Daewoo Doosan Mega 300-V Shop Manual K1003701E – PDF DOWNLOAD

DESCRIPTION:

Daewoo Doosan Mega 300-V Shop Manual K1003701E – PDF DOWNLOAD

• 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.

TO THE OPERATOR OF A DOOSAN DAEWOO WHEEL LOADER

• 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

• 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.

LEARN SIGNAL WORDS USED WITH SAFETY ALERT SYMBOL

The words “CAUTION,” “WARNING,” and “DANGER” used throughout this manual and on decals on the machine indicate degree of risk of hazards or unsafe practices. All three degrees of risk 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

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 you are unsure about the safety of some procedures, contact a DOOSAN distributor.

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.

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

TABLE OF CONTENTS:

Daewoo Doosan Mega 300-V Shop Manual K1003701E – PDF DOWNLOAD

Publication Request for Proposed Revision.......................................................................  7
Safety..........................................................................................................  9
	Wheel Loader Safety S0103010K............................................................................... 11
		To the Operator of a DOOSAN Daewoo Wheel Loader......................................................... 13
			Learn Signal Words Used with Safety Alert Symbol.................................................... 15
		General Safety Essentials............................................................................... 16
			Accessory Applications.............................................................................. 16
		Location of Safety Labels............................................................................... 16
		Unauthorized Modifications.............................................................................. 16
		General Hazard Information.............................................................................. 17
			Safety Rules........................................................................................ 17
			Safety Features..................................................................................... 17
			Inside Operator's Compartment....................................................................... 18
			Clothing and Personal Protective Items.............................................................. 18
			Breathing Masks, Ear Protection May Be Required..................................................... 19
			Vibration Level Information......................................................................... 19
			Asbestos Dust Hazard Prevention..................................................................... 19
			Mounting and Dismounting............................................................................ 20
			Fuel, Oil and Hydraulic Fluid Fire Hazards.......................................................... 20
			Precautions When Handling Fluids at High Temperature................................................ 21
			Injury from Work Equipment.......................................................................... 21
			Fire Extinguisher and First Aid Kit................................................................. 22
			Protection from Falling or Flying Objects........................................................... 22
			Install Additional Safety Equipment If Conditions Require........................................... 23
			Maintain Standard Safety Equipment in Good Condition................................................ 23
			Attachment Precautions.............................................................................. 24
			Accumulator......................................................................................... 24
			Engine Ventilation.................................................................................. 24
		Before Starting Engine.................................................................................. 25
			Work Site Precautions............................................................................... 25
			Checks Before Starting Engine....................................................................... 26
			Engine Starting..................................................................................... 26
			Before Operating Machine............................................................................ 27
		Machine Operation....................................................................................... 28
			Operate While Seated at Operator's Station ONLY..................................................... 28
			Seat Belts Must Be Used at All Times................................................................ 28
			Movement Alarms..................................................................................... 28
			Travel Precautions.................................................................................. 29
			Sloping Terrain Requires Caution.................................................................... 29
			Avoid High Voltage Cables........................................................................... 30
			Before Starting to Dig, Contact Authorities......................................................... 30
			Be Aware of Height Obstacles........................................................................ 30
			Use Care on Loose Support........................................................................... 30
			Use Solid Support Blocking.......................................................................... 31
			Digging Beneath Overhangs........................................................................... 31
			Digging Beneath Wheel Loader........................................................................ 31
			Stay Alert for People Moving Through Work Area...................................................... 31
			Be Aware of and Conform to Local Regulations........................................................ 31
			Never Use Ether Starting Aids....................................................................... 32
			Observe General Safety Rules........................................................................ 32
			Take Time to Provide Good Visibility................................................................ 32
			Keep "Pinch Point" Areas Clear  Use Caution in Reverse............................................. 33
			Operate Carefully on Snow and Ice and in Very Cold Temperatures..................................... 33
			Parking Machine..................................................................................... 33
			Shutdown Control Functions.......................................................................... 34
			Never Let Anyone Ride on Attachment................................................................. 34
		Maintenance............................................................................................. 35
			Use Warning Tag During Service...................................................................... 35
			clean Before Inspection or Maintenance.............................................................. 35
			Proper Tools........................................................................................ 36
			Use of Lighting..................................................................................... 36
			Fire Prevention and Explosion Prevention............................................................ 36
			Burn Prevention..................................................................................... 37
			Welding Repairs..................................................................................... 38
			Precautions for Removal, Installation, and Storage of Attachments................................... 38
			Precautions When Working on Machine................................................................. 39
			Lock Inspection Covers.............................................................................. 39
			Crushing Prevention and Cutting Prevention.......................................................... 39
			Do Not Run Engine If Repairs or Work Are Being Performed Alone...................................... 39
			Always Use Adequate Equipment Supports and Blocking................................................. 40
			Do Not Work on Hot Engines or Hot Cooling or Hydraulic Systems...................................... 40
			Hydraulic Cylinder Seals Require Periodic Replacement............................................... 40
			Highpressure Hydraulic Lines Can Store a Great Deal of Energy...................................... 40
			Precautions with Highpressure Line, Tubes and Hoses................................................ 41
			Obtain Immediate Medical Attention if Pressurized Oil Pierces Skin.................................. 41
			Use Correct Replacement Fasteners Tightened to Proper Torque........................................ 42
			Safety Critical Parts Must Be Replaced Periodically................................................. 42
			Dispose of All Petroleum Based Oils and Fluids Properly............................................. 42
			Check Tire Pressure and Condition................................................................... 42
		Battery................................................................................................. 43
			Battery Hazard Prevention........................................................................... 43
			Disconnect Batteries Before Electrical Service or Electrical Welding................................ 43
			Use Low Heat Portable Lighting...................................................................... 44
			Boost Starting or Charging Engine Batteries......................................................... 44
		Towing.................................................................................................. 45
			Precautions When Towing............................................................................. 45
		Shipping and Transportation............................................................................. 46
			Obey State and Local OvertheRoad Regulations...................................................... 46
			Summary of Safety Precautions for Lifting........................................................... 46
	Specifications for Mega 300V S0203085...................................................................... 47
		Component Locations..................................................................................... 50
		General Specifications.................................................................................. 53
		Engine Performance Curves............................................................................... 54
		Working Range and Dimensions............................................................................ 56
		Working Capacities...................................................................................... 59
			Bucket Capacity..................................................................................... 59
			Tipping Load........................................................................................ 59
		Material Weight......................................................................................... 59
			Approximate Weight of Workload Materials............................................................ 59
Specifications.................................................................................................. 63
General Maintenance............................................................................................. 65
	General Maintenance Procedures S0302000..................................................................... 67
		Welding Precautions and Guidelines...................................................................... 69
		Hydraulic System  General Precautions.................................................................. 70
		Maintenance Service and Repair Procedure................................................................ 71
			General Precautions................................................................................. 71
		Hydraulic System Cleanliness and Oil Leaks.............................................................. 72
			Maintenance Precautions for Hydraulic System Service................................................ 72
			Oil Leakage Precautions............................................................................. 72
		Cleaning and Inspection................................................................................. 73
			General Guidelines.................................................................................. 73
			Bearing inspection.................................................................................. 74
				Normal Bearing.................................................................................. 75
				Bent Cage....................................................................................... 75
				Galling......................................................................................... 75
				Abrasive Step Wear.............................................................................. 76
				Etching......................................................................................... 76
				Misalignment.................................................................................... 76
				Indentations.................................................................................... 76
				Fatigue Spalling................................................................................ 77
				Brinelling...................................................................................... 77
				Cage Wear....................................................................................... 77
				Abrasive Roller Wear............................................................................ 77
				Cracked Inner Race.............................................................................. 78
				Smears.......................................................................................... 78
				Frettage........................................................................................ 78
				Heat Discoloration.............................................................................. 79
				Stain Discoloration............................................................................. 79
	Standard Torques S0309000................................................................................... 81
		Torque Values for Standard Metric Fasteners............................................................. 83
		Torque Values for Standard U.S. Fasteners............................................................... 84
		Type 8 Phosphate Coated Hardware........................................................................ 86
		Torque Values for Hose Clamps........................................................................... 87
		Torque Values for Split Flanges......................................................................... 88
		Torque Wrench Extension Tools........................................................................... 89
			Torque Multiplication............................................................................... 89
			Other Uses for Torque Wrench Extension Tools........................................................ 90
			Tightening Torque Specifications (Metric)........................................................... 90
				I. "Loctite" Fastener Adhesives................................................................. 91
				II. "Loctite" Pipe Thread Sealant............................................................... 91
				III. "Loctite" gasket/flange sealer............................................................. 91
				IV. "Loctite" retaining compounds............................................................... 92
				V. "Loctite" Adhesives.......................................................................... 92
Upper Structure................................................................................................. 93
	Counterweight S0403030K..................................................................................... 95
		Specifications.......................................................................................... 97
		Counterweight........................................................................................... 97
	Fuel Transfer Pump S0405500................................................................................. 99
		General Description.....................................................................................101
			Theory of Operation.................................................................................101
		Troubleshooting.........................................................................................102
		Replacement of Rotor and Vane...........................................................................102
		Replacement of Rear Cover...............................................................................103
		Replacement of Armature.................................................................................104
	Hydraulic Oil Tank S0406055.................................................................................105
		General Description.....................................................................................107
			Parts List..........................................................................................107
			Specifications......................................................................................108
Lower Structure and Chassis.....................................................................................109
	Center Joint (Articulation Joint) S0502030K.................................................................111
		General Description.....................................................................................113
			Maintenance Standard................................................................................114
Engine and Drive Train..........................................................................................117
	Front Axle (ZFMTL 3095) S0602250..........................................................................119
		General Description.....................................................................................123
			Outline.............................................................................................123
			Drive Axle..........................................................................................123
				Axle Mount......................................................................................123
			Differential........................................................................................126
				Differential Operation..........................................................................126
				Limited Slip Differential Cross Section.........................................................126
			Lubrication Instructions............................................................................128
				Oil Drain.......................................................................................129
				Oil Filling.....................................................................................129
				Check...........................................................................................129
				Oil Change Intervals............................................................................129
				Oil Level Check.................................................................................129
				Bleeders........................................................................................129
				Brake...........................................................................................129
				Brake Bleeding at Vehicle.......................................................................129
			Make Wear Measurement on Multidisk Brake............................................................130
				Wear measurement  Multidisk brake..............................................................130
			Inscriptions On Model Identification Plate..........................................................131
			Torque Limits for Screws............................................................................132
				Torque Limits for Screws (In Nm) According to ZFStandards 148..................................132
			Examples of Gear Tooth Contact Patterns for the Gleason Geartooth System...........................133
		Special Tool............................................................................................136
			List of Special Tools for Disassembly and Reassembly................................................136
		ZFMultitrac Rigid Axle MTL 3095.......................................................................145
			Disassembly of Output and Brake.....................................................................145
			Reassembly of Output and Brake......................................................................154
			Disassembly of Differential Carrier and Brake Tubes.................................................167
				Disassembly of Differential Carrier.............................................................167
				Disassembly of Limited Slip Differential........................................................170
				Disassembly of Drive Pinion.....................................................................172
				Disassembly of Brake Tubes......................................................................174
			Reassembly of Brake Tubes and Differential Carrier..................................................175
				Reassembly of Oil Pipes.........................................................................175
				Reassembly of Differential Carrier..............................................................178
				Determine Shim Thickness for Tooth Contact Pattern..............................................178
				Install Drive Pinion............................................................................179
				Reassemble of Limited Slip Differential.........................................................183
				Determine Disk Clearance 0.2  0.8mm...........................................................185
				Adjustment of Backlash and Bearing Preload......................................................188
		Parking Brake...........................................................................................191
			Functional Characteristics and Maintenance Instructions for Springloaded Sliding Caliper Brakes....191
			1. Functional Characteristics of Springloaded Sliding Caliper Brakes...............................191
			2. Mounting and Basic Setting Regulations...........................................................192
			3. Adjusting Regulations............................................................................192
			4. Emergency Release of Parking Brake...............................................................192
			5. Maintenance and Repair Work......................................................................193
				Maintenance and Exchange of Brake Pads..........................................................193
				Changing the Seal...............................................................................194
			6. General..........................................................................................194
	Rear Axle (ZFMTL 3085) S0602260...........................................................................195
		General Description.....................................................................................199
			Outline.............................................................................................199
			Drive Axle..........................................................................................199
				Axle Mount......................................................................................199
			Differential (Standard).............................................................................202
				Differential Operation..........................................................................202
				Limited Slip Differential Cross Section.........................................................202
			Lubrication Instructions............................................................................204
				Oil Drain.......................................................................................205
				Oil Filling.....................................................................................205
				Check...........................................................................................205
				Oil Change Intervals............................................................................205
				Oil Level Check.................................................................................205
				Bleeders........................................................................................205
				Brake...........................................................................................205
				Brake Bleeding at Vehicle.......................................................................205
			Make Wear Measurement on Multidisk Brake............................................................206
				Wear Measurement of Multidisk Brake.............................................................206
			Inscriptions on Model Identification Plate..........................................................207
			Torque Limits for Screws............................................................................208
				Torque Limits for Screws (In Nm) According to ZFStandards 148..................................208
			Examples of Gear Tooth Contact Patterns for the Gleason Geartooth System...........................209
		Special Tool............................................................................................212
			List of Special Tools for Disassembly and Reassembly................................................212
		ZFMultitrac Rigid Axle MTL 3085.......................................................................222
			Disassembly of Output and Brake.....................................................................222
			Reassembly of Output and Brake......................................................................231
			Disassembly of Differential Carrier and Brake Tubes.................................................244
				Disassembly of Differential Carrier.............................................................244
				Disassembly of Limited Slip Differential........................................................247
				Disassembly of Drive Pinion.....................................................................249
				Disassembly of Brake Tubes......................................................................251
			Reassembly of Brake Tubes and Differential Carrier..................................................252
				Reassembly of Brake Tubes.......................................................................252
				Reassembly of Differential Carrier..............................................................255
				Determine Shim Thickness for Tooth Contact Pattern..............................................255
				Install Drive Pinion............................................................................256
				Reassemble of Limited Slip Differential.........................................................260
				Determine Disk Clearance 0.2  0.8mm...........................................................262
				Adjustment of Backlash and Bearing Preload......................................................266
	Parking Brake Caliper (ZF) S0603001.........................................................................269
		Functional Characteristics and Maintenance Instructions.................................................271
			Functional Characteristics of Springloaded Sliding Caliper Brakes..................................271
			Mounting and Basic Setting Regulations..............................................................272
			Adjusting Regulations...............................................................................272
			Emergency release of parking brake..................................................................272
			Maintenance and Repair Work.........................................................................273
				Maintenance and Exchange of Brake Pads..........................................................273
				Changing Seal...................................................................................274
			General.............................................................................................274
	Air Conditioner S0605050K...................................................................................275
		General Description.....................................................................................277
		Refrigerant Circulation.................................................................................278
		Control Panel...........................................................................................280
		Control Specifications..................................................................................281
		Temperature Level Control and Display...................................................................282
		Air Discharge According to Path Selection...............................................................283
			Vent................................................................................................283
			Foot................................................................................................284
			Defroster...........................................................................................285
		Airconditioning System Circuit Diagram.................................................................286
		Troubleshooting.........................................................................................288
			Refrigerant Pressure Check..........................................................................288
		Weight of R134a Gas Used In Machines....................................................................291
		Refrigerant System Repairs..............................................................................293
			Refrigerant Safe Handling Procedures................................................................293
			Repair and Replacement Procedure....................................................................294
			Refrigerant Recovery................................................................................296
			Vacuuming Refrigerant System........................................................................296
			Leakage Check.......................................................................................298
			Refrigerant Charging................................................................................298
			Inspecting System for Leakage.......................................................................300
	Transmission and Torque Converter (ZF4WG210) S0607090K....................................................301
		Drive Train Description.................................................................................306
		Transmission and Torque Converter.......................................................................308
			Powershift Transmission.............................................................................309
			Transmission Control................................................................................309
			Schedule of Measuring Points and Connection 4 WG210................................................311
			Oil Circuit Diagram 4WG210 Forward 1st Speed.......................................................313
		Transmission Electrical Components......................................................................316
			TCU (Transmission Control Unit).....................................................................317
			Transmission Control Valve..........................................................................318
			Transmission Oil Temperature Sensor.................................................................318
			Engine Pickup Sensor................................................................................319
			Central Gear Pickup Sensor..........................................................................319
			Turbine Pickup Sensor...............................................................................319
			Output Speed Sensor.................................................................................320
			Shift Lever Switch (DW3)...........................................................................320
			Auto Selector Switch................................................................................322
			Display.............................................................................................322
		Transmission Faults Codes...............................................................................323
			Fault Display.......................................................................................323
			CAN  Message.......................................................................................323
			Description of Fault Codes..........................................................................323
			Abbreviations.......................................................................................324
			Definition of Operation Modes.......................................................................324
				Normal..........................................................................................324
				Substitute Clutch Control.......................................................................324
				Limphome.......................................................................................324
				Transmission Shut Down..........................................................................324
				TCU Shut Down...................................................................................324
			Table of Fault Codes................................................................................325
			Measurement of Resistance at Actuator/sensors and Cable.............................................325
				Actuator........................................................................................325
				Cable...........................................................................................325
		Transmission Electrical Circuits........................................................................326
			Transmission Controller Circuit.....................................................................326
			Traveling Circuits..................................................................................328
				Neutral.........................................................................................328
				Forward First Gear..............................................................................329
				Forward Second Gear.............................................................................330
				Forward Third Gear..............................................................................331
				Forward Fourth Gear.............................................................................332
				Reverse First Gear..............................................................................333
				Reverse Second Gear.............................................................................334
				Reverse Third Gear..............................................................................335
			Kickdown...........................................................................................336
				Overview........................................................................................336
				Kickdown: Forward Second Gear to Forward First Gear (Auto Selector Switch "O" Manual Mode)....338
				Kickdown (Auto Selector Switch "I"  Auto Mode)................................................340
			Transmission Cutoff.................................................................................341
			LIS (Load Isolation System)  Option................................................................343
		Installation View (S/N 1001 thru 2000)..................................................................346
			Inner Section.......................................................................................346
			Front View..........................................................................................347
			Front View with Disk Brake..........................................................................348
			Side View...........................................................................................349
			Side View with Disk Brake...........................................................................350
			Rear View...........................................................................................351
			Rear View with Disk Brake...........................................................................352
		Installation View (S/N 2001 thru 3000, 3001 and Up).....................................................353
			Inner Section.......................................................................................353
			Front View..........................................................................................354
			Front View with Disk Brake..........................................................................355
			Side View...........................................................................................356
			Side View with Disk Brake...........................................................................357
			Rear View...........................................................................................358
			Rear View with Disk Brake...........................................................................359
		Special Tools...........................................................................................360
			Gearshift System....................................................................................360
			Engine Connection...................................................................................362
			Pressure Oil Pump...................................................................................363
			Gearbox Housing.....................................................................................364
			Input...............................................................................................366
			Coupling............................................................................................367
			Output..............................................................................................373
			Power Takeoff......................................................................................374
		Hydraulic Control Unit (HSG94).........................................................................375
			Disassembly.........................................................................................377
			Reassembly..........................................................................................380
		Transmission Disassembly................................................................................386
			Hydraulic Control Unit (HSG94) and Duct plate......................................................386
			Engine Connection  Converter.......................................................................387
			Hydraulic Pump......................................................................................389
			Converter Back Pressure Valve.......................................................................390
			Remove Output, Input and Clutches...................................................................391
			Disassemble Clutch  KV and KR......................................................................396
			Disassemble Clutch  K1, K2 and K3..................................................................399
			Disassemble Clutch  K4.............................................................................401
			Disassemble Drive Shaft.............................................................................402
		Transmission Reassembly.................................................................................404
			Install Oil Tube....................................................................................404
			Reassemble Clutch  KV and KR.......................................................................406
			Reassemble Clutch  K1, K2 and K3...................................................................412
			Reassemble Clutch  K4..............................................................................419
			Preassemble Drive Shaft.............................................................................426
			Preassemble and Install Output......................................................................427
			Install Preassembled Drive Shaft and Clutches.......................................................429
			Install Pump Shaft (Power Takeoff).................................................................432
			Install Output Flanges..............................................................................434
			Converter Back Pressure Valve.......................................................................435
			Oil Feed Housing  Transmission Pump................................................................435
			Engine Connection  Converter.......................................................................437
			Converter Safety Valve..............................................................................440
			Mount Duct Plate and Hydraulic Control Unit.........................................................440
			Install Plugs and Oil Level Tube....................................................................441
			Speed Sensor and Inductive Transmitters.............................................................442
	Transmission Error Codes (ZF) S0607900C.....................................................................445
		Introduction............................................................................................448
		Abbreviations...........................................................................................448
		Display.................................................................................................448
			Description of Fault Codes..........................................................................449
		Display During Operation................................................................................450
		Definition of Operating Modes...........................................................................452
			Normal..............................................................................................452
			Substitute Clutch Control...........................................................................452
			Limphome...........................................................................................452
			Transmission shut Down..............................................................................452
			TCU Shut Down.......................................................................................452
		Clutch Pack and Solenoid Valve Crossreference Table....................................................453
		Table of Fault Codes....................................................................................454
		Table of Fault Codes  ERGOControl.....................................................................476
		Measurement of Resistance at Actuator/ sensors and Cable................................................479
			Actuator............................................................................................479
			Cable...............................................................................................479
Hydraulics......................................................................................................481
	Accumulator S0703000........................................................................................483
		General Description.....................................................................................485
			Specifications......................................................................................486
		Accumulator Charging....................................................................................489
			Charging the Accumulator with Nitrogen..............................................................489
	Cylinders S0705005K.........................................................................................491
		General Description.....................................................................................494
			Theory of Operation.................................................................................495
			Parts List..........................................................................................496
				Bucket Hydraulic Cylinder.......................................................................496
				Lift Hydraulic Cylinder.........................................................................498
				Steering Hydraulic Cylinder.....................................................................500
		Troubleshooting, Testing and Adjustment.................................................................502
		Disassembly.............................................................................................506
		Cleaning and Inspection (Wear Limits and Tolerances)....................................................508
		Reassembly..............................................................................................509
	Fan Drive Hydraulic Motor (Haldex) S0707112.................................................................517
		General Description.....................................................................................519
			Theory of Operation.................................................................................519
			Parts List..........................................................................................521
			Specifications......................................................................................522
	Main Pump (Denison) S0708485K...............................................................................523
		General Description.....................................................................................526
			General.............................................................................................526
			Description.........................................................................................526
			Theory of Operation.................................................................................527
			Parts List..........................................................................................530
			Specifications......................................................................................532
		Special Tools...........................................................................................533
			Seal Driver.........................................................................................533
			Protective Cone.....................................................................................533
		Troubleshooting.........................................................................................534
		Overhaul................................................................................................536
			General.............................................................................................536
			Changing Rotation...................................................................................537
			Changing Cartridges.................................................................................538
			Changing Port Locations.............................................................................538
			Changing Shaft or Shaft Seal........................................................................539
			Disassembly of Pump.................................................................................540
				End Cap.........................................................................................540
				Shaft End.......................................................................................541
				Shaft...........................................................................................541
			Reassembly of Pump..................................................................................541
				Shaft End.......................................................................................541
				Center Housing and "D" Unitized Cartridge (P1)..................................................542
				"C" Unitized Cartridge (P2) and End Cap.........................................................542
				Unitized Pumping Cartridges.....................................................................543
			Disassembly of "C" Cartridge........................................................................544
			Reassembly of "C" Cartridge.........................................................................545
			Disassembly of "D" Cartridge........................................................................546
			Reassembly of "D" Cartridge.........................................................................547
		Installation............................................................................................548
			Mounting............................................................................................548
			Piping..............................................................................................548
			Fluids..............................................................................................549
				Type............................................................................................549
				Antiwear Additives..............................................................................549
				Non Petroleum Base or Fire Resistant Fluids.....................................................549
				Operating Temperature...........................................................................549
				Pump inlet Conditions...........................................................................550
		Startup Procedures.....................................................................................551
			Prestart Check......................................................................................551
			Priming.............................................................................................551
	Brake Pedal Valve S0709250K.................................................................................553
		General Description.....................................................................................555
			Theory of Operation.................................................................................555
			Specification.......................................................................................556
		Brake System (S/N 1001 thru 2000).......................................................................557
		Brake System (S/N 2001 thru 3000, 3001 and Up)..........................................................558
		Brake, Pilot and Fan Motor Supply Valve.................................................................560
			S/N 1001 thru 3000..................................................................................560
			S/N 3001 and Up.....................................................................................561
		Hydraulic Circuit.......................................................................................562
			S/N 1001 thru 2000..................................................................................562
			S/N 2001 thru 3000, 3001 and Up.....................................................................562
		Specifications..........................................................................................563
			S/N 1001 thru 2000..................................................................................563
			S/N 2001 thru 3000, S/N 3001 and Up.................................................................563
	Main Control Valve (Toshiba) S0709456K......................................................................565
		General Description.....................................................................................567
		Specifications..........................................................................................569
		Operation...............................................................................................570
			Neutral.............................................................................................570
			Bucket/option Spool Operation.......................................................................570
			Boom Spool Operation................................................................................571
				Boom Float......................................................................................571
			Relief Valve........................................................................................571
				Main Relief Valve...............................................................................571
				Port Relief Valve...............................................................................571
			Operation (Main Relief Valve).......................................................................572
				Operation in Inoperative State..................................................................572
				Operation (A)...................................................................................572
				Operation (B)...................................................................................572
			Operation (Port Relief Valve).......................................................................573
				In the Inoperative State........................................................................573
				Operation (A)...................................................................................573
				Operation (B)...................................................................................573
				Operation (C)...................................................................................574
				Sucking Operation...............................................................................574
	Pilot Control Valve S07094775...............................................................................575
		General Description.....................................................................................577
			Pilot Valve Operation...............................................................................577
			Mono Lever..........................................................................................578
		Pilot System............................................................................................580
	Pilot Control Valve (FNR) S07094776.........................................................................583
		Joystick Valve Assembly.................................................................................585
		HRC6  LV...............................................................................................587
			Dual Axis Section...................................................................................588
			Single Axis Section.................................................................................589
				Dual Axis: Actuation Components and Flange......................................................590
				Single Axis: Actuation Components and Flange....................................................591
				Spring capsule assemblies and joint plate.......................................................592
				Valve Body, Bushing Assembly and Shuttle Valve..................................................593
	EHPS (Electric Hydraulic Power Steering) S0709715...........................................................595
		Steering Control System.................................................................................598
			EHPS Valve..........................................................................................598
				Description of operation of EHPS with integrated priority valve.................................599
			Steering Spool at Neutral Position..................................................................600
			Steering Spool Operated.............................................................................601
				1. Turning Left.................................................................................601
				2. Turning Right................................................................................602
			Pressure Reducing Valves............................................................................603
				Pilot Relief Valve..............................................................................604
		Function................................................................................................605
			Picture of Components in the EHPS...................................................................605
	Power Steering Unit S0709735................................................................................607
		General Description.....................................................................................609
			Steering Unit.......................................................................................609
			Function............................................................................................609
				Exploded View of a Steering Unit................................................................610
	Restriction Valve S0709751K.................................................................................611
		General Description.....................................................................................613
			Theory of Operation.................................................................................613
			UNLOADING CIRCUIT (S/N 1001 thru 2000)..............................................................614
			UNLOADING CIRCUIT (S/N 2001 thru 3000, 3001 and Up).................................................615
			Unloader Cartridge Identification (S/N 1001 thru 2000)..............................................616
			Unloader Cartridge Identification (S/N 2001 thru 3000, 3001 and Up).................................617
			Specifications......................................................................................618
	Hydraulic Schematic (Mega 300V) S0793070K..................................................................619
		General Description.....................................................................................621
		Mega 300V (Tier I) (S/N 1001 thru 2000)................................................................622
		Mega 300V (Tier II) (S/N 2001 thru 3000)...............................................................624
		Mega 300V (S/N 3001 and Up)............................................................................626
Electrical System...............................................................................................629
	Electrical System S0802205K.................................................................................631
		Overview................................................................................................635
			Electric Wire Color.................................................................................635
		Electric Supply System..................................................................................636
		Engine Starting Circuit.................................................................................638
			Operation During Start Process......................................................................638
			Operation After Start Process.......................................................................640
		Engine Preheating System (S/N 1001 thru 2000)...........................................................642
			Principle of Operation..............................................................................642
		Engine Preheating System (S/N 3001 and Up)..............................................................644
			Principle of Operation..............................................................................644
		Engine Stop System......................................................................................646
			Operation In Engine Running Mode....................................................................646
			Operation In Engine Stop Mode.......................................................................648
		Charging System.........................................................................................650
		Monitoring System.......................................................................................651
			Monitoring System (S/N 1001 thru 2000)..............................................................651
			Instrument Panel (S/N 1001 thru 2000)...............................................................652
			Function Check (S/N 1001 thru 2000).................................................................653
			Monitoring System Schematic (S/N 1001 thru 2000)....................................................654
			Monitoring System (S/N 3001 and Up).................................................................656
			Instrument Panel (S/N 3001 and Up)..................................................................657
			Function Check (S/N 3001 and Up)....................................................................658
			Monitoring System Schematic (S/N 3001 and Up).......................................................658
			Operation...........................................................................................660
				Instruments.....................................................................................660
				Indicator Lights................................................................................661
				Initial Operation...............................................................................663
				Control Unit Operation..........................................................................663
				Characteristic of Operation.....................................................................665
		Windshield Wiper........................................................................................666
			Front windshield wiper..............................................................................666
				Front Windshield Wiper Circuit..................................................................666
			Rear Windshield wiper...............................................................................667
		Lighting System.........................................................................................670
			Light Circuit (S/N 1001 thru 2000)..................................................................670
			Light Circuit (S/N 3001 and Up).....................................................................674
		Emergency Steering System (Option)......................................................................678
			Block Diagram.......................................................................................678
			Emergency Steering System Components................................................................679
				Emergency Steering Timer........................................................................679
				Emergency Steering Pump.........................................................................680
				Emergency Steering Switch.......................................................................680
			Emergency Steering System Electric Circuit..........................................................681
		Electric Detent System..................................................................................682
			Electric Circuit....................................................................................682
			Boom Kickout.......................................................................................682
			Return To Dig.......................................................................................683
				Proximity Switch................................................................................683
	Electrical Schematic (Mega 300V) S0893070K.................................................................685
		General Description.....................................................................................687
		Mega 300V..............................................................................................688
Attachments.....................................................................................................691

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