (I)
(3' 6")
5,166 mm
Minimum Tire Turning Radius (J)
(16' 11")
Bucket Angle, Raised (a) 46°
Bucket Angle (b), Lowered (at carry) 45°
Bucket Angle (b), Lowered (on ground) 38°
20.5 x 25 - 16 PR
Tire Size
20.5 x R25 (Option)

Page 15
Figure 6 illustrate working range when machine is equipped with optional pallet or log fork.
A
B
E
D
b
C
AOS0960L
Figure 6
Reference Reference
Dimension Dimension
Number Number
1,652 mm 2,395 mm
A D
(5' 5") (7' 10")
2,346 mm 3,698
B E
(7' 8") (12' 1")
1,500 mm a 45°
C
(4' 11") b 39°

Page 16
WORKING CAPACITIES
BUCKET CAPACITY
Standard toothed bucket has a capacity of 2.4 m3 (3.1yd3).
TIPPING LOAD
Static Tipping Load with bucket in Over Front position is 12,000 kg (26,455 lb). With bucket in Fully Turned
position, Static Tipping Load is 9,800 kg (21,605 lb).
MATERIAL WEIGHT
The data below describes weight of a cubic meter (cubic yard) of many types of workload materials.
APPROXIMATE WEIGHT OF WORKLOAD MATERIALS
LOW WEIGHT OR MEDIUM WEIGHT OR HIGH WEIGHT OR

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

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

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

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

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

--------------------- ---------------------
bed (2,943 lb/yd3)
Cement, Portland, DRY 1,506 kg/m3

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

Page 17
LESS LESS LESS
Cement, Portland, DRY 1,362 kg/m3

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

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

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

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

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

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

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

--------------------- ---------------------
2 or 2 (2,295 lb/yd3)
1,522 kg/m3
Limestone, crushed --------------------- ---------------------
(2,565 lb/yd3)
1,602 kg/m3
Limestone, fine --------------------- ---------------------
(2,705 lb/yd3)
1,282 kg/m3
Phosphate, rock --------------------- ---------------------
(2,160 lb/yd3)
929 kg/m3
Salt --------------------- ---------------------
(1,566 lb/yd3)

Page 18
LESS LESS LESS
529 kg/m3
Snow, light density --------------------- ---------------------
(891 lb/yd3)
1,522 kg/m3
Sand, DRY, loose --------------------- ---------------------
(2,565 lb/yd3)
1,922 kg/m3
Sand, WET, packed --------------------- ---------------------
(3,240 lb/yd3)
1,362 kg/m3
Shale, broken --------------------- ---------------------
(2,295 lb/yd3)
529 kg/m3
Sulphur, broken --------------------- ---------------------
(1,620 lb/yd3)
IMPORTANT
Weights are approximations of estimated average volume and mass. Exposure to rain, snow or
ground water; settling or compaction due to overhead weight and chemical or industrial
processing or changes due to thermal or chemical transformations could all increase value of
weights listed in table.

Page 19
Page 20
1GENERAL MAINTENANCE
S0302000
R1
1GENERAL
MAINTENANCE
PROCEDURES
CAUTION!
GENERAL MAINTENANCE PROCEDURESS0302000

ALL MODELS ALL RANGES

January 2011
General Maintenance Procedures S0302000

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

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

Page 2
WELDING PRECAUTIONS AND GUIDELINES
IMPORTANT
To avoid accidents, personal injury and the possibility of causing damage to the machine or to
components, welding must only be performed by properly trained and qualified personnel, who
possess the correct certification (when required) for the specific welding fabrication or
specialized repair being performed.
WARNING!
Structural elements of the machine may be built from a variety of steels. These could contain
unique alloys or may have been heat treated to obtain particular strength characteristics. It is
extremely important that welding repairs on these types of steel are performed with the proper
procedures and equipment. If repairs are performed incorrectly, structural weakening or other
damage to the machine (that is not always readily visible) could be caused. Always consult
Doosan After Sales Service before welding on integral components (loader arm, frames, car
body, track frames, turntable, attachment, etc.) of the machine. It is possible that some types of
structurally critical repairs may require Magnetic Particle or Liquid Penetrant testing, to make
sure there are no hidden cracks or damage, before the machine can be returned to service.
CAUTION!
Always perform welding procedures with the proper safety equipment on hand. Adequate
ventilation and a dry work area are absolutely essential. Keep a fire extinguisher nearby and
always wear protective clothing and the recommended type of eye protection.

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

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

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

GENERAL PRECAUTIONS
Fluid level and condition should always be checked whenever any other type of maintenance service or
repair is being performed.
NOTE: If the unit is being used in an extreme temperature environment (in subfreezing climates or
in high temperature, high humidity tropical conditions), frequent purging of moisture
condensation from the hydraulic reservoir drain tap 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 filters are overloaded (and will require more
frequent replacement) or that disintegrating bearings or other component failures in the hydraulic circuit
may be imminent or have already occurred. Open the drain plugs on the main pump casings and check
and compare drain oil in the pumps. Look for evidence of grit or metallic particles.
Vibration or unusual noise during operation could be an indication of air leaking into the circuit (Refer to the
appropriate Troubleshooting section for component or unit for procedures.), or it may be evidence of a
defective pump. The gear type pilot pump could be defective, causing low pilot pressure, or a main pump
broken shoe or piston could be responsible.
NOTE: If equipped, indicated operating pressure, as shown on the multidisplay digital gauge on
the Instrument Panel ("F-Pump" and "R-Pump") will be reduced as a result of a
mechanical problem inside the pump. However, pressure loss could also be due to
cavitation or air leakage, or other faults in the hydraulic system.
Check the exterior case drain oil in the main pumps. If no metallic particles are found, make sure there is
no air in the system. Unbolt and remove the tank return drain line from the top part of the swing motor, both
travel motors and each main pump. If there is air in any one of the drain lines, carefully prefill the assembly
before bolting together the drain line piping connections. Run the system at low rpm.

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

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

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

GENERAL GUIDELINES
All parts must be clean to permit an effective inspection. During assembly, it is very important that no dirt or
foreign material enters unit being assembled. Even minute particles can cause malfunction of close fitting
parts such as thrust bearing, matched parts, etc.
WARNING!
Care should be exercised to avoid inhalation of vapors, exposure to skin and creating fire
hazards when using solvent type cleaners.
1. Clean all metal parts thoroughly using a suitable cleaning fluid. It is recommended that parts be
immersed in cleaning fluid and moved up and down slowly until all oils, lubricants, and/or foreign
materials are dissolved and parts are thoroughly clean.
2. For bearings that can be removed, soak them in a suitable cleaning fluid for a minute or two, then
remove bearings from cleaning fluid and strike flat against a block of wood to dislodge solidified
particles of lubricant. Immerse again in cleaning fluid to flush out particles. Repeat above operation
until bearings are thoroughly clean. To dry bearings, use moisture-free compressed air. Be careful to
direct air stream across bearing to avoid spinning bearings that are not lubricated. DO NOT SPIN
BEARINGS WHEN DRYING; bearings may be rotated slowly by hand to facilitate drying process.
3. Carefully inspect all bearing rollers, cages and cups for wear, chipping or nicks to determine
condition. Do not replace a bearing cone or cup individually without replacing mating cup or cone at
the same time. After inspection, dip bearings in light weight oil and wrap in clean lintless cloth or
paper to protect them until installation.
For those bearings that are to be inspected in place; inspect bearings for roughness of rotation,
scoring, pitting, cracked or chipped races. If any of these defects are found, replace bearings. Also,
inspect defective bearing housing and/or shaft for grooved, galled or burred conditions that indicate
bearing has been turning in its housing or on its shaft.
4. It is more economical to replace oil seals, O-rings, sealing rings, gaskets and retaining rings when
unit is disassembled than waiting for premature failures; refer to latest Micro Fiche and/or Parts Book
for replacement items. Be extremely careful when installing sealing members, to avoid cutting or
scratching.

Page 7
Curling under of any seal lip will seriously impair its efficiency. Apply a thin coat of Loctite #120 to
outer diameter, of metal casing, on oil seals to assure an oil tight fit into retainer. Use extreme care
not to get Loctite on lips of oil seals. If this happens, that portion of the seal will become brittle and
allow leakage.
When replacing lip type seals, make sure spring loaded side is towards oil to be sealed.
5. If available, use magna-flux or similar process for checking for cracks that are not visible to the eye.
Examine teeth on all gears carefully for wear, pitting, chipping, nicks, cracks or scores. Replace all
gears showing cracks or spots where case hardening has worn through. Small nicks may be
removed with suitable hone. Inspect shafts and quills to make certain they have not been sprung,
bent, or splines twisted, and that shafts are true.
NOTE: Spline wear is not considered detrimental except where it affects tightness of splined
parts.
Inspect thrust washers for distortion, scores, burs, and wear. Replace thrust washer if defective or
worn.
6. Inspect bores and bearing surfaces of cast parts and machined surfaces for scratches, wear, grooves
and dirt. Remove any scratches and burrs with crocus cloth. Remove foreign material. Replace any
parts that are deeply grooved or scratched which would affect their operation.
BEARING INSPECTION
The conditions of the bearing are vital to the smooth and efficient operation of the machinery. When any
component containing bearings is disassembled, always carefully examine the condition of the bearings
and all of its components for wear and damage.
Once the bearing is removed, clean all parts thoroughly using a suitable cleaning solution. If the bearing is
excessively dirty soak the bearing assembly in a light solution and move the bearing around until all
lubricants and or foreign materials are dissolved and the parts are thoroughly clean.
When drying bearings, moisture free compressed air can be used. Be careful not to direct the air in a
direction which will force the bearing to dry spin while not being properly lubricated.
After the bearings have been cleaned and dried, carefully inspect all bearing rollers, cages and cups for
wear, chipping or nicks. If the bearing cannot be removed and is to be inspected in place, check foe
roughness of rotation, scoring, pitting, cracked or chipped races. If any of these defects are found replace
the whole bearing assembly. NEVER replace the bearing alone without replacing the mating cup or the
cone at the same time.
After inspection lightly coat the bearing and related parts with oil and wrap in a clean lintless cloth or paper
and protect them from moisture and other foreign materials until installation.
It is also important to inspect the bearing housing and/or shaft for grooved, galled or burred conditions that
indicate that the bearing has been turning in its housing or on its shaft.
If available, use magna-flux or similar process for checking for cracks that are not visible to the naked eye.
The following illustrations will aid in identifying and diagnosing some of the bearing related problems.
NOTE: The illustrations will only show tapered roller bearings, but the principles of identifying,
diagnosing and remedying the defects are common to all styles and types of bearings.

Page 8
Normal Bearing
Smooth even surfaces with no discoloration or
marks.
Figure 2
Bent Cage
Cage damage due to improper handling or tool
usage.
Replace bearing.
Figure 3
Figure 4
Galling
Metal smears on roller ends due to overheat,
lubricant failure or overload.
Replace bearing - check seals and check for
proper lubrication.
Figure 5

Page 9
Abrasive Step Wear
Pattern on roller ends caused by fine abrasives.
Clean all parts and housings, check all parts
and housings, check seals and bearings and
replace if leaking, rough or noisy.
Figure 6
Etching
Bearing surfaces appear gray or grayish black
in color with related etching away of material
usually at roller spacing.
Replace bearings - check seals and check for
proper lubrication.
Figure 7
Misalignment
Outer race misalignment due to foreign object.
Clean related parts and replace bearing. Make
sure races are properly seated.
Figure 8
Indentations
Surface depressions on race and rollers caused
by hard particles of foreign materials.
Clean all parts and housings, check seals and
replace bearings if rough or noisy.
Figure 9

Page 10
Fatigue Spalling
Flaking of surface metal resulting from fatigue.
Replace bearing - clean all related parts.
Figure 10
Brinelling
Surface indentations in raceway caused by
rollers either under impact loading or vibration
while the bearing is not rotating.
Replace bearing if rough or noisy.
Figure 11
Cage Wear
Wear around outside diameter of cage and roller
pockets caused by abrasive material and
inefficient lubrication.
Replace bearings - check seals.
Figure 12
Abrasive Roller Wear
Pattern on races and rollers caused by fine
abrasives.
Clean all parts and housings, check seals and
bearings and replace if leaking, rough or noisy.
Figure 13

Page 11
Cracked Inner Race
Race cracked due to improper fit, cocking or
poor bearing seat.
Replace all parts and housings, check seals and
bearings and replace if leaking.
Figure 14
Smears
Smearing of metal due to slippage caused by
poor fitting, lubrication, overheating, overloads
or handling damage.
Replace bearings, clean related parts and check
for proper fit and lubrication.
Replace shaft if damaged.
Figure 15
Frettage
Corrosion set up by small relative movement of
parts with no lubrication.
Replace bearing. Clean all related parts. Check
seals and check for proper lubrication.
Figure 16

Page 12
Heat Discoloration
Heat discoloration can range from faint yellow to
dark blue resulting from overload or incorrect
lubrication.
Excessive heat can cause softening of races or
rollers.
To check for loss of temper on races or rollers, a
simple file test may be made. A file drawn over a
tempered part will grab and cut metal, whereas
a file drawn over a hard part will glide readily
with no metal cutting.
Figure 17
Replace bearing if over heating damage is
indicated. Check seals and other related parts
for damage.
Stain Discoloration
Discoloration can range from light brown to
black caused by incorrect lubrication or
moisture.
if the stain can be removed by light polishing or
if no evidence of overheating is visible, the
bearing can be reused.
Check seals and other related parts for damage.
Figure 18

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

January 2011
Standard Torques S0309000

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

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

Page 2
TORQUE VALUES FOR STANDARD METRIC
FASTENERS
NOTE: The units for the torque values are kg•m (ft lb).
Grade
Dia. x Pitc
h (mm)
3.6 4.6 4.8 5.6 5.8 6.6 6.8 6.9 8.8 10.9 12.9
(4A) (4D) (4S) (5D) (5S) (6D) (6S) (6G) (8G) (10K) (12K)
0.15 0.16 0.25 0.22 0.31 0.28 0.43 0.48 0.50 0.75 0.90
M5 x Std.
(1.08) (1.15) (1.80) (1.59) (2.24) (2.02) (3.11) (3.47) (3.61) (5.42) (6.50)
0.28 0.30 0.45 0.40 0.55 0.47 0.77 0.85 0.90 1.25 1.50
M6 x Std.
(2.02) (2.16) (3.25) (2.89) (3.97) (3.39) (5.56) (6.14) (6.50) (9.04) (10.84)
0.43 0.46 0.70 0.63 0.83 0.78 1.20 1.30 1.40 1.95 2.35
M7 x Std.
(3.11) (3.32) (5.06) (4.55) (6.00) (5.64) (8.67) (9.40) (10.12) (14.10) (16.99)
0.70 0.75 1.10 1.00 1.40 1.25 1.90 2.10 2.20 3.10 3.80
M8 x Std.
(5.06) (5.42) (7.95) (7.23) (10.12) (9.04) (13.74) (15.18) (15.91) (22.42) (27.48)
0.73 0.80 1.20 1.00 1.50 1.35 2.10 2.30 2.40 3.35 4.10
M8 x 1
(5.28) (5.78) (8.67) (7.23) (10.84) (9.76) (15.18) (16.63) (17.35) (24.23) (29.65)
1.35 1.40 2.20 1.90 2.70 2.35 3.70 4.20 4.40 6.20 7.20
M10 x Std.
(9.76) (10.12) (15.91) (13.74) (19.52) (19.99) (26.76) (30.37) (31.18) (44.84) (52.07)
1.50 1.60 2.50 2.10 3.10 2.80 4.30 4.90 5.00 7.00 8.40
M10 x 1
(10.84) (11.57) (18.08) (15.18) (22.42) (20.25) (31.10) (35.44) (36.16) (50.63) (60.75)
2.40 2.50 3.70 3.30 4.70 4.20 6.30 7.20 7.50 10.50 12.50
M12 x Std.
(17.35) (18.08) (26.76) (23.86) (33.99) (30.37) (45.56) (52.07) (54.24) (75.94) (90.41)
2.55 2.70 4.00 3.50 5.00 4.50 6.80 7.70 8.00 11.20 13.40
M12 x 1.5
(18.44) (19.52) (28.93) (25.31) (36.16) (32.54) (49.18) (55.69) (57.86) (81.00) (96.92)
3.70 3.90 6.00 5.20 7.50 7.00 10.00 11.50 12.00 17.00 20.00
M14 x Std.
(26.76) (28.20) (13.23) (37.61) (54.24) (50.63) (72.33) (83.17) (86.79) (122.96) (144.66)
4.10 4.30 6.60 5.70 8.30 7.50 11.10 12.50 13.00 18.50 22.00
M14 x 1.5
(29.65) (31.10) (47.73) (41.22) (60.03) (54.24) (80.28) (90.41) (94.02) (11.26) (158.12)
5.60 6.00 9.00 8.00 11.50 10.50 15.50 17.90 18.50 26.00 31.00
M16 x Std.
(40.50) (43.39) (65.09) (57.86) (83.17) (75.94) (112.11) (129.47) (133.81) (188.05) (224.22)
6.20 6.50 9.70 8.60 12.50 11.30 17.00 19.50 20.00 28.00 35.50
M16 x 1.5
(44.84) (47.01) (70.16) (62.20) (90.41) (81.73) (122.96) (141.04) (144.66) (202.52) (256.77)
7.80 8.30 12.50 11.00 16.00 14.50 21.00 27.50 28.50 41.00 43.00
M18 x Std.
(56.41) (60.03) (90.41) (79.56) (115.72) (104.87) (151.89) (198.90) (206.14) (296.55) (311.01)
9.10 9.50 14.40 12.50 18.50 16.70 24.50 27.50 28.50 41.00 49.00
M18 x 1.5
(65.82) (68.71) (104.15) (90.41) (133.81) (120.79) (177.20) (198.90) (206.14) (296.55) (354.41)
11.50 12.00 18.00 16.00 22.00 19.00 31.50 35.00 36.00 51.00 60.00
M20 x Std.
(83.17) (86.79) (130.19) (115.72) (159.12) (137.42) (227.83) (253.15) (260.38) (368.88) (433.98)
12.80 13.50 20.50 18.00 25.00 22.50 35.00 39.50 41.00 58.00 68.00
M20 x 1.5
(92.58) (97.64) (148.27) (130.19) (180.82) (162.74) (253.15) (285.70) (296.55) (419.51) (491.84)
15.50 16.00 24.50 21.00 30.00 26.00 42.00 46.00 49.00 67.00 75.00
M22 x Std.
(112.11) (115.72) (177.20) (151.89) (216.99) (188.05) (303.78) (332.71) (354.41) (484.61) (542.47)
17.00 18.50 28.00 24.00 34.00 29.00 47.00 52.00 56.00 75.00 85.00
M22 x 1.5
(122.96) (133.81) (202.52) (173.59) (245.92) (209.75) (339.95) (44.76) (405.04) (542.47) (614.80)
20.50 21.50 33.00 27.00 40.00 34.00 55.00 58.00 63.00 82.00 92.00
M24 x Std.
(148.27) (155.50) (238.68) (195.29) (289.32) (245.92) (397.81) (419.51) (455.67) (593.10) (655.43)
23.00 35.00 37.00 31.00 45.00 38.00 61.00 67.00 74.00 93.00 103.00
M24 x 1.5
(166.35) (253.15) (267.62) (224.22) (325.48) (202.52) (441.21) (484.61) (535.24) (672.66) (744.99)

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

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

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

8 8
Quenched and Tempered Special Carbon or Alloy Steel.
Recommended torque, in foot pounds, for all Standard Application Nuts and Bolts, provided:
1. All thread surfaces are clean and lubricated with SAE 30 engine oil. (See Note.)
2. Joints are rigid, that is, no gaskets or compressible materials are used.
3. When reusing nuts or bolts, use minimum torque values.
NOTE: Multiply the standard torque by:
0.65 when finished jam nuts are used.
0.70 when Molykote, white lead or similar mixtures are used as lubricants.
0.75 when parkerized bolts or nuts are used.
0.85 when cadmium plated bolts or nuts and zinc bolts w/waxed zinc nuts are used.
0.90 when hardened surfaces are used under the nut or bolt head.
NOTE: When reusing bolts and nuts in service, use minimum torque values.

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

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

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

NOMINAL THREAD
DIAMETER
KILOGRAM METER FOOT POUNDS
(kg•m) (ft lb)
1/4" 1.1 8
5/16" 2.2 16
3/8" 3.9 28
7/16" 6.2 45
1/2" 9.7 70
9/16" 13.8 100
5/8" 19.4 140
3/4" 33.2 240
7/8" 53.9 390
1" 80.2 580
1 - 1/8" 113.4 820
1 - 1/4" 160.4 1160
1 - 3/8" 210.2 1520
279.4 2020
1 - 1/2"
347.1 2510
1 - 3/4"
522.8 3780
2

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

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

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

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

"Ultra-Tite"

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

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

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

Page 8
TORQUE WRENCH EXTENSION TOOLS
Very large diameter, high grade fasteners (nuts, bolts, cap screws, etc.) require a great deal of turning
force to achieve recommended tightening torque values.
Common problems that could occur as a result are:
• Recommended torque exceeds the measuring capacity of the torque wrench.
• Specialized sockets do not fit the adapter on the front end (nose) of the torque wrench.
• Generating adequate force on the back end (handle) of the wrench is difficult or impossible.
• Restricted access or an obstruction may make use of the torque wrench impossible.
• A unique application requires fabrication of an adapter or other special extension.
Most standard torque wrenches can be adapted to suit any one of the proceeding needs or situations, if
the right extension tool is used or fabricated.
TORQUE MULTIPLICATION
A wrench extension tool can be used to
increase the tightening force on a high capacity
nut or bolt.
For example, doubling the distance between the
bolt and the back (handle) end of the torque
wrench doubles the tightening force on the bolt.
It also halves the indicated reading on the scale
or dial of the torque wrench. To accurately
adjust or convert indicated scale or dial
readings, use the following formula:
I = A x T / A + B where:
I = Indicated force shown on the torque wrench Figure 1
scale or dial.
T = Tightening force applied to the nut or bolt (actual Torque).
A = Length of the torque wrench (between the center of the nut or bolt and the center of the handle).
B = Length of the extension.
As an example, if a 12" extension is added to a 12" torque wrench, and the indicated torque on the dial
reads "150 ft lb," the real force applied to the bolt is 300 ft lb:
AxT 12 x 300 3600

I= = = = 150
A+B 12 + 12 24
NOTE: The formula assumes that there is no added deflection or "give" in the joint between the
extension and torque wrench. Readings may also be inaccurate:
• If the extension itself absorbs some of the tightening force and starts to bend or bow out.
• If an extension has to be fabricated that is not perfectly straight (for example, an extension made
to go around an obstruction, to allow access to a difficult to tighten fastener), the materials and
methods used must be solid enough to transmit full tightening torque.

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

(For coated threads, prelubricated assemblies.)
CAUTION!
Disassembly, overhaul and replacement of components on the machine, installation of new or
replacement parts and/or other service related maintenance may require the use of thread or
flange sealing assembly compound.
Use the information on this page as a general guide in selecting specific formulas that will meet
the particular requirements of individual assembly installations. Doosan does not specifically
endorse a specific manufacturer or brand name but the following table of "Loctite" applications
is included for which cross-references to other makers' products should also be widely
available.
IMPORTANT
Use primer "T" or "N" for all cold weather assembly of fastener adhesives, with Thread locker
sealers 222, 242/243, 262, 271, 272, or 277.

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

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

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

Page 11
IV. "Loctite" retaining compounds

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

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

Page 12
1UPPER STRUCTURE
Return to Master Table of Contents
S0403030K
R3
1COUNTERWEIGHT
CAUTION!
COUNTERWEIGHT S0403030K

January 2011
Counterweight S0403030K
Page 1
TABLE OF CONTENTS
Specifications ................................................................................................. 3
Counterweight ................................................................................................ 3
S0403030K Counterweight
Page 2
SPECIFICATIONS
NOTE: Weight.
Model Weight Serial Number Range

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

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

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

January 2011
Fuel Transfer Pump S0405500

Page 1
Solar 220LL 1001 and Up
Solar 220N-V 1001 and Up
Solar 225NLC-V 1001 and Up
Solar 55W-V PLUS 1001 and Up
TABLE OF CONTENTS
General Description........................................................................................ 3
Theory of Operation ................................................................................ 3
Troubleshooting.............................................................................................. 4
Replacement of Rotor and Vane .................................................................... 4
Replacement of Rear Cover........................................................................... 5
Replacement of Armature .............................................................................. 6
S0405500 Fuel Transfer Pump

Page 2
GENERAL DESCRIPTION
THEORY OF OPERATION
Figure 1
Reference Reference
Number Number
1 Motor 3 Inlet Hose
2 Pump 4 Outlet Hose
2-1 Pump Cover 5 Check Valve
2-2 Rotor and Vane 6 Strainer Cap
The fuel pump consists of a motor, pump,

switch, and hose assembly.
Figure 2

Page 3
TROUBLESHOOTING
On some pumps the ON-OFF switch is installed separately at a remote location.
A thermal limiter, built into the motor, will automatically shut off power if motor is overheating to protect it
from being damaged.
NOTE: OPEN TEMP: 150 ±5°C (302 ±41°F). After circuit is automatically shut off due to
overheating the pump will stop running. When temperature drops below 143°C (289°F) the
circuit will reactivate allowing the pump to restart.
Figure 3 WITH TOGGLE SWITCH Figure 4 WITHOUT TOGGLE SWITCH
Check resistance at connectors "A." If reading is zero, or very close to zero, the motor is bad and must be
replaced.
On units equipped with a toggle switch, check the resistance through the toggle switch, while the switch is
in the "ON" position. If continuity is not present, the switch is bad. Be sure to check resistance through the
motor.
REPLACEMENT OF ROTOR AND VANE

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

Page 4
Insert vane, with the circled edge of vane facing
in the counterclockwise direction. (Detail A)
Insert a new O-ring again at reassembly of the
pump cover.
Figure 6
REPLACEMENT OF
REAR COVER
Brush assembly and a thermal limiter are
installed in the rear cover. If you find any
damage, replace them with new ones.
Remove the switch cover and screw (M5 x L95)
from the rear cover.
Remove cover.
At reassembly of rear cover, widen the space of
the brush and insert it to the armature. Then fit Figure 7
the hole of screw in the housing.
Be careful when installing the screw. The cover
screw may be attracted by the motor magnet.

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

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


January 2011
Hydraulic Oil Tank S0406060C

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

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

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

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

Page 6
3
SECTION A
S=1/2.5
7
SECTION B
S=1/5
BAS0120L
Reference Reference
Number Number

Page 7
SPECIFICATIONS
Mega 200-V Mega 250-V

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

Page 8
1LOWER STRUCTURE AND CHASSIS
S0502050C
1CENTER JOINT
(ARTICULATION JOINT)
CAUTION!
CENTER JOINT (ARTICULATION JOINT)S0502050C


January 2011
Center Joint (Articulation Joint) S0502050C

Page 1
TABLE OF CONTENTS
Maintenance Standard ............................................................................ 4
S0502050C Center Joint (Articulation Joint)

Page 2
GENERAL DESCRIPTION
The loader frame is an articulated type: the front frame is joined to the rear frame with two hinge pins
around which the loader pivots for steering.
CAUTION!
When the loader is steered, the area near
the center hinge pins becomes so narrow
that you might get caught between the
front and rear frames. Before trying to
service the loader, make sure to set the
frame lock plate.
Before moving (traveling) the loader, make
sure the frame lock plate is set to the
original position. Figure 1

Page 3
MAINTENANCE STANDARD
DETAIL B
S=1/2
(LOWER HINGE BEARING)
DETAIL A
S=1/2
(UPPER HINGE BEARING)
AOS0170L
Figure 2

Page 4
Unit: mm
No. Check item Criteria Remedy
Standard Standard Clearance
Tolerance
size clearance limit
Clearance between upper -0.065 +0.029 0.034 -
1 57.2 -
hinge pin and rear frame -0.101 -0.031 0.13
Clearance between upper
-0.065 +0.035 0.070 -
2 hinge pin and spacer 57.2 -
-0.101 +0.005 0.136
(small)
Clearance between upper -0.065 +0.136 0.215 -
3 57.2 -
hinge pin and bearing -0.101 -0.090 0.264
Clearance between upper
-0.065 +0.035 0.070 -
4 hinge pin and spacer 57.2 -
-0.101 +0.005 0.136
(large)
Clearance between rear +0.076 -0.036 0.112 -
5 68 -
frame and spacer (large) +0.030 -0.090 0.066
Replace
Clearance between front
-0.013 +0.013 0.013 -
6 frame and upper hinge 112.7 -
-0.039 -0 0.103
bearing
Clearance between lower -0.065 +0.029 0.034 -
7 57.2 -
hinge pin and rear frame -0.101 -0.031 0.130
Clearance between lower -0.065 -0.037 0.015 -
8 57.2 -
hinge pin and bearing -0.101 -0.05 0.064
Clearance between front
-0.013 +0.013 0.013 -
9 frame and lower hinge 112.7 -
-0.039 -0 0.103
bearing
Height of upper hinge 57.2 +0.035
11 +0.005 - - 0 0
spacer (small)
Height of upper hinge 57.2 +0.035
12 +0.005 - - 0 0
spacer (large)
Shim thickness for upper
1.124 -
13 hinge and retainer - - - -
1.644
(front frame)
Shim thickness for upper
14 hinge and retainer 1.5-2.5 - - - -
(rear frame)
Tightening torque of upper When adjusting with shim: 4 ±0.2 kg•m
15 hinge retainer mounting
bolt Final value: 8 ±1.0 kg•m
Tightening torque of upper When adjusting with shim: 4 ±0.2 kg•m
16 hinge retainer mounting
bolt Final value: 13 ±1.0 kg•m
Tightening torque of upper Retight
17 8 ±1.0 kg•m en
hinge pin mounting bolt
Tightening torque of lower When adjusting with shim: 4 ±0.2 kg•m
18
hinge pin mounting bolt Final value: 8 ±1.0 kg•m
Shim thickness for lower
19 hinge and retainer 1.124 - 1.644 mm
(front frame)

Page 5
Page 6
1ENGINE AND DRIVE TRAIN
S0602270
2REAR AXLE
(ZF - MT-L 3075)
CAUTION!
REAR AXLE (ZF - MT-L 3075)S0602270


January 2011
Rear Axle (ZF - MT-L 3075) S0602270

Page 1
TABLE OF CONTENTS
Outline..................................................................................................... 5
Mega 250-V ..................................................................................... 6
Lubrication Instructions ........................................................................... 8
Oil Drain ........................................................................................... 9
Oil Filling .......................................................................................... 9
Check............................................................................................... 9
Oil Change Intervals ........................................................................ 9
Oil Level Check................................................................................ 9
Bleeders........................................................................................... 9
Brake................................................................................................ 9
Brake Bleeding at Vehicle................................................................ 9
Make Wear Measurement on Multidisk Brake ...................................... 10
Wear measurement - Multidisk brake ............................................ 10
Inscriptions on Model Identification Plate.............................................. 11
Torque Limits for Screws ...................................................................... 12
Torque Limits for Screws (In Nm) According to ZF-Standards 14812
Examples of gear-tooth-contact patterns for the gleason gear-tooth system
13
Special Tool.................................................................................................. 16
List of Special Tools for Disassembly and Reassembly........................ 16
ZF - Multitrac Rigid Axle MT-L 3075............................................................. 26
Disassembly of output and brake.......................................................... 26
Reassembly of Output and Brake ......................................................... 36
Disassembly of differential carrier and brake tubes .............................. 49
Disassembly of differential carrier.................................................. 49
Disassembly of limited slip differential ........................................... 52
Disassembly of drive pinion ........................................................... 54
Disassembly of brake tubes........................................................... 56
Reassembly of brake tubes and differential carrier............................... 58
Reassembly of brake tubes ........................................................... 58
S0602270 Rear Axle (ZF - MT-L 3075)

Page 2
Reassembly of differential carrier .................................................. 60
Determine shim thickness for a perfect tooth contact pattern........ 60
Install drive pinion .......................................................................... 62
Reassembly of limited slip differential............................................ 66
Determine disk clearance 0.2 ~ 0.8 mm ........................................ 69
Adjust backlash and bearing preload............................................. 72

Page 3
Page 4
GENERAL DESCRIPTION
OUTLINE
Rear Axle
Trunnion Mounting
Type
Semifloating
Overall Reduction Ratio 23.680:1
Hub Reduction Ratio 6:1
Differential Reduction Ratio 3.946:1
Differential Type Limited Slip (Locking Ratio:45%)
Max. Output Torque 8,000 kg•m (57,900 ft lb)
24,500 kg
Max. Static Load
(54,010 lb)
Type Multi Wet Disk

Brake 3,602 kg•m @ 68.5 Bar per axle
Torque
(26,053 ft lb @ 993 psi)
Drive Flange 6C

Page 5
Mega 250-V
Figure 1 DRIVE AXLE ASSEMBLY

Page 6
Reference Reference
Number Number
1 Front Axle 6 Bushing
2 Rear Axle 7 Thrust Plate
3 Axle Support (Front) 8 Thrust Cap
4 Axle Support (Rear) 9 Thrust Washer
5 Packing
NOTE: 1) 28 kg•m (123 ft lb)

NOTE: 2) 95 ±5 kg•m (687 ±36 ft lb)
NOTE: 3) 95 ±5 kg•m (687 ±36 ft lb)
NOTE: 4) Inner surface:Grease (Assemble with chamfered surface toward axle)
NOTE: 5) Assemble with lip pointing outward.
NOTE: 6) Assemble with groove pointing toward plate (7)
NOTE: 7) Apply grease and assemble
NOTE: 8) 28 kg•m (202 ft lb) Threaded area:Loctite #242
NOTE: 9) Tightening Torque:80±8 kg•m (Bolt M22x1.5)

Page 7
LUBRICATION INSTRUCTIONS
Oils according to ZF List of lubricants TE-ML 05 that are allowed to be used for ZF-Axles MT-L 3075.
The basic condition for a correct oil change of axle is the horizontal plane of installation in every direction.
Place vehicle in a horizontal position.
All drain, filter and level plugs must be cleaned carefully before opening.
Only drain oil immediately after a longer running time.
Reference
Description
Number
1 Oil Drain Hole M24x1.5
Axle Casing
2 Oil Drain Hole M24x1.5
Outputs
3 Oil Filler Hole M36x1.5
4 Brake Bleeder
5 Bleeder
Figure 2
Figure 3

Page 8
Oil Drain
Remove drain plugs 1 and 2 and drain oil.
Oil Filling
Provide drain plugs (M24x1.5) with new O-ring and install them.
Tightening torque MA = 7.14 kg•m (51.63 ft lb).
Fill oil to overflow on fill/level plug 3.
Filling quantity approximately 24 liters (6.3 U.S. gal.).
Check
Check oil level after a few minutes and fill up to specified level, until level remains constant.
Provide fill/level plug (M36x1.5) with new O-ring and install it.
Oil Change Intervals

1st oil change after 500 operating hours, further oil changes every 1,000 operating hours, however, at least
once a year.
Oil Level Check

Oil level check once a month, but especially before starting a vehicle with new or repaired axles and axle
components respectively.
Bleeders
At initial operation and during the oil change intervals, clean Bleeder 3 and 5 and make a functional check.
Brake
For the pneumatic-hydraulic or via an accumulator system operated brake actuation following oils are
permissible:
1. Motor oils SAE 10W according to specification MIL-L 2104 C, MIL-L 46152, API-CC, CD, SC, SD, SE
2. ATF-Oils Type A, Suffix A, Dexron of II D
Brake Bleeding at Vehicle

1. Open bleeder (4).
2. Slowly depress the brake pedal until oil flows from bleeder.
3. Close bleeder again.
4. Slowly pressurize the brake and hold pressure for some seconds.
NOTE: The brake piston extends and the cylinder chamber fills p with oil. The air accumulates in
upper section of cylinder chamber.
5. Release the brake pedal and loosen the brake.
NOTE: The reversing piston presses the air from upper section of cylinder into brake line.

Page 9
6. Open bleeder (4) again.
NOTE: Repeat procedure - Item 3 ~ 7 - until - at Item 7 - from beginning of actuation no more air
exits from bleeder.
MAKE WEAR MEASUREMENT ON MULTIDISK BRAKE

NOTE: A wear measurement on multidisk brake has to be made at least once a year, especially in
case of a changed braking behavior like, e.g.
• Braking noise
• Braking power reduced
• Deceleration changed
• Brake fluid level changed
• Braking pressure changed
Wear measurement - Multidisk brake

A wear measurement has to be made on both
output sides.
Remove plug, actuate brake and determine
Dimension X according to Figure 4 and Figure 5
using a feeler gauge. Dimension X corresponds
with thickness of inner clutch disk on piston
side.
NOTE: If Dim. X <= 4.0 mm, the lined
disks on both output sides have
to be replaced.
Figure 4
Following to this provide level plug with a new
O-ring and install it.
Tightening torque MA = 7.14 kg•m (51.63 ft lb)
Figure 5

Page 10
INSCRIPTIONS ON MODEL IDENTIFICATION PLATE
Figure 6
Reference
Description
Number
1 Axle Type
2 Axle Serial No.
3 ZF - Parts - List No.
4 Total-Ratio of Axle / Version with or without
ZF-multidisk self locking differential
5 Type of lubricant
6 Lubricant specifications
NOTE: ZF - List of lubricants for ZF - Axles TE - ML 05

Page 11
TORQUE LIMITS FOR SCREWS
Torque Limits for Screws (In Nm) According to ZF-Standards 148

Coefficient of friction: m total 0.12 for screws and nuts without after treatment and for phosphated
nuts.
NOTE: Tighten by hand.
Torque limits, if not specifically shown, can be taken from following list:
Metric ISO-Standard Thread DIN 13 Metric ISO-Fine Thread DIN 13

Size 8.8 10.9 12.9 Size 8.8 10.9 12.9
M4 2.8 4.1 4.8 M8x1 24 36 43
M5 5.5 8.1 9.5 M9x1 36 53 62
M6 9.5 14.0 16.5 M 10 x 1 52 76 89
M7 15 23.0 28.0 M 10 x 1, 25 49 72 84
M8 23 34 40 M 12 x 1, 25 87 125 150
M 10 46 68 79 M 12 x 1, 5 83 120 145
M 12 79 115 135 M 14 x 1, 5 135 200 235
M 14 125 185 215 M 16 x 1, 5 205 300 360
M 16 195 280 330 M 18 x 1, 5 310 440 520
M 18 280 390 460 M 18 x 2 290 420 490
M 20 390 560 650 M 20 x 1, 5 430 620 720
M 22 530 750 880 M 22 x 1, 5 580 820 960
M 24 670 960 1,100 M 24 x 1, 5 760 1,100 1,250
M 27 1,000 1,400 1,650 M 24 x 2 730 1,050 1,200
M 30 1,350 1,900 2,250 M 27 x 1, 5 1,100 1,600 1,850
M 33 1,850 2,600 3,000 M 27 x 2 1,050 1,500 1,800
M 36 2,350 3,300 3,900 M 30 x1, 5 1,550 2,200 2,550
M 39 3,000 4,300 5,100 M 30 x 2 1,500 2,100 2,500
M 33 x 1, 5 2,050 2,900 3,400
M 33 x 2 2,000 2,800 3,300
M 36 x 1, 5 2,700 3,800 4,450
M 36 x 3 2,500 3,500 4,100
M 39 x 1, 5 3,450 4,900 5,700
M 39 x 3 3,200 4,600 5,300

Page 12
EXAMPLES OF GEAR-TOOTH-CONTACT PATTERNS FOR THE GLEASON GEAR-TOOTH SYSTEM
Ideal Tooth-contact Pattern I. E. Pinion Distance Is Correct
Coast side (concave).
Figure 1
Drive side (convex).
Figure 2
Pinion distance must be increased.
Figure 3

Page 13
Figure 4
Figure 5
Pinion distance must be decreased.
Figure 6
Figure 7

Page 14
Figure 8

Page 15
SPECIAL TOOL
LIST OF SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY
ZF - Multitrac MT - L 3075 / Output and Brake
4474 051 009 / 011
Disassembly Reassembly Subject No. Designation / Application Special Tools (S)

Figure 16 5870 350 000 Assembly truck assembly with tilting device
5870 350 077 Holding fixture (set of 2)
5870 350 075 Clamps
Figure 19 5870 345 065 Pry bar (set of 2)
Figure 49
Figure 51
Figure 20 5870 650 001 Striker
Figure 21 Figure 92 5870 656 077 Socket Spanner #
5870 912 028 Centering bracket #
Figure 22 Figure 90 5870 281 043 Lifting bracket
Figure 27 5870 300 019 Extractor
Figure 28 Figure 83 5870 900 015 Set of external pliers A1-A2-A3-A4
Figure 29 5870 971 002 Three - armed puller
Figure 30 5873 001 026 Gripping insert
5873 026 100 Back off insert
Figure 31 5870 970 007 Two-armed puller
Figure 46
5870 654 034 Clamping bracket (set of 2)
5870 506 140 Press bushing
Figure 36 5870 900 016 Set of external pliers A11-A21-A31-A41
Figure 40 Figure 69 5870 900 051 Assembly pliers #
Figure 43 5870 400 001 Adjusting device
Figure 47 Figure 59 5870 281 047 Lifting chain
5870 204 071 Eyebolts (set of 2)
Figure 50 5873 014 016 Rapid grip #
5873 004 001 Basic device #
Figure 52 5870 610 010 Wheel bolt puller - Basic set
5870 610 005 Insert 3/4" - 16UNF
Figure 54 5870 506 141 Pressure ring # EBM = 16.8 - 0.2 mm
Figure 56 5870 051 052 Driver # EBM = 6 + 0.2 mm
Figure 65 5870 345 096 Assembly fixture #
Figure 66
Figure 72 5870 705 011 Drive mandrel EBM = 4 mm
Figure 79 5870 204 029 Adjusting screws (set of 2)
Figure 84 5870 200 072 Digital depth gauge # 200 mm
Figure 87 5870 200 022 Straightedge # 580 mm
5870 200 066 Gauge blocks # 60 mm

Page 16
Figure 96 5870 287 007 HD-Pump #
5870 950 115 Measuring hub # 9/16" - 18UNF
5870 350 075 Clamps
Figure 101 Figure 189
Figure 104 Figure 184 5870 281 044 Lifting tackle
5870 350 004 Holding fixture (Clamping adapter)
5870 350 101 Clamping ring (CK)
Figure 107 Figure 180 5870 656 080 Socket spanner
Figure 108 5870 221 500 Hot-air blower # 230 V
Figure 112 5873 001 037 Gripping insert #
5870 026 100 Back off insert (size 1)
5873 002 001 Basic set (size 2)
5870 240 025 Fixture #
Figure 122 5870 970 007 Two-armed puller #
5873 002 001 Basic set (size 2)
Figure 140 5870 500 028 Adapter pieces #
Figure 141 5870 500 001 Measuring shaft #
5870 351 016 Measuring pin #
5870 351 021 Stop washer
Figure 170 5870 200 066 Gauge blocks # 60 mm
Figure 171
Figure 145 5870 058 089 Driver
5870 260 002 Handle
5870 260 002 Handle
5870 260 002 Handle
Figure 155 5870 048 225 Driver EBM = 16.6 mm
Figure 180 5870 200 055 Magnetic stand #
5870 200 057 Dial indicator #
Figure 181 5870 200 058 Caliper gauge 0 - 500 mm

Page 17
# Particularly important special tools for partial
repair (wear part repair).

Page 18
Figure 9

Page 19
Figure 10

Page 20
Figure 11

Page 21
Figure 12

Page 22
Figure 13

Page 23
Figure 14

Page 24
Figure 15

Page 25
ZF - MULTITRAC RIGID AXLE MT-L 3075
DISASSEMBLY OF OUTPUT AND BRAKE
1. Fasten axle on assembly truck.
(S) Assembly truck 5870 350 000
(S) Holding fixtures 5870 350 077
(S) Clamps 5870 350 075
Figure 16
2. Remove plugs (3x, Figure 17 and Figure
18) and drain oil from axle casing.
Figure 17
Figure 18

Page 26
3. Remove cover from output shaft.
(S) Pry bar set 5870 345 065
Figure 19
4. Remove slotted pin using striker (S) from
bore in slotted nut.
(S) Striker 5870 650 001
Figure 20
5. Remove slotted nut.
(S) Socket spanner 5870 656 077
(S) Centering bracket 5870 912 028
Figure 21
6. Secure output using lifting tackle (S) and
remove hexagon screws.
(S) Lifting bracket 5870 281 043
Figure 22

Page 27
7. Separate complete output from axle
casing.
NOTE: Pay attention to released O-ring
(see arrow).
Figure 23
8. Remove stub shaft from sun gear shaft.
NOTE: Pay attention to possibly
released shim(s).
Figure 24
9. Remove shim(s) from sun gear shaft.
Figure 25
10. Remove sun gear shaft from planet gears.
Figure 26

Page 28
11. Remove planet carrier from brake housing.
(S) Internal extractor 5870 300 019
Figure 27
12. Remove retaining ring.
(S) Set of external pliers 5870 900 015
Figure 28
13. Remove planet gear and inner bearing
race.
(S) Three-armed puller 5873 971 002
Figure 29
14. Remove inner bearing race.
(S) Gripping insert 5873 001 026
(S) Basic set 5873 026 100
Figure 30

Page 29
15. Separate ring gear from brake housing
using two-armed puller (S).
(S) Two-armed puller 5870 970 007
Figure 31
16. Remove O-rings (see arrows) from
annular grooves of ring gear.
Figure 32
17. Remove O-ring (see arrow) from recess of
brake housing.
Figure 33
18. Remove disk pack from brake housing.
Figure 34

Page 30
19. Install slotted pins (6x) in support shim
until they are flush mounted.
Figure 35
Figure 36
21. Remove piston from brake housing using
compressed air.
Figure 37
22. Remove support shim from piston using
automatic piston adjusting.
Figure 38

Page 31
23. Remove slotted pins (6x) from support
shim.
Figure 39
24. Preload cup springs using a press and
remove retaining ring.
(S) Assembly pliers 5870 900 051
(S) Assembly fixture 5870 345 096
Figure 40
25. Remove pin from support shim and
remove released cup springs.
Figure 41
26. Remove gripping rings from pin.
Figure 42

Page 32
27. Remove piston from brake housing.
(S) Adjusting device 5870 400 001
Figure 43
28. Remove guide ring, support rings and
U-rings from annular grooves of brake
housing.
NOTE: See Figure 45, for installation
position of single parts.
Figure 44
Reference
Description
Number
1 Brake housing
2 Guide ring
3 Support ring
4 U-ring
5 U-ring
6 Support ring
7 Output shaft
Figure 45

Page 33
29. Remove brake housing using two-armed
puller (S) from output shaft and remove
released inner bearing race.
(S) Clamping bracket 5870 654 034
(S) Press bushing 5870 506 140
Figure 46
30. Remove brake housing with lifting tackle
(S) from output shaft.
(S) Lifting chain 5870 281 047
(S) Eyebolts 5870 204 071
Figure 47
31. If necessary drive both outer bearing races
from bearing bores in brake housing.
Figure 48
32. Remove shaft seal from brake housing.
(S) Pry bar set 5870 345 065
Figure 49

Page 34
33. Remove inner bearing race from output
shaft.
(S) Rapid grip 5873 014 016
(S) Basic set 5873 004 001
Figure 50
34. Remove bearing sheet from output shaft.
(S) Pry bar set 5870 345 065
Figure 51

Page 35
REASSEMBLY OF OUTPUT AND BRAKE
1. Insert wheel bolt into output shaft until
seated.
(S) Wheel bolt puller - basic set 5870 610
010
(S) Insert (3/4" - 16 UNF) 5870 610 005
Figure 52
2. Assemble bearing sheet (shaft seal / Part
2).
Figure 53
3. Press bearing sheet over collar of output
shaft.
(S) Pressure ring 5870 506 141
NOTE: The exact installation position
of bearing sheet will be
obtained by using specified
pressure ring.
Figure 54
4. Heat roller bearing and install it until
seated.
NOTE: After cooling down bearing, it
has to be installed immediately.
Figure 55

Page 36
5. Press both outer bearing races into brake
housing until seated.
Figure 56
6. Install shaft seal with the sealing lip visible
to oil chamber (see Figure 58).
(S) Driver 5870 051 052
of shaft seal will be obtained by
using specified driver (S).
NOTE: Just before installation, wet
outer diameter of shaft seal with
mineral spirits.
Figure 57
Reference
Description
Number
1 Brake housing
2 Shaft seal
* Grease filling
NOTE: Fill space between sealing -

and dust lips with grease.
Figure 58
7. Install preassembled brake housing using
lifting tackle (S) over output shaft until
seated.
(S) Eyebolts 5870 204 071
Figure 59

Page 37
seated.
Figure 60
9. Insert support - and U-rings into annular
grooves of brake housing.
NOTE: Pay attention to installation
position, see Figure 62.
Figure 61
Reference
Description
Number
1 Brake housing
2 Guide ring
3 Support ring
4 U-ring
5 U-ring
6 Support ring
7 Output shaft
Figure 62

Page 38
10. Clean annular groove of brake housing
with spirit.
Then insert the guide ring into annular
groove (also see Figure 62) and secure
with Loctite #415 at its extremities.
NOTE: Guide ring must have seated on
whole circumference.
NOTE: Upon installation of the orifice
of guide ring must show
upwards (12 o'clock).
Figure 63
11. Insert piston into brake housing and install
it cautiously until seated.
NOTE: Apply sufficiently oil on sliding
surface of piston or support
rings, U-rings and guide ring
(use W-10 oils).
Figure 64
12. Insert pins into assembly fixture (S) until
seated.
Figure 65
13. Press gripping rings (4x, see arrows) onto
pins until seated on assembly fixture (S).
NOTE: The exact installation
dimension (see Figure 68) of
gripping rings is obtained when
using specified assembly
fixture.
NOTE: Observe installation position,
install gripping rings with
orifices offset by 180° to each
other.
Figure 66

Page 39
14. Install cup springs (7 pieces each / pin).
position of cup springs, see
Figure 68.
Figure 67
Reference
Description
Number
1 Pin
2 Gripping rings
3 Cup springs
4 Support shim
5 Retaining Ring
X Installation dimension
Gripping rings 10.5
+0.3
mm
Figure 68
15. Insert preassembled pins into support
shim and secure using retaining ring.
NOTE: Pay attention to clearance of
cup springs.
Figure 69
16. Insert preassembled support shim into
piston.
Figure 70

Page 40
17. Install support shim using retaining ring.
Figure 71
18. Drive slotted pins (6x) into bores of
support shim to lock retaining ring.
(S) Drive mandrel 5870 705 011
Figure 72
Reference
Description
Number
1 Brake housing
2 Retaining Ring
3 Slotted pin
4 Support shim
5 Piston
4.0 - 0.5 mm
Figure 73
19. Drive stop bolt into planet carrier until
seated.
Then wet spline with anticorrosive Weicon
Antiseize (ZF Part Number: 0671 196 001)
(see arrow).
Figure 74

Page 41
20. Insert planet carrier into spline of output
shaft until seated.
Figure 75
21. Install outer and inner clutch disks
alternately starting with an outer clutch
disk.
NOTE: Oil clutch disks according to ZF
List of Lubricants TE-ML 05.
Figure 76
22. Insert O-ring (see arrow) into recess of
brake housing.
Figure 77
23. Grease both O-rings (see arrows) and
insert them into annular grooves of ring
gear.
Figure 78

Page 42
24. Install two adjusting screws (S) and insert
ring gear into brake housing until seated.
(S) Adjusting screws 5870 204 029
NOTE: Pay attention to radial location.
Figure 79
25. Heat inner bearing races and install them
until seated with the big radius showing to
planet carrier (downwards).
NOTE: Subsequently install inner
bearing races after cooling
down.
Figure 80
26. Put planet gears onto inner bearing races.
Figure 81
on planet gears until seated.
down.
Figure 82

Page 43
28. Fasten planet gears using retaining rings.
Figure 83
29. Adjust end play of sun gear shaft 0.5 ~
2.0 mm
Fasten ring gear using cap screws until
seated.
Then determine Dimension I, from
mounting face of ring gear up to face of
stop bolt.
Dimension I e.g. 36.00 mm
(S) Digital depth gauge 5870 200 072
(S) Gauge blocks 5870 200 066
Figure 84
(S) Straightedge 5870 200 022
30. Insert stub shaft into spline of axle bevel
gear until seated.
Figure 85

Page 44
31. Assemble sun gear shaft until seated.
Figure 86
32. Determine Dimension II from face of sun
gear shaft up to mounting face of axle
casing.
Dimension II e.g. 32.80 mm
Figure 87
EXAMPLE
Dimension I 36.00 mm (1.4173 in)

Dimension II - 32.80 mm (1.2913 in)
Difference 3.20 mm (0.1260 in)
required end play e.g. - 1.00 mm (0.0394 in)
Difference = shim e.g. = 2.20 mm (0.0866 in)
33. Insert sun gear shaft into planet carrier.
Figure 88

Page 45
34. Install determined shim(s), e.g. s =
2.20 mm, into sun gear shaft using grease.
Figure 89
35. Install O-ring (see arrow) into recess of
axle casing using grease and install
preassembled output to axle casing until
seated using lifting tackle (S).
Figure 90
36. Fasten output using hexagon screws and
washers.
Tightening torque (M18 / 10.9) MA = 39.77
kg•m (287.65 ft lb)
Figure 91
37. Unscrew slotted nut by hand and then
fasten it.
Tightening torque MA = 71.38 - 101.97
kg•m (516.29 - 737.56 ft lb)
Figure 92

Page 46
38. Secure slotted nut using slotted pin.
Figure 93
39. Assemble O-ring (see arrow) to cover.
Figure 94
40. Insert cover into output shaft until seated.
(S) Hammer (Plastic ø60) 5870 280 004
Figure 95
41. Leakage test of brake hydraulics
NOTE: Before start the test, ventilate
the brake hydraulics
completely.
1. Open bleeder.
2. Slowly actuate HP-pump until oil
flows from bleeder.
4. Slowly pressurize HP-pump with p >
10 bar and hold pressure for some
seconds. Figure 96

Page 47
NOTE: The brake piston extends and the cylinder chamber fills up with oil. The air accumulates in
5. Remove the shutoff valve on HP-pump.
NOTE: The reversing piston presses air from upper section of cylinder into brake line.
6. Open bleeder again.
7. Slowly actuate HP-pump until oil flows from bleeder.
NOTE: Repeat procedure - Item 3~7 - until - at Item 7 - from beginning of actuation no more air
exits from bleeder.
NOTE: Then pressurize the brake temporarily (5x) with p = 100 bar max.
High-pressure test
Increase test pressure up to p = 100 -10 bar and close connection to HD-pump using shutoff valve.
During a 5 min. testing time, a pressure drop of max. 2% (2 bar) is allowed.
NOTE: If maximum pressure of 100 bar is exceeded, there will be an excessive piston adjustment
and a repeated disassembly of brake or the adjusting is required to reset the gripping rings
to adjusting dimension.
Low-pressure test
Reduce test pressure to p = 5 bar and close the shutoff valve again.
During a 5 min. testing time, a pressure drop is not allowed.
Test media
Motor oils SAE 10-W corresponding with,
MIL-L 2104 C, MIL-L 46152,
API-CC, CD, SC, SD, SE,
ATF-Oils Type A, Suffix A Dexron of II D.
(S) HD-Pump 5870 287 007
(S) Mini-measuring hub (9 / 16" - 18UNF) 5870 950 115
NOTE: Before putting axle into operation, fill in oil according to “Lubrication Instructions” on
page -8.

Page 48
DISASSEMBLY OF DIFFERENTIAL CARRIER
AND BRAKE TUBES
Disassembly of differential carrier

(S) Clamps 5870 350 075
Figure 97
2. Remove plugs (3x, Figure 98, Figure 99)
and drain oil from axle casing.
Figure 98
Figure 99
NOTE: Repeat steps (Figure 100 thru
Figure 102) on both output
sides.
Figure 100

Page 49
casing.
(see arrow).
Figure 101
NOTE: Pay attention to released
shim(s).
Figure 102
6. Remove hexagon screws.
NOTE: Mark location of differential
carrier to axle casing (see
arrows).
Figure 103
7. Remove differential carrier using lifting
tackle (S) from axle casing.
(S) Lifting tackle 5870 281 044
Figure 104

Page 50
8. Fasten differential carrier to assembly
truck.
(S) Holding fixture 5870 350 004
(S) Clamping ring 5870 350 101
Figure 105
9. Remove slotted pins.
Figure 106
10. Remove both adjusting nuts.
Figure 107
11. Heat axle drive housing using hot-air
blower (S).
(S) Hot-air blower 230 V 5870 221 500
(S) Hot-air blower 115 V 5870 221 501
NOTE: Hexagon screws are installed
with Loctite #262)
Figure 108

Page 51
12. Remove hexagon screws and bearing
bracket.
NOTE: Mark bearing bracket to
housing (see arrow).
NOTE: Remove hexagon screws by
hand only.
Figure 109
13. Remove both outer bearing races.
Figure 110
14. Remove differential from housing using
lifting tackle (S).
Figure 111
Disassembly of limited slip differential
1. Remove inner bearing race form the
differential housing.
(S) Basic set 5870 026 100
Figure 112

Page 52
2. Remove inner bearing race from housing
cover.
(S) Rapid grip 5873 012 011
(S) Basic set 5873 002 001
Figure 113
3. Fasten differential using press and remove
locking screws.
Figure 114
4. Remove housing cover from differential
housing.
Figure 115
5. Remove all single parts from differential
housing.
Figure 116

Page 53
6. Remove crown wheel from differential
housing.
Figure 117
Disassembly of drive pinion
1. Heat slotted nut using hot-air blower (S).
(S) Hot-air blower 230 V 5870 221 500
(S) Hot-air blower 115 V 5870 221 501
NOTE: Slotted nut is locked with
Loctite #262.
Figure 118
2. Remove hexagon nut and remove washer
behind it.
(S) Fixture 5870 240 025
Figure 119
3. Remove input flange from drive pinion.
Figure 120

Page 54
4. Remove shaft seal from axle drive
housing.
Figure 121
5. Remove drive pinion from axle drive
housing using two-armed puller (S) and
remove released inner bearing race.
Figure 122
6. Take off spacer ring and remove inner
bearing race from drive pinion.
(S) Basic set 5873 002 001
Figure 123
7. If necessary drive out both outer bearing
races from axle drive housing.
Figure 124

Page 55
Disassembly of brake tubes
1. Remove plug with vent valve from axle
casing.
Figure 125
2. Remove hexagon nut.
NOTE: Step (Figure 126 thru Figure
130) to be made on both sides.
Figure 126
3. Remove union screw.
Figure 127
4. Remove pipe union and remove released
brake tube from axle casing.
Figure 128

Page 56
5. Remove vent valve from connection part.
Figure 129
6. Remove connection part and remove it
from axle casing.
Figure 130

Page 57
REASSEMBLY OF BRAKE TUBES AND
DIFFERENTIAL CARRIER
Reassembly of brake tubes

1. Preassemble connection part as shown in
opposite figure.
Reference
Description
Number
1 Vent valve
2 Connection part
3 O-ring Figure 131
4 Rectangular ring

137) is to be made on both
output sides.
2. Install connection part.
Tightening torque MA = 13.26 kg•m (95.88
ft lb)
Figure 132
3. Provide union screw with new O-ring and
install it.
Tightening torque MA = 19.37 kg•m
(140.14 ft lb)
Figure 133

Page 58
4. Insert O-ring (see arrow) into annular
groove of brake tube.
Figure 134
5. Insert brake tube into axle casing,
assembling the connection part (see arrow
1) through the union screw (see arrow 2).
Figure 135
6. Fasten brake tube using hexagon nut and
union nut (see below figure).
ft lb)
Figure 136
7. Tightening torque MA = 8.16 kg•m (59.0 ft
lb)
Figure 137

Page 59
8. Preassemble plug as shown in opposite
figure.
Reference
Description
Number
1 O-ring
2 Plug
3 Vent valve
Figure 138
9. Install plug.
Tightening torque MA = 7.14 kg•m (51.63 ft
lb)
Figure 139
Reassembly of differential carrier

NOTE: If crown wheel or drive pinion are damaged, both parts have to be replaced together.
For new installation of a complete bevel gear set pay attention to same pair number of
drive pinion and crown wheel.
Determine shim thickness for a perfect tooth contact pattern

NOTE: Make the following measuring steps at maximum accuracy.
Inexact measurements result in a faulty tooth contact pattern and require a repeated
disassembly and reassembly of drive pinion and of differential.
10. Install adapter pieces(1) and preliminarily
fasten the bearing bracket using hexagon
screws.
Then install stop washer (4) and
measuring pin (3) and assemble
measuring shaft (2) (Figure 140).
(S) Adapter piece 5870 500 028
(S) Measuring shaft 5870 500 001
(S) Measuring pin 5870 351 016
(S) Stop washer 5870 351 021
Figure 140

Page 60
11. Determine gap (Dimension b) between
measuring shaft and measuring pin using
a feeler gauge.
Dimension b e.g. 0.75 mm
Figure 141
EXAMPLE "A"
Dimension a (= Measuring 167.00 mm (6.5748 in)

pin + stop washer)
Dimension b + 0.75 mm (0.0295 in)
Dimension c + 15.00 mm (0.5906 in)
Dimension X = 182.75 mm (7.1949 in)
12. Determine Dimension I (bearing width).

Figure 142

Page 61
13. Read Dimension II (dimension for pinion).
Figure 143
EXAMPLE "B"

Dimension II + 148.05 mm (5.8287 in)
Dimension Y = 181.55 mm (7.1476 in)
EXAMPLE "C"
Dimension X 182.75 mm (7.1949 in)

Dimension Y - 181.55 mm (7.1476 in)
Difference = Shim e.g. = 1.20 mm (0.0473 in)
Install drive pinion

1. Place determined shim e.g. s = 1.20 mm
into bearing bore.
Figure 144
2. Cool down outer bearing race and insert it
into bearing bore until seated.
(S) Driver 5870 058 089
(S) Handle 5870 260 002
Figure 145

Page 62
3. Cool down outer bearing race on input
flange side and inset it until seated.
(S) Driver 5870 058 073
(S) Handle 5870 260 002
Figure 146
4. Press inner bearing race on drive pinion
until seated.
Figure 147
5. Adjust rolling moment of drive pinion
bearing 0.11 - 0.23 kg•m (0.81 - 1.70 ft lb)
(Figure 148 thru Figure 156).
Assemble spacer ring (e.g. s = 8.90 mm).
NOTE: As per experience the required
rolling moment is obtained by
use of spacer ring (e.g. s =
8.90 mm) available at
disassembly.
However, a later checking of
rolling moment is imperative.
Figure 148
6. Insert preassembled drive pinion into axle
drive housing and assemble the heated
inner bearing race until seated.
Figure 149

Page 63
7. Press dust protection on input flange until
seated.
(S) Driver 5870 056 012
Figure 150
8. Assemble input flange.
Figure 151
9. Assemble washer.
Figure 152
10. Unscrew slotted nut by hand and tighten it.
(516.29 ft lb)
(S) Fixture 5870 240 025
NOTE: When tightening rotate drive
pinion in both directions several
times.
Figure 153

Page 64
11. Check rolling moment (0.11 - 0.23 kg•m
(0.81 - 1.70 ft lb)).
NOTE: For new bearings it should be
tried to achieve the max. value
of rolling moment.
NOTE: IF the required rolling moment
is not obtained, correct it with
an adequate spacer ring
(Figure 148), according to
following indications:
Rolling moment too low - install
a thinner spacer ring
Figure 154
Rolling moment too high -
install a thicker spacer ring.
Then remove slotted nut again and
remove input flange from drive pinion.
to oil chamber (downwards).
(S) Driver 5870 048 225
of shaft seal with be obtained
by using exact driver (S).
mineral spirits and fill the space
between sealing and dust lip
with grease.
Figure 155
13. Assemble input flange and finally fasten in
using washer and slotted nut.
(516.29 ft lb)
NOTE: Apply Loctite #262 onto thread
of slotted nut.
Figure 156

Page 65
Reassembly of limited slip differential
1. Install sealing covers (6x).
position.
Figure 157
Reference
Description
Number
1 Differential housing
2 Sealing cover
3 Installation dimension
2.0 ± 0.5 mm
Figure 158
2. Insert retaining ring into annular groove
(see arrow) on differential housing bottom.
NOTE: Before installation all single
parts of differential must be
oiled according to ZF List of
lubricants TE-ML 05.
Figure 159
3. Insert driving pins (6x) into grooves of
differential housing (see arrow).
Figure 160

Page 66
4. Place both thrust washers into differential
housing.
Figure 161
5. Starting with an outer clutch disk install
alternately the outer and inner clutch disks.
NOTE: Thickness of disk pack must be
identical on both sides.
Figure 162
6. Assemble pressure ring into differential
housing.
Figure 163
7. Insert axle bevel gear until seated and at
the same time, assemble all inner clutch
disks with the spline.
Figure 164

Page 67
8. Preaseemble differential spider and insert
it into differential housing.
Figure 165
9. Put on second axle bevel gear.
Figure 166
10. Insert the second pressure ring into
Figure 167
11. Starting with an inner clutch disk install
alternately the inner and outer clutch disk.
NOTE: Thickness of clutch disk pack
must be identical on both sides.
Figure 168

Page 68
12. Insert driving pin (6x) into differential
housing.
Figure 169
Determine disk clearance 0.2 ~ 0.8 mm
1. Determine Dimension I, from mounting
face of differential housing to plane face of
outer clutch disk.
Figure 170
2. Determine Dimension II, from contact
surface of outer clutch disk to mounting
face of housing cover.
Figure 171
EXAMPLE "D"

Difference = Disk clearance = 0.40 mm (0.0157 in)
NOTE: If the required disk clearance is not obtained, correct it with the adequate outer clutch
disks (s = 2.1, s = 2.2, s = 2.3, s = 2.4 or s = 2.5 mm), taking care that the difference in
thickness between the left and the right disk pack must only be 0.1 at a maximum.

Page 69
3. Install both thrust washers with grease into
recess of housing cover.
Figure 172
4. Put on housing cover.
Figure 173
5. Heat crown wheel and install it until
seated.
Figure 174
6. Install differential using press and fasten
crown wheel using new locking screws.
(184.39 ft lb)
NOTE: Only new locking screws are
allowed to be used.
Figure 175

Page 70
7. Press on both outer bearing races until
seated.
Figure 176
8. Insert differential into axle drive housing
using lifting tackle (S).
Figure 177
9. Install both outer bearing races and
preliminarily fix them using adjusting nuts.
Figure 178
10. Put on both bearing brackets and fasten
them using hexagon screws and washers.
kg•m (516.29 ft lb)
adjusting nut.
NOTE: Apply Loctite #262 onto threads
of hexagon screws.
Figure 179

Page 71
Adjust backlash and bearing preload
1. Place dial indicator at a right-angle at the
outer diameter of tooth flank (crown
wheel).
Then install both adjusting nuts only to
such an extent that the required backlash -
see the value etched on outer diameter of
crown wheel - is reached.
(S) Magnetic stand 5870 200 055
(S) Dial indicator 5870 200 057
Figure 180
NOTE: At this step rotate the
differential several times.
2. Determine bracket width and correct it on
both adjusting nuts, if required.
Bracket width 291.90 +0.10 mm

(S) Caliper gauge 5870 200 058
Then check backlash once again.
NOTE: Adjusting of bracket width
results in required bearing
preload.
Figure 181
3. Cover some tooth flanks of crown wheel
with marking ink and roll crown wheel in
both directions over drive pinion.
Compare the obtained tooth contact
pattern with the examples on (See page
-13)
NOTE: If the tooth contact pattern
differs, there has been a
measuring error at
determination of shim (Figure
144), what is imperative to be
corrected.
Figure 182

Page 72
4. Secure both adjusting nuts using slotted
pins.
Figure 183
5. Install two adjusting screw (S) and insert
differential carrier into axle casing until
NOTE: Observe radial location (see
marking Figure 103).
NOTE: Apply sealing compound (Three
Bond Type 1215, ZF Part
Number 0666 791 002) on
mounting face.
Figure 184
6. Fasten differential carrier using new
locking screws.
(184.39 ft lb)
NOTE: Only use of new locking screws
is permissible.
Figure 185
gear until seated.
Then fix O-ring (see arrow) using grease
into recess of axle casing.
output sides.
Figure 186

Page 73
8. Thrust washer(s) removed at disassembly
have to be fixed in sun gear shaft using
grease.
Figure 187
9. Place complete output using lifting tackle
(S) to axle casing until seated.
Figure 188
washers.
kg•m (287.65 ft lb)
NOTE: Before putting into operation of
axle, fill oil in accordance with
“Lubrication Instructions” on
page -8.
Figure 189

Page 74
S0602280
3FRONT AXLE
(ZF - MT-L 3085)
4
CAUTION!
FRONT AXLE (ZF - MT-L 3085)S0602280


January 2011
Front Axle (ZF - MT-L 3085) S0602280

Page 1
TABLE OF CONTENTS
Outline..................................................................................................... 5
Mega 250-V ..................................................................................... 6
Lubrication instructions ........................................................................... 8
Oil drain............................................................................................ 9
Oil filling ........................................................................................... 9
Check............................................................................................... 9
Oil change intervals ......................................................................... 9
Oil level check.................................................................................. 9
Bleeders........................................................................................... 9
Brake................................................................................................ 9
Brake bleeding at the vehicle........................................................... 9
Make Wear Measurement on Multidisk Brake ...................................... 10
Wear measurement - Multidisk brake ............................................ 10
Inscriptions on Model Identification Plate.............................................. 11
Torque Limits for Screws ...................................................................... 12
Torque Limits for Screws (In Nm) According to
ZF-Standards 148 .......................................................................... 12
Examples of gear-tooth-contact patterns for the
gleason gear-tooth system.................................................................... 13
Special Tool.................................................................................................. 16
List of Special Tools for Disassembly and Reassembly........................ 16
ZF - Multitrac Rigid Axle MT-L 3085............................................................. 25
Disassembly of output and brake.......................................................... 25
Reassembly of Output and Brake ......................................................... 35
Disassembly of differential carrier and brake tubes .............................. 48
Disassembly of differential carrier.................................................. 48
Disassembly of limited slip differential ........................................... 51
Disassembly of drive pinion ........................................................... 53
Disassembly of brake tubes........................................................... 55
Reassembly of brake tubes and differential carrier............................... 57
S0602280 Front Axle (ZF - MT-L 3085)

Page 2
Reassembly of oil pipes ................................................................. 57
Reassembly of differential carrier .................................................. 60
Determine shim thickness for a perfect tooth contact pattern........ 60
Install drive pinion .......................................................................... 61
Reassemble of limited slip differential............................................ 65
Determine disk clearance 0.2 ~ 0.8 mm ........................................ 67
Adjustment of backlash and bearing preload................................. 70

Page 3
Page 4
GENERAL DESCRIPTION
OUTLINE
Front Axle
Frame-Fixed
Type
Semifloating
Overall Reduction Ratio 23.334:1
Hub Reduction Ratio 6:1
Differential Reduction Ratio 3.889:1
Differential Type Limited Slip (Locking Ratio:45%)
Max. Output Torque 8,000 kg•m (57,900 ft lb)
33,000 kg
Max. Static Load
(72,750 lb)
Type Multi Wet Disk

Brake 2,792 kg•m @ 53.8 Bar per axle
Torque
(20,194 ft lb @ 780 psi)
Drive Flange 6C

Page 5
Mega 250-V
Figure 1 DRIVE AXLE ASSEMBLY

Page 6
Reference Reference
Number Number
1 Front Axle 6 Bushing
2 Rear Axle 7 Thrust Plate
3 Axle Support (Front) 8 Thrust Cap
4 Axle Support (Rear) 9 Thrust Washer
5 Packing
NOTE: 1) 28 kg•m (123 ft lb)

NOTE: 2) 95±5 kg•m (687 ±36 ft lb)
NOTE: 3) 95±5 kg•m (687 ±36 ft lb)
NOTE: 4) Inner surface: Grease (Assemble with chamfered surface toward axle)
NOTE: 5) Assemble with lip pointing outward.
NOTE: 6) Assemble with groove pointing toward plate (7)
NOTE: 7) Apply grease and assemble
NOTE: 8) 28 kg•m (202 ft lb) Threaded area: Loctite #242
NOTE: 9) Tightening Torque: 80±8 kg•m (Bolt M22x1.5)

Page 7
LUBRICATION INSTRUCTIONS
Oils according to ZF List of lubricants TE-ML 05 are allowed to used for ZF-Axles MT-L 3085.
The basic condition for a correct oil change of axle is the horizontal plane of installation in every
direction.
Place vehicle in a horizontal position.
All drain, filter and level plugs must be cleaned carefully before opening.
Drain oil only immediately after a longer running time.
Reference
Description
Number
1 Oil drain hole M24x1.5
Axle casing
2 Oil drain hole M24x1.5
Outputs
3 Oil filler hole M36x1.5
4 Brake bleeder
5 Bleeder
Figure 2
Figure 3

Page 8
Oil drain
Remove drain plugs 1 and 2 and drain oil.
Oil filling
Provide drain plugs (M24x1.5) with new O-ring and install them.
Fill up oil to overflow on filler-resp. level plug 3.
Filling quantity approximately 30 liters (8 U.S. gal.).
Check
Check oil level after a few minutes and fill up to specified level, until level remains constant.
Provide filler-resp. level plug (M36x1.5) with new O-ring and install it.
Oil change intervals

1st oil change after 500 operating hours, further oil changes every 1000 operating hours, however, at
least once a year.
Oil level check

Oil level check once a month, but especially before starting a vehicle with new or repaired axles and
axle components respectively.
Bleeders
At initial operation and during the oil change intervals, clean Bleeder 3 and 5 and make a functional
check.
Brake
For the pneumatic-hydraulic or via an accumulator system-operated brake actuation following oils are
permissible:
1.Motor oils SAE 10W according to specification MIL-L 2104 C, MIL-L 46152, API-CC, CD, SC, SD,
SE
2.ATF-Oils Type A, Suffix A, Dexron of II D
Brake bleeding at the vehicle

1. Open bleeder (4).
4. Slowly pressurize the brake and hold pressure for some seconds.
NOTE: The brake piston extends and the cylinder chamber fills p with oil.
The air accumulates in upper section of cylinder chamber.
5. Release the brake pedal and remove brake.

Page 9
NOTE: The reversing piston presses the air from upper section of cylinder into brake line.
6. Open bleeder (4) again.
NOTE: Repeat procedure - Item 3 ~ 7 - until - at Item 7 - from beginning of actuation no more air
exits from bleeder.
MAKE WEAR MEASUREMENT ON MULTIDISK BRAKE

NOTE: A wear measurement on multidisk brake has to be made at least once a year, especially in
case of a changed braking behavior like, e.g.
• Braking noise
• Braking power reduced
• Deceleration changed
• Brake fluid level changed
• Braking pressure changed
Wear measurement - Multidisk brake

A wear measurement has to be made on both
output sides.
Remove plug, actuate brake and determine
Dimension X according to Figure 4 using a
feeler gauge. Dimension X corresponds with
thickness of inner clutch disk on piston side.
NOTE: If Dim. X <= 4.0 mm, the lined
disks on both output sides have
to be replaced!
Figure 4
Following to this provide level plug with a new
O-ring and install it!
Tightening torque MA = 7.14 kg•m (51.63 ft lb)
Figure 5

Page 10
INSCRIPTIONS ON MODEL IDENTIFICATION PLATE
Figure 6
Reference
Description
Number
1 Axle Type
2 Axle Serial No.
3 ZF - Parts - List No.
4 Total-Ratio of Axle / Version with or without
ZF-multidisk self locking differential
5 Type of lubricant
6 Lubricant specifications
NOTE: ZF - List of lubricants for ZF - Axles TE - ML 05

Page 11
TORQUE LIMITS FOR SCREWS
Torque Limits for Screws (In Nm) According to

ZF-Standards 148
Coefficient of friction: m total 0.12 for screws and nuts without after treatment and for phosphated
nuts.
NOTE: Tighten by hand.
Torque limits, if not specifically shown, can be taken from following list:
Metric ISO-Standard Thread DIN 13 Metric ISO-Fine Thread DIN 13

Size 8.8 10.9 12.9 Size 8.8 10.9 12.9
M4 2.8 4.1 4.8 M8x1 24 36 43
M5 5.5 8.1 9.5 M9x1 36 53 62
M6 9.5 14.0 16.5 M 10 x 1 52 76 89
M7 15 23.0 28.0 M 10 x 1, 25 49 72 84
M8 23 34 40 M 12 x 1, 25 87 125 150
M 10 46 68 79 M 12 x 1, 5 83 120 145
M 12 79 115 135 M 14 x 1, 5 135 200 235
M 14 125 185 215 M 16 x 1, 5 205 300 360
M 16 195 280 330 M 18 x 1, 5 310 440 520
M 18 280 390 460 M 18 x 2 290 420 490
M 20 390 560 650 M 20 x 1, 5 430 620 720
M 22 530 750 880 M 22 x 1, 5 580 820 960
M 24 670 960 1,100 M 24 x 1, 5 760 1,100 1,250
M 27 1,000 1,400 1,650 M 24 x 2 730 1,050 1,200
M 30 1,350 1,900 2,250 M 27 x 1, 5 1,100 1,600 1,850
M 33 1,850 2,600 3,000 M 27 x 2 1,050 1,500 1,800
M 36 2,350 3,300 3,900 M 30 x1, 5 1,550 2,200 2,550
M 39 3,000 4,300 5,100 M 30 x 2 1,500 2,100 2,500
M 33 x 1, 5 2,050 2,900 3,400
M 33 x 2 2,000 2,800 3,300
M 36 x 1, 5 2,700 3,800 4,450
M 36 x 3 2,500 3,500 4,100
M 39 x 1, 5 3,450 4,900 5,700
M 39 x 3 3,200 4,600 5,300

Page 12
EXAMPLES OF GEAR-TOOTH-CONTACT PATTERNS FOR THE
GLEASON GEAR-TOOTH SYSTEM
Ideal tooth-contact pattern i.e. pinion distance is correct
Coast side (concave)
Figure 1
Drive side (convex)
Figure 2
Pinion distance must be increased
Figure 3

Page 13
Figure 4
Figure 5
Pinion distance must be decreased
Figure 6
Figure 7

Page 14
Figure 8

Page 15
SPECIAL TOOL
LIST OF SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY
ZF - Multitrac MT - L 3085 / Output and Brake
4474 052 014 / 015

5870 350 075 Clamps
Figure 19 5870 345 065 Pry bar (set of 2)
Figure 49
Figure 51
Figure 20 5870 650 001 Striker
Figure 21 Figure 92 5870 656 077 Socket Spanner #
5870 912 028 Centering bracket #
Figure 27 5870 300 019 Extractor
Figure 28 Figure 83 5870 900 015 Set of external pliers A1-A2-A3-A4
Figure 29 5870 971 002 Three - armed puller
Figure 30 5873 001 020 Gripping insert
5873 026 100 Back off insert
Figure 31 5870 970 007 Two-armed puller
Figure 46
5870 654 034 Clamping bracket (set of 2)
5870 506 140 Press bushing
Figure 36 5870 900 016 Set of external pliers A11-A21-A31-A41
Figure 40 Figure 69 5870 900 051 Assembly pliers #
Figure 43 5870 400 001 Adjusting device
Figure 47 Figure 59 5870 281 047 Lifting chain
5870 204 071 Eyebolts (set of 2)
5873 004 001 Basic device #
Figure 52 5870 610 010 Wheel bolt puller - Basic set
5870 610 005 Insert 3/4" - 16UNF
Figure 54 5870 506 141 Pressure ring # EBM = 16.8 - 0.2 mm
Figure 56 5870 051 052 Driver # EBM = 6 + 0.2 mm
Figure 65 5870 345 096 Assembly fixture #
Figure 66
Figure 72 5870 705 011 Drive mandrel EBM = 4 mm
Figure 87 5870 200 022 Straightedge # 580 mm
5870 200 066 Gauge blocks # 60 mm

Page 16
Figure 96 5870 287 007 HD-Pump #
5870 950 115 Measuring hub # 9/16" - 18UNF
5870 350 075 Clamps
Figure 101
Figure 107 Figure 176 5870 656 080 Socket spanner
5873 002 001 Basic set (size 2)
5873 002 001 Basic set (size 2)
5870 240 002 Fixture #
Figure 121 5870 970 007 Two-armed puller #
5873 002 001 Basic set (size 2)
Figure 139 5870 500 044 Adapter pieces #
Figure 140 5870 500 001 Measuring shaft #
5870 351 016 Measuring pin #
5870 351 027 Stop washer
Figure 164 5870 200 066 Gauge blocks # 60 mm
Figure 165
5870 260 002 Handle
5870 260 002 Handle
5870 260 002 Handle
Figure 154 5870 048 225 Driver EBM = 16.6 mm
Figure 176 5870 200 055 Magnetic stand #
5870 200 057 Dial indicator #
Figure 177 5870 200 058 Caliper gauge 0 - 500 mm
# Particularly important special tools for partial
repair (wear part repair).

Page 17
Figure 9

Page 18
Figure 10

Page 19
Figure 11

Page 20
Figure 12

Page 21
Figure 13

Page 22
Figure 14

Page 23
Figure 15

Page 24
ZF - MULTITRAC RIGID AXLE MT-L 3085
DISASSEMBLY OF OUTPUT AND BRAKE
(S) Clamps 5870 350 075
Figure 16
2. Remove plugs (3x, Figure 17 and Figure
18) and drain oil from axle casing.
Figure 17
Figure 18

Page 25
3. Remove cover from output shaft.
(S) Pry bar set 5870 345 065
Figure 19
4. Remove slotted pin using striker (S) from
bore in slotted nut.
(S) Striker 5870 650 001
Figure 20
5. Remove slotted nut.
Figure 21
Figure 22

Page 26
casing.
(see arrow).
Figure 23
NOTE: Pay attention to possibly
released shim(s).
Figure 24
9. Remove shim(s) from sun gear shaft.
Figure 25
10. Remove sun gear shaft from planet gears.
Figure 26

Page 27
11. Remove planet carrier from brake housing.
(S) Internal extractor 5870 300 019
Figure 27
Figure 28
13. Remove planet gear and inner bearing
race.
(S) Three-armed puller 5873 971 002
Figure 29
14. Remove inner bearing race.
(S) Back off insert 5873 026 100
Figure 30

Page 28
15. Separate ring gear from brake housing
using two-armed puller (S).
Figure 31
16. Remove O-rings (see arrows) from
annular grooves of ring gear.
Figure 32
17. Remove O-ring (see arrow) from recess of
brake housing.
Figure 33
18. Remove disk pack from brake housing.
Figure 34

Page 29
19. Install slotted pins (6x) in support shim
until they are flush mounted.
Figure 35
Figure 36
21. Remove piston from brake housing using
compressed air.
Figure 37
22. Remove support shim from piston using
automatic piston adjusting.
Figure 38

Page 30
23. Remove slotted pins (6x) from support
shim.
Figure 39
24. Preload cup springs using a press and
remove retaining ring.
Figure 40
25. Remove pin from support shim and
remove released cup springs.
Figure 41
26. Remove gripping rings from pin.
Figure 42

Page 31
27. Remove piston from brake housing.
(S) Adjusting device 5870 400 001
Figure 43
28. Remove guide ring, support rings and
U-rings from annular grooves of brake
housing.
NOTE: See Figure 45, for installation
position of single parts.
Figure 44
Reference
Description
Number
1 Brake housing
2 Guide ring
3 Support ring
4 U-ring
5 U-ring
6 Support ring
7 Output shaft
Figure 45

Page 32
29. Remove brake housing using two-armed
puller (S) from output shaft and remove
released inner bearing race.
(S) Clamping bracket 5870 654 034
(S) Press bushing 5870 506 140
Figure 46
30. Remove brake housing with lifting tackle
(S) from output shaft.
(S) Eyebolts 5870 204 071
Figure 47
31. If necessary drive both outer bearing races
from bearing bores in brake housing.
Figure 48
32. Remove shaft seal from brake housing.
(S) Pry bar set 5870 345 065
Figure 49

Page 33
33. Remove inner bearing race from output
shaft.
(S) Rapid grip 5873 014 017
(S) Basic set 5873 004 001
Figure 50
34. Remove bearing sheet from output shaft.
(S) Pry bar set 5870 345 065
Figure 51

Page 34
REASSEMBLY OF OUTPUT AND BRAKE
1. Insert wheel bolt into output shaft until
seated.
(S) Wheel bolt puller - basic set 5870 610
010
(S) Insert (3/4" - 16 UNF) 5870 610 005
Figure 52
2. Assemble bearing sheet (shaft seal / Part
2).
Figure 53
3. Press bearing sheet over collar of output
shaft.
(S) Pressure ring 5870 506 141
of bearing sheet will be
obtained by using specified
pressure ring.
Figure 54
seated.
NOTE: After cooling down bearing, it
has to be installed immediately.
Figure 55

Page 35
5. Press both outer bearing races into brake
housing until seated.
Figure 56
to oil chamber (see Figure 58).
(S) Driver 5870 051 052
of shaft seal will be obtained by
using specified driver (S).
mineral spirits.
Figure 57
Reference
Description
Number
1 Brake housing
2 Shaft seal
* Grease filling
NOTE: Fill space between sealing -

and dust lips with grease.
Figure 58
7. Install preassembled brake housing using
lifting tackle (S) over output shaft until
seated.
(S) Eyebolts 5870 204 071
Figure 59

Page 36
seated.
Figure 60
9. Insert support - and U-rings into annular
grooves of brake housing.
Figure 61
Reference
Description
Number
1 Brake housing
2 Guide ring
3 Support ring
4 U-ring
5 U-ring
6 Support ring
7 Output shaft
Figure 62

Page 37
10. Clean annular groove of brake housing
with spirit.
Then insert the guide ring into annular
groove (also see Figure 62) and secure
with Loctite #415 at its extremities.
NOTE: Guide ring must have seated on
whole circumference.
NOTE: Upon installation of the orifice
of guide ring must show
upwards (12 o'clock).
Figure 63
11. Insert piston into brake housing and install
it cautiously until seated.
NOTE: Apply sufficiently oil on sliding
surface of piston or support
rings, U-rings and guide ring
(use W-10 oils).
Figure 64
12. Insert pins into assembly fixture (S) until
seated.
Figure 65
13. Press gripping rings (4x, see arrows) onto
pins until seated on assembly fixture (S).
NOTE: The exact installation
dimension (see Figure 68) of
gripping rings is obtained when
using specified assembly
fixture.
NOTE: Observe installation position,
install gripping rings with
orifices offset by 180° to each
other.
Figure 66

Page 38
14. Install cup springs (7 pieces each / pin).
position of cup springs, see
Figure 68.
Figure 67
Reference
Description
Number
1 Pin
2 Gripping rings
3 Cup springs
4 Support shim
5 Retaining Ring
Gripping rings 10.5
+0.3
mm
Figure 68
15. Insert preassembled pins into support
shim and secure using retaining ring.
cup springs.
Figure 69
16. Insert preassembled support shim into
piston.
Figure 70

Page 39
17. Install support shim using retaining ring.
Figure 71
18. Drive slotted pins (6x) into bores of
support shim to lock retaining ring.
(S) Drive mandrel 5870 705 011
Figure 72
Reference
Description
Number
1 Brake housing
2 Retaining Ring
3 Slotted pin
4 Support shim
5 Piston
4.0 - 0.5 mm
Figure 73
19. Drive stop bolt into planet carrier until
seated.
Then wet spline with anticorrosive Weicon
Antiseize (ZF Part Number: 0671 196 001)
(see arrow).
Figure 74

Page 40
20. Insert planet carrier into spline of output
shaft until seated.
Figure 75
21. Install outer and inner clutch disks
alternately starting with an outer clutch
disk.
NOTE: Oil clutch disks according to ZF
List of Lubricants TE-ML 05.
Figure 76
22. Insert O-ring (see arrow) into recess of
brake housing.
Figure 77
23. Grease both O-rings (see arrows) and
insert them into annular grooves of ring
gear.
Figure 78

Page 41
24. Install two adjusting screws (S) and insert
ring gear into brake housing until seated.
NOTE: Pay attention to radial location.
Figure 79
until seated with the big radius showing to
planet carrier (downwards).
down.
Figure 80
26. Put planet gears onto inner bearing races.
Figure 81
on planet gears until seated.
down.
Figure 82

Page 42
28. Fasten planet gears using retaining rings.
Figure 83
29. Adjust end play of sun gear shaft 0.5 ~
2.0 mm
Fasten ring gear using cap screws until
seated.
Then determine Dimension I, from
mounting face of ring gear up to face of
stop bolt.
Figure 84
gear until seated.
Figure 85

Page 43
31. Assemble sun gear shaft until seated.
Figure 86
32. Determine Dimension II from face of sun
gear shaft up to mounting face of axle
casing.
Figure 87
EXAMPLE

Difference 3.20 mm (0.1260 in)
required end play e.g. - 1.00 mm (0.0394 in)
Difference = shim e.g. = 2.20 mm (0.0866 in)
33. Insert sun gear shaft into planet carrier.
Figure 88

Page 44
34. Install determined shim(s), e.g. s =
2.20 mm, into sun gear shaft using grease.
Figure 89
35. Install O-ring (see arrow) into recess of
axle casing using grease and install
preassembled output to axle casing until
Figure 90
washers.
kg•m (287.65 ft lb)
Figure 91
37. Unscrew slotted nut by hand and then
fasten it.
Tightening torque MA = 71.38 - 101.97
kg•m (516.29 - 737.56 ft lb)
Figure 92

Page 45
38. Secure slotted nut using slotted pin.
Figure 93
39. Assemble O-ring (see arrow) to cover.
Figure 94
40. Insert cover into output shaft until seated.
(S) Hammer (Plastic ø60) 5870 280 004
Figure 95
41. Leakage test of brake hydraulics
NOTE: Before start the test, ventilate
the brake hydraulics
completely.
1. Open bleeder.
2. Slowly actuate HP-pump until oil
flows from bleeder.
4. Slowly pressurize HP-pump with p >
10 bar and hold pressure for some
seconds. Figure 96

Page 46
NOTE: The brake piston extends and the cylinder chamber fills up with oil. The air accumulates in
5. Remove the shutoff valve on HP-pump.
NOTE: The reversing piston presses air from upper section of cylinder into brake line.
6. Open bleeder again.
7. Slowly actuate HP-pump until oil flows from bleeder.
NOTE: Repeat procedure - Item 3~7 - until - at Item 7 - from beginning of actuation no more air
exits from bleeder.
NOTE: Then pressurize the brake temporarily (5x) with p = 100 bar max.
High-pressure test
Increase test pressure up to p = 100 -10 bar and close connection to HD-pump using shutoff valve.
During a 5 min. testing time, a pressure drop of max. 2% (2 bar) is allowed.
NOTE: If maximum pressure of 100 bar is exceeded, there will be an excessive piston adjustment
and a repeated disassembly of brake or the adjusting is required to reset the gripping rings
to adjusting dimension.
Low-pressure test
Reduce test pressure to p = 5 bar and close the shutoff valve again.
During a 5 min. testing time, a pressure drop is not allowed.
Test media
Motor oils SAE 10-W corresponding with,
MIL-L 2104 C, MIL-L 46152,
API-CC, CD, SC, SD, SE,
ATF-Oils Type A, Suffix A Dexron of II D.
(S) HD-Pump 5870 287 007
(S) Mini-measuring hub (9 / 16" - 18UNF) 5870 950 115
NOTE: Before putting axle into operation, fill in oil according to “Lubrication instructions” on
page -8.

Page 47
DISASSEMBLY OF DIFFERENTIAL CARRIER
AND BRAKE TUBES
Disassembly of differential carrier

(S) Clamps 5870 350 075
Figure 97
2. Remove plugs (3x, Figure 98, Figure 99)
and drain oil from axle casing.
Figure 98
Figure 99
NOTE: Repeat steps (Figure 100 thru
Figure 102) on both output
sides.
Figure 100

Page 48
casing.
(see arrow).
Figure 101
NOTE: Pay attention to released
shim(s).
Figure 102
6. Remove hexagon screws.
NOTE: Mark location of differential
carrier to axle casing (see
arrows).
Figure 103
7. Remove differential carrier using lifting
tackle (S) from axle casing.
Figure 104

Page 49
8. Fasten differential carrier to assembly
truck.
(S) Holding fixture 5870 350 004
Figure 105
9. Remove slotted pins.
Figure 106
10. Remove both adjusting nuts.
Figure 107
11. Heat axle drive housing using hot-air
blower (S).
(S) Hot-air blower 230 V 58770 221 500
(S) Hot-air blower 115 V 5870 221 501
NOTE: Hexagon screws are installed
with Loctite #262.
Figure 108

Page 50
12. Remove hexagon screws and bearing
bracket.
NOTE: Remove hexagon screws by
hand only.
Figure 109
13. Remove both outer bearing races.
Figure 110
14. Remove differential from housing using
lifting tackle (S).
Figure 111
Disassembly of limited slip differential
1. Remove inner bearing race form the
(S) Basic set 5873 002 001
Figure 112

Page 51
2. Remove inner bearing race from housing
cover.
(S) Rapid grip 5873 012 012
(S) Basic set 5873 002 001
Figure 113
3. Fasten differential using press, remove
locking screws and remove released
housing cover.
Figure 114
4. Remove all single parts from differential
housing.
Figure 115
5. Remove crown wheel from differential
housing.
Figure 116

Page 52
Disassembly of drive pinion
1. Heat slotted nut using hot-air blower (S).
(S) Hot-air blower 230 V 5870 221 500
(S) Hot-air blower 115 V 5870 221 501
NOTE: Slotted nut is locked with
Loctite #262.
Figure 117
2. Remove hexagon nut and remove washer
behind it.
(S) Fixture 5870 240 002
Figure 118
3. Remove input flange from drive pinion.
Figure 119
4. Remove shaft seal from axle drive
housing.
Figure 120

Page 53
5. Remove drive pinion from axle drive
housing using two-armed puller (S) and
remove released inner bearing race.
Figure 121
6. Take off spacer ring and remove inner
bearing race from drive pinion.
(S) Basic set 5873 002 001
Figure 122
7. If necessary drive out both outer bearing
races from axle drive housing.
Figure 123
8. Remove plug with vent valve from axle
casing.
Figure 124

Page 54
Disassembly of brake tubes
1. Remove hexagon nut.
129) to be made on both sides.
Figure 125
2. Remove union screw.
Figure 126
3. Remove pipe union and remove released
brake tube from axle casing.
Figure 127
4. Remove vent valve from connection part.
Figure 128

Page 55
5. Remove connection part and remove it
from axle casing.
Figure 129

Page 56
REASSEMBLY OF BRAKE TUBES AND
DIFFERENTIAL CARRIER
Reassembly of oil pipes

1. Preassemble connection part as shown in
opposite figure.
Reference
Description
Number
1 Vent valve
2 Connection part
3 O-ring Figure 130
4 Rectangular ring

output sides.
2. Install connection part.
ft lb)
Figure 131
3. Provide union screw with new O-ring and
install it.
(110.63 ft lb)
Figure 132

Page 57
4. Insert O-ring (see arrow) into annular
groove of brake tube.
Figure 133
5. Insert brake tube into axle casing,
assembling the connection part (see arrow
1) through the union screw (see arrow 2).
Figure 134
6. Fasten brake tube using hexagon nut and
union nut (see below figure).
ft lb)
Figure 135
7. Tightening torque MA = 8.16 kg•m (59.0 ft
lb)
Figure 136

Page 58
8. Preassemble plug as shown in opposite
figure.
Reference
Description
Number
1 O-ring
2 Plug
3 Vent valve

ft lb)
Figure 137
9. Install plug.
Tightening torque MA = 7.14 kg•m (51.63 ft
lb)
Figure 138

Page 59
Reassembly of differential carrier
NOTE: If crown wheel or drive pinion are damaged, both parts have to be replaced together.
For new installation of a complete bevel gear set pay attention to same pair number of
drive pinion and crown wheel.
Determine shim thickness for a perfect tooth contact pattern

NOTE: Make the following measuring steps at maximum accuracy.
Inexact measurements result in a faulty tooth contact pattern and require a repeated
disassembly and reassembly of drive pinion and of differential.
10. Install adapter pieces(1) and preliminarily
fasten the bearing bracket using hexagon
screws.
Then install stop washer (4) and
measuring pin (3) and assemble
measuring shaft (2) (Figure 140).
(S) Adapter piece 5870 500 044
(S) Measuring shaft 5870 500 001
(S) Measuring pin 5870 351 016
(S) Stop washer 5870 351 027
Figure 139
11. Determine gap (Dimension b) between
measuring shaft and measuring pin using
a feeler gauge.
Dimension b e.g. 0.25 mm
Figure 140
EXAMPLE "A"
Dimension a (= Measuring 190.00 mm (7.4803 in)

pin + stop washer)
Dimension b + 0.25 mm (0.0098 in)
Dimension c + 15.00 mm (0.5906 in)
Dimension X = 205.25 mm (8.0807 in)

Page 60
12. Determine Dimension I (bearing width).
Figure 141
13. Read Dimension II (dimension for pinion).
Figure 142
EXAMPLE "B"

Dimension II + 168.05 mm (6.6161 in)
Dimension Y = 204.05 mm (8.0335 in)
EXAMPLE "C"
Dimension X 205.25 mm (8.0807 in)

Dimension Y - 204.05 mm (8.0335 in)
Difference = Shim e.g. = 1.20 mm (0.0472 in)
Install drive pinion

1. Place determined shim e.g. s = 1.20 mm
into bearing bore.
Figure 143

Page 61
2. Cool down outer bearing race and insert it
into bearing bore until seated.
(S) Driver 5870 058 060
(S) Handle 5870 260 002
Figure 144
3. Cool down outer bearing race on input
flange side and inset it until seated.
(S) Driver 5870 058 087
(S) Handle 5870 260 002
Figure 145
4. Press inner bearing race on drive pinion
until seated.
Figure 146
5. Adjust rolling moment of drive pinion
bearing 0.15 - 0.31 kg•m (1.11 - 2.21 ft lb)
(Figure 147 thru Figure 155).
Assemble spacer ring (e.g. s = 8.70 mm).
NOTE: As per experience the required
rolling moment is obtained by
use of spacer ring (e.g. s =
8.70 mm) available at
disassembly. However, a later
checking of rolling moment is
imperative.
Figure 147

Page 62
6. Insert preassembled drive pinion into axle
drive housing and assemble the heated
inner bearing race until seated.
Figure 148
7. Press dust protection on input flange until
seated.
(S) Driver 5870 056 012
(S) Handle 5870 260 002
Figure 149
8. Assemble input flange.
Figure 150
9. Assemble washer.
Figure 151

Page 63
10. Unscrew slotted nut by hand and tighten it.
(516.29 ft lb)
(S) Fixture 5870 240 002
NOTE: When tightening rotate drive
pinion in both directions several
times.
Figure 152
11. Check rolling moment (0.15 - 0.31 kg•m
(1.11 - 2.21 ft lb)).
NOTE: For new bearings it should be
tried to achieve the max. value
of rolling moment.
NOTE: IF the required rolling moment
is not obtained, correct it with
an adequate spacer ring
(Figure 147), according to
following indications:
Rolling moment too low - install
a thinner spacer ring
Figure 153
Rolling moment too high -
install a thicker spacer ring.
Then remove slotted nut again and
remove input flange from drive pinion.
to oil chamber (downwards).
(S) Driver 5870 048 225
of shaft seal with be obtained
by using exact driver (S).
mineral spirits and fill the space
between sealing and dust lip
with grease.
Figure 154

Page 64
13. Assemble input flange and finally fasten in
using washer and slotted nut.
(516.29 ft lb)
(S) Fixture 5870 240 002
NOTE: Apply Loctite #262 onto thread
of slotted nut.
Figure 155
Reassemble of limited slip differential
1. Place both thrust washers into differential
housing.
NOTE: Before installation all single
parts of differential must be
oiled according to ZF List of
Figure 156
2. Starting with an outer clutch disk install
alternately the outer and inner clutch disks.
NOTE: Thickness of disk pack must be
identical on both sides.
Figure 157
3. Put on pressure ring.
Figure 158

Page 65
4. Insert axle bevel gear until seated and at
the same time, assemble all inner clutch
disks with the spline.
Figure 159
5. Preassemble differential spider and insert
it into differential housing.
Figure 160
6. Put on second axle bevel gear.
Figure 161
7. Insert the second pressure ring into
Figure 162

Page 66
8. Starting with an inner clutch disk install
alternately the inner and outer clutch disks.
NOTE: Thickness of clutch disk pack
must be identical on both sides.
Figure 163
Determine disk clearance 0.2 ~ 0.8 mm
1. Determine Dimension I, from mounting
face of differential housing to plane face of
outer clutch disk.
Figure 164
2. Determine Dimension II, from contact
surface of outer clutch disk to mounting
face of housing cover.
Figure 165
EXAMPLE "D"

Difference = Disk clearance = 0.30 mm (0.0118 in)
NOTE: If the required disk clearance is not obtained, correct it with the adequate outer clutch
disks (s = 2.9, s = 3.0 or s = 3.3 mm), taking care that the difference in thickness between
the left and the right disk pack must only be 0.01 at a maximum.

Page 67
3. Install both thrust washers with grease into
recess of housing cover.
Figure 166
4. Put on housing cover.
Then heat crown wheel and install it until
seated.
Figure 167
5. Install differential using press and fasten
crown wheel using new locking screws.
(302.40 ft lb)
is permissible.
Figure 168
6. Press on both outer bearing races until
seated.
Figure 169

Page 68
7. Insert differential into axle drive housing
using lifting tackle (S).
Figure 170
8. Place outer bearing race into axle drive
housing.
Figure 171
9. Preliminarily fix the outer bearing race
using adjusting nut.
Figure 172
10. Install crown wheel-sided outer bearing
race.
Figure 173

Page 69
11. Preliminarily fix the crown wheel-sided
outer bearing race using second adjusting
nut.
Figure 174
12. Put on bearing bracket and fasten it using
hexagon screws and washers.
Tightening torque (M16/10.9) MA = 28.55
kg•m (206.52 ft lb)
adjusting nut.
NOTE: Apply Loctite #262 onto threads
of hexagon screws.
Figure 175
Adjustment of backlash and bearing preload
1. Place dial indicator at a right-angle to the
outer diameter of tooth flank (crown
wheel).
Then install both adjusting nuts only to
such an extent that the required backlash -
see the value etched on outer diameter of
crown wheel - is reached.
(S) Magnetic stand 5870 200 055
NOTE: At this step rotate the
Figure 176
differential several times.

Page 70
2. Determine bracket width and correct it on
both adjusting nuts, if required.
Bracket width 367.90 -0.05 mm

(S) Caliper gauge 5870 200 058
Then check backlash once again.
NOTE: Adjusting of bracket width
results in required bearing
preload.
Figure 177
3. Cover some tooth flanks of crown wheel
with marking ink and roll crown wheel in
both directions over drive pinion.
Compare the obtained tooth contact
pattern with the examples on (See page
-13)
NOTE: If the tooth contact pattern
differs, there has been a
measuring error at
determination of shim (Figure
143), what is imperative to be
corrected.
Figure 178
4. Secure both adjusting nuts using slotted
pins.
Figure 179
5. Install two adjusting screw (S) and insert
differential carrier into axle casing until
NOTE: Observe radial location (see
marking Figure 103).
NOTE: Apply sealing compound (Three
Bond Type 1215, ZF Part
Number 0666 791 002) on
mounting face.
Figure 180

Page 71
6. Fasten differential carrier using new
locking screws.
(184.39 ft lb)
is permissible.
Figure 181
gear until seated.
Then fix O-ring (see arrow) using grease
into recess of axle casing.
output sides.
Figure 182
8. Thrust washer(s) removed at disassembly
have to be fixed in sun gear shaft using
grease.
Figure 183
9. Place complete output using lifting tackle
(S) to axle casing until seated.
Figure 184

Page 72
washers.
kg•m (287.65 ft lb)
NOTE: Before putting into operation of
axle, fill oil in accordance with
“Lubrication instructions” on
page -8.
Figure 185

Page 73
Page 74
S0603001
1PARKING BRAKE
CALIPER (ZF)
CAUTION!
PARKING BRAKE CALIPER (ZF)S0603001


January 2011
Parking Brake Caliper (ZF) S0603001

Page 1
TABLE OF CONTENTS
Functional Characteristics and Maintenance Instructions .............................. 3

Functional Characteristics of Spring-loaded Sliding Caliper Brakes ....... 3
Mounting and Basic Setting Regulations ................................................ 4
Adjusting Regulations ............................................................................. 4
Emergency release of parking brake ...................................................... 4
Maintenance and Repair Work................................................................ 5
General ................................................................................................... 6
S0603001 Parking Brake Caliper (ZF)

Page 2
FUNCTIONAL CHARACTERISTICS AND
MAINTENANCE INSTRUCTIONS
FUNCTIONAL CHARACTERISTICS OF SPRING-LOADED SLIDING CALIPER BRAKES
The two identical brake pads (3 and 4) must slide freely on guide bolt (2), which is fastened in housing (1).
The guide bolts (2) are guided in an additional brake anchor plate which in turn is screwed onto the
vehicle, i.e. at its axle.
When actuated, the brake generates a clamping force between the brake lining plates (3 and 4). This
causes a tangential force/braking moment to be generated at the brake disk, the extent of which depends
on the coefficients of friction generated by the linings.
The clamping force is generated by a stack of cup springs (5), that move piston (6) along with adjusting
screw (7), thrust bolt (8) and brake pad (3), towards brake disk.
When brake pad (3) comes into contact with brake disk, reaction force moves housing (1) on guide bolts
(2) until brake pad (4) is pressed against brake disk.
The brake is released by compressing the stack of cup springs (5). Pressurized hydraulic oil enters cavity
(10) overcoming cup spring force. This pressure moves piston (6) back until it meets pressure ring (9). The
brake disk is then free to rotate.
The clamping force will diminish with wear of brake lining and brake disk. The brake must be periodically
adjusted according to specification below (point 3).
Figure 1

Page 3
MOUNTING AND BASIC SETTING REGULATIONS
Basic brake setting is required after mounting new brake lining plates or brake disks, and during all repair
stages and in case of insufficient braking performance.
All mounting and basic adjustments must be carried out on brake when cold. Proceed as follows:
1. Release screw cap (12).
2. Release lock nut (11) (size 24 or 30 mm) and turn adjusting screw (7) counterclockwise using a 8 or
10 mm socket wrench until pressure bolt (8) comes to rest against face surface of piston (6).
3. In this status, brake can be mounted onto brake disk and fastened.
4. Mount pressure connection and apply necessary release pressure to brake until stack of cup springs
(5) are completely compressed.
5. Turn adjusting screw (7) manually clockwise until both brake pads (3 and 4) make contact with brake
disk (it is then no longer possible to turn adjusting screw (7) without exerting a major amount of
force).
6. Turn adjusting screw (7) counterclockwise in order to set following rated clearances:
Type Adjusting screw Clearance (mm) Revolutions

min. 0.5 1/4
Small M16 (size 8) Rated clearance 1.0 1/2
max. 1.5 3/4
min. 1.0 2/5
Large M20 (size 10) Rated clearance 2.0 4/5
max. 3.0 1 1/5
7. Hold adjusting screw in position (7) with a hexagonal socket wrench and lock with lock nut (11).
8. Mount screw cap (12) and tighten as far as possible manually.
9. Mount pressure connection in accordance with instructions of axle / gear manufacturer and bleed
piston chamber using bleeding valve (19), socket size 13.
ADJUSTING REGULATIONS
During this adjusting process, parking brake must be released, i.e. stack of cup springs (5) must be
completely compressed
1. Park machine on firm, level ground, and block tires. Only then, release parking brake.
2. Release screw cap (12) and unscrew.
3. Release lock nut (11) (size 24 or 30 mm) and turn adjusting screw (7) with an 8 or 10 mm socket
wrench manually clockwise until two brake pads (3 and 4) make contact with brake disk.
4. Turn adjusting screw (7) counterclockwise and set clearance specified in above table.
5. Hold adjusting screw (7) in position with hexagonal socket wrench and lock with lock nut (11).
6. Mount screw cap (12) and tighten as far as possible manually.
7. Actuate brake valve several times and check braking efficiency of parking brake on a slope.
EMERGENCY RELEASE OF PARKING BRAKE

After a pressure failure, release parking brake by using following manual procedure.

Page 4
1. The vehicle has to be against moving away.
wrench manually counterclockwise until brake disk is free.
NOTE: A force of 4.08 -7.14 kg•m (29.50 - 51.63 ft lb) must be applied for emergency release of
parking brake.
4. Mount lock nut (11) and screw cap (12) and manually tighten both as far as possible. (Protection
against dirt)
NOTE: Now, vehicle will not have any brake function. The vehicle must be secured against
moving away with proper means. Before putting vehicle into operation again, the brake
has to be adjusted according to point 2. respectively point 3.
MAINTENANCE AND REPAIR WORK
Maintenance and Exchange of Brake Pads

The brake pads themselves are maintenance free. All that is required here is a check for damaged parts,
and inspection to ensure that brake disk remains easy running.
The thickness of brake lining must be subjected to a visual inspection at regular intervals, which depend on
vehicle usage, but every six months at the latest. In case of a minimal residual lining thickness, these
intervals must be reduced accordingly in order to avoid major damage to brake or disk.
Small brake: min. residual thickness 1.0 mm per brake lining plate (6 mm carrier plate thickness)
Large brake: min. residual thickness 2.0 mm per brake lining plate (8 mm carrier plate thickness)
Once these thicknesses are reached, brake lining must be replaced in accordance with the following
regulation:
1. Park machine on firm, level ground, and block tires. Only then, release the parking brake by applying
the necessary release pressure.
wrench manually clockwise until it lies flush with inside of piston (6).
4. Press back pressure bolt (8) using a suitable screwdriver until it comes to rest against piston (6) (i.e.
by levering)
5. Depending on free space available, release one of two guide bolts (2), removing safety splint (21),
unscrewing castellated nut (22) and pulling guide bolt (2) out of brake anchor plate (1). brake lining
plates (3 and 4) can now be removed tangentially to brake disk.
NOTE: In case of minimal clearance, i.e. it is not possible for space reasons to exchange brake
lining plate in accordance with these instructions, brake must be removed completely. To
do this, pull two guide bolts out of brake anchor plate.
NOTE: Check pressure hose. If pressure hose is too short, it must be unscrewed in order to allow
brake to be removed.
Steps 4.1.3 and 4.1.4 must always have been performed beforehand, than release
pressure by actuating hand brake valve.
6. Exchange brake pads (3 and 4) and insert guide bolts (2) into brake anchor plate (1), checking
whether permanent magnets (20) still have sufficient magnetic force to hold brake lining plates (3 and
4).

Page 5
NOTE: Should this not be case, permanent magnets (20) must also be changed ("lever out" using
a suitable screwdriver).
NOTE: When brake has been completely removed, pressure hose must be screwed back on and
brake bled.
7. Secure guide bolts (2) with castellated nut (22) and locking splint (21).
NOTE: Only Knott original spare lining plates may be used. If any other spare parts are used, no
warranty claims will be accepted either for brakes or for their functional characteristics.
After mounting new brake lining plates or their repair, brake must be correctly set in accordance with
instructions under point 3.
Changing Seal
Faulty seals must be exchanged in accordance with instructions below:
1. Park machine on firm, level ground, and block tires. Only then, release parking brake by applying
necessary release pressure.
wrench manually counterclockwise until adjuster screw (7) measured 27 mm - 30 mm outside of
piston (6).
4. Release pressure by actuating hand brake valve, than unscrew pressure hose and completely
remove brake. The stack of cup springs (5) is now completely depressurized.
5. Remove retaining ring (18) and remove pressure ring (9) from housing (1).
6. Remove stack of cup springs (5) and piston (6).
7. Exchange seals (14, 15 and 17) and replace individual parts in reverse sequence.
NOTE: Pay attention to mounting direction of seal rings (14 and 15), otherwise leaks can occur.
NOTE: When mounting new seal rings, pay attention not to damage sealing lip by using a suitable
mounting device with rounded edges.
When mounting piston, sliding and sealing surfaces must be greased lightly using lubricating grease
to DIN 51825.
The dust protection cap (13) is fitted with a vulcanized steel ring that is used to press it through
locating hole. For exchanging, "lever out" ring using a suitable tool. The new dust protection cap must
be pressed in with the aid of a suitable mounting ring and screw clamps or a lever press.
8. Mount brake in accordance with above procedure into vehicle / at axle.
NOTE: For exchange purpose, only use Knott original spares and spare parts sets. These must
be ordered through vehicle manufacturer.
GENERAL
Any discovered defects or damage to parts not listed here must naturally be repaired or replaced using
original parts.
For any other information not contained in these instructions or for more detailed instructions, please
contact vehicle or brake manufacturer.

Page 6
S0605050K
1AIR CONDITIONER
CAUTION!
AIR CONDITIONER S0605050K

Mega 500-V 1001 thru 2000

January 2011
Air Conditioner S0605050K

Page 1
TABLE OF CONTENTS
Refrigerant Circulation.................................................................................... 4
Control Panel.................................................................................................. 6
Control Specifications..................................................................................... 7
Temperature Level Control and Display......................................................... 8
Air Discharge According to Path Selection..................................................... 9
Air-conditioning System Circuit Diagram...................................................... 12
Troubleshooting............................................................................................ 14
Weight of R134a Gas Used In Machines ..................................................... 18
Refrigerant System Repairs ......................................................................... 20
Refrigerant Safe Handling Procedures ................................................. 20
Repair and Replacement Procedure..................................................... 21
Refrigerant Recovery ............................................................................ 23
Vacuuming Refrigerant System ............................................................ 23
Leakage Check ..................................................................................... 25
Refrigerant Charging............................................................................. 25
Inspecting System for Leakage............................................................. 27
S0605050K Air Conditioner

Page 2
GENERAL DESCRIPTION
AJS0880L
Figure 1
The heater and air conditioner are combined into one blower unit in the right control stand of operator's
seat. If necessary, the operator can control inner temperature using the operation panel installed in the top
of the right side door.
The unit is equipped with an air filtration system
which filters out dirt and dust particles from air
being circulated into the operator's cab. This
filter (1, Figure 2) should be cleaned out at 1
approximately every 500 hours and replaced
with a new one every 1,000 hours.
NOTE: In the event that the unit is
being operated in a dusty
environment, cleaning and
replacement should be
performed more frequently.
WARNING!
AJS0530L
All service and inspection of the
air-conditioning system should be Figure 2
performed with the starter switch in the
"O" (OFF) position.
NOTE: Refer to appropriate operation

and maintenance manual for
latest service intervals.

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

Page 4
Shading Temperature Refrigerant State

High High-pressure Gas
High High-pressure Liquid
Low Low-pressure Liquid
High High-pressure Gas/Liquid
Low Low-pressure Gas
• Refrigerant (R134a) is compressed to approximately 15 kg/cm2 (213 psi) within the compressor.
• The compressed refrigerant flows into the condenser at high temperature (approximately 80°C
(176°F)).
• The refrigerant in the condenser is cooled to approximately 60° by the condenser fan. At this
time the refrigerant changes from the gas to the liquid state, even though the temperature has
only been reduced 20°C (68°F). (From 80° - 60°C (176° - 140°F)).
• The refrigerant in its liquid form is injected into the evaporator through the expansion valve. At
this time the pressure is reduced by approximately 2 kg/cm2 (28 psi) and the temperature is also
reduced. As a result, the refrigerant absorbs the heat from the air surrounding the evaporator
creating a cooling effect and changes from the gas to the liquid state.
• The refrigerant again flows into the compressor in the gaseous state and the process is
repeated.
WARNING!
Refrigerant gas is pressurized and sealed in the air-conditioning system. Special
precautions are required for the proper recharging or release of refrigerant. Release of
refrigerant into the atmosphere is strictly regulated by law. Make sure that you are in
compliance with all mandated federal, state and municipality requirements, before starting
any service or repair of the air conditioner. Refrigerant gas used in the system must meet or
exceed specifications for R134a refrigerant, or any subsequently issued environmentally
mandated standard.

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

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

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

Page 6
CONTROL SPECIFICATIONS
Control Item Control Switch Control Specifications

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

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

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

Page 7
TEMPERATURE LEVEL CONTROL AND DISPLAY

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

Page 8
AIR DISCHARGE ACCORDING TO PATH SELECTION

Vent
AJS0540L
Figure 9
Reference Reference
Number Number
1 Selector Switch 3-2 Rear Vent (L)
2 Front Vent 4 Heater Core
2-1 Front Vent (R) 5 Evaporator Core
2-2 Front Vent (L) 6 Air Filter
3 Rear Vent 7 Blower Motor
3-1 Rear Vent (R)

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

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

Page 11
AIR-CONDITIONING SYSTEM CIRCUIT DIAGRAM
Figure 12

Page 12
Reference Reference
Number Number
1 Battery 14 A/C Control Panel
2 Battery Relay 15 A/C Unit
3 Fusible Link 15-1 Blower Motor
4 Circuit Breaker 15-2 Resister
5 Fuse Box 15-3 High Speed Relay
6 Headlight Switch 15-4 Mid Speed Relay
7 Condenser Fan Relay 15-5 Low Speed Relay
8 Condenser Fan Motor 15-6 Recirculate / Fresh Air
9 Compressor Relay Control Actuator
10 Foot / Defrost Control 15-7 Vent Actuator
Actuator 15-8 Temperature Control
11 Receiver Drier Actuator
12 Diode 15-9 Temperature Sensor
(Evaporator)
13 Compressor

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

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

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

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

Page 14
High-pressure: Approximately 20 - 25 kg/cm 2 (284 - 356 psi)

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

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

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

Page 15
High-pressure: Over 22 - 23 kg/cm2 (313 - 327 psi)

6
Low-pressure: 2.5 kg/cm 2 (36 psi)
Possible Cause: Refrigerant pressure problem due to defective expansion valve or temperature sensor.
Inspect whether the temperature sensor is Yes Replace expansion valve.
1
installed properly. No Exchange duct sensor.
High-pressure: Over 7 - 11 kg/cm2 (100 - 156 psi)

7
Low-pressure: 4 - 6 kg/cm 2 (57 - 85 psi)
Possible Cause: Low refrigerant pressure due to poor compressor compression
Inspect and replace compressor if necessary.

Page 16

Page 17
WEIGHT OF R134A GAS USED IN MACHINES
Model Weight of Gas

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

Page 18
Model Weight of Gas

Solar 290LL 850 ±20 grams (30 ±0.7 oz)
Solar 300LL 850 ±20 grams (30 ±0.7 oz)
Solar 55 750 ±20 grams (26 ±0.7 oz)
Solar 55-V PLUS 750 ±20 grams (26 ±0.7 oz)
Solar 55W-V PLUS 750 ±20 grams (26 ±0.7 oz)
Solar 75-V 750 ±20 grams (26 ±0.7 oz)

Page 19
REFRIGERANT SYSTEM REPAIRS
WARNING!
Always wear protective glasses and gloves when handling refrigerant. If refrigerant comes in
contact with the skin or eyes, immediately flush with clean, running water and consult a
physician.
Select a clean and well ventilated area to work.
The refrigerant container is under high-pressure and should be stored below 40°C (104°F). Be
careful not to drop the container from a high location
The contents are under high-pressure and should not be used with compressed air or near an
open flame.
REFRIGERANT SAFE HANDLING PROCEDURES
UNION NUT
TORQUE WRENCH
CORRECT WRONG
WRONG
WRONG
CORRECT
O - RING POSITION
CAP & PLUG CORRECT WRONG WRONG
HDA6066L
Figure 14
The following procedures should be observed for safe handling of refrigerant during vacuum and charging
process.
1. Use an approved recovery / charging device which can safely perform vacuum and charge work
simultaneously.
2. The new refrigerant has improved cooling characteristics than the old type and care should be used
not to overcharge the system.
3. Do not over tighten connections when working on refrigerant system.
4. The new refrigerant system standards require new tools, equipment and parts. Do not attempt to use
equipment use in servicing the old refrigerant system.

Page 20
5. The new refrigerant oil (PAG type) has a high moisture absorption characteristic. When the
refrigerant system vacuum seal has been broken, immediately plug up all openings to prevent
moisture from entering into the system.
6. When joining unions which use O-ring seals, lightly coat O-rings with refrigerant oil. Be careful not to
drip oil on the threads of the nut.
7. Be certain the O-rings are seated properly on the refrigerant line lip. Always use new O-rings when
reassembling parts. Do not reuse old O-rings.
8. Use a vacuum pump to evacuate refrigerant system of air.
9. When charging the refrigerant system with the engine running, do not open the high-pressure valve
on the manifold gauge as the reverse flow of high-pressure refrigerant will rupture the hose.
10. When releasing the high-pressure hose after completing the charging process, quickly disconnect the
hose to minimize refrigerant released to the air.
REPAIR AND REPLACEMENT PROCEDURE

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

Page 21
INSTALL REPAIR TOOL
RECOVER REFRIGERANT
REPAIR / REPLACE DEFECTIVE PARTS
VACUUM SYSTEM (OVER 5 MINUTES)
CHECK SYSTEM FOR AIR LEAKAGE REPAIR
VACUUM SYSTEM (OVER 20 MINUTES)
CHARGE SYSTEM (APPROXIMATELY 100 g)
CHECK SYSTEM FOR REFRIGERANT LEAKAGE
CHARGE SYSTEM TO PROPER LEVEL

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

HDA6067L
Figure 15

Page 22
REFRIGERANT RECOVERY
Reference
Description 2 3
Number
1 To Compressor 1 4
2 Low-pressure Side
3 High-pressure Side
4 From Receiver
5 Refrigerant Recovery Tank
1. Attach the manifold gauges and the

refrigerant recovery unit to the refrigerant 5
lines as shown. HDA6067L
Figure 16
NOTE: Be careful not to switch the
connections for the low and
high-pressure valves.
2. Open the high-pressure valve slowly to release the refrigerant to the recovery unit.
NOTE: Open the valve slowly, while checking to see that refrigerant is not leaking out.
3. When the manifold gauge dial falls below 3.5 kg/cm2 (50 psi), slowly open the low-pressure valve.
4. Open both the high and low-pressure valves slowly until the manifold gauge dials indicates 0 kg/cm2
(0 psi).
VACUUMING REFRIGERANT SYSTEM
Reference 2 3
Description
Number 1 4
1 To Compressor
2 Low-pressure Side
4 From Receiver
5 Vacuum Pump
1. Vacuuming Procedure. 5
HDA6068L
NOTE: When the A/C system has been Figure 17
exposed to the air, it must be
vacuumed out. Perform vacuum
process for 30 minutes for
complete moisture and air
evacuation.
A. Attach the manifold gauges and vacuum pump to the refrigerant system as shown.
B. Turn on the vacuum pump and open both valves.
C. When the low-pressure gauge shows approximately 710 mmHg, close both valves and turn off
vacuum pump.

Page 23
2. Check system for vacuum leak.

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

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

Page 24
LEAKAGE CHECK
NOTE: Perform the leakage check after completing vacuuming process.
1. After attaching the manifold gauge, open the high side valve.
2. Charge system until the low side gauge dial indicates a pressure of 1 kg/cm2 (14 psi) and close the
high side valve.
3. Using a refrigerant leak detector or soapy
water check each joint for leakage.
Reference
Description
Number
Refrigerant Leak
1
Detection Device
4. If a leak is detected, check for O-ring

damage or correct tightening torque and
replace or repair as necessary.
5. If no leaks are detected, proceed with the
charging process. Figure 20
WARNING!
For accurate refrigerant leak
detection, perform leak detection
procedure in a well ventilated area.
REFRIGERANT CHARGING
1. Perform the vacuuming procedure, vacuum holding and leaking tests as described in the proceeding
headings.
NOTE: First charge the refrigerant system with 100 g (3.5 ounces) of refrigerant with the engine
off. Then using the manifold gauges as a guide fully charge the system with the engine
running.
When exchanging refrigerant containers, press the manifold gauge low side valve to
eliminate air from the charging hose.
Reference
Description 2 3
Number
1 To Compressor 1 4
2 Low-pressure Side
4 From Receiver
5 Refrigerant Supply
Container
2. Charge the system by opening the manifold 5

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

Page 25
3. If refrigerant does not flow freely into system, try starting engine first before operating air conditioner.
• Temperature control switch setting: Maximum Cooling
• Blower Speed Setting: Hi (3 step)
• Engine Speed: 1,300 - 1,500 rpm
WARNING!
When charging refrigerant system with the engine running;
• Always keep refrigerant supply container in the upright position.
• Never open the high side pressure valve.
4. Open the manifold gauge low side valve and charge system to standard capacity.
Gauge Dial Standard Reading
High Side Gauge 13 - 20 kg/cm2

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

(21 - 50 psi)
NOTE: These standards are for outside temperatures between 30° - 35°C (86° - 95°F). The
gauge readings may vary for extreme temperature conditions.
WARNING!
• When outside temperature is low, warm the refrigerant supply container with
warm water not exceeding 40°C (104°F). Do not allow water to come in contact
with the charging adapter valve handle.
• When outside temperature is high, cool off refrigerant supply container and
condenser to aid the refrigerant charging process.
5. Close low-pressure side valve.

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

Page 26
INSPECTING SYSTEM FOR LEAKAGE

After completing charging procedures, clean all
joints and connections with a clean dry cloth.
Using a refrigerant leak detecting device or
soapy water, inspect system for leaks starting
from the high-pressure side.
NOTE: When the refrigerant circulation
has been stopped the
high-pressure will start to
decrease and the low-pressure
will start to increase until they
are equalized. Starting the
inspection from the high side
will result in a accurate test. Figure 22
Reference
Description
Number
1 Pressure
2 High-pressure
3 Low-pressure
4 Compressor Stop
Inspection Procedure
1. High-pressure side.
Compressor outlet → condenser inlet → receiver dryer inlet → air conditioner unit inlet
2. Low-pressure side.
Compressor inlet → air conditioner unit outlet
3. Compressor.
Compressor shaft area, bolt hole area and magnetic clutch area.
4. Receiver dryer.
Pressure switch and plug area.
5. Connection valve area.
Inspect all valve areas.
Verify all valves are capped to prevent leaking.
Check for foreign material inside of valve cap.
6. Interior of air conditioner unit.
After stopping engine, insert detector probe into drain hose. (Leave inserted for 10 seconds
minimum.)
NOTE: When inspecting leakage from the air conditioner unit, perform the inspection in a well
ventilated area.

Page 27

Page 28
S0607140
1TRANSMISSION AND
TORQUE CONVERTER
(ZF 4WG-190)
CAUTION!
TRANSMISSION AND TORQUE CONVERTER (ZF 4WG-190)S0607140


January 2011
Transmission and Torque Converter S0607140

(ZF 4WG-190) Page 1
TABLE OF CONTENTS
Drive Train Description................................................................................... 6

Transmission and Torque Converter.............................................................. 8
Powershift Transmission ......................................................................... 9
Transmission Control .............................................................................. 9
The Chart of Measuring Points and Connection 4 WG-190.................. 11
Oil Circuit Diagram 4WG-190................................................................ 13
Transmission Electric Components.............................................................. 15
TCU (Transmission Control Unit) .......................................................... 16
Transmission Control Valve .................................................................. 16
Transmission Oil Temperature Sensor ................................................. 17
Engine Pickup Sensor........................................................................... 17
Central Gear Pickup Sensor ................................................................. 17
Turbine Pickup Sensor.......................................................................... 18
Output Speed Sensor............................................................................ 18
Shift Lever Switch (DW-3)..................................................................... 18
Auto Selector Switch ............................................................................. 20
Display .................................................................................................. 20
Transmission Electrical Circuits ................................................................... 21
T/M Controller Circuit ............................................................................ 21
Traveling Circuits .................................................................................. 22
Downshift .............................................................................................. 30
Transmission Cut Off ............................................................................ 33
LIS (Load Isolation System) - Option .................................................... 34
Installation View ........................................................................................... 35
Inner Section ......................................................................................... 35
Front View ............................................................................................. 36
Side View .............................................................................................. 37
Rear View.............................................................................................. 38
Special Tools................................................................................................ 39
Gearshift System................................................................................... 39
S0607140 Transmission and Torque Converter

Page 2 (ZF 4WG-190)
Engine Connection................................................................................ 41
Pressure Oil Pump ................................................................................ 42
Gearbox Housing .................................................................................. 43
Input ...................................................................................................... 45
Clutch .................................................................................................... 46
Output ................................................................................................... 52
Power Take-off...................................................................................... 53
Hydraulic Control Unit (HSG-94) .................................................................. 54
Disassembly.......................................................................................... 55
Reassembly .......................................................................................... 58
Transmission Disassembly........................................................................... 65
Hydraulic Control Unit (HSG-94) and Duct Plate .................................. 65
Engine Connection - Converter............................................................. 66
Hydraulic Pump..................................................................................... 68
Converter Back Pressure Valve ............................................................ 69
Remove Output, Input and Clutches ..................................................... 70
Disassemble Clutch - KV and KR ......................................................... 75
Disassemble Clutch - K1, K2 and K3 .................................................... 78
Dissemble Clutch - K4........................................................................... 80
Disassemble Drive Shaft....................................................................... 81
Transmission Reassembly ........................................................................... 83
Install Oil Tube ...................................................................................... 83
Reassemble Clutch - KV and KR .......................................................... 85
Reassemble Clutch - K1, K2 and K3..................................................... 92
Reassemble Clutch - K4 ....................................................................... 99
Preassemble Drive Shaft .................................................................... 105
Preassemble and Install Output .......................................................... 106
Install Preassembled Drive Shaft and Clutches .................................. 108
Install Pump Shaft (Power Take-off) ................................................... 111
Install Output Flanges ......................................................................... 112
Converter Back Pressure Valve .......................................................... 114
Oil Feed Housing - Transmission Pump ............................................. 114
Engine Connection - Converter........................................................... 116

(ZF 4WG-190) Page 3
Converter Safety Valve ....................................................................... 119
Mount Duct Plate and Hydraulic Control Unit...................................... 119
Install Plugs and Oil Level Tube.......................................................... 120
Speed Sensor and Inductive Transmitters .......................................... 122
Setting Inductive Transmitter .............................................................. 123
Speed Sensor (Hall Sensor) N Output and Speedometer .................. 125

Page 4 (ZF 4WG-190)
(ZF 4WG-190) Page 5
DRIVE TRAIN DESCRIPTION
Figure 1, shows layout of drive train assemblies. The engine (1, Figure 1) drives a torque converter (2),
which drives a power shift transmission (3). Two output shafts extend out of transmission. Each output
shaft has a drive shaft attached to it. Front drive shaft (4) drives a final drive shaft (6) that drives front
differential (7).
A parking brake (8, Figure 1) is mounted on transmission output shaft. The front differential is enclosed in
front axle housing (9). Each end of front axle housing contains reduction gearing (10). Each end of front
axle housing also contains a service brake (11). Rear drive shaft (5) drives the rear differential (12). The
rear differential is enclosed in rear axle housing (13). Each end of rear axle housing contains reduction
gearing (10). Each end of rear axle housing also contains a service brake (11).
10 11 10 11
9
8
2 3
4 6
13
12 5
BZS0050L
Figure 1

Page 6 (ZF 4WG-190)
Reference Reference
Number Number
1 Engine 8 Parking Brake
2 Torque Converter 9 Front Axle Housing
3 Transmission 10 Reduction Gearing
4 Center Drive Shaft 11 Service Brake
5 Rear Drive Shaft 12 Rear Differential
6 Front Drive Shaft 13 Rear Axle Housing
7 Front Differential

(ZF 4WG-190) Page 7
TRANSMISSION AND TORQUE CONVERTER
The machine contains a powershift transmission that has four forward speeds and three speeds in
reverse. Gear changes are made by an electrohydraulic control valve that is mounted on transmission.
Moving gear select lever in cab, generates an electrical signal that is transmitted to control valve. The
control valve contains proportional valves that direct pressurized fluid to various clutches that control the
forward and reverse gears.
Item Mega 250-V

Model 4WG-190 (Full Auto)
Type 3-Element, 1-Stage, Single-phase,
E/G mounted with flexible plate
Oil Cooler Water-cooled (multi-plate) and Air-cooled
Torque Converter Charging Pump 105 lpm at 2,000 rpm
Hydraulic Pump P.T.O 1:1
T/C Size ∅ 340 mm (13.39 in)
Stall Ratio 2.873
Safety Relief 11 Bar (160 psi)
Type Full Power Shift, Counter shaft
Speeds 4 Forward / 3 Reverse
Ratio F: 3.632 / 2.184 / 1.072 / 0.636
Transmission R: 3.444 / 1.981 / 1.017
Power Shift Control 16 - 18 bar (232 - 261 psi)
Pressure
Shift Control Electric Shift with Proportional Valve
Oil Capacity 27 l (10 U.S. gal)
Dry Weight 470 kg (1,036 lb)
Front 7 C Mechanics
Output Flange
Rear 6 C Mechanics

Page 8 (ZF 4WG-190)
POWERSHIFT TRANSMISSION
The multispeed reversing transmission in layshaft design is engaged under load by hydraulically controlled
multidisk clutches.
All gears wheels are constantly meshing and running in antifriction bearings.
The gear wheels, bearings and clutches are cooled and lubricated with oil.
The 4-speed reversing transmission is equipped with 6 multidisk clutches.
At the shifting, the corresponding plate pack is compressed by a piston, movable in axial direction, which is
pressurized by pressure oil.
A compression spring is pushing back the piston, thus the releasing the plate pack. As to layout of
transmission and the indication of closed clutches in single speeds, See “The Chart of Measuring Points
and Connection 4 WG-190” on page -11. and “Oil Circuit Diagram 4WG-190” on page 13.
TRANSMISSION CONTROL
Transmission control, See “The Chart of Measuring Points and Connection 4 WG-190” on page -11.,
Electrohydraulic unit on page -12 and “Oil Circuit Diagram 4WG-190” on page 13.
The transmission pump, necessary for the oil supply of converter, and the transmission control, is
input-side mounted from outside, together with stator shaft and oil supply flange, on transmission. The
drive is realized by the pump-wheel flange of converter.
The feed rate of pump is Q = 105 lpm at nEngine = 2000 min-1.
This pump is sucking the oil through the coarse filter out of oil sump and delivers it through the ZF-Fine
filter can be fitted also externally from transmission - to system pressure valve.
ZF-Fine filter
Grade of filtration according to ISO 4572: β30 ≥ 75 β15 = 25 β10 = 5.0
Filter area at least: 3,900 cm2
Dust capacity according to ISO 4572 at least: 40 g
The six clutches of transmission are selected via the 6 proportional valves P1 to P6.
The proportional valve (pressure regulator unit) consist of pressure regulator (e.g. Y1). follow-on slide and
oscillation damper.
The pilot pressure of 9 bar (130.54 psi) for the control of follow-on slides is created by the reducing valve.
The pressure oil (16 +2 bar (230 +29 psi)) is directed through the follow-on slide to corresponding clutch.
By the direct proportional selection with separated pressure modulation for each clutch, the pressure to
clutches, taking part in gear change, are controlled. In this way, a hydraulic intersection of clutches to be
engaged and disengaged becomes possible. This is loading due to fast shifting without traction force
interruption.
At the shifting, the following criteria will be considered:
- Speed of engine, turbine, central gear train and output.
- Transmission temperature.
- Shifting mode (up-, down-, reverse shifting and speed engagement out of Neutral).
- Load condition (full and part load, traction, coasting inclusive consideration of load cycles during the
shifting).
These shifting procedures are exactly adapted to different models and types of vehicle.

(ZF 4WG-190) Page 9
The system pressure valve is limiting the max. control pressure to 16 +2 bar (230 +29 psi) and releases the
main stream to converter and lubricating circuit.
A converter relief valve is installed in converter inlet, which protects the converter against high internal
pressure (opening pressure 11 bar (160 psi)).
Within the converter, the oil is the medium of power transmission according to well-known hydrodynamic
principle.
To avoid cavitation, the converter must be always completely filled with oil.
This is achieved by a converter pressure holding valve, following the converter, with an opening pressure
of at least 3.5 bar (51 psi).
The oil, escaping from converter, is directed to a heat exchanger.
The oil is directed from heat exchanger to transmission and from there to lubricating oil circuit so that all
lubricating points are supplied with cooled oil.
In the electrohydraulic control unit there are 6 pressure regulators installed See “Hydraulic Control Unit
(HSG-94) and Duct Plate” on page -65..
The allocation of pressure regulators to single speeds can be seen on “The Chart of Measuring Points and
Connection 4 WG-190” on page 11 and “Oil Circuit Diagram 4WG-190” on page 13.

Page 10 (ZF 4WG-190)
THE CHART OF MEASURING POINTS AND CONNECTION 4 WG-190
The measurements have to be carried out at hot transmission (about 80° - 95°C).
Marking on
No. Denomination of Position Connection
Valve Block
Measuring Points for Pressure Oil and Temperature
51 Converter Inlet - Opening pressure 9 bar (130 psi) M10 x 1 H
52 Converter Exit - Opening pressure 3.5 bar (51 psi) M14 x 1.5
53 Clutch Forward 16+2 bar (230 - 260 psi) KV M10 x 1 B
55 Clutch Reverse 16 +2 bar (230 +29 psi) KR M10 x 1 E
56 Clutch 16 +2 bar (230 +29 psi) K1 M10 x 1 D
57 Clutch 16 +2 bar (230 +29 psi) K2 M10 x 1 A
58 Clutch 16 +2 bar (230 +29 psi) K3 M10 x 1 C
60 Clutch 16 +2 bar (230 +29 psi) K4 M10 x 1 F
63 Converter Exit
M14 x 1.5
Temperature 100°C, Short-time 120°C
65 System Pressure 16 +2 bar (230 +29 psi) K4 M10 x 1 K
Measuring points for Delivery Rates
15 Connection to Heat Exchanger 1 5/16" - 12UNF-2B
16 Connection from Heat Exchanger 1 5/16" - 12UNF-2B
Inductive Transmitters and Speed Sensor
21 Inductive Transmitter n Turbine M18 x 1.5
34 Speed Sensor n Output and Speedometer -------
47 Inductive Transmitter n Central Gear Train M18 x 1.5
48 Inductive Transmitter n Engine M18 x 1.5
Connections
49 Plug Connection on Hydraulic Control Unit
68 Pilot Pressure (Option) M16 x 1.5 J
69 System Pressure (Option) M16 x 1.5 G

(ZF 4WG-190) Page 11
Figure 2

OIL CIRCUIT DIAGRAM 4WG-190
Reference
Positions
Number
WT Heat Changer
WGV Converter Back Pressure Valve 3.50 bar (50 psi)
WSV Converter Relief Valve 11 bar (160 psi)
HDV System Pressure Valve 16 +2 bar (230 +30 psi)
RV-9 Pressure Reducing Valve 9 bar (130 psi)
NFS Follow-on Slide
D Oscillation Damper
B Orifice
P1 Proportional Valve - Clutch K4
P2 Proportional Valve - Clutch KR
P5 Proportional Valve - Clutch KV
Y1 - Y6 Pressure Regulator
TEMP Temperature Sensor
Figure 3

Page 14
S0607140
Figure 4
LEGEND:
= System Pressure
= Controlled Clutch Pressure
= Pilot Pressure
= Converter Inlet Pressure

= Converter Exit Pressure
= Lubrication
= Return Flow Into The Sump
AMS1111L
Transmission and Torque Converter

(ZF 4WG-190)
TRANSMISSION ELECTRIC COMPONENTS
21
13
10
18
19
14 17
20
8
15
1
16
9 3
11 4
12 5
6
2
AJS0191L
Figure 5
Reference Reference
Number Number
1 T/M Controller 12 T/M Cutoff Pressure Switch
2 T/M Control Valve 13 Downshift Switch
3 T/M Oil Temperature Sensor 14 Safety Starter Switch
4 Engine Pickup Sensor 15 Fuse Box
5 Central Gear Pickup Sensor 16 Parking Brake Switch
6 Turbine Pickup Sensor 17 Control Unit
7 Output Speed Sensor 18 Starter Controller
8 Shift Lever Switch 19 LIS (Load Isolation System)
9 Auto Selector Switch Switch (Option)
10 Display 20 LIS Solenoid Valve
11 T/M Cutoff Switch 21 Speedometer

TCU (TRANSMISSION CONTROL UNIT)
1. Sending a control signal transmitted from
shift lever to control valve, generates a
speed.
2. In auto mode, transmits the appreciate
signals to control valves according to load
and engine rpm.
3. Detecting a fault, controls various
clutches.
AJS0200L
Figure 6
TRANSMISSION CONTROL VALVE
1. The transmission control valve contains a
temperature sensor and proportional
solenoid valves (Y1-Y6) that direct
pressurized fluid to various clutches that
generates a speed with control the shift
gears.
2. Specification of proportional solenoid
valve.
• Resistance: 19 ohm ±1.9 ohm at
20°C. AJS0210L
Figure 7
• Pressure: 0.8 kg/cm2 → 8.3 kg/cm2
(11 - 118 psi)
3. The contained temperature sensor detects
the temperature of control valve and
transmits the electrical signal to TCU, and
serves TCU determines gears to change.
• Neutral: At temperature less than
-30°C
• 1st or 2nd gear: At temperature less
than -10°C
• Normal Operation: At temperature
greater than -10°C

TRANSMISSION OIL TEMPERATURE
SENSOR
1. Detecting a oil temperature of
transmission and send a control signal to
transmission oil temperature gauge.
2. Specification
• Resistance
216 Ohm ±30 Ohm (at 60°C)
81.2 Ohm ±10 Ohm (at 90°C)
AJS0200L
36.5 Ohm ±3.5 Ohm (at 120°C)
Figure 8
18.7 Ohm ±2.1 Ohm (at 150°C)
ENGINE PICKUP SENSOR

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

TURBINE PICKUP SENSOR
1. Detect a revolution of gear array in turbine
side.
2. Specification
• Gap: 0.5 - 0.8 mm
(0.0197 - 0.0315 in)
• Output: 59 Pulse/Rev. AJS0250L
Figure 11
OUTPUT SPEED SENSOR
3(+)
1. Detect a revolution of gear array in
transmission output side. 2(SIG)
1(-)
2. Specification.
• Voltage Supply: 20 V - 32 V
• Operation Frequency: 2 Hz - 5 KHz
• Fasten torque (M8): 2.3 kg•m
(17 ft lb)
1.5 40
• Gap: 1.0 - 1.5 mm AJS0260L
(0.0394 - 0.0591 in)
Figure 12
• Output: 60 Pulse/Rev.
SHIFT LEVER SWITCH (DW-3)

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

4. Switch Circuit
B A AD3 (B3)
1 2 G B AD2 (B2)
1 2 L X1
C AD1 (B1)
1 2 V
D AD7 (KD)
R A ED1 (+/VP)
2 Gr
1 D AD6 (N)
3 2
1
3 Y B AD4 (F) X2
2
1
3 P C AD5 (R)
AJS0280L
Figure 14
5. Terminal position and color
TERMINAL COLOR
(AD6) GREY
D C B A
(AD5) PINK
X2
(AD4) YELLOW
(VP) RED
(AD7) VIOLET
D C B A
(AD1) BLUE
X1
(AD2) GREEN
(AD3) BLACK
AJS0290L
Figure 15
6. Switch Connection
GEAR FORWARD REVERSE NEUTRAL KICK

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

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

TRANSMISSION ELECTRICAL CIRCUITS
T/M CONTROLLER CIRCUIT
AJS0312L
Figure 18
The transmission proportioning solenoid valves are shown here as (Y1 thru Y6, Figure 18).

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

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

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

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

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

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

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

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

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

Kick-down: Forward Second Gear to Forward First Gear
(Auto Selector Switch "O"- Manual Mode)
AJS0390L
Figure 28
With the auto selector switch (Figure 29) is in

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

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

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

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

LIS (LOAD ISOLATION SYSTEM) - OPTION
Excessive bucket pitching is drastically reduced
and good floatation is maintained for minimum
operator fatigue and maximum productivity.
LIS is useful for sites where frequent cycles of
loading and carry are needed or rough terrain.
O
When the LIS switch is "I" and the vehicle speed
is above 8 km/h (4.97 MPH), the LIS solenoids
valves (14) are energized and the LIS system is I
"ON."
When the LIS switch is "I" and the vehicle speed
is below 6 km/h (3.73 MPH) the LIS solenoids HA0O2026
valves (14) are de-energized and the LIS Figure 33
system is "OFF."
NOTE: If the LIS switch is in 'O' position, regardless of vehicle speed the LIS solenoid valves (14)
de-energized and the LIS system is not operating.
AJS0440L
Figure 34

INSTALLATION VIEW
INNER SECTION
Figure 35
Reference Reference
Number Number
1 Clutch Shaft "KR" 9 Transmission Pump
2 Power Take-off; Coaxial; 10 Flexible Plate
Engine-dependent 11 Converter
3 Clutch Shaft "KV" 12 Input Transmitter for Engine
4 Clutch Shaft "K2" Speed
5 Clutch Shaft "K3" 13 Clutch Shaft "K4"
6 Output Flange - Rear 14 Converter Relief Valve
7 Output Flange - Converter 15 Clutch Shaft "K1"
Side
8 Output Shaft

FRONT VIEW
Figure 36
Reference Reference
Number Number
1 Lifting Lugs 6 output Flange - Converter Side
2 Flexible Plate 7 Oil Drain Plug with Magnetic
3 Transmission Suspension Insert M38x1.5
Bores M20 8 Attachment Possibility for Oil
4 Attachment Possibility for Filter Pipe with Oil Dipstick
Emergency Steering Pump (Not (Converter Side)
Used)
5 Model Identification Plate

SIDE VIEW
1 2 3 4 5
12
11 9
10
BZS0060L
Figure 37
Reference Reference
Number Number
1 Flexible Plate 7 Box Filter (Fine Filter)
2 Converter 8 Parking Brake
3 Converter Bell Housing 9 Output Flange - Rear
4 Breather 10 Oil Drain Plug with Magnetic
5 Transmission - Case Cover Insert M38x1.5
6 Filter Head 11 Output Flange - Converter Side
12 Transmission Case

REAR VIEW
1 2
6
4
HOT
BZS0070L
Figure 38
Reference Reference
Number Number
1 Lifting Lugs 5 Transmission Suspension Bores
2 Power Take-off; Coaxial; M20
Engine-dependent 6 Output Flange - Rear
3 Electrohydraulic Control 7 Parking Brake
4 Oil Filter Pipe 8 Box Filter (Fine Filter)
9 Filter Head

SPECIAL TOOLS
GEARSHIFT SYSTEM
Figure 39

Figure 40

ENGINE CONNECTION
Figure 41

PRESSURE OIL PUMP
Figure 42

GEARBOX HOUSING
Figure 43

Figure 44

INPUT
Figure 45

CLUTCH
Clutch KV
Figure 46

Clutch KR
Figure 47

Clutch K1
Figure 48

Clutch K2
Figure 49

Clutch K3
Figure 50

Clutch K4
Figure 51

OUTPUT
Figure 52

POWER TAKE-OFF
Figure 53

HYDRAULIC CONTROL UNIT (HSG-94)
Figure 54, shows a sectional view of HSG-94.
IMPORTANT
Different versions in relation to position of cable harness are possible.
In this connection, pay attention to Specifications of Vehicle Manufacturer.
Figure 54

Section A -A
Figure 55
DISASSEMBLY
1. Figure 56, shows complete control unit.
Figure 56

2. Mark installation position of different
covers, housing and cable harness with
valve housing.
Figure 57
3. Remove socket head screws.
4. Separate duct plate, 1st gasket,
intermediate plate and 2nd gasket from
valve housing.
(S) Box spanner (Torx TX-27) - 5873 042
002
Figure 58
5. Remove retaining clip.
Figure 59
7. Separate cover from housing and cable
harness.
002
Figure 60

8. Disassemble opposite cover.
9. Disconnect pressure regulator and remove
cable harness.
Figure 61
10. Remove socket head screws, remove
fixing plate and pressure regulators (3x).
002
Figure 62
11. Remove two socket head screws and
locate housing provisionally, using
adjusting screws. (Housing is under spring
preload). Remove remaining socket and
screws.
002
(S) Adjusting screws - 5870 204 036
Figure 63
12. Separate housing from valve housing by
loosening adjusting screws uniformly.
Figure 64

13. Remove components (Figure 65).
14. Remove opposite pressure regulators,
housing and components accordingly
(Figure 66).
Figure 65
Figure 66
REASSEMBLY
NOTE: Check all components for
damage and replace if
necessary. Before installation,
check free travel of all moving
parts in housing. Spools can be
exchanged individually. Oil
components before reassembly
according to ZF-List of
Insert diaphragms with concave
side facing up until seated.
Figure 67
NOTE: Installation position, see
arrows.

1. Figure 68, shows the following
components:
Reference
Description
Number
1 Vibration Damper (3x
Spool and
Compression Spring)
2 Follow On Site (3x
Spool and
Compression Spring)
3 Pressure Reducing
Valve (1x Spool and Figure 68
Compression Spring)
2. Install components according to Figure 68.

NOTE: Preload compression spring of
follow on sitie slides and locate
spool provisionally using
cylindrical pins Ø 5.0 mm
(0.1969 in) (assembly aid), See
Figure 69.
Figure 69
3. Install two adjusting screws.
4. Assemble gasket (1, Figure 70) and
housing cover (Figure 70). Position
housing cover uniformly, using adjusting
screws, until seated and remove
cylindrical pins (assembly aid) again
(Figure 70).
NOTE: Pay attention to different
housing covers.
5. Install recess Ø 15.0 mm (0.5906 in)
(2, Figure 70), facing spring of pressure
reducing valve. Figure 70

Figure 71
6. Fasten housing cover using socket head
screws.
NOTE: Torque limit 0.56 kg•m (4 ft lb).
002
Figure 72
7. Install pressure regulators and attach
using fixing plates and socket head
screws.
NOTE: Install fixing plate, with claw
facing down. Pay attention to
radial installation position of
pressure regulators, see Figure
73.
002
Figure 73

8. Preassemble opposite side.
A. Figure 74, shows the following
components:
Reference
Description
Number
1 Main Pressure Valve
(1x Spool and
Compression Spring.)
2 Follow On Slide (3x
Spool and
Compression Spring)
Figure 74
3 Vibration Damper (3x
Spool and
Compression Spring)
B. Install components according to

Figure 74.
C. Preload compression springs of
follow on slides and locate spool
provisionally using cylindrical pins
Ø 5.0 mm (0.1969 in) (assembly aid).
See arrows.
D. Install two adjusting screws.
E. Assemble gasket (1, Figure 75) and
housing cover, and position them
uniformly against shoulder, using
adjusting screws.
housing covers, install recess Ø
19.0 mm (0.7480 in) (2, Figure
75), facing main pressure
valve.
F. Down, fasten housing cover using
socket head screws. Figure 75
G. Remove cylindrical pins (assembly
aid) again.
002

H. Install pressure regulators and attach
using fixing plates and socket head
screws.
NOTE: Install fixing plates, with claw
facing down.
I. Pay attention to radial installation
position of pressure regulators, see
Figure 76.
NOTE: Torque limit 5.5 N.
002
Figure 76
J. Install cable harness and connect
pressure regulators (6x).
position of cable harness, see
also markings (Figure 57).
Figure 77
K. Install female connector against
shoulder, with groove facing guide
nose of cover.
L. Install gaskets (Figure 78) and fasten
cover using socket head screws.
002
Figure 78
M. Install female connector using
retaining clamp, see Figure 79.
N. Install opposite cover.
Figure 79

O. Install two adjusting screws and
mount gasket I.
gaskets, see Figure 80 and
Figure 83.
Figure 80
9. Intermediate plate-version with screens:
A. Insert screens (6x) flash -mounted
into bore of intermediate plate, see
Figure 81.
position screens are facing up
(facing duct plate).
Figure 81
B. Mount intermediate plate, with
screens with screens facing up.
Figure 82
C. Mount gasket II.
Figure 83

D. Mount duct plate and fasten it
uniformly using socket head screws.
NOTE: Torque limit 1 kg•m (7 ft lb).
002
Figure 84
E. install new O-rings on plugs (8x) and
install them.
NOTE: Torque limit 0.61 kg•m
(4.4 ft lb).
NOTE: The installation of hydraulic
control unit is described in
following section, “Mount Duct
Plate and Hydraulic Control
Unit” on page 119.
Figure 85

TRANSMISSION DISASSEMBLY
1. Fasten transmission on assembly car.
(S) Assembly car - 5870 350 000
(S) Strips - 5870 350 063
(S) Support - 5870 350 090
Figure 86
HYDRAULIC CONTROL UNIT (HSG-94) AND
DUCT PLATE
1. Remove two socket head screws and
install adjusting screws.
2. Remove remaining socket head screws
and valve housing from duct plate.
(S) Adjusting screws (M6) - 5870 204 063
002
Figure 87
3. Remove both gaskets and intermediate
plate.
4. Remove socket head screws and hex.
nuts (Figure 88). Remove duct plate from
gearbox housing. Remove gasket.
004
Figure 88

5. Remove converter safety valve out of
housing bore.
Figure 89
ENGINE CONNECTION - CONVERTER
1. Remove lock plate and hex. head screws.
2. Remove disk and pry drive flange off shaft.
Figure 90
3. Remove screw connection.
NOTE: Mark radial installation position
of housing cover.
Figure 91
4. Separate converter along with cover from
transmission, using lifting device.
(S) Set of eyebolts - 5870 204 002
Figure 92

5. Remove drive shaft resp. converter out of
cover (ball bearing).
Figure 93
6. Remove retaining ring and ball bearing.
(S) Set of internal pliers - 5870 900 013
Figure 94
7. Remove hex. head screws and diaphragm
from converter.
Figure 95
8. Remove hex. head screws and drive shaft
from diaphragm.
Figure 96

9. Remove inductive transmitter (n Engine).
Figure 97
10. Remove hex. head screws and converter
bell.
Figure 98
HYDRAULIC PUMP
Figure 99
2. Install device (S) on gear teeth run out of
stator shaft and remove (compl.) using
two-armed puller carefully out of housing
bores.
(S) Separating device - 5870 300 024
(S) Two-armed puller - 5870 970 004
Figure 100

3. Separate hydraulic pump from stator shaft.
4. Separate control disk from pump.
NOTE: If traces due to running-in
should be encountered in pump
housing or on control disk,
complete pump has to be
replaced.
5. Lay on control disk again and attach it
using grooved pins (2x).
Figure 101
6. Remove socket head screws and two hex.
head screws and oil feed housing.
Remove gasket.
(S) Box spanner (Torx, TX-40) - 5873 023
004
Figure 102
CONVERTER BACK PRESSURE VALVE
1. Preload compression spring and remove
lock plate.
2. Remove released components.
Figure 103
3. Remove hex. head screws.
Remove cover and gasket.
Figure 104

REMOVE OUTPUT, INPUT AND CLUTCHES
1. Remove lock plate, remove hex. head
screws and pry converter-side output
flange off shaft.
2. Pry shaft seal out of housing bore.
3. Tilt transmission 180° and remove
rear-side output flange.
(S) Pry bar - 5870 345 065
Figure 105
4. Remove speed sensor and both inductive
transmitters (Arrows).
Figure 106
5. Remove hex. nuts and both covers
(Arrows).
6. Remove screw connection (housing/
housing cover).
Figure 107
7. Remove both cylindrical pins (Arrows).
NOTE: The following figures show
common removal of all
clutches.
8. The removal of single clutches without use
of special tool (Handles - 5870 260 010) is
difficult due to installation arrangement.
NOTE: There is also a danger of
injuries.
Figure 108

9. Locate all clutches using handles (S) in
housing cover.
10. Install eyebolts and hang in lifting device.
(S) Handles (6 pieces needed) - 5870 260
010
(S) Eyebolt 2x (M20) - 0636 804 003
(S) Eyebolt 1x (M16) - 0636 804 001
(S) Puller device - 5870 000 017
(S) Lifting chain - 5870 281 047
Figure 109
11. Separate housing cover along with
clutches from gearbox housing using lifting
device.
Figure 110
12. Fasten housing cover on assembly car.
(S) Assembly car - 5870 350 000
(S) Clamping bracket - 5870 350 089
Figure 111
13. Remove socket head screws, output shaft
and two oil collecting plate.
Figure 112

14. Remove tapered roller bearing.
15. Remove opposite tapered roller bearing.
(S) Grab sleeve - 5873 002 038
(S) Basic set - 5873 002 001
Figure 113
o
16. Tilt gearbox housing 180 .
17. Figure 114, shows arrangement of single
clutches and input in housing cover.
Reference
Description
Number
AN Input
KV Clutch - Forward
KR Clutch - Reverse
K1 Clutch - 1st Speed
K2 Clutch - 2nd Speed
Figure 114
K3 Clutch - 3rd Speed
K4 Clutch - 4th Speed
18. Remove handles (S) (Figure 115).

(S) Handles - 5870 260 010
Figure 115

19. Remove Clutch-K4 a bit using pry bars
and remove Clutch-K1.
Figure 116
20. Remove Clutch-K2.
Figure 117
21. Remove Clutch-K3.
Figure 118
22. Remove Clutch - KV and KR using pry
bars and remove Clutch - K4.
(S) Pry bar - 5870 345 065
Figure 119

23. Remove Clutch - KV and Clutch - KR with
input together out of housing cover.
24. Remove outer bearing races out of
housing bores.
IMPORTANT
If contrary to ZF-Recommendation
the tapered roller bearing of clutches
and of input and output are not
replaced, the allocation (inner
bearing races to outer bearing races) Figure 120
must at least be maintained.
Mark inner bearing races and outer
bearing races accordingly to each
other.
25. Tilt housing cover 90o.

26. Remove retaining ring and pump shaft
from housing cover.
Figure 121
27. Remove rectangular ring (Arrow) and
press ball bearing from shaft.
Figure 122

DISASSEMBLE CLUTCH - KV AND KR
1. Remove rectangular ring (Arrow).
disassembly of Clutch - KV.
The disassembly of Clutch - KR
is similar.
Figure 123
2. Remove tapered roller bearing from shaft.
(S) Grab sleeve - 5873 001 057
(S) Grab sleeve - 5873 001 059
(S) Basic set - 5873 001 000
Figure 124
Figure 125
5. Separate plate carrier from shaft.
(S) Three Leg Puller - 5870 970 003
Figure 126

6. Remove retaining ring and plate pack.
Figure 127
7. Preload compression spring, squeeze
retaining ring out and remove
components.
(S) Assembly aid - 5870 345 088
Figure 128
8. Remove piston using compressed air out
of cylinder bore and remove it.
Figure 129
9. Remove both O-ring (Arrows).
Figure 130

10. Remove idler gear a bit using pry bars
(Figure 131).
11. Apply puller and remove idler gear from
clutch shaft (Figure 132).
Figure 131
12. Remove retaining ring and ball bearing.
NOTE: The disassembly of Clutch - KR
has to be carried out.
Figure 132
Figure 133

DISASSEMBLE CLUTCH - K1, K2 AND K3
disassembly of Clutch - K3. The
disassembly of Clutches - K1
and K2 is similar.
1. Remove rectangular ring. Remove tapered
roller bearing from shaft.
(S) Grab sleeve (Bearing 33800) - 5873
001 059
(S) Grab sleeve (Bearing 33800) - 5873 Figure 134
002 038
(S) Basic set - 5873 001 000
(S) Basic set - 5873 002 001
3. Remove running disk, axial needle cage
and axial washer.
Figure 135
4. Remove idler gear.
Figure 136

5. Remove needle bearings and axial
bearing (compl.).
Figure 137
Figure 138
7. Preload cup-spring pack and squeeze
retaining ring out. Remove released
components.
(S) Assembly aid - 5870 345 088
Figure 139
8. Install retaining ring (S) into groove of
plate carrier.
9. Apply puller on retaining ring and remove
plate carrier from clutch shaft.
(S) Puller - 5870 970 004
(S) Retaining ring - 0630 502 053
Figure 140

DISSEMBLE CLUTCH - K4
1. Remove rectangular ring (Arrow).
Figure 141
2. Remove tapered roller bearing from shaft.
(S) Grab sleeve - 5873 001 057
(S) Grab sleeve - 5873 001 059
(S) Basic set - 5873 001 000
Figure 142
4. Remove retaining ring and plate carrier
from shaft.
(S) Three-armed puller - 5870 971 003
Figure 143
Figure 144

6. Preload cup-spring pack and squeeze
retaining ring out.
7. Remove released components. Remove
piston.
(S) Assembly aid - 5870 345 088
Figure 145
8. Remove piston using compressed air out
of cylinder bore and remove it.
Figure 146
9. Take off idler gear and remove released
components.
NOTE: The separation of shaft and
gear is not possible (shrink fit).
Figure 147
DISASSEMBLE DRIVE SHAFT
1. Remove rectangular ring.
2. Remove tapered roller bearing. Remove
opposite tapered roller bearing.
(S) Grab sleeve - 5873 002 045
(S) Basic set - 5873 002 001
(S) Basic set - 5873 002 006
Figure 148

3. If necessary, press turbine shaft out of
drive shaft.
NOTE: The turbine shaft is axially fixed
with a retaining ring which will
be destroyed while pressing it
out.
Figure 149

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

and pressure pipe lubrication (3) into
housing bores.
2. Fasten suction and pressure pipes using
socket head screws.
NOTE: Torque limit (M8/8.8) 2.35 kg•m
(16.96 ft lb)
Figure 150
o
3. Tilt housing 180 .
4. Roll suction and pressure pipes (Arrows)
into housing bores, using special tool.
IMPORTANT
The pipe end must be maximally
plane with the housing face. If
necessary, equalize projection of
pipe.
Figure 151
(S) Rolling tool - 5870 600 003
(S) Rolling tool - 5870 600 005
(S) Rolling tool - 5870 600 007

5. Insert O-rings (2x/pipe) into annular
grooves of two oil tubes and oil them.
Figure 152
6. Assemble both oil tubes (Arrows) until
seated.
7. Install new O-ring on plug and install it.
(103.26 ft lb).
Figure 153
8. Insert both oil tubes (Arrows) into housing
cover, tilt housing cover 180o and roll oil
tubes into housing bores.
(S) Rolling tool - 5870 600 008
IMPORTANT
The pipe end must be maximally
plane with the housing face. If
necessary, equalize projection of
pipe. Figure 154

9. Mount studs (M8 x 25).
NOTE: Torque limit (studs) 0.92 kg•m
(6.64 ft lb).
NOTE: Wet screw thread with Loctite
#262.
10. Install new O-rings on plugs (Arrows) and
install them.
NOTE: Torque limit (M16x1.5) 4.08
kg•m (29.50 ft lb).
kg•m (36.88 ft lb). Figure 155
kg•m (59.0 ft lb).
11. Insert sealing cover, with recess facing up.
NOTE: Wet contact face with Loctite
#262.
Figure 156
REASSEMBLE CLUTCH - KV AND KR
reassembly of Clutch - KV. The
reassembly of Clutch - KR has
to be carried out.
1. Preassemble Plate Carrier (Figure 157
thru Figure 160).
A. Check function of purge valve.
NOTE: Ball must not stick, if
necessary, clean with
compressed air.
Figure 157
B. Insert both O-rings (Arrows) scroll
free into grooves of piston and oil.

C. Install piston until seated.
Figure 158
D. Install disk, compression spring and
guide ring.
Figure 159
E. Preload compression spring and
attach it using retaining ring.
(S) Assembly aid - 5870 345 088
Figure 160

F. Plate pack - KV, KR
The right draft shows installation
position of components.
NOTE: The plate arrangement resp.
stacking of clutch - KV and KR
is identical.
Reference
Description
Number
1 Plate Carrier
2 Piston
3 Outer Plate - One Sided
Coated (1 Piece)
4 Inner Plates (10 Pieces)
5 Outer Plate - Coated On Figure 161
Both Sides (10 Pieces)
6 Retaining Ring (Optional
S = 2.1 - 4.2 mm
{0.08 - 0.17 in})
7 End Shim
NOTE: Effective number of friction

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

mm
(0.11 in)
NOTE: For adjustment of plate
clearance there are retaining
rings of different thickness
available. To ensure a faultless
measuring result, install plates
for the moment without oil.
2. Install plate pack accordingly to Figure
161.
Figure 162

3. Lay on end shim and squeeze retaining
ring in (e.g. s = 2.50 mm {0.10 in}).
Figure 163
4. Press on end shim with about 100 N
{10 kg (22 lb)}, apply dial indicator and set
it at zero (Figure 164).
Figure 164
5. Push end shim, using screwdriver against
retaining ring until seated (upward) and
read plate clearance on dial indicator
(Figure 165).
NOTE: In case of a deviation from
required plate clearance,
correct with corresponding
retaining ring (s = 2.1 - 4.2 mm
{0.08 - 0.17 in}).
6. After adjustment of plate clearance has
been carried out, remove plate pack, oil
plates and install it again.
Figure 165
(S) Magnetic stand - 5870 200 055
IMPORTANT
Use oil according to list of lubricants
TE-ML 03.

7. Install idler gear until all inner plates are
accommodated.
NOTE: This step makes later assembly
of idler gear easier.
8. Remove idler gear again.
Figure 166
9. Mount stud (Arrow).
#241.
NOTE: Torque limit (M10) 1.73 kg•m
(12.54 ft lb).
Figure 167
10. Insert ball bearing until seated and attach
using retaining ring.
Figure 168
11. Assemble needle bearing.
Figure 169

12. Press idler gear against shoulder.
NOTE: Support it on inner bearing
race.
Figure 170
13. Heat inner diameter of plate carrier (about
120oC).
(S) Hot-air blower 220V - 5870 221 500
(S) Hot-air blower 110V - 5870 221 501
Figure 171
14. Assemble preassembled plate carrier until
seated.
Figure 172
15. Locate plate carrier axially using retaining
ring.
Figure 173

16. Check function of clutch using
compressed air.
NOTE: At correctly installed
components, closing resp.
opening of clutch is clearly
audible.
Figure 174
17. Press tapered roller bearing against
shoulder.
18. Install opposite tapered roller bearing.
Figure 175
19. Install rectangular rings into groove.
Figure 176

REASSEMBLE CLUTCH - K1, K2 AND K3
1. The following figures show reassembly of
Clutch-K3. The reassembly of Clutches-K1
and K2 has to be carried out.
2. Install stud (Arrow).
#241.
(12.54 ft lb).
Figure 177
3. Heat inner diameter of plate carrier (Figure
178) and assemble plate carrier until
seated (Figure 179).
(S) Hot-air blower 220V - 5870 221 500
(S) Hot-air blower 110V - 5870 221 501
Figure 178
Figure 179
4. Check function of purge valve.
NOTE: Ball must not stick, if necessary
clean with compressed air.
5. Insert both O-rings (Arrows) scroll free into
grooves of piston and oil.
Figure 180

6. Install piston until seated.
Figure 181
7. Lay on cup-spring pack and guide ring.
NOTE: Pay attention to stacking of cup
springs, see page -94.
Figure 182
8. Preload cup-spring pack and attach it
(S) Assembly aid - 5870 345 088
Figure 183

A. Plate pack - K1
IMPORTANT
The plate arrangement of Clutch-K1is
not identical with Clutch-K2 and K3.
In this connection see Figure 184.
Reference
Description
Number
1 Plate Carrier
2 Piston
3 Outer Plate - One Sided Figure 184
Coated (1 Piece)
5 Outer Plate - Coated On
S = 2.1 - 4.2 mm
{0.08 - 0.17 in})
7 End Shim
NOTE: Effective number of friction surface = 18

• Adjust plate clearance = 2.4 +0.2
mm (0.09 in)
B. Plate pack - K2 and K3
Reference
Description
Number
1 Plate Carrier
2 Piston
Coated (1 Piece)
S = 2.1 - 4.2 mm
{0.08 - 0.17 in})
7 End Shim

surface = 14 Figure 185
• Adjust plate clearance = 1.8+0.2 mm
(0.07 in)

IMPORTANT
Install outer plate (3) with uncoated side facing piston.
9. Install plate pack according to Figure 184

and Figure 185.
clearance there are retaining
rings with different thickness
Figure 186
ring in (e.g. s = 3.1 mm (0.12 in)).
Figure 187
(10 kg {22 lb}), apply dial indicator and
set it at zero (Figure 188).
12. Push end shim using screwdriver against
(Figure 189).
retaining ring (s= 2.1 - 4.2 mm
{0.08 - 0.17 in}).
Figure 188

IMPORTANT
TE-ML 03.

(S) Dial indicator - 5870 200 057
Figure 189
14. Assemble running disk 1 (55 x 78 x 5),
axial needle cage 2 and axial washer 3
(55 x 78 x 1).
NOTE: Install running disk 1, with
chamber facing axial needle
cage.
Figure 190
15. Assemble both needle bearing.
Figure 191
accommodated.
Figure 192

17. Assemble axial washer 3 (55 x 78 x), axial
needle cage 2 and running disk 1
(55 x 78 x 5).
chamber facing axle needle
cage.
IMPORTANT
Only if the running disk is overlapping
with the shaft collar is ensured that all
inner plates are accommodated. Figure 193

shoulder.
Press opposite tapered roller bearing
against shoulder.
Figure 194
compressed air.
NOTE: If components are correctly
installed, the closing resp.
audible.
Figure 195

20. Install rectangular ring into groove. Install
opposite rectangular ring.
21. Tilt clutch into horizontal position and
install spur gear K4 until all inner plates
are accommodated.
Figure 196

REASSEMBLE CLUTCH - K4
1. Cool down shaft (about -80oC) and

assemble it until seated.
Figure 197
2. Attach gear axially using retaining ring.
(S) set of external pliers - 5870 900 015
Figure 198
3. Install stud (Arrow).
#241.
(12.54 ft lb).
Figure 199
4. Check function of purge valve.
NOTE: Ball must not stick, if necessary
clean with compressed air.
5. Insert both O-rings (Arrows) scroll free into
grooves of piston and oil them.
Figure 200

6. Install piston until seated.
Figure 201
7. Install cup-spring pack and guide ring.
NOTE: Pay attention to stacking of cup
springs, see Figure 204.
Figure 202
8. Preload cup-spring pack and attach it
(S) Assembly aid - 5870 345 088
Figure 203

Page 100 (ZF 4WG-190)
9. Plate pack - K4
Figure 204, shows the installation position
of components.
Reference
Description
Number
1 Plate Carrier
2 Piston
Coated (1 Piece)
S = 2.1 - 4.2 mm
{0.08 - 0.17 in}) Figure 204
7 End Shim

surface = 10
• Adjust plate clearance = 1.2+0.2 mm
IMPORTANT
Install outer plate (3) with uncoated side facing piston.
10. Install plate pack according to Figure 204.

clearance are retaining rings
with different thickness
Figure 205

(ZF 4WG-190) Page 101
ring in (e.g. s = 3.4 mm (0.13 in)).
Figure 206
{10 kg (22 lb)}, apply dial indicator and set
it at zero (Figure 207).
13. Push end shim using screwdriver against
(Figure 209).
retaining ring. (S = 2.1 - 4.2 mm
{0.08 - 0.17 in}).
Figure 207
IMPORTANT
TE-ML 03.

(S) Dial indicator - 5870 200 057
Figure 208
accommodated.
NOTE: This step makes later
assembling of idler gear easier.
16. Remove idler gear again.
Figure 209

Page 102 (ZF 4WG-190)
17. Assemble both axial washer and needle
cage.
NOTE: Upper and lower axial washer
have same thickness
(55 x 78 x 1).
Figure 210
18. Assemble both needle bearings.
Figure 211
19. Assemble idler gear.
Figure 212
20. Assemble axial washer (3) (55 x 78 x 1),
needle cage (2) and running disk (1)
(55 x 78 x 5).
chamber facing needle cage.
Figure 213

(ZF 4WG-190) Page 103
21. Heat inner diameter of plate carrier (about
120oC). Assemble preassembled plate
carrier until all inner plates are
accommodated.
CAUTION!
Use safety gloves.
Figure 214
22. Attach plate carrier axially using retaining
ring.
(S) Set of external pliers - 5870 900 015
Figure 215
compressed air.
NOTE: At correctly installed
components, the closing resp.
audible.
Figure 216
shoulder. Install opposite tapered roller
bearing.
Figure 217

Page 104 (ZF 4WG-190)
25. Install rectangular ring into groove. Install
opposite rectangular ring.
Figure 218
PREASSEMBLE DRIVE SHAFT
1. Cool down drive shaft (about -80 oC). heat

gear (about +120 oC) and assemble it until
seated.
Figure 219
2. Attach gear axially using retaining ring.
Figure 220
3. Install retaining ring into groove of turbine
shaft.
Figure 221

(ZF 4WG-190) Page 105
4. Install turbine shaft until retaining ring
snaps into groove of drive shaft - turbine
shaft is axially fixed.
Figure 222
shoulder.
Install rectangular ring into groove of drive
shaft.
Figure 223
PREASSEMBLE AND INSTALL OUTPUT
1. Lay on screening plate.
Figure 224
2. Heat tapered roller bearing and assemble
it until seated.
Figure 225

Page 106 (ZF 4WG-190)
4. Insert all outer bearing races into bearing
bores of housing. Install O-ring (Arrows).
NOTE: When reusing already run
bearings, pay attention to
allocation of outer bearing
races.
Reference
Description
Number
AN Input
KV Clutch - Forward
KR Clutch - Reverse
K1 Clutch - 1st Speed Figure 226
AB Output
5. Lay on screening plate.
Figure 227
6. Insert preassembled output shaft.
NOTE: Attach screening plates using
socket head screws.
(16.96 ft lb).
Figure 228

(ZF 4WG-190) Page 107
INSTALL PREASSEMBLED DRIVE SHAFT
AND CLUTCHES
1. Insert all outer bearing races into bearing
bores of housing cover.
NOTE: When reusing already run
bearings, pay attention to
allocation of bearing outer
races.
Reference
Description
Number
AN Input
KV Clutch - Forward
KR Clutch - Reverse
K1 Clutch - 1st Speed
AB Output
Figure 229
2. Insert Clutch - KR, drive shaft and Clutch -
KV together into housing cover.
IMPORTANT
Before installation of clutches and
drive shaft, grease rectangular rings
and align them centrally.
Figure 230
3. Remove drive gear and position Clutch -
K4.
Figure 231

Page 108 (ZF 4WG-190)
4. Install Clutch - K3.
Figure 232
5. Position Clutch - K2.
Figure 233
6. Remove Clutch - K4 and position Clutch -
K1.
Figure 234
7. Figure 235, shows installation position of
single clutches in housing cover.
8. Grease rectangular rings (Arrows) and
align them centrally.
Figure 235

(ZF 4WG-190) Page 109
9. Attach all clutches using handles (S).
(S) Handle (6 pieces needed) - 5870 260
010
Figure 236
o
10. Tilt housing cover 180 C.
11. Install eyebolts (Arrows).
(S) Eyebolt 2x (M20) - 0636 804 003
(S) Eyebolt 1x (M16) - 0636 804 001
(S) Puller device - 5870 000 017
Figure 237
12. Grease O-rings on two oil tubes (see also
Figure 152). Wet mounting face with
sealing compound Loctite #574.
13. Position preassembled housing cover
using lifting device carefully on gearbox
housing until seated (Figure 238).
NOTE: Pay attention to overlapping of
oil tubes with the bores in
housing cover.
(S) Lifting chain - 5870 281 047
Figure 238
14. Remove handles (S) again.
Figure 239

Page 110 (ZF 4WG-190)
15. Install both cylindrical pins centrally to
housing face.
Figure 240
16. Fasten housing cover using hex. head
screws.
NOTE: Torque limit (M10/8.8) 4.69
kg•m (33.93 ft lb).
NOTE: Pay attention to position of
fixing plates, see Arrow.
Figure 241
INSTALL PUMP SHAFT (POWER TAKE-OFF)
1. Install ball bearing.
2. Install rectangular ring into groove.
Figure 242
3. Grease rectangular ring, align it centrally
and install pump shaft until seated.
Figure 243

(ZF 4WG-190) Page 111
4. Attach pump shaft using retaining ring.
Figure 244
5. Insert O-ring (Arrow) into annular groove
of oil feed covers.
Figure 245
6. Fasten both covers (Arrows) using hex.
nuts (use plain washers).
(16.96 ft lb).
Figure 246
INSTALL OUTPUT FLANGES
1. Install shaft seal with sealing lip facing oil
chamber.
NOTE: During use of prescribed driver,
the exact installation position is
obtained. Wet rubber-coated
outer diameter with spirit.
Grease sealing lip.
(S) Driver - 5870 048 213
Figure 247

Page 112 (ZF 4WG-190)
2. Assemble output flange.
3. Insert O-ring (Arrow) into gap of drive
flange and shaft.
Figure 248
4. Fasten output flange using disk and hex,
head screws.
kg•m (33.93 ft lb).
Figure 249
5. Attach hex. head screws using lock plate.
(S) Driver 5870 057 009
(S) Handle 5870 260 002
6. Install converter-side output flange.
Figure 250

(ZF 4WG-190) Page 113
CONVERTER BACK PRESSURE VALVE
1. Figure 251, shows components of
converter back pressure valve.
Reference
Description
Number
1 Piston
2 Compression Spring
3 Pressure Plate
4 Lock Plate
NOTE: Install pressure plate with

spigot (∅ 6 mm (0.24 in)) facing Figure 251
lock plate.
2. Install components according to Figure
251, preload and attach using lock plate.
3. Install new O-ring on plug (Arrow) and
install it.
NOTE: Torque limit (M14 x 1.5) 2.55
kg•m (18.44 ft lb).
Figure 252
OIL FEED HOUSING - TRANSMISSION PUMP
1. Install two adjusting screws (Arrows) and
lay on gasket.
Figure 253

Page 114 (ZF 4WG-190)
2. Lay on oil feed housing and attach it
provisionally using socket head screws.
NOTE: Screw socket head screws only
in until seated - do not tighten.
Figure 254
3. Install two adjusting screws and install
stator shaft until contract is obtained.
NOTE: Pay attention to overlapping of
bores.
Figure 255
4. Insert O-ring (Arrow) into annular groove
and oil it.
Figure 256
5. Install transmission pump (compl.) and put
it using socket head screws (for the
moment without O-rings) evenly against
shoulder.
6. Remove socket head screws again.
Figure 257

(ZF 4WG-190) Page 115
7. Install new O-rings on socket head screws
(Arrow).
NOTE: Grease O-rings.
Figure 258
8. Fasten transmission pump using socket
head screws.
(33.93 ft lb).
Figure 259
9. Fasten oil feed housing using socket head
screws and hex. head screws (2 pieces).
NOTE: Torque limit (Socket head
screws) 2.35 kg•m (16.96 ft lb).
NOTE: Torque limit (Hex. head screws)
4.69 kg•m (33.93 ft lb).
NOTE: Pay attention to position of
fixing plate, see Arrow.
(S) Box spanner (Torx, TX-40) - 5870 042
004
Figure 260
ENGINE CONNECTION - CONVERTER
1. Fasten converter bell using hex. head
screws.
kg•m (50.15 ft lb).
Figure 261

Page 116 (ZF 4WG-190)
2. Screw drive shaft and diaphragm together.
kg•m (84.82 ft lb).
Figure 262
3. Fasten diaphragm using hex. head screws
on converter.
kg•m (84.82 ft lb).
NOTE: Insert hex. head screws with
Loctite #262.
Figure 263
4. Install converter until seated.
NOTE: Pulse disk of converter must be
positioned centrally to bore of
inductive transmitter, see
Figure 265. Only in this way will
it be ensured that the converter
is properly installed.
Figure 264
Figure 265

(ZF 4WG-190) Page 117
5. Insert ball bearing until seated and attach
it using retaining ring.
Figure 266
6. Assemble housing cover.
7. Install drive flange, lay on disk and remove
cover using hex. head screws evenly
against shoulder.
kg•m (25.08 ft lb).
NOTE: Pay attention to radial
installation position of cover,
see Figure 267.
Figure 267
8. Attach hex. head screws using lock plate.
(S) Driver - 5870 057 010
(S) Handle - 5870 260 002
Figure 268
9. Fasten cover using hex. head screws and
nuts on converter bell.
kg•m (33.93 ft lb).
Figure 269

Page 118 (ZF 4WG-190)
10. Mount gasket and fasten cover using hex.
head screws.
(16.96 ft lb).
Figure 270
CONVERTER SAFETY VALVE
1. Insert converter safety valve (compl.) into
housing bore.
Figure 271
MOUNT DUCT PLATE AND HYDRAULIC
CONTROL UNIT
1. Install components according to Figure
272.
(16.96 ft lb) (Hex. nuts and
socket head screws).
position of different gaskets,
see Figure 272.
Reference
Description
Number
1 Gasket
2 Duct Plate Figure 272
3 Gasket
4 Intermediate Plate
5 Gasket

004

(ZF 4WG-190) Page 119
2. Install new O-ring on plug (Arrow) and
install it.
kg•m (22.13 ft lb).
Figure 273
3. Fasten hydraulic control unit (HSG-94)
using socket head screws.
(7.01 ft lb).
002
Figure 274
INSTALL PLUGS AND OIL LEVEL TUBE
1. Install new O-rings on plugs (Arrows) and
install them.
kg•m (36.88 ft lb).
kg•m (59.0 ft lb).
Figure 275

Page 120 (ZF 4WG-190)
2. Install oil level tube (Arrow).
NOTE: Mount new gasket.
NOTE: Torque limit (M8/109) 33.47
kg•m (25.08 ft lb).
Figure 276
3. Install cover plate (1, Figure 277).
NOTE: Install new gasket.
(16.96 ft lb).
4. Install new O-ring on plug (2, Figure 277)
and install it.
kg•m (103.26 ft lb).
Figure 277

(ZF 4WG-190) Page 121
SPEED SENSOR AND INDUCTIVE
TRANSMITTERS
1. Figure 278 and Figure 279 show
installation position of single inductive
transmitters and speed sensor.
Reference
Description
Number
34 Speed Sensor
n-Output and Speedometer
21 Inductive Transmitter
n-Turbine
47 Inductive Transmitter Figure 278
n-Central gear train
48 Inductive Transmitter
n-Engine
2. Grease O-rings and install speed sensor

and inductive transmitters.
(16.96 ft lb) (Socket head screw
/ speed sensor).
(22.13 ft lb) inductive
transmitter).
Figure 279
3. Install breather (Arrow).
(8.85 ft lb).
Figure 280

Page 122 (ZF 4WG-190)
SETTING INDUCTIVE TRANSMITTER
1. The following illustrations describe the reassembly, resp. the setting of inductive transmitter N engine
(48, Figure 278). The reassembly of Inductive transmitter N turbine (21) and N central gear train (47)
has to be carried out.
IMPORTANT
Pay attention to different setting dimensions. Setting dimension corresponds to distance
between contact face-inductive transmitter and tooth tip, see Figure 281.
2. Setting dimensions - Inductive transmitter

N engine (48, Figure 278) and n turbine
(21, Figure 278) = 0.03 - 0.08 mm (0.0012
- 0.0031 in).
3. Setting dimension - Inductive transmitter N
central gear train (47, Figure 278) = 0.03 -
0.04 mm (0.0012 - 0.0016 in).
Figure 281
4. Turn counting disk radially until one tooth
tip is situated centrally to inductive
transmitter hole.
5. Insert measuring pin (S) until end face has
got seated on tooth tip, resp. retaining ring
on screw - in face of housing.
Figure 282
6. Remove measuring pin and measure
Dimension I from end face/measuring pin
to retaining ring.
NOTE: Dimension I e.g. 30.10 mm
(1.1850 in).
7. Measure Dimension II from contact face
inductive transmitter to contact face.
NOTE: Dimension II e.g. 30.00 mm
(1.1811 in).
Figure 283

(ZF 4WG-190) Page 123
EXAMPLE L:

Required Gap (0.03 - - 0.60 mm (0.0236 in)
0.08 mm (0.0012 -
0.0031 in)) e.g
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)
8. Assemble corresponding shim and wet

thread (Figure 284) with Loctite #574.
Figure 284
9. Install inductive transmitter N engine (9,
Figure 285), N turbine (14) and N central
gear train (5).
NOTE: Torque limit 3 kg•m (22 ft lb).
10. Install plugs (Figure 285).
NOTE: Install new O-rings on plugs.
NOTE: Torque limit (M26x1.5)
8.16 kg•m (59 ft lb).
NOTE: Torque limit (M18 x 1.5)
5.10 kg•m (37 ft lb).
Figure 285

Page 124 (ZF 4WG-190)
SPEED SENSOR (HALL SENSOR) N
OUTPUT AND SPEEDOMETER
1. Figure 286, shows speed sensor 13.
Reference
Description
Number
1 Speed Sensor
2 Plate
3 O-ring
Figure 286
2. Grease O-ring and fasten speed sensor
(Figure 287) using socket head screw.
(17 ft lb).
IMPORTANT
Before putting transmission into
service, carry out oil filling according
to Operation and Maintenance
Manual.
Figure 287
3. Setting dimension - speed sensor = 1.0 -
1.5 mm (0.0394 - 0.0591 in).
Figure 288

(ZF 4WG-190) Page 125
Page 126 (ZF 4WG-190)
S0607900C
R3
1TRANSMISSION ERROR
CODES (ZF)
CAUTION!
TRANSMISSION ERROR CODES (ZF)S0607900C

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

January 2011
Transmission Error Codes (ZF) S0607900C

Page 1
TABLE OF CONTENTS
Introduction..................................................................................................... 4
Abbreviations.................................................................................................. 4
Display............................................................................................................ 4
Description of Fault Codes...................................................................... 5
Display During Operation ............................................................................... 6
Definition of Operating Modes........................................................................ 8
Normal..................................................................................................... 8
Substitute Clutch Control ........................................................................ 8
Limp-home .............................................................................................. 8
Transmission shut Down......................................................................... 8
TCU Shut Down ...................................................................................... 8
Clutch Pack and Solenoid Valve
Cross-reference Table.................................................................................... 9
Table of Fault Codes .................................................................................... 10
Table of Fault Codes - ERGO-Control ......................................................... 32
Measurement of Resistance at Actuator/sensors and Cable ....................... 35
Actuator................................................................................................. 35
Cable..................................................................................................... 35
S0607900C Transmission Error Codes (ZF)

Page 2
Page 3
INTRODUCTION
The "WG" series of ZF Transmissions use an electronic control system called "ZF-Ergopower."
The Ergo System (for short) allows the transmission to function either in a manual powershift mode, or in a
fully automatic mode.
An LCD display (Figure 1) is in the cab. This display gives the machine operator a continuos status of the
operating condition of the system. It displays normal operational codes, and fault codes.
ABBREVIATIONS
Throughout this section the following abbreviations are used to indicate various conditions.
Abbreviations
ABS Anti Blocking System
Ausgeschaltet Digital Minus
ADM (1 - 6)
(Switched Off Digital Minus)
Automatic Filling Parameter
AFP
Adjustment
CAN Controller Area Network
Load Isolation System
LIS (1 and 2)
(Solenoids 1 and 2)
O.C. Open Circuit
OP-Mode OPeration Mode
S.C. Short Circuit
TCU Transmission Control Unit
VPS (1 and 2) Variable Power Supply
DISPLAY h f e d
left
character
right
character
If a fault is detected, the display shows a

spanner symbol (g) for a fault. The display
shows the fault code, if the gear selector is in
S
neutral position. T
O
If more than one fault is detected, each fault
code is shown for about 1 second. P
Reference Description a b c g
Letter
(special symbols a-h) HBOE630L
a, f Automatic Range (Upshifting
and Downshifting) Figure 1
b, c, d, e Preselected Gear
g EST-37 has detected an
error and is flashing.
h This character will not be
used at the EST-37.

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

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

Page 5
DISPLAY DURING OPERATION
Symbol Meaning Remarks

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

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

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

TCU cannot change gears or direction under control of normal clutch modulation. TCU uses substitute
strategy for clutch control. All modulations are only time controlled. (Comparable with EST 25.)
LIMP-HOME
The detected failure in the system has strong limitations to transmission control. TCU can engage only one
gear in each direction. In some cases only one direction will be possible.
TCU will shift the transmission into neutral at the first occurrence of the failure. First, the operator must shift
the gear selector into neutral position.
If output speed is less than a threshold for neutral to gear and the operator shifts the gear selector into
forward or reverse, the TCU will select the limp-home gear.
If output speed is less than a threshold for reversal speed and TCU has changed into the limp-home gear
and the operator selects a shuttle shift, TCU will shift immediately into the limp-home gear of the selected
direction.
If output speed is greater than the threshold, TCU will shift the transmission into neutral. The operator has
to slow down the vehicle and must shift the gear selector into neutral position.
TRANSMISSION SHUT DOWN

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

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

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

Mega 250-V
Mega 300-V
Mega 400-V
Mega 500-V
Clutch Pack
Mega 130
Mega 160
4WG-100
4WG-130
4WG-190
4WG-210
4WG-260
4WG-260
4WG-310
K1 Y3 Y3 Y3 Y3 Y3 Y3 Y3
K2 Y6 Y6 Y6 Y6 Y6 Y6 Y6
K3 Y4 Y4 Y4 Y4 Y4 Y4 Y4
K4 Y1 Y1 Y1 Y1 Y2 Y2 Y2
KR Y2 Y2 Y2 Y2 Y1 Y1 Y1
KV Y5 Y5 Y5 Y5 Y5 Y5 Y5

Page 9
TABLE OF FAULT CODES
The fault codes shown in this table are a complete list of codes that are common to more than one version
of the transmission. Some of the versions are 4WG (four speed) and 6WG (six speed).
NOTE: This fault code list is valid for the ZF Software Versions V 53.x to V58.0
Fault Meaning of the Fault Code Reaction of the Possible Steps to Remarks
Code (Possible reason for fault TCU Repair
(hex) detection.)
11 Logical error at gear range TCU shifts Check cables from Failure cannot be
signal. transmission to TCU to shift lever. detected in systems
neutral. with DW2/DW3 shift
TCU detected a wrong signal Check signal
lever.
combination for gear range. Op-Mode: combinations of shift
transmission shut lever positions for Fault is taken back if
• Cable from shift lever to TCU
down. gear range. TCU detects a valid
is broken.
signal for position.
• Cable is defective and is
contacted to battery voltage or
vehicle ground.
• Shift lever is defective.
12 Logical error at direction TCU shifts Check cables from Fault is taken back if
select signal. transmission to TCU to shift lever. TCU detects a valid
neutral. signal for direction at
TCU detected a wrong signal Check signal
shift lever.
combination for direction. Op-Mode: combinations of shift
transmission shut lever positions
• Cable from shift lever to TCU
down. F-N-R.
is broken.
contacted to battery voltage or
vehicle ground.
• Shift lever is defective.
17 ** S.C. to ground at Solenoid Customer specific. Check cable from 1)See
LIS1 (Function No. 1). TCU to Solenoid “Measurement of
LIS1 (Function No. Resistance at
TCU detected a wrong
1) device. Actuator/sensors
voltage at output pin, that
looks like a S.C. to vehicle Check connectors and Cable” on page
ground. from Solenoid LIS1 35.
(Function No. 1) to
TCU.
contacted to vehicle ground.
Check resistance of
• Solenoid LIS1 (Function No.
Solenoid LIS1
• 1) device has an internal
(Function No. 1)
defect.
device.
• Connector pin is contacted
to vehicle ground.
* Only Mega 400-III PLUS
** Only Series "V"
Gray shaded boxes are error codes for other applications. They are only given for general reference purposes.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

contacted to vehicle ground. of starter interlock
• Starter interlock relay has an relay.
internal defect.
to vehicle ground.
95 * O.C. at LIS1 solenoid valve. No reaction. Check the cable from If fault code 95 and
TCU to the valve. 98 are both being
The measured resistance Op-Mode: normal.
displayed for about
value of the valve is out of Check the
one second each,
limit. connectors from
see combined fault
valve to TCU.
• Cable/connector is defective code.
and has no contact to TCU. Check the valve
resistance.
• Valve has an internal defect.
95 ** S.C. to battery voltage at relay No reaction. Check cable from 1)See
starter interlock. TCU to starter “Measurement of
Op-Mode: normal.
looks like a S.C. to battery from starter interlock and Cable” on page
voltage. relay to TCU. 35.

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

Page 24
(hex) detection.)
96 ** O.C. at relay starter interlock. No reaction. Check cable from 1)
See
TCU to starter “Measurement of
TCU detected a wrong Op-Mode: normal.
looks like a O.C. for this output Check connectors Actuator/sensors
pin. from starter interlock and Cable” on page
relay to TCU. 35.
no connection to TCU. Check resistance 1)
• Starter interlock relay has an of starter interlock
internal defect. relay.
connection to TCU.
98 * O.C. at LIS2 solenoid valve. No reaction. Check the cable from If fault code 95 and
TCU to the valve. 98 are both being
The measured resistance Op-Mode: normal.
displayed for about
value of the valve is out of Check the
one second each,
limit. connectors from
see combined fault
valve to TCU.
• Cable/connector resistance code.
and has no contact to TCU. Check the valve
resistance.
B1 Slippage at clutch K1. TCU shifts to neutral. Check pressure at ---------------
clutch K1.
TCU calculates a differential Op-Mode: limp
speed at closed clutch K1. If home. Check main
this calculated value is out of pressure in system.
If failure at another
range, TCU interprets this as
clutch is pending. Check sensor gap at
slipping clutch.
internal speed
• Low-pressure at clutch K1. sensor.
Op-Mode: TCU shut
• Low main pressure. Check sensor gap at
down.
• Wrong signal at internal
speed sensor. Check signal at
internal speed
• Wrong signal at output
sensor.
speed sensor.
Check signal at
• Clutch is defective.
Replace clutch.
** Only Series "V"

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

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

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

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

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

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

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

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

Page 32
Error Code
Number
7A Short circuit to battery voltage at converter clutch. Not used.
7B Short circuit to ground at converter clutch. Not used.
7C Open circuit at converter clutch. Not used
81 Short circuit battery voltage at clutch K4.
84 Short circuit to battery voltage at clutch KV.
85 Short circuit to ground at clutch KV.
86 Open circuit at clutch KV.
87 Short circuit to battery voltage at clutch KR.
88 Short circuit to ground at clutch KR.
89 Open circuit at clutch KR.
91 Short circuit battery voltage at relay reverse warning alarm.
92 Short circuit to ground at relay reverse warning alarm.
93 Open circuit at relay reverse warning alarm.
94 Short circuit to battery voltage at relay starter interlock.
95 Short circuit to ground at relay starter interlock.
96 Open circuit at relay starter interlock.
97 Short circuit to battery voltage at park brake solenoid.
98 Short circuit ground at park brake solenoid.
99 Open circuit at park brake solenoid.
B1 Slippage at clutch K1.

Page 33
Error Code
Number
B5 Slippage at clutch KV.
B6 Slippage at clutch KR.
BA Differential pressure oil filter.
D1 Short circuit to battery voltage at power supply for sensors.
D2 Short circuit to ground at power supply for sensors.
D3 Low power at battery.
D4 High power at battery.
D5 Error at switch 1 for valve power supply.
D6 Error at switch 2 for valve power supply.
E1 Short circuit to battery at speedometer output. Not used.
E2 Short circuit to ground or open circuit at speedometer output. Not used.
E3 Short circuit to battery voltage at display output. Not used.
E4 Short circuit to ground or open circuit at display output. Not used.
E5 Error at communication on CAN.
F1 General EEPROM fault.
F2 Configuration lost.
F3 Application error.

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

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

Gnd
HBOE650I
Figure 3

Page 35
Page 36
1HYDRAULICS
S0703010K
1ACCUMULATOR
CAUTION!
ACCUMULATOR S0703010K
Solar 225NLC-V 1001 and Up
Models continued on back of cover.

January 2011
Accumulator S0703010K
Page 1
Solar 55 0001 and Up
Solar 55-V PLUS 1001 and Up
Solar 55W-V PLUS 1001 and Up
Solar 75-V 1001 and Up
TABLE OF CONTENTS
Specifications .......................................................................................... 4
S0703010K Accumulator
Page 2
GENERAL DESCRIPTION
The accumulator is a gas-charged storage
device designed to hold a reserve quantity of 1
hydraulic fluid under pressure. Accumulators
are used in hydraulic circuits in much the same 2
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 3
accumulator.
Reference
Description
Number
1 Screw Plug
2 Steel Pressure Vessel
4
3 Diaphragm ARS1790L
4 Fluid Valve Figure 1
Accumulators are solidly constructed to resist the high operating pressures of the fluids they contain. There
are only three main moving parts: a plug at the top allows precharging or expelling gas from the
compressible, precharged upper chamber; a valve assembly at the bottom of the accumulator for passing
hydraulic fluid in and out, and an elastic diaphragm to separate the two chambers. The flexible diaphragm
changes shape to conform to the changing pressures and volumes of the two fluids in the upper and lower
chambers.
There are six possible positions the diaphragm
can be in and they are as follows: Pressure Fluid Nitrogen
1. With no gas charge in the upper chamber

0 bar (0 psi, empty) and no oil in the
bottom 0 bar (0 psi, dry) the elastic
diaphragm hangs loosely.
2. When the prepressure charge of gas
(usually nitrogen) is introduced through the
port at the top of the accumulator, the 1 2 3
diaphragm expands to maximum size. The
valve button in the center of the diaphragm
pushes into the fluid opening in the bottom
chamber, sealing off the lower valve. If the
pressure of the gas charge exceeds
system oil pressure, no fluid enters the
accumulator. The button also keeps the
diaphragm from protruding into the lower
4 5 6
valve opening. ARS1800L
Figure 2
Page 3
NOTE: Precharge 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 precharge 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 counterpressure
from system oil - the valve button on the bottom of the diaphragm eventually seals off the
lower oil passage. Just after the needle on the gauge reaches its highest point (when there
is 0 bar (0 psi) resistance from hydraulic system pressure) pressure on the gauge will drop
sharply to zero, as the accumulator is completely emptied of oil and the diaphragm button
closes.
Record the highest gauge reading and compare to the "P1" rated precharge pressure on the
accumulator manufacturer's data label. Repeat this test at least once a year to verify proper
functioning of the accumulator.
3. As hydraulic system pressure overcomes accumulator precharge pressure, the flexible diaphragm
begins to retract upward.
4. When system oil is at highest working pressure and the accumulator fills to maximum reserve
capacity, the flexible diaphragm is pushed up into the top of the upper chamber.
The highest working pressure is sometimes referred to as the "P3" pressure and can also be
referenced on the manufacturer's data label on the exterior of the accumulator.
5. If system oil pressure begins to fall off or is momentarily checked or interrupted, the energy stored on
the other side of the diaphragm, in the form of compressed gas, pushes oil back out of the lower
chamber, maintaining oil pressure of the circuit.
6. With minimal system pressure, an equilibrium point may be reached in which accumulator precharge
pressure and hydraulic system oil pressure achieve a rough balance. In this condition a minimal
amount of oil is stored in the accumulator.
SPECIFICATIONS
Charge
Model Serial Number System Volume
Pressure
Mega 200-V (Tier I 30 kg/cm2 750 cc
S/N 1001 and Up Brake System
& II) (427 psi) (45.77 in3)
Mega 200-V (Tier I 15 kg/cm2 320 cc
S/N 1001 and Up Pilot
& II) (213 psi) (19.53 in3)
30 kg/cm2 750 cc
Mega 250-V (Tier I) S/N 1001 thru 2000 Brake System
(427 psi) (45.77 in3)
15 kg/cm2 320 cc
Mega 250-V (Tier I) S/N 1001 thru 2000 Pilot
(213 psi) (19.53 in3)
30 kg/cm2 750 cc
Mega 250-V (Tier II) S/N 2001 and Up Brake System
(427 psi) (45.77 in3)
15 kg/cm2 320 cc
Mega 250-V (Tier II) S/N 2001 and Up Pilot
(213 psi) (19.53 in3)
10 kg/cm2 750 cc
Solar 140LC-V S/N 1001 and Up Pilot / Travel
(142 psi) (45.77 in3)
Solar 140W-V 30 kg/cm2 750 cc
S/N 1000 and Up Brake System
/160W-V (427 psi) (45.77 in3)
Page 4
Charge
Pressure
S/N 1000 and Up Pilot
/160W-V (213 psi) (19.53 in3)
S/N 1000 and Up Transmission
/160W-V (114 psi) (45.77 in3)
10 kg/cm2 750 cc
Solar 175LC-V S/N 1001 thru 1099 Pilot / Travel
(142 psi) (45.77 in3)
30 kg/cm2 750 cc
Solar 180W-V S/N 1001 and Up Brake System
(427 psi) (45.77 in3)
15 kg/cm2 320 cc
Solar 180W-V S/N 1001 and Up Pilot
(213 psi) (19.53 in3)
8 kg/cm2 750 cc
Solar 180W-V S/N 1001 and Up Transmission
(114 psi) (45.77 in3)
30 kg/cm2 750 cc
(427 psi) (45.77 in3)
15 kg/cm2 320 cc
Solar 210W-V S/N 0001 and Up Pilot
(213 psi) (19.53 in3)
8 kg/cm2 750 cc
Solar 210W-V S/N 0001 and Up Transmission
(114 psi) (45.77 in3)
10 kg/cm2 750 cc
(142 psi) (45.77 in3)
10 kg/cm2 750 cc
Solar 225NLC-V S/N 1001 and Up Pilot / Travel
(142 psi) (45.77 in3)
10 kg/cm2 750 cc
Solar 225LL S/N 1001 and Up Pilot / Travel
(142 psi) (45.77 in3)
10 kg/cm2 320 cc
(142 psi)) (19.53 in3)
10 kg/cm2 750 cc
(142 psi) (45.77 in3)
10 kg/cm2 320 cc
(142 psi) (19.53 in3)
10 kg/cm2 750 cc
(142 psi) (45.77 in3)
10 kg/cm2 750 cc
Solar 300LL S/N 1100 and Up Pilot / Travel
(142 psi)) (45.77 in3)
10 kg/cm2 320 cc
(142 psi) (19.53 in3)
10 kg/cm2 750 cc
(142 psi)) (45.77 in3)
10 kg/cm2 320 cc
(142 psi) (19.53 in3)
10 kg/cm2 750 cc
(142 psi)) (45.77 in3)
Page 5
Charge
Pressure
10 kg/cm2 320 cc
(142 psi) (19.53 in3)
10 kg/cm2 750 cc
(142 psi)) (45.77 in3)
10 kg/cm2 320 cc
Solar 55-V S/N 0001 and Up Pilot
(142 psi) (19.53 in3)
10 kg/cm2 320 cc
Solar 55-V PLUS S/N 1001 and Up Pilot
(142 psi) (19.53 in3)
25 kg/cm2 320 cc
(356 psi) (19.53 in3)
Pilot/Parking 15 kg/cm2 320 cc
Solar 55W-V S/N 1001 and Up
Brake (213 psi) (19.53 in3)
25 kg/cm2 320 cc
Solar 55W-V PLUS S/N 1001 and Up Brake System
(356 psi) (19.53 in3)
Pilot/Parking 15 kg/cm2 320 cc
Solar 55W-V PLUS S/N 1001 and Up
Brake (213 psi) (19.53 in3)
10 kg/cm2 320 cc
Solar 75-V S/N 1001 and Up Pilot
(142 psi) (19.53 in3)
Page 6
S0705005K
1CYLINDERS
CAUTION!
CYLINDERS S0705005K
Mega 250-V (Tier II) 2001 and 4000

January 2011
Cylinders S0705005K
Page 1
TABLE OF CONTENTS
Parts List ................................................................................................. 6
Troubleshooting, Testing and Adjustment.................................................... 12
Disassembly ................................................................................................. 16
Cleaning and Inspection (Wear Limits and Tolerances)............................... 18
Reassembly.................................................................................................. 19
S0705005K Cylinders
Page 2
Cylinders S0705005K
Page 3
GENERAL DESCRIPTION
The machine contains boom cylinders, buckets cylinders and steering cylinders. Each cylinder contains a
cylinder tube, piston rod, piston, and cylinder head. See Figure 1. The piston is held to piston rod by a nut.
A dust seal protects the U-ring and oil seal from dirt and also prevents oil from leaking out of the cylinder.
Figure 1
Reference Reference
Number Number
1 Retaining Ring 10 Seal O-ring
2 Dust Seal 11 Piston
3 U-ring 12 Spring
4 Seat O-ring 13 Cylinder Tube
5 Port (A) 14 O-ring, Backup Ring
6 Cushion Plate 15 Bushing
7 Wear Ring 16 Cylinder Head
8 Piston Nut 17 Bolt
9 Port (B) 18 Piston Rod
S0705005K Cylinders
Page 4
THEORY OF OPERATION
1. Piston
2. Oil Path A
3. Oil Path B
Cylinder piston rods are extended or retracted

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

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

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

the cylinder rod (Q1) is greater than the volume
of oil required to retract the cylinder rod, it takes
more time to decrease cylinder stroke length
than it does to lengthen it.
Q1 = S x π(B2)
4
Figure 3
Q2 = S x π(B2-R2)
4
Q1 > Q2
Cylinders S0705005K
Page 5
PARTS LIST
Bucket Hydraulic Cylinder
29
23
25 24
20
19
22
26
27
14
28
16
15
17
18
11
12
13
7
21 6
9 5
8
10
29
BAS0170L
Figure 4
S0705005K Cylinders
Page 6
Reference Reference
Number Number
1 Tube Assembly 16 Wear Ring
2 Steel Bushing 17 Dust Ring
3 Rod Assembly 18 O-ring
4 Steel Bushing 19 Piston Nut
5 Rod Cover 20 Lock Ring
6 DU-bushing 21 Socket Hex Bolt
7 Retaining Ring 22 Pipe Assembly
8 U-packing 23 O-ring
9 Backup Ring 24 Spring Washer
10 Dust wiper 25 Hex Bolt
11 O-ring 26 Pipe Clamp
12 Backup Ring 27 Spring Washer
13 O-ring 28 Hex Bolt
14 Piston 29 Grease Fitting Seal Kit
15 Glyd Ring
Cylinders S0705005K
Page 7
Lift Hydraulic Cylinder
33 2
22
23
21
30 24
32
29
30
31
26 25
27
28
19
18
13
15
14
17 7
20 10
12 11
6
5
8 4
7
9
BAS0180L
Figure 5
S0705005K Cylinders
Page 8
Reference Reference
Number Number
1 Tube Assembly 18 Piston Nut
2 Steel Bushing 19 Lock Ring
3 Rod Assembly 20 Socket Hex Bolt
4 Rod Cover 21 Pipe Assembly
5 DU-bushing 22 O-ring
6 Retaining Ring 23 Spring Washer
7 U-packing 24 Hex Bolt
8 Backup Ring 25 Pipe Assembly
9 Dust wiper 26 O-ring
10 O-ring 27 Spring Washer
11 Backup Ring 28 Socket Hex Bolt
12 O-ring 29 Pipe Clamp
13 Piston 30 Spring Washer
14 Glyd Ring 31 Hex Bolt
15 Wear Ring 32 Hex Bolt
16 Dust Ring 33 Grease Fitting Seal Kit
17 O-ring
Cylinders S0705005K
Page 9
Steering Hydraulic Cylinder
27
27
23
24
26
1
25
21
22
20
19
14
16
15
18 17
10
11
6
12
13
5
7
8
9
27
BAS0190L
Figure 6
S0705005K Cylinders
Page 10
Reference Reference
Number Number
1 Tube Assembly 15 Glyd Ring
2 Steel Bushing 16 Wear Ring
3 Rod Assembly 17 Dust Ring
4 Steel Bushing 18 O-ring
5 Rod Cover 19 Piston Nut
6 DU-bushing 20 Lock Ring
7 U-packing 21 Cushion Plunger
8 Backup Ring 22 Stop Ring
9 Dust wiper 23 Check Valve
10 O-ring 24 Spring
11 Backup Ring 25 Plug
12 O-ring 26 O-ring
13 Washer 27 Grease Fitting Seal Kit
14 Piston
Cylinders S0705005K
Page 11
TROUBLESHOOTING, TESTING AND ADJUSTMENT
Problem Possible Cause Remedy
Oil leaking between cylinder Foreign material in U-ring (3). Remove foreign material.
head (16) and piston rod (18). Scratches in U-ring (3). Replace U-ring (3).
(Index nos. refer to Figure 1)
Damage to U-ring (3). Replace U-ring (3).
Foreign material in dust seal (2). Remove foreign material.
Scratches to dust seal (2). Replace dust seal.
Damage to dust seal (2). Replace dust seal.
Foreign material in seal O-ring Remove foreign material.
(4).
Scratches in seal O-ring (4). Replace O-ring (4).
Damage to seal O-ring (4). Replace O-ring (4).
Scratches on sealing surface of If scratches are not deep, hone
piston rod (18). with an oil stone and lubricate. If
scratches are deep, replace
piston rod (18).
Deep scratches on inner surface Replace bushing.
of bushing (15).
Oil leaking between cylinder Damage to O-rings (14). Replace O-rings (14).
head (16) and cylinder tube (13).
Oil leaking from welded area of Damage to welded area. Replace cylinder tube (13).
cylinder tube (13).
S0705005K Cylinders
Page 12
Problem Cause Remedy
Oil leaking between cylinder Foreign material in U-ring (3, Remove foreign material.
head (16) and piston rod (18). Figure 1)
(Index nos. refer to Figure 1). Scratches in U-ring (3, Figure 1). Replace U-ring (3).
Damage to U-ring (3, Figure 1). Replace U-ring (3).
Foreign material in dust seal (2, Remove foreign material.
Figure 1).
Scratches in dust seal (2, Figure Replace dust seal (2).
1).
Damage to dust seal (2, Figure Replace dust seal (2).
1).
Foreign material in seal O-ring Remove foreign material.
(4, Figure 1).
Scratches in seal O-ring (4, Replace O-ring (4).
Figure 1).
Damage to seal O-ring (4, Replace O-ring (4).
Figure 1).
Scratch on sealing surface of If scratches are not deep, hone
piston rod (18, Figure 1). with an oil stone and lubricate. If
scratches are deep, replace
piston rod (18).
Deep scratches on inner surface Replace bushing.
of bushing (15, Figure 1).
Oil leaking between cylinder Damage to O-rings (14, Figure Replace O-rings (14).
head (16) and cylinder tube (13). 1).
Oil leaking from welded area of Damage to welded area. Replace cylinder tube (13).
cylinder tube (13).
Cylinder drops from pull of Light scratches on sealing Hone out scratches with oil
gravity. surface of cylinder tube (13, stone.
Figure 1).
Deep scratches on sealing Replace cylinder tube (13).
surface of cylinder tube (13,
Figure 1).
Deep scratches on sealing Replace O-rings (10).
surface of piston O-rings (10,
Figure 1).
Foreign material in U-ring (3, Remove foreign material.
Figure 1).
Scratches in U-ring (3, Figure 1). Replace U-ring (3).
Damage to U-ring (3, Figure 1). Replace U-ring (3).
Nylon wear rings (7, Figure 1) Replace nylon wear rings (7).
twisted.
scratched.
have other damage.
Cylinders S0705005K
Page 13
Slow bucket and boom Reduced oil flow due to dirty Disassemble and clean parts.
movements. filter or dirty intake line.
Air drawn into circuit through Tighten intake connections.
loose connections.
Reservoir oil level too low. Fill reservoir to correct level.
Relief valve pressure setting Adjust relief valve pressure.
incorrect.
Damaged pump shaft or pump Replace damaged parts.
drive sleeve.
Pump worn or damaged Replace worn or damaged
internally. parts.
Relief valve sticking. Disassemble and inspect
cartridge. Clean or replace
cartridge.
Air in pressure line. Perform cylinder bleeding
procedure to remove air. Tighten
or replace pressure line.
Damaged pipe or hose. Replace pipe or hose.
Worn cylinder seals. Replace worn parts.
Low-pressure, shown by weak Reduced oil flow due to dirty Disassemble and clean parts.
upward movement of boom and filter or dirty intake line.
bucket. Reservoir oil level too low. Fill reservoir to correct level.
Relief valve pressure setting Adjust relief valve pressure.
incorrect.
Pump worn or damaged Replace worn or damaged
internally. parts.
Relief valve sticking. Disassemble and inspect
cartridge. Clean or replace
cartridge.
Worn cylinder seals. Replace worn parts.
Low pump output due to dirty Remove and clean pump
discharge pipes. discharge pipes.
Relief valve spring is weak. Replace worn parts.
Relief valve poppet worn.
Cylinder drops when control Worn plunger in control valve. Replace plunger.
valve is in neutral. Stuck overload relief valve due Replace worn parts.
to worn seat surface.
Loose pipes or joints. Tighten parts.
Worn piston seal on hydraulic Replace seal.
cylinder.
Vibration or excessive noise. Excessive resistance in pump Inspect intake line and clean or
intake line. replace as necessary.
Air being drawn into intake line. Inspect pipe joints and tighten.
Chattering relief valve. Change oil, replace valve.
S0705005K Cylinders
Page 14
Air bubbles in oil. Wrong type of operating oil. Drain and fill with proper type of
oil.
Oil level too low. Raise to proper level.
Air trapped in system. Perform cylinder bleeding
procedure to remove air.
Frequent rubber hose damage. System pressure too high. Adjust relief valve pressure.
Hoses breaking due to contact Restrain hoses to prevent
with another machine parts. contact.
Cylinders S0705005K
Page 15
DISASSEMBLY
NOTE: Keep on hand a container large enough to hold all of the oil in cylinder being repaired.
When cylinder rod and head are removed, oil will run out of cylinder.
NOTE: Dispose of drained fluids according to local regulations.
1. Use an allen wrench to remove bolts that
hold cylinder head to cylinder tube. See
Figure 7.
Figure 7
2. Support cylinder rod with a lifting sling.
See Figure 8. Slide cylinder rod out of
cylinder tube. Rotate cylinder rod slightly
as it is being pulled from cylinder tube.
This will make it easier to pull rod out of
tube.
Figure 8
3. Set cylinder rod assembly in a repair
fixture and secure rod in place. See Figure
9. Use a power wrench and socket to
remove nut that holds piston on rod.
Figure 9
S0705005K Cylinders
Page 16
4. Remove piston nut (1, Figure 10), piston
assembly (2), cushion flange (3), and
cylinder head assembly (4).
Reference
Description
Number
1 Piston Nut
2 Piston Assembly
3 Cushion Flange
4 Cylinder Head
Assembly
Figure 10
5. Do not remove slipper seal, backup ring,
and back ring from piston. If these three
items are not scratched or damaged. See
Figure 11. Once these 3 items are
removed from piston, they must be
replaced. They cannot be reused.
Exercise caution when removing slipper
seal to prevent damage to piston O-ring
groove. Remove wear rings from piston.
Figure 11
6. When disassembling cylinder head do not
remove slipper seal, backup ring, back
ring, or dust seal unless items are
scratched or damaged. If seals are
removed from head, they must be
replaced. They cannot be reused. Remove
retaining ring, (1, Figure 12). Use a
screwdriver to remove dust seal (2) from
head.
Reference
Description
Number
1 Retaining Ring
Figure 12
2 Dust Seal
Cylinders S0705005K
Page 17
7. Use caution to prevent damage to any
parts of U-packing (1, Figure 13). Remove
U-packing (1). Remove O-ring (2), and ring
(3).
Reference
Description
Number
1 U-Packing
2 O-ring
3 Ring
Figure 13
CLEANING AND INSPECTION (WEAR LIMITS AND

TOLERANCES)
For general cleaning and inspection procedures, refer to "General Maintenance Procedures" section.
S0705005K Cylinders
Page 18
REASSEMBLY
NOTE: Check cylinder head grooves
for U-packing and dust seal. If
edges of grooves are sharp or
have burns, use an oil stone to
smooth surface. See Figure 14.
Figure 14
1. Apply grease to inner part of cylinder head
and to U-packing groove. See Figure 15.
Figure 15
2. Install split backup ring into its groove by
compressing ring. See Figure 16. Make
sure that ends of ring do not overlap.
NOTE: The U-packing can be installed
by hand or by using a seal
installing jig. The jig should be
made of copper, aluminum, or
plastic. If a jig is used, be sure
that jig does not have sharp
edges that could damage
U-packing.
Figure 16
Cylinders S0705005K
Page 19
3. Insert one side of U-packing in its groove.
See Figure 17.
Figure 17
4. Carefully push down on other side of
U-packing until entire U-packing is seated
in its groove. See Figure 18.
Figure 18
5. Check to be sure that U-packing and
backup ring are correctly installed by
pushing with your hand on inner diameter
of U-packing. See Figure 19.
NOTE: There are 2 backup rings used
on outside of cylinder head.
One backup ring is continuous.
The other backup ring is open,
split by an angled cut.
Figure 19
6. Use grease or an adhesive to hold split
backup ring (1, Figure 20) in place. Install
split backup ring (1) in groove closets to
flange on cylinder head.
Reference
Description
Number
1 Split Backup Ring
2 Continuous Backup
Ring
Figure 20
S0705005K Cylinders
Page 20
7. Place continuous backup ring in warm
water. See Figure 21. Water temperature
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.
Figure 21
8. Install an O-ring over each of backup
rings. See Figure 22.
Figure 22
9. Use a seal installing jig to install dust seal
into cylinder head. See Figure 23. Install
retaining ring.
Figure 23
Cylinders S0705005K
Page 21
10. On piston, check corners of grooves that
piston rings will be mounted in. See Figure
24. If any burrs, roughness, or sharp
edges (1) are present, use an oil stone to
smooth roughened areas and dull sharp
edges.
Figure 24
11. Apply grease or hydraulic oil to corner of
piston at position A. See Figure 25.
Figure 25
12. Insert one end of backup ring into its
groove. See Figure 26. Use your hand to
slide other end of ring into groove.
Figure 26
13. Use warm water to expand slipper seal.
See Figure 27. This will make seal easier
to install. Set slipper seal in 60 -100° C
(140 - 212° F) water for 5 minutes or
longer.
Figure 27
S0705005K Cylinders
Page 22
14. Insert one end of slipper seal, (1, Figure
28) into its groove. Use your hand to slide
other end of slipper seal into groove.
WARNING!
Before piston is inserted into
cylinder tube, make sure that slipper
seal is no longer expanded. If seal is
still expanded, it could catch on
threaded portion of cylinder tube. An
expanded seal could also jam inside Figure 28
cylinder tube.
15. Install two backup rings, (1, Figure 29).

One ring fits on either side of slipper seal
(2).
Reference
Description
Number
1 Backup Ring
2 Slipper Seal
Figure 29
Cylinders S0705005K
Page 23
16. Install wear ring (1, Figure 30) on piston.
Figure 30
17. Set cylinder rod (1, Figure 31) into a repair
fixture (2). Securely clamp rod to fixture.
Exercise caution to prevent nicks or
scratches to chrome plated areas of rod.
chrome plated area is oil sealing surface of
rod.
Reference
Description
Number
1 Cylinder Rod
2 Repair Fixture
Figure 31
18. Slide cylinder head assembly (1, Figure
32) onto cylinder rod (2). Use caution to
prevent threads on rod from damaging
seal inside cylinder head.
Reference
Description
Number
1 Cylinder Head
2 Cylinder Rod
Figure 32
S0705005K Cylinders
Page 24
19. Install cushion flange (1, Figure 33) on
cylinder rod (2). Slide piston assembly (3)
onto cylinder rod (2).
Reference
Description
Number
1 Cushion Flange
2 Cylinder Rod
3 Piston Assembly
Figure 33
20. Install piston nut (1, Figure 34) and tighten
it with an impact wrench. Then use a
torque wrench to tighten nut (1) to
specified torque.
After nut has been tightened, check to see
that cushion flange moves.
Figure 34
21. Slide rod assembly into cylinder tube.
Align punch mark (1, Figure 35) with port
(2) in cylinder tube. This will align hole (3)
in cylinder head with port (2).
Reference
Description
Number
1 Punch Mark
2 Port
3 Hole
Figure 35
Cylinders S0705005K
Page 25
22. Install bolts in cylinder head and tighten
them to torque specified in bolt torque
chart. See Figure 36. Double check to
make sure that hole in cylinder head is
align with port in cylinder tube.
NOTE: After rebuilding a cylinder, or
after loosening a cylinder
hydraulic line, air must be bled
from hydraulic system. To
bleed air from system, first
extend and retract a cylinder (or
pair of cylinders) about 5 times
at low engine rpm. Stop Figure 36
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.
S0705005K Cylinders
Page 26
S0707110C
1FAN DRIVE
HYDRAULIC MOTOR
(HALDEX)
CAUTION!
FAN DRIVE HYDRAULIC MOTOR (HALDEX)S0707110C

Mega 200-V (Tier I) 1001 thru 3000 (Europe Low Noise Kit)
Mega 250-V (Tier I) 1001 thru 2000 (Europe Low Noise Kit)

January 2011
Fan Drive Hydraulic Motor (Haldex) S0707110C

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

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

SUPPLY VALVE - (2)
(6)
APS0410L
Figure 1 FAN DRIVE SYSTEM SCHEMATIC
Reference Reference
Number Number
1 Pump (Brake, Pilot, Fan Drive) 4 Fan Motor
2 Supply Valve 5 Fan
(Brake, Pilot, Fan motor) 6 Relief Valve
3 Sequence Valve 7 Oil Cooler
The main components of the fan drive system are pump (1), motor (4), brake / pilot / fan motor supply valve
(2), fan (5) and oil cooler (7). Oil is drawn from tank through pump (1) and brake / pilot filter, to the brake
valve and accumulators, at the same time to the sequence valve (3) of brake / pilot / fan motor supply valve
(2). In case that the pressure of brake circuit rise up to 120 kg/cm2 (1,710 psi), the sequence valve (3)
allows oil to flow fan motor (4). From fan motor (4), oil flows through oil cooler (7) and to the tank.
Fan drive pump (common as brake and pilot pump) is a fixed displacement, gear pump. The pump is
attached to the end of steering pump and common suction port as steer pump.

Page 4
On the fan drive motor, at engine speed of 1,620
FAN RPM
rpm and above 1,620 rpm, the relief valve on the
fan drive pump opens to dump excess flow back
to hydraulic tank and thus the fan motor speed
1,300
const
will constantly be 1,300 rpm. At low idle engine
speed (between 975 and 1,620 rpm), the fan
speed will be approximately between 750 and
750
1,300 rpm.
Fan speed can be changed by adjusting the
relief valve on the fan drive pump.
970 1,620 2,350
E/G RPM AJS0790L
Figure 2

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

SUPPLY VALVE - (2)
AOS0190L
Figure 3 FAN DRIVE SYSTEM SCHEMATIC
Reference Reference
Number Number
1 Pump (Brake, Pilot, Fan Drive) 4 Fan Motor
2 Supply Valve 5 Fan
(Brake, Pilot, Fan motor) 6 Relief Valve
3 Sequence Valve 7 Oil Cooler
The main components of the fan drive system are pump (1), motor (4), brake / pilot / fan motor supply valve
(2), fan (5) and oil cooler (7). Oil is drawn from tank through pump (1) and brake / pilot filter, to the brake
valve and accumulators, at the same time to the sequence valve (3) of brake / pilot / fan motor supply valve
(2). In case that the pressure of brake circuit rise up to 120 kg/cm2 (1,710 psi), the sequence valve (3)
allows oil to flow fan motor (4). From fan motor (4), oil flows through oil cooler (7) and to the tank.
Fan drive pump (common as brake and pilot pump) is a fixed displacement, vane pump. The pump is
attached to the end of steering pump and common suction port as steer pump.

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

Page 7
PARTS LIST
2
3
4
5
7
1 6
7
5
10
9
8
4
3
2
13
14
12
16
AJS0780L
Figure 5
Reference Reference
Number Number
1 Front Bearing 9 Drive Gear
2 Backup Ring 10 Coupling
3 Seal 11 Cover
4 Bearing Block 12 Bolt
5 O-ring 13 Plug
6 Gear Housing 14 Spring
7 Dowel Pin 15 Ball
8 Idler Gear 16 Relief Valve Cartridge

Page 8
SPECIFICATIONS
Specification
Item
Mega 200-V Mega 250-V
Fan Motor Displacement 16 cc (0.97 in3) 23 cc (1.40 in3)
Relief Valve Setting 90 ±5 kg/cm2 (1,305 ±70 psi) 105 ±5 kg/cm2 (1,522 ±70 psi)
Δ p/1 turn
16.5 kg/cm2 (235 psi) 16.5 kg/cm2 (235 psi)
Maker (Model) HALDEX (WM9A1-16C) HALDEX (WM9A1-23C)
Fan Fan Size ∅ 660.4 mm (26 in) ∅ 712 mm (28 in)
Type Sucker, plastic -7 driven by hydraulic motor
Fan rpm 1,300 rpm @ 90 ±5 kg/cm2 1,400 rpm @ 105 ±5 kg/cm2
(at motor relief Δ p) (1,305 ±70 psi)) (1,522 ±70 psi))
Fan Drive Pump 14 cc 19.8 cc
(0.85 in3) (1.20 in3)

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

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

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

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

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

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

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

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

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

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

Page 15
REASSEMBLY
NOTE: New seals should be installed
upon reassembly of pump or
motor. Refer to page 8 for the
necessary kit part numbers for
the W-600, W-900 and W-1500
pumps and motors.
1. Install new shaft seal in mounting flange
with part number side facing outboard.
Press seal into seal bore until seal reaches
bottom of bore. Uniform pressure must be
used to prevent misalignment or damage
to seal.
Figure 20
2. Install retaining ring in groove in seal bore
of mounting flange.
Figure 21
3. Place front and back bearing blocks on a
clean surface with E-seal grooves facing
up. Apply a light coating of petroleum jelly
in grooves. Also, coat E-seal and backup
with petroleum jelly, this will help keep
seals in place during reassembly.
Figure 22

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

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

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

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

Page 19
Page 20
S0708500C
1MAIN PUMP
(DENISON T67CCA
SERIES)
CAUTION!
MAIN PUMP (DENISON T67CCA SERIES)S0708500C


January 2011
Main Pump (Denison T67CCA Series) S0708500C

Page 1
TABLE OF CONTENTS
Parts List ................................................................................................. 4
Service Kits ............................................................................................. 6
Dimensions ............................................................................................. 7
Specification............................................................................................ 8
Model Number Code Series T6DC .................................................. 8
Specifications................................................................................... 8
Special Tools.................................................................................................. 9
Seal Driver .............................................................................................. 9
Protective Cone....................................................................................... 9
Disassembly ................................................................................................. 10
Reassembly.................................................................................................. 14
S0708500C Main Pump (Denison T67CCA Series)

Page 2
GENERAL DESCRIPTION
THEORY OF OPERATION
The hydraulic pump is a triple vane pump which contains three pumping sections. The first pumping
section supplies oil for the front attachment. The second pumping section supplies oil for the steering
cylinders. Surplus oil which is not necessary for the steering function is directed into control valve to join
the first pump's oil by the priority valve. The third pump section, is the pilot pump, used for brakes and pilot
line operation.
Figure 1
1. First pumping section (Figure 1).
Pumping displacement: 58.3 cc/rev. (3.56 in3/rev)

Front attachment.
2. Second pumping section (Figure 1).
Pumping volume: 63.8 cc/rev. (3.89 in3/rev)

Steering and front attachment.
3. Pilot pumping section (Figure 1).
Pumping volume: 19.8 cc/rev. (1.208 in3/rev)

Brakes and pilot line operation.

Page 3
PARTS LIST
Figure 2

Page 4
Reference Reference
Number Number
1 End Cap T67CBA 19 Mounting Cap T67CCA
2 Dowel Pin 20 Round Section Ring
3 Pin-vane Holdout T67BB 21 Plate Name
4 O-ring 22 Rivet Pop
5 Port Block T67CBA 23 Rotor T6CM Assembly
6 Square Section Seal 24 Dowel pin
7 Backup Ring 25 Rotor T6CM Assembly
8 Vane T6CM 26 Pin-vane Holdout T6CM
Cam Ring T6C 020 27 Port Plate Pressure T6CC
9
Cam Ring T6C 017 28 Square Section Seal
10 Dowel Pin 29 Bushing
11 Bushing 30 Cam Ring T7A 006
12 Port Plate Rear T6CC 31 Vane T7A
13 Housing T67CBA 32 Rotor T7A Assembly
14 O-ring 33 Port Plate Pressure T67CB "A"
15 Retaining Ring 34 Square Section Seal
16 Ball Bearing 35 Square Section Seal
Splined Shaft SAE-C 36 Screw
17
T67CCA-Code3 37 Screw
18 Shaft Seal (S1-0.7 bar) 38 Screw

Page 5
SERVICE KITS
Figure 3
Reference
Kit Code Number Remark
Number
1 P1 Cartridge (B17) S24-40164-0 Rotor, vane, holdout pins, port-plates
2 P2 Cartridge (B20) R14-11226-0
3 P3 Cartridge (B06) R14-11229-0
- Seal Kit S1 R14-11230-0 All seals included: shaft seal,
square-rings, O-rings
4 Shaft Assembly R14-11231-0 Shaft, bearing, retaining ring

Page 6
DIMENSIONS
Figure 4

Page 7
SPECIFICATION
Model Number Code Series T6DC
T67CCA - B17 - B20 - B06 3 R 41 - A 1 - Z0

1
2
3
4
5
6
7
8
9
10
AMS1090L
Figure 5
Reference
Description
Number
1 Modification
2 Seal Class
3 Design Letter
4 Porting Combination
5 Direction of Rotation
6 Type of Shaft
7 Cam Ring for "P3"
8 Cam Ring for "P2"
9 Cam Ring for "P1"
10 Series
Specifications
Specification
Item
Main Pump Steering Pump Pilot Pump
Model Number T67CCA-B17-B20-B06-3R41-A1Z0
Type Vane
58.3 cc/rev 63.8 cc/rev 19.8 cc/rev
Displacement
(3.56 in3/rev) (3.89 in3/rev) (1.208 in3/rev)
Intermittent Pressure 285 kg/cm2 245 kg/cm2

(4,060 psi) (3,480 psi)
Continuous Pressure 245 kg/cm2 215 kg/cm2

(3,480 psi) (3,050 psi)
Max. Speed 2,800 min-1
Min. Speed 600 min-1

Page 8
SPECIAL TOOLS
Special tools will help to properly install the shaft seal. A shaft seal driver of propel size must be used to
install the shaft seal. A protective cone must be used over the shaft end to prevent damage to the shaft
seal when installing the shaft.
The remainder of the pump disassembly and assembly can be accomplished with normal repair shop tools
and good repair practices. Refer to Figure 6 and Figure 7 for proper configuration and dimensions for the
seal driver and protective cone.
SEAL DRIVER
A seal driver is required to install shaft seal
in the pump mounting cap.
NOTE: 1. Material: 4140 or equivalent.
2. Remove all burrs and break
sharp edges: 0.25/0.13R.
3. Length 19 mm ("A" dia) to be
heat treated Rc 50/55.
NOTE: A dia: 34.90 - 34.75
B dia: 57.10 - 56.92
C: 145 Figure 6
Tool ref.: SS2
PROTECTIVE CONE
A protective cone is to be used when
installing shaft assembly in the mounting
cap. The protective cone prevents
damaging the lips of the shaft seal during
insertion.
NOTE: 1. Material: TEFLON preferred.
2. Remove all burrs and break
sharp edges: 0.25/0.13 R.
NOTE: A: 60
B dia: 35.00 - 34.95
Figure 7
C dia: 31.33 - 31.25
Tool ref.: CP14

Page 9
DISASSEMBLY
1. Securely hold pump in a vise or similar
equipment, on mounting cap (19) making
sure pump is level.
Figure 8
2. Remove end cap (1) screws (36).
Figure 9
3. Match mark pump so that proper port
orientation can be done during
reassembly.
4. Remove end cap (1).
Figure 10

Page 10
5. Remove O-ring (4, Figure 2)
Figure 11
6. P3 cartridge is not held together.
7. Remove port-plate (33, Figure 12) and
cam ring (30, Figure 13).
Figure 12
8. Carefully remove rotor (32) and vanes
(31).
Figure 13
9. Carefully remove port block (5) and P2
cartridge together.
Figure 14

Page 11
10. Remove O-ring (4).
Figure 15
11. Extract P2 cartridge from port block (5) by
using a gear puller or by prying upward.
Use care not to damage parts.
Figure 16
12. Turn pump vertically 180°.
13. Remove screws (38).
Figure 17
14. Remove mounting cap (19) and P1
cartridge from housing (13).
Figure 18

Page 12
15. Remove O-ring (14).
Figure 19
16. Extract P1 cartridge from mounting cap
(19) by using a gear puller or by prying
upward. Use care not to damage parts.
Figure 20

Page 13
REASSEMBLY
1. Securely hold pump in a vise or similar
equipment, on housing (13). Be sure it is
level (light grip).
2. Carefully insert P1 cartridge.
WARNING!
Replace all seals and backup rings
with new ones.
Make sure the dowel pin(s) (10) are
properly inserted in corresponding Figure 21
hole in housing (13).
3. Install new O-ring (14) in housing (13).
Figure 22
4. Aligning match marks made during
disassembly, insert mounting cap (19) and
shaft assembly. Shaft (17) should go
smoothly through P1 cartridge.
WARNING!
When inserting P1 cartridge in
mounting cap, make sure the white
teflon backup ring is not damaged
and securely in place
Figure 23
5. Use screws (38) to ensure mounting cap
(19) goes down straight and does not tilt.
NOTE: Tighten screws (38) to 110 Nm
(80 ft lb).
6. Turn pump vertically 180°. Then securely
hold it in vise on mounting cap, making
sure it is level.

Page 14
7. Insert P2 cartridge.
WARNING!
Make sure the dowel pin is properly
inserted in the corresponding hole in
housing (13).
Figure 24
8. Install new O-ring (14) in housing (13).
Figure 25
9. Aligning match marks made during
disassembly, install port block (5) on
housing (13).
Figure 26
10. Position rotor (32), with vanes (31), on
splines of shaft (17).
Figure 27

Page 15
11. Install dowel pin (2) in port block (5).
12. Install cam ring (9).
WARNING!
Make sure rotation is as per required.
13. Install dowel pin (2) in cam ring (9).
Figure 28
14. Install pressure plate (33).
Figure 29
15. Install new square section seal (35)
16. Install new O-ring (4) in port block (5).
17. Install new square section seal (34) in end
cap (1).
Figure 30
18. Install end cap (1) on P3 cartridge.
Figure 31

Page 16
19. Use screws (38) to ensure end cap (1)
goes down straight and does not tilt.
NOTE: Tighten screws (38) to 190 Nm
(140 ft lb).
Figure 32

Page 17
Page 18
S0709271
1BRAKE PEDAL
VALVE
CAUTION!
BRAKE PEDAL VALVES0709271


January 2011
Brake Pedal Valve S0709271

Page 1
TABLE OF CONTENTS
Component Locations .................................................................................... 4

General Specifications ................................................................................... 8
Engine Performance Curves ........................................................................ 10
Working Range and Dimensions.................................................................. 14
Working Capacities ...................................................................................... 17
Bucket Capacity .................................................................................... 17
Tipping Load ......................................................................................... 17
Material Weight ............................................................................................ 17
Approximate Weight of Workload Materials .......................................... 17
S0709271 Brake Pedal Valve

Page 2
GENERAL DESCRIPTION
THEORY OF OPERATION
The brake pedal valve is attached to, and operated by, the brake pedal. See Figure 1. The valve contains
two spools. See Figure 2. One spool ports fluid to the brake pistons in the front axle, and the other spool
ports fluid to the brake pistons in the rear axle. Maximum system operating pressure is 60 ±3 bars
(870 ±44 psi). If something in one of the circuits should fail, the other circuit will continue to operate.
AJS0720L
Figure 1

Page 3
When the brake pedal is depressed, force is applied to the working element (6, Figure 2). This force is
transferred to the primary control spool (1) and the secondary control spool (2) by the main control spring
(5). This causes the control spool lands to close the path from the supply ports (P1 and P2) to the tank
ports (T1 and T2). Simultaneously, the spool then open a path from the brake circuit ports (Br1 and Br2) to
the supply ports (P1 and P2). Drilled passages in the control spools (1 and 2) allow fluid pressure in the
ports P1 and P2 to act against the main control spring (5). This allows the brake pressure in both circuits to
rise proportionally to the force applied to the brake pedal.
As the force applied to the brake pedal becomes constant, the control spools (1 and 2) move into a
balanced position and hold the braking pressure constant.
When force is removed from the brake pedal, this removes force from the control spring. The return springs
(3 and 4) now move the control spools (1 and 2) to the upward. The spools open a path from the brake
circuit ports (Br1 and Br2) to the tank ports (T1 and T2) and this releases the pressure from the brake
circuits.
4
1 5
P2 T2 P1 T1
3
6
BR BR BL
BL
2 BR2 BR1
P2 T2 P1 T1
AJS0740L
Figure 2
Reference Reference
Number Number
1 Primary Control Spool 4 Upper Spring
2 Secondary Control Spool 5 Main Control Spring
3 Lower Spring 6 Working Element
SPECIFICATION
Item Specification
Braking Pressure 60 ±3 kg/cm2

(853 ±43 psi)
18 ±2 kg
Pedal Force
(40 ±4 lb)
Operating Angle 18 ±2°

Page 4
BRAKE SYSTEM
Multiple wet disk brakes for stopping vehicle movement are contained in the axle-end planetary gear sets.
A brake pump (10, Figure 3) supplies pressurized fluid to the brake hydraulic system. Force on the brake
pedal (5) moves two spools in the brake valve (9). The spools are proportional. The farther the brake pedal
is pushed, the greater the amount of fluid that passes through each spool. One spool ports fluid to brake
pistons in the front axle (3). The other spool ports fluid to brake pistons in the rear axle (1). Pressure on the
brake pistons applies pressure to the brake disks, and this stops axle shaft and wheel rotation.
The brake hydraulic system also contains three accumulators (8). The accumulators hold a volume of
pressurized fluid large enough to allow the brakes to be applied nine times with full pressure, after the
engine has been turned off.
The brake hydraulic system includes a pressure operated transmission cutoff switch (2, Figure 3).
Pressing the brake pedal (5) will open cutoff switch (2). When the transmission cutoff switch in the
operator's cab is selected, this will cut off current to a solenoid operated hydraulic valve in the
transmission. This prevents operation of the forward clutch in the transmission. This prevents the
transmission from driving the wheels forward when the brake pedal is pressed.
BRAKE AND PILOT SUPPLY VALVE
(3) (4)
(1)
(9) (6)
CLOSES 3 B
FRONT AXLE STOP
(2) REAR AXLE

L.H Brake valve BR1 BR2
OPENS 25 B
(5) T/M DISCONNECT
60B T/M
P1 T1 P2 T2 (7)
E/G
(8)
R.H Brake pedal
(12)
0.5 BAR
30B 30B 30B

LPWS 0.75L 0.75L 0.75L
* TUV Only parking brake
65 bar A1 P1 P2 A2 A3
1.5 BAR (PFO1/4) (PFO3/8) (PFO3/8) (PFO3/8) (PFO3/8) (PFO3/8)
C1 C2
ULTP
(PFO1/4)
C3
P
TANK (PFO1/2)
C10
C4
PARK
(PFO3/8)
PKWS
(14)
C6
C9 (PFO1/4)
C5 to PILOT
(PFO3/8)
28B
(10) (15) C7 TP
T1 C8 (PFO1/4)
(11)
(PFO1/2) (PFO3/8) (PFO1/4) (PFO1/4)
BRAKE/PILOT 10 micron
PUMP A4 15B T3 T2
3
19.8 cm/rev BRAKE & PILOT SUPPLY VALVE 0.32L
STEER PUMP
3
63.8 cm/rev
H.P FILTER
LOADER PUMP
3
58.3 cm/rev
BZS0080L
Figure 3 BRAKE HYDRAULIC CIRCUIT (S/N 3001 thru 4000)

Page 5
BRAKE, PILOT AND FAN MOTOR SUPPLY VALVE
(3) (4)
(1)
(6)
(9)
CLOSES 3 B
FRONT AXLE STOP
(2) REAR AXLE

(5) L.H Brake valve BR1 BR2
OPENS 25 B
T/M DISCONNECT
60B T/M
P1 T1 P2 T2
E/G
(8)
R.H Brake pedal
0.5 BAR (12)
15B
65bar 0.32L
(PFO1/4) (PFO3/8) (PFO3/8) (PFO3/8)
(PFO3/8) A1 LPWS P1 P2 A2 A3 TP1

1.5 BAR
C3-1 C3-2 (11)
ᣍ1.2 C2 C3-3
TP2
(PFO1/4) (PFO3/8)
TANK to PILOT
28 kgf/
C4
60 kgf/ C6
FO SAFETY
(PFO1/2)
C3-4 PARK
(PFO3/8)
100 L/MIN FI
(PFO1/2) C1
LPWS
Fan motor C7 C5
0.75" 150 kgf/
OIL COOLER M
PK
(PFO1/4)
(PFO1/2)
(10) 105bar A4 T1 T2
(PFO3/8) (PFO3/8) (PFO1/4) (14)
10 micron 23ccr 30B
BRAKE/PILOT
* TUV only 0.75L
PUMP
3
(13)
19.8 cm/rev BRAKE & PILOT & FAN MOTER SUPPLY VALVE
STEER PUMP
0.5"
63.8 cm/rev3
H.P FILTER (15)
LOADER PUMP
58.3 cm/rev3
BZS0110L
Figure 4 BRAKE HYDRAULIC CIRCUIT (S/N 4001 and Up)
Reference Reference
Number Number
1 Rear Axle 9 Brake Valve
2 Transmission Cutoff Switch 10 Pilot Pump
3 Front Axle 11 Pilot Supply Line
4 Brake 12 Low-pressure Warning Switch
5 Brake Pedal 13 Parking Brake Valve
6 Stop Light Switch 14 Low-pressure Warning Switch
7 Parking Brake 15 Brake and Pilot Filter
8 Accumulators: Brake

Page 6
This valve controls oil flow to the brake pedal valve for braking, to the pilot controller for operation of bucket
and boom.
BRAKE AND PILOT SUPPLY VALVE
AOS0540L
Figure 5 BRAKE AND PILOT SUPPLY VALVE (S/N 3001 thru 4000)
Reference Reference
Number Number
1 Block (79*127*180) 6 Solenoid Valve (C8,C9)
2 Check Valve (C1,C2) 7 Coil (C8,C9)
3 Check Valve (C3,C4,C5) 8 Priority Valve (C10)
4 Unloading Valve (C6) 9 Dummy Plug (C11)
5 Relief Valve (C7) 10 Bar

Page 7
AOS0550L
Figure 6 HYDRAULIC CIRCUIT (S/N 3001 thru 4000)
Specifications
Item Specifications
Max. Rated Pressure 210 kg/cm2

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

(1,710 - 1,990 ±28 psi)
Setting Pressure 28 - 31 kg/cm2
C7
(398 - 441 psi)
C11 Dummy Plug
P, T1 PF 1/2 O-ring
UL, TP, T2, T3 PF 1/4 O-ring
Port Size
LP. PK ∅ 30 PF 1/4 BSP
All other ports PF 3/8 O-ring

Page 8
AOS0560L
Figure 7 BRAKE & FAN MOTOR SUPPLY VALVE (S/N 4001 and Up)
Reference Reference
Number Number
1 Body (200*127*79) 6 Coil (C4,C5)
2 Sequence (C1) 7 Relief (C6)
3 Reducing (C2) 8 Plug
4 Check (C3-1, C3-2, C3-3, 9 Plug
C3-4) 10 Orifice (∅4.0-M8*1.25)
5 Solenoid (C4, C5)

Page 9
AOS0570L
Figure 8 HYDRAULIC CIRCUIT (S/N 4001 and Up)
Specifications
Item Specifications
Max. Rated Pressure 210 kg/cm2

(3,000 psi)
57 lpm
Rated Flow
(15.05 gpm)
120 ±2 kg/cm2 (1,710 ±28 psi)
C1
(Input P:180 kg/cm2 (2,560 psi),
Q:57 lpm (15.05 gpm))
28 ±2 kg/cm2 (398 ±28 psi)
Setting Pressure C2
(Input P:120 kg/cm2 (1,710 psi),
Q:20 lpm (5.3 gpm))
C6 150 ±2 kg/cm2 @ 57 lpm

(2,130 ±28 psi @ 15.05 gpm)
C3 Cracking Pressure 2.40 kg/cm2 (34.1 psi)
F0, F1, M PF 1/2 O-ring
TP1, TP2, T2 PF 1/4 O-ring
Port Size
LP. LK ∅ 30 PF 1/4 BSP
All other ports PF 3/8 O-ring

Page 10
S0709456K
1MAIN CONTROL VALVE

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


January 2011
Main Control Valve (Toshiba) S0709456K

Page 1
TABLE OF CONTENTS
Specifications ................................................................................................. 5
Operation........................................................................................................ 6
Neutral..................................................................................................... 6
Bucket/option Spool Operation ............................................................... 6
Boom Spool Operation............................................................................ 7
Boom Float....................................................................................... 7
Relief Valve ............................................................................................. 7
Main Relief Valve ............................................................................. 7
Port Relief Valve .............................................................................. 7
Operation (Main Relief Valve) ................................................................. 8
Operation in Inoperative State ......................................................... 8
Operation (A) ................................................................................... 8
Operation (B) ................................................................................... 8
Operation (Port Relief Valve) .................................................................. 9
In the Inoperative State.................................................................... 9
Operation (A) ................................................................................... 9
Operation (B) ................................................................................... 9
Operation (C) ................................................................................. 10
Sucking Operation ......................................................................... 10
S0709456K Main Control Valve (Toshiba)

Page 2
GENERAL DESCRIPTION
The main control valve controls the operation of the bucket, boom, and option cylinders. The bucket spool
has priority over the boom spool.
Pump output flows to port P on the main control valve.See Figure 1. Maximum pressure is prevented from
exceeding the desired level by the main relief valve (1). See hydraulic schematic (Figure 2). When all
spools on the main control valve are in the neutral position (when the pilot valve is not being operated), oil
passes through port P, the bucket spool, the boom spool, the option spool, and passes out T, the tank port.
Oil that passes out the tank port passes through a filter and returns to tank.
Two overload relief valve (2) are installed in the bucket circuit to protect circuit components in the event of
abnormally high-pressure. One valve works as a relief valve while the other valve works as an
anticavitation valve to provide additional oil flow to the opposite side of the bucket cylinders.
Boom spool has two important roles in loader work at the floating position. One is that it is possible to lower
the boom by its weight without oil supply from the pump, and that, at the same time, the oil from the pump
makes it possible to combine with the bucket crowd at the max. height of bucket through the bucket line.
Another is that boom and bucket are positioned at the level as the cylinder ports A and B are open as a
leveling function of ground. There is a suction check valve (3) in the boom power port. When the boom is
dropped suddenly by its weight, the cylinder bottom has a cavitation with a lack of oil supply. The check
valve supplements oil to prevent the cavitation.
AMS0330L
Figure 1

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

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

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

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

Page 5
OPERATION
NEUTRAL
When the spools of the bucket section and the boom section are in neutral, both the cylinder ports A (rod
side) and B (tail side) are closed by the spools.
The pressure oil which has reached the control valve flows through the inlet section, past the neutral oil
passages in the bucket section and the boom section to the outlet section from which it is directed to the
low-pressure oil passage and leaves the control valve through the exhaust port of the inlet section.
BUCKET/OPTION SPOOL OPERATION
Figure 3 OPERATION IN BUCKET/OPTION
Reference Reference
Number Number
1 Load Check 4 Tank Passage
2 Port A1 5 Center Bypass Passage
3 Port B1
When the bucket spool moves in the direction indicated by the arrow the neutral oil passage is closed by
the spool and the pressure oil pushes open the load check valve to flow to the cylinder port (A1) from
which it is directed into the bucket cylinder rod side.
The oil discharged from the bucket cylinder tail side flows through the cylinder port (B1) to the low-pressure
oil passage.

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

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

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

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

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

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

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

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

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

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

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

Page 9
Operation (C)
The pressures across the relief valve poppet (3)
loses balance. Due to pressure differential, the
relief valve poppet moves so that the pressure
oil at the cylinder port (HP) flows directly to the
low-pressure oil passage (LP).
Figure 11 OPERATION (C)

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

Page 10
S07094765A
1PILOT CONTROL
VALVE
CAUTION!
PILOT CONTROL VALVES07094765A


January 2011
Pilot Control Valve S07094765A

Page 1
TABLE OF CONTENTS
Pilot Valve Operation .............................................................................. 3
Parts List ................................................................................................. 4
Pilot System ................................................................................................... 6
Mega 250-V............................................................................................. 7
S07094765A Pilot Control Valve

Page 2
GENERAL DESCRIPTION
When no force is applied to the lever (1, Figure 1), the return spring (4) positions the lever at the
"NEUTRAL" position. When the lever is moved, plunger (5) is moved, which pushes down the return spring
(4). At the same time, spool (2) is moved by spring (3). When spool (2) moves down, a groove (6) in the
spool opens the pilot pressure line to the line that the lever controls. This allows the pilot pressure to flow to
the boom or bucket control valve, where the pilot pressure operates the control valve. When the lever is
completely moved in one direction, the solenoid (7) energizes the electromagnet (8) and holds the lever in
the fully moved position.
PILOT VALVE OPERATION

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

Page 3
PARTS LIST
33
29 34
32 30
25
31
27
20
26
28 24
17 23
16
22
15
21
19
9 18
5 12
4 13
8
11
7
22
6
3 20
2
1 35
42
41 40 39 38 36 37 38 39
BAS0130L
Figure 1

Page 4
Reference Reference
Number Number
1 Body 22 Plate
2 O-ring 23 Washer
3 Plug 24 Nut
4 Spring 25 Plug
5 Spring Seat 26 Nut
6 Spool 27 Set Screw
7 Spring Seat 28 Nut
8 Spring 29 Nut
9 Stopper 30 Connector
10 Plug 31 Nut
11 Rod Seal 32 Boot
12 O-ring 33 Handle Assembly
13 Push Rod 34 Spring Pin
14 Plate 35 Plug
15 Rod Stopper 36 Housing
16 Du-bushing 37 Holder Rear
17 Rod 38 Terminal
18 Magnet 39 Seal Wire
19 Plate 40 Housing
20 Joint Assembly 41 Holder Rear
21 Joint Assembly 42 Clip Band

Page 5
PILOT SYSTEM
The pilot system uses low-pressure oil to operate the main control valves. The main components of the
pilot system are pump (1), pressure reducing valve (3), accumulator (4), pilot cutoff valve (5) and pilot
valves (6 and 7).
With the engine running, oil flows from hydraulic tank to pilot pump (1) The oil flows from the pump through
pressure reducing valve (3) to pilot cutoff valve (5). The pressure reducing valve maintains pilot system
pressure at 28 kg/cm2 (398 psi).
From the pilot cutoff valve the oil flows into the pilot control valves. Pilot valve (6) is a closed center valve.
The oil cannot flow through the valve when it is in the HOLD position because it is a closed center valve.
When the control lever is moved to the DUMP position, oil flows through oil lines to the ends of the bucket
spool of main control valve (8). This causes the main control valve spool to move. Movement of the spool
opens passages for attachment pressure oil to flow to the rod end of the bucket cylinder (9).
Spool movement also opens a passage for return oil from the head end of the bucket cylinder to flow back
to hydraulic tank. Attachment pressure oil acts on the rod end of the bucket cylinder and, because the
head end of the cylinder is now vented to tank, the bucket will dump.
When the control lever is moved to the CROWD position, oil flows through oil lines to the ends of the
bucket spool of main control valve (8). This causes the main control valve spool to move in the opposite
direction.
Movement of the spool in this direction opens passages for pressure oil to flow to the head end of the tilt
cylinder. Spool movement also opens a passage for return oil from the rod end of the tilt cylinder to flow
back to the hydraulic tank. Attachment pressure oil acts on head end of the tilt cylinder and because the
rod end of the cylinder is now vented to tank, the bucket will crowd.

Page 6
MEGA 250-V
(7) Kick-down Horn
OPT.
DUMP CROWD AUTO RETURN RAISE LOWER OPT.
TO DIG
D.C D.R D.F D.R D.F
T
P
2 4 3 1 5 6
0.5 BAR
* TUV Only
30B 30B 30B
0.75L 0.75L 0.75L
LPWS A1 P1 P2 A2 A3
1.5 BAR (PFO3/8)
(6)
(PFO1/4) (PFO3/8) (PFO3/8) (PFO3/8) (PFO3/8)
C1 C2
ULTP Horn Kick-down
(PFO1/4)
C3
P
OIL TANK (PFO1/2)
C10
C4 DUMP CROWD AUTO RETURN RAISE LOWER
TO DIG
PARK D.C D.R D.F
(PFO3/8)
C6 PKWS
C9 (PFO1/4)
T
C5 PILOT P 2 4 3 1
(PFO3/8)
OIL COOLER 100 L/MIN

(5)
28B
C7 TP
T1 C8
(1) (2)
(PFO1/4)
(PFO3/8) (PFO3/8) (PFO1/4) (PFO1/4)

BRAKE & PILOT 10 micron
PUMP A4 15B T3 T2
3
19.8 cm/rev BRAKE & PILOT SUPPLY VALVE 0.32L
STEER PUMP
3
63.8 cm/rev
PILOT FILTER (3) (4)
MAIN PUMP P1 P3 200 l/min at 6.9 B at 2,400 rpm
3
58.3 cm/rev 1.25 1.25"
C3 TPM 320 l/min max
0.25" 200 BAR
<
(8) WA28D4F1-51
(2-SPOOL,STD.)
TPS EF
O.25" 0.75
C1
C2 AUTO RETURN TO DIG
160 (9)
<
BUCKET
230 B
R2 R1
1.5 (Dump) (Crowd)
1.5
1B
160x 80x500
C BOOM RAISE
(10) KICK-OUT Bucket cylinder 1A
0.75"
HT
PRIORITY V/V
BOOM
BLOCK
VALVE (Lower/Float)
140x 80X777 2B
FROM PRIORITY V/V Boom cylinder

(Raise) 2A
PRIORITY V/V 60B

OPTION
5L
230 B
OPT. EQUIPMENT
LIS SYSTEM(OPT., included Piping)
3B
WA28D4F1D4-51
3A
* (3-SPOOL, OPTION)
LOG & FORK SYSTEM
FG017847
Figure 2
Reference Reference
Number Number
1 Pilot Pump 6 Pilot Valve (Mono, STD.)
2 Brake and Pilot Filer 7 Pilot Valve (Two-lever, OPT.)
3 Pressure Reducing Valve 8 Main Control Valve
4 Accumulator: Pilot 9 Bucket Cylinder
5 Pilot Cutoff Valve 10 Boom Cylinder

Page 7
Page 8
S07094776
1PILOT CONTROL
VALVE (FNR)
CAUTION!
PILOT CONTROL VALVE (FNR)S07094776


January 2011
Pilot Control Valve (FNR) S07094776

Page 1
TABLE OF CONTENTS
Joystick Valve Assembly ................................................................................ 3

HRC6 - LV ...................................................................................................... 5
Dual Axis Section .................................................................................... 6
Single Axis Section ................................................................................. 7
Dual Axis: Actuation Components and Flange ................................ 8
Single Axis: Actuation Components and Flange.............................. 9
Spring capsule assemblies and joint plate..................................... 10
Valve Body, Bushing Assembly and Shuttle Valve ........................ 11
S07094776 Pilot Control Valve (FNR)

Page 2
119.8
84.3
56.8
Figure 1
G 1/4"
26.1 NƁ8

45
CURVA N028CA N028CA CURVE
CIRCUITO IDRAULICO/HYDRAULIC CIRCUIT
UTILIZZO 1-2-3 PORT 1-2-3 P T
T2 6
CURVA CARATTERISTICA / CONTROL DIAGRAM
1
bar (Nm) (N) 2
30
4.26
18.5
164.5
7
21 -0.5/+1.5
52
10
11
90
4 24 VDC 24 VDC
36.8
25
3.4
131.5
20 ( 20 ૙ 1 )
3 4
15 85.7 P2 3 24 VDC
Axsial force
5 ૵ 0.7 2 5
FORZA ASSIALE
2.22
10
Pilot Control Valve (FNR)

PRESSIONE DI PILOTAGGIO / Pilot pressure
MOMENTO TORCENTE / Operating Torque
1 34.7
5 0.90
T2 T1
18.4
0.48
0 0 0 26 P2 P1
1 2 3 4 5 6 7 8 7
1 +0.2/-0.8 6.9 ૵ 0.1 NƁ 4
52
7.5 +0.2/-0.4
161.8
CORSA SPINTORE - Pusher stroke
2 4 3 1 T P 5 6
24Ɓ
17 23.2Ɓ
OLO ASSE AZIONAM

ENTO SING ENTO
DOPPI
23 AZIONAM 2 O ASSE
Ɓ 45Ɓ
CURVA N028AA N028AA CURVE
3
UTILIZZO 4-5-6 PORT 4-5-6
1
CURVA CARATTERISTICA / CONTROL DIAGRAM
4
bar (Nm) (N)
30
21 -0.5/+1.5
25 4
5
3.03 CABLAGGIO / CONNECTION TABLE
20 3 115.7
PIN CAVO WIRE
15 90.9 15 SOLENOIDE UT 2 PORT 2 SOLENOID
Axsial force
5 ૵ 0.7 2
FORZA ASSIALE
2.4 14 SOLENOIDE UT 1 PORTS 1-3 SOLENOID
10 13 NON IN USO NOT USED
PRESSIONE DI PILOTAGGIO / Pilot pressure

MOMENTO TORCENTE / Operating Torque
1 34.7 12 SOLENOIDE UT 3 PORT 6 SOLENOID
5 0.90
18.4 11 SOLENOIDE UT 3 PORT 3 SOLENOID
0.48 10 FERMA CAVO KEYING PIN
212.5
0 0 0
1 2 3 4 5 6 7 8 9 SOLENOIDE UT 1 PORT 1 SOLENOID
1 +0.2/-0.8 7.5 +0.2/-0.4
8 SOLENOIDE UT 2 PORT 2 SOLENOID
7 GIALLO (TASTI 2-3) YELLOW (BUTTONS 2-3)
CORSA SPINTORE - Pusher stroke
6 BLU (TASTO 4) BLUE (BUTTON 4)
5 ROSSO (TASTO 5) RED (BUTTON 5)
4 MARRONE (TASTO 3) BROWN (BUTTON 3)
3 BIANCO (TASTO 2) WHITE (BUTTON 2)
JOYSTICK VALVE ASSEMBLY
328.5
2 VERDE (TASTO 1) GREEN (BUTTON 1)
1 GIALLO (COMUNE) YELLOW (COMMON)
281
29.35
24.3
1 4 7 10 13
2 5 8 11 14
3 6 9 12 15
A A
4.5
52.6
T1
11
SCHEMA ELETTRICO / ELECTRICAL DIAGRAM
1 2 3 4 5 6 7 8 9 11 12 14 15
P1
+10
-5
1000
45Ɓ
2 3 UT 2 UT 3
850
੻)
( 45
੻) 1
( 35
4
UT 1
( 45
੻)
A-A
BZS0120L
Page 3
S07094776
Code Description Q.ty Wrench (mm) Tightening (Nm)
2IM6117000 VKWG/PULN DAEWOO KNOB 1 16 19

3ANE110030 SPACER Ref.938200 4
3ANE114020 5x14x1.2 RING 6
3ANE114021 3.6x14x1.2 OPEN RING 6
3ANE117110 SV06-07 SPRING GUIDE 6
3ANE121170 SV06-07 (8.5mm) RING 6
3ANE462080 SV06-07 SELECTOR RING Ref.938247 1
3AST106625 SV06-07 ROD 6
3AST341010 M10x105 SV06-07 CROCKED ROD Ref.938116 1
3BOC324153 SV06-07 BUSHING Ref.938256 3
3CO3060000 SV06 BODY Ref.999359 1
3FLA411040 SV06-07 FLANGE 2
3MOL609320 5.5 - 25.5 bar SPRING 6
3MOL617420 RETURN SPRING TYPE "A" 3
3MOL623480 PREFEELING SPRING Ref.937503 6
3SOF111080 SV06-07 RUBBER BELLOW Ref.938205 1
3SOF190782 SV06-07 RUBBER BELLOW Ref.938204 1
4ANE610005 PS 5x10x0.5 DIN-988 SEEGER RING 6
4DAD206102 UNI 5588 M6-NUT 6 10 5
2IM6117000 * 4DAD310150 UNI-5589/M10 GALVANIZED NUT 1 16 19
4DAD320150 UNI 5589 M20 X 1.5-NUT 1 30 50
A B 4IMP121050 ELESA I.580/50 N-10 24831 KNOB 1
4ROS320040 UNI 1751 A20 WASHER 1
4VIT604007 TCEI UNI 5931-M4x6-8.8 SCREW 1 3 6.6
4VIT604035 TCEI UNI 5931-M4x35-8.8 SCREW 4 3 6.6
4VIT605040 UNI-5931/M5x40-8.8 GALVANIZED SCREW 4 4 6.6
W0202011 AMP 15p (350736-1) CONNCTOR Ref.998005 1
W0202012 AMP MATE-N-LOK KEYING PIN Ref.998007 1
W0252004 AMP TERMINAL Ref.998006 13
W0309001 16.5x9.7 CLIP Ref.527924 5
W9901023 PVC DIAM.13 PROTECTIVE COVERING 0.85
3SOF111080 * XBUS332460 SV06-07 BUSHING KIT 3
XCIN600000 SV06-07 MOUNTING KIT 1
XFLA417051 SV06-07 DAEWOO FLANGE 1
XGIU626415 G1/4-SAE10 SV06-07 JOINT 6 22 42
XPER605540 SV06-07 PLUNGER KIT 3
XPIA428310 SV06-07 PIN KIT 3 2.5 /
XPIA428311 NO DETENT PIN KIT 1 2.5 /
XPIA428381 NO DETENT PIN KIT LONG 2 2.5 /
XSOL528460 LISK HS125163-1 (24 VDC) SOLENOID KIT 3
* 5AST341010 5FLA411040 *
4IMP121050 4VIT605040
3AST341010 W0309001
3SOF190782 3FLA411040
4DAD310150 3ANE110030
3FLA411040
C
* 5CINC13000
4DAD206102
4VIT604035
5CUR6N028AA *
XPIA428381
XBUS332460
XCIN600000 5CINC02001 * 5CUR6N028CA *
3ANE121170
4DAD320150 XSOL528460
3ANE114021
4ROS320040 XPER605540
3ANE114020
4DAD206102 3ANE121170
3ANE117110
3ANE462080 3ANE114021
3MOL609320
XPIA428310 3ANE114020
4ANE610005
XPIA428311 3ANE117110
3AST106625
XFLA417051 3MOL609320
3MOL617420
4ANE610005
3AST106625
3MOL617420
3BOC324153
3MOL623480
4,5,6
1 2
4
6 3
5
TO LETTERS
A,B,C
W9901023 * 1,2,3
5CO3060300N *
4VIT604007
W0309001
3CO3060000 Crimp on
all wires.
XGIU626415
W0252004 *
* W0202012
W0202011 *
Insert in
pos.10 Pos.10
BZS0130L
Figure 2

Page 4
HRC6 - LV
Figure 1

Page 5
DUAL AXIS SECTION
Figure 2

Page 6
SINGLE AXIS SECTION
Figure 3

Page 7
Dual Axis: Actuation Components and Flange
Figure 4

Page 8
Single Axis: Actuation Components and Flange
Figure 5

Page 9
Spring capsule assemblies and joint plate
Figure 6

Page 10
Valve Body, Bushing Assembly and Shuttle Valve
Figure 7

Page 11
Page 12
S0709650
R1
1PRIORITY VALVE
CAUTION!
PRIORITY VALVE S0709650


January 2011
Priority Valve S0709650

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

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

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

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

Page 5
SPECIFICATIONS
Priority Valve Specification

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

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

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

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

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

TOLERANCES)
For general cleaning and inspection procedures, refer to "General Maintenance Procedures" section.
Clean all parts with a nonflammable, nontoxic solvent.
Carefully inspect all parts. Replace all worn or broken parts. Use only new O-rings to assemble the valve.
Cost all parts with oil before assembling them.

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

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

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

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

Page 10
6. Assemble valve needle, spring and set

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

Page 11

Page 12
S0709735
1POWER STEERING
UNIT
CAUTION!
POWER STEERING UNITS0709735


January 2011
Power Steering Unit S0709735

Page 1
TABLE OF CONTENTS
Steering Unit ........................................................................................... 3
Function .................................................................................................. 3
Exploded View of a Steering Unit .................................................... 4
S0709735 Power Steering Unit

Page 2
GENERAL DESCRIPTION
STEERING UNIT
Figure 1
Reference Reference
Number Number
1 Bearing 7 Sleeve
2 Neutral Position Spring 8 Cardan Shaft
3 Cross Pin 9 Spool
4 Housing 10 Check Valve
5 Gear Wheel 11 Distributor Plate
6 Gear Rim 12 End Cover
FUNCTION
The steering unit consists of a rotary valve and a rotary metering unit.
Via a steering column the steering unit is connected to the steering wheel of the vehicle.
When the steering wheel is turned, oil is directed from the steering system pump via the rotary valve (spool
and sleeve) and rotary metering (gear wheel set) to the cylinder ports L or R, depending on the direction of
turn. The rotary meter, meters the oil flow to the steering cylinder in proportion to the rotation of the
steering wheel.
Power Steering Unit S0709735

Page 3
Exploded View of a Steering Unit
Figure 2
Spool (9) is connected directly to the drive shaft of steering wheel. It is connected to sleeve (7) by center
pin (3) (not in contact with the spool when the steering wheel is at Neutral) and neutral position spring.
Cardan shaft (8) is meshed at the top with center pin (3) and forms one unit with the sleeve (7).
At the same time, the cardan shaft is meshed with the gear rim (5) of the Gerotor set, by the splices.
There are four ports in valve body. They are connected to the pump circuit, tank circuit, and the head, and
left and right steering cylinder. In addition, the pump port and tank port are connected inside the body by
the check valve. If there is on flow available, oil will be sucked in directly from the tank through the check
valve (Emergency steering).
S0709735 Power Steering Unit

Page 4
S0709865A
1UNLOADER VALVE
CAUTION!
UNLOADER VALVE S0709865A


January 2011
Unloader Valve S0709865A

Page 1
TABLE OF CONTENTS
Unloader Cartridge Identification............................................................. 5
Specifications .......................................................................................... 6
S0709865A Unloader Valve

Page 2
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.
BRAKE/PILOT
PUMP
3
19.8 cm/rev
STEER PUMP
3
LOADER PUMP P1 P3 to CONTROL VALVE

3
58.3 cm/rev 1.25 1.25"
C3 TPM
0.25"
<
TPS EF
O.25" 0.75
C1
C2
to TANK
160
<
R2 R1
from CONTROL VALVE
1.5 1.5
C
0.75"
HT
to PRIORITY V/V
0.75
BLOCK
VALVE
from PRIORITY V/V
to PRIORITY V/V
FG017848
Figure 1 UNLOADING CIRCUIT

Page 3
Figure 2 UNLOADING VALVE CARTRIDGES
Reference Reference
Number Number
1 C3 Spring C2 Valve Cartridge
2 C3 Check Spool C3 Valve Cartridge
3 C2 Spring D C1 Port
4 C4 Check Spool E C1 Port
5 C1 Check Spool EF Unloading Valve Port
6 C1 Spring P1 C3 Port
7 Orifice P2 C3 Port
C C2 Spool Chamber T Tank
C1 Valve Cartridge

Page 4
UNLOADER CARTRIDGE IDENTIFICATION
C2
R1 TPS P3
5 6 1 4 11 12
C3
EF
C1
HT
2
TPM
10 9
7 8
R2 P1
BZS0210L
Figure 3 VALVE CARTRIDGE IDENTIFICATION
Reference
Description Remark
Number
1 Body 125×99×263
2 Directional Valve C1
3 Logic Valve C2
4 Check Valve C3
5 Plug PF 3/4
6 O-ring P24
7 Hex Plug PF 1/2
8 O-ring P18
9 Plug PF 3/8
10 O-ring P14
11 Bolt M8x1.25x20L
12 Cover

Page 5
SPECIFICATIONS
Item Specification
Maximum Rated Pressure 210 Bar
Rated Flow Ports to R 150 lpm
Rated Flow Ports to P3 300 lpm
Rated Flow Ports to R1, R2 400 lpm
Rated Flow Ports to C, HT 100 lpm
C1 160 - 165 Bar
Setting Pressure
C3 2 ±0.2 Bar Cracking Pressure
R1, R2 1-1/2" SAE Flange Port (M12, 1.75)
P1, P3 1-1/4" SAE Flange Port (M12, 1.75)
Port Size
HT, C, EF 3/4" PF O-ring
TPM, TPS 1/4" PF O-ring

Page 6
Page 7
Page 8
S0793005D
1HYDRAULIC
SCHEMATIC
(MEGA 250-V)
CAUTION!
HYDRAULIC SCHEMATIC (MEGA 250-V)S0793005D


January 2011
Hydraulic Schematic (Mega 250-V) S0793005D

Page 1
TABLE OF CONTENTS
Mega 250-V (Tier I) S/N 1001 thru 2000 ........................................................ 4
Mega 250-V (Tier II) S/N 2001 thru 3000 ....................................................... 6
Mega 250-V (Tier I) S/N 3001 thru 4000 ........................................................ 8
Mega 250-V (Tier II) S/N 4001 and Up......................................................... 10
S0793005D Hydraulic Schematic (Mega 250-V)

Page 2
GENERAL DESCRIPTION
Schematic(s) presented in this section are laid out on facing pages.
An overlapping edge has been taken into consideration so that a photocopy can be made and pasted
together to make a complete schematic.
Figure 1

Page 3
MEGA 250-V (TIER I) S/N 1001 THRU 2000
Hydraulic Schematic

Page 4
* OPTIONAL EQUIPMENT
MEGA 250-V
BAS0060L

Page 5
MEGA 250-V (TIER II) S/N 2001 THRU 3000
Hydraulic Schematic
Figure 3 (S/N 1001 thru 2000 (Europe Low Noise Kit))

(S/N 2001 and Up)

Page 6
* OPTIONAL EQUIPMENT
MEGA 250-V
BAS0070L

Page 7
MEGA 250-V (TIER I) S/N 3001 THRU 4000

Page 8
* OPTION EQUIPMENT
MEGA 250-V (Tier I)
BSS0220L

Page 9
MEGA 250-V (TIER II) S/N 4001 AND UP
CLOSES 3 B
STOP
L.H Brake valve BR1 BR2

FRONTAXLE
OPENS 25 B
T/M DISCONNECT
60B
P1 T1 P2 T2
R.H Brake pedal

0.5 BAR
30B 30B
15B
0.75L 65bar 0.75L 0.32L
(PFO1/4) (PFO3/8) (PFO3/8) (PFO3/8)
(PFO3/8) A1 LPWS P1 P2 A2 A3
1.5 BAR
C3-1 C3-2
1.2 C2 C3-3
TP2
(PFO1/4)
TANK
28 kgf/cm†
FO SAF
(PFO1/2)
120 kgf/cm† C3-4
100 L/MIN FI
(PFO1/2) C1
Fan motor(Opt.) C7
0.75" 150 kgf/cm†
OILCOOLER M
(PFO1/2)
105bar A4 T1 T2
(PFO3/8) (PFO3/8)
23ccr 30B (PFO1/4)
10 micron
BRAKE/PILOT
* TUV only 0.75L
PUMP
19.8 cm3/rev BRAKE & PILOT &FAN MOTER SUPPLY VALVE
STEER PUMP
0.5" (Option)
63.8 cm3/rev
H.P FILTER
LOADER PUMP 200 l/min at 6.9 Bat 2,400
58.3 cm3/rev
PUMP
BLOCK
EMERG.STEER VALVE
CHECK V/V P3
P1
1.25 1.25"
C3 TPM
3Bar 0.25"
<
TPS EF
O.25" 0.75
EMERG.STEER C1
PRESS/ S/W C2
160 STEER UNIT

R
<
R2 R1
1.5 1.5
C
0.75"
HT 175 BAR
0.75
P T LS
16ccr
- M
P
24v DC MOTER PUMP

for EMERG. STEER
LS
* ELECTRIC EMERGENCY STEERING

CF EF
PRIORITY V/V
75x 35x430 STEERING C
15BAR 15BAR
CUSHION V/V
< <

Page 10
* JOYSTICK VALVE Kick-down Horn
(3-SP. OPT.)
DUMP RAISE LOWER OPT. OPT.

CROWD AUTO RETURN
TO DIG
CLOSES 3 B D.C D.R D.F D.R D.F
STOP
BR2
OPENS 25 B
T/M DISCONNECT
REAR AXLE
T
60B
P
P2 T2 3
2 4 1 5 6
T/M
30B
15B
0.75L 0.32L
(PFO3/8) (PFO3/8) (PFO3/8)
P1 P2 A2 A3 TP1
C3-1 C3-2
JOYSTICK VALVE Horn Kick-down
1.2 C2 C3-3 (2-SP. STD.)
PILOT
(PFO3/8)
28 kgf/cm† DUMP CROWD AUTO RETURN RAISE LOWER

C4 TO DIG
SAFETY D.C D.R D.F
0 kgf/cm† C3-4 PARK

(PFO3/8)
LPWS T
C5 P 2 4 3 1
PK
(PFO1/4)
A4 T1 T2
(PFO3/8) (PFO3/8) (PFO1/4)
30B
only 0.75L
ALVE
200 l/min at 6.9 Bat 2,400rpm
200 BAR
(2-SPOOL,STD.)
CONTROL V/V
BUCKET
230 B
(DUMP) (CROWD)
1B
160x 80x500
BUCKET CYL
. 1A
STEER UNIT
R
BOOM
(LOWER/FLOAT)
140x 80X777 2B
BOOM CYL. (RAISE) 2A
LS
60B
OPTION
5L
230 B
* LIS DEVICE (INC.PIPING)

OPTION DEVICE(INC. PIPING)
3B
3A
* (3-SPOOL, OPTION)
PRIORITY V/V LOG FORK SYSTEM

320 l/min max
STEERING CYL.
15BAR
CUSHION V/V
MEGA 250-V (Tier II)
FG017849

Page 11
Page 12
1ELECTRICAL SYSTEM
S0802015C
R1
1ELECTRICAL SYSTEM
CAUTION!
Electrical System S0802015C


January 2011

Page 1
S0802015C Electrical System
Page 2
TABLE OF CONTENTS
Overview ........................................................................................................ 5
Electric Wire Color ........................................................................... 5
Electric Supply System................................................................................... 6
Engine Starting Circuit.................................................................................... 8
Operation During Start Process .............................................................. 8
Operation After Start Process (Mega 200-V) ........................................ 10
Operation After Start Process (Mega (250-V) ....................................... 11
Engine Preheating System........................................................................... 12
Mega 200-V / 250-V (Tier I) .................................................................. 12
Mega 200-V / 250-V (Tier II) ................................................................. 16
Principle of Operation .................................................................... 16
Engine Stop System..................................................................................... 20
Operation In Engine Running Mode...................................................... 20
Operation In Engine Stop Mode............................................................ 22
Charging System.......................................................................................... 24
Monitoring System........................................................................................ 25
Instrument Panel ................................................................................... 26
Function Check ..................................................................................... 27
Monitoring System Schematic............................................................... 28
Mega 200-V ................................................................................... 28
Mega 250-V ................................................................................... 30
Operation .............................................................................................. 32
Instruments .................................................................................... 32
Indicator Lights............................................................................... 34
Initial Operation.............................................................................. 35
Control Unit Operation ................................................................... 36
Characteristic of Operation ............................................................ 37
Windshield Wiper ......................................................................................... 38
Front windshield wiper .......................................................................... 38
Front Windshield Wiper Circuit ...................................................... 38

Page 3
Rear Windshield wiper .......................................................................... 39
Lighting System............................................................................................ 42
Light Circuit (Mega 200-V) .................................................................... 42
Light Circuit (Mega 250-V) .................................................................... 46
Emergency Steering System (Option).......................................................... 49
Block Diagram....................................................................................... 49
Emergency Steering System Components ........................................... 50
Emergency Steering Timer ............................................................ 50
Emergency Steering Pump ............................................................ 51
Emergency Steering Switch........................................................... 51
Emergency Steering System Electric Circuit......................................... 52
Electric Detent System ................................................................................. 53
Electric Circuit ....................................................................................... 53
Boom Kick-out....................................................................................... 54
Return To Dig........................................................................................ 55
Proximity Switch............................................................................. 55

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

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

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

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

Page 6
5
6
3
8
4 2
AJS0010L
Figure 1 ELECTRICAL POWER CIRCUIT DIAGRAM
Reference Reference
Number Number
1 Battery 5 Starter Switch
2 Battery Relay 6 Fuse Box
3 Fusible Link 7 Alternator
4 Circuit Breaker 8 Diode

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

Page 8
AJS0020L
Figure 2 STARTER CIRCUIT (1) - WHILE STARTING
Reference Reference
Number Number
1 Battery 8 Starter Relay
2 Battery Relay 9 Starter
4 Circuit Breaker 11 Transmission Selector Switch
5 Starter Switch 12 Diode
6 Fuse Box 13 Transmission Controller
7 Starter Controller 14 Safety Starter Relay

Page 9
OPERATION AFTER START PROCESS (MEGA 200-V)
Once the engine has been started, the belt driven alternator (10) generates a current. The output
generated by the alternator is a square wave pulse voltage through the "P" terminal and the frequency of
the pulse voltage is proportional to rotation of the alternator. Starter controller (7) monitors the frequency of
the output current. Once the frequency equivalent to 500 rpm is sensed the connection between "S" and
"E" terminals and the connection between "B" and "PP" terminals are opened. As a result the rotation of
starter (9) is stopped. Once the engine is running, starter (9) will not operate even if starter switch (5) is
moved to the start position, preventing possible damage to starter (9).
BAS0090L
Figure 3 OPERATION OF START CIRCUIT (2) - IMMEDIATELY AFTER START
Reference Reference
Number Number

Page 10
OPERATION AFTER START PROCESS (MEGA (250-V)
Once the engine has been started, the belt driven alternator (10) generates a current. The output
generated by the alternator is a square wave pulse voltage through the "P" terminal and the frequency of
the pulse voltage is proportional to rotation of the alternator. Starter controller (7) monitors the frequency of
the output current. Once the frequency equivalent to 500 rpm is sensed the connection between "S" and
"E" terminals and the connection between "B" and "PP" terminals are opened. As a result the rotation of
starter (9) is stopped. Once the engine is running, starter (9) will not operate even if starter switch (5) is
moved to the start position, preventing possible damage to starter (9).
AJS0030L
Figure 4 OPERATION OF START CIRCUIT (2) - IMMEDIATELY AFTER START
Reference Reference
Number Number

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

Page 12
3
6
4
12 5
2
13
7
13
8 1
10
11
AJS0040L
Figure 5 ENGINE PREHEAT CIRCUIT
Reference Reference
Number Number
1 Battery 8 Preheat Relay
2 Battery Relay 9 Glow Plug
3 Fusible Link 10 Thermal Switch
4 Circuit Breaker 11 Alternator
5 Starter Switch 12 Instrument Panel
6 Fuse Box 13 Diode
7 Preheat Controller

Page 13
NOTE: The preheat relay has a
replaceable protective fuse.
See Figure 6.
Reference
Description
Number
1 Terminal B
2 Fuse
3 Amperage Marked
4 Terminal H
5 Terminal C
Figure 6

Page 14
Page 15
MEGA 200-V / 250-V (TIER II)
This circuit uses a thermal switch to monitor engine temperature. An independently operating electronic
preheat controller operates only when the engine is cold. It turns "ON" a grid type resistance heater
between the engine air cleaner and intake manifold. Incoming air that is warmed before entry into the
manifold and engine cylinder combustion chambers. This improves engine starting efficiency. See Figure
5.
Principle of Operation
The contacts inside thermal switch (10) are normally open. When the temperature of the coolant drops
below 10°C (50°F), the contacts close. When starter switch (5) is turned to the "PREHEAT" position, the
closed contacts allow controller (7) to begin current flow to preheat relay (8), which controls current flow
(120 amps) to air heater (9). Controller (7) also turns "ON" the preheat indicator light in the operator's cab
(12) after the air heater has been heated for 19 seconds. Air heater (9) will heat for 19 seconds each time
the starter switch is turned to the "PREHEAT" position.
The controller switches "OFF" current flow to the heater 200 seconds after the engine has started.
The heater remains "ON" for 200 seconds in order to promote more complete cylinder combustion, speed
warm-up and reduce start-up cycle emissions.
A pulse signal is generated at alternator terminal "P" as soon as engine rpm exceeds 500 rpm.
The signal goes to controller terminal "2" to allow timing the 200 second shut off sequence.
NOTE: As long as the starter switch is at the "PREHEAT" position, signal current between the "RI"
starter terminal and controller terminal "8" sends a signal from the "5" terminal of the
controller to the "C" of the preheat relay, closing the relay contacts to turn "ON" the heater.
See Figure 6.
When the engine is already warm, and coolant temperature is above 10°C (50°F), intake air preheating is
not required. The contacts inside the thermal switch are closed at that temperature, cutting off controller
current flow and turning "ON" the preheat indicator light at the top corner of the gauge panel as soon as the
key is turned, not after 200 seconds.

Page 16
3
6
4
12 5
2
13
8 1
10
11
BAS0100L
Figure 7 ENGINE PREHEAT CIRCUIT
Reference Reference
Number Number
1 Battery 7 Preheat Controller
2 Battery Relay 8 Preheat Relay
3 Fusible Link 9 Air Heater
4 Circuit Breaker 10 Thermal Switch
5 Starter Switch 11 Alternator
6 Fuse Box 12 Instrument Panel
13 Diode

Page 17
NOTE: The preheat relay has a
replaceable protective fuse.
See Figure 6.
H B
Reference
Description D C
Number
1 Terminal B
2 Fuse
3 Terminal H 1 3
4 Terminal C 4
2
5 Terminal D
BAS0160L
Figure 8

Page 18
Page 19
ENGINE STOP SYSTEM
The engine stop circuit consists of a starter switch (3), engine stop motor (6), and engine stop relay (5).
There are two modes of operation - engine running and engine stop.
OPERATION IN ENGINE RUNNING MODE

When starter switch (3) is turned to "ON" position, the contact points "30" and "87" of engine stop relay (5)
are closed due to current flowing from battery (1), to fusible link (2), to the "B" terminal of starter switch (3),
to the "ACC" terminal of starter switch (3), to the "86" terminal of engine stop relay (5) to battery (1) and
then to the ground. As a result, engine stop motor (6) is rotated by the current flow from battery (1) to
fusible link (2) to fuse box (4) to the "B" terminal of engine stop motor (6) to the "P2" terminal of engine stop
motor (6), to the "87" terminal of engine stop relay (5), to the "30" terminal of engine stop relay (5), to the
"A" terminal of engine stop motor (6) to the "E" terminal of engine stop motor (6), and then to the ground.
The engine stop motor opens (pushes) the fuel shutoff lever of the fuel injection pump and the system is in
the running mode. The engine stop motor rotates 180° and comes to a stop due to the cam switch which
shuts off the current to the motor.
AJS0050L
Figure 9 ENGINE STOP CIRCUIT - RUNNING MODE
Reference Reference
Number Number
1 Battery 4 Fuse Box
2 Fusible Link 5 Engine Stop Relay
3 Starter Switch 6 Engine Stop Motor

Page 20
When the starter switch is in the "ON" position, the internal components of the engine stop motor's cam
switch is in the position shown.
AJS0060L
Figure 10

Page 21
OPERATION IN ENGINE STOP MODE
When starter switch (3) is in the "OFF" position, the electric current flow to the coil of engine stop relay (5)
is shut off.
As a result, the "30" and "87a" contact point of the engine stop relay are connected and current is supplied
to the engine stop motor from battery (1), to fusible link (2), to fuse box (4) to the "B" terminal of engine
stop motor (6), to the "P1" terminal of engine stop motor (6), to the "87a" terminal of engine stop relay (5),
to the "30" terminal of engine stop relay (5), to the "E" terminal of engine stop motor (6), to the ground, and
then the motor is rotated. The shutoff lever of the fuel injection pump, linked to the engine stop motor by a
cable, is moved to the close (pull) position and the engine is stopped. The engine stop motor moves 180°
from the running mode position and is stopped by the internal cam switch which cuts off the current to the
motor.
5
6
4
2
AJS0070L
Figure 11 ENGINE STOP CIRCUIT - STOP MODE
Reference Reference
Number Number
1 Battery 4 Fuse Box
2 Fusible Link 5 Engine Stop Relay
3 Starter Switch 6 Engine Stop Motor

Page 22
When the starter switch is in the "OFF" position, the internal components of the engine stop motor's cam
switch is in the position shown.
AJS0080L
Figure 12

Page 23
CHARGING SYSTEM
When starter switch (5) is turned to the "ON" position, an initial excited current flows to the field coil of
alternator (7) through battery relay (2) and circuit breaker (4). When the engine is started from this
condition alternator (7) starts charging. Current flows from the "B+" terminal of alternator (7), to circuit
breaker (4), to battery relay (2), and to battery (1).
The alternator also supplies electric current to other electrical components. When alternator (7) starts to
operate, a current flows from the "R" terminal of alternator to diode (8) and then to battery relay (2) coil
securing a path for the charging current to battery (1). Thus, preventing the possibility of a high voltage
build up and possible damage to the electric system.
AJS0090L
Figure 13 CHARGING CIRCUIT
Reference Reference
Number Number
1 Battery 5 Starter Switch
2 Battery Relay 6 Fuse Box
4 Circuit Breaker 8 Diode

Page 24
MONITORING SYSTEM
2
20
19 3
18
4
1
5
17
F/R
6
16
15
7
13 14 12 11 10 9 BIS0041L
Figure 14
Reference Reference
Number Number
1 Instrument Panel 11 Engine Oil Pressure Switch
2 Battery 12 Hazard Warning Light Switch
3 Alternator 13 Turn Signal Light Switch
4 Speed Sensor 14 High Beam Switch
5 Coolant Temperature Sensor 15 Working Light Switch
6 Fuel Sensor 16 Brake Oil Pressure Switch
Transmission Oil Temperature 17 Parking Brake Pressure Switch
7
Sensor 18 Emergency Steering Switch
8 Preheat Controller 19 Control Unit
9 Air Cleaner Indicator 20 Transmission Control Unit
Engine Coolant Temperature
10
Switch
The monitoring system displays various data and warning signals onto the instrument panel by processing
information gathered from various sensors throughout the equipment.

Page 25
INSTRUMENT PANEL
9 10 11 12 13 14 15 16 17
F/R
8 18
7 19
4 1 3 2 5 6
AMP MIC 13P AMP MIC 17P
(CN1) (CN2)
AOS0921L
Figure 15

Page 26
Reference Reference
Number Number
1 Speed Meter 11 Charging Warning Light
2 Tachometer Turn and Hazard Warning
12
3 Hour Meter Light
4 Fuel Gauge 13 High Beam Indicator Light
Engine Coolant Turn and Hazard Warning
5 14
Temperature Gauge Light
Transmission Oil Working Light Indicator
6 15
Temperature Gauge Light
Preheat Completion Brake Oil Pressure
7 16
Indicator Light Warning Light
Air Cleaner Clogged 17 F/R Select Indicator
8
Warning Light Parking Brake Indicator
18
Engine Coolant Light
9
Temperature Warning Light Emergency Steering
19
Engine Oil Pressure Indicator Light
10
Warning Light
FUNCTION CHECK
When the starter switch is turned to the "ON" position, all displays, switch lights, and warning lights except
the turn and hazard warning light, high beam indicator, working light indicator, and emergency steering
indicator will be turned "ON" for two seconds and the warning buzzer will sound. Any lights that do not turn
"ON" during the function check should be replaced.

Page 27
MONITORING SYSTEM SCHEMATIC
Mega 200-V
F/R Select
BZS1360L
Figure 16

Page 28
Reference Reference
Number Number
1 Instrument Panel Coolant Temperature
17
2 Headlight Switch Switch
3 Forward Lever Switch 18 Brake Oil Pressure Switch
4 Reverse Lever Switch Parking Brake Pressure
19
Switch
5 High Beam Switch
20 Alternator
6 Left Turn Signal Switch
21 Control Unit
7 Right Turn Signal Switch
22 Alarm Buzzer
8 Work Light Switch
23 Alarm Relay
9 Emergency Steering Switch
24 Battery
10 Speed Sensor
25 Battery Relay
Coolant Temperature
11 26 Circuit Breaker
Sensor
12 Fuel Sensor 27 Fuse Box
Transmission Oil 28 Fusible Link
13
Temperature Sensor 29 Preheat Controller
Air Cleaner Clogged 30 Transmission Control Unit
15
Warning Light
16 Engine Oil Pressure Switch

Page 29
Mega 250-V
F/R Select
BZS1370L
Figure 17

Page 30
Reference Reference
Number Number
1 Instrument Panel Coolant Temperature
17
2 Headlight Switch Switch
3 Forward Lever Switch 18 Brake Oil Pressure Switch
4 Reverse Lever Switch Parking Brake Pressure
19
Switch
5 High Beam Switch
20 Alternator
6 Left Turn Signal Switch
21 Control Unit
7 Right Turn Signal Switch
22 Alarm Buzzer
8 Work Light Switch
23 Alarm Relay
9 Emergency Steering Switch
24 Battery
10 Speed Sensor
25 Battery Relay
Coolant Temperature
11 26 Circuit Breaker
Sensor
12 Fuel Sensor 27 Fuse Box
Transmission Oil 28 Fusible Link
13
Temperature Sensor 29 Preheat Controller
Air Cleaner Clogged 30 Transmission Control Unit
15
Warning Light
16 Engine Oil Pressure Switch

Page 31
OPERATION
Instruments
Sensor Specification
Function Display Input
Input Specification
Terminal
10 km/h- 905 Hz
20 km/h- 1811 Hz
M200-V 30 km/h- 2716 Hz
40 km/h- 3622 Hz
*ƒ = 90.55 V [Hz]
CN1-4 10 km/h- 704 Hz
Speedometer
CN1-5 20 km/h- 1407 Hz
M250-V 30 km/h- 2111 Hz
40 km/h- 2814 Hz
*ƒ = 70.36 V [Hz]
ƒ : Frequency of T/M Controller
v : Speed [km/h]
500 rpm - 90 Hz
1000 rpm - 179 Hz
1500 rpm - 268 Hz
2000 rpm - 358 Hz
2500 rpm - 447 Hz
Tachometer CN1-3
3000 rpm - 537 Hz
*ƒ = 0.179 N [Hz]
ƒ: Frequency of alternator "P"
terminal
N : Engine rpm
ALTERNATOR "P"
Hour Meter CN1-2
Terminal voltage (24V)
0012.eps

Page 32
Sensor Specification
Function Display Input
Input Specification
Terminal
EMPTY - Above 90 Ohm

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

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

Oil
CN1-8 120°C - 36.5 Ohm
Temperature
Gauge 150°C - Below 18.6 Ohm

Page 33
Indicator Lights
Input
Symbol Description Termina Operation Remarks
l
Preheat CN2-1 Light turns "ON" when
preheat process is
completed. (Approximately
HAOA630L
19 seconds from start.)
Air Cleaner CN2-2 Light turns "ON" when air
cleaner is clogged
HAOA660L
Coolant CN2-3 Light turns "ON" when

Temperature coolant temperature
increases over 102°C.
HAOA51AL
(When terminal input is
connected.)
Engine Oil CN2-4 Light turns "ON" when After starting engine, if
Pressure engine oil pressure drops engine oil pressure is
below 1.6 kg/cm2 (23 psi) insufficient after 8 seconds,
HAOA620L
a warning buzzer will
sound.
Charging CN2-5 Light turns "ON" when not Under normal conditions,
charging, and "R" terminal will light up before engine
output drops below 24V. start up and shut off once
HAOA610L
engine is running.
Left Turn and CN2-6 Light turns "ON" when left
Hazard Light turn signal or hazard light
is operated. (Terminal
input is to 24V.)
Right Turn CN2-8 Light turns "ON" when right
and Hazard turn signal or hazard light
Light is operated. (Terminal
input is to 24V.)
High Beam CN2-7 Light turns "ON" when high
beam is operated.
(Terminal input is to 24V.)
HGB2008L
Work Light CN2-9 Light turns "ON" when Light off when the engine is
work light is operated. started.
(Terminal input is to 24 V.)
Brake Oil CN2-10 Lights off when brake oil Under normal conditions,
Pressure pressure increases over 65 will light up before engine
kg/cm2 (925 psi) and light start up and shut off once
0717B
turns "ON" when brake oil engine is running.
pressure drops below 60
kg/cm2 (850 psi). (When
terminal input is
connected.)

Page 34
Input
Symbol Description Termina Operation Remarks
l
Parking CN2-12 Light turns "ON" when the Under any conditions, will
Brake parking brake switch is be turned "ON" before
P applied and parking brake engine start up.
0717A pressure is above 65 kg/
cm2 (925 psi).
(24V is inputted to the
input terminal)
Emergency CN2-13 Light turns "ON" when the This is option parts.
Steering vehicle speed is above 5
km/h and the steering
AJO0450L pressure is below 10 kg/
cm2 (140 psi).
(When the test switch is
applied)
F/R Select CN2-11 Light turns "ON" when the This is option parts.
another travel device is
F/R selected.
BSO0510L
Initial Operation
Input
Item Output (Operation and initial setting mode)
(Terminal)
Initial Operation CN 1-1 • All warning lights are turned "ON" and turned "OFF"
after 2 seconds. (Except for turn signal indicator, high
beam indicator, working light indicator and transmission
cutoff indicator and emergency steering indicator.
• Warning buzzer is activated and turned "OFF" after 2
seconds.
• Monitoring system displays present conditions.

Page 35
Control Unit Operation
5
2
1
6
7 8
13 AMP MIC 13P

9
10
11
12 AOS0940L
Figure 18
Reference Reference
Number Number
1 Instrument Panel 8 Alternator
2 Starter Switch 9 Engine Oil Pressure Switch
3 Forward Lever Switch Coolant Temperature
10
4 Reverse Lever Switch Switch
5 Fuse Box 11 Brake Oil Pressure Switch
6 Control Unit Parking Brake Pressure
12
Switch
7 Warning Buzzer
13 Alarm Relay

Page 36
Characteristic of Operation
Input Output
All warning lights are
turned "ON" and turned
1 When the starter switch is "ON."
"OFF" after 2 - 2.5
seconds.
Battery warning light
is below 12 ±1 V
When "R" terminal voltage of turns "ON" L5
2
alternator Battery warning light
is above 12 ±1 V
turns "OFF" L5
Warning buzzer sounds
Engine oil pressure switch is "ON."
after 8 ±1 seconds.
Coolant temperature switch is "ON."
immediately
When "R" terminal voltage of
3 Warning buzzer sounds
alternator is above 12 ±1 V Brake oil pressure switch is "ON."
immediately
Forward or Reverse lever switch is
"ON" and Parking brake pressure
immediately
switch is "ON."

Page 37
WINDSHIELD WIPER
FRONT WINDSHIELD WIPER
You can control the windshield wiper by operating wiper washer switch (2).
1. Low speed wiper action (1st).
Wiper acts in low speed through fuse box (1) to the 15,53 terminal of wiper switch (2) to the L,E
terminal of wiper motor (5).
2. High speed wiper action (2nd).
Wiper acts in high speed through fuse box (1) to the 15,53b terminal of wiper switch (2) to the H,E
3. When you turn "OFF" the switch during low speed wiper action (1st) or high speed wiper action (2nd),
electric currents flow through Fuse box (1) to the B,S terminal of wiper motor (5) to the 87a,30
terminal of wiper relay (3) to the 31b,53 terminal of wiper switch (2) - L,E terminal of wiper motor (5).
Wiper acts until the wiper rotates to the stop position, than the wiper stops.
4. Intermittent wiper action.
Fuse box (1) to the 15,J terminal of wiper switch (2) to the 1,4 terminal of wiper timer (4) are
connected intermittently, and electric current flow into 86,85 terminal of wiper relay (3) than the 87
terminal and 30 terminal are connected.
Therefore, electric current flow through fuse box (1) to the 87,30 terminal of wiper relay (3) to the
31b,53 terminal of wiper switch (2) to the L,E terminal of wiper motor (5), and the wiper operates
intermittently in low speed.
Front Windshield Wiper Circuit
Figure 19

Page 38
Reference Reference
Number Number
1 Fuse Box 5 Wiper Motor
2 Wiper Washer Switch 6 Washer Tank
3 Wiper Relay 7 Diode
4 Wiper Timer
REAR WINDSHIELD WIPER

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

Fuse box (1), to the B,L terminal of wiper motor (3), to the 4,2 terminal of switch (2) are connected,
then activates the wiper.
3. When you turn off windshield wiper switch in 1st or 2nd position, electric current flows fuse box (1), to
the B,L terminal of wiper motor (3), to the 4,6 terminal of wiper switch (2), to diode (6), to the S,E

Page 39
1
3
2
6 5
5
4
AJS0160L
Figure 21 REAR WINDSHIELD WIPER STOP CIRCUIT
Reference Reference
Number Number
1 Fuse Box 4 Washer Tank
2 Wiper/washer Switch 5 Diode
3 Wiper Motor 6 Diode

Page 40
Page 41
LIGHTING SYSTEM
LIGHT CIRCUIT (MEGA 200-V)
27
28
19 21
20
23 26
25
2
7
8 3
12 10 11 13
6
18
4
24
14 16 15
5
BAS0150L
Figure 22 LIGHT CIRCUIT

Page 42
Reference Reference
Number Number
1 Fuse Box 1 15 Rear Combination Light (R)
2 Blinker Unit 16 License Plate Light
3 Headlight Switch 17 Instrument Panel
4 Combination Switch 18 Diode
5 Shift Lever Switch 19 Front Working Light Switch
6 Hazard Switch 20 Front Working Light
7 Stop Light Switch 21 Rear Working Light Switch
8 Headlight Relay 22 Working Light Relay
9 Reverse Relay 23 Rear Working Light
10 Headlight (L) 24 Fuse Box 2
11 Headlight (R) 25 Starter Switch
12 Front Combination Light (L) 26 Pilot Buzzer
13 Front Combination Light (R) 27 Alarm Relay 1
14 Rear Combination Light (L) 28 Alarm Relay 2
The lighting system consists of the headlight, the position light, the turn signal light, the hazard light, the
stop light, the license plate light, the working light, the rotating beacon light (option) and the switches,
which are used to turn "ON" the lights.
1. When the headlight switch (3) is in the first step, through the fuse box 1 (1) to the "2," "6" terminal of
headlight switch (3), the following lights will be turned "ON."
A. The front combination light (L) (12) and rear combination light (L) through the fuse box 2 (23).
B. The front combination light (R) (13) and rear combination light (R) through the fuse box 2 (23).
C. The illumination lights through the "9" terminal of all kind of rocker switches include the
headlight switch (3), the front working light switch (19), the rear working light (21) and the
hazard switch (6).
D. The license plate light (16).
2. When the headlight switch (3) is in the second step, the current flows through the fuse box 1 (1), to
the "2," "3" terminal of headlight switch (3) and to the "86," "85" terminal of headlight relay (8), and the
"30," "87" terminal of headlight relay (8) is connected. As a result, through the fuse box 1 (1) to the
"30," "87" terminal of headlight relay (8), the voltage is applied to the "56" terminal of combination
switch (R) (4).
A. At this time if the combination switch (4) is in the "0" position, the current flows to the "56b"
terminal and it allow the low light, which is in the headlight (L) (10) and the headlight (R) (11), to
be light turns "ON."
B. Also, if the combination switch (4) is in the "t " position, the current flows to the "56a" terminal
and it allow the high light, which is in the headlight (L) (10) and the headlight (R) (11), to be light
turns "ON." At the same time the current flows to the "CN2-7" terminal of instrument panel (17)
and the headlight indicator L7 will be turned "ON."
C. And if the combination switch (4) is in the "s " position, the current flows to the "56b" terminal
and it allows the low light, which is in the headlight (L) (10) and the headlight (R) (11), to be light
turns "ON."
At the same time another current flows from the fuse box 1 (1) to the "15/1," "56b" terminal of
combination switch (4) and the high light, which is in the headlight (L) (10) and the headlight (R)
(11) will be turned up, and the other current flows to the "CN2-7" terminal of instrument panel
(17) and the headlight indicator will be turned "ON." The combination switch (4) is returned
automatically.

Page 43
3. When the combination switch (4) is in the "←" (or "→")position, the current flows from the fuse box 1
(1), to the blinker unit (2), to the "L" (or "R") terminal through "49a" terminal of combination switch (4),
to the "C" terminal of front combination light (L) (12) and the rear combination light (L) (14) (or to the
front combination light (R) (13) and the rear combination light (R) (15)). This current makes the turn
signal light turned up. At the same time the current flows to the "CN2-6" terminal (or to the CN2-8
terminal) of instrument panel and the turn signal light indicator L6 (or L8) will be turned "ON."
4. If you operates the hazard light switch (6), the current flows from to the fuse box 1 (1), to the blinker
unit (2), to the "5," "1" terminal of hazard switch (6), to the diode (18), to the front combination light (L)
(12) and the front combination light (R) (13), to the "C" terminal of rear combination light (L) (14) and
rear combination light (R) (15). This current makes the turn signal light turned up. At the same time
through the "2," "6" terminal of hazard switch (6), the voltage is applied to the "9" terminal and the
illumination light used to symbol light will be turned "ON." Also, the current flows to the "CN2-6,"
"CN2-8" terminal of instrument panel (17) and the turn signal light indicator "L," "L8" will be turned
"ON."
5. When the shift lever switch (5) is in the "R" position, the contact points "30" and "87" of the reverse
relay (9) are closed due to current flowing from the fuse box 2 (23), to the shift lever switch (5), to the
"86" terminal of reverse relay (9) and to the ground. Thus the current flows from fuse box 2 (23), to
the reverse relay (9) and to the "D" terminal of rear combination light (L) (14) and rear combination
light (R) (15), and the reverse light will be turned "ON."
6. When the brake pedal is depressed and at the same time the stop light switch (7) is turned up, the
current flows the from fuse box 1 (1), to the stop light switch (7) and to the "F" terminal of rear
combination light (L) (14) and rear combination light (R) (15), and the stop light will be turned "ON."
7. When the front working light switch (19) is in the "ON" position, the current flows from the fuse box 1
(1), to the "5," "1" terminal of front working light switch (19) and to the front working light (20). This
current makes the front working lights turned up. At the same time the working light indicator, L9," is
turned up due to the "CN2-9" terminal of instrument panel (17).
8. When the rear working light switch (21) is in the first step, the current flows from the fuse box (1), to
the "5" and "1" terminal of the working light switch (21). As a result the rear working light (23)
mounted on the cabin turns "ON."
When the headlight switch (3) is in the first step or in the second step while the starter switch (25) is in the
"OFF" position, the contact point "30," "87" of alarm relay 1 (27) is closed due to the excited current, which
flows to the coil of alarm relay 1 (27) and the pilot buzzer (26) will sound. But when the headlight switch (3)
is in the first step or in the second step while the starter switch (25) is in the "ON" position, the contact point
"3," "87" of alarm relay 2 (28) is closed due to the excited current, which flows to the coil of alarm relay 2
(28). At the same time the current is not supplied to the "30" terminal of alarm relay 1 (27) and the pilot
buzzer will not sound any more.

Page 44
Page 45
LIGHT CIRCUIT (MEGA 250-V)
22
28 29
23
20 19 21
24 27
18 18
17
1
26
2
7
8 3
12 10 11 13
6
18
4
25
14 16 15
5
AJS0180L
Figure 23 LIGHT CIRCUIT

Page 46
Reference Reference
Number Number
1 Fuse Box 1 16 License Plate Light
2 Blinker Unit 17 Instrument Panel
3 Headlight Switch 18 Diode
4 Combination Switch 19 Front Working Light Switch
5 Shift Lever Switch 20 Front Working Light
6 Hazard Switch 21 Rear Working Light Switch
7 Stop Light Switch 22 Working Light Relay
8 Headlight Relay 23 Rear Working Light 1
9 Reverse Relay 24 Rear Working Light 2
10 Headlight (L) 25 Fuse Box 2
11 Headlight (R) 26 Starter Switch
12 Front Combination Light (L) 27 Pilot Buzzer
13 Front Combination Light (R) 28 Alarm Relay 1
14 Rear Combination Light (L) 29 Alarm Relay 2
15 Rear Combination Light (R)
The lighting system consists of the headlight, the position light, the turn signal light, the hazard light, the
stop light, the license plate light, the working light, the rotating beacon light (option) and the switches,
which are used to turn "ON" the lights.
1. When the headlight switch (3) is in the first step, through the fuse box 1 (1) to the "2," "6" terminal of
headlight switch (3), the following lights will be turned "ON."
A. The front combination light (L) (12) and rear combination light (L) through the fuse box 2 (23).
B. The front combination light (R) (13) and rear combination light (R) through the fuse box 2 (23).
C. The illumination lights through the "9" terminal of all kind of rocker switches include the
headlight switch (3), the front working light switch (19), the rear working light (21) and the
hazard switch (6).
D. The license plate light (16).
2. When the headlight switch (3) is in the second step, the current flows through the fuse box 1 (1), to
the "2," "3" terminal of headlight switch (3) and to the "86," "85" terminal of headlight relay (8), and the
"30," "87" terminal of headlight relay (8) is connected. As a result, through the fuse box 1 (1) to the
"30," "87" terminal of headlight relay (8), the voltage is applied to the "56" terminal of combination
switch (R) (4).
A. At this time if the combination switch (4) is in the "0" position, the current flows to the "56b"
terminal and it allow the low light, which is in the headlight (L) (10) and the headlight (R) (11), to
be light turns "ON."
B. Also, if the combination switch (4) is in the "t " position, the current flows to the "56a" terminal
and it allow the high light, which is in the headlight (L) (10) and the headlight (R) (11), to be light
turns "ON." At the same time the current flows to the "CN2-7" terminal of instrument panel (17)
and the headlight indicator L7 will be turned "ON."
C. And if the combination switch (4) is in the "s " position, the current flows to the "56b" terminal
and it allows the low light, which is in the headlight (L) (10) and the headlight (R) (11), to be light
turns "ON."

Page 47
At the same time another current flows from the fuse box 1 (1) to the "15/1," "56b" terminal of
combination switch (4) and the high light, which is in the headlight (L) (10) and the headlight (R)
(11) will be turned up, and the other current flows to the "CN2-7" terminal of instrument panel
(17) and the headlight indicator will be turned "ON." The combination switch (4) is returned
automatically.
3. When the combination switch (4) is in the "←" (or "→")position, the current flows from the fuse box 1
(1), to the blinker unit (2), to the "L" (or "R") terminal through "49a" terminal of combination switch (4),
to the "C" terminal of front combination light (L) (12) and the rear combination light (L) (14) (or to the
front combination light (R) (13) and the rear combination light (R) (15)). This current makes the turn
signal light turned up. At the same time the current flows to the "CN2-6" terminal (or to the CN2-8
terminal) of instrument panel and the turn signal light indicator L6 (or L8) will be turned "ON."
4. If you operates the hazard light switch (6), the current flows from to the fuse box 1 (1), to the blinker
unit (2), to the "5," "1" terminal of hazard switch (6), to the diode (18), to the front combination light (L)
(12) and the front combination light (R) (13), to the "C" terminal of rear combination light (L) (14) and
rear combination light (R) (15). This current makes the turn signal light turned up. At the same time
through the "2," "6" terminal of hazard switch (6), the voltage is applied to the "9" terminal and the
illumination light used to symbol light will be turned "ON." Also, the current flows to the "CN2-6,"
"CN2-8" terminal of instrument panel (17) and the turn signal light indicator "L," "L8" will be turned
"ON."
5. When the shift lever switch (5) is in the "R" position, the contact points "30" and "87" of the reverse
relay (9) are closed due to current flowing from the fuse box 2 (23), to the shift lever switch (5), to the
"86" terminal of reverse relay (9) and to the ground. Thus the current flows from fuse box 2 (23), to
the reverse relay (9) and to the "D" terminal of rear combination light (L) (14) and rear combination
light (R) (15), and the reverse light will be turned "ON."
6. When the brake pedal is depressed and at the same time the stop light switch (7) is turned up, the
current flows the from fuse box 1 (1), to the stop light switch (7) and to the "F" terminal of rear
combination light (L) (14) and rear combination light (R) (15), and the stop light will be turned "ON."
7. When the front working light switch (19) is in the "ON" position, the current flows from the fuse box 1
(1), to the "5," "1" terminal of front working light switch (19) and to the front working light (20). This
current makes the front working lights turned up. At the same time the working light indicator, L9," is
turned up due to the current flowing from the diode (8) to the "CN2-9" terminal of instrument panel
(17).
8. When the rear working light switch (21) is in the second step, the contact points "30" and "87" of the
working light relay (22) is closed due to the flowing current from the fuse box 1 (1), to the "2" and "6"
terminal of the working light switch (21), to the "86" terminal of the working light relay (22) and to the
ground. Thus the current flows from the fuse box 1 (1), to the working light relay (22) and to the rear
working light 1 (23) mounted on right/left rear fender. As a result the rear working light (23) light turns
"ON." At the same time the working indicator light "L9" turns "ON" due to the current flowing from the
diode (18) to the "CN2-9" terminal of the instrument panel.
9. When the rear working light switch (21) is in the second step, the contact points "30" and "87" of the
working light relay (22) is closed due to the flowing current from the fuse box 1 (1), to the "2" and "6"
and "3" terminal of the working light switch (21), the rear working (23) is operated like being described
above clause "8" and the rear working light (24) mounted on the cabin turns "ON" at the same time.
10. When the headlight switch (3) is in the first step or in the second step while the starter switch (26) is
in the "OFF" position, the contact point "30," "87" of alarm relay 1 (28) is closed due to the excited
current, which flows to the coil of alarm relay 1 (28) and the pilot buzzer (27) will sound. But when the
headlight switch (3) is in the first step or in the second step while the starter switch (26) is in the "ON"
position, the contact point "3," "87" of alarm relay 2 (29) is closed due to the excited current, which
flows to the coil of alarm relay 2 (29). At the same time the current is not supplied to the "30" terminal
of alarm relay 1 (28) and the pilot buzzer will not sound any more.

Page 48
EMERGENCY STEERING SYSTEM (OPTION)
BLOCK DIAGRAM
3
5
6
1
8
4
AJS0460L
Figure 24 EMERGENCY STEERING SYSTEM BLOCK DIAGRAM
Reference Reference
Number Number
1 Fuse Box 5 Emergency Steering Pump
2 Emergency Steering Switch Emergency Steering Indicator
6
3 Emergency Steering Timer Light
Emergency Steering Pressure 7 Transmission Controller
4
Switch 8 Battery
When the speed of the vehicle exceeds 5 km/h and the secondary steering pressure is less than 10 kg/cm2
(140 psi), an electrically powered hydraulic pump will be operated for a time limited 60 seconds and thus
the emergency steering is possible. This system includes the electrically powered hydraulic pump, which is
controlled by the emergency steering timer (3). The emergency steering timer (3) obtains signals from the
emergency steering pressure switch (4) and the transmission controller (7). When the emergency steering
is activated, the emergency steering indicator (6) light turns "ON."

Page 49
EMERGENCY STEERING SYSTEM COMPONENTS
Emergency Steering Timer

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

characteristic of operation is following.
AJS0450L
No. Wire Size and Color
Figure 25
1 0.85 WL
2 0.85 G
3 0.85 WB
4 0.85 W
5 0.85 B
Reference
Description
Number 4
5
1 Emergency Steering Timer
Emergency Steering 1
2
Pressure Switch
3 Transmission Controller 2
4 Emergency Steering Pump
5 Starter Switch
3
AJS0470L
Figure 26 EMERGENCY STEERING TIMER
CIRCUIT
Input Condition Output

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

Page 50
Emergency Steering Pump
This is an electrically powered hydraulic pump
and includes an emergency steering relay (1,
Figure 27), which is excited by the signal of the 1
emergency steering timer.
AJS0480L
Figure 27 EMERGENCY STEERING PUMP

Emergency Steering Switch
1. When the switch is in the "I" position, the
emergency steering pump and the
emergency steering indicator of the
instrument panel are activated
simultaneously. O
2. The basic usage of this switch is testing
function whether the emergency steering
system is all right or not.
I
AJO0011L
Figure 28 EMERGENCY STEERING SWITCH
WARNING
Make sure that no persons are near the machine when testing the function of the emergency
steering system, there is a risk that someone may be crushed between the front and the rear
frame.
3. This returns automatically when not pressed down.

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

Page 51
EMERGENCY STEERING SYSTEM ELECTRIC CIRCUIT
When the control signal, which is transmitted from the "36" terminal of the transmission controller, is
inputted to the "2" terminal of emergency steering timer (3) and emergency steering pressure switch (4) is
"OFF," the contact points "A" and "B" of emergency steering pump (5) is closed due to the current flowing
from fuse box (1), to the "C" and "D" coil of emergency steering pump (5), and to the "4" and "5" terminal of
emergency steering timer (3).
Thus the high current flows from battery (11) to the "A" and "B" terminal of emergency steering pump (5),
which is operated. At the same time the emergency steering indicator light turns "ON" due to the current
flowing from the "B" terminal of steering pump (5), to fusible link (7) and to the emergency steering
indicator.
6 7
11
5
8
1 10
9 3
AJS0490L
Figure 29 EMERGENCY STEERING SYSTEM CIRCUIT
Reference Reference
Number Number
1 Fuse Box Emergency Steering Indicator
6
2 Emergency Steering Switch Light
3 Emergency Steering Timer 7 Fusible Link
Emergency Steering Pressure 8 Diode
4
Switch 9 Transmission Controller
5 Emergency Steering Pump 10 Headlight Switch
11 Battery

Page 52
ELECTRIC DETENT SYSTEM
The electric detent system is separated into boom kick-out and return to dig.
Each part consists of magnetic locking lever and proximity switch detecting position of bucket or boom.
ELECTRIC CIRCUIT
FLOAT KICK-OUT (OPTION)

6
2
5
11 3
9
7 4
8
1
10 11
AJS0500L
Figure 30 ELECTRIC DETENT CIRCUIT
Reference Reference
Number Number
1 Fuse Box 7 Return to Dig Magnetic
2 Float Kick-out Switch (Option) 8 Raise Proximity Switch
3 Raise / Float Relay 9 Float Proximity Switch (Option)
4 Return to Dig Relay 10 Return to Dig Proximity Switch
5 Raise Magnetic 11 Diode
6 Float Magnetic

Page 53
BOOM KICK-OUT
When the work lever (joystick) is in the "FLOAT" (or "RAISE") position, lever is locked and boom is lowered
(or lifted). When the boom is matched to setting position, lever locking is released and lever is returned to
"NEUTRAL" position automatically and boom lowering (or lifting) is stopped.
1. Boom Raise Kick-out
With the raise magnetic (5) is energized and the work lever (joystick) is held in "RAISE," then boom is
approaching to the raise proximity switch (8). When the raise proximity switch (8) and the boom are
matched, the contact points "30" and "87a" of the raise/float relay (3) is opened due to the current
flowing from the fuse box (1), to the coil of the raise relay (3) and to the "0" and "-" terminal of the
raise proximity switch (8). As a result the magnetic (5) is de-energized and the locked lever is
returned to "NEUTRAL" position, boom lifting is stopped.
2. Boom Float Kick-out (Option)
With the float kick-out switch shown in Figure 31, is in the "I" position and the float magnetic (6) is
energized and the work lever (joystick) is held in "FLOAT," then boom is approaching to the float
proximity switch (9).
When the float proximity switch (9) and the
boom are matched, the contact points "30"
and "87a" of the raise/float relay (3) is
opened due to the current flowing from the
fuse box (1), to the coil of the raise/float
relay (3), to the terminal "5" and "1" of the O
float kick-out switch (2) and to the "0" and
"-" terminal of the raise proximity switch
(9). As a result the magnetic (6) is I
de-energized and the locked lever is
returned to "NEUTRAL" position, and
boom lowering is stopped. HA0O2027
Figure 31

Page 54
RETURN TO DIG
After dumping, if the work lever (joystick) is in the "CROWD" position, the work lever (joystick) will be
locked and the bucket will be crowded. When the bucket is matched to setting position, the lever is
returned to the "NEUTRAL" position and bucket crowding will be stopped. After this operation, if the boom
is lowered the bucket is in parallel with ground.
With the return to dig proximity switch (10) and the bucket positioner are matched, the contact points "30"
and "87" of the return to dig relay (4) is closed due to the current flowing from fuse box (1), to the coil of the
return to dig relay (4) and to the "0" and "-" terminal of the return to dig proximity switch (10). In this state, if
the work lever (joystick) is in the "CROWD" position, the lever is locked and the bucket positioner is
approaching out of the return to dig proximity switch (10). That is, bucket is crowded. If the bucket
positioner is out of the return to dig proximity switch (10), the float magnetic (9) is de-energized. As a result
the lever is returned to "NEUTRAL" position and bucket is set to the selected digging angle.
Proximity Switch
• Operating Distance: 10±1 mm OPERATION INDICATOR
• Operation Indicator light POSITIONER
: Light turns "ON" when the object is

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

Page 55
Page 56
S0893005C
R1
1ELECTRICAL
SCHEMATIC
(MEGA 250-V)
CAUTION!
ELECTRICAL SCHEMATIC (MEGA 250-V)S0893005C


January 2011
Electrical Schematic (Mega 250-V) S0893005C

Page 1
TABLE OF CONTENTS
Mega 250-V (Tier I) ........................................................................................ 4
Mega 250-V (Tier II) ....................................................................................... 6
S0893005C Electrical Schematic (Mega 250-V)

Page 2
GENERAL DESCRIPTION
Schematic(s) presented in this section are laid out on facing pages.
An overlapping edge has been taken into consideration so that a photocopy can be made and pasted
together to make a complete schematic.
Figure 1

Page 3
MEGA 250-V (TIER I)
0.85RG REAR WORKING LAMP

ROTATING BEACON (2534-9049C)x4
87a ALARM RELAY 1
(FR)
(OPTION) FRONT 0.85B
24V 70W
87
30 1.25RY (2544-9033 )
WORKING LAMP 0.85RW 1.25RW 87a
CN1 AMP MIC 13P 30
ROTATING BEACON (2534-1127)x2 0.85W
0.85RG (RR) 0.85B 85 86
+ SIG (2RL006846-111) 24V 70W 0.5B 0.5RG 0.85B 87
CN1-4 0.85G
HELLA (FL) 0.85B 0
SPEED - CN1-5 0.85R (RADIATOR) 85 86 0.5WR
0.85RW REAR LAMP SW
0.85B 1.25RG (2549-9109 )
+ S (RL) REAR LAMP RELAY
CN1-3 0.5WG 0.85B +(2190-2036D20)
TACHO 0.85R 1 (2544-9033 )
- CN1-13 0.85B 1.25RG
1 5 1.25RY 0
0.85RW 2
+ S CN1-6 W/TEMP SENSOR 5 7 6 I 1.25RY
0.85L 0.85RY
WATER (2547-6028) (CR) 0.85B 1.25B
- 7 1.25RW 3 II
TEMP 10 9 0.5WR
(17) 0.5B 9 10 0.5WR
10 9 (CABIN)
+ S 0.5B 0.5WR
CN1-7 0.85YR 0.85B FUEL SENSOR 0.85RW (18)
FRONT LAMP SW
FUEL - (547-00019A) 0.5B (2549-9098) (CL) 0.85B
BEACON SW +(2190-2036D5)
+ (2549-9098) 0.5RL 0.5RL 2RY
S CN1-8 0.85GR 0.85B
T/M OIL TRANSMISSION OIL +(2190-2036D10) 1.25RY
1.25RY
- TEMP SENSOR
TEMP 0.5WG 0.5WG 0.5WG
(ZF 0510 308 844)
1 3 0.5RW 0.5RW 0.5RW 0.5RW
CN1-2
HOUR 2 0.85WR 0.85WR 0.85WR 0.85WR
0.85BW 0.85B 1.25R 1.25R 1.25R 1.25R
ILLUMINATION
0.85G 0.5BrW 0.5BrW
INDICATOR 0.85LB 0.85LB
(2170-9005)
CN1-9 0.85WR CONTROL UNIT 0.85L 0.85L
(543-00001)
CN1-1 1.25R
B 0.85L CIGAR LIGHTER
+ REAR WIPER SW
CHARGE CN2-5 0.5W 0.5W 3 1 0.85R STOP RUN E 0.85B (2549-9129 ) (545-00001)
L5
+(2190-2036D18)
ENG OIL PRESS CN2-4 0.5BY 0.5BY 4 2 0.5RW M L 2 0.85B
L4 0.85LW 0.85LW 4 II - 0.85B
TIME DELAY -
WATER TEMP CN2-3 0.5YB 0.5YB 5 S 0.85Y 0.85YB +
L3 6 0
BUZZER CIRCUIT 7 0.85B
0.85BR 5 I 0.85W
BRAKE OIL PRESS CN2-10 0.5YL 0.5YL 6 (19) 9 0.5WR
L10 10 0.5WR
REAR WIPER MOTOR
PARK BRAKE CN2-12 0.5Lg 0.5Lg 7 8 0.5BrW (2538-9005) 0.85G
L12
(11) 0.5B 0.85L
AIR CLEANER CN2-2 0.85BW (12) B
L2 0.85W
0.85L 0.85BR 0.85BR
BRAKE OIL FILTER CN2-11 0.85GR 0.85LR 10 9 0.85LB E 0.85B
L11 BLINKER
1.25RB 5 2 1 UNIT
PREHEAT CN2-1 0.5LB 0.85B 13 WINDOW WASHER
L1 (4916-9006) (2525-1011)
15A 15A 15A L
3W
CN2-16 0.85LR CN1 AMP MIC 13P + (R) - 0.85GY
0.85L 0.85BR 9 7
P 2W
WORKING CN2-9 0.5RL 0.5RL
L9 FUSE BOX 2 0.85RY
0.5GR 0.5GR 0.85BR + (F) - 0.85B
TURN SIGNAL (R) CN2-8 P (570-00002) HORN (H) H.F
L8 0.85B
0.5GL 0.5GL 2W (2516-9015)
TURN SIGNAL (L) CN2-6 0.5R 0.5R
L6 0.85BR 0.85B 10 8 0.85WR
HI BEAM 2RW EMERGENCY PUMP (OPT) NOTE.3
CN2-7 30A 10A 10A
L7 (13)
0.5LB 0.5LB 0.85RY
EMG STEERING CN2-13 6 4 3 HORN (L)
L13 L.F 0.85B
0.85BY (2516-9016)
ENG OIL PRESS SWITCH
0.85WR
0.85RW
CN2-17
0.85WR
0.85WL
0.7bar (65.27441-7007)
CN2 AMP MIC 17P 0.85YB 0.85B WATER TEMP SWITCH
0.85B 0.5LB 3W
GAUGE PANEL ASS'Y 103˚C (66.27435-6008)
1.25RB 0.5LB
(539-00014) 0.85YL 0.85B
BRAKE OIL PRESS SW 0.85RW 0.85RW
BRAKE OIL FILTER SW 0.85B 0.85GR 65bar (2549-9093 )
(2471-9054) 2RL 2RL
0.85Lg 0.85B PARK BRAKE PRESS SW 0.85BR 0.85BR 0.85RY
65bar (2549-9093 )
0.85WL
FLOAT KICK-OUT ASS'Y (OPTION) STD 0.85RB
0.85RB 0.85RB
FLOAT KICK-OUT SW OPT (FLOAT KICK-OUT)
0.85WR
(FLOAT KICK-OUT) (2549-9098)
(16) 1 0.85R
+ 0.85RB +(2190-2036D22) 0.85R 0.85RY
4 HORN RELAY
1 RAISE FRONT FRONT
O 0.85W (2544-9033)
5 MAGNET RAISE RELAY COMBI LAMP(L) HEAD LAMP(L) HEAD LAMP(R) COMBI LAMP(R) 0.85
0.85RY 87a
- 0.85B 7 (2544-9033) (2534-1138A) (2534-1141A) (2534-1141A) (2534-1151A)
FLOAT (14)
2 87a 30
MAGNET 21W 10W 75/70W 75/70W 10W 21W 87
PROXIMITY SW 0.5B 10 9 0.5WR 0.85B 5 30 0.85RB
(4549-1148 ) 87 0.85B 0.85B
85 86 0.5L
0.5WR 85 86 0.85RB 0.5W

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

WIPER MOTOR
(position)
(position)
(back up)
(back up)
(2549-9098)
(turn sig)
0.85RL (turn sig)

0.85GW
0.85GW
(stop)
(stop)
(stop)
(stop)
0.85GR
0.85WR
0.85RY
0.85RY
0.85GL
SAFETY START
0.85WL
0.85GW
0.85GW
+(2190-2036D3) (4538-9017)
RELAY BACK UP RELAY 0.85B 0.85B
0.85RY 1 (2544-9033) H 0.85RY
(2544-9033)
5 0.85RB 87a 87a L 0.85YB
0.5BrW
7 30 30 C A B D F E E F D B A C
0.5RL 0.85RL
87 87 0.85RY 0.85B S 0.85Y 87a
0.5B 10 9 0.5WR LO
0.5Gr 85 86 85 86 0.5RL HI 0.85LB 87
0.5RL 0.5P 21W 21W 10W 12W 12W 12W 12W 10W 21W 21W M STOP
0.85RY 5W
REAR COMBI LAMP (LH) REAR COMBI LAMP (RH) 0.5L 86
LICENCE LAMP - RUN B 0.85L
LIS SOL-VALVE (2534-1159B) (2534-1158B)
(2534-1139A)
(4420-9446B)x2
(1) 0.85LY DISPLAY
0.5Gr 52 5 0.5P (4539-6036) 0.85GW 0.85GW E
0.85GY 0.85B
0.85RY 30 0.85RL 2-4 1-4 0.5BY 5bar
0.85LY 8 STOP LAMP SW PARKING BRAKE SW 4
14 0.85WG 2-1 2-3 0.85B (549-00010) 0.5L
0.85LY 0.85LY 53 (2549-9098)
(2) 0.85GR + +(2190-2036D16)
0.85BL 57 BACK BUZZER
0.85B - (2516-1124) 1
(ZF 0750 133 022) 5 5
0.85BR 11 0.85WL 0.5B
7 0.85Or
15 0.85GW 2 1 0.85RL DOWN SHIFT SW
0.85R 12 18 0.85BrL 4 3 0.85B 0.85V 0.85WL 0.85WL 0.5WR 9 10
+ VPS1 7 0.85R 13 23 0.85RW 4 2
0.85G
4WG-190 T/M SELECTOR SWITCH C

2RL
CHECK CONN (4549-6072)

TRANSMISSION TRANSMISSION 68 0.85RW (ON JOYSTICK)-R
DW-3 (ZF 0501 210 702)
VALVE ASS'Y Y1 1 0.85LW 56 CONTROLLER 36 0.85B
0.85G
HSG-94 EST-37 KICK 1 2 3 4
Y2 2 0.85YG 10 F N R 0.85Or
DOWN STEP STEP STEP STEP
Y3 3 0.85GL 32 (543-00019) 45 0.85RL 0.85RL X2-A VP (8)
Y4 4 0.85WB 55 (ZF 6009 065 284) 67 0.85Gr 0.85Gr X2-D AD6
Y5 5 0.85GR 9 DW-3 20 0.85BW 0.85BW X1-A 0.85B PARKING BRAKE
AD3
Y6 6 0.85WL 51 22 0.85V 0.85V X1-D RELEASE SOL-VALVE
AD7
63 0.85L 0.85L X1-C AD1
TEMP 8 0.85LB 39 65 0.85G 0.85G X1-B
(543-00036) AD2 COMPRESSOR
TEMP 9 0.85Br 46 43 0.85Y 0.85Y X2-B RECEIVER D
(ZF 6009 065 285) AD4 (2208-6013B) (2204-6039A
ERGO-II (OPT) 64 0.85P 0.85P X2-C AD5 MAGNET
0.85LgR 19 21 0.85Or 0.85Or CLUTCH 0.85LW
(ENGINE) 0.85Lg 29 0.85W 0.85W
PILOT CUT OFF SW HIGH PRESS
SPEED 0.85LgW 41 1 1 (AUTO)
66 0.85RY 0.85L 0.85W (2549-9098) (4) CUT OFF SW
PICK-UP (TURBINE) 0.85Lg 5 0.85RL 5 +(2190-2036D17)
25bar 0.85RL
(ZF 0501 7 7 (MANU) PILOT CUT OFF
0.85LgB 42 T/M CUT OFF SW 1 0.85BW 1
209 688)x3 SOL-VALVE 0.85B 0.85B
(CENTRAL 5 0.85WL
0.85Lg 3 (4549-9080)
GEAR CHAIN) 0.5B 10 9 0.5WR 0.5WR 9 10 0.5B (9) 7
1 0.85B
2 0.85B 10 9 0.5WR
2 0.85YR 62 0.85B
T/M CUT OFF SW 2 AUTO SELECT SW 0.5B
1 0.85RB 4 6 (2549-9098) (2549-9098)
3 CN6 AMP 68P +(2190-2036D15) +(2190-2036D9)
0.85RL
SPEED SENSOR 0.85RL 0.5WR
(ZF 0501 209 560)
Figure 2

Page 4
ALARM RELAY 1
Y (2544-9033 ) ALARM RELAY 2 STARTER SWITCH CONNECTION
87a (2544-9033 ) ANTENNA SPEAKER TML B
PST BR R1 R2 C ACC
30 0.85WL 87a (2541-9020)x2 NOTE.
OFF
G 0.85B 87 30 0.85WB (LH) (RH) 1. DIODE PART NO.
0.85LB 87 PREHEAT
85 86 0.5WR - DIODE (11)~(19) : 2548-1026
REAR LAMP SW ON
85 86 0.5LR - DIODE (1)~(9) : 2548-1027
(2549-9109 ) + - + - START
(2190-2036D20) 3 7 0.85GrR
CAR TERMINAL NO
0 0.5B 10 1 0.85BY
STEREO
6 I 2 1.25RY 8
(2541-9019) 0.85GrL
HRS NO.GT7A-26PD-DS 26P AMP 9PT 1-480673 AMP 9PR 1-480672-0
3 II PILOT BUZZER 0.85LW 4 2 0.85BW AMP MIC 13P AMP MIC 17P
10 0.5WR (2516-1102A) 6 5 4 3 2 1 8 7 6 5 4 3 2 1
- 13 12 11 2 1
0.85WB 3 10 9 8 7 6 5 4 3 3 2 1 1 2 3
0.85B 9 0.85BR
0.85RW + 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 26 25 24 23 22 21 20 19 18 17 16 15 14 6 5 4 4 5 6
11 0.85L 0.85L 2 DC / DC
CONVERTER (CN1) (CN2) (CN3) 9 8 7 7 8 9
2RY 1
0.85WR (2531-1003 )
1.25RY (CN4) (CN5)
STEREO RELAY T/M CONTROLLER (ZF 68P)
0.5WG (2544-9033 ) T/M SELECTOR SWITCH (PACKARD)
0.5RW 87a 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2
23 1
30 0.85L
0.85WR 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24
0.85LW 87
1.25R 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46
A B C D D C B A
0.5BrW 0.5B 85 86 0.5LR
(CN6) X1 X2
0.85LB
0.85L
STARTER STARTER
CONTROLLER STARTER RELAY (65.26201-7049)
R SW CIGAR LIGHTER 0.5LR (2543-9015) (2544-1022) 24V 6KW
) (545-00001)
0.5BrW 0.5BrW N S 0.85BW 0.85BW D PP 2Y C
18)
2 0.85B - 0.85B 0.85WG 0.5WG P 15R B
0.85BY C B 2W
0.5RW 0.5LR B E 0.85B
+
(3)
7 0.85B 2RY
0.85W 60R
9 0.5WR 0.5WR 0.85RW 0.5RW
0.85G 0.85G 1.25RW/0.85WR 1.25RW
A
85L 1.25RY 1.25WR
B A
0.85W 0.85L
60B
E 0.85B
BLINKER P1 0.85LY 87a
1 UNIT 9 10 11 12 13 14 30
(2525-1011) P2 0.85LW 87
15A L 15A 15A 15A 15A 10A 10A
3W 1.25WR
0.85GY A B 85 86
17 18 19 0.85RW
2W 2WR
3W E
0.85RY
HORN (H) 0.5B FUEL PUMP
H.F 0.85B FUSE BOX 1 (2401-1277A)
2W (2516-9015) 5W ENG STOP RELAY
(4510-1012A) 0.85B
ENG STOP MOTOR (2544-9033) 1.25RW 1.25B
0.85WR 15 16 5W (2523-9016) P
10A 15A 15A 15A 15A 20A 15A 15A 30A
0.85RY 1.25WR 0.85BY
3 HORN (L) 1 2 3 4 5 6 7 8
L.F 0.85B 2WR
(2516-9016) ROOM LAMP
2RG/0.85GY
(2534-9063)
0.85WR
0.85RW
0.85GY
0.5LR 0.5LR
1.25LR
0.85LB
0.85WL
1.25R 5W 0.85RW 10W

0.85R
2LR
2RL
3W 3W 1.25WG
8W FUSIBLE LINK
0.5LB 0.5LB 0.5RW 15R (2527-1023A)
0.85RW 0.85RG 2LR 2WR
2RL 2RL 1.25LR 2R
CIRCUIT BREAKER 0.5G
0.85RY 0.85LB 0.5RW 60R
(2527-9004)
0.85WL 0.85WL 0.5LB B A
8W 8W
1.25WR
0.85BY
1.25RG 0.85RG
0.5LR
0.85WR 0.85WR 0.85WR

1.25Br 1.25BrW 1.25BrW BR
0.85RY 0.85GY C
HORN RELAY HEAD LAMP RELAY ACC
1.25LR
E
0.5RW
1.25BrW
LAMP SWITCH (1) 1.25B
(2544-9033) (2544-9033)
2LR
0.85LY 1 1.25RG (2549-9109 ) B

87a 87a 85R
1.25Br
5 0.85GY +(2190-2036D4) 8W
30 30 R2 BATTERY RELAY
7 0 15R
87 87 (2544-9024)
1.25WY
6 I 2 R1 BR
85 86 0.5LY 2 85 86 STARTER 60B 60R
6 0.5B 0.5WY 3 II
SWITCH (2)
0.5WR 8 9 10 (2549-1152 )
0.5WL
0.85LY
0.5WR
1.25RW
0.5B 0.5B 10 9 1.25WG
0.85WR
0.85WR
0.85WL
0.85BR
0.5B - + - +
HORN SWITCH 2 0.5RW
HAZARD SWITCH 12V 150AH 12V 150AH
0.5LB 0.5BrY SW TURN SIGNAL HEAD LAMP
1 3 (2549-9138) BATTERY
0.5BW
N
0.5BG
(5) (6) +(2190-2036D2) TML

0.5LB
(ON JOYSTICK)-L 0.85GY CN4-8 (2506-6008)x2

49a
0.85GR 0.85GR CN4-4 AVX 8W
R 7 4 8
0.85GL 0.85GL CN4-1 2 0.5WG 1.25WG AVX 1.25WG
L COMBINATION PREHEAT
0.85RW 1.25WY CN4-5 AVX 2RW
56 SWITCH (R) CONTROLLER 5 0.5BrY 0.85BrY 15R
0.85R 0.85RW CN4-6 (4549-9418) (2523-9007)
56b R P B
C B
0.85R CN4-7
56a 1 3 6 (7)
0.85GY 0.85GY 0.85RG CN4-9
15/1 0.85B
0.85YB
CN5-6
0.85LR
0.5LB 0.85LB 0.85B

15(53a)
0.85BR 0.85BR CN5-8
53c SG
0.85BrY CN4-2
WIPER MOTOR H
0.5BL CN5-7 PREHEAT
(4538-9017) J 15˚C RELAY H
H 0.85RY 0.85RY CN5-3 (2544-9015)
53b 15L
L 0.85YB 0.85YB CN5-1 R
53 F
0.85BrL CN5-4
S 0.85Y 87a 31b AIR HEATER E
LO 30 0.85BrL TML J 0 I II OFF ON OFF ON THERMO 22V 2.6KW
HI 0.85LB 87 SWITCH (65.26803 E
M STOP SW WIPER WASHER HORN 8B ALTERNATOR
86 85 (65.27435 -7028) (2502-9009)
- RUN 0.5L 0.5B
B 0.85L -6003) 24V 50A
15B
1.25LR AIRCON UNIT 4WG-190 TRANSMISSION CONNECTION
E WIPER RELAY (4920-9050A)
0.85B 2LR FORWARD REVERSE
(2544-9033) CLUTCH SOLENOID
BLOWER 1 2 3 4 1 2 3
PARKING BRAKE SW 4 1 15
0.5L 0.5BL A/C CONTROL PANEL 2LR + - KV Y5
(2549-9098) M
(2543-9031A) 0.5RW 0.85LR 14 KR Y2
+(2190-2036D16) WIPER TIMER 2 0.5BL
1 (2537-9002) 22 K1 Y3
5 0.5B 5 3 0.5BL
0.85WL
7 K2 Y6
0.85Or
13 1.25LR K3 Y4
L 0.5WR 9 10 CONDENSER FAN RELAY
K4 Y1
(2544-9033)
CONDENSER ASS'Y 87a
(2520-6004) 30 0.85LR
3 0.5LB 11 HIGH ERGO-II SELECTOR SWITCH (OPT)
0.85B - + 0.85L 87 5 0.5LY 12 MID
M 549-00009 (ZF 0501 209 869)
0.85Or 8 0.5LW 13 LOW
0.5YB 85 86 KICK
0.5LR F R N T+ T-
18 0.5GrG 9 REC DOWN
(8) X2-A
19 10 FRE + VP
0.5GrY INTAKE
0.85B X2-D AD7 AS
PARKING BRAKE 0.5YB 10 ACTUATOR
M X1-A
RELEASE SOL-VALVE AD3 B3
X1-D AD8 KD
23 0.5OrR 7 OPEN
X1-C AD1 B1
COMPRESSOR RELAY 20 0.5OrW 8 CLOSE
COMPRESSOR RECEIVER DRIER (2544-9033) VENT X1-B AD2 B2
(2208-6013B) (2204-6039A) 87a ACTUATOR
M X2-B
30 AD5 V
MAGNET 0.85LR X2-C
CLUTCH 0.85LW 0.85BW 87 AD6 R
14 0.5LgW 3 (WARM)
0.5RB 85 86 15 0.5LgB 2 (COOL)

HIGH PRESS LOW PRESS 0.5LR M
CUT OFF SW CUT OFF SW 2 0.5YR 4 MIX
(4)
16 0.5YW 5 ACTUATOR
0.5RB 9 4 0.5YG 1
0.85B 0.85B
5WL
0.5WR 11 1 0.5B 0.85B 6
THERMISTOR
LED 1~12
WR
DUCT/DEF 26 1.25B 2B 16
DEF 2 0.5G 7
ACTUATOR
DUCT 3 0.5GW 6
(2213-9002 ) M CN3 HRS 26P CN1 AMP MIC 13P + 250 4P
MEGA 250-V
WR
AOS0970L

Page 5
MEGA 250-V (TIER II)
Figure 3

Page 6
MEGA 250-V (Tier II)
BAS0210L

Page 7
Page 8
1ATTACHMENTS

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Mega 250-V

K1000898AE Shop Manual

Trim Out The Label Along

Pub. No. K1000898AE

Lower Structure and Chassis

Engine and Drive Train

WHEEL LOADER SAFETYS0103010K

Copyright 2011 Doosan

Wheel Loader Safety S0103010K

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

S0103010K Wheel Loader Safety

Wheel Loader Safety S0103010K

S0103010K Wheel Loader Safety

LEARN SIGNAL WORDS USED WITH SAFETY ALERT SYMBOL

Safety precautions are described in SAFETY from page 6 on.

Wheel Loader Safety S0103010K

LOCATION OF SAFETY LABELS

S0103010K Wheel Loader Safety

Wheel Loader Safety S0103010K

CLOTHING AND PERSONAL PROTECTIVE

S0103010K Wheel Loader Safety

VIBRATION LEVEL INFORMATION

ASBESTOS DUST HAZARD PREVENTION

Wheel Loader Safety S0103010K

FUEL, OIL AND HYDRAULIC FLUID FIRE

S0103010K Wheel Loader Safety

Wheel Loader Safety S0103010K

PROTECTION FROM FALLING OR FLYING

S0103010K Wheel Loader Safety

INSTALL ADDITIONAL SAFETY EQUIPMENT IF CONDITIONS REQUIRE

MAINTAIN STANDARD SAFETY EQUIPMENT IN GOOD CONDITION

Wheel Loader Safety S0103010K

S0103010K Wheel Loader Safety

Wheel Loader Safety S0103010K

S0103010K Wheel Loader Safety

Wheel Loader Safety S0103010K

OPERATE WHILE SEATED AT OPERATOR'S

SEAT BELTS SHOULD BE USED AT ALL

S0103010K Wheel Loader Safety

SLOPING TERRAIN REQUIRES CAUTION

not possible to level area or avoid working on a

On sloping surfaces, use caution when

Wheel Loader Safety S0103010K

Voltage Minimum Safe Distance

Use these minimum distances as a guideline

BEFORE STARTING TO DIG, CONTACT AUTHORITIES

BE AWARE OF HEIGHT OBSTACLES

USE CARE ON LOOSE SUPPORT

S0103010K Wheel Loader Safety

DIGGING BENEATH OVERHANGS

DIGGING BENEATH WHEEL LOADER

STAY ALERT FOR PEOPLE MOVING

BE AWARE OF AND CONFORM TO LOCAL REGULATIONS

Wheel Loader Safety S0103010K

OBSERVE GENERAL SAFETY RULES

TAKE TIME TO PROVIDE GOOD VISIBILITY

S0103010K Wheel Loader Safety

OPERATE CAREFULLY ON SNOW AND ICE AND IN VERY COLD TEMPERATURES

Wheel Loader Safety S0103010K